Maintenance Manual for J2 Sedan

Foreword

Maintenance Manual for J2 Sedan

Foreword Master Table of Contents

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.

It is not allowed to copy or modify

contents of this manual in any form,

including but not limited to electronic,

paper, video, audio and etc., without a

written authorization of JAC Passenger

Car Marketing Company.

Use of non genuine spare parts for

JAC passenger cars or nonconforming

oils during maintenance and service

processes of JAC passenger car

products may cause vehicle damage.

Sub-Volume of Chassis

General Description & Maintenance

Engine

Clutch & Manual Transmission

Drive Train/Axle

Suspension

Brake

Steering

Body Electrical

Body Structure

Body Dimension Data

Sub-Volume of Engine

Sub-Volume of Circuit

Troubleshootin

Sub-Volume of Body Electrical

& Structure

AMT Transmission

Maintenance Manual for J2 Sedan

Sub-Volume of Chassis Content

Sub-Volume of Chassis

Clutch & Manual Transmission CL-1

CL Clutch CL-1

Precautions CL-1

Preparation CL-1

System Description CL-1

Clutch pedal and control mechanism CL-3

Clutch CL-5

Trouble Diagnosis CL-7

Service Data and Specifications CL-10

MT Manual Transmission MT-1

Precautions MT-1

Preparation MT-1

Gear Select and Shift Control Mechanism MT-4

Transmission Oil MT-6

Speed sensor MT-7

Transmission Assembly MT-9

Trouble Diagnosis MT-40

Data and Specification of Maintenance MT-41

AMT Transmission AMT-1

Transmission machinery AMT-1

Precautions AMT-1

Preparation AMT-1

Transmission assembly AMT-4

Hydraulic system AMT-14

Precautions AMT-14

System instruction AMT-14

Maintenance Manual for J2 Sedan

Sub-Volume of Chassis Content

Fluid power unit AMT-16

Valve body assembly AMT-20

Air exhaust of hydraulic oil duct AMT-31

Pressure relief for energy accumulator AMT-33

This operation is required in case of the following status AMT-32

Self-learning of gear position AMT-34

Electronic control AMT-36

System instruction AMT-36

Transmission Control Unit TCU AMT-36

System diagnosis, safety and recovery strategy AMT-40

Maintenance data and specification AMT-49

Annex: AMT Transmission Fault Code Trouble Shoot AMT-52

Drive Train/Axle FAX-1

FAX Front Axle FAX-1

Precautions FAX-1

Preparation FAX-1

Front wheel hub and steering knuckle FAX-2

Front drive shaft FAX-7

Trouble Diagnosis FAX-15

Service Data and Specification FAX-17

RAX Rear Axle RAX-1

Precautions RAX-1

Preparation RAX-1

Wheel hub RAX-1

Service Data and Specification RAX-3

Suspension FSU-1

FSU-Front Suspension FSU-1

Maintenance Manual for J2 Sedan

Sub-Volume of Chassis Content

Precautions FSU-1

Preparation FSU-1

Front Suspension Assembly FSU-2

Front shock absorber FSU-5

Lower swing arm FSU-7

Front sub frame assembly FSU-9

Engine suspension FSU-9

Trouble Diagnosis FSU-11

Service Data and Specification FSU-12

RSU Rear Suspension RSU-1

Precautions RSU-1

Preparation RSU-1

Rear Suspension Assembly RSU-1

Rear Shock Absorber RSU-2

Rear crossbeam assembly RSU-5

Trouble Diagnosis RSU-6

Service Data and Specification RSU-6

WT Wheel and Tire WT-1

Precautions WT-1

Tire WT-1

Wheel and tire assembly WT-3

Trouble Diagnosis WT-5

Service Data and Specification WT-6

Brake BR-1

BR Brake System

BR-1

Precautions BR-1

Preparation BR-2

Brake Pedal BR-2

Maintenance Manual for J2 Sedan

Sub-Volume of Chassis Content

Brake Master Cylinder BR-4

Brake Fluid BR-5

Brake Pipe BR-5

Brake Vacuum Booster BR-8

Front disc brake caliper BR-10

Rear Drum Brake System BR-15

Trouble Diagnosis BR-17

Service Data and Specification BR-18

PB Parking Brake PB-1

Precautions PB-1

Parking brake control PB-1

Trouble Diagnosis PB-4

Anti-Lock Brake System (ABS) ABS-1

Precautions ABS-1

Preparation ABS-1

System Description ABS-2

Wheel speed sensor ABS-5

ABS Hydraulic Assembly ABS-7

ABS control module check ABS-9

Air Bleeding of ABS System ABS-11

Trouble Diagnosis ABS-14

Analysis of ABS trouble code ABS-18

Steering EPS-1

EPS Electric Power Steering EPS-1

Precautions EPS-1

Preparation EPS-1

Overview of Electric Power Steering System EPS-2

Composition of Electric Power Steering System EPS-2

Maintenance Manual for J2 Sedan

Sub-Volume of Chassis Content

Schematic diagram EPS-3

Pin Definition EPS-3

Steering wheel EPS-4

Steering Column Assembly EPS-8

Trouble Diagnosis EPS-11

Service Data and Specification EPS-12

Maintenance Manual for J2 Sedan

CL Clutch

CL-1

Clutch & Manual Transmission

CL Clutch

Precautions

 Do not clean clutch pressure plate using gasoline!

 Release bearing is filled with grease. Please do not clean it using oils or liquids.

Warning:

 When cleaning clutch friction plate, please use a dust collector. Never use

compressed air to clean it up!

Preparation

The special tool used is shown below:

List of Special Tools

SN Tool Outline drawing Number Description

Flywheel

stopper

JAC-T1F011 Fixing flywheel

System Description

System diagram:

Clutch Control System Diagram

1 – Rocker arm 2 – Bracket 3 – Clutch cable 4- Clutch pedal 5- Release fork 6- Release

bearing

Maintenance Manual for J2 Sedan

CL Clutch

CL-2

Clutch Control Schematic Diagram

1- Clutch pedal 2 – Clutch cable 3 – Release bearing 4 – Pressure plate assembly 5 –

Driven disc 6 – Flywheel 7 – Rocker arm

Brief principle:

The clutch operation is functioned in such manner that the engagement and

disengagement of the clutch is controlled by means of the remote clutch cable control

mode to realize the power transmission and cut-off between the engine and the

transmission. The specific implementation is as follows:

At disengagement: When the driver steps down the clutch pedal 1, the pedal and

clutch cable 2 pull the release rocker arm 7, the release rocker arm pushes the release

bearing 3, and the release bearing 3 pushes the release fingers of the clutch pressure

plate 4 so that a gap is formed between he driven disc 5 connected with differential

input shaft spline and the engine flywheel and the driven disc 5 can’t transmit the

power. In such case, the power transmission is cut off.

At engagement: When the driver slowly releases the clutch pedal 1, under the spring

forces of the release fingers and return spring, the clutch pedal is lifted slowly and the

release bearing moves axially on the transmission input shaft and slowly disengages

from the release fingers of the clutch pressure plate 4 so that the gap between the

pressure plate 4 and the driven disc 5 clamped between flywheel 6 and pressure plate

4 and connected with transmission input shaft spline disappears. In such case, the

driven disc gradually starts the power transmission and the power transmission is

engaged.

Maintenance Manual for J2 Sedan

CL Clutch

CL-3

Clutch pedal and control mechanism

Part

Diagram of Clutch Pedal and Control Mechanism

1 – Clutch pedal 2 – Clutch cable 3 – Bracket 4 – Rocker arm

Removal:

① Take out the clutch cable from the

clutchp pedal barb and remove the

clutch cable rubber connector from

the pedal opening.

② Disconnect the connecting pins

between brake pedal and vacuum

booster.

③ Remove the fixing bolts and nuts of

the clutch and brake pedals and

remove the clutch and brake pedals.

 Tightening torque: 8～10N·m

CL001

CL002 CL002

Maintenance Manual for J2 Sedan

CL Clutch

CL-4

④ Remove the fixing bracket of clutch

cable.

 Tightening torque: 15～20N•m

⑤ Disconnect the clutch cable from the

opening of clutch release rocker

arm.

⑥ Remove the clutch cable.

Installation

Install in reverse order of removal procedure.

Notice:

 Check the following items before assembly:

 ■ Check the clutch cable for presence of damage or poor movement.

 ■ Check the clutch and brake pedal assembly for presence of damage.

 ■ The sway of the pedals on the clutch and brake pedal assembly shall not exceed

3mm.

 ■ Check whether the springs are installed in correct positions on the clutch and

brake pedals.

Adjustment after assembly:

 To guarantee 0.5~1mm gap between release bearing and pressure plate within the

transmission and guarantee the normally disengaged state, the manual adjustment

of this gap is required after the installation of locating nuts between clutch cable

and rocker arm. The appropriate method is to tighten the location nuts till the

locating nuts are almost secured (in such case the release bearing is pressed onto

the pressure plate).

CL004

CL003

Maintenance Manual for J2 Sedan

CL Clutch

CL-5

Clutch:

Components:

Exploded View of Clutch

1 – Bush 2 – Release shaft assembly 3 – Release bearing assembly 4 – Release

shaft spring 5 – Bush 6 – Release shaft oil seal assembly 7 – Clutch rocker arm

assembly 8 – Bolt 9 – Clutch pressure plate and housing assembly 10 – Clutch

driven disc assembly

Removal:

Remove as per the numerical order of the exploded view.

Note:

 Guard the surfaces of clutch driven disc, pressure plate, and flywheel against

contamination of any oil or grease.

Inspection after removal

① Clutch driven disc

 Check the surfaces for presence of loose rivet, single face contact, deterioration

due to scalding, and contamination of oil and grease. If yes, replace the clutch

driven disc.

 Measure the recessing depth of rivets. If out-of-tolerance, replace the clutch

driven disc.

Maintenance Manual for J2 Sedan

CL Clutch

CL-6

 Check the return spring for presence of

looseness and damage. If yes, replace the

clutch driven disc.

 Install the clutch driven disc onto the

input shaft and check the sliding status

and the looseness in rotation direction. In

event of poor sliding, clean the driven. In

event of poor sliding after assembly,

replace the driven disc. If event of clear

looseness, replace the clutch driven disc

or input shaft or replace both.

② Clutch pressure plate

 Inspect the end of the diaphragm spring for wear and height difference. In the

case of obvious wear or the height difference exceeds the limit value, replace the

clutch pressure plate.

Limit value:0.5 mm

 Inspect the surface of pressure plate for the presence of wear, crack and

discoloration.

 Inspect the rivet on the pressure plate for looseness. If so, replace the clutch

pressure plate.

③ Release bearing

 Inspect the bearing for the presence of burn, damage, abnormal noise and

unsmooth rotation.

 Check the contact surfaces between release bearing and diaphragm spring or

release fork for presence of wear. If yes, replace.

Installation

① Clean the clutch friction plate and input shaft key groove to get rid of the grease

and metal chips.

② Apply some grease on the input shaft key groove.

Note:

 Recommended grease: SAE J310 or like product

 Make sure to apply the grease to specified position or it would lead to noise, poor

release or damage of clutch. And too much grease may lead to slip or tremble.

③ Install the clutch driven disc and the clutch pressure plate with special tools.

④ Perform in the order as shown in the figure, tighten the fixing bolts for the clutch

pressure plate one by one.

CL005

Maintenance Manual for J2 Sedan

CL Clutch

CL-7

Note:

 Tighten each bolt of 1~2 laps once.

Tightening torque: 15~22N·m

(Confirm the torque) In addition, confirm how

many bolts are used to fasten the pressure plate.

⑤ Install the release bearing.

Trouble Diagnosis

The performance diagnosis of clutch assembly and clutch control system shall be

conducted by experienced driver or skilled auto service technician.

The following (fault) diagnosis only covers the common problems and possible

causes. After the proper diagnosis, perform the adjustment or replace the parts as

required in accordance with corresponding troubleshooting in the diagnosis table and

the appropriate sections of corresponding detailed procedure in the maintenance

manual.

During the maintenance of the vehicle, the clutch pressure plate and the clutch friction

plate are non-repairable. If any of these parts is damaged, replace the entire assembly.

If the rivets of the clutch friction plate are worn or the clutch friction plate is subject

to the contamination of engine oil or grease, make sure to replace the clutch friction

plate.

When it’s necessary to replace one part, make sure to use a new qualified part for

replacement.

This diagnosis table helps the diagnosis against the faults of clutch system arising

from the following conditions: Disengagement failure, incomplete disengagement,

incomplete engagement, skid, noise, and vibration.

The numbers in the diagnosis table do not mean the checking sequence and there is no

successive relationship amongst all possible causes.

Diagnostic Table for Common Faults

Check Possible cause Solution

Disengagement

failure

Disengagement failure means clutch cannot

function and cut power transmitted from engine.

Check the following:

1. Clutch release lever for deformation.

2. Diaphragm spring for deformation.

3. Diaphragm spring support ring for fracture.

4. Improper adjustment of clutch pedal control

system and clutch cable

5. Clutch friction plate for binding with

flywheel or clutch pressure plate.

Replace deformed, worn, or

broken parts.

Adjust the clutch system.

CL006

Maintenance Manual for J2 Sedan

CL Clutch

CL-8

Check Possible cause Solution

Drag

Clutch drag will result in failure to cut power

transmitted from engine normally and difficulty

to operate shift lever due to continued rotation of

clutch friction plate and transmission input shaft.

Check the following:

1. Clutch friction plate for deformation

(shimmy will occur when it rotates).

2. Clutch friction plate for damage.

3. Clutch friction plate spline for mismatch

with transmission input shaft spline, or

spline facing for damage.

4. Clutch friction plate for partial binding with

flywheel or seizure with clutch pressure

plate.

5. If thickness of flywheel/clutch pressure

plate/clutch friction plate exceeds given size.

6. Clutch pedal control system for mechanical

breakdown or improper adjustment.

Replace deformed, worn,

broken and out-of-size parts.

If clutch friction plate does

not work well with

transmission input shaft

spline, replace the former; if

necessary, replace

transmission input shaft.

If clutch friction plate

exceeds given size or is

damaged, replace it.

Replace unsuitable clutch

thrust bearing.

Adjust clutch system in order

to remove unnecessary

clearance and eliminate

mechanical breakdown.

Reinstall improperly

assembled parts.

Halfway

engagement

Halfway clutch engagement will result in failure

to transmit engine power to transmission input

shaft normally and clutch friction plate slipping.

Check the following:

1. Clutch friction plate for oil or grease stains.

2. Clutch friction plate for damage.

3. Clutch pedal for zero free play.

4. Diaphragm spring/clutch pressure

plate/clutch release lever/clutch friction plate

spline for deformation or damage.

5. Mechanical malfunction or improper

adjustment of clutch pedal control system

and clutch cable

Replace deformed, worn, and

broken parts.

Replace clutch friction plate

or defective clutch assembly.

Adjust free play of clutch

pedal correctly.

Adjust clutch system in order

to remove unnecessary

clearance and eliminate

mechanical breakdown.

Reinstall improperly

assembled parts.

Maintenance Manual for J2 Sedan

CL Clutch

CL-9

Check Possible cause Solution

Slipping

Clutch friction plate slipping will result in failure

to transfer engine power normally.

Check the following:

1. Clutch friction plate for wear.

2. Clutch friction plate for oil or grease

contamination.

3. Clutch for halfway engagement.

4. If thickness of flywheel/clutch pressure

plate/clutch friction plate exceeds given size

and friction surface is beyond specification.

5. Interior of clutch housing for excess

temperature caused by improper driving.

6. For unsuitable clutch installed.

Replace deformed, worn,

broken, and

out-of-size-and-specification

parts.

Same as corresponding

solutions for “Drag” and

“Halfway engagement”.

Shut down engine, cool

interior of clutch housing (in

the case of excess

temperature), and then go to

further diagnosis.

Install designated clutch

correctly.

Adjust the clutch system and

clutch cable, in order to

eliminate unnecessary cap

and mechanical malfunction.

Reinstall improperly

assembled parts.

Do not allow driver to

always keep his/her foot on

clutch pedal.

Noise

Check the following:

1. Incorrect clutch friction plate.

2. Poor balance.

3. Clutch thrust bearing for malfunction.

4. Torsion damping spring of clutch friction

plate for damage.

Replace deformed, worn, and

broken parts.

Install designated clutch

friction plate.

If a part is poorly balanced,

replace clutch assembly.

Adjust the clutch cable.

Reinstall improperly

assembled parts.

Jitter

This will occurs when clutch friction plate can not

engage with flywheel softly.

Check the following:

1. Damping spring of clutch friction plate out

of specification.

2. Clutch friction plate out of specification.

3. Clutch friction plate for oil or grease

contamination.

Replace clutch assembly.

Maintenance Manual for J2 Sedan

CL Clutch

CL-10

Service Data and Specifications

1.Technical Data

Technical Data Sheet

Free travel of clutch 6~13mm

2. Tightening Torque

Tightening Torque Table

Item Tightening torque (N·m)

Fixing nuts of clutch and brake pedals

20～25

Fixing bolts of clutch and brake pedals

20～25

Fixing bracket of clutch cable

15～20

Bleeder bolt

7～13

Installing bolt on clutch pressure plate

20～30

Maintenance Manual for J2 Sedan

MT Manual Transmission

MT-1

MT Manual Transmission

Precautions

■ Please do not reuse drained manual transmission gear oil.

■ When checking or changing manual transmission gear oil, keep your vehicle

level.

■ When removing and installing transmission, keep its interior free from dust and

foreign materials.

■ Before removing or disassembling, check and determine correct installing

position. If fitting marks are required, ensure functions of involved components

will not be affected after these marks are made.

■ Tighten middle bolts and nuts first and then outer ones diagonally in steps as

required. If a tightening order is required, follow it.

■ Be careful not to damage sliding surfaces and mating surfaces.

Preparation

The special tools used are shown in the following table:

SN Tool Number Outline drawing Description

Bearing

remover

JAC-T1B001

For installation/removal

of bearing and bush on

input shaft

Bearing

remover

JAC-T1B002

For installation/removal

of bearing and bush on

input shaft

Remover of

spring pin

JAC-T1B003

To remove spring pin of

shifting yoke

Bearing

remover

JAC-T1B004

To remove bearing shell

and roller bearing from

clutch housing

Installer

Cover

JAC-T1B005

To install bearings and

other parts on

input/output shaft of

transmission with

Installer and Adapter

Maintenance Manual for J2 Sedan

MT Manual Transmission

MT-2

SN Tool Number Outline drawing Description

6 Installer JAC-T1B006

To install bearings and

other parts on

input/output shaft of

transmission with

Installer Cover and

Adapter

7 Installer JAC-T1B007

To install bearings and

other parts on

input/output shaft of

transmission with

Adapter and Installer

Cover

8 Adapter JAC-T1B008

To install ball bearing

on input shaft of

transmission with

Installer

9 Adapter JAC-T1B009

To install rear bearing

of transmission input

shaft with Installer

10 Adapter JAC-T1B010

Mating with installer to

install ball bearing on

transmission input

shaft, roller bearing

shell, ball bearing, R

gear, and bearing shell

of R gear on output

shaft

11 Adapter JAC-T1B011

Mating with installer to

install 4

gear, 5

gear

sliding bush,

synchronizer of 5

-R

gear on output shaft of

transmission

12 Adapter JAC-T1B012

Mating with installer to

install 2

gear, 3

gear and 1

gear sliding

bush on output shaft of

transmission

13 Adapter JAC-T1B013

Mating with installer to

install tapered roller

bearing and inner race

of the differential

14 Adapter JAC-T1B014

Mating with installer to

install 4

gear sliding

bush and 5

gear on

input shaft of

transmission

Maintenance Manual for J2 Sedan

MT Manual Transmission

MT-3

SN Tool Number Outline drawing Description

15 Adapter JAC-T1B015

Mating with installer to

install 1

gear sliding

bush and 1,2

synchronizer bush on

output shaft of the

transmission

16 Handle JAC-T1B016

Mating with Installers

to install bearings

17 Adapter JAC-T1B017

Mating with the Handle

to install seal ring on

lower cap of the

transmission

18 Adapter JAC-T1B018

Mating with the Handle

to install outer shell of

roller bearing on clutch

housing

Installer for

differential

seal

JAC-T1B019

The oil seal on

transmission case

where differential

installed

20 Adapter JAC-T1B020

Mating with the Handle

to install outer shell of

tapered roller bearing

on clutch housing

Installer for

differential

seal

JAC-T1B021

The oil seal on

transmission case

where differential

installed

Installation

block for

idle shaft of

transmission

JAC-T1B022

Maintenance Manual for J2 Sedan

MT Manual Transmission

MT-4

Gear Select and Shift Control Mechanism

Components:

Figure of gear select and shift control mechanism

1. Washer; 2. Lock pin; 3. Snap lug; 4. Cable holder; 5. Mounting plate of shifting

cable;6. Shifting cable;7. Handle； 8. Shifting Control Assembly

Removal:

① Remove console.

② Remove bolts connecting gear select

and shift control support with body

floor.

■ Tightening torque: 30~35N·m

MT001

Maintenance Manual for J2 Sedan

MT Manual Transmission

MT-5

③ Remove lock pin and spring clip of

gear select and shift cables and

detach cables from gear select

control mechanism.

④ Remove lock pin and snap lug which

hold the shift cable on the arm.

Note:

■ There is a mark as the red arrow

indicated on the end of cable.

⑤ Remove mounting plate and

attaching bolts with the floor.

■ Tightening torque: 12 - 17N·m

MT002

MT003

MT004

MT005

Maintenance Manual for J2 Sedan

MT Manual Transmission

MT-6

⑥ Remove bracket of the shifting cable.

■ Tightening torque: 12 - 17N·m

Installation:

Installation is the reverse order of removal.

Caution:

■ A proper quantity (approximately 4-5 gram) of lithium base grease must be

applied on moving parts of the shifting control mechanism.

■ Do not install the spring clip in wrong direction.

■ After assembly, the device should work smartly without jamming, gear select

and shift should be clear and accurate, and device status should be satisfactory.

Transmission Oil

1. Change oil of transmission

1). Draining

① Remove drain plug allowing oil

drained.

■ Tightening torque: 18 - 23N·m

② Check for scrap iron on drain plug

surface and remove immediately.

MT006

MT007

Maintenance Manual for J2 Sedan

MT Manual Transmission

MT-7

2). Filling

① Remove the filler cap. Top up with

new gear oil until level close the

limit near the installation hole.

② Gear oil grade and quantity:

API GL-4 SAE 75W-90

Quantity : 2.1L

③ Recheck oil level after filling.

④ Screw the filler cap tightly.

■ Tightening torque: 18 - 23N·m

2. Inspection of the transmission gear

oil

■ Be sure that there is no oil leakage

around the transmission.

① Remove the filler cap. Check oil

level through the filler tube as

shown in the figure.

② Screw the filler cap tightly.

Note:

■ Be sure to check oil level with the

engine not running.

Note:

■ Be sure to stop the engine and stop the car on level surface before oil change and

checking.

■ Threads of filler cap and drain plug must be coated with a film of white lead

putty before installation.

Speed sensor

Removal:

① Disconnect cable from negative post

of the battery.

② Remove connector of the speed

sensor.

MT008

MT009

MT010

Maintenance Manual for J2 Sedan

MT Manual Transmission

MT-8

③ Remove the speed sensor.

Installation

① Install the speed sensor on the

transmission assembly.

■ Tightening torque: 8 - 12N·m

■ Check for cracks or other failures on

surface of the O-ring and case of the

speed sensor. Before installation,

apply some oil on the O-ring and

driven gear of the sensor.

② Reinstall connector of the speed

sensor.

③ Install cable on negative post of the

battery.

MT011

MT012

Maintenance Manual for J2 Sedan

MT Manual Transmission

MT-9

Transmission Assembly

Components

Sectional view of the transmission

1- Input shaft; 2- 5th gear synchronizer assembly; 3- 5

driving gear; 4- 4

driving

gear; 5- High range synchronizer assembly; 6- 3

driving gear; 7- Central case; 8-

Gear R idler shaft; 9- Gear R idler; 10- Front case; 11- Idle shaft; 12- Rear case; 13-

driven gear; 14- 4

driven gear; 15- 3

driven gear; 16- 2

driven gear; 17- Low

range synchronizer assembly; 18- 1

driven gear; 19- Main reducer driven gear; 20-

Differential housing; 21- Speedometer driven gear

Maintenance Manual for J2 Sedan

MT Manual Transmission

MT-10

Exploded view of the transmission power line

1- Input shaft; 2- Oil seal; 3- Right bearing of the input shaft; 4- 3

driving gear; 5-

Needle bearing between gear 3 and gear 4; 6- High range synchronizer; 7- High range

snap ring; 8- High range synchronizer assembly; 9- High range slider; 10- Snap ring;

11- 4

driving gear; 12- Left bearing of the input shaft; 13- 5

driving gear; 14- Gear

5 bush; 15- Gear 5 needle bearing; 16- Gear 5 synchronizer; 17- Washer; 18- Gear 5

snap ring; 19- Gear 5 synchronizer assembly; 20- Gear 5 slider; 21- Thrust plate; 22-

Snap ring; 23- Gear R idler shaft; 24- Gear R idler; 25- Washer; 26- Right bearing of

the idle shaft; 27- Idle shaft; 28- 1

driven gear; 29- Gear 1 synchronizer; 30- Snap

ring low range; 31- Low range synchronizer assembly; 32- Low range slider; 33- Snap

ring; 34- Gear 2 synchronizer; 35- Needle bearing between Gear 1 and Gear 2; 36- 2

driven gear; 37- 3

driven gear; 38- Spacer between gear 3 and gear 4; 39- 4

driven

gear; 40- left bearing of idle shaft; 41- shim of bearing; 42- 5

driven gear; 43-

Locking nut of 5

gear; 44- bolts of Gear R idler shaft

Maintenance Manual for J2 Sedan

MT Manual Transmission

MT-11

Gear selection/shifting mechanism system view

1-Shifting yoke; 2- Gear R yoke; 3- Pilot of gear R and gear 5; 4- Shifting shaft of

Gear R and Gear 5; 5- Shifting shaft of Gear 3 and Gear 4; 6- Shifting shaft of Gear

1 and Gear 2; 7- Gear selection lever; 8- Shifting cam between Gear R and Gear 5;

9- Gear R and Gear 5interlock screw; 10- Pilot case; 11- Interlock plate; 12- Gear

retaining screw 13- Gear selection shaft; 14- Gear selection arm; 15- Gear shifting

arm;

Gear selection direction

Gear shiftin

direction

Gear selection direction

Gear shiftin

direction

Gear 5, Gear R

Gear 3, Gear 4

Gear 1, Gear 2

Gear 5, Gear R

Gear 3,

Gear 4

Gear 1,

Gear 2

Gear selection direction

Maintenance Manual for J2 Sedan

MT Manual Transmission

MT-12

Disassembly:

Disassemble the transmission in sequence indicated by the number of the Exploded

view. Disassembly of some special components is described as following:

1) 5

gears

① Remove 8 mounting bolts of the rear

case and then remove it.

② Remove snap ring 1 and then the

thrust plate 2.

Note:

■ The snap ring must not be deformed

during removal.

③ Remove mounting screw1 and

locating ball of gear 5 shifting yoke.

④ Remove spring pin 2 with hammer

and the special tool, remove snap

ring 3.

⑤ Take off Gear 5 shifting yoke 1, Gear

5 synchronizer assembly and ring 4.

MT013

MT014

MT015

Maintenance Manual for J2 Sedan

MT Manual Transmission

MT-13

⑥ Mounting nut of the output shaft:

release crushed portion the nut with a

punch, and then remove the nut.

⑦ Remove the 5th driven gear, 5th driving gear and central case thrust plate;

2) Shifting control mechanism, input

shaft, output shaft, idle shaft

① Remove 3 bolts and washers of the

shifting yoke shaft, remove the

spring and steel ball.

② Remove 4 bolts of the gear pilot

housing, remove the clip.

③ Remove gear retaining bolts and

washers.

④ Remove reversing lamp switch

assembly.

⑤ Position shift lever at N, remove

shifting control mechanism

assembly.

⑥ Remove Gear R bolts and washers.

MT016

MT017

Mounting

hole of the

reversing

lamp switch

Gear selector

bracket (lug)

Gear shifting

control assembly

Bolts

Gear retaining screw

Gear selection

lever

Gear shifting

control

assembly

Reversing

lamp switch

assembly

Gear

retaining

screw

Maintenance Manual for J2 Sedan

MT Manual Transmission

MT-14

⑦ Remove 11 mounting bolts of the

central case, then remove other 3

mounting bolts of the Central case

from front case in the clutch housing.

⑧ Insert a screwdriver in the gap

between front and central case,

separate the central and front case

while another screwdriver pulled on

the other side.

Note:

■ The screwdriver must not be applied

on the mating surface of both case,

otherwise this surface may be

damaged.

⑨ Completely separate front case from

central case and then lift it. By this

way, the input shaft, output shaft and

differential etc. are all left in the

front case assembly.

⑩ Remove 2 mounting bolts of the

Gear R shifting yoke, and then

remove the yoke.

⑪ Remove Gear R shaft 2 and washer,

take off the idler 3.

⑫ Remove shifting yoke shaft assembly

1 of Gear R and Gear 5.

MT019

MT020

MT021

MT022

Central case

Front case

Maintenance Manual for J2 Sedan

MT Manual Transmission

MT-15

Note:

■ It is easier to remove shifting yoke shaft assembly of Gear R and Gear 5 with the

Gear 3/4 shifting yoke at Gear 4 position.

Knock on the end face of primary

shaft with a rubber hammer making

input shaft 5 displaced. Hold input

shaft 5, idle shaft 4, Gear 1/2 shifting

yoke assembly 2 and Gear 3/4

shifting yoke assembly together and

take them off.

Remove tapered bearing outer shell

of the secondary shaft from central

case.

Remove oil seal of differential from

central case.。

3) Front case assembly

① Remove differential assembly 1 from

the front case.

② Remove mounting bolts and then

take off speed sensor driven gear

assembly 2 from front case assembly

Note:

■ Be aware not to damage the outer

surface of speed sensor during

removal of the driven gear.

MT023

MT024

MT025

Maintenance Manual for J2 Sedan

MT Manual Transmission

MT-16

③ Remove input shaft oil seal 1 by

using special tool.

④ Remove tapered bearing outer shell 2

of idle shaft by using special tool.

Note:

■ The input shaft bearing should by

pulled out by special tool if it is on

the front case.

⑤ Remove differential oil seal from front case.

Note:

■ The used oil seal should be discard.

4) Input shaft assembly

① Remove right bearing of input shaft by using special tool.

② Holding 4th driving gear tightly by using the special tool, pull out it with Gear 5

bush and left bearing together.

Note:

■ The jaw of special should not applied on the gear tooth to avoid damage of the

tooth.

③ Remove Gear 4 needle bearing and

high range synchronizer 2.

④ Remove small clip 1 by using special

tool 3.

Note:

■ Both jaws of special tool should be

in same plane to remove the clip

conveniently.

MT026

MT027

Maintenance Manual for J2 Sedan

MT Manual Transmission

MT-17

⑤ Remove high range synchronizer

assembly 2 and 3rd driving gear 4.

⑥ Remove needle bearing of the 3rd

driving gear.

Inspection and reinstallation of the high

range synchronizer assembly:

① Clean all parts thoroughly; Check for

any abnormity and replace with new

ones as required.

② In case that any parts of the

synchronizer need to be repaired,

inspect clearance “a” between

synchronizer ring 2 and the gear.

Chamfer on each tooth of the gear

and coupling spline should also be

checked. If any characteristics go

beyond specification, replace the

part.

■ Clearance “a”: Standard 1.0 - 1.4mm Limit: 0.5mm

③ Blow compressed air into oil path of

the input shaft 1 to clean any

blockage, ensuring clear oil path to

holes 2.

MT028

MT029

MT030

Maintenance Manual for J2 Sedan

MT Manual Transmission

MT-18

④ Install high range synchronizer

assembly, insert 3 sliders, and then

install the spring as shown in the

figure.

Note:

■ Be aware of directions of parts of the

synchronizer.

■ Be aware of any difference between

snap ring 1, high range slider 2, high

range coupling spline 3, high range

outer gear ring 4 and any parts of the

low range synchronizer assembly,

gear 5 synchronizer assembly.

⑤ Install right bearing 1 of the input

shaft 2 by using special tool.

⑥ Install gear 3 needle bearing, apply

oil on the bearing; install the 3

gear

2 and high range synchronizer ring 3.

⑦ Install high range synchronizer

assembly 4 by using hammer and

special tool.

Note:

■ Be sure to align Slider groove with the slider during assembly of the

synchronizer.

■ Check for free revolving of the 3rd gear after the high range synchronizer is

installed.

■ The needle bearing, synchronizer ring of Gear 3 are same as those of gear 4.

MT031

MT032

MT033

Clutch side

(3rd gear)

A = B

C: Width boss (clutch side)

D: Position of the slider

A: Slider position

Maintenance Manual for J2 Sedan

MT Manual Transmission

MT-19

⑧ Install clip 1, needle bearing 2, apply

oil on needle bearing and then install

synchronizer ring 3 and 4th driving

gear 4.

Note:

■ Be sure to install snap ring properly

in the groove of input shaft.

⑨ Install left bearing 2 by using special

tool and hammer.

⑩ Install 5th gear bush 1 by using same

tools.

Note:

■ The 5th gear bush should not be

pressured together with the left

bearing to avoid overload on the

bush.

5) Idle shaft assembly

① Hold 4th driven gear by special tool and then remove it with tapered left bearing.

Note:

■ Don't catch gear on the tooth, otherwise the gear may be damaged.

② Hold 2nd driven gear by special tool, remove it together with 3rd driven gear and

spacer.

Note:

■ Don't catch gear on the tooth, otherwise the gear may be damaged.

③ Remove the needle bearing and Gear

2 synchronizer ring.

④ Remove the snap ring 2 by using the

special tool.

Note:

■ Both jaws of the special tool should

be a same plane to ensure successful

removal of the snap ring.

MT034

MT035

MT036

Maintenance Manual for J2 Sedan

MT Manual Transmission

MT-20

⑤ Remove low rang synchronizer

assembly and gear 1 synchronizer

ring 3.

⑥ Remove 1st driven gear 4 and needle

bearing.

Inspection and reassembly of the idle shaft:

① Clean all parts thoroughly. Check for any abnormity and replace with new part as

required.

② If any part of the synchronizer needs

to be repaired, check clearance “a”

between synchronizer ring 2 and gear

1, chamfer of the gear teeth and

spline should also be checked. If any

characteristics go beyond

specification, replace the part.

■ Clearance “a”: Standard 1.0 - 1.4mm Limit: 0.5mm

③ Blow compressed air into oil path of

the input shaft 1 to clean any

blockage, ensuring clear oil path to

holes 2.

MT037

MT038

MT039

Maintenance Manual for J2 Sedan

MT Manual Transmission

MT-21

④ Install low range synchronizer

assembly, insert three sliders 2, and

then install spring as shown in the

figure.

Note:

■ Low range coupling spline and slider

are not directional.

■ Low range snap ring 1 and slider 2

are biggest ones among similar parts

of all synchronizer assemblies.

⑤ Install tapered right bearing 1 by

using special tool and hammer.

⑥ Install the needle bearing, apply

some oil on it; then install 1st driven

gear and gear 1 synchronizer ring.

Note:

■ Slider groove 1 on gear 1

synchronizer is less wide than that of

gear 2. Don’t confuse.

■ Width “b”: 8.2mm; “c”: 8.8mm

■ Needle bearing of gear 1 and gear 2

are same.

⑦ Install low range synchronizer

assembly 1 through knocking with

hammer and special tool.

Note:

■ Support right end of the secondary

shaft. The tapered bearing protector

is used to protect the cage of bearing

from crushed.

MT040

MT041

MT042

MT043

Clutch side

C: Slider groove

A: Align the slider with the slider groove

Maintenance Manual for J2 Sedan

MT Manual Transmission

MT-22

■ When the synchronizer assembly is installed, make sure slider groove on the ring

aligning with the slider of the synchronizer assembly. After the synchronizer

assembled, check for free revolving of the 1st gear.

⑧ Install clip 3, needle bearing 4, apply

oil on needle bearing and then install

gear 2 synchronizer ring 5 and 2nd

driving gear 6

Note:

■ Be sure to install snap ring properly

in the groove.

⑨ Install 3rd driven gear 2 and spacer 1

by using special tool.

Note:

■ It is recommended to install 3rd

driven gear 2 and spacer 1, and then

the 4th driven gear. By this way, the

secondary shaft need not endure over

compression.

⑩ Install 4th driven gear 2 by using

same tool as above.

⑪ Install tapered left bearing 1 by using

special tool and hammer.

Note:

■ The tapered bearing must be always

supported by the special as shown in

the figure during installation.

MT044

MT045

MT046

Maintenance Manual for J2 Sedan

MT Manual Transmission

MT-23

6) Gear shifting mechanism

Gear shifting control assembly:

Systematic view of gear shifting control assembly

1- Gear selector shaft; 2- Washer; 3- Spring pin; 4- Gear selector arm; 5- Spring pin;

6- Spring seat; 7- Returning spring of gear shifting cam; 8- GearR/5 shifting cam; 9-

Gear shifting arm; 10- Shim; 11- Gear shift pin; 12- Snap ring; 13- Spring pin; 14- Oil

seal; 15- Boot; 16- Spring pin; 17- Pilot case; 18- Returning spring of high range; 19-

Interlock plate; 20- Spring pin; 21- Returning spring of low range;22- E-clip

Removal / reinstallation

① Remove 5 pins and 3 E-clips from gear selector shaft, and then remove other

components.

② Clean all parts thoroughly; check all parts and replace as required.

③ Reassemble in reversed sequence of removal.

Note:

■ The gear selector shaft should be supported with wood block when knocking in

the spring pin.

■ During installation of the Gear R/5 interlock cam, the returning spring should be

wound before the spring pin is knocked in.

■ Wire of 2 returning springs of the high range is thicker than that of the low range.

■ The gear selector arm should be installed in same direction of the Gear R/5 cam

and spring seat.

Maintenance Manual for J2 Sedan

MT Manual Transmission

MT-24

Gear 1/2 and 3/4 shift yoke shaft assembly:

Systematic view of Gear 1/2 shifting yoke assembly

1- Gear 1/2 shifting shaft; 2- Gear 1/2 shifting arm; 3- Gear 1/2 shifting yoke

Systematic view of Gear 3/4 shifting yoke assembly

1- Gear 3/4 shifting shaft; 2- Gear 3/4 shifting arm; 3- Gear 3/4 shifting yoke

Removal / Reinstallation

① Using special tool (spring pin remover), remove 3 pins from gear selector shaft

and the remove all the components.

② Clean all parts thoroughly; check all parts and replace as required.

③ Reassemble in reversed sequence of removal.

Note:

■ Two spring pins in the yoke holes should be installed with 180 degree

misaligned.

Maintenance Manual for J2 Sedan

MT Manual Transmission

MT-25

Inspection of the yoke and outer gear ring

①

Check clearance between yoke

and the outer gear 2 ring. If this

clearance is over 1.0mm, replace both

parts.

Note:

■ Contact position of the yoke and the

outer gear ring should be check for

correct replacement of the part.

■ Clearance “a”: Limit: 1.0mm

② Install the shifting shaft into mounting hole in the case. Check for free revolving.

If there is any sticking, correct with hone, reamer or other tools.

Gear R/5 shifting yoke shaft assembly:

Systematic view of Gear R/5 shifting yoke assembly

1- Gear R shifting yoke; 2- Spring; 3- Steel ball; 4- Spring pin; 5- Gear R/5 shifting

shaft; 6- Gear R/5 shifting arm 7- Gear R/5 guiding rod; A: split end of the spring pin

should be forward.

MT047

Maintenance Manual for J2 Sedan

MT Manual Transmission

MT-26

Removal / Reinstallation

1. Remove the spring pin with special tool, remove all the parts.

2. Clean all part thoroughly and inspect, replace with new part as necessary.

3. Reinstall parts as shown in the figure.

Note:

■ Be aware to distinguish Gear R shifting yoke retaining spring from low range

returning spring;

■ Never forget to install the two steel balls of Gear R shifting yoke.

■ Spring pin of the Gear R shifting yoke should be installed forward.

7) Differential assembly

Systematic view of the differential assembly

1- Driven gear of the main reducer; 2- Dual-action locking washer; 3- Nut; 4-

Planetary gear unit washer; 5- Driving gear of the speedometer; 6- Right bearing; 7-

Semi-shaft gear; 8- Planetary gear; 9- Differential screw; 10- Differential housing; 11-

Pin of the planetary unit shaft; 12- Planetary unit shaft; 13- Washer of semi-shaft gear;

14- Left bearing

① Remove right bearing by using special tool.

② Pull out driving gear of speedometer.

Maintenance Manual for J2 Sedan

MT Manual Transmission

MT-27

③ Remove left bearing by using special tool.

④ Hold differential housing into the vice, then remove 8 nuts, 8 bolts which hold

the differential and 4 locking nuts, and then take off the driven gear of main

reducer.

⑤ Knock out spring pin with hammer

and the special pin, remove

planetary unit shaft 3, planetary unit

and semi-shaft gear 2.

Adjustment and reassembly:

After all parts disassembled, check for any abnormity such as deformations through

view inspection and note; replace damaged parts. Clean all part to reassemble.

① Install semi-shaft gear and measure

end play as shown in the figure.

■ End play: 0.03 - 0.40 mm

Left:

Hold differential housing into the

vice, and then put measuring point

of the dial meter onto tooth top of

the semi-shaft gear 2.

Move gear up and down with two

screwdrivers 1 to read.

Right:

Using same procedure as previous

step, put measuring point of the put

measuring point of the dial meter

onto shoulder of the semi-shaft gear

Move gear up and down by your

hand to read.

MT048

MT049

MT050

Left

Right

Maintenance Manual for J2 Sedan

MT Manual Transmission

MT-28

② If the axial runout exceeds the specified value, select proper adjusting shims for

the differential gear and carry out reinstallation and re-measurement in order to

achieve the gear runout that is in accordance with relevant specifications.

Optional gears

Adjusting shim

Unit: mm

0.70

0.80

0.90

1.00

1.10

Note:

■ Semi-shaft gear shims, planetary unit shims, mating surface of the planetary gear

and the gear shaft, and mating surface of semi-shaft gear and the differential

housing should all be applied with oil.

③ Knocking in the spring pin with its end fully getting into differential housing.

④ Reinstall left bearing by using special tool and he copper hammer.

⑤ As shown in the figure, reinstall the

deriving gear 2 of speed sensor with

left bearing supported by the special

tool at a floating position, and then

install right bearing 1 as described in

step ④

⑥ Hold differential housing into the

vice, then install driven gear 2 of the

reducer, and then tighten 8 mounting

bolts 1 to specified torque.

Note:

■ Bolts other than specified should

never be used.

■ Tightening torque:80 - 100N·m

MT051

MT052

Maintenance Manual for J2 Sedan

MT Manual Transmission

MT-29

Installation

1). Front case assembly

① Install oil seal 2 of the input shaft

with spring side upward by using

special tool and hammer. The lip of

the seal should be applied with

grease.

② Install outer shell 2 of right bearing

by using hammer and special tool.

③ Install right oil seal 1 of differential

by using special tool and hammer.

Outer surface of the seal should be

flush with case surface. The lip of

the seal should be applied with

grease.

Note:

■ Spring side of the oil seal should be

inward.

2) Central case

① If the oil deflector 1 is removed,

reinstall and tighten the screw to

specified torque.

■ Tightening torque:：8 - 12 N·m

② Install left oil seal 1 of differential

by using special tool and hammer.

Outer surface of the seal should be

flush with case surface. The lip of

the seal should be applied with

grease.

MT053

MT054

MT055

MT056

Maintenance Manual for J2 Sedan

MT Manual Transmission

MT-30

③Gently tap to install bearing outer ring

2 at the left of the intermediate shaft

with the rubber hammer.

3) Transmission assembly

① Install differential assembly 1 on the

front case.

② Apply oil on the O-ring and gear,

install driven gear assembly of

speedometer and then tighten bolts

to specified torque.

■ Tightening torque:：8 - 12 N·m

Note:

■ During installation of the

speedometer driven gear, turn the

gear gently allowing easily meshing

of the gears.

■ Gap portion of the speedometer housing should never be pressed or knocked,

otherwise the housing may be broken.

MT058

MT059

Maintenance Manual for J2 Sedan

MT Manual Transmission

MT-31

③ Hold input shaft assembly 4, idle

shaft assembly 5, Gear 1/2 shifting

yoke 2 and Gear 3/4 shifting yoke 3

together, install them in the front

case.

Note:

■ Right bearing of the input shaft

should be installed in the front case

by using a rubber hammer.

■ Be sure gears of the main reducer

meshed after installation.

■ The spline portion of the input shaft should be wrapped with PVC tapes to

protect the oil seal from damaged.

④ Install Gear R operating yoke and, tighten the bolts.

■ Tightening torque: 18 - 28 N·m

Note:

■ When the Gear R operating yoke is installed, clearance between end face of the

yoke and shaft bore should be approximately 5mm.

■ Clearance “a”: 5mm

■ With the 5mm of the clearance “a”, clearance between end face of the yoke and

the idler guiding groove of Gear R should be 1mm.

⑤ Install Gear R/5 shifting yoke

assembly 1.

MT060

MT061

Maintenance Manual for J2 Sedan

MT Manual Transmission

MT-32

⑥ Install gear R idler 5 and shaft 1 with

mark A on idler aligning with boss B

on the front case 2.

Note:

■ Be sure to install shim(s) on reverse

gear.

■ Make sure clearance between end

face of the yoke and the idler

guiding groove of Gear R to be

1mm.

⑦ Clean mating faces of front case 2

and central case 1, apply sealant

onto mating face of the central case

and then assemble the both cases.

Sealant: Silicone oil-resistant sealant

（HZ1213Q/320222 YAP02-92）

⑧ Tighten mounting bolts of central case to specification from outside.

■ Tightening torque:：15 - 22 N·m

⑨ Install mounting bolts and aluminum washer of Gear R, tighten the bolts to

specification.

■ Tightening torque:：18 - 28 N·m

⑩. Tighten 3 mounting bolts of central case in the clutch housing space.

■ Tightening torque:：15 - 22 N·m

⑪ Check length of the retaining spring of shifting yoke and replace as required.

Free length of the retaining spring Standard Limit

Spring of gear R/5 shifting yoke (red) 33.8 32.7

High/low range spring (green) 33.6 32.5

MT062

MT063

Maintenance Manual for J2 Sedan

MT Manual Transmission

MT-33

⑫ Install steel ball 4 and spring of the

shifting yoke shaft, tighten bolts.

■ Tightening torque:：10 - 16 N·m

4) 5th gear

① Knock on outer shell of the idle shaft

left bearing 2 by using hammer and

the special tool, push the shell down

to tapered bearing position.

② Put a shim onto outer shell of the bearing, then press a ruler onto shim to

measure clearance “a” (distance between surface of the case and the ruler) with

your hand pushes the ruler.

■ Clearance “a” (Visible height of the shim): 0.08 - 0.12mm

③ Repeat previous step with suitable shims positioned on the outer shell of bearing.

Note: A 0.1mm feeler may be helpful to determine the proper shim thickness.

Thickness of available

bearing shim

0.40, 0.45, 0.50, 0.55, 0.60, 0.65, 0.70, 0.75, 0.80, 0.85,

0.90, 0.95, 1.00, 1.05, 1.10, 1.15

④ Install bearing cap with its ends

pushed into groove 4 on the Gear

R/5 shifting shaft. Apply locking

compound onto threads of the screw

and then tighten.

Note:

■ Turn the idle shaft after screws

tightened. The shaft should be turned

freely with a little effort.

■ Thread locking compound:

Anaerobic Adhesive 262

MT064

MT065

MT066

Maintenance Manual for J2 Sedan

MT Manual Transmission

MT-34

■ Tightening torque:：8 - 12 N·m

⑤ Install outer gear ring, coupling spline, slider and snap ring of Gear 5.

Note:

■ As shown in the figure, the narrow side C, long boss D of the spline and bottom

angle F (on 5th gear side) of outer gear ring should be installed inward.

⑥ Install 5th driven gear onto idle shaft

with A side inward, as shown in the

figure.

⑦ Install the oil coated needle bearing

onto input shaft, and then install the

5th driving gear.

MT067

Width side

arrow side C

C: Narrow side C (inward)

D: Long boss D (inward)

E: Position of the slider

F: Bottom angle (inward)

Clutch side

Maintenance Manual for J2 Sedan

MT Manual Transmission

MT-35

⑧ Tighten locking nut of the 5th gear

to specified torque and then chip the

nut with a punch to lock. If the nut

cracks ,replace.

■ Tightening torque of the nut: 60 -

80N·m

⑨ Install Gear 5 synchronizer ring 1.

⑩ Install Gear 5 synchronizer assembly

and shifting yoke. Install coupling

spline on the input with oil hole on

the shaft align with oil deflector on

the spline.

MT068

MT069

MT070

Maintenance Manual for J2 Sedan

MT Manual Transmission

MT-36

⑪ Knock in the pin with split end

outward.

⑫ Install steel balls, apply Anaerobic

Adhesive 262 onto threads of Gear 5

shifting yoke’s mounting bolt and

then tighten the bolts.

■ Tightening torque: 8 - 12N·m

⑬ Install thrust plate 1 and snap ring 2.

⑭ Install snap ring onto end portion of

the guiding rod of Gear R/5 .

⑮ Clean mating faces of central case 1

and rear case 2, apply sealant on

mating face of central case. After oil

delivery tube plugged into holes on

the input shaft, tighten 8 bolts.

■ Sealant: Silicone oil-resistant sealant

（HZ1213Q/320222 YAP02-92）

■ Tightening torque: 8 - 12N·m

5) Gear shifting control assembly

① During reassembly of the pilot case,

the bolts should be tightened to

specified torque and the vent tube 1

should be checked ensuring clear.

■ Tightening torque: 8 - 12N·m

② Clean mating face of pilot case and

central case.

③ Install gear shifting control assembly.

Note:

■ To install gear shifting control assembly, shift arm of each gear must be in

neutral position.

MT072

MT073

MT071

Maintenance Manual for J2 Sedan

MT Manual Transmission

MT-37

④ Install gear retaining screw 1. Apply

thread locking compound onto

threads, install the washer and then

tighten the bolts.

■ Thread locking compound:

Anaerobic Adhesive 262

■ Tightening torque: 18 - 28N·m

⑤ Clean mating face of pilot case in central case and apply sealant envenly.

■ Sealant: Silicone oil-resistant sealant （HZ1213Q/320222 YAP 02-92）

⑥ Install gear shifting control assembly

2 and the clip. Tighten 4 bolts to

specified torque.

■ Tightening torque: 8 - 12N·m

⑦ Install reversing lamp switch assembly.

■ Tightening torque: 18 - 28N·m

6) Release arm assembly of the clutch

Release arm assembly of the clutch

MT074

MT075

B directional

view

Assembly

symbol

Maintenance Manual for J2 Sedan

MT Manual Transmission

MT-38

1- Bush 1; 2- Release arm assembly; 3- Returning spring; 4- Bush 2; 5- Bolt; 6- nut;

7- Clip; 8- Clutch lever

Removal:

① Remove the clip, release the bolts, and then take off the clutch lever.

② Turn the release arm 1, allowing

release bearing to be removed.

③ Remove the returning spring from

the hook with a pair of plier.

④ Knock on the bush 2 to displace it by

using hammer and the special tool.

⑤ Take off release shaft and returning

spring.

⑥ Remove bush by using special tool.

Inspection:

Release bearing:

Check for free revolving of the release

bearing.

Note:

■ Don't clean the bearing or the grease

may be flushed resulting in damage.

MT076

MT077

MT078

Maintenance Manual for J2 Sedan

MT Manual Transmission

MT-39

Clutch axis:

Check for distortion and damage of the

axis and the spring pin, replace as

required.

Installation:

① Knock the bush 1 onto the shaft after

applying some grease into the it.

② Install release bearing and returning

spring.

③ Apply some grease in the bore of

bush 2 and then press it onto shaft by

using special tool.

④ Apply grease on oil seal of the

release shaft, then install in onto the

shaft with the lid on seal downward.

The outer surface should be flush

with case face after installation.

⑤ Punch 3 pits at Position A with a

hammer and special tools.

MT079

MT080

MT081

MT082

Maintenance Manual for J2 Sedan

MT Manual Transmission

MT-40

⑥ Install the returning spring.

⑦ Apply a film of grease on inner

surface of the release bearing 1 and

the release arm 2, then install the

release bearing.

⑧ Apply a little grease on spline and

end face of the primary shaft.

⑨ Align marks (A) on clutch lever 2

and axis, tighten the bolts and then

install the clip.

MT084

MT083

Maintenance Manual for J2 Sedan

MT Manual Transmission

MT-41

Troubleshooting

Diagnose of common failures

Conditions Possible Cause Action

Disturbed

meshing

z Worn yoke shaft;

z Worn shifting yoke and outer

shell of the synchronizer

z Soft or damaged retaining spring

z Worn bearing of input and/or

output shaft

z Worn tooth or spline or gear

Replace

Replace the spline and gear

Difficult

shifting

z Short of oil

z Incorrect free travel of the clutch

pedal

z Worn or broken clutch driven

plate

z Damaged pressure plate of the

clutch

z Worn synchronizer

z Worn tooth or spline or gear

Top up

Adjustment

Replace

Replace clutch cover

assembly

Replace

Replace the spline and gear

Noise

z Short of oil

z Worn or damaged bearing

z Worn or damaged gear

z Worn or damage synchronizer

Top up

Replace

Maintenance Manual for J2 Sedan

MT Manual Transmission

MT-42

Data and Specification of Maintenance

List of Specified Tightening Torque

Position Torque (N·m)

Oil Draining Screw 18—23

Shifting shaft mounting bolts 32—36

Shifting arm mounting bolts 31.5—35.5

Speedometer housing mounting bolts 8—12

Shifting shaft limiting bolts 10—16

Gear R yoke mounting bolts 18—28

Central case attaching bolts 15—20

Pilot case mounting bolts (4) 8—12

Gear retaining screw 18—28

Locating screw of yoke shaft (3) 10—16

Front mounting bolts of Central case(14) 15—22

Central case cover mounting bolts (3) 8—12

Rear bracket mounting bolts 18—28

Bearing stop mounting screw (5) 8—12

Locking nut of idle shaft 60—80

Rear case mounting bolts (8) 8—12

Filler cap 18—23

Gear R idler shaft mounting bolt 18—28

Central case baffle mounting bolts (3) 8—12

Screw of Gear 5 shifting yoke 8—12

Oil channel mounting bolts 8—12

Clutch lever mounting bolts 10—16

Mounting bolts (nuts) of the transmission

assembly

50—55

Maintenance Manual for J2 Sedan

MT Manual Transmission

MT-43

Gear Ratio

Transmission: DABS10-8B

Type Mechanical, Gear Meshing Type

Gears Ratio Teeth

Gear 1 3.416 41/12

Gear 2 1.894 36/19

Gear 3 1.28 32/25

Gear 4 0.914 32/35

Gear 5 0.757 25/33

Gear R 3.818 42/35/11

Main Reducer Gear 4.388 79/18

Speedometer 0.944 17/18

Max Torque Input 88 N·m

Overall Dim. 400×392×342.7 (mm)

Inclination of

Transmission

5°

Oil Artificial oil #18 for hyperbolic gear (Q/SH006·1·27-89)

Ratio of Differential 68:16

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-1

AMT transmission

Transmission machinery

Precautions:

 Don’t reuse the gear oil discharged from transmission.

 Vehicle shall be kept horizontal in checking and replacing transmission gear oil.

 Before carrying out any maintenance to AMT, it must be cleaned up with a

wiping cloth and it is not allowed to be cleaned with any liquid.

 Before removal and disassembly, check and make sure the correct installation

position. If any mounting mark is needed, it shall be ensured that the mark will

not affect the function of the labeled component.

 By rule, it shall be successively screwed up with bolt and nut from middle to

exterior position in cornerwise sequence. If there are requirements for the

tightening up sequence, those requirements shall prevail.

 Don’t damage the sliding surface and matching surface.

 In the process of replacing parts, the part shall be strictly prevented from being

polluted by any pollutant.

 Before carrying out any maintenance on AMT, the pressure in energy storage

tank must be released by diagnostic unit.

 The mark on oil can is the lowest oil level position.

 When pressure exists on energy storage tank, the oil level must be close to the

lowest liquid level mark.

Preparation work

See the list below for the special tools used in this equipment:

No. Tool Number Outline drawing Description

Shaft bearing

replacer

JAC-T1B001

Used for mounting and removing (input

shaft) bearing, bearing and sleeve barrel

Shaft bearing

replacer

JAC-T1B002

Used for mounting and removing

(output shaft) bearing, bearing and

sleeve barrel

Spring pin

remover

JAC-T1B003

Used for removing shifting-fork spring

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-2

No. Tool Number Outline drawing Description

Bearing

remover

JAC-T1B004

Used for removing the bearing race and

cylindrical roller shaft at the clutch

housing

5 Erector cover JAC-T1B005

In coordination with erector and

erection joint, it’s used for mounting

input/output shaft bearing and on the

transmission etc.

6 Erector JAC-T1B006

In coordination with erection joint and

erecting tools cover, it’s used for

mounting input/output shaft bearing and

on the transmission etc.

7 Erector JAC-T1B007

In coordination with erection joint and

erecting tools cover, it’s used for

mounting input/output shaft bearing and

on the transmission etc

8 Erection joint JAC-T1B008

In coordination with erector, it’s used

for mounting ball bearing on the input

shaft of transmission

9 Erection joint JAC-T1B009

In coordination with erector, it’s used

for mounting back bearing on the

output shaft of transmission

10 Erection joint JAC-T1B010

In coordination with erector, it’s used

for mounting ball bearing on the input

shaft of transmission and erecting roller

bearing inner race, ball bearing, R-gear

and R-gear bearing housing on the

output shaft of transmission

11 Erection joint JAC-T1B011

In coordination with erector, it’s used

for mounting 4-gear wheel, 5-gear slide

sleeve and 5/R-gear synchro hub of

5-gear on the output shaft of

transmission

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-3

No. Tool Number Outline drawing Description

12 Erection joint JAC-T1B012

In coordination with erector, it’s used

for mounting the gear wheels of 2-gear

and 3-gear and 1-gear slide sleeve on

the output shaft of transmission

13 Erection joint JAC-T1B013

In coordination with erector, it’s used

for mounting the inner race of

differential gear conical roller and

tapered roller bearing of differential

gear

14 Erection joint JAC-T1B014

In coordination with erector, it’s used

for mounting 4-gear slide sleeve and

5-gear wheel on the input shaft of

transmission

15 Erection joint JAC-T1B015

In coordination with erector, it’s used

for mounting 1-gear slide sleeve and

1/2-gear synchro hub on the output

shaft of transmission

16 Handle JAC-T1B016

In coordination with related erector, it’s

used for mounting bearing

17 Erection joint JAC-T1B017

In coordination with erecting handle,

it’s used for mounting the lower cover

packing collar of transmission

18 Erection joint JAC-T1B018

In coordination with erecting handle,

it’s used for mounting the outer race of

cylindrical roller bearing on clutch

housing

Installation

tool of

differential

gear oil seal

JAC-T1B019

Used for mounting oil seal at the

position of differential gear on the

housing of transmission

20 Erection joint JAC-T1B020

In coordination with erecting handle,

it’s used for mounting the outer race of

conical bearing on clutch housing

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-4

No. Tool Number Outline drawing Description

Installation

tool of

differential

gear oil seal

JAC-T1B021

Used for mounting oil seal at the

position of differential gear on the

housing of transmission

The second

shaft pad of

transmission

JAC-T1B022

Transmission assembly

Components:

Section drawing of transmission

1- input shaft 2- 5-gear synchro assembly 3- 5-gear driving gear 4- 4-gear

driving gear 5- assembly of high speed synchronizer 6- 3-gear driving gear 7-

center casing shell 8- reverse intermediate gear shaft 9- reverse intermediate gear

10-front casing shell 11- intermediate shaft 12- rear casing shell 13- 5-gear driven

gear 14- driven gear of gear 4 15- 3-gear driven gear 16- 2-gear driven gear

17- assembly of low speed synchronizer 18- 1-geardriven gear 19- driven gear of

main retarder 20-differential housing 21- driven gear of autometer

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-5

Decomposition drawing of the transmission system

1-oil seal 2-right bearing of input shaft 3-input shaft 4-3/4-gear needle roller

bearing 5- 3-gear driving gear 6- high speed synchronizer ring 7-elastic ring

8-high speed spring clamp ring 9-high speed reducing sleeve gear 10-high speed

slider 11-high speed external gear ring 12-closing ring 13- 4-gear driving gear

14-left bearing of input shaft 15- 5-gear liner bushing 16- 5-gear driving gear

17- 5-gear synchronizer ring 18- 5-gear spring clamp ring 19- 5-gear reducing

sleeve gear 20- 5-gear slider of gear 5 21- 5-gear external gear ring 22-thrust

collar 23-lock nut of input shaft 24-right bearing of intermediate shaft 25-

intermediate shaft 26-1/2-gear needle roller bearing 27- 1-geardriven gear 28-

1-gear synchronizer ring 29-low speed reducing sleeve gear

30-presynchronization bundle 31-low speed external gear ring 32-elestic collar

33-1/2-gear needle roller bearing 34- 2-gear synchronizer ring 35- 2-gear driven

gear 36- 3-gear driven gear 37- 3/4-gear distance sleeve 38- 4-gear driven gear

39-left bearing of intermediate shaft 40-bearing shim 41- 5-gear driven gear

42-5-gear wheel lock nut 43- reverse intermediate gear 44-packing collar 45-

shaft of reverse intermediate gear 46-pad 47-bolt of reverse intermediate shaft

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-6

System drawing on operating gear for selecting and shifting gear

1-reverse shifting fork assembly 2-R-gear control fork 3-R/5-gear guiding axle

4- R/5-gear shift fork shaft 5- 3/4-gear shift fork shaft 6- 1/2-gear shift fork shaft

7-gear-shift selecting handle 8-transfer point 9-gear shift stylus 10- R/5-gear

mutual interlocking gear 11- gear position bolt 12- gear-shift selecting shaft

Gear shift

Reverse

Gear select

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-7

Dismounting:

Dismounting sequence shall be in accordance with the number order or refer to that of

hand operated transmission. The following shows the dismounting methods for

special components:

1) Speed selector

① Open the plastic cover, rotate gear

select operating rod for 90°with a

slotted screwdriver and then remove

the fixed bolt (three pieces) of gear

select/shift actuator.

② Take off the clutch lacing wire from

the separated branch arm.

③ Remove the fixed actuator 1 (three

pieces) from clutch actuator, so as

to dismount speed selector 2 from

the transmission.

AMT003

AMT001

AMT002

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-8

2) Gear shift operating gear, input

shaft and intermediate shaft

① Dismount the five bolts on the fixed

transfer point 3 with an inner

hexagon spanner of 6mm in length.

② Dismount the gear position bolt.

③ Pull out the gear shifting operating

gear along the axle direction.

④ Remove the switch assembly of

backup lamp.

AMT007

AMT006

AMT005

AMT004

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-9

⑤ When gear is in the neutral gear,

take out the gear shift operating

gear assembly.

⑥ Disassemble the bolt and packing

collar on reversing shaft.

⑦ Dismount the 11 center casing bolts

from shell and other 3 center casing

bolts from the front case clutch

housing.

⑧ Separate center casing from front

casing by inserting a screwdriver

into the gaping between the two

cases to pry them up and put

another screwdriver on the opposite

of the casing shell.

Notice:

■ Don’t plug the tool into the joint

face of two case shells; otherwise

the joint face would be damaged.

⑨ Separate and pickup the center

casing shell (assembly) from the

front casing shell, leaving all the

internal parts (e.g. input shaft,

output shaft and differential gear,

etc.) on the front casing shell

(assembly).

⑩ Dismount two reverse shifting fork

bolts 4 and take off the reverse

shifting fork assembly.

⑪ Take off reverse gear shaft and

packing collar and remove the

reverse intermediate gear 3.

⑫ Take off the R/5-gear shift fork

assembly 1.

Notice:

AMT011

AMT010

AMT009

AMT008

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-10

■ It’s helpful for removal of the R/5-gear shift fork assembly to engage the

3/4-gear shifting fork shaft into 4-gear.

⑬ Slightly tap one end of a shaft with

rubber mallet to pull out input shaft

5 to a little extent; hold the input

shaft assembly, intermediate shaft

assembly 4, 1/2-gear shift shaft

assembly 2 and 3/4-gear shift shaft

assembly 3 to take them off all

together.

⑭ Remove the second cone bearing

outer ring from the center casing.

⑮ Remove the differential oil seal from the center casing.

3) Gear shift actuator assembly

System diagram of gear shift actuator

1-gear shift stylus 2- closing ring of gear shift stylus 3- closing piece of gear shift

stylus 4-spring pin 5-gear-shifting selector shaft 6-oil seal 7-transfer point

8-reverse/5-gear return spring 9-interlock 10-gear-shift selecting handle 11-spring

pin 12-low speed return spring 13-R-gear locking piece

① Dismount four pins and four E- rings from the gear shift actuator with a special

tool (spring pin detacher), then dismount modules from shaft.

② Completely clean up and check all parts. If necessary, replace it.

③ The mounting sequence is in reversal of that of the removal order.

AMT012

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-11

Notice:

■ When tapping spring pin, it shall be supported with a wood block to prevent gear

shift and select shaft from being bent.

■ Between the two return springs, the free length and diameter of reverse/5-gear

are larger than that of the low speed spring.

■ The mounting directions of gear shift select handle, R/5-gear shift cam and

spring seat are in accordance with that shown in the diagram.

4) Clutch release arm system

Diagram on the clutch release arm system

1-liner busing 1 2-release arm assembly 3-release spring 4-liner bushing 2 5-bolt

6-nut 7-clutch arms 8-elastic collar

Disassembly:

① Take off clamp, loose the bolt and

dismount the clutch arms.

② Rotate the release arm to take off

release bearing.

③ Hook off the release shaft return

spring with a pincer.

AMT013

Rotate in direction B

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-12

④ Tap off the bushing with hammer

and special tools.

⑤ Take off release shaft and return

spring.

⑥ Dismount bushing 1 with special

tools.

Testing:

Release bearing:

Notice

■ Don’t clean the bearing, otherwise

there may be oil leakage and

bearing damage.

Clutch release shaft:

Check whether clutch release shaft and

spring pin are oblique or damaged; if

any, replace it.

Installation:

① Punch liner bushing 1 in with

special tool and apply grease to the

inside of bushing.

② Mount release shaft and return

spring.

AMT017

AMT016

AMT015

AMT014

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-13

③ Apply grease to the inside of liner

bushing 2 and press liner bushing 2

with special tool to mount it.

④ Apply grease to the oil seal of

release shaft, mount oil seal with a

special tool to keep its lip down

(inward) and the outside surface of

oil seal even with the casing shell.

⑤ Punch 3 craterlets at position A with

hammer and special tool.

⑥ Hook on return spring.

⑦ Apply grease to the inside of release

bearing 2 and release arm 2, then

mount the release bearing.

⑧ Apply a spot of grease to the spline

and end face of input shaft 3.

Apply grease at position A and B

⑨ Line up the punching A of clutch

arms 2 and release shaft, then screw

up bolt 1 and fit over elastic collar

AMT021

AMT020

AMT019

AMT018

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-14

Hydraulic system

Precautions

■ Before any maintenance, it must be cleaned up with a wiping cloth and it is not

allowed to be cleaned with any liquid.

■ In the process of replacing parts, the part shall be strictly prevented from being

polluted by any pollutant.

■ Before carrying out any maintenance, the pressure in energy storage tank must be

released by diagnostic unit.

■ The mark on oil can is the lowest oil level position.

■ When pressure exists in energy storage tank, the oil level must be near to the

lowest liquid level mark.

System instruction

1. Structural representation

Structural representation of hydraulic screen

2. Composition

It is composed of two essential parts: fluid power unit (hydraulic oil pump, oil can)

and valve body assembly (valve body subassembly, solenoid valve and clutch

actuator).

Gear select

position sensor

Gear select solenoid

valve (EV4)

Gear select solenoid

valve (EV3)

Hydraulic oil

pump

Oil can

High-

ressure

fuel pipe

Clutch actuator

Clutch position

sensor

Gear shift

position sensor

Valve body

subassembly

Gear shift solenoid

valve (EV2)

Gear shift solenoid

valve (EV1)

Energy

accumulator

Clutch solenoid

valve(EV0)

Wiring harness

assembly

Low-pressure

fuel pipe

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-15

3. Working principle of hydraulic system

Name Function

Clutch solenoid valve(EV0) Drive the clutch actuator to work

Gear shift solenoid valve 1(EV1) Control 1/3/5-gear shift

Gear shift solenoid valve

2(EV2)

Control 2/4/R-gear shift

Gear select solenoid valve

1(EV3)

Control the stroke of 1/2-gear

Gear select solenoid valve

2(EV4)

Control the stroke of 5/R-gear

Oil pressure sensor (OPS) Test system pressure

Gear select position sensor

(SPS)

Decide shifting position

Gear shift position sensor (GPS) Decide selecting position

Clutch position sensor (CPS)

Decide the wiredrawing stroke of

clutch actuator

Clutch speed sensor Decide to close clutch or declutch

Energy accumulator (PDA)

Provide the system with pressure to

keep it stable and continuous

Hydraulic oil pump (OEP) Provide system oil pressure

Hydraulic oil can (OTK) Store hydraulic oil

Non return valve (NRV)

Diagram on the working principle of hydraulic system

Working principle:

(1) Set up system oil pressure: TCU is used to timely collect signal of pressure

sensor. When system pressure is lower than 40Bar, it can start oil pump to suck

out hydraulic oil from oil can and add some pressure to open the non return valve,

and then hydraulic oil will be transmitted to energy accumulator for storage to

maintain a certain system pressure. When system pressure is higher than 50 bars,

the oil pump will be turned off. Thus the system pressure is set up.

(2) Gear shift: TCU can work out the current gear position according to vehicle

operating conditions (speed of vehicle and speed of engine) and driver’s intent

(accelerator, gear shift handle and brake pedal), control clutch solenoid valve and

gear select & shift solenoid valve and drive clutch actuator and selecting &

shifting action element to put transmission into corresponding gear position.

(3) In the process of gear shift, clutch position sensor can timely monitor the

position of clutch actuator; TCU will collect that signal and control the clutch

actuator in combination with the transmission ratio of engine and clutch to

ensure a comfort gear shift. Selecting & gear shift position sensor are used for

monitoring gear select and shift action element to ensure the reliability of gear

shift.

(4) When system oil pressure is lower than 40 bar, TCU will start oil pump to set up

oil pressure again.

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-16

Fluid power unit

1. Maintenance parameters

■ Working pressure: 36.5～46bar

■ Working temperature:-30 ℃～+125 ℃

■ Pump flow: higher than 0.81 L/min (60 ) ℃

■ Capacity of energy storage tank: 250cm3 (24bar, 20 ) ℃

■ volume of oil tank: 0.5L

■ Nominal particulates diameter of outlet filter: 150μm

2. Hydraulic oil pump

Hydraulic oil pump

(1) Maintenance parameters

■ Nominal flow capacity: 0.8l/min Voltage: 13V

■ Liquid temperature: 60 ℃ Pressure: 50bar

■ Cycle of operation: 30% Gear pump: 0.25cm3/r

■ Working pressure of motor: start motor when the pressure of energy accumulator

is lower than 36.5bar and turn it off when the pressure reaches 46bar.

(2) Removal and installation

1) Removal

① Discharge all the oil in oil can.

AMT022

Joint of motor

Gear pump

Motor

Bracket

mounting point

Input of

hydraulic oil

Clutch of motor

Output of

high-pressure

hydraulic oil

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-17

② Remove the oil can.

③ Disconnect the wiring harness joint

of oil pump.

④ Screw down the Joint screw for high

pressure pipe

Notice:

■ Partial oil may flow out from the oil

pump and high-pressure pipe.

■ Tightening torque: 14～15N·m

⑤ Screw down the three fixed screws

on oil pump in order.

■ Tightening torque: 10～11N·m

⑥ Shift oil pump to the left to

disconnection its connection with

high-pressure pipe.

AMT026

AMT024

AMT023

AMT025

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-18

2) Installation

① Mount it in reverse of the removal sequence.

② Add oil of FL CS Speed type into oil can and check the oil level, which shall be

14～17 mm higher than the marked lowest oil level.

③ Calibrate the Kiss point with diagnostic unit.

④ Carry out self-learning with diagnostic unit.

⑤ After that, make sure the oil level is near to the lowest oil level after

self-learning.

3. Oil can

① Removal and installation

1) Removal

① Discharge all the oil in oil can.

② Cut off the lathe dog at the joint of

oil tank and then plug out the

low-pressure oil pipe.

③ Unscrew the two fixed screws on oil

can and take off the oil can.

Notice:

■ Take off the packing collar blocked

at the outlet of oil pump.

■ Tightening torque: 10～11N•m.

AMT029

AMT028

AMT027

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-19

2) Installation

① Mount it in reverse of the removal

sequence

Notice:

■ Keep the packing collar surface from

being damaged.

② Add oil into oil can and check the oil level

③ Calibrate the Kiss point with diagnostic unit.

④ Carry out self-learning with diagnostic unit.

⑤ After that, make sure the oil level is near to the lowest oil level after

self-learning.

AMT031

AMT030

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-20

Valve body assembly

EV0—a valve to control the flow ratio of clutch actuator EV2—a valve to control the

pressure ratio of even numbered gear shift

EV3—a switch valve to control the stroke of 1/2-gear EV4—a switch valve to

control the stroke of 5/R-gear

1. Removal and installation

(1) Oil pressure sensor

1) Removal

① Disconnect the connecting wiring

harness from oil pressure sensor.

AMT032

Gear select

position

sensor

Gear shift

position

sensor

Gear select

solenoid valve

(EV3)

Gear select

solenoid valve

(EV4)

Gear shift

solenoid valve

(EV2)

Clutch solenoid

valve (EV0)

Gear shift

solenoid valve

(EV1)

Energy

accumulator

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-21

② Unscrew the oil pressure sensor with

14# spanner.

③ Check if there is any damage on the

outer surface of packing collar on

the oil pressure sensor.

2) Installation

① Mount it in reverse of the removal sequence. Tightening torque: 15～16.5N•m.

② Check the oil level.

③ Calibrate the Kiss point with diagnostic unit.

④ Carry out self-learning with diagnostic unit.

⑤ After that, make sure the oil level is near to the lowest oil level after

self-learning.

(2) Energy accumulator

1) Removal

① Unscrew the energy accumulator.

AMT035

AMT034

AMT033

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-22

② Check if there is any damage on the

outer surface of packing collar on

the energy accumulator.

2) Installation

① Mount it in reverse of the removal sequence. Tightening torque: 90～99N•m.

② Check the oil level.

③ Calibrate the Kiss point with diagnostic unit.

④ Carry out self-learning with diagnostic unit.

⑤ After that, make sure the oil level is near to the lowest oil level after

self-learning.

(3) Gear shift position sensor

1) Removal

① Disconnect the connecting wiring

harness (A) of shift position sensor.

② Loosen two screws (B) and remove

the gear shift position sensor(C).

2) Installation

① Align the surface of red mark on the

deplanate shaft (D) with the red

surface of gear shift position sensor.

AMT038

AMT037

AMT036

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-23

② After that, fit on the shift position

sensor, then rotate the sensor along

deplanate shaft (D) in clockwise, till

collimate the position of mounting

hole.

③ Tighten the sensor with two screws.

■ Tightening torque: 3.6～4.2 N•m.

Connect the wiring harne④ ss connector

(4) Clutch position sensor

1) Removal

① Disconnect the connecting wiring

harness (A) of clutch position

sensor;

② Loosen the two screws (B) and take

off the clutch position sensor (C);

2) Installation

① Check whether the packing collar of

clutch position sensor is located in

the sensor seat.

AMT042

AMT041

AMT040

AMT039

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-24

② Align the surface of red mark on

deplanate shaft (D) with the red

surface of clutch position sensor.

③ After that, fit on the clutch position

sensor, then rotate the sensor along

with deplanate shaft (D) in

clockwise, till collimate the position

of mounting hole.

④ Tighten the sensor with two screws.

■ Tightening torque: 3.6～4.2 N•m.

⑤ Connect the wiring harness

connector

(1) Low-pressure oil pipe

1) Removal

① Cut off the lathe dog at the joint of

valve body oil pipe and then pluck

off the low-pressure oil pipe.

AMT046

AMT045

AMT044

AMT043

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-25

② Cut off the lathe dog at the joint of

oil tank and then plug out the

low-pressure oil pipe.

2) Installation

① Mount it in reverse of the removal sequence and clamp the clip with special

calipers.

② Check the oil level; if necessary, add oil of FL CS Speed type into oil can and

check the oil level, which shall be 14～17 mm higher than the marked lowest oil

level.

③ Calibrate the Kiss point with diagnostic unit (refer to section OX30 in the AMT

maintenance manual).

④ Carry out self-learning with diagnostic unit.

⑤ After that, make sure the oil level is near to the lowest oil level after

self-learning.

(6) High pressure pipe of oil pump

1) Removal

Unscrew the screw on the clamp of ①

high-pressure double pipe and take

off the clamp.

■ Tightening torque: 10～11N•m.

② Unscrew the screw on the joint of

high-pressure pipe from the valve

body with a 13# spanner.

■ Tightening torque: 14～15N·m

Notice:

■ Partial oil may flow out from the

valve body and high-pressure pipe.

AMT049

AMT048

AMT047

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-26

③ Unscrew the screw on the joint of

high-pressure pipe from the oil

pump with a 13# spanner.

■ Tightening torque: 14～15N•m.

Notice:

■ Partial oil may flow out from the oil

pump and high-pressure pipe.

④ Take off the high-pressure pipe of oil

pump.

2) Installation

① Mount it in reverse of the removal sequence.

② Calibrate the Kiss point with diagnostic unit.

③ Carry out self-learning with diagnostic unit.

④ After that, make sure the oil level is near to the lowest oil level after

self-learning.

(7) High-pressure pipe of clutch

1) Removal

① Unscrew the screw fitted on the

clamp of high-pressure double pipes

and take off the clamp from the

double pipes.

■ Tightening torque:10～11N•m.

② Loosen the lathe dog on the

high-pressure pipe of clutch.

AMT052

AMT051

AMT050

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-27

③ Pull down the joint of master wiring

harness.

④ Unscrew the two screws from the

supporting plate of wiring harness.

■ Tightening torque: 3.6～4.2N•m

⑤ Unscrew the screw on the joint of

high-pressure pipe from the valve

body with a 13# spanner.

Notice:

■ Partial oil may flow out from the

valve body and high-pressure pipe.

■ Tightening torque: 14～15N•m.

⑥ Unscrew the screw on the joint of

high-pressure pipe from clutch with

a 13# spanner.

Notice:

■ Partial oil may flow out from the

clutch and high-pressure pipe.

■ Tightening torque: 14～15N•m.

⑦ Take off the high-pressure pipe of clutch.

AMT056

AMT055

AMT054

AMT053

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-28

2) Installation

① Mount it in reverse of the removal sequence.

② Check the oil level.

③ Calibrate the Kiss point with diagnostic unit.

④ Carry out self-learning with diagnostic unit.

⑤ Make sure the oil level is near to the lowest oil level after self-learning.

(8) Wiring harness

1) Removal

① Remove all the wiring harness

joints.

② Unfasten the tape fixed on wiring

harness and take out the wring

harness.

③ Pull out the large joint of Wiring

harness

2) Installation

① Plug in all the joints in accordance with the corresponding position number.

② Reclamp the wring harness fixed clip and well fix the 24-needle wiring harness

large joint.

AMT059

AMT058

AMT057

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-29

③ Check the oil level.

④ Calibrate the Kiss point with diagnostic unit.

⑤ Carry out self-learning with diagnostic unit.

⑥ Make sure the oil level is near to the lowest oil level after self-learning.

(9) Clutch controller assembly

1) Removal

① Pour out all the oil from oil can as

much as possible.

② Disconnect the joint of clutch

position sensor.

③ Unscrew the three fixed screws from

oil pump in order.

■ Tightening torque: 10～11N•m

AMT062

AMT061

AMT060

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-30

④ Unscrew the screw on the joint of

high-pressure pipe from the clutch

with a 13# spanner.

Notice:

■ Partial oil may flow out from the

clutch body and high-pressure pipe.

■ Tightening torque: 14～15N•m

⑤ Take off the clutch controller

assembly.

2) Installation

① Mount it in reverse of the removal sequence.

② Check the oil level.

③ Calibrate the Kiss point with diagnostic unit.

④ Carry out self-learning with diagnostic unit

⑤ Make sure the oil level is near to the lowest oil level after self-learning.

AMT064

AMT063

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-31

Air exhaust of hydraulic oil duct

This operation is required in case of the following status:

1. Refilling oil after replacing hydraulic system assembly

2. After maintaining the hydraulic screen and replacing hydraulic elements

(solenoid valve, hydraulic oil pump, pressure sensor and oil pipe, etc.).

3. The clutch will be switched on/off through the clutch mechanism, so as to

exhaust the potential air existing in hydraulic oil duct, caused by replacing the

above elements.

Operational procedures for air exhaust of hydraulic oil duct are as follows:

Operational procedures

1. Swith the key to position of “Key ON”(do not start the engine);

2. Connect the diagnostic unit, enter into J2 AMT transmission system and select

“Offline functional testing” to enter into the “air exhaust of hydraulic oil duct”

and then operate it as per requirement of diagnostic unit;

3. After “Finish” displays in the diagnostic unit, switch off ignition key to position

“Key off” and keep it still for ten seconds to ensure it is completely powered

down;

4. Repeat the above procedures for three to five times.

Precautions:

■ This process for powering down may be kept on for about ten seconds.

■ It can be judged by whether the working noise of clutch solenoid valve or

hydraulic oil pump is heard or whether there is any change being observed to the

RLI 32 “position of clutch actuator” by the diagnostic unit, to confirm the

execution of air exhaust.

All the following conditions must be met in the execution of this program:

■ The engine is not started.

■ Brake pedal is depressed.

■ Clutch position sensor is in normal status.

■ Clutch actuator is in normal status.

■ If any one of the above conditions is not met, a fault code would appear when the

debugging program is finished.

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-32

Pressure relief for energy accumulator

This operation is required in case of the following status:

1. When maintaining hydraulic system, this operation must be done before

replacing hydraulic elements (solenoid valve, hydraulic oil pump, pressure

sensor and oil pipe, etc.).

2. This operation is targeted to relief pressure from the system and make hydraulic

oil flow back to oil can before replacing any of the above elements, so as to

avoid human being hurt by the spilled-out hydraulic oil.

Operational procedures for releasing pressure from energy accumulator are as

follows:

Operational procedures

1. Swith the key to position of “Key ON”(do not start the engine);

2. Connect the diagnostic unit, enter into J2 AMT transmission system and select

“Offline functional testing” to enter into the “Pressure relief for energy

accumulator” and then operate it as per requirement of diagnostic unit;

3. Depress brake pedal till “Finish” displays on diagnostic unit, namely, this

pressure releasing operation is finished.

Precautions:

■ It can be judged by whether the working noise of clutch solenoid valve or

hydraulic oil pump is heard or whether there is any change being observed to the

RLI 32 “position of clutch actuator” in the diagnostic unit, to confirm the

execution of pressure relief.

■ Examine RLI 35 with diagnostic unit, to ensure that the oil pressure in hydraulic

oil duct has been decreased to the pre-charged pressure of energy accumulator,

2~3Bar.

This program must be operated when all the following conditions are met:

■ The engine is not started.

■ Brake pedal is depressed.

■ Clutch position sensor is in normal status.

■ Clutch actuator is in normal status.

■ If any of the above conditions is not met, a fault code would appear when the

program is finished.

■ Self-learning of clutch meshing point

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-33

This operation is required in case of the following status:

1. After the whole vehicle is offline;

2. After replacing TCU;

3. After maintenance or replacing of transmission;

4. After maintenance or replacing of hydraulic actuator;

5. After replacing of clutch;

6. This operation is targeted to work out the meshing point of clutch in working,

namely the position where clutch initially starts transferring engine torque.

Operational procedures for self-learning of clutch are as follows:

Operational procedures

1. Swith the key to position of “Key ON”(do not start the engine);

2. Connect the diagnostic unit, enter into J2 AMT transmission system and select

“Offline functional testing” to enter into the “set up the meshing point for clutch”

and then operate it as per requirement of diagnostic unit;

3. After “Finish “displays in the diagnostic unit, switch off ignition key to position

“Key off” and keep it still for ten seconds to ensure it is completely powered

down;

4. Repeat the above procedures for three to five times.

Precautions:

■ This process for powering down may be kept on for about ten seconds.

■ This program shall be done under the condition that engine is not started and in

neutral gear and the key is switched to position “Key on”. Then start the engine.

■ If only the transmission is in neutral gear, debugging can be done after starting

the engine. If not, this program will not be done until transmission is in neutral

gear.

■ TCU must have finished five working cycles before switching the key to position

“Key off”.

■ The five working cycles are automatically operated after sending an instruction.

All the following conditions must be met in the execution of this program:

■ Gear is not shifted.

■ In neutral gear.

■ Engine is in operation.

■ This program will not be on-hook and waiting if any of the above conditions is

not met, the program will be operated until all the above conditions are met.

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-34

■ When running this program, the following conditions will be tested continuously.

■ In neutral gear.

■ Clutch position sensor is in good condition.

■ Actuator is in good condition.

■ The power supply for sensor/actuator/TCU is in normal status.

■ If any of the above conditions is not met, the debugging program will quit, which

means the debugging is failed.

■ After this program is put into running, it will not available to be interrupted by

diagnostic unit.

■ During the running of this program, gear shift will be out of service.

Self-learning of gear position

This operation is required in case of the following status:

1. Before the whole vehicle is offline.

2. Replacing or repairing the transmission.

3. Replacing or repairing Kit.

4. Replacing of gear select position sensor or gear shift position sensor.

5. Replacing TCU.

6. This operation is aimed to store the transmission grid into the TCU memory.

Operational procedures for self-learning of gear position are as follows:

Operational procedures

1 .Swith the key to position of “Key ON”(do not start the engine);

2. Connect the diagnostic unit, enter into J2 AMT transmission system and select

“Offline functional testing” to enter into the “Self-learning of transmission gear

position” and then operate it as per requirement of diagnostic unit;

3. After 3-5mins and “Finish” displays in the diagnostic unit, switch off the ignition

key;

4. Switch off ignition key to position “Key off” and keep it still for ten seconds to

ensure it is completely powered down.

Precautions:

■ It may take about five minutes to run this program.

■ This program shall be done under the condition that engine is not started and the

key is switched to position “Key on”.

■ The system oil pressure of hydraulic oil duct must be larger than the minimum

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-35

oil pressure (36～46Bar) required by gear shift.

■ Battery voltage shall be larger than 10.5V.

■ To ensure that related data has been stored in TCU, the key must be switched to

position “Key off” to wait for powering down.

■ The process for powering down may be kept for about 15 seconds.

■ This program will automatically execute the following operations:

■ Rapid self-learning of clutch at make position.

■ Testing the stroke of clutch.

■ Air exhaust for hydraulic oil duct.

■ Self-learning of the working current of clutch solenoid valve.

■ Self-learning of transmission gear shift grid.

■ When finishing the process, a fault code would appear if debugging is

unsuccessful.

■ After the debugging is failed, RLI 5F can be read to check the self-learning fault

code, so as to facilitate finding out the cause.

In execution of this process, the following conditions must be met:

■ Battery pressure is able to ensure the normal work of the system.

■ The key is switched to “Key ON”.

■ The system pressure is within normal range.

■ The self-learning will be unsuccessful if any of the above conditions is not met.

Self-learning will also be unsuccessful in the following cases:

■ Gear shift/select/clutch position sensor is out of work.

■ Selecting & shifting actuator and clutch actuator are out of work.

■ The driver of actuator is out of work.

■ The power supply of sensor, actuator and TCU are abnormal.

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-36

Electronic control

System instruction

1. Structural representation

Composition of transmission system

1. Engine control unit(ECU) 2. Hydraulic system of the pump drive of motor

3. Transmission control unit (TCU) 4. Gear and driving mode display instrument

5.Brake pedal (with biswitch) 6. Gear shift operating rod

7. Electronic accelerator pedal

2. Working principle

Transmission control unit (TCU) ③ could identify the driver’s requirements

according to sensors on the position of electronic accelerator pedal (8), gear shift

operating rod ⑦ and brake pedal (6). In addition, TCU could automatically manage

the change of gear and directly control the separation and closure of clutch and the

torque of engine.

Transmission Control Unit TCU

Technical parameters:

1. Type: CFC 318G

Siemens V23542-A 1280-B300 80-needle adapter

2. Operating ambient temperature: -30 - +65℃

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-37

3. Operating voltage:

Minimum operating voltage: 6.2V

Maximum operating voltage: 16v

Rated operating voltage: 12v

4. Communication line:

K line: KW2000 for diagnosis communication

CAN communication: CAN 500K/bytes for data exchange

5. Special hardware functions:

— Wake up TCU through driver’s door switch

— There is built-in delay relay in the system

TCU Label:

TCU identification label includes significant information such as client code, version

number and calibration numbers of hardware and software, etc., see the following

explanation for detail information:

A. Client drawing number B. Date C. Bar code of client’s information D. Voltage

supplied E. EPROM Type (E=solidification, Z= with slot, M= sheltered, F= flash

memory) F. Marelli code H. Project code L. Supplier register number N.

Authentication code P. Production batch no.

Input signals required by TCU

(1) Gear select position signal

Gear select position sensor lies close to transmission piston in hydraulic actuator, it

measures vertical moving distance of gear select piston which reflects gear select

stroke of transmission gear select and change, and shifting block. Through its signal,

TCU judges if gear select progress meets set value.

(2) Gear shift position signal

Gear shift position sensor lies close to gear shift piston in hydraulic actuator; it

measures horizontal moving distance of gear shift piston which reflects gear shift

stroke of transmission gear shifting block. Through its signal, TCU judges if gear shift

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-38

progress meets set value, and it is significant basis to judge working condition of

synchronizer.

(3) Clutch position signal

Clutch position sensor lies in the end of clutch actuator piston cylinder；It measures

moving distance of clutch piston which reflects stroke of clutch pressure plate.

Through its signal and clutch speed signal, TCU judges working condition of clutch.

(4) Clutch speed signal

Clutch speed clutch is fixed on transmission case and is close to input shaft 2-gear

wheel; it measures rotation speed of input shaft, i.e. rotation speed of clutch driven

disc. TCU collects clutch speed signal mainly use them to realize stage-divided

control clutch in gear shift progress.

(5) Door open signal

TCU collects door open signal from driver’s side, when driver’s side door opens, TCU

is waken up, system begins to drive engine and starts pressure accumulation thus to

ensure timely create pressure and get ready for driver's gear shift operation.

In addition, when engine is in operation, if driver’s side door opens over a certain time,

TCU will automatically shift gear to N to ensure safety.

(6) Brake pedal signal

TCU collects brake pedal signal. After receiving brake signal when brake penal is

depressed,, TCU will judge operation intent of driver and execute corresponding

operations such as slow down and downshifting, etc.

(7) Vehicle speed signal

TCU has high requirements for vehicle speed signal accuracy, thus vehicle speed

sensor of transmission has improved from 4 pulses (ordinary) to 8 pulses.

(8) Gear shift level signal

Gear shift request signal of driver comes from electronic gear shift level which can

transform gear request information into electric signal and transfer them to TCU,

based on this, TCU controls hydraulic system to realize gear shift.

Definitions of various TCU terminals:

Pin number Information description

Category

76 CRANKRQ start input switch(KL50) I

69 CRSBRK brake input switch I

77 SPT model input switch I

52 CLUTCHPOS clutch position sensor I

39 GEARPOS gear shift position sensor I

51 SHFPOS gear select position sensor I

40 HYDPRES pressure sensor I

26 GSL0 gear shift level 0 position I

67 GSL1 gear shift level 1 position I

74 GSL2 gear shift level 2 position I

68 GSL3 gear shift level 3 position I

43 CLUTCH solenoid valve direct O

32 GEAR1 gear shift solenoid valve directive 1 O

44 GEAR2 gear shift solenoid valve directive 2 O

29 SHIFT1 gear select solenoid directive 1 O

３ SHIFT2 gear select solenoid valve directive 2 O

42 CRANKCND starting relay directive O

31 HYDPMP pump relay directive O

27 TCU constant power supply PWR

73 SNSSPLY1 5 V external sensor power supply O

79 SNSSPLY2 5V external sensor power supply O

1 PWRGND1 TCU grounding PWR

2 PWRGND2 TCU grounding PWR

66 SNSGND1 external sensor grounding PWR

65 SNSGND2 external sensor grounding PWR

59 SNSGND3 sensor grounding PWR

19 CAN instrument high O

7 CAN instrument low O

36 VEHSPD vehicle speed input I

Notes: PWR=power, I=input, O=output, I/O =both-way

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-40

System diagnosis, safety and recovery strategy

System includes the following diagnosis functions:

Transmission control unit input/output diagnosis (for safety and maintenance)

System diagnosis (for safety)

Maintenance/off-line detection

Input/output (I/O) diagnosis of electronic control unit (TCU):

Frequency input signal diagnosis includes diagnosis of rotation speed sensor and

clutch speed sensor, mainly check for signal miss.

Analogue input signal diagnosis through checking if maximum and minimum signals

and its change are proper.

Control unit output diagnosis includes driving stage diagnosis with three proportional

solenoid valves, two switch solenoid valves, and one oil pump relay.

Especially check for short circuit to earth, and short circuit and open circuit to power.

Determination, deletion, storage and reading of faults:

Faults can be read only after being determined;

When system closes, determined faults will be stored in internal memory

(Eeprom) automatically and can be read through diagnostic unit.

Determine progress of faults includes: fault occurs, fault stable, fault determine;

As faults determine progress, there is a delete progress to eliminate fault, but

memory fault will not be eliminated;

After fault is determined, system will run recovery strategy to refrain from

interfere;

After fault is determined, system will decide to or not to light up fault light on

basis of strategy.

Safety strategies:

Safety strategy includes three grades:

Grade 1: Components and parts electrical diagnosis and rationality inspection

Grade 2: Functionality supervision to control object and drive control of driver

Grade 3: Supervision to main processor through safety microprocessor

Maintenance/off-line diagnosis

Interface of TCU and diagnostic unit passes K line. Diagnosis protocol is keyword

2000 protocal.

The following operations can be achieved through diagnostic unit:

Read system operating parameter (single or packing)

Execute special operation, such as system self-learning (transmission gear select

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-41

and shift positions, clutch parameter, etc.), system pressure relief and deflation,

etc.

Fault code table:

DTC code Description

P0880 TCU +5V power supply

P0932 Hydraulic oil pressure sensor

P0823 Gear shift level signal 3

P0561 Battery voltage is too low(less than 3V)

P0914 & P290A Gear shift position sensor

P0822 Gear shift level signal 2

P0805 Clutch position sensor

P0821 Gear shift level signal 1

P0820 Gear shift level signal 0

P0904 Gear select position sensor

P0710 Water temperature of engine

P2906 CAN line engine torque

P2903 CAN line accelerator pedal position

P0719 Wiring harness brake switch signal

P0703 CAN line brake switch signal

P0725 Engine rotation speed

P0715 Clutch rotation speed sensor

P0720 Vehicle speed signal

P2901 Pressure relief of energy storage tank

P2909 Gear select failure or dead lock

P2905 Transmission fault

P2904 Clutch fault

P2908 Clutch control error

P2900 sport button

P0825 Gear shift level dead lock or misoperation

P0933 Oil pump relay dead lock

P0755 Even number gear shift solenoid valve

P0750 Odd number gear shift solenoid valve

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-42

DTC code Description

P0900 Clutch solenoid

P290E 5－R gear area gear select solenoid valve

P290D 1－2 gear area gear select solenoid valve

P0701 Solenoid valve internal drive

P0881 TCU 12V power supply

P081A Starter motor relay

P0945 Oil pump relay fault(open circuit, or short circuit to earth or to power supply)

P0560 Low battery voltage

P0780 System misoperation

P2712 Hydraulic circuit leakage is too much

P0942 Oil pressure is too low or oil pump is too hot

P0613 SMP (assistant microprocessor) fault

P060C MMP (main microprocessor) fault

U1701 CAN communication fault

U1601 CAN communication fault

P0604 Microprocessor fault

Fault recovery table

After fault being found, TCU diagnosis system will active professional overhaul

procedure who are classified as per fault components as shown in the following table:

Fault components Fault lamps Influence and function recovery

Gear shift solenoid

valve

Gear shift is obstructed (neutral position excluded)(neutral

position) vehicle stops

Gear select solenoid

valve(on/off)

Gear shift is obstructed (neutral position excluded)(neutral

position) vehicle stops

Gear select and shift

position sensor

Gear shift takes a long period of time, only shift among 1,

2, reverse gear and neutral position can be done

Engine rotation

speed, transmission

input/output rotation

speed, vehicle speed

Shift can be done only among 1, 2, neutral position and

reverse gear

Oil pressure sensor On Open-loop control

Gear shift level On Can be shift to AUTO mode, no reverse gear is allowed

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-43

Fault components Fault lamps Influence and function recovery

Clutch proportional

control valve

Gear shift is obstructed (neutral position excluded)(neutral

position) vehicle stops

Clutch position

sensor

Gear shift is obstructed (neutral position excluded)(neutral

position) vehicle stops

Oil pump relay On Vehicle stops

Buzzing signal On Always on

Starter motor sensor On

Only 1, 2, reverse gear and neutral position can be

operated

Brake switch On

Gear shift cannot be done when engine is closed and can

be started only at neutral position

CAN line data

transfer

Off

ECU can not carry on torque control, urban model can be

carried out

CAN line data

reception

Only 1, 2, reverse gear and neutral position are allowed to

be operated, ECU can not carry on torque control

TCU microprocessor On

Only 1, 2, reverse gear and neutral position can be

operated

TCU grounding On System is completely blocked

TCU memory On

Only 1, 2, reverse gear and neutral position can be

operated

Energy accumulator

empty

On No recovery strategy

Pump relay dead lock On No recovery strategy

Acceleration pedal On

1－2 and reverse gear, neutral position can not be used

and engine rotation speed is limited

Typical fault analysis:

Engine cannot be started

The first thing to be explained is that if starter motor operates normally during engine

starting process (can be distinguished from sound), the reason of engine starting

failure has no relation to AMT system.

Inspect if battery voltage is greater than 11V prior to any judgment and maintenance

operation.

Firstly inspect if AMT system allows engine starting, the inspection method is shown

as follows:

Through data stream check function of diagnostic equipment, make screen show:

engine is allowed to start, and then turn the key to start (CRANK) position. At this

time, “engine allow to start” showing “1” represents that system allows engine to start

and if data stream “engine allow to start” showing “0”, it represents that system does

not allow engine to start.

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-44

If AMT system allows engine to start, the problem of start failure has no relation to

AMT system. In this situation, inspect if other on-board systems and components

work normally.

If AMT system does not allow engine to start, inspect as per the following methods in

sequence.

If system is at neutral position, read fault code firstly. If there is fault code, refer to

annex Fault Code Trouble Shoot to deal with the corresponding fault. If the above

mentioned faults do not exist, please check starter relay and relevant circuit.

If system is not at neutral position, then read fault code firstly. If there is fault code,

refer to annex Fault Code Trouble Shoot to deal with the corresponding fault.

If no problem is found out after above mentioned inspections, please check system

fluid level, hydraulic pressure and pump efficient, then inspect brake switch signal

and verify if there is mechanical fault of transmission at last. Care shall be taken that

AMT system cannot be started if any gear is meshed, thus engine start can not be done

if transmission blocked at some gear and cannot get back to neutral position.

Engine starts but cannot engage gear

If there is fault code, refer to annex Fault Code Trouble Shoot to deal with the

corresponding fault.

Especially for DTC0820(GSL0) or DTC0821(GSL1) or DTC0822(GSL2) or

DTC0823(GSL3) fault, there are the following recovery strategies: when brake pedal

is depressed, turn the key to start (Crank) and keep it for a period of time, engine can

be started and automatically enters into first gear after starts and switches to automatic

mode, in this situation, vehicle can stroke under automatic mode, but system refuses

reverse gear request.

Through diagnostic unit, inspect clutch position and its rotation speed simultaneously,

under engine starting condition, clutch shall at open condition and its speed shall be 0.

If no problem is found out after above mentioned inspections, please check system

fluid level, hydraulic pressure and pump efficient, then inspect brake switch signal

and verify if there is mechanical fault of transmission at last.

Stalling of engine

Vehicle speed is low and system has fault code

Inspect fault code in transmission control unit: if there is fault code, refer to annex

Fault Code Trouble Shoot to deal with the corresponding fault.

If both DTC2904 and DTC0805 exist, please inspect wiring harness connected to

clutch position sensor.

If there is DTC2904 fault which means problem relating to clutch control and the

reasons maybe: clutch hasn’t been loosed, clutch cannot engaged or clutch radiating

problem. Firstly inspect AMT oil level, if air is found from liquid route, clutch

decompression valve can be turned on. Through data stream of diagnostic unit,

inspect clutch meshing point self-learning data and repeat clutch meshing point

self-learning, and inspect if clutch is used too frequently. Inspect wiring harness status

(especially those between control unit and position sensors). Open connector to

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-45

inspect intactness and if there is pin bending, poor contact or damage (oxidation,

corrosion). Inspect conduction and grounding of wiring harness and short circuit at

battery positive pole or between pins. If no problem is found from above mentioned

inspections, replace clutch position sensor. If problem still exists, check clutch disc

condition.

If there is DTC2905 fault which means problem relating to clutch control and may be

caused by AMT system or transmission, detailed reason maybe unnecessary shift

down or shift down failure, gear select or engage error, and clutch overspeed. Inspect

clutch meshing point self-learning data and repeat clutch meshing point self-learning,

wiring harness condition (especially between control modules and position sensors).

Open connector to inspect intactness, if there is pin bending, poor contact or damage

(oxidation, corrosion). If DTC 2904 still displays, replace gear select sensor and gear

shift sensor. After all the above mentioned operations, if problem still exists, please

check transmission.

Vehicle speed is low and AMT system has no fault code

If system at neutral position, check engine idle speed control quality (emergent speed

up and release accelerator, etc.) or engine control when instant load appears (connect

or disconnect air conditioner, heat up resistance wire, and fast steer to the end).

Inspect if there is error in ECU.

If system is not at neutral position, reasons for engine stalling may include: clutch

engage and engine idle problem. Inspect as per the following procedure:

Connect diagnostic unit, start vehicle and engage neutral position. Inspect if clutch

rotation is higher than 0 (engine idle speed) through diagnostic unit, if it is, clutch is

engaged, repeat clutch meshing point self-learning and inspect again; if still engaged,

replace clutch mechanism. If clutch is disengaged, make engine achieve normal

working temperature, quickly heat up clutch (depress accelerator to the end and keep

for a period of time), then repeat clutch rotation speed inspection, if higher than 0,

replace clutch mechanism.

Check engine idle speed control quality (emergent speed up and release accelerator,

etc.) or engine control when instant load appears (connect or disconnect air

conditioner, heat up resistance wire, and fast steer to the end). Inspect if there is error

in ECU.

Inspect if engine stalling is requested by other system.

Vehicle speed is high

AMT can not stall engine at this moment. Check if there is fault in ECU, and if there

is other system requests engine stalling.

If above mentioned fault do not exist, the problem may be clutch cannot be controlled

occasionally, it is caused by one of the following reasons: there is hydraulic oil

leakage in clutch actuator, there is fault of sensor wiring harness (temporary virtual

access) of sensor at clutch position, there is fault of clutch position sensor

occasionally, clutch actuator is jammed, or there is clutch mechanical fault.

Check if there is liquid leakage under clutch actuator. If there is, replace actuator

components. If there is not, check condition of clutch position sensor wiring harness.

If there is wiring harness problem, maintain or replace relevant part, if there is not,

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-46

replace clutch position sensor. If the problem hasn’t been solved after above

mentioned operations, please contact technology support department of Jianghuai

Passenger Car Marketing Co..

Gear position is stuck or limited when driving

Attention: System fault will result in system entering into recovery strategy, which

means only 1 gear, 2 gear, 3 gear, neutral position, and reverse gear can be used when

driving. If the fault appears, gear is higher than 3, only shift down is allowed, after

going back to gear 3, shift up request will not be accepted again. If the fault is

intermittent, driver will find shift up limited intermittently. Thus please read DTC

fault code in TCU firstly.

If there is fault code, refer to annex Fault Code Trouble Shoot to deal with the

corresponding fault.

If all above mentioned problems do not exist, please check brake switch signal, carry

on meshing point self-learning, check gear shift level condition, check if hydraulic

system is normal, check oil pump efficiency and if there is mechanical fault.

Alarm lamp lights up and buzzer alarms

If there is fault code, refer to annex Fault Code Trouble Shoot to deal with the

corresponding fault.

In addition, if there is one of the following situations, buzzer will alarm: when vehicle

stops, gear shift to neutral position automatically if no other operation executed within

3 minutes after brake pedal is loosened, gear shift to neutral position automatically if

no other operation executed within 10 minutes after vehicle stops and brake pedal is

depressed all the time, gear shift to neutral position automatically within 3s after door

opens.

Connect diagnostic unit and display clutch rotation speed through examine data

stream function. Start engine and inspect if clutch rotation is higher than 0, if it is,

clutch meshing point self-learning is required. If problem still exists, clutch shall be

replaced. After above mentioned inspection, warm up turbine and preheat clutch,

repeat a series of operations of depressing pedal (about semi-accelerator) and then

loose, and then repeat above mentioned inspection, if clutch rotation speed still higher

than 0, replace clutch.

Vehicle jumps neutral position

If there is fault code, refer to annex Fault Code Trouble Shoot to deal with the

corresponding fault.

When vehicle stops, gear shift to neutral position automatically if no other operation

executed within 3 minutes after brake pedal is loosened, gear shift to neutral position

automatically if no other operation executed within 10 minutes after vehicle stops and

brake pedal is depressed all the time, gear shift to neutral position automatically

within 3s after door opens and vehicle speed is close to 0.

When vehicle speed is less than 80km/h, if accelerator didn’t be depressed, neutral

position may be caused by some reasons like hands is always on gear shift level or

misoperation of gear shift level.

If there is DTC2904 fault which means problem is relevant to clutch control and may

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-47

be caused by the following problems: clutch hasn’t been engaged, clutch disengages

out of control or clutch radiating problem. Firstly inspect liquid level, if air is found

out, system exhausting operation can be done or directly open clutch relief valve.

Inspect clutch meshing point self-learning data and repeat clutch meshing point

self-learning, and inspect if clutch is used too frequently. Inspect for break over and

grounding of wiring harness and short circuit at battery positive pole or between pins.

If no problem is found from above mentioned inspection, replace clutch position

sensor. If problem still exists, check clutch disc condition.

If there is DTC2905 fault which means problem is relevant to clutch control and may

be caused by AMT system or transmission, especially liable to unnecessary shift

down or shift down failure, gear select or engage error, and clutch overspeed. Inspect

clutch meshing point self-learning data and repeat clutch meshing point self-learning,

wiring harness condition (especially between control modules and position sensors).

Open connector to inspect intactness, if there is pin bending, poor contact or damage

(oxidation, corrosion). If DTC 2904 still display, replace gear select sensor and gear

shift sensor. After all the above mentioned operations, if problem still exists, please

check transmission for gearing stuck, disconnection between engine flywheel and

input shaft of transmission, etc.

If no problem is found out from above mentioned inspections, please check liquid

level, oil pump efficiency, door switch signal and gear shift level handle signal.

Mode automatically changes

Jump from automatic mode to manual mode automatically (A in display screen

disappears)

If there is fault code, refer to annex Fault Code Trouble Shoot to deal with the

corresponding fault.

If only A in display screen disappears and there is no other above mentioned problems

exist in TCU, then the problem has no relation to AMT system. In this situation, it is

recommended to inspect if display screen and AMT system function are normal.

Jump from manual mode to automatic mode automatically (A appears in display

screen)

If there is fault code, refer to annex Fault Code Trouble Shoot to deal with the

corresponding fault. No matter which mode it is, inspection of gear shift level signal

is required.

Gear position skips automatically

For AMT system, engine will shift up automatically when its rotation speed is close to

fuel-cut speed and will shift down automatically when its rotation speed is close to

idle speed. If there is fault code, refer to annex Fault Code Trouble Shoot to deal with

the corresponding fault. If driver makes shift too frequently, AMT system will alarm

and jumps to neutral position under vehicle speed less than 10km condition and gear

position is restricted to be under gear 3, engine rotation speed shall be no more than

4000RPM, shift down can be done when rotation speed is low but Kick Down

function can not be accepted. Above mentioned recovery strategies only used to

reduce oil pump temperature, no maintenance of system is required, and driver shall

avoid frequent shift.

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-48

Gear shift results in run away speed

If engine rotation speed is too high and gear at neutral position can be seen from

display screen during gear shift process, please diagnose as jumping to neutral

position.

If it is not at neutral position, inspect fault code:

If there is fault code, refer to annex Fault Code Trouble Shoot to deal with the

corresponding fault.

Run away speed during gear shift maybe caused by: there is fault in torque control of

engine control unit ECU, clutch meshing point learning error or clutch abrasion.

Analyze error in TCU and repair or replace broken parts. Connect diagnostic unit and

start it when implement meshing point self-learning and aging parameter self-learning.

If problem still exists and no error is found from TCU, inspect clutch for problem and

replace failure part.

Clutch skidding and start shuttering

If there is fault code, refer to annex Fault Code Trouble Shoot to deal with the

corresponding fault.

If it is not caused by above mentioned problems, it may be caused by clutch meshing

point learning error or clutch abrasion. Analyze error in TCU and repair or replace

broken parts. Connect diagnostic unit, start it when implement meshing point

self-learning and aging parameter self-learning. If problem still exists and no error is

found from TCU, inspect clutch for problem and replace failure part.

Suddenly change of gear

Attention: Under AUTO mode, when driver depresses accelerator pedal with fast

speed, system will execute Kick Down function automatically, e.g. shift down from

gear 5 to gear 3 directly.

If it is not caused by above mentioned situations, sudden gear shift may be caused by

failing to engage the right gear. To find out problem correctly, verify if shift up or

shift down can be engaged when vehicle is running or engine stalling is required. If

can not, inspect if there is problems in synchronizer of transmission and actuator.

Speed selector leaks oil

Attention: If there is oil leakage problem feedback by client (e.g. there is a puddle of

spilled oil at the place where vehicle parks in garage), before any inspection to AMT

system, it’s better to verify if oil leakage is caused by other on-board systems (e.g.

fuel tank cap is not well covered)

After above mentioned verification, inspect as per the following procedure:

If surface of hydraulic oil in storage tank is higher than its calibrated maximum value,

it means hydraulic oil in storage tank is too much. In this situation, hydraulic oil

leakage resulted by reducing oil surface to its calibrated maximum value cannot be

seen as suite function problem but belongs to normal function.

If hydraulic oil surface is lower than the minimum calibrated value, inspect hydraulic

components, and inspect connection between hydraulic pipe and oil pump of actuator,

connection between oil pump and oi tank, connection between solenoid valve group

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-49

and oil return pipe, connection between clutch actuator and solenoid valve group pipe,

and the exhaust bolt of clutch actuator. If oil leakage really exists, maintenance or

replacement of relevant parts is necessary.

If no oil leaks but oil height in hydraulic oil tank is lower than its separation shelf,

leaked oil is likely to enter into transmission (oil height situation of transmission shall

exceed normal level in this tank). If the problem is confirmed, replace of actuator

suite. Marked line MIN is the lowest fluid level and 14mm above MIN is the highest

fluid level, fluid level shall between the two limits under normal condition. After

maintenance, fluid level shall reach normal position.

Maintenance data and specification

Tightening torque table

Items Tightening torque(N·m)

Oil drain plug 18—23

Velocity sensor case fixing bolt 8—12

Reverse gear shifting fork fixing bolt 18—28

Intermediate cartridge receiver bolt 15—20

Shift assembly fixing bolt (5) 15—20

Gear position bolt 18—28

Front center casing connecting bolt (14) 15—22

Rear bracket dowel 18—28

Bearing baffle bolt (5) 8—12

Large intermediate shaft locking nut 60—80

Input shaft locking nut 60—80

Rear casing bolt (8) 8—12

Refueling bolt 18—23

Reverse gear intermediate shaft fixing bolt 18—28

Center casing oil baffle plate bolt (3) 8—12

gear shifting fork bolt 8—12

Fixing bolt of guide bearing oil pot 8—12

Clutch arms clamping nut 10—16

Fixing bolt of speed selector (6) 15—20

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-50

Transmission ratio table of various gears

DABSA10F type transmission

Type Mechanical gear mesh manual and automatic integrated shifting

Gear position Speed ratio Gear ratio

I gear 3.416 41/12

II gear 1.894 36/19

III gear 1.280 32/25

IV gear 0.914 32/35

V gear 0.757 25/33

Reverse gear 3.818 42/35/11

Main reducing gear 4.388 79/18

Autometer 0.944 17/18

Maximum input torque 110 N·m

Overall dimensions 345×490×480(mm) / L×W×H

Transmission inclination 5°

Lube GL-4 or GL-5 (GB13895-92)

Required maintenance material

Material Specification Purpose

Grease & lube

Lithium 2#low

temperature grease

z Oil seal lip

z Bearing

z Clutch release bearing glide internal diameter

z Clutch arm sliding place

lube

z Needle roller bearing

z Gear

Sealant

Oil proof silicone

sealant(HZ1213Q/3

20222 YAP02-92)

z Matching surface of front casing shell and center

casing shell

z Matching surface of center casing shell and rear

casing shell

z Matching surface of center casing and gear shift

actuator

White lead oil

z Refuel plug screw

z Oil drainage block

Thread

tightening

agent

262 anaerobic

adhesive

z 5

gear shifting fork bolt

z Gear limiting position

z Center casing dowel

z Rear bracket dowel

Maintenance Manual for J2 Sedan

AMT Transmission

AMT-51

Electrically controlled hydraulic system parameter table

Final speed ratio 4.563

Electronic control hydraulic system

System working voltage 12V

Max. working current 30A

Actuator lube TUTELA CS-SPEED FF 0.5L

Working temperature

-30℃～125℃

Max. working pressure 52bar

Position/pressure/speed sensor working

voltage

Gear select static force/pressure 188N/50bar

Gear shift static force/pressure 1570N/50bar

Clutch static working force/pressure 1608N/50bar

Shift valve working current

0～2.5A

Clutch valve working current

0～2A

Maintenance Manual for J2 Sedan AMT Transmission

AMT-52

Annex: AMT Transmission Fault Code Trouble Shoot

Fault components Fault code

Fault type

code

Fault type Possible reason Inspection and method Maintenance method

Gear shift

position sensor

P0914

(pin 39)

0001 Below lower limit

Short circuit to earth, wiring harness

fault

Inspect wiring harness through

diagnostic unit

Repair relevant wiring harness and

connector

Sensor internal fault Replace sensor

0010

Higher than upper

limit

Short circuit or open circuit to power,

wiring harness fault

Inspect wiring harness through

diagnostic unit

Repair relevant wiring harness and

connector

Wrong connection of connector

Inspect TCU and sensor connector

(all sensors need to be inspected)

Reconnect connector

Sensor internal fault Replace sensor

1000

Abnormal sensor

reading

Sensor internal fault or installation

incorrect

Replace sensor

P290A

(pin 73)

0001

Abnormal power

supply

Short circuit to earth, wiring harness

fault

Inspect wiring harness through

diagnostic unit

Repair relevant wiring harness and

connector

Sensor internal fault Replace sensor

0010

Abnormal power

supply

Short circuit to earth, wiring harness

fault

Inspect wiring harness through

diagnostic unit

Repair relevant wiring harness and

connector

Sensor internal fault Replace sensor

Gear select

position sensor

P0914

(pin 51)

0001

Higher than upper

limit

Short circuit and open circuit to power,

wiring harness fault

Inspect wiring harness through

diagnostic unit

Repair relevant wiring harness and

connector

Wrong connection of connector

Inspect TCU and sensor connector

(all sensors need to be inspected)

Reconnect connector

Sensor internal fault Replace sensor

0010 Below lower limit

Short circuit to earth, wiring harness

fault

Inspect wiring harness through

diagnostic unit

Repair relevant wiring harness and

connector

Sensor internal fault Replace sensor

1000

Abnormal sensor

reading

Sensor internal fault or installation

incorrect

Replace sensor

P290A

(pin 73)

0001

Abnormal power

supply

Short circuit to power, wiring harness

fault

Inspect wiring harness through

diagnostic unit

Repair relevant wiring harness and

connector

Sensor internal fault Replace sensor

Maintenance Manual for J2 Sedan AMT Transmission

AMT-53

Fault components Fault code

Fault type

code

Fault type Possible reason Inspection and method Maintenance method

0010

Abnormal power

supply

Short circuit to earth, wiring harness

fault

Inspect wiring harness through

diagnostic unit

Repair relevant wiring harness and

connector

Sensor internal fault Replace sensor

Clutch position

sensor

P0805

(pin 52)

0001

Higher than upper

limit

Short circuit to earth, wiring harness

fault

Inspect wiring harness through

diagnostic unit

Repair relevant wiring harness and

connector

Sensor internal fault Replace sensor

0010 Below lower limit

Short circuit or open circuit to power,

wiring harness fault

Inspect wiring harness through

diagnostic unit

Repair relevant wiring harness and

connector

Wrong connection of connector

Inspect TCU and sensor connector

(all sensors need to be inspected)

Reconnect connector

1000

Sensor internal fault or installation

incorrect

Replace sensor

P290B

(pin 79)

0001

Abnormal sensor

reading

Abnormal power

supply

Short circuit to power, wiring harness

fault

Inspect wiring harness through

diagnostic unit

Repair relevant wiring harness and

connector

Sensor internal fault Replace sensor

0010

Abnormal power

supply

Short circuit to earth, wiring harness

fault

Inspect wiring harness through

diagnostic unit

Repair relevant wiring harness and

connector

Sensor internal fault Replace sensor

Hydraulic

position sensor

P0932

(pin 40)

0010 Below lower limit

Short circuit or open circuit to earth,

wiring harness fault

Inspect wiring harness through

diagnostic unit

Repair relevant wiring harness and

connector

Sensor internal fault Replace sensor

0001

Higher than upper

limit

Short circuit to power, wiring harness

fault

Inspect wiring harness through

diagnostic unit

Repair relevant wiring harness and

connector

Wrong connection of connector

Inspect TCU and sensor connector

(all sensors need to be inspected)

Reconnect connector

Sensor internal fault Replace sensor

1000

Sensor internal fault or installation

incorrect

Replace sensor

P290A 0001

Abnormal sensor

reading

Short circuit to power, wiring harness

fault

Inspect wiring harness through

diagnostic unit

Repair relevant wiring harness and

connector

Maintenance Manual for J2 Sedan AMT Transmission

AMT-54

Fault components Fault code

Fault type

code

Fault type Possible reason Inspection and method Maintenance method

(pin 79) Abnormal power

supply

Sensor internal fault Replace sensor

0010

Abnormal power

supply

Short circuit to earth, wiring harness

fault

Inspect wiring harness through

diagnostic unit

Repair relevant wiring harness and

connector

Sensor internal fault Replace sensor

Gear shift level

GSL0[0820]

(pin 26)

GSL1[p0821]

(pin 67)

GSLO[0822]

(pin 74)

GSL1[p0823]

(pin 68)

0001

Higher than upper

limit

Short circuit or open circuit to power,

wiring harness fault

Inspect wiring harness through

diagnostic unit

Repair relevant wiring harness and

connector

Wrong connection of connector

Inspect TCU and sensor connector

(all pins need to be required)

Reconnect connector

0010 Below lower limit

Short circuit to earth, wiring harness

fault

Inspect wiring harness through

diagnostic unit

Repair relevant wiring harness and

connector

P0825

0100 Abnormal

There is at least one internal sensor

fault

Inspect power and earth wire

connection

Repair relevant wiring harness and

connector or replace gear shift level

1000 Misoperation

Gear shift level operates over

frequently, or stays too much time at

unstable position

Correctly operate gear shift level

Clutch speed

sensor

P0715

(pin 38,50)

0010 Signal appears

Wiring harness fault (Wiring harness

damage, short circuit to earth or to

other wiring harness)

Inspect wiring harness Repair wiring harness

Wrong connector connection

Inspect TCU and sensor connector

(all pins need to be required)

Reconnect connector

Sensor didn’t installed to transmission

correctly

Remove sensor and inspect Reinstall sensor or replace sensor

1000 Abnormal signal

Wiring harness fault (Wiring harness

damage, short circuit to earth or to

other wiring harness)

Inspect wiring harness Repair wiring harness

Connector pin virtual access

Inspect TCU and sensor connector

(all pins need to be required)

Reconnect connector

Sensor didn’t installed to transmission

correctly

Remove sensor and inspect Reinstall sensor or replace sensor

Maintenance Manual for J2 Sedan AMT Transmission

AMT-55

Fault components Fault code

Fault type

code

Fault type Possible reason Inspection and method Maintenance method

Key switch P081 0010 Discontinuous

Wiring harness fault (open circuit,

short circuit to earth)

Inspect wiring harness through

diagnostic unit

Repair wiring harness

Discontinuous (pin 28) Switch malfunction Inspect switch Replace switch

Brake switch

(wiring harness)

P0719

(pin 69)

0100 Error rated value Brake switch open circuit Inspect wiring harness Repair wiring harness

0010

Excess normal

range

W wiring harness malfunction (wiring

harness damage, short circuit to earth

or to other wiring harness)

Inspect wiring harness Repair wiring harness

Connector damage or incorrect

connection

Inspect TCU connector

Reconnect connector or repair

connector

Brake switch damage Inspect brake switch Repair or replace switch

0001

Sensor is jammed

W wiring harness malfunction (wiring

harness damage, short circuit to earth

or to other wiring harness)

Inspect wiring harness Repair wiring harness

Brake switch damage or installation

problem

Inspect brake switch and

installation position

Reconnect connector or repair

connector

1000 Discontinuous Brake switch damage Replace switch Replace switch

Economic switch

P2900

(pin 77)

0010

Switch is jammed

Wiring harness fault (wiring damage,

short circuit to earth t or to other wiring

harness)

Inspect wiring harness Repair wiring harness

Economic switch is jammed or

damaged

Inspect economic switch

Reconnect connector or repair

connector

Door switch

P1215

(pin 78)

[1000] Switch is jammed

Wiring harness (wiring damage, short

circuit to earth)

Inspect wiring harness and body

computer

Repair relevant components: wiring

harness or body computer

Door switch damage Inspect door switch at driver’s side Replace door switch at driver’s side

Engine rotation

speed

P0725

0010 Abnormal signal

Rotation speed transmitted by ECU

through CAN is 0*FFFF

Inspect engine control system

Please follow ECU diagnosis

instruction

Wiring harness fault (wiring damage,

short circuit to earth t or to other wiring

harness)

Inspect wiring harness through

diagnostic unit

Repair relevant wiring harness and

connector or replace gear shift level

0100 Signal disappears Incorrect connector connection

Inspect connectors of ECU and

TCU (all pins)

Reconnect connector

Maintenance Manual for J2 Sedan AMT Transmission

AMT-56

Fault components Fault code

Fault type

code

Fault type Possible reason Inspection and method Maintenance method

Engine control system fault Inspect engine control system

Please follow ECU diagnosis

instruction

Wiring harness fault (wiring damage,

short circuit to earth t or to other wiring

harness)

Inspect wiring harness through

diagnostic unit

Repair relevant wiring harness and

connector or replace gear shift level

1000 Abnormal signal

Connector pin virtual access

Inspect connectors of ECU and

TCU (all pins)

Tighten all pins

Engine control system fault Inspect engine control system

Please follow Engine Control

System Diagnosis Instruction

Engine idle - - Abnormal signal Abnormal engine idle Inspect engine control system

Please follow Engine Control

System Diagnosis Instruction

Accelerator P2930 1000 Abnormal signal

Abnormal accelerator signal

transmitted by ECU through CAN

Inspect engine control system

Please follow Engine Control

System Diagnosis Instruction

Wiring harness fault (wiring damage,

short circuit to earth t or to other wiring

harness)

Inspect wiring harness through

diagnostic unit

Repair relevant wiring harness and

connector

Engine torque P2906 0100 Abnormal signal

Abnormal engine torque signal

transmitted by ECU through CAN

Inspect engine control system

Please follow Engine Control

System Diagnosis Instruction

Engine friction

torque

P2906 0001 Abnormal signal

Abnormal engine torque signal

transmitted by ECU through CAN

Inspect engine control system

Please follow Engine Control

System Diagnosis Instruction

Engine expected

torque

P2906 1000 Abnormal signal

Abnormal engine torque signal

transmitted by ECU through CAN

Inspect engine control system

Please follow Engine Control

System Diagnosis Instruction

Engine driving

torque

- Abnormal signal

Abnormal engine torque si

gnal

transmitted by ECU through CAN

Inspect engine control system

Please follow Engine Control

System Diagnosis Instruction

Engine nominal

torque

P2906 0010 Abnormal signal

Engine torque signal transmitted by

ECU through CAN is 0*0000

Inspect engine control system

Please follow Engine Control

System Diagnosis Instruction

Engine maximum

torque

P2907 1000 Abnormal signal

Abnormal engine torque signal

transmitted by ECU through CAN

Inspect engine control system

Please follow Engine Control

System Diagnosis Instruction

Brake switch

(CAN)

P0703 0100 Abnormal signal

Abnormal engine torque signal

transmitted by ECU through CAN

Inspect engine control system

Please follow Engine Control

System Diagnosis Instruction

Maintenance Manual for J2 Sedan AMT Transmission

AMT-57

Fault components Fault code

Fault type

code

Fault type Possible reason Inspection and method Maintenance method

0010

Excess normal

range

W wiring harness malfunction (wiring

harness damage, short circuit to earth

or to other wiring harness)

Inspect wiring harness

Repair relevant wiring harness and

connector

Wrong connector connection

Inspect connectors of ECU and

TCU (all pins)

Reconnect connector

Brake switch fault or installation

problem

Inspect brake switch Repair or replace switch

0001 Switch is jammed

W wiring harness malfunction (wiring

harness damage, short circuit to earth

or to other wiring harness)

Inspect wiring harness

Repair relevant wiring harness and

connector

Wrong connector connection

Inspect connectors of ECU and

TCU (all pins)

Reconnect connector

Brake switch fault or installation

problem

Inspect brake switch and

installation position

Reinstall or replace switch

1000 Discontinuous Brake switch damage Replace switch Replace switch

Engine water

temperature

P0710 0100 Abnormal signal

Abnormal engine water temperature

signal transmitted by ECU through

CAN

Inspect engine control system

Please follow Engine Control

System Diagnosis Instruction

W wiring harness malfunction (wiring

harness damage, short circuit to earth

or to other wiring harness)

Inspect wiring harness through

diagnostic unit

Repair relevant wiring harness and

connector

External

temperature

P0710 1000 Abnormal signal

Abnormal engine external temperature

signal transmitted by ECU through

CAN

Inspect engine control system

Please follow Engine Control

System Diagnosis Instruction

Abnormal engine external temperature

signal transmitted by ECU through

CAN

Wheel speed -- Abnormal signal - - -

Vehicle speed P0720 0100 Signal disappears

W wiring harness malfunction (wiring

harness damage, short circuit to earth

or to other wiring harness)

Inspect wiring harness through

diagnostic unit

Repair relevant wiring harness and

connector

Maintenance Manual for J2 Sedan AMT Transmission

AMT-58

Fault components Fault code

Fault type

code

Fault type Possible reason Inspection and method Maintenance method

Wrong connector connection

Inspect connectors of ECU and

TCU (all pins)

Reconnect connector

Engine control system fault Inspect engine control system

Please follow Engine Control

System Diagnosis Instruction

P0720 1000 Error signal

W wiring harness malfunction (wiring

harness damage, short circuit to earth

or to other wiring harness)

Inspect wiring harness through

diagnostic unit

Repair relevant wiring harness and

connector

Wrong connector connection

Inspect connecters of ECU and

TCU (all pins)

Reconnect connector

Engine control system fault Inspect engine control system

Please follow Engine Control

System Diagnosis Instruction

Key switch - - Abnormal signal - - -

Door switch

(CAN)

See Door Switch Construction

Engine node on

CAN

U1701

0100 Node disappears

Engine control system is refreshed and

calibrated

If engine control system refreshed

and calibrated

Make clear of TCU fault

Wiring harness fault (wiring damage,

short circuit to earth t or to other wiring

harness)

Inspect wiring harness

Repair relevant wiring harness and

connector

Wrong connector connection Inspect engine control system

Please follow Engine Control

System Diagnosis Instruction

Engine control system fault

Inspect connectors of ECU and

TCU (all pins)

Reconnect connector

1000

Abnormal frame

length

Wiring harness fault (wiring damage,

short circuit to earth t or to other wiring

harness)

Inspect wiring harness

Repair relevant wiring harness and

connector

Wrong connector connection Inspect engine control system

Please follow Engine Control

System Diagnosis Instruction

Engine control system fault Inspect engine control system

Please follow Engine Control

System Diagnosis Instruction

CAN body

U1700 0100 Node disappears Body computer system is updated If body computer system is updated Erase the error inside TCU

Maintenance Manual for J2 Sedan AMT Transmission

AMT-59

Fault components Fault code

Fault type

code

Fault type Possible reason Inspection and method Maintenance method

computer node

Wiring harness fault (wiring damage,

short circuit to earth t or to other wiring

harness)

Inspect wiring harness

Repair relevant wiring harness and

connector

Wrong connector connection Inspect engine control system

Please follow Engine Control

System Diagnosis Instruction

Body computer is damaged Inspect body computer system

Please follow Body Computer

System Diagnosis Instruction

1000

Abnormal frame

length

Wiring harness fault (wiring damage,

short circuit to earth t or to other wiring

harness)

Inspect wiring harness

Repair relevant wiring harness and

connector

Wrong connector connection Inspect engine control system

Please follow Engine Control

System Diagnosis Instruction

Body computer is damaged Inspect body computer system

Please follow Body Computer

System Diagnosis Instruction

CAN line U1601

0000 CAN is interrupted

Wiring harness fault (wiring damage,

short circuit to earth t or to other wiring

harness)

Inspect wiring harness

Repair relevant wiring harness and

connector

Wrong connector connection

Inspect all connecters on TCIU and

relevant CAN node

Reconnect connector

0100 CAN has no signal

Wiring harness fault (wiring damage,

short circuit to earth t or to other wiring

harness)

Inspect wiring harness

Repair relevant wiring harness and

connector

Wrong connector connection

Inspect all connecters on TCIU and

relevant CAN node

Reconnect connector

No node on CAN is connected

Inspect if other nodes are connected

to CAN and if that's normal

Please follow Diagnosis Instruction

of other relevant nodes

Abnormal TCU working condition Inspect if TCU working normally Refresh again or replace TCU

0010 TCU is damaged Replace TCU Replace TCU

Clutch solenoid

valve

P0900

(pin 43)

0100 Open circuit

Connector is not connected, TCU pin is

damaged, wiring harness is damaged

Inspect TCU connector, inspect

solenoid valve connector, inspect

wiring harness through diagnostic

unit

Reconnect connector, Repair

relevant wiring harness and

connectors

Maintenance Manual for J2 Sedan AMT Transmission

AMT-60

Fault components Fault code

Fault type

code

Fault type Possible reason Inspection and method Maintenance method

Solenoid internal fault

Inspect if solenoid valve resistor is

normal

Replace solenoid valve

TCU is damaged

Replace a normal TCU and inspect

if problem still exists

Replace TCU

0001

Short circuit to

power

Wiring harness fault (is damaged or

short circuit to earth)

Inspect if TCU pin is connected to

power

Reconnect connector

TCU is damaged

Replace a normal TCU and inspect

if problem still exists (make

self-learning and drive and shift

normally)

Replace TCU

Clutch solenoid valve is damaged

Inspect if solenoid valve resistor is

normal

Replace clutch solenoid valve

0010

Short circuit to

earth

Between #43 pin and ground Check the harness connection

between TCU pins and solenoid

valve, and connect the connectors

again.

Repair the corresponding harness

and connector, and replace the

harness.

Damages of clutch solenoid valve Check the normality of solenoid

valve resistance.

Replace the clutch solenoid valve.

TCU is damaged

Replace a normal TCU to check

whether the fault still exists

(self-learning and normal driving or

shifting).

Replace TCU.

1000

Short-circuit or

broken circuit to

power supply

Wiring harness fault (wiring damage,

short circuit to earth t or to other wiring

harness)

Inspect wiring harness through

diagnostic unit

Repair relevant wiring harness and

connector

Wrong connector connection

Inspect TCIU and solenoid valve

connectors

Reconnect clutch solenoid valve

Solenoid internal fault

Inspect if solenoid valve resistor is

normal

Replace solenoid valve

Maintenance Manual for J2 Sedan AMT Transmission

AMT-61

Fault components Fault code

Fault type

code

Fault type Possible reason Inspection and method Maintenance method

Gear shift

solenoid valve

P0750

(pin 32)

P 0755 (pin 44)

0100 Open circuit

Connector is not connected, TCU pin is

damaged, wiring harness is damaged

Inspect TCU connector and clutch

connector, inspect wiring harness

through diagnostic unit, and then

replace a normal TCU and inspect

if problem still exists (make

self-learning and drive and shift

normally)

Reconnect connector. repair

relevant wiring harness and

connector, replace TCU

Solenoid internal fault

Inspect if solenoid valve resistor is

normal

Replace solenoid valve

0001

Short circuit tot

power

Short circuit to power, short circuit to

other wiring harness, wiring harness is

damaged

Inspect wiring harness through

diagnostic unit, inspect if TCU pin

is connected to power

Repair relevant wiring harness and

connector

0010

Short circuit tot

earth

Short circuit to power, short circuit to

other wiring harness, wiring harness is

damaged

Inspect wiring harness through

diagnostic unit, and connection

between pin and earth

Repair relevant wiring harness and

connector

1000

Short circuit or

open circuit to

power

Wiring harness fault (wiring damage,

short circuit to earth or other wiring

harness)

Inspect wiring harness through

diagnostic unit

Repair relevant wiring harness and

connector

Wrong connector connection

Inspect TCU connector and

solenoid connector

Reconnect connector

Solenoid internal fault

Inspect if solenoid valve resistor is

normal

Replace solenoid valve

Gear select

solenoid valve

P290D

(pin 29)

P290E (pin 3)

0001

Short circuit or

open circuit to

power

Wiring harness fault (wiring damage,

short circuit to earth or to other wiring

harness)

Inspect connection among solenoid

valve and power and TCU,

reconnect connector

Repair relevant wiring harness and

connector

Solenoid valve is damaged Inspect solenoid valve Replace solenoid valve

TCU is damaged

Replace a normal TCU and inspect

if problem still exists (make

self-learning and drive and shift

normally)

Replace TCU

0010

Short circuit to

earth

Wiring harness fault (wiring damage,

short circuit to earth t or to other wiring

harness)

Inspect connection between pin and

earth, reconnect connector

Repair relevant wiring harness and

connector

Maintenance Manual for J2 Sedan AMT Transmission

AMT-62

Fault components Fault code

Fault type

code

Fault type Possible reason Inspection and method Maintenance method

Solenoid valve is damaged Inspect solenoid valve Replace solenoid valve

TCU is damaged

Replace a normal TCU and inspect

if problem still exists (make

self-learning and drive and shift

normally)

Replace TCU

Hydraulic oil

pump

P0945

(pin 31)

1000 Open circuit

Relay is damaged

Inspect relay and relay seat, replace

relay and inspect

Replace relay

Wiring harness fault or connector fault

Inspect if wiring harness between

TCU and relay is short circuit to

earth, to power or to other wiring

harness, inspect TCU connector,

inspect fuse of oil pump

Reconnect connecter or replace

wiring harness

0001

Short circuit to

power

Relay is damaged or hasn’t been

connected

Inspect relay and relay seat, replace

relay and inspect

Replace relay

Wiring harness fault or connector fault

Inspect wiring harness between

TCU and relay, inspect TCU

connector, inspect if relay is short

circuit to power

Reconnect connecter. repair or

replace wiring harness

0010

Short circuit to

earth

Relay is damaged or wiring harness

fault

Inspect if relay is short circuit to

earth, inspect relevant wiring

harness, replace relay and inspect,

replay new TCU and inspect

Repair or replace wiring harness,

replace relay

Starter relay

P081A (pin 42) 0010

Short circuit or

open circuit to

earth

Wiring harness fault or connector fault

or relay fault

Inspect if relay is short circuit to

earth, inspect relevant wiring

harness, replace relay and inspect

Repair or replace wiring harness,

replace relay

P081A (pin 42) 0001

Short circuit to

power

Wiring harness fault or connector fault

or relay fault

Inspect if relay is short circuit to

earth, inspect relevant wiring

harness, replace relay and inspect

Repair or replace wiring harness,

replace relay

Clutch system P2904

0100

Gear shift front

clutch is not

engaged

Clutch actuator/clutch solenoid valve is

damaged

Inspect clutch actuator, clutch

solenoid valve and wiring harness

Repair relevant damaged

components: clutch actuator, clutch

solenoid valve, clutch solenoid

valve or wiring harness

1000

Clutch engaged

when shifting

Maintenance Manual for J2 Sedan AMT Transmission

AMT-63

Fault components Fault code

Fault type

code

Fault type Possible reason Inspection and method Maintenance method

0010 Clutch is over heat Inspect driving operation of driver See User Manual

P2908 0010 Clutch control Oil route or mechanical structure fault

Inspect if there is fault in oil route

and mechanical structure

Repair or replace relevant damaged

components

Transmission

system

P2905

1000 Fail to remove gear

Oil route or mechanical structure fault

Inspect if there is fault in oil route

and mechanical structure

Repair or replace relevant damaged

components

0100 Fail to engage gear

0001

Accident out of

gear

0010 Clutch overspend

Malfunction of oil route, or mechanical

structure, or clutch rotation speed

sensor

P2909

1000 Fail to select gear Oil route or mechanical structure fault

0010

Gear shift is

jammed

Oil route or mechanical structure fault

Inspect if there is fault in oil route

and mechanical structure or clutch

rotation speed sensor

Repair or replace relevant damaged

components

Hydraulic oil

route

P0942

0100

Oil pressure too

low

Mechanical fault

Electrical equipment fault

Leakage

Inspect oil pump, hydraulic oil level

and high-pressure oil pipe

Replace damaged oil pump or oil

pipe, fill oil till normal liquid level

1000 Oil pump over heat

P2712 1000 Leaks too much

P2901 1000

Energy storage

tank failure

P0780 1000 Misoperation

Too frequent gear shift request under

manual mode

Too frequent accelerator change under

AUTO mode

Inspect driving operation of driver See User Manual

P0933 1000

Oil pump relay is

jammed

Electrical fault Inspect oil pump relay Replay oil pump relay

TCU grounding P2902 (Pin 1, 2) 0100

Open circuit of pin

1 and 2

Inspect pin 1 and 2 Inspect pin 1 and 2

Repair relevant wiring harness and

connector

TCU power

supply

P0561 (pin 27) 0100 Pin 27 open circuit Inspect pin 27 Inspect pin 27

Repair relevant wiring harness and

connector

Battery voltage P0560 0010 Voltage is too low Voltage is too low Inspect battery voltage Charge battery or replace battery

Maintenance Manual for J2 Sedan AMT Transmission

AMT-64

Fault components Fault code

Fault type

code

Fault type Possible reason Inspection and method Maintenance method

0100

1000

ROM

P0604

0010 ROM data change

Hardware damage

Read fault code through diagnostic

unit

Refresh and calibrate again and

make self-learning, if fault can not

be solved, replace TCU

Abnormal ROM data

Inspect connectors of TCU and

sensor (all pins)

RAM 0100 RAM is damaged

RAM is damaged and fails to read or

white

Read fault code through diagnostic

unit

Replace TCU

Inspect connectors of TCU and

sensor (all pins)

Flash

1000

Off-line

self-learning value

change

Hardware damage

System enters into recovery

strategy and comfortableness is

reduced

Refresh and calibrate again and

make self-learning, if fault can not

be solved, replace TCU

Inspect fault code through

diagnostic unit

Inspect connectors of TCU and

sensor (all pins)

0001

Self-learning value

change

System enters into recovery

strategy and comfortableness is

reduced

Make self-learning, if fault can not

be solved, replace TCU

SMP P0631

0010 SMP fault

Hardware is damaged

Inspect fault code through

diagnostic unit

Replace TCU

Incorrect TCU is used Inspect if Installed TCU is correct

Refresh and calibrate or replace

TCU

Wrong TCU internal software

Inspect if TCU internal software is

normal

Refresh and calibrate

0100

SMP

communication

fault

Hardware is damaged

Replace TCU

1000

SMP control

module fault

Maintenance Manual for J2 Sedan AMT Transmission

AMT-65

Fault components Fault code

Fault type

code

Fault type Possible reason Inspection and method Maintenance method

MMP P060C

1000

Grade 2 module

inspect grade 1

module

Hardware is damaged

Replace TCU

0010

Grade 3 module

inspect grade 2

module

0001

A/D shift fault of

MMP

Clutch position

sensor drive

P0810 1000 SPI fault Hardware damage - Replace TCU

Solenoid valve

drive

P0701

0010 SPI fault

Hardware damage Replace TCU

0001 Overheat alarm

0100 Drive is closed

1000 Drive is started

12V internal

power supply

P0881

0010 Drive is started

Hardware damage Replace TCU

0001 Drive is closed

5V internal power

supply

P0880

1000 Drive fault

Hardware damage Replace TCU

0100 Open circuit

0001

Short circuit to

power

0010 Drive is closed

Maintenance Manual for J2 Sedan

FAX Front Axle

FAX-1

Drive Train/Axle

FAX Front Axle

Precautions

1. Precautions to be cautioned during the repair of drive shaft

1) Do not remove any parts other than overhaul parts, such as steering knuckle.

2) Operate at a dust-free worktable as far as possible.

3) Please clean the outer surfaces of parts before the disassembly and assembly.

4) During working, make sure to take cautions to prevent contaminating the parts

and prevent the ingress of foreign materials.

5) The parts disassembled must be re-assembled carefully as per correct sequence.

If the operation is interrupted, make sure to cover the parts with a clean

enclosure.

6) Make sure to use paper cloth, as the use of fiber fabric may lead to adhesion of

fiber onto the parts.

7) The parts disassembled (except rubber parts) shall be cleaned with kerosene,

blown dry or wiped dry with paper cloth.

2. Issues to be cautioned during checking of system or replacement of parts

1) Check the tightening torques for the fasteners after the assembly.

2) Conduct the necessary locating checking after the assembly of system.

3) One-time parts can’t be reused.

4) Check thoroughly before the repair or replacement of parts.

Preparation

Remove and install with suitable servicing tools.

1. Common tool:

Table of Common Service Tool

SN Tool Outline drawing Description

1 Power tool

Install and remove the bolts, nuts

Maintenance Manual for J2 Sedan

FAX Front Axle

FAX-2

2. Special tool:

Table of Special Tool

SN Tool Outline drawing Number Description

The steering drive rod

pull tool

JAC-T1D003

Remove linkage ball

head.

Front wheel hub and steering knuckle

On vehicle inspection:

Confirm each part for the fixing (clearance) and abrasion condition is normal or not.

1) Wheel bearing check

 Pull the wheel hub and bearing assembly along axial direction by hand, to make

sure that the bearing is loose or not. If it is loose, it is recommended to replace the

bearing or reinstall it.

 Rotate the wheel hub, to judge whether there is abnormal noise or other abnormal

condition. If any, it is recommended to replace the bearing.

Removal and installation:

1) Part

Figure of Front Wheel Hub and Steering Knuckle Part

1 – Front wheel hub 2 – Mudguard 3 – Steering knuckle

Maintenance Manual for J2 Sedan

FAX Front Axle

FAX-3

2) Removal

① Lift up the vehicle, remove front tires.

② Remove the wheel speed sensor from

steering knuckle.

 Tightening torque: 8～10N·m

Caution:

 Do not pull wire harness of wheel speed sensor.

 Check the clearance between wheel speed sensor and wheel hub as installation.

 Standard clearance: 0.5mm

③ Unscrew the securing bolt to brake hose, take the brake hose away.

④ Remove front brake clipper assembly from the steering knuckle and hang it up

for fixation.

 Tightening torque: 65～75N·m

Caution:

 After removal of the brake clipper, the

brake pedal must not be depressed.

⑤ Remove the brake disc stopper bolts

from wheel hub, and take off the brake

disc.

 Tightening torque: 9～16N·m

⑥ Remove the split pin, release the wheel

hub lock nut

 Tightening torque: 200～260N·m

⑦ Knock the propeller shaft with rubber

hammer (or other suitable tool) and

wood block, to separate wheel hub and

steering knuckle, then remove the wheel

hub lock nut.

Caution:

 The support case (universal joint), shaft and other part and component must be

supported as the propeller shaft is put down.

FAX001

FAX002

Maintenance Manual for J2 Sedan

FAX Front Axle

FAX-4

 If the above operation still cannot detach the wheel hub from propeller shaft, the

puller (or other suitable tools) may be used.

⑧ Remove steering tie rod ball joint from

the steering knuckle.

Caution:

 The special or suitable tools should be

used so as to avoid ball joint boot

damage.

⑨ Remove the securing bolt of shock

absorber and steering knuckle.

 Tightening torque: 130～150N·m

⑩ Remove propeller shaft form wheel

hub.

Caution:

 The located angle of propeller shaft

universal joint should not be too large.

 Avoid excessive stretching, so as to

prevent ball joint falling off.

⑪ Remove the lower swing arm ball

joint from the steering knuckle.

Please refer to “Lower Swing Arm”.

 Tightening torque: 60～72N·m

Caution:

 Special tool should be applied to avoid

ball joint boot damage.

⑫ Take off the wheel hub and steering

knuckle.

FAX004

FAX003

FAX005

FAX006

Maintenance Manual for J2 Sedan

FAX Front Axle

FAX-5

3) Check after removal

Caution:

 Check the part for deformation, crack or other damages. If any, please replace it.

 Check the tie rod outer ball joint boot for breakage, large clearance to shaft and

distortion.

4) Installation

 Installation is the reverse order of removal.

 Caution: Please do not use damaged parts or components.

 When installing the tie rod ball joint, the bolt should be fixed to avoid rotation

and then tighten the nut.

 Perform final tightening to each part removed during front wheel hub and rear

steering knuckle removal with no load.

 Check the wheel alignment.

 Check whether the wheel speed sensor wire harness is connected correctly.

Disassembly and assembly:

1) Disassembly

① Remove the snap clip with inner snap

ring pliers.

② Remove wheel hub and dust deflector

from steering knuckle.

③ Remove inner race of wheel bearing

from wheel hub.

④ Remove outer race of wheel bearing

from steering knuckle.

Caution:

 The operation must conform to the specification, avoid bearing falling, which

may lead to personal injury.

 If the steering knuckle cannot be separated from wheel bearing successfully by

many times attempt, please replace the steering knuckle.

2) Check after disassembly

① Steering knuckle

 Check the contact surface of steering knuckle and wheel bearing for scratch,

crack or other damage.

 If any, please repair or replace it according to the condition.

② Brake disc

FAX007

Maintenance Manual for J2 Sedan

FAX Front Axle

FAX-6

 Check surface of the brake disc for crack or other damage.

③ Snap clip

 Check the snap clip for crack or other damage.

Caution:

 Please do not use damaged parts and components.

④ Wheel hub

 Check whether the wheel hub bolt is elongated.

 Check the wheel hub and wheel bearing contact surface for scratch, crack or other

damage.

 If any, please repair or replace it.

3) Assembly

① Apply appropriate quantity of grease to the steering knuckle and wheel bearing

contact surface.

② Press new wheel bearing into the steering knuckle, install new snap clip.

Caution:

 The inner race of wheel bearing should not be pressed, to avoid damage of wheel

bearing assembly.

 The model of left and right wheel hub bearings must be identical.

 Do not reuse any damaged part.

③ Install dust deflector

④ Press wheel hub into the steering knuckle.

Caution:

 The outer race of wheel bearing should not be pressed, to avoid damage of wheel

bearing assembly.

4) Check after assembly

 Check whether the wheel hub and wheel bearing is assembled in position.

 Measure the axial play of the bearing.

Limit value: 0.064～0.088mm

Caution:

 If the axial play exceeds the limit value, please reinstall the bearing.

The wheel bearing replacement:

As to the removal and installation, please refer to steps of "front wheel hub and

steering knuckle".

Caution:

 Please do not use damaged parts and components.

 The model of left and right wheel bearings must be identical.

Maintenance Manual for J2 Sedan

FAX Front Axle

FAX-7

 Perform necessary road test.

Front drive shaft

On board inspection and service:

1) Check the propeller shaft and universal joint for loose or other damage.

2) Check the boot for crack or other damage.

Caution:

 If there is noise or vibration on the propeller shaft, please replace the propeller

shaft assembly.

Propeller shaft boots replacement:

1) Raise the vehicle and remove the front wheel tire.

 Tightening torque: 90~110N.m

2) Remove the wheel speed sensor from the steering knuckle.

Notice:

 Do not pull the wheel speed sensor harness.

 Tightening torque: 8~10N.m

3) Remove the front brake caliper assembly from the steering knuckle and hang and

secure.

Notice:

 Do not step down the brake pedal after the removal of brake calipers.

 Tightening torque: 65～75N•m

4) Remove the split pin and loosen the lock nuts of wheel hub.

 Tightening torque: 200～260N•m

5) Use a hammer (or an appropriate tool) and wood block to lightly knock the drive

shaft to separate the wheel hub and steering knuckle assembly and then remove

the lock nut of wheel hub.

Notice:

 While lowering the drive shaft, make sure to support the housing (universal joint

subassembly), shaft, and other parts.

 If the wheel hub and drive shaft can't still be separated by above-mentioned

operations, the puller (or appropriate tool) can be used.

6) Remove the steering tie rod ball joint from the steering knuckle.

Notice:

 Use special tool to prevent damaging the dust cover of ball joint.

 Tightening torque: 15～34N•m

Maintenance Manual for J2 Sedan

FAX Front Axle

FAX-8

7) Loosen the fixing bolts and nuts of shock absorber and steering knuckle.

 Tightening torque: 75～90N•m

8) Separate the drive shaft from the wheel hub and bearing assembly.

Notice:

 The arrangement angle of the drive shaft and universal joint shall not be too large.

Avoid the excessive tension, in order to prevent the fall-off of ball cage.

9) Avoid the dust cover clamp.

10) Screw the drive shaft puller (or

appropriate tool) into the threaded

hole of universal joint subassembly

and pull out the universal joint

subassembly from the shaft.

Caution:

 If the universal joint sub assembly

cannot be pulled out, remove the

propeller shaft assembly firstly and

then try it again.

11) Remove the snap clip from propeller shaft, and take off the boot.

12) Mop grease on universal joint sub-assembly off with paper towel.

13) Apply appropriate quantity of grease

to the universal joint sub-assembly

dentoid hole, until the grease flow out

from the circular groove and dentoid

hole. After the grease has been

applied, wipe off the effluent old

grease with towel.

14) Wrap the spline with adhesive tape to

avoid damage to boot. Install new boot

and clamps on the propeller shaft.

Caution:

 The boot and clamps cannot be reused.

15) Remove adhesive tape wrapped on the shaft.

FAX009

Sub-assembly

FAX008

Maintenance Manual for J2 Sedan

FAX Front Axle

FAX-9

16) Put snap clip into groove at edge of the

shaft, align the intermediate shaft at

shaft edge to the universal joint

sub-assembly, then secure the shaft to

universal joint sub-assembly with snap

clip.

Caution:

 The clips cannot be reused.

 It is recommended that use special

tools to install the snap clip.

17) Fit the universal joint sub-assembly to propeller shaft with rubber hammer.

Caution:

 Make sure that the universal joint sub-assembly has engaged correctly when

rotating the propeller shaft.

18) Apply appropriate quantity of grease to the boot from the large diameter end.

19) Fit boot into the groove as figure below.

Caution:

 If there is grease adhere to fixing

surface of the boot, (* mark), the boot

may fall off. Clean off all the grease on

boot surface.

20) Put a slotted screwdriver into the boot

from large diameter end, bleed the

boot, and adjust the installation length

of boot, prevent the boot from

deformation.

Caution:

 If the boot installation length is too

excessive, it may cause boot damage.

 Be careful to use the flat screwdriver;

do not touch inside of the boot.

21) Fix the new boot clamp with tools.

Caution:

 The boot clamp cannot be reused.

22) Fix the universal joint sub-assembly and propeller shaft, and then determine

correct location when rotating the boot.

FAX012

FAX011

Sub-assembly

FAX010

Prevent the boot from

deformation

Flat screwdriver

Maintenance Manual for J2 Sedan

FAX Front Axle

FAX-10

Caution:

 For wrong installation location of boot, please reinstall it with new clamps.

23) Make sure that the snap clips on drive axle have been all in engaged.

24) Insert propeller shaft into the wheel hub and bearing assembly, and then tighten

the wheel hub lock nut.

25) Install the fixing bolts and nuts of shock absorber and steering knuckle.

26) Install the tie rod ball joint, and then fasten the lock nut as standard torque.

Caution:

 When installing, fix the bolt firstly to prevent it from rotation, and then lock the

nut.

27) Install brake clipper and fix the brake hose.

28) Install wheel speed sensor to the steering knuckle.

29) Tighten the lock nut to standard torque.

 Tightening torque: 200～260N·m

30) Install the cotter pin

Caution:

 The cotter pin may not be reused.

31) Install the tire and tighten as standard torque.

Removal and installation:

1) Removal

① As to the removal of front wheel and steering knuckle.

② Remove the propeller shaft from the transmission side.

Caution:

 The location angle of propeller shaft universal joint should not be too large when

removing the propeller shaft. Avoid excessive stretch on the universal joint.

2) Check after removal

① Turn the universal joint to check whether the universal joint is flexible and with

badly loose.

② Check the boot for crack, damage and grease leakage.

③ If there are conditions which is not conform to the specification, please

disassemble the propeller shaft and replace the fault part and component.

2) Installation

Caution:

 When installing propeller shaft, the oil seal at transmission side should be

replaced with new one.

Maintenance Manual for J2 Sedan

FAX Front Axle

FAX-11

① Install the removable end firstly, and then apply gear oil on the propeller shaft

spline. Turn the snap clip open downward before installing the propeller shaft.

② When installing the removable end of propeller shaft, it should be turned a little

to make the spline engagement, a click sound represent it is in position, pay

attention to that the spline shaft should be alignment to the transfer inner spline

when moving the removable end spline shaft, do not touch the oil seal when

installing, avoid scratching the oil seal (seal ring).

③ After installation, pull the removable end to confirm it is fixed tightly.

Caution:

 The special structure of lower swing arm and propeller shaft is likely lead to the

boot damage. After the propeller shaft has been installed on power train, the boot

of fixed section may run into edge of lower swing arm, which may impact the

boot and shorten its service life greatly, even worse will damage it directly. So the

propeller shaft installed must be protected or the steering knuckle should be

installed immediately, or take other measures to assure that the propeller shaft

fixed section will not contact the lower swing arm.

④ Install end of fixed section

⑤ To install the fixed section end, the spline need to be turned a little and make it

engaged with the wheel hub spline, then push the wheel hub inside, then install

the washer, nut, cotter pin.

⑥ Pay attention to that the convex side of washer should be in outside when

installing. Install the nut, the tightening torque is 200～260N·m; Install the cotter

pin, the two feet of cotter pin inserted should be divided to avoid drop.

Disassembly and assembly:

1) Disassembly

① Transmission side

a. Secure the propeller shaft in pliers.

Caution:

 Protect the propeller shaft with aluminum or copper plate as it is fixed in the

pliers.

b. Remove the boot clamp, and then take off boot from the case.

Maintenance Manual for J2 Sedan

FAX Front Axle

FAX-12

c. Make marks on the case and propeller

shaft, and then pull the case out of the

propeller shaft.

Caution:

 Make marks with paint or similar

materials.

Do not scratch the surface.

d. Remove the snap clip, and then remove

the trident assembly from the propeller

shaft.

e. Remove the boot from propeller shaft.

f. Wipe off the old grease on case with

paper towel.

② Wheel side

a. Secure the propeller shaft in pliers.

Caution:

 Protect the propeller shaft with aluminum or copper plate as it is fixed in the

pliers.

b. Remove the boot clamp, and then remove the boot from universal joint sub

assembly.

c. Screw the propeller shaft puller (or other suitable tool) into the universal joint

sub assembly screw hole; pull the universal joint sub assembly from the propeller

shaft.

Caution:

 If the universal joint sub-assembly cannot be removed by attempt of many times,

please replace the propeller shaft assembly.

d. Remove the snap clip from propeller shaft, and take off the boot.

e. Remove the dust cover and wheel speed sensor form the propeller shaft.

f. Mop old grease on universal joint sub assembly off with paper towel when

turning the ball joint.

2) Check after disassembly

① Propeller shaft

Check the propeller shaft for run-out, crack or other damages. If any, please replace

the propeller shaft assembly.

FAX04

FAX013

Fitting mark

Snap clip

Maintenance Manual for J2 Sedan

FAX Front Axle

FAX-13

a. Universal joint sub-assembly (wheel side)

Check the following item:

 Check if the universal joint sub-assembly turning excessively and the propeller

shaft is loose excessively.

 There is foreign material in the universal joint sub-assembly.

 Whether there are pressed marks, crack or inside damage on the universal joint

sub-assembly. If it is not conform to the specified condition, please replace the

universal joint sub-assembly.

b. Case and trident assembly (transmission side)

If the running contact surface of case or trident assembly is scratched or worn, please

replace the case or trident assembly.

Caution:

 The case and trident assembly are applied in on unit.

② Boot and wheel speed sensor

Check for crack or other damage. If any, please replace it.

2) Assembly

① Transmission side

a. Wrap the spline on propeller shaft with

adhesive tape to avoid boot damage.

Install new boot and clamps on the

propeller shaft.

Caution:

 The boot and clamps cannot be reused

b. Remove the adhesive tape around the propeller shaft spline.

c. The paint marks should be aligned

when installing the trident assembly.

Make the chamfer towards shaft to

install the trident assembly

d. Secure trident assembly to the case

with clamps.

FAX016

Propeller shaft

Fitting mark

Spline

Fitting mark

Adhesive tap

Cross shaft component

FAX015

Maintenance Manual for J2 Sedan

FAX Front Axle

FAX-14

e. Apply the recommended grease to

trident assembly and the sliding

surface.

f. Install the case to trident assembly,

and then apply the recommended

grease.

g. Install clamps in the groove as the

figure below.

Caution:

 If there is grease adhering to fixing surface of the boot, the boot may fall off.

Clean off all the grease on boot surface.

h. Put a flat screwdriver into the boot

from the large diameter end, bleed the

boot, and adjust the installation length

of boot, prevent the boot from

deformation

Caution:

 If the boot installation length is too excessive, it may cause boot damage.

 Be careful to use the flat screwdriver; do not touch inside of the boot.

i. Fix the new boot clamps with special tool.

Caution:

 The boot clamp cannot be reused.

j. Fix the case and propeller shaft, and then verify the correct position when turning

the boot.

Note: For wrong installation location of boot, please reinstall it with new boot clamp.

k. Install wheel speed sensor and boot to the case.

② Wheel side

Assemble according to the steps of "replace of propeller shaft boot".

Caution:

 The universal joint sub-assembly and propeller shaft must be in one line when

installing.

 When installing, make sure that the wheel speed sensor and case have been

FAX018

FAX017

Snap clip

Flat screwdriver

Prevent the boot from deformation

Maintenance Manual for J2 Sedan

FAX Front Axle

FAX-15

engaged.

 The wheel speed sensor should be installed after the dust deflector has been

pressed in.

Trouble Diagnosis

The faults of propeller shaft are usually the following 4 types:

1) Abnormal sound.

① The ball joint is worn badly, which lead to excessive clearance, so there is

abnormal sound when driving or turning the steering wheel.

② Outer ball joint axial clearance is too excessive, which lead to abnormal sound

when the vehicle driving.

2) The boot rupture lead to ball joint damage.

① The outer ball joint boot early aging and chap.

② The boot is cut or hitched to break by foreign things.

3) The clamp is loose or fall off by foreign force, which lead to oil leakage, water

entered, further more will cause abnormal abrasion of inner and outer ball joint.

4) The outer ball joint is disintegrated by foreign force, the intermediate shaft is

crashed to slant, broken, or the inner ball joint has fallen off.

Trouble diagnosis steps and requirements:

1) After the whole vehicle has been lifted up, check the propeller shaft\outer and

inner ball joint boot for crack or oil leakage, the outer ball joint clamp for loose

or falling off.

2) Check the fastened bolt for loose.

3) The service person will make further diagnosis by test the vehicle; exclude other

chassis abnormal sound brought by other system trouble.

4) If there is propeller shaft abnormal sound or other trouble decided by the vehicle

test, it is need to be removed and make further check.

5) Check the outer ball joint for turning lightly, the inner ball joint for axial

travelling smoothly.

① Appearance check:

 Whether it is original propeller shaft. Check the intermediate shaft, fixed section,

removable section for marks of original replacement parts, and compare the

outlines. The original hollow shaft tube is connected by friction welding, but the

others are connected by fitting.

 Whether it has been removed without permission .For example: The boot clamp

is replaced with iron wire or the clamp fixing position has changed.

 Whether the user has applied non-original fittings without permission.

 Whether the propeller shaft has been damaged by foreign force. For example:

Maintenance Manual for J2 Sedan

FAX Front Axle

FAX-16

The ball joint boot is scrabbled or the ball joint carrier is broken.

② Check with hand:

Clearance check

a. Outer ball joint axial play: Grasp the intermediate shaft with left hand, push and

pull it with right hand grasping the outer ball joint handle, feel carefully whether

there is excessive clearance. (There is little clearance or without clearance at

normal condition)

b. The assembly circular clearance: Catch hold of the spline sections on both end of

the propeller shaft, rotate it in circular direction, feel carefully whether there is

excessive clearance. (There is little clearance or without clearance at normal

condition)

Rotation checking of outer ball joint:

 Grasp the intermediate shaft with left hand and grasp the shank of outer ball

joint with right hand and swing in circumferential direction repeatedly to check

for flexible rotation.

The outer ball joint rotation check:

 Grasp the intermediate shaft with left hand, push and pull it with right hand

grasping the outer ball joint handle, to check whether it may move freely.

Inner ball joint move check:

 Set the propeller shaft in perpendicular direction, catch hold of the inner ball

joint with two feet, check whether the inner ball joint is stuck and the inner and

outer spline may move relatively, take care not to operate too roughly during the

check, otherwise the inner ball joint may fall off inside.

Solution proposal for the check result:

1) If problems were found as outer ball joint appearance and hand feeling check

according to above steps, then perform service operation according to removal

and installation standard steps and requirements.

2) If no problems were found, this shows that the propeller shaft does not fail and

may keep on function. It is suggested to check other parts for loose, sealed off or

other failures.

Maintenance Manual for J2 Sedan

FAX Front Axle

FAX-17

Service Data and Specification

Tightening Torque Table

Item Tightening torque (N·m)

Propeller shaft lock nut 260～300

Connecting nuts between steering knuckle and

shock absorber assembly

75-90

Connecting nuts between lower swing arm ball

joint and steering knuckle

60-72

Wheel nut 100～120

Rear wheel hub bearing lock nut 180-220

Connecting nuts between rear shock absorber and

rear steering knuckle

75-90

Connecting nuts of rear cantilever and rear

steering knuckle

130-150

Nuts of stabilizer bar fixing bracket 17-26

Connecting nuts between stabilizer bar and tie rod 35-45

Connecting nuts between rear suspension and

body

100-120

Eccentric nuts of rear cantilever 80-100

Brake disc limit bolt 10-15

Maintenance Manual for J2 Sedan

RAX Rear Axle

RAX-1

RAX Rear Axle

Precautions

 After installation, all the fasteners must be inspected for specified torques.

 After installation, the system must be inspected for necessary alignment.

 All the non-reusable parts or components can not be reused.

 Please inspect the parts completely before repair or replacement.

Preparation

Remove and install with suitable service tools.

Table of Service Tools

Number Tool Outline drawing Description

1 Power tool

Installing and removing bolts and

nuts

Wheel hub

1. On board inspection

Judge whether each part is in normal fixing (clearance) and worn conditions.

2. Wheel bearing inspection

 Push the wheel hub and bearing assembly along axial direction by hand to judge

whether the bearing is loose. If any, it is recommended that you replace the

bearing or reinstall it.

 Rotate the wheel hub to judge whether there is abnormal noise or other abnormal

condition. If any, it is recommended that the bearing be replaced.

Maintenance Manual for J2 Sedan

RAX Rear Axle

RAX-2

Removal and installation:

Rear Axle Exploded View

1 – Rear cross beam 2 – Rear coil spring 3 – Rear shock absorber assembly 4 –

Rear wheel hub assembly

1) Removal

① Wheel hub and bearing assembly

a. Lift up the vehicle, remove the wheel

and tire.

b. Remove the limit screw of rear brake

drum and remove the brake drum.

 Tightening torque: 9～16N•m

RAX001

RAX002

Maintenance Manual for J2 Sedan

RAX Rear Axle

RAX-3

c. Disconnect the wheel speed sensor

connector, remove four fixing bolts of

rear wheel hub, and remove the rear

wheel hub.

 Tightening torque: 60～80N•m

2） Inspection after removal

① Inspect the part for deformation, crack or other damages. If any, please replace

the part.

② Inspect the rear wheel hub bearing for abrasion, noise or other damages.

③ Inspect the wheel hub inner surface for abrasion, scratch and crack.

3) Installation

Installation is the reverse order of removal.

Caution:

 Please do not use damaged parts or components.

 Check whether the wheel speed sensor is correctly connected.

 The bearings for left and right wheels must be consistent in model.

 Perform final tightening to each part removed during rear steering knuckle

removal with on load.

 Inspect the wheel alignment.

Service Data and Specification

Table of Tightening Torques

Item Tightening torque (N·m)

Limit screw of brake drum 9～16

Fixing bolt between rear crossbeam and body 100～120

Fixing bolts of rear shock absorber 60～80

Fixing bolts of rear wheel hub 60～80

Fixing bolts of rear coil spring 60～80

RAX003

Maintenance Manual for J2 Sedan

FSU Front Suspension

FSU-1

Suspension

FSU-Front Suspension

Precautions

 To install the suspension or rubber sleeve, the final tightening must be performed

with tires on ground and in unloaded condition. Oil may shorten service life of

rubber sleeve. So the oil spilled must be cleaned off.

 The unloaded condition means that the fuel, engine coolant and oil all have been

filled, the spare tire, lifting jack, attachment tools and foot pad have been in

specified position.

 Make sure to check the wheel alignment after the repair of suspension parts.

 The lock nut must not be used again. New nuts should always be used for

installation.

Preparation

The special tool used is shown below:

List of Special Tools

SN Tool

Outline drawing Number Description

Steering drive

rod pull tool

JAC-T1D003

To remove linkage

ball joint

Damping spring

puller

JAC-T1D004

Remove and install

damping spring

Maintenance Manual for J2 Sedan

FSU Front Suspension

FSU-2

Front Suspension Assembly

Diagram of Front Suspension System

1 – Front wheel hub assembly 2 – Front steering knuckle assembly 3 – Shock

absorber and coil spring assembly 4 – Stabilizer bar tie rod 5 – Lower swing arm

assembly 6. Lateral stabilizer bar

On board inspection:

Confirm each part for the tightening (clearance) and abrasion condition is normal or

not.

1) Inspect the tie rod clearance.

① Stop the vehicle with front wheel face straightly forward.

② Put the pull bar (or similar tools) between the tie rod and steering knuckle.

③ Pull up and down to inspect the clearance.

Caution:

 Do not damage the ball joint boot.

 Do not damage the installation position with too excessive force.

2) Shock absorber check.

Check the installation position for oil leakage, damage or breakage.

Front wheel alignment check:

1) Instruction

Test the wheel alignment in unloaded condition.

Note: The unloaded condition means that the fuel, engine coolant and oil all have

been filled, the spare tire, lifting jack, attachment tools and foot pad have been in

specified position.

Maintenance Manual for J2 Sedan

FSU Front Suspension

FSU-3

2) Pre-check

Check the following item:

① Check whether the tire pressure is normal, and the tire is worn.

② Test run-out of the wheel.

③ Check axial clearance of wheel bearing.

④ Check end clearance of tie rod.

⑤ Check each anchor point on axle and suspension for loose or deformation.

⑥ Check each suspension part, steering knuckle, shock absorber and tie rod for

crack, deformation and other damage.

⑦ Height of vehicle body.

Front wheel toe-in inspection:

Caution:

 The wheel alignment must be conducted on horizontal ground and with no load.

 Front wheel toe-in: 0°±15′ (Front toe-in)

If the toe-in is out of the standard range, please adjust as following steps:

1) Inspect the set of toe-in on four-wheel

alignment instrument.

2) Set the steer wheel in origin position and

fixed it.

3) Loosen the lock nut on toe rod end.

4) Rotate the left and right tie rod in

clockwise direction or counterclockwise

direction, set the toe-in to standard value.

Caution:

 The turns of left and right tie rod should

be equal.

5) Fasten the lock nut on tie rod end.

FSU002

FSU001

Maintenance Manual for J2 Sedan

FSU Front Suspension

FSU-4

Inspection of camber, kingpin caster angle and kingpin inclination angle:

Front wheel camber: -1°26′～ -0°26′

Kingpin caster angle: 2°02′～3°32′

Kingpin inclination angle: 9°33′

Caution:

 The camber, kingpin caster angle and kingpin inclination angle have been set

before delivery, do not adjust them.

 If the camber, kingpin caster angle and kingpin inclination angle are not in the

standard range, please check the front suspension, steering knuckle, shock

absorber and tie rod for abrasion or damage. If any, please replace the suspected

part.

Maintenance Manual for J2 Sedan

FSU Front Suspension

FSU-5

Front shock absorber

Part:

Diagram of Front Shock Absorber and Coil Spring Assembly

1 – Shock absorber assembly 2 – Coil spring 3 – Bumper block 4 – Spring

support 5 – Shock isolator

Removal and installation:

1) Removal

① Remove the front wheel tire.

② Disconnect the wheel speed sensor connector.

Caution:

 Do not pull wire harness of the wheel speed sensor.

③ Remove clips of brake hose, and disconnect the brake hose.

④ Remove fixing nuts from shock absorber upper support.

 Tightening torque: 85～105N·m

Maintenance Manual for J2 Sedan

FSU Front Suspension

FSU-6

⑤ Remove the securing bolts and nuts to

shock absorber and steering knuckle.

 Tightening torque: 100～120N·m

⑥ Remove the shock absorber assembly.

2) Checking after removal

① Shock absorber

 Check for presence of deformation, cracking, and damage. If yes, replace the

shock absorber.

 Check the piston push rod for presence of damage, wear, and deformation. If yes,

replace the piston push rod.

 Check the piston for presence of oil leakage. If yes, replace the piston

② Spring shock isolator, bumper block, and dust cover.

Check for presence of cracking and check rubber parts for presence of wear. If yes,

replace.

③ Coil spring

Check the coil spring for presence of cracking, wear, and damage. If yes, replace.

④ Spring upper support

Check for presence of cracking, wear, deformation, and other damages. If yes,

replace.

3) Installation

 Installation is the reverse order of removal. For tightening torque, see the section

“Maintenance Parameters”.

Caution: Please do not use damaged parts.

 Perform final tightening to each part removed during shock absorber removal

with no load.

 Inspect the wheel alignment.

FSU003

Maintenance Manual for J2 Sedan

FSU Front Suspension

FSU-7

Lower swing arm

Part:

Diagram of Lower Swing Arm Assembly

Removal and installation:

1) Removal

① Lift up the vehicle, remove wheels and

tires.

② Remove the lock nut of stabilizer bar tie

rod at lower swing arm side.

 Tightening torque: 30～50N·m

③ Remove the lock nut between lower

swing arm and steering knuckle.

 Tightening torque: 60～72N·m

Note: The lower swing arm ball joint

should be fixed firstly when removing

before unscrewing the lock nut so as to

avoid rotation of ball joint.

④ Remove the fixing bolts of lower swing arm

front bracket.

 Tightening torque: 100～120N·m

FSU004

Maintenance Manual for J2 Sedan

FSU Front Suspension

FSU-8

⑤ Remove the fixing bolts of lower swing

arm rear bracket.

 Tightening torque:100～120 N·m

⑥ Remove the lower swing arm assembly.

2) Check after removal

① Visual Check

 Check the bush for abrasion or damage. If any, please replace it.

 Check the lower swing arm for deformation or other damages. If any, please

replace it.

 Check the lower swing arm ball head dust deflector for cracks. If any, please

replace it.

 Check all the fixing bolts and nuts for damage. If any, please replace it.

3) Installation

Installation is the reverse order of removal.

Note: Please do not use damaged parts and components.

 The bolts of lower swing arm front rubber sleeve and fixed support should be

pre-tightened, so as to avoid distortion or deformation.

 Perform final tightening to each part removed during lower swing arm removal

with no load.

 Inspect the wheel alignment.

FSU007

Maintenance Manual for J2 Sedan

FSU Front Suspension

FSU-9

Front sub frame assembly

Part:

Diagram of Front Subframe Assembly

Removal and installation:

 Please remove and install the subframe and related accessories as per the

specified torque in the diagram.

Engine suspension

Component:

Illustration of Engine Suspension Position

1 – Rear suspension 2 – Rear suspension bracket 3 – Right suspension 4 –

Left suspension bracket 5 – Left suspension

Maintenance Manual for J2 Sedan

FSU Front Suspension

FSU-10

Removal and Installation:

 Please remove and install the left

suspension and related components as

per the torque shown in the figure.

 Please remove and install the right

suspension and related components as

per the torque shown in the figure.

 Please remove and install the rear

suspension and related components as

per the torque shown in the figure.

FSU008

FSU009

FSU010

Maintenance Manual for J2 Sedan

FSU Front Suspension

FSU-11

Trouble Diagnosis

Diagnostic Table for Common Faults

Check Possible cause Solution

Heavy steering

Front wheel improper alignment Adjust

Rotate to exceed the lower swing arm ball joint Replace

Tire air pressure too low Inflate

Non-power steering Repair or replace

Return badly

Front wheel improper alignment Adjust

Shock absorber fault Repair or replace

Transverse stabilizer bar abrasion or damage Replace

Helical spring abrasion or damage Replace

Lower swing arm bush abrasion Replace

Tire abnormal abrasion

Front wheel improper alignment Adjust

Tire air pressure too low or too high Adjust air pressure

Shock absorber fault Repair or replace

Vehicle running

deviation

Front wheel improper alignment Adjust

Insufficient lower swing arm ball joint linkage

steering resistance force

Replace

Lower swing arm bush loose or abrasion Replace

Vehicle running

deviation in one side

Front wheel improper alignment Adjust

Insufficient lower swing arm ball joint linkage

steering resistance force

Replace

Lower swing arm bending Replace

Helical spring abrasion or damage Replace

The steering wheel

wobbling

Front wheel improper alignment Adjust

Insufficient lower swing arm ball joint linkage

steering resistance force

Replace

Lower swing arm bush loose or abrasion Replace

Shock absorber fault Repair or replace

Transverse stabilizer bar abrasion or damage Replace

Helical spring abrasion or damage Replace

Vehicle sinkage

Helical spring abrasion or damage Replace

Shock absorber fault Repair or replace

Maintenance Manual for J2 Sedan

FSU Front Suspension

FSU-12

Service Data and Specification

Technical Specification Table

Item Parameter and specification

Type of front suspension McPherson independent suspension with helical spring

Suspension stiffness (N/mm) 10.3

Shock absorber

Type Two-way hydraulic cylinder

Travel 161mm

Helical spring

Free height 310mm

Diameter 11mm

Wheel alignmen

Wheel toe-in (front) +1.4~+5.8

Kingpin camber angle

-1°26′～ -0°26′

Kingpin inclination angle 9°33′

Kingpin caster angle

2°02′～3°32′

Tightening Torque Table

Item

Tightening torque

(N.m)

Fixing nuts of front shock absorber upper support 85-105

Fixing bolts between front shock absorber and front steering

knuckle

100-120

Self-locking nut of stabilizer bar tie rod 30-50

Fixing nuts between lower swing arm and steering knuckle 60-72

Fixing bolts of lower swing arm front bracket 100-120

Fixing bolts of lower swing arm rear bracket 100-120

Subframe front fixing bolts 100-120

Subframe middle fixing bolts 100-120

Subframe rear fixing bolts 60-80

Fixing bolts between left suspension and left longitudinal beam 45-55

Fixing bolts between left suspension and left suspension bracket 60-70

Fixing bolts of left suspension bracket and transmission 45-55

Fixing bolts between right suspension and right longitudinal beam 45-55

Fixing bolts between right suspension and engine 60-70

Fixing bolts between rear suspension and subframe 120-160

Fixing bolts between rear suspension and rear suspension bracket 90-110

Fixing bolts between rear suspension rear bracket and transmission 45-55

Maintenance Manual for J2 Sedan

RSU Rear Suspension

RSU-1

RSU Rear Suspension

Precautions

 When installing the suspension, the final tightening must be performed with tires

on ground and in unloaded condition.

 The wheel alignment must be checked after suspension components have been

repaired.

 When installing the rubber sleeve, the final tightening must be performed with

tires on ground and in unloaded condition.

 The oil may shorten service life of rubber sleeve. So the oil spilled must be

cleaned off.

 The unloaded condition means that the fuel, engine coolant and oil all have been

filled, the spare tire, lifting jack, attachment tools and foot pad have been in

specified position.

 The lock nut must not be used again. New nuts should always be used as

installation. The anticorrosive oil on lock nut should not be cleaned off before the

nuts are tightened.

Preparation

The common and special service tools used are listed in the table below:

List of Common Tools

SN Tool Outline drawing Description

1 Power tool Install and remove the bolts, nuts

List of Special Tools

SN Tool Outline drawing Number Description

The steering

drive rod pull

tool

JAC-T1D003

Remove linkage

ball head.

Maintenance Manual for J2 Sedan

RSU Rear Suspension

RSU-2

Rear Suspension Assembly

Part:

Part Drawing of Rear Suspension Assembly

1 – Rear crossbeam assembly 2 – Rear coil spring 3 – Rear spring upper cushion

4 – Rear shock absorber assembly 5 – Rear wheel hub assembly 6 – Rear spring

lower cushion

On board inspection:

Check each part for tightening condition (clearance, loose) and other conditions

(abrasion, damage).

1) Shock absorber check

Check the installing region for oil leakage or damage.

2) Check the axial clearance of wheel bearing

① Jack up the vehicle, check the axial clearance while the vehicle is stationary, if

there is axial clearance, remove the wheel hub cover and release the park brake

handle, to continue the steps below.

② Check the axial clearance of wheel bearing end.

a. Put the micrometer on surface of wheel hub; turn the hub to check the axial

clearance.

 Standard clearance: 0～0.22mm

b. If axial clearance is out of the specified range, tighten the wheel bearing nut as

specified torque, then check the axial clearance again.

c. If the axial clearance can not be adjusted to specified range, please replace the

rear wheel bearing.

Maintenance Manual for J2 Sedan

RSU Rear Suspension

RSU-3

Rear wheel alignment check:

Caution:

 If the parts of rear suspension is worn or changed, the rear wheel alignment

parameters should be checked according to the requirements, if any inconformity

is found, please adjust in time as following steps:

 If it is impossible to get standard parameter by adjustment, please replace the

deformed or worn part and component.

 Standard value:

Rear wheel camber angle: -1°26′～ -0°26′

1) Instruction

Test the wheel alignment in unloaded condition.

2) Pre-check

Check the following item:

① Test whether the tire pressure is normal, and check the tire for abrasion.

② Test run-out of the wheel

③ Test axial clearance of wheel bearing.

④ Check clearance between parts of the suspension, whether the fixed point is

loose.

⑤ Maneuverability of shock absorber.

⑥ Check each cantilever for crack, deformation and other damages.

⑦ Body height.

Rear Shock Absorber

Part:

Part Drawing of Rear Shock Absorber Assembly

Removal and installation:

1) Removal

① Lift up the vehicle, remove the wheel and tire.

Maintenance Manual for J2 Sedan

RSU Rear Suspension

RSU-4

② Remove the clips of brake tube and

move the brake tube away.

③ Remove the shock absorber dust cover.

④ Remove the assembly nuts between

shock absorber and body.

 Tightening torque: 30~40N.m

⑤ Remove the securing bolts and nuts of

shock absorber and rear steering

knuckle.

 Tightening torque: 60～80N·m

Warning:

 Pay attention to sudden falling of shock absorber assembly when removing so as

to avoid personal injury!

⑥ Remove rear shock absorber assembly.

2) Check after removal

Check for oil leakage, deformation, crack or other damages. If any, please replace it.

3) Installation

Installation is the reverse order of removal.

Caution:

 Please do not use damaged parts or components.

RSU001

Dust cover

Body

Bolt

Q33410

Rear shock

absorber

Rear

crossbeam

Rear shock

absorber

Bolt

2911280U8050

Maintenance Manual for J2 Sedan

RSU Rear Suspension

RSU-5

 Tighten each part that has been removed when removing the shock absorber with

no load.

 Check the wheel alignment.

 Bleed the brake system.

Rear crossbeam assembly

Part:

Diagram of Rear Crossbeam

Removal and installation:

1) Removal

① Remove the connecting bolts

between rear crossbeam and body.

 Tightening torque: 100～120N•m

② Use a jack to support the rear

crossbeam assembly.

Notice:

 The jack must not slide off when

removing.

③ Remove the fixing bolts and nuts

between rear shock absorber and

rear crossbeam.

 Tightening torque: 60～80N•m

2) Installation

Installation is the reverse order of removal.

Caution:

 Please do not use damaged parts and components.

 Pay attention to installing direction when installing rear sub frame.

Bolt

2911110U80

Body

Rear

crossbeam

Maintenance Manual for J2 Sedan

RSU Rear Suspension

RSU-6

Trouble Diagnosis

Diagnostic Table for Common Faults

Check Possible cause Solution

Abnormal sound

Loose installation Fasten

Fatigue or damage of wheel bearing Replace

Shock absorber assembly damage Replace the damaged component

Tire defects Replace

Vibration

Excessive tire air pressure Adjust the pressure

Shock absorber assembly damage Replace the damaged component

Tire nut loose Tighten

Helical spring is shortened or broken Replace

Tire defects Replace

Body incline Helical spring is shortened or broken Replace

Service Data and Specification

Technical Specification Table

Rear suspension system

Type Torsion beam semi-independent suspension

Rear shock absorber Two-way hydraulic cylinder type, with stroke at 210mm

Rear coil spring Free height at 310mm and diameter at Ø11mm

Rear wheel toe-in (mm) +1.4～ +5.8 (total toe-in)

Rear wheel camber angle -1°26′～ -0°26′

Suspension rigidity (N/mm) 12.7

Tightening Torque Table

Item Tightening torque (N.m)

Bolts of rear wheel hub assembly 60~80

Fixing bolts between rear shock absorber and rear

crossbeam

60~80

Fixing bolts between shock absorber and body 60~80

Connecting bolts between rear crossbeam and body 100~120

Maintenance Manual for J2 Sedan

WT Wheel and Tire

WT-1

WT Wheel and Tire

Precautions

 Please use the original manufactured wheel.

 In the run-in period of new tires, quick start, sharp turn and emergency brake

should be avoided in bad working condition, to prevent the new tire untimely

damage.

 The new tire should be balanced before usage.

Tire

Inspection:

1) Air pressure inspection

① Inspect the tire for inflation pressure. If the pressure is not in standard pressure

range, please adjust it.

Standard value: 230kPa for front/220kPa for rear

Notice:

 Test tire pressure with good tire pressure gauge.

 Determine whether the wheel is worn, improper inflation, with cracks or other

damages.

 As the ambient temperature fluctuate violently, the tire pressure should be

inspected frequently.

② The incorrect tire pressure may

result:

a. The insufficient inflation will lead

tire shoulder to wear rapidly, tire

deflection, as well as rolling

resistance increasing.

b. The excessive air pressure will make

the tire crown worn quickly, and

decrease the tire buffering capacity.

WT002

WT001

Maintenance Manual for J2 Sedan

WT Wheel and Tire

WT-2

2) Incorrect alignment inspection

Too large or small toe-in of rear wheel

and front wheel will cause the tire

feathered worn as shown in the figure.

3) Tire tread inspection

① Measure depth of tire treads.

Note: Tire specification 165/65 R14 79T

 As the depth of tire tread is worn to

limit or smaller, the worn marks

should appear on the tire tread. If the

worn marks appear, please replace

the tire.

② Inspect whether there are foreign materials in the tire tread. If any, please clear

them off.

4) Inspect the wheel to see whether there are cracks or other damages.

If there is deformation, please test the wheel run-out.

① Remove the tire from the wheel, and

install it on the tire balancing

machine.

② Set micrometer gauge as the figure

below.

As wheel run-out value, please refer to

"service data and specification". If the tire

run-out has exceed the limit, please

replace it.

WT004

WT003

Worn for too large front toe-in

Inside

Worn for too small front toe-in

Radial run-out

Lateral run-ou

WT005

WT006

Maintenance Manual for J2 Sedan

WT Wheel and Tire

WT-3

Interchange:

 The tires should be interchanged as

the vehicle has driven for 8000km.

The tires should also be interchanged as

new tires are applied.

Note: It is recommended that tires are

interchanged as shown in the figure.

Replace:

① The tires should be replaced if the vehicle has driven normally for 50000km.

② The tires should also be replaced if one of the symptoms below is found:

 More than 3 worn marks appear on the tire tread.

 The cord or cord wire was exposed on the tire rubber.

 Cracks on tire tread or tire shoulder, the cord layer is uncovered.

 There are surface bulging, protrusion or delamination on the tire.

 The tire is punctured, cut or with other damages that can not be repaired.

Wheel and tire assembly

Remove and install:

1) Remove

① Remove the wheel bolt.

 Tightening torque: 90～110N·m

② Remove the wheel and tire assembly.

2) Install

Install the wheel and tire assembly as well

as tire bolt.

Notice:

 If it is installed by hand, please

pre-tighten in turn firstly, and then

tighten the nut in diagonal sequence.

 If it is tighten automatically, the

tightening torque should be adjusted,

and tightened at one time.

 All wheel bolts should be fastened according to the sequence shown in the figure.

WT009

WT007

WT008

Maintenance Manual for J2 Sedan

WT Wheel and Tire

WT-4

Wheel balance:

1) Remove

① Remove tires which need adjustment.

② Remove old balance weight on both sides of wheel, and clear the objects on tire

tread.

Notice:

 Be careful not to hurt the wheel as removing.

 The adhesive tapes on new tires should be removed.

2) Adjustment of wheel balance

① Take the center hole as alignment surface, mount the wheel on wheel balancing

machine, and start the machine.

② As the imbalance value of both side displayed on screen of balancing machine,

the outside imbalance value should be multiplied with 5/3 to determine the actual

balance weight used. Then choose outside balance weight which is most close to

the calculated value, and mount it to specified outside position, or to angle

position specified relative to the wheel.

Notice:

 The inside balance weight should be mounted after the outside balance weight

has been mounted.

 The matched surface must be clean off before the balance weights are mounted.

a. Mount the balance weight as

shown in the figure.

b. As the balance weight is mounted

on the wheel, the weight should be

put on inside of wheel with

grooves, make the center of weight

alignment to specified position on

wheel balancing machine (or

angle).

c. If the calculated balance weight is

more than 50g, mount the two

balance weights in one line.

Notice:

 The balance weights may not be

used again, please replace with new

ones.

 The balance weights mounted

should not be more than three parts.

WT011

Weight pasted

Align to

groove

Gravity center

Position indicated by the balancing

machine (angle)

Position indicated by the

balancing machine (angle)

WT010

Maintenance Manual for J2 Sedan

WT Wheel and Tire

WT-5

 The origin balance weights should

always be used.

 The balance weight can't be put on

another.

③ Start the wheel balancing machine again.

④ Strike the balance weight into inner side of wheel according to position (or angle)

pointed by the balance machine.

⑤ Start the balancing machine, make sure that remain imbalance weight of inside

and outside is 5g or smaller, if imbalance weight of either side is more than 5g,

repeat the steps above.

Trouble diagnosis

Table of Common Malfunction Diagnosis

Fault symptom Possible cause Solution

The steering wheel

vibration in

circumference

The tire and wheel run-out is excessive

The wheel nut is loose

tire imbalance

The tire is worn unevenly

Insufficient tire pressure

Front wheel bearing is damaged or worn

Steering system fault

Suspension system fault

Replace

Fasten

Adjust

Adjust or replace

Adjust

Adjust or replace

Tire is worn in advance Incorrect tire pressure Adjust

Tire noise

Incorrect tire pressure

Tire degenerate

Adjust

Replace

Road noise or the body

vibration

Insufficient tire pressure

Tire imbalance

Deformation of wheel rim or tire

Tire is worn unevenly

Adjust

Repair or replace

Adjust or replace

The steering wheel

vibrates up and down

The tire and wheel run-out is excessive

The wheel nut is loose

Tire imbalance

The engine support rubber is broken or worn

The transmission support rubber is broken or

worn

Replace

Fasten

Adjust

Replace

The steering wheel is

deflected

Incorrect tire pressure

The tire is worn excessively or unevenly

Steering system fault

Brake system fault

Suspension system fault

Adjust

Adjust or replace

Maintenance Manual for J2 Sedan

WT Wheel and Tire

WT-6

Fault symptom Possible cause Solution

Driving unstable

The tire pressure on both side is different

Deformation of wheel rim or tire

The wheel nut is loose

Steering system fault

Suspension system fault

Adjust

Repair or replace

Fasten

Adjust or replace

Brake deflected

The tire pressure on both side is different

Brake system fault

Adjust

Adjust or replace

Steering wheel is hard

to move

Insufficient tire pressure

Steering system fault

Suspension system fault

Adjust

Adjust or replace

Steering wheel return

ability is bad

Insufficient tire pressure

Steering system fault

Suspension system fault

Adjust

Adjust or replace

Service Data and Specification

Technical Specification Table

Item Parameter

Tire specification Front 230kPa/Rear 220kPa

Wheel rim specification 165/65 R14 79T

Table of Tightening Torque

Item Tightening torque

Wheel bolt

90～110

N·m

Maintenance Manual for J2 Sedan

BR Brake System

BR-1

Brake

BR Brake System

Precautions

 Recommended brake fluid is “DOT 4”;

 Please don not reuse the drained brake fluid

 Be careful not splash brake fluid on paintwork, avoid paintwork damage. If it is

splashed on paintwork, please clean it off with water.

 Clean all parts of brake wheel cylinder with cleaning brake fluid.

 Please do not use mineral oil such as gasoline and kerosene, otherwise, the rubber

parts of hydraulic system will be corroded.

 Please use special oil tube wrench when removing and installing oil tube.

 When installing the brake tube, the fastening torque must be checked.

 The brake contact surface must be run in after repair or replacement of brake disc,

brake shoe, or when the braking became soft after a very short distance driving.

 The brake wheel cylinder and brake shoe must be cleaned thoroughly, such the

damage caused by particles in air and other matters will be minimum.

 When removing the brake wheel cylinder, the brake pedal must not be depressed,

prevent the piston from being bounced out, which may lead to the piston boot

damage.

 The bolts on brake wheel cylinder fixing support and brake hose must not be

removed unless disassemble or replace the brake wheel cylinder. After being

removed, the brake wheel cylinder can be hung up with rope to avoid pulling the

brake hose.

 If the brake shoe shim or the shim retainer ring is corroded seriously, please

replace the brake shoe shim and shim retainer ring with new ones.

 The brake shoe shim and shim retainer ring must be replaced either every time the

brake shoe is replaced.

 Make sure that no brake fluid on brake disc, please do not splash brake fluid on the

brake disc, otherwise will cause brake failure.

Maintenance Manual for J2 Sedan

BR Brake System

BR-2

Preparation

Apply special service tool to remove and install as necessary.

Table of Service Tool

SN Tool Outline drawing Description

Oil pipe

wrench

Remove and install the

brake tube

2 Power tool

Remove and install the

bolts, nuts

Brake Pedal

Check and adjustment:

Adjustment of clearance between brake

pedal and brake limit switch bolt:

1) Remove the lower protecting panel

assembly on driver side.

2) Disconnect the brake lamp connector,

Unscrew the brake limit switch nut,

release the brake pedal, turn the switch

bolt to get the clearance between switch

bolt and brake pedal is 0.5～1mm.

 Tightening torque: 8～10N·m

Brake pedal free travel:

1) Depress the brake pedal for 2～3 times

with the engine switched off.

2) Make sure that vacuum in vacuum

booster is eliminated, depress the pedal

by hand.

3) Check whether the pedal free travel is in

standard range before any resistance

force arising.

BR001

Locking nut

Brake pedal retainer

BR002

Maintenance Manual for J2 Sedan

BR Brake System

BR-3

 Standard value: 3～8mm

4) If the free travel is out of standard range,

please adjust.

Caution:

 If the free travel can not be adjusted to the standard range, please replace the

damaged part and components.

Removal and installation:

1) Removal

① Remove the lower protect panel

assembly on driver side.

② Disconnect the brake lamp connector.

③ Remove the locking pin to brake

vacuum booster, disconnect link to

brake vacuum booster.

④ Remove the fixing bolt of brake pedal

to body, and fixing nut to brake

vacuum booster.

 Tightening torque: 20～25N·m

⑤ Take out the brake pedal.

2) Check after removal

① Brake pedal

 Check the movable pin of brake pedal for abrasion or deformation.

 Check the brake pedal for crack, twist or other damages.

② Locking pin and bush

 Check locking pin and bush for damage or deformation, if any, please replace.

③ Brake lamp switch

BR003

Maintenance Manual for J2 Sedan

BR Brake System

BR-4

a. Test the 2 terminals of brake lamp with

multimeter, press and release the brake

lamp switch to check whether it is in

connection

b. As shown in the figure, if the switch is

depressed for more than 4mm, the two

terminals being not in connection, and

being in connection as released, thus the

brake lamp switch function normally.

3) Installation

Install is the reverse order of removal.

Caution:

 Check whether the brake pedal can travel freely.

 Check the brake pedal free travel.

 Check the clearance between brake pedal and brake lamp.

Brake Master Cylinder

On board inspection:

Check the fitting surface of master cylinder, oil pot and whether there is leakage from

brake tube connector.

Removal and installation:

1) Removal

① Drain off the brake fluid.

② Remove the battery.

③ Remove the air filter assembly.

④ Remove the plug of brake fluid level

switch.

⑤ Remove the fastening nuts of master

pump and remove the master pump

subassembly.

Caution:

 Do not bend or damage the brake pipe.

In connection

ot in connection

BR005

BR004

Maintenance Manual for J2 Sedan

BR Brake System

BR-5

2) Installation

Caution:

 Apply grease to the axis pin before installation: SAE J310 or similar products.

① Install the master cylinder component to brake vacuum booster, and fasten the nut.

Caution:

 Do not damage the sliding surface of piston push rod, no foreign matters should on

the surface.

② Install the brake tube on master cylinder component, and pre-tighten it.

③ Tighten the brake pipe nut with oil pipe wrench or similar tool.

④ Install brake fluid level switch connector.

⑤ Fill new brake fluid and bleed.

Brake Fluid

Check position of brake fluid level:

1) Confirm whether level of brake fluid in oil pot is in specified range (between

MAX and MIN marks), if the fluid level is too low, please check whether there is

leakage around the oil pot and brake system.

2) Start the vehicle, release brake handle to observe whether the brake warning lamp

turn off. If it does not turn off, please check the parking brake switch, brake fluid

level switch for faults.

Brake Pipe

Hydraulic pipe diagram:

Hydraulic Pipeline Illustration

1 – Right rear wheel 2 – Right rear wheel cylinder 3, 6, 11, 13 – ABS sensor 4 – Brake

pedal 5 – Vacuum booster assembly with brake master pump 7 – Right front wheel cylinder

8 – Right front wheel 9 – Left front wheel cylinder 10 – Left front wheel 12 – ABS

module assembly 14 – Left rear wheel cylinder 15 – Left rear wheel

Maintenance Manual for J2 Sedan

BR Brake System

BR-6

Caution:

 All the brake pipes can not be bent, twisted and pulled.

 Make sure that all brake pipe will not interfere with other parts whenever the

vehicle is parked or steering.

 The brake pipe is important security part, if there is brake fluid leakage, tighten it

to fixing position all the time. If there are damaged part and component, please

replace suitable new parts.

 If the brake pipe is disconnected, please plug both ends of the pipe to avoid the

dust ingress.

Front brake pipe and hose:

1) Removal

① Remove the wheel tire.

② Remove the brake hose bolt.

Caution:

■ Pay attention the bolt washer not to fall off.

③ Remove the joint of brake hose and brake tube with oil pipe wrench, take off the

snap clip.

④ Take off the brake hose and brake tube.

2) Installation

Installation is the reverse order of removal.

Caution:

 Please reuse the shim and oil pipe clip.

 Pay attention to the installing direction of brake hose.

 Refill brake fluid and bleed.

Rear brake pipe and brake hose:

1) Removal

① Remove the fixing bolt to rear brake wheel cylinder hose.

② Remove the joint of rear brake hose and brake tube, take off the snap clip.

③ Take off the brake hose and brake tube.

2) Installation

Installation is the reverse order of removal.

Maintenance Manual for J2 Sedan

BR Brake System

BR-7

Brake Master Cylinder and Brake Tube of ABS Hydraulic Adjuster:

1) Removal

① Remove the battery.

② Remove oil pipes joint of brake master

cylinder.

③ Firstly disconnect the joint of brake

master cylinder oil pipe to ABS

hydraulic adjuster assembly, and then

disconnect the other joints in turn.

Caution:

 The brake fluid in ABS hydraulic

adjuster assembly must not be drained

off or disassemble the ABS hydraulic

adjuster.

 Tightening torque: 18～30 N·m

2) Installation

Caution:

 Install the ABS hydraulic adjuster

bracket firstly, and then fasten it with

bolt, fix the hydraulic adjuster assembly

to ABS bracket, the installation

sequence of hydraulic adjuster assembly

is as below:

 The brake pipes may not be changed due to installation difficulty; all the fixing

clips and casing must be installed in position when installing each pipe assemblies.

① Attach left front brake hose assembly to left front brake caliper, pass the whole

pipes through the shock absorber bracket and body bracket to connect with left

front brake tube and fit the snap clip, fit snap clip on the shock absorber bracket at

last. The installation of right side is identical to that of left side.

② Fix the rear brake master pipe assembly to underside of the body with bolt.

③ Install the air filter assembly.

④ Refill brake fluid and bleed.

3) Check after installation

BR007

BR006

Maintenance Manual for J2 Sedan

BR Brake System

BR-8

Caution:

 If there is leakage from joint of brake tube and brake hose, please tighten it again,

if there are damaged part, please replace it.

① Check the brake hose, brake pipes and joint for fluid leakage, damage, twist,

deformation, interference with other part and loose.

② When the engine is running, apply a definite brake force and keep for several

seconds, check each part for fluid leakage.

Brake Vacuum Booster

Part:

Schematic Drawing of Brake Vacuum Booster

1-Cacuum booster assembly 2-Brake master cylinder 3-Brake oil pot 4-Brake pedal assembly

On board inspection:

1) Operation check

Turn the engine off; depress the brake pedal

for several times, make the vacuum in brake

vacuum booster is equal to atmosphere.

Depress the brake pedal to limitation, start

the engine, confirm whether the clearance

between brake pedal and the floor has

decrease when the vacuum arrives at

standard value.

Caution:

 The interval time between brake pedal

depressing is 5 seconds.

BR008

Maintenance Manual for J2 Sedan

BR Brake System

BR-9

2) Air-tightness check

 Start the engine and keep it on idle

running for 1 minute, turn it off when

the brake vacuum booster is in vacuum

condition. Depress the brake pedal

normally, to eliminate the vacuum.

Make sure whether the distance between

brake pedal and floor is increasing

slowly.

 Depress the brake pedal when the engine is running, and hold the brake pedal until

the engine turns off. Hold the pedal for 30 seconds; make sure that the pedal travel

does not change.

Removal and installation:

Caution:

 Do not bend the brake pipe when removing the brake vacuum booster.

 Please replace the damaged locking pin.

 Please do not damage thread of fixing bolt to brake vacuum booster.

1) Removal

① Remove the battery.

② Take off the clamp on vacuum hose; remove vacuum hose from the brake vacuum

booster.

③ Remove locking pin and washer from the brake pedal.

④ Remove the union nut of brake pedal and brake vacuum booster.

⑤ Remove brake vacuum booster from the engine compartment.

2）Check after Removal

Check for damage or crack. If any, please replace it.

3) Installation

① Install the brake master cylinder and vacuum booster assembly on the body, pass

brake pedal assembly through the vacuum booster push rod to install on the

vacuum booster bolt, fasten the installing nut.

② Install the brake pedal and vacuum booster push rod axis pin, apply SAE J310,

NLGI No.0 grease on the axis pin surface .If the axis pin can not be installed

normally, adjust the length of pedal adjusting bolt to assure that the axis pin may

be installed in natural condition, but the length of vacuum booster push rod must

not be adjusted, or the vacuum booster push rod is in pressed condition.

③ Fix the brake pedal upper bracket with hexagon combination bolt.

BR019

Good

Bad

First

Second

Third

Maintenance Manual for J2 Sedan

BR Brake System

BR-10

④ Fix the vacuum hose assembly and clamp to correct position on vacuum booster.

Caution:

 The vacuum hose should be inserted at least 20mm as installation.

 No lubricating oil should be applied when installing.

⑤ Adjust the brake pedal free travel.

⑥ Tighten the push rod locking nut as specified torque.

⑦ Install the air filter assembly.

⑧ Refill brake fluid and bleed.

Front disc brake caliper

On board inspection:

1) Brake shoe abrasion check

Caution:

 Standard thickness: 11mm

 Abrasion limit thickness: 2mm

Brake shoe removal and installation:

1) Removal

① Remove the wheel tire.

② Remove brake caliper assembly

sliding pin.

③ Hang the brake caliper assembly up with ropes, remove the brake shoe etc.

2) Installation

① Install the brake shoe shim and shim retainer ring to respective brake shoe.

Caution:

 Install as the silencer fixing direction.

② Press the piston when installing the

brake shoe, and then install the brake

wheel cylinder on its fixing support.

BR010

BR011

Maintenance Manual for J2 Sedan

BR Brake System

BR-11

③ Install the brake shoe to break wheel

cylinder fixing support.

Caution:

 Pay attention to brake fluid level in oil

pot.

④ Install the brake wheel cylinder sliding

pin and tighten it.

⑤ Fix the brake disc, depress brake pedal

until the brake force arises.

⑥ Check the rotating resistance of brake.

⑦ Install the wheel tire.

Brake caliper component removal and installation:

1) Removal

① Remove the wheel tire.

② Remove brake hose bolt and disconnect

the brake hose.

Caution:

 Pay attention bolt washer not to fall off.

③ Remove the brake caliper assembly

fixing support bolt, and remove the

brake caliper component.

2) Installation

Installation is the reverse order of removal.

BR012

BR013

BR014

BR015

Maintenance Manual for J2 Sedan

BR Brake System

BR-12

Disassembly and assembly:

1) Disassembly

① Remove the brake wheel cylinder sliding pin, and remove brake wheel cylinder

from its fixing support. If necessary, remove the brake shoe, brake shoe silencer

from brake wheel cylinder fixing support.

Caution:

 The brake shoe, brake shoe silencer must not fall off.

② Remove pump sliding pin and sliding

pin boot from brake pump fixing

support.

③ As shown in the figure, put a suitable

wood block, and blow evenly to the

brake hose fixing bolt hole, to remove

the piston and piston boot.

Caution:

 Be careful that the finger being clamped by piston.

④ Remove the piston seal ring from

brake wheel piston with flat

screwdriver.

Caution:

 Be careful not damage inner surface

of the brake wheel cylinder.

2) Check after disassembly

① Brake wheel cylinder block

Caution:

 Clean the cylinder block with new brake fluid. Do not use gasoline or kerosene

etc.

 Check the cylinder block inner surface for abrasion or damage. If any, please

replace the brake wheel cylinder.

② Brake wheel cylinder fixing support

 Check fixing support for abrasion, crack or damage. If any, please replace it.

③ Piston

BR016

Piston sealing collar

BR017

Maintenance Manual for J2 Sedan

BR Brake System

BR-13

 Check surface of piston for corrosion, abrasion or damage. If any, please replace it.

 Do not use abrasive paper to polish surface of the piston.

④ Sliding pin, pin bolt and pin boot

 Check the sliding pin, pin bolt and pin boot for abrasion and crack. If any, please

replace it.

3) Assembly

Caution:

 Apply the specified rubber grease when

assembling.

 Please do not reuse the piston seal ring

and piston boot.

① Apply rubber grease to piston seal ring,

and install it in the cylinder block.

② Apply brake fluid to the piston, and

rubber grease to piston boot. Plug the

piston port with piston boot, and fix the

cylinder block side of piston boot

slowly into groove on cylinder block.

③ Put hand in the cylinder block and insert the cylinder block side of piston boot in

the piston groove.

Caution:

 Press the piston down evenly, avoid friction to cylinder inner surface.

Piston boot

Piston

BR019

Piston seal ring

BR018

Maintenance Manual for J2 Sedan

BR Brake System

BR-14

④ Install the sliding pin and the boot to

brake wheel cylinder fixing support.

⑤ Install the brake shoe silencer to brake

shoe.

Caution:

 Install as the silencer fixing direction.

⑥ Install brake shoe component to brake wheel cylinder fixing support.

⑦ Hold the piston to install the brake shoe, and install the brake wheel cylinder to its

fixing support.

⑧ Tighten the pin bolt.

Check brake disc:

1) Visual check

 Check surface of the brake disc for uneven abrasion, crack or serious damage. If

any, please replace it.

2) Run-out check

① Fix the brake disc to wheel hub.

Caution:

 Before measurement, make sure that

the axial clearance of wheel bearing

is not too large.

② Measure run-out with micrometer. (measure at 10mm away from edge of brake

disc inner side)

 Limit value of run-out: 0.05mm

③ If the run-out is more than the specified value, please replace it or process as

necessary.

BR021

BR020

Maintenance Manual for J2 Sedan

BR Brake System

BR-15

3) Thickness check

 Check brake disc thickness with

micrometer. If the thickness is less

than abrasion limit, please replace

the brake disc.

Standard thickness: 25mm

Abrasion limit: 23mm

Brake run-in steps:

Repair or replace the brake disc, if there is insufficient brake force symptom after

brake shoe replacement or driving a short distance, please run in the contact surface of

brake disc and brake shoe as following steps.

 The brake effect is bad before running-in, so take care to control the vehicle speed.

 Perform this step on safe road and traffic condition, take care of the safety.

1) Drive the vehicle on smooth and straight road.

2) Control the force on brake pedal, brake the vehicle in 3～5 second.

3) Stop the vehicle for 3 minutes after driving a stretch to cool the brake system.

4) Repeat the step 1～3 until the brake shoe and brake disc run in well.

Rear Drum Brake System

1. Onboard Checking

1) Wear checking of brake shoe

■ Check the thickness of brake shoe through the access hole of the brake baseplate.

2. Removal and Installation:

1) Removal

① Remove the wheel tires.

② Release the parking brake.

③ Remove the rear wheel hub dust cap and wheel bearing assembly lock nut and

washer, and remove the wheel bearing assembly.

④ Remove the limit bolt of rear brake drum and remove the brake drum.

⑤ Remove the rear bake tube.

⑥ Remove the wheel speed sensor.

Notice:

BR022

Maintenance Manual for J2 Sedan

BR Brake System

BR-16

■ Do not pull the wheel speed sensor harness.

⑦ Remove the rear brake shoe and parking brake cable.

⑧ Remove the fixing bolts of brake baseplate from the rear steering knuckle.

⑨ Remove the rear brake from the rear steering knuckle.

2) Checking after removal

① Brake drum

■ Check whether the inside diameter and

circular run-out of the brake drum are

within the standard tolerance. If

out-of-tolerance, process or replace the

brake drum.

Standard value: 204mm.

Circular run-out: <0.05mm

② Brake Shoe

■ Check the thickness of brake shoe and

the contact status against brake drum. If

out-of-tolerance, replace the brake shoe.

Standard thickness of brake shoe (A):

5mm

Allowable limit thickness (A): 1mm

③ Brake bottom plate

Check if brake bottom plate is worn or any other damages.

3) Installation

■ Operate as per the reverse order of removal.

■ The fixing bolts of the brake baseplate shall be tightened in crossing manner.

■ Before installation, adjust the diameter of brake shoe to help the installation.

■ During the installation, clean the inner surfaces of brake drum and guard the

contact surfaces of brake shoe and brake drum against contact of oil and grease. In

event of any contact, clean with acetone. Under serious condition, replace with

same model of brake shoe assembly.

■ After installation of brake drum, step down the brake pedal for several times to

position the brake shoe.

BR023

BR024

nner

amete

Maintenance Manual for J2 Sedan

BR Brake System

BR-17

Notice:

■ This brake is equipped with automatic clearance regulator. During the

above-mentioned braking process, the shoe clearance will be automatically

adjusted to the normal value.

■ Adjust the parking brake cable.

■ Bleed the air from the brake system.

Maintenance Manual for J2 Sedan

BR Brake System

BR-18

Trouble Diagnosis

Table of Common Trouble Diagnosis

Fault symptom Possible cause Solution

The vehicle running

deviation in one side as

brake

Under-inflation for left and right tires Adjust

Front wheel adjustment incorrect Adjust

The brake shoe contact badly Adjust

There is grease or oil on brake shoe surface Replace

The brake wheel cylinder is installed incorrectly Adjust

Fault of self-adjusting mechanism Adjust

Insufficient brake force

Brake fluid insufficient or polluted

Add or replace the

brake fluid

Air in brake system Bleed the system

Brake vacuum booster fault Adjust

The brake shoe contact badly Adjust

There is grease or oil on brake shoe surface Replace

Fault of self-adjusting mechanism Adjust

The brake rotating part overheat due to the brake

shoe sluggish

Adjust

Brake pipe limit Adjust

The brake pedal travel

increase (the distance

etween brake pedal and

floor decrease)

Air in brake system Bleed the system

Brake fluid leakage Adjust

Fault of self-adjusting mechanism Adjust

The clearance between push rod and brake master

cylinder is too large

Adjust

Brake retard

The parking brake has not been released completely Release

The parking brake adjustment incorrect Adjust

Brake pedal return spring abrasion Replace

Brake master cylinder oil return limit Adjust

Sliding part lubrication insufficient Lubricate

Brake master cylinder check valve or piston return

spring defect

Replace

The clearance between push rod and brake master

cylinder is too small.

Adjust

Maintenance Manual for J2 Sedan

BR Brake System

BR-19

Fault symptom Possible cause Solution

The parking brake

function insufficient

Rear brake shoe damage Adjust

There is grease or oil on rear brake shoe surface Replace

The parking brake pulling wire is clamped Adjust

Fault of self-adjusting mechanism Adjust

The travel of parking brake handle is too excessive Adjust

Service Data and Specification

Table of Technical Specification

Item Value

Rolling radius of front and rear wheels (mm) 277

Diameter of brake master cylinder (mm) 22.22

Travel of brake master cylinder (mm) (front/rear

chambers)

16/15.5

Model of front and rear brakes Front disc and rear drum

Braking efficiency factor of front and rear brakes 1.722

Power cylinder diameter of vacuum booster (mm) ￠230

Stroke of vacuum booster (mm) ≥33

Cylinder diameter of front and rear wheels (mm) 48/17.46

Front brake disc run-out limit (mm) 0.05

Front brake disc standard thickness (mm) 25

Front brake disc wear limit (mm) 23

Boosting ratio of vacuum booster 5.4±0.2

Standard thickness of front brake caliper friction plate

(mm)

Limit thickness of front brake caliper friction plate

(mm)

Standard value of rear brake drum inside diameter

(mm)

204

Circular run-out (mm) < 0.05

Standard thickness of rear brake shoe (mm) 5

Allowable limit thickness of rear brake shoe (mm) 1

Maintenance Manual for J2 Sedan

BR Brake System

BR-20

Tightening Torque Table

Item Torque (N.m)

Connecting bolt between front brake caliper and

steering knuckle

65~75

Air bleeding bolt of front and rear brake calipers 7～13

Fixing bolts of brake pedal upper bracket 20～25

Fixing nuts of brake pedal 20～25

Connecting bolts between brake hose and brake

caliper

18~30

Brake tube connector 18~30

Fixing torque for front and rear oil pipes and double

two-way pipes

18~30

Hexalobular socket counter sunk head screws 9~16

Brake hose through bolt 25~30

Maintenance Manual for J2 Sedan

PB Parking Brake

PB-1

PB Parking Brake

Precautions

 The parking brake should be checked and adjusted while service brake function

normally.

 The vehicle should be parked on level ground, and the wheel be blocked with

triangle wood for brake system check.

Parking brake control

On board inspection:

1) Travel of parking handle

 Pull the parking brake handle up with the force of 200N, make sure that the pawl

is in specified groove (one click sound may be heard as the pawl passing through

each tooth, check by listening to the click sounds of pawl).

 Standard value: 8～9 teeth

2) Part check

① Confirm each part for the tightening (clearance) is normal or not.

② Check the parking brake handle assembly for bending, damage or crack. If any,

please replace it.

③ Check the parking brake pulling wire for abrasion or damage. If any, please

replace it.

④ Check whether the warning lamp of parking brake function normally or not. If it

can not function well, please check or replace it.

⑤ Remove the connector of parking brake switch so as to check the connection of

positive terminal and body.

 It should be in connection as the parking handle upward.

 It should not be in connection as the parking handle downward.

3) Adjustment

① Insert left and right parking brake pulling wire joint into the installing hole on

parking brake handle balancing plate. As the figure below, after the pulling wire

has been installed, tighten the adjusting nut to assure that the distance L between

adjusting nut and pulling wire end is 8±2mm.

Maintenance Manual for J2 Sedan

PB Parking Brake

PB-2

Schematic Diagram of Parking Brake

1-Parking brake handle assembly 2-Adjusting nut 3- Thread tie rod

4-Joint of parking wire assembly

② After finishing the adjustment, pull parking brake handle up by the force of

200N·m which is perpendicular to the handle, the handle may be pulled up by

8～9 teeth, otherwise the distance L should be adjusted by the adjusting nut. The

specific method is: If the number of pulled teeth is less than 8, L should be

decreased; if the number of pulled teeth is more than 8, the L should be

increased;

Part:

System Diagram of Parking Brake Pulling Wire

1-Parking brake handle assembly 2-The union clamp fixing left and right wires

3-Right parking brake pulling wire assembly

Maintenance Manual for J2 Sedan

PB Parking Brake

PB-3

1) Removal and installation

① Removal

a. Remove the auxiliary instrument panel

rear segment assembly.

b. Unscrew the adjusting nut; remove the

left and right parking brake pulling wire

assembly from the pulling wire clips.

c. Disconnect wire of parking brake

switch; remove the securing bolt of

parking brake handle, and take out the

parking brake assembly.

 Tightening torque: 20～25N·m

d. Unscrew adjusting nut; remove the

parking brake pulling wire assembly

from wire clips.

e. Take out parking brake pulling wire

from the installing hole at bottom of

body.

② Check after removal

 Check whether the button mechanism may operate flexibly. If the button can not

reset normally, please replace it.

 Check the pawl of parking brake handle for abrasion.

 Check the parking brake pulling wire for deformation, abrasion, bend or loose. If

any, please replace it.

③ Installation

Installation is the reverse order of removal.

PB003

PB004

PB005

Maintenance Manual for J2 Sedan

PB Parking Brake

PB-4

Trouble Diagnosis

The indicator light normally ON or OFF:

① Check the indicator light for function fault.

② Check bolt to indicator light and tooth plate support for loose.

Servicing:

If any fault found, please replace the indicator light or install it again.

The braking force is insufficient or deteriorated:

① Check the connection of wire connecting plate to brake pulling wire.

② Check the lock nut for distorted thread.

③ Check whether the current brake distance is the same as the brake distance

specified by the vehicle or not.

Servicing:

① First symptom: Connect the wire connecting plate to the brake pulling wire.

② Second symptom: Please replace the lock nut.

③ Third symptom: Please adjust the lock nut distance.

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-1

Anti-Lock Brake System (ABS)

Precautions

 While driving on rough, gritty, or sloppy (such as snowy) roads, the braking

distance of the vehicle may be longer than that of the vehicle without ABS.

 When the ABS or other warning lamp indicates the presence of fault, before

starting the repair, collect all necessary information (Which symptoms occur

under which conditions) from the customers to find out the simple causes.

Besides the check of electric system, further check the operation of vacuum

booster and the level and quality of brake fluid for leakage.

 If the tire size and type fail to meet the requirements or the brake shoe plate is

other than the JAC genuine parts, the braking distance or the steering stability

may be deteriorated.

 If the vehicle is installed with the components purchased from the market (such

as automotive stereo audio device, CD player, and others), check the electric

harness for being clamped, open-circuit, short-circuit, or incorrect wiring.

 Before conducting the electric welding, disconnect the connectors from the ABS

control module.

 As the components of the anti-lock brake system (ABS) are extremely sensitive

to electromagnetic interference (EMI), carefully caution the arrangement,

location, installation and positioning of all components and eliminate all

interferences from the wiring arrangement, connectors, clamps, and supports.

 Do not start the engine nor charge the battery still being connected with rapid

charger, otherwise it may lead to battery failure or damage of ABS components.

 During the repair, make sure to turn off the ignition switch, disconnect the

negative battery terminal, and then disconnect the connector of ABS control

module assembly, otherwise it may damage the control module.

 Do not try to repair any components of anti-lock brake system. The faults for all

components of ABS can only be resolved by replacement.

 Do not hang the components of suspension part onto the wheel speed sensor

harness, in order to prevent damaging the sensor harness.

 Do not place the ABS control module in the environment with above 105ºC

temperature.

 Do not use the fluid with petroleum-based content in the brake master pump, as

the petroleum will lead to the expansion and deformation of rubber components

in the hydraulic brake system.

 When turning the ignition switch to “ON” position to start the vehicle, the brake

pedal may vibrate or the operating noise of the motor may be heard from the ABS

hydraulic assembly, which is the normal status of check.

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-2

Preparations

The common repair tool and special tool will be used in the repair.

List of Special Tools

SN Tool Outline drawing No. Description

X-431

diagnosis

instrument

JAC-T1Z001

ABS System

Fault

Diagnosis

System Description

System Diagram:

ABS System Diagram

1- Left front brake assembly 2- Vacuum booster with brake master cylinder assembly 3- ABS

control module with hydraulic assembly 4- Brake pedal assembly 5- Right front brake

assembly 6- Brake pipeline 7- Right rear brake assembly 8- Left rear brake assembly

ABS function:

The anti-lock brake system (ABS) controls the hydraulic brake devices of four wheels

to prevent wheel locking in event of emergency braking or braking on hazardous

roads. The main advantages of the ABS are as below:

(1) Capable of reliable steering in event of confrontation of obstacles during the

emergency braking.

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-3

(2) Capable of maintaining the stable and controllable stop during the emergency

braking on bends.

Notice:

 If the electric system is interrupted, the failure protection mode will be activated

so that the ABS enters into inactive status and the ABS warning lamp lights up.

 The JAC-provided special diagnosis instrument may be used for diagnosis of

ABS electric system.

 During the braking, the brake pedal may vibrate slightly and some mechanical

noise may be heard. This is the normal operating condition of ABS.

EBD function:

The electronic brake-force distribution (EBD) is one proportional system used to

maintain the vehicle stability during the braking. Under the normal braking conditions,

it effectively balances the equal wheel speed required by the braking. Under difficult

braking condition, as the vehicle weight conveys onto the front wheels and the rear

wheels requires relatively lower braking force, the EBD maintains the braking

pressure required by the rear wheels via the ABS pressure increasing valve and

reducing valve, in order to provide the effective braking and vehicle stability.

Emergency protection function:

The ABS warning lamp lights up in event of electric fault of ABS system. In event of

EBD electric fault, the braking warning lamp and ABS warning lamp will both light

up.

At the same time, the ABS system will turn to one of the following emergency

protection functions:

1) For ABS fault, only the EBD is activated and the vehicle status is same with that

of the vehicle without ABS system.

2) For EBD fault, both EBD and ABS are inactive and the vehicle status is same

with that of the vehicle without both ABS and EBD systems.

Anti-lock braking mode:

Upon the detection of wheel slip during the braking, the ABS will enter into anti-lock

braking mode. During the anti-lock braking, the pressures of hydraulic circuit for

various wheels are under control, in order to prevent the wheel slip. Each wheel is

equipped with individual hydraulic pipeline and valve. ABS can reduce, maintain or

increase the hydraulic braking pressure for various wheels. However, the ABS can’t

increase the hydraulic pressure to a pressure in excess of the pressure conveyed by the

master cylinder during the braking. During the anti-lock braking, one series of rapid

vibration can be felt on the brake pedal. The pedal vibration occurs during the

anti-lock braking and stops during the normal braking or when the vehicle completely

stops. Due to the rapid recirculated operation of the solenoid valve, the operation

noise can be heard. While activating the anti-lock braking on dry roads, the tires will

generate intermittent and sharp noise when the tires close to slip. This noise and the

pedal vibration are normal during the operation of the anti-lock braking. The

operation of brake pedal shall be same with that of vehicle without ABS system

during the normal braking. Maintaining the equal stepping force of pedal can

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-4

guarantee the shortest stopping distance while maintaining the vehicle stability.

1. Pressure maintaining

When the ABS control module detects the wheel slip, it will close the inlet valve and

close the outlet valve of hydraulic assembly to isolate the system. This can maintain

the stable pressure of the brake and prevent the hydraulic pressure from increasing or

reducing.

2. Pressure reducing

If the ABS control module still can detect the wheel slip under the pressure

maintaining mode, it will reduce the pressure of the wheel being influenced. By

keeping the inlet valve closed and opening the outlet valve, the excessive

fluid/pressure will be temporarily stored in the accumulator of the hydraulic assembly,

till the pump motor can convey the brake fluid back to the oil reservoir of the master

cylinder.

3. Pressure increasing

If the ABS control module detects the reduced wheel slip under the pressure

maintaining or pressure reducing mode, the ABS control module will increase the

pressure of the wheel being influenced via the pressure of master cylinder. By

opening the inlet valve and closing the outlet valve, all pressure or partial pressure

from the brake master pump will be applied to the wheel.

4. Operating process of ABS

During the driving of the vehicle, each wheel speed sensor generates one voltage

signal in proportional to the wheel speed. The ABS control module receives the wheel

speed data and judges the presence of excessive deceleration of one or more wheels

(compared with the reference vehicle speed), which is referred to as slip. Depending

on the needs, the ABS control module will activate the module and the module will

control the braking pressure of each wheel to realize the best optimization.

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-5

Hydraulic Schematic Diagram of ABS System:

Hydraulic Schematic Diagram of ABS System

1- Master pump 2- Inlet valve/LF 3- Outlet valve/LF 4- Inlet valve/RR 5- Outlet valve/RR

6- Damper 7- Reflux pump 8- Accumulator 9- Inlet valve/RF 10- Outlet valve/RF

11- Inlet valve/LR 12- Outlet valve/LR

Wheel speed sensor

Consisted of the sensor itself and the gear ring, one set for each wheel. This vehicle

model adopts the active wheel speed sensor, which requires the external power supply

(12V) for operating. It can provide one constant amplitude signal, no matter what the

size of the wheel speed is.

Component:

Consisted of the sensor itself and the gear ring, one set for each wheel.

Removal:

1) Front wheels

① Lift the vehicle.

② Remove the fender and disconnect the

sensor connector.

③ Loosen the fixing bolts of sensor and

slowly take out the sensor.

2 9

Right front/RF

Left front/LF

Right rear/RR

Left rear/LR

ABS001

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-6

Notice:

 Do not pull the wheel speed sensor harness with force.

 Notice the clearance between wheel speed sensor and the signal gear ring during

the installation.

Standard value: 0.8mm

2) Rear wheels

① Lift the vehicle and remove the rear

tires.

② Remove the lower trim panel of pillar

③ Disconnect the sensor connector.

④ Loosen the fixing bolts of wheel speed

sensor and slowly take out the wheel

speed sensor.

Notice:

 Do not pull the wheel speed sensor harness with force.

 Notice the clearance between wheel speed sensor and the signal gear ring during

the installation.

Standard value: 0.8mm

Check after removal:

1) Check the installation hole of sensor for presence of foreign matters and check

the surface of brake plate for presence of foreign matters (such as metal chips).

2) Before installation, clean the sensor installing hole and surface of brake plate.

Installation

Installation is the reverse order of removal and tighten the bolts to specified torque.

Notice:

 The harness shall be free of torsion after the installation.

ABS002

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-7

ABS Hydraulic Assembly

Removal and Installation:

1) Removal

① Turn off the ignition switch and

disconnect the negative wiring post of

the battery.

② Remove the connector of ABS control

module.

③ Step down the pedal by >60mm and

secure the pedal bracket.

 Close the central valve of hydraulic assembly so that the brake fluid will not flow

out from the outlet while the system is opened.

④ Remove from the hydraulic assembly the brake tubing that connected to the

master pump, add the marking, and plug the outlet with plug immediately.

⑤ Remove the brake tubing that connected to various wheels, add the marking, and

plug the outlet with plug immediately.

⑥ Remove the bolts from the fixing bracket of ABS hydraulic assembly.

2) Installation

Notice:

 The connectors of the brake pipeline that connected to the ABS hydraulic

assembly shall be tightened to the specified torque.

 The plug at the hydraulic outlet of the ABS hydraulic assembly shall be removed

only right before the installation of brake tubing, in order to prevent the ingress of

foreign matters.

 Replace the ABS hydraulic assembly in event of fault of ABS hydraulic

assembly.

① Install the ABS hydraulic assembly onto the bracket and tighten to specified

torque.

② Remove the plug from the hydraulic outlet, install the brake tubing, and confirm

the correct connection of the tubing.

③ Connect the brake tubing from hydraulic assembly to the master pump.

④ Install the brake tubing and tighten to the specified torque.

⑤ Add new brake fluid to the oil reservoir, till the fluid level reaches to marking

MAX, and bleed the air according to the specified method.

⑥ Turn the ignition switch to “ON” position. The ABS warning lamp lights up and

then goes out.

ABS003

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-8

⑦ Clear the trouble codes from the memory and re-read the memory for the

presence of trouble code.

⑧ Test run the vehicle to determine whether the ABS functions normally.

ABS control module

Component:

This vehicle model adopts the Delphi 7.8 anti-lock brake system. The ABS control

module is integrated with the hydraulic assembly.

Description of pins of ABS control module:

Pin Diagram of ABS Control Module

Description Table of pins of ABS Control Module:

Pin No. Description Pin No. Description

Power terminal of motor (Positive)

Vacant pin

Right front wheel speed (low)

Vacant pin

Right front wheel speed (low)

Vacant pin

Left rear wheel speed (low)

Brake warning lamp

Right rear wheel speed (low)

Diagnosis K-wire

Power supply

Vacant pin

None

Vacant pin

None

Left front wheel speed (high)

None

Right front wheel speed (high)

None

Left rear wheel speed (high)

None

Right rear wheel speed (high)

None

Power terminal of the motor

(grounding)

None

Vacant pin

None

Brake switch

None

Vacant pin

None

ABS warning lamp

None

ECU reminder

None

Vacant pin

ABS Control Module Gounded

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-9

ABS control module check:

Notice:

 Without special needs, do not disassemble the ABS hydraulic assembly (inclusive

of control module).

1) Basic check of brake system

① Check the level of brake fluid. If the fluid level is low, add brake fluid.

② Check the surrounding area of brake pipeline and ABS hydraulic assembly for

leakage. Upon the detection of leakage, conduct the following check:

a. If the connector of ABS hydraulic assembly is loose, tighten the oil pipe nuts of

the pipeline to the specified torque (18~30N.m). Re-check the leakage and

confirm there is no leakage of brake fluid.

b. If oil pipe nut at the connector and the threaded part of actuator are damaged,

replace the damaged components. Re-check the leakage and confirm there is no

leakage of brake fluid.

c. If the leakage is detected in the location other than the actuator connectors,

please wipe with clean cloth and re-check. If the leakage still exists, replace the

damaged components.

d. If the leakage is detected on the hydraulic assembly, wipe with clean cloth and

re-check. If the leakage still exists, replace the hydraulic assembly.

③ Check the brake shoe plate for wear.

④ Check the power supply terminals and the positive/negative terminals of the

battery for looseness and abnormal voltage.

2) Check of ABS warning lamp and brake warning lamp

① Make sure that, when turning the ignition switch to “ON” position, the ABS

warning lamp lights up for about 1s and the brake warning lamp lights up. If not,

please refer to the “Fault diagnosis”.

② Check whether the ABS warning lamp goes out about 1s after the ignition switch

is turned to “ON” position and whether the brake warning lamp goes out after the

engine is started. If not, please refer to “Fault diagnosis”.

③ If the ABS warning lamp fails to go out 10s after the engine is started, please

refer to “Fault diagnosis”.

Notice:

The brake warning lamp lights up when the parking brake is applied (when the switch

is at “ON” position) and when the brake fluid sensor functions (insufficient brake

fluid).

3) Check the ABS control module with diagnosis instrument

Check the control data of the control module and the stored trouble codes with the

diagnosis instrument. In event of any abnormal conditions, repair according to the

fault tips.

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-10

List of ABS Trouble Codes

Fault code Fault description

C0011 ABS warning lamp fault

C0012 Brake warning lamp fault

C0014 System relay contact or coil circuit open

C0017 Failures of grounded pump motor

C0018 Short-circuit of pump motor and battery, open-circuit to ground/high

resistance of motor

C0021* Left front wheel speed =0kph

C0022* Right front wheel speed =0kph

C0023* Left rear wheel speed =0kph

C0024* Right rear wheel speed =0kph

C0025 Change fault of left front wheel speed

C0026 Change fault of right front wheel speed

C0027 Change fault of left rear wheel speed

C0028 Change fault of right rear wheel speed

C0032*

Open-circuit wheel (LH,FR)speed or grounded／short-circuit of battery

C0033*

Open-circuit wheel (RH,FR)speed or grounded／short-circuit of battery

C0034*

Open-circuit wheel (LH,RR)speed or grounded／short-circuit of battery

C0035*

Open-circuit wheel (RH,RR)speed or grounded／short-circuit of battery

C0036* Too low voltage

C0037* Too high voltage

C0042* Open-circuit of pump motor circuit

C0043 Bump motor stopping

C0055 Malfunction detected

C0056 System relay always connected

C0061 Failures of pressurization solenoid valve (LH, FR)

C0062 Failures of pressure relief solenoid valve (LH, FR)

C0063 Failures of pressurization solenoid valve(RH,FR)

C0064 Failures of pressure relief solenoid valve (RH, FR)

C0065 Failures of pressurization solenoid valve (LH, RR)

C0066 Failures of pressure relief solenoid valve (LH, RR)

C0067 Failures of pressurization solenoid valve (RH, RR)

C0068 Failures of pressure relief solenoid valve (RH, RR)

C0091 Response less brake pedal during speed down

C0093 Response less brake pedal during last ignition period

C0094 Failures of brake pedal acting during not decelerating

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-11

Fault code Fault description

C0095* open-circuit of brake switch

C0118 failures related with pressurization solenoid valve (LH,RR)

C0121 failures related with pressurization solenoid valve (RH,RR)

C0122 failures related with pressure relief or last pressurization solenoid valve

C0127 failures regarding to last ignition period no slow down, brake pedal acting all

The time

C0151 Wheel (LH,FR)relief time too long

C0152 Wheel (RH,FR)relief time too long

C0153 Wheel (LH,RR)relief time too long

C0154 Wheel (RH,RR)relief time too long

C0191 There is no current of bump motor

C0192 Current overload of bump motor

C0194 Circuit short-cut of bump motor

Air Bleeding of ABS System

Air bleeding conditions of ABS system:

The air bleeding procedure shall be taken for the ABS system following whichever

the following conditions:

1) When the traditional air-bleeding method for the brake pipeline can’t realize the

required pedal height or feeling.

2) When the ABS hydraulic assembly is replaced.

3) When extremely high fluid loss occurs.

4) When in suspect of air suction.

■ This procedure adopts the diagnosis instrument to drive the system valve and run

the pump motor to bleed the air from the secondary circuits. These secondary circuits

are normally close and are opened only during the initialization at the vehicle startup

and during the ABS operations. The automatic air-bleeding procedure opens these

secondary circuits, bleeds and collects all the air in the hydraulic assembly, in which

the air can be bled from the system.

Air bleeding procedure of ABS system:

1) Required items

① Diagnosis instrument, with correct software.

② Brake fluid.

③ Lifter

④ Air bleeding tank, equipped with hose for recovery of automotive brake fluid.

⑤ Proper safety equipment, including the safety goggles.

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-12

⑥ Two repair operators are required: One operator steps down the brake pedal and

controls the diagnosis instrument and another operator maintains the hydraulic

oil level of brake master pump main chamber and opens/closes the air bleeding

bolt according to the instruction of the diagnosis instrument.

2) Initial check

① Check the charging status of the battery and repair the battery and the charging

system based on the needs.

② Connect the diagnosis instrument and select the current and historic diagnosis

trouble codes. Before conducting the ABS air bleeding procedure, clear all

diagnosis trouble codes. If the diagnosis trouble codes can’t be cleared, resolve

the faults first.

③ Check the appearance for damage and leakage. Repair when necessary.

3) Actions before air bleeding

① Start the engine.

② Connect the diagnosis instrument and establish the communication with ABS

control module.

③ Lift the vehicle and support properly.

4) Bleed the air on the vehicle.

Notice:

 By pressing the EXIT button on the diagnosis instrument, the automatic air

bleeding procedure can be terminated at any time.

① Select “Automatic air bleeding function” on the diagnosis instrument and operate

according to the instructions.

② During the basic air bleeding and automatic air bleeding, it’s necessary To step

down the brake pedal and maintain the brake fluid level of the brake master

pump.

③ When bleeding the air for one wheel, make sure to connect the hose to the air

bleeding bolt and drain to a container with brake fluid. This container must be

higher by 30mm than the bolt with the hose fully filled with brake fluid. This is

intended to prevent the air from ingress into the brake pipeline.

④ The first step is the basic air bleeding. This step must be taken before the

automatic air bleeding, in order to obtain good pedal height and pedal feeling and

guarantee the best performance of ABS.

⑤ During the next step, the diagnosis instrument will require the repair operator to

open one air bleeding bolt. Then, the diagnosis instrument will check repeatedly

the pressurizing valve and the pump motor for about 30s. During the entire

process, the brake pedal shall be always pressurized and released.

⑥ For remaining air bleeding bolts, the diagnosis instrument will repeat step ⑤ for

air bleeding.

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-13

⑦ When the automatic air bleeding procedure is complete, the diagnosis instrument

will display the relevant information.

⑧ Step down the brake pedal and measure the pedal height and feeling. Repeat step

① to ⑦, till the pedal restores to normal height.

Warning:

 When repeating certain step or the entire air bleeding procedure, make sure to

wait for 5min to cool down the solenoid valve, or the solenoid valve may be

damaged due to overheating.

5) Automatic air bleeding procedure

Onboard diagnosis procedure:

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-14

Trouble Diagnosis

Diagnosis flowchart:

The diagnosis procedure is as below:

Clear self-diagnosis result and drive the vehicle

at a speed of 30km/h or above for more tha

1min.

Determine fault

symptom

erstand “Precautions” and how to

conduct rapid diagnosis and rapidly find ou

fault

Conduct initial check

Does ABS warning lamp

light up?

Does diagnosis instrument display

trouble code?

Conduct self-diagnosis

Check and repair faulty components

Re-conduct self-diagnosis

Check result

Check ABS actuator, electric

components and data connector harness

Conduct symptom diagnosis

procedure

Confirm symptom

ormal

Abnormal

Yes

ormal

Abnormal

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-15

Diagnosis Information and Procedure:

1) Self-diagnosis

The ABS control module conducts the self-diagnosis to the system and is capable of

the detection of system faults. Upon the detection of system faults, it sets up the

diagnosis trouble code (DTC), lights up the ABS warning lamp, and at the same time

turns off the ABS system.

2) Display diagnosis trouble code (DTC)

By means of the special diagnosis instrument, the diagnosis trouble code can be

displayed.

3) Clear diagnosis trouble code (DTC)

The diagnosis trouble codes in the memory of the ABS control module can be cleared

by means of the diagnosis instrument.

Notice:

 After clearing the diagnosis trouble codes, make sure to verify the system for

normal functioning and confirm that the diagnosis trouble codes never reoccur.

 The diagnosis trouble codes can’t be cleared by disconnecting the ABS control

module connector, disconnecting the battery wiring, or stopping the engine.

4) The intermittent fault or poor contact is mostly caused by any condition as

below:

① Error of electric wiring.

② Error of electric connection.

③ Stagnation of relay or solenoid valve.

5) Initialization procedure

The ABS control module conducts the initialization testing at the beginning of each

ignition period.

The initialization procedure is as below: Check the components of the solenoid valve

and pump motor for normal functioning. Upon the detection of fault, the ABS control

module will set up corresponding diagnosis trouble code. During the initialization

procedure, some actions may be heard and felt, which are the constituent parts of the

normal system functioning. If the ABS control module detects no signal input of the

brake switch (namely the foot is released from the brake pedal), the initialization

starts immediately. If the brake switch has signal input (namely the foot is put onto

the brake pedal), the initialization will not start, till the brake switch has no signal

input (namely the foot is released from the brake pedal) or the vehicle speed reaches

16km/h.

Check of Diagnosis Circuit:

1) System description

The diagnosis circuit can detect the problems arising from the fault of ABS system.

The check of diagnosis circuit will guide the repair technicians to conduct the next

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-16

step of fault diagnosis.

2) Diagnosis procedure

The procedure for repair of ABS system is as below:

① Check the vehicle for brake system related mechanical faults.

 Check the brake oil reservoir for correct level.

 Check the brake fluid of master cylinder for contamination.

 Check the brake master pump/ABS hydraulic assembly for leakage.

 Check the brake components of all wheels.

 Verify the presence of braking stagnation.

 Verify the stable braking (Without rear pulling or forward rushing).

 Check the brake shoe plate for wearing/damage.

 Check the wheel bearings for damage.

 Check the wheel speed sensors and harness.

 Check the wheel speed sensor connector/gear ring for damage and check the tread

depth/wear of tires.

 Conduct the road test, verify the status, and correct accordingly.

② Conduct check of diagnosis circuit and operate according to the appropriate fault

diagnosis procedure. After all system faults are resolved, clear the ABS

diagnosis trouble codes.

Table of Trouble Diagnosis

Step Diagnosis Yes No

1. If possible, connect or install all components disconnected

or removed before.

2. Shift the ignition switch to ON position and stop the

engine.

3. Install appropriate diagnosis instrument to DLC and

enable it to communicate with ABS control module.

To step 2 To step 4

2 Is there any current or old trouble code? To step 3 To step 7

1. Record current trouble code.

2. Record old diagnosis trouble code.

3. Record the history data, such as the number of setup for

each diagnosis trouble code; number of first setup for each

trouble code; number of previous setup for each trouble

code; the vehicle speed when the diagnosis trouble code is

set; other reinforced data helping the diagnosis.

4. Before recording the information from diagnosis

instrument, do not clear diagnosis trouble codes.

Can the diagnosis instrument communicate with other modules

in same data line?

To step 5 To step 6

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-17

Step Diagnosis Yes No

To “No communication with ABS control module” in

diagnosis procedure of ABS control module.

6 To other electric control modules for diagnosis.

1. Stop the engine.

2. Wait for 10s.

3. Start the engine.

4. Observe ABS warning lamp after engine start.

To step 8 To step 9

8 Is there any lamp still ON? To step 9

To step

9 To diagnosis procedure of “ON” for corresponding lamp.

10 To diagnosis procedure of “Inactive” for corresponding lamp.

Common ABS Symptoms and Analysis Procedures:

2) No communication with ABS control module

The typical causes for communication failure of ABS control module are as below:

 Poor contact of diagnosis port.

 No grounding of ABS control module.

 No battery or ignition switch supplied voltage of ABS control module.

 Open-circuit/short-circuit/excessive resistance of data line.

2) No light-up of ABS warning lamp/No diagnosis trouble code

The typical causes for failure of ABS warning lamp and no setup of diagnosis trouble

code are as below:

 Failure of ABS warning lamp bulb/loose connector.

 Breakage of instrument panel fuse

 Fault of instrument warning lamp drive module.

 Fault of ABS control module.

 Open-circuit or short-circuit between ABS control module and instrument.

3) Light-up of ABS warning lamp/No diagnosis trouble code

The typical causes for light-up of ABS warning lamp without setup of diagnosis

trouble code are as below:

 Open-circuit between instrument and ABS control module.

 No grounding of ABS control module.

 Short-circuit between instrument and ABS control module.

 Fault of instrument warning lamp drive module.

 Fault of ABS control module.

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-18

4) Light-up of brake warning lamp

The typical causes for light-up of brake warning lamp without setup of diagnosis

trouble code are as below:

 Failure of parking brake switch.

 Low brake fluid level or failure of brake fluid switch.

 Open-circuit between instrument and ABS control module.

 Failure of warning lamp circuit.

 Instrument fault.

 Fault of ABS control module.

5) No light-up of brake warning lamp/without setup of diagnosis trouble code

The typical causes for failure of brake warning lamp and no setup of diagnosis trouble

code are as below:

 Bulb fault/loose connector.

 Breakage of instrument panel fuse

 Instrument fault.

 Fault of ABS control module.

 Circuit grounding between instrument and ABS control module.

Analysis of ABS trouble code

C0011-ABS warning lamp fault

Description of circuit

ECU gives a low-level output to the other end output of pin 38 interface to lamp drive

module or instrument lamp. In any case, the output is increased at unactivated state

and reduced at activated state.

Conditions for setting the diagnostic trouble code

Set the diagnostic trouble code-C0011 after turning off the ignition switch, and:

1.When the output voltage of lamp drive is up to and over the voltage to be

determined (TBD), the short-circuit fault of battery is detected at #38 pin output

circuit of ECU, while the indicator lamp drive output ON=drive is low.

2.Open-circuit or short-circuit to ground of #38 pin output circuit of ECU will make

the voltage of output circuit grounded. When the output voltage of lamp drive is

below the voltage to be determined, it detects the open-circuit or grounded

short-circuit fault, while the indicator lamp drive output OFF= is recognized as

externally high.

When the output of ABS warning lamp is a fault and lasts for 30ms, this fault is set.

Measures taken when setting the diagnostic trouble code

The diagnostic trouble code will be stored in ECU.

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-19

Conditions for removing the diagnostic trouble code

If no conditions for setting the diagnostic trouble code-C0011 appear, it’s allowed to

remove this diagnostic trouble code with a corresponding diagnostic unit.

If no diagnostic trouble code appears within the successive 100 periods, remove it

from its historical data.

Diagnostic help

Typical causes for diagnostic trouble code-C0011:

1. Open-circuit between #38 pin and auto lamp interface of ECU.

2. Grounded short-circuit between #38 pin and lamp interface of ECU.

3. Short-circuit between #38 pin and lamp interface of ECU to battery.

4. ECU faults.

C0011-ABS warning lamp fault

Step Diagnostic actions Expected value Yes No

1 Do you complete the check of diagnostic

circuit?

Go to

Step 2

Go to

Step 5

2 1. Flame breaking.

2. Disconnect ECU harness on ECU.

3. IGNITION.

4. Connect a jumper wire with a fuse

between Terminal 38 of ECU harness

and body ground.

Is amber ABS lamp OFF?

Go to

Step 6

Go to

Step 3

3 1. Flame breaking

2. Still disconnect ECU harness.

3. Remove the instrument assembly from

the instrument panel.

4. Disconnect color instrument wire

harness from the instrument assembly.

5. Connect an ohmmeter to the terminal

of instrument harness (color), and

reconnect it to Terminal A2 of

instrument harness.

Is the resistance within the specified

range?

Below 2 Ohm Go to

Step 4

Go to

Step 7

It’s required to add a step, i.e. check the

battery of auto wire for short-circuit.

4 Replace the instrument assembly.

Do you complete the repair?

Go to

Step 10

5 Perform the diagnostic check of harness.

6 Replace ECU.

Do you complete the repair?

Go to

Step 10

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-20

C0011-ABS warning lamp fault

Step Diagnostic actions Expected value Yes No

7 It’s required to perform some check

regarding ECU grounding before

replacing ECU

8 Remove the short-circuit or

high-resistance fault between ECU and

instrument.

Do you complete the repair?

Go to

Step 10

9 Remove the short-circuit fault of harness

battery.

Do you complete the repair?

Go to

Step 10

10 Remove the diagnostic trouble code with a

diagnostic unit.

Is this diagnostic trouble code reset?

Go to

Step 1

System is

OK.

C0012-Brake warning lamp fault

Description of circuit

EC gives a low-level output to #25pin. The other end output of its interface is to lamp

drive module or instrument lamp. In any case, the output is increased at unactivated

state and reduced at activated state.

Conditions for setting the diagnostic trouble code

Set the diagnostic trouble code-C0011 after turning off the ignition switch, and:

1. When the output voltage of lamp drive is up to and over the voltage to be

determined (TBD), the short-circuit fault of battery is detected at #38 pin output

circuit of ECU, while the indicator lamp drive output ON=drive is low.

2. Open-circuit or short-circuit to ground of #38 pin output circuit of ECU will

make the voltage of output circuit grounded. When the output voltage of lamp

drive is below the voltage to be determined, it detects the open-circuit or

grounded short-circuit fault, while the indicator lamp drive output OFF= is

recognized as externally high.

When the output of ABS warning lamp is a fault and lasts for 30ms, this fault is set.

Measures taken when setting the diagnostic trouble code

The diagnostic trouble code will be stored in ECU.

Conditions for removing the diagnostic trouble code.

If no conditions for setting the diagnostic trouble code-C0012 appear, it’s allowed to

remove this diagnostic trouble code with a corresponding diagnostic unit.

If no diagnostic trouble code appears within the successive 100 periods, remove it

from its historical data.

Diagnostic help

Typical causes for diagnostic trouble code-C0012:

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-21

1. Lamp drive output closed.

2. Lamp drive output is short-circuited to ground.

3. Short-circuit between ABS lamp drive and battery.

C0012-brake warning lamp fault

Step Diagnostic actions Expected value Yes No

1 Do you complete the check of diagnostic

circuit?

Go to

Step 2

Go to

Step 6

2 1. Battery load test. Refer to the Battery

Maintenance Manual.

2. Check the charging system. Refer to the

Maintenance Manual for Starter and

Charging System.

3. Perform the additional load test.

Do you pass the tests of battery, charging

system and additional load?

The battery must be

capable of maintaining

at least 9.6V for 10s.

Not more than 30mA.

Go to

Step 3

Go to

Step 7

3 1. Flame breaking.

2. Disconnect the positive and negative

poles of battery.

3. Disconnect the harness from ECU.

4. Check the conditions of following

harness connection.

• Battery terminal wiring.

• Negative cable to engine block and/or

chassis.

• Positive cable to starter solenoid valve

and/or wiring box.

• ECU terminals 16,46 and 1.

• ECU grounding wire to chassis to

ground.

Are all the above connections good?

Go to

Step 4

Go to

Step 8

4 1. Still disconnect ECU.

2. Still disconnect ECU harness.

3. Connect an ohmmeter between

Terminal 1 of ECU harness and

negative pole of battery cable.

Is its resistance within the specified range?

Below 2 Ohm Go to

Step 5

Go to

Step 9

5 1. Reconnect the battery cable.

2. Still disconnect ECU.

3. Ignition.

4. Measure the voltage of Terminals 16

and 46 of ECU harness with a

voltmeter.

Is the voltage between both terminals

within the specified range?

Battery voltage Go to

Step 11

Go to

Step 10

6 Check the diagnostic circuit.

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-22

C0012-brake warning lamp fault

Step Diagnostic actions Expected value Yes No

7 Repair the charging system.

And/or

Recharge/replace the battery.

And/or

Find out the causes for excess use and

repair it.

Do you complete the repair?

Go to

Step 12

8 If necessary, repair the terminals and/or

connectors.

Do you complete the repair?

Go to

Step 12

9 Check the cause for high resistance

between negative cable of battery and ECU

harness connector, and repair it.

Do you complete the repair?

Go to

Step 12

10 Check the cause for low voltage of ECU

terminal, and repair it.

Do you complete the repair?

Go to

Step 12

11 Replace ECU.

Do you complete the repair?

Go to

Step 12

12 Remove the diagnostic trouble code with a

diagnostic unit.

Is this trouble code reset?

Go to

Step 1

System

is OK.

C0014-System relay contact or coil circuit open

Description of circuit

Electromagnetic relay is an indispensable part of ECU. The battery voltage is

continually supplied to the switch of relay through Terminal 46. When the ignition

switch is closed, the battery voltage from Terminal 16 can be supplied to the relay coil.

Then ECU makes the circuit of relay coil grounded to power on the relay and supply

the battery voltage to the electromagnet and motor. So long as the ignition switch is

closed, the relay will be still in closed position, otherwise the diagnostic trouble code

will be set to disconnect the relay.

Conditions for setting the diagnostic trouble code

When the ignition switch is closed, ECU indicator relay is closed. If the ignition

voltage is more than 10.5V, and the voltage drop of switch relay is below 8.0V within

1/4s, the diagnostic trouble code-C0014 will appear. These values can be changed

according to the customer’s detailed nominal setting.

Measures taken when setting the diagnostic trouble code

1. The electromagnetic relay is indicated as disconnected, and no battery voltages

exist on all the electromagnets and pump motors.

2. ABS fails, and ABS warning lamp goes on.

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-23

Conditions for removing the diagnostic trouble code

1. If no conditions for setting the diagnostic trouble code-C0014 appear, remove

this diagnostic trouble code with a corresponding scanning tool.

2. If no diagnostic trouble code appears within the successive 100 periods, remove

it from its historical data.

Diagnostic help

Typical causes for diagnostic trouble code-C0014:

1. Weak voltage or discharge of battery.

2. Loosening or rusting of battery wiring terminal.

3. Poor grounding of engine block from the battery.

4. Poor contact or loosening of ABS fuse.

5. Poor contact of ECU terminal 16, 46, 1.

6. Overlow voltage of ECU terminal 46.

7. Internal faults of ECU.

C0014-System relay contact open

Step Diagnostic actions Expected value Yes No

Do you complete the check of diagnostic

circuit?

Go to

Step 2

Go to

Step 6

1. Battery load test. Refer to the Battery

Section of Maintenance Manual.

2. Check the charging system. Refer to the

Maintenance Manual for Starter and

Charging System.

3. Perform the additional load test.

Do you pass the tests of battery, charging

system and additional load?

The battery must

be capable of

maintaining at

least 9.6V for 10s.

Not more than

30mA.

Go to

Step 3

Go to

Step 7

1. Flame breaking.

2. Disconnect the positive and negative

poles of battery.

3. Disconnect the harness from ECU.

4. Check the conditions of following

contacts.

• Battery wiring.

• Negative cable to engine block and/or

chassis.

• Positive cable to starter magnet and/or

wiring box.

• ECU terminals 16,46 and 1.

• ECU grounding wire to chassis to ground.

Are all the above connections good in

contact?

Go to

Step 4

Go to

Step 8

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-24

C0014-System relay contact open

Step Diagnostic actions Expected value Yes No

1. Still disconnect ECU.

2. Still disconnect ECU harness.

3. Connect an ohmmeter between Terminal

1 of ECU harness and negative pole of

battery cable.

Is its resistance within the specified range?

Below 2 Ohm

Go to

Step 5

Go to

Step 9

1. Reconnect the battery cable.

2. Still disconnect ECU.

3. Ignition.

4. Measure the voltage of Terminals 16 and

46 of ECU harness with a voltmeter.

Is the voltage on these terminals within the

specified range?

Battery voltage

Go to

Step 11

Go to

Step 10

6 Check the diagnostic circuit.

Repair the charging system.

And/or

Recharge/replace the battery.

And/or

Find out the causes for excess use and repair

it.

Do you complete the repair?

Go to

Step 12

If necessary, repair the terminals and/or

connectors.

Do you complete the repair?

Go to

Step 12

Check the cause for high resistance between

negative cable of battery and ECU harness

connector, and repair it.

Do you complete the repair?

Go to

Step 12

Check the cause for low voltage of ECU

terminal, and repair it.

Do you complete the repair?

Go to

Step 12

Replace ECU.

Do you complete the repair?

Go to

Step 12

1.Remove the diagnostic trouble code with a

diagnostic unit.

Is this trouble code reset?

Go to

Step 1

System

is OK.

C0017-Open-circuit of pump motor power circuit

Description of circuit

The pump motor is included in hydraulic control unit(HCU). The voltage of pump

motor is supplied by Terminal 46 of ECU, which is controlled by one power terminal

solid drive. It’s grounded through Terminal 31 of ECU.

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-25

Conditions for setting the diagnostic trouble code

C0017 can be only set when the key is put in opened position, the pump motor runs,

and ECU detects the open-circuit of pump motor circuit.

Measures taken when setting the diagnostic trouble code

1. ECU will disconnect the power supply of pump motor.

2. Store the diagnostic trouble code-C0017.

3. Failure of ABS.

4. Turn on ABS warning lamp.

5. Turn on red brake warning lamp.

Conditions for removing the diagnostic trouble code

1. If no conditions for setting the diagnostic trouble code-C0017 appear, remove

this diagnostic trouble code with a corresponding scanning tool.

2. If no diagnostic trouble code appears within the successive 100 ignition cycles,

remove it from its historical data.

Diagnostic help

Typical causes for diagnostic trouble code-C0017:

1. Disconnection or poor contact of pump motor socket harness or connector

(Terminal 46).

2. ECU faults.

C0017-Open-circuit of pump motor power circuit

Step Diagnostic actions Expected value Yes No

1 Do you complete the check of diagnostic

circuit?

Go to

Step 2

Go to

Step 4

2 1. Flame breaking.

2. Disconnect ECU harness from ECU.

3. Ignition.

4. Measure the voltage of Terminal 46 of

ECU harness connector with a

voltmeter.

Is its voltage within the specified range.

Battery voltage Go to

Step 5

Go to

Step 3

3 Find the reason why there is high resistance

between the battery anode and terminal 46

of ECU wire harness connector or it is open

between them and repair it.

Do you complete the repair?

Go to

Step 6

4 Complete the check of diagnostic circuit.

5 Replace ECU.

Do you complete the repair?

Go to

Step 6

6 1. Remove the diagnostic trouble code

Go to System is

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-26

C0017-Open-circuit of pump motor power circuit

Step Diagnostic actions Expected value Yes No

with a diagnostic unit.

Is this trouble code reset?

Step 1 OK

C0018- Short-circuit of pump motor and battery, open-circuit to ground/high

resistance of motor

Description of circuit

The pump motor is included in hydraulic control unit(HCU). The voltage of pump

motor is supplied by Terminal 46 of ECU, which is controlled by one power terminal

solid drive. It’s grounded through Terminal 31 of ECU.

Conditions for setting the diagnostic trouble code

C0017 can be only set when the key is put in opened position, the pump motor runs,

and ECU detects the open-circuit of pump motor circuit.

Measures taken when setting the diagnostic trouble code

1. Activate the electromagnetic relay, disconnect the power supply of pump motor

and electromagnet.

2. Store the diagnostic trouble code-C0018.

3. Failure of ABS.

4. Failure of DRP.

5. Turn on ABS warning lamp.

6. Turn on red brake warning lamp.

Conditions for removing the diagnostic trouble code

1. If no conditions for setting the diagnostic trouble code-C0018 appear, remove

this diagnostic trouble code with a corresponding scanning tool.

2. If no diagnostic trouble code appears within the successive 100 ignition cycles,

remove it from its historical data.

Diagnostic help

Typical causes for diagnostic trouble code-C0018:

1. Poor contact of Terminal 31.

2. Short-circuit and no voltage of Terminal 31 grounded circuit.

3. Open-circuit of Terminal 31 grounded circuit.

4. High resistance when grounding Terminal 31 grounded circuit.

5. ECU faults.

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-27

C0018-short-circuit of pump motor and battery or open-circuit to ground/high

resistance of motor

Step Diagnostic actions Expected value Yes No

1 Do you complete the check of diagnostic circuit? ---- Go to

Step 2

Go to

Step 8

2 1. Flame breaking.

2. Disconnect ECU harness from ECU.

3. Ignition.

4. Connect a voltmeter between Terminal 31 of

ECU harness and body ground.

Is its voltage within the specified range?

Below 1V Go to

Step 3

Go to

Step 9

3 1. Flame breaking.

2. Disconnect the negative pole of battery cable.

3. Still disconnect ECU harness from ECU.

4. Connect an ohmmeter between the negative

pole of battery cable and Terminal 31 of ECU

harness.

Is its resistance within the specified range?

Below 2Ω Go to

Step 4

Go to

Step 10

4 1. Connect from the negative battery cable to

engine block and/or chassis ground. Check

whether they are clean or their connection is

firm.

2. Find out the circuit grounding position from

Terminal 31 of ECU harness along the circuit

to chassis. Check whether they are clean and

their connection is firm.

Is their connection clean or firm?

Go to

Step 5

Go to

Step 11

5 1. Still disconnect ECU harness from ECU.

2. Remove ECU from HCU.

3. Check the connector from ECU to HCU for

damages, rusting, poor contact or brake fluid

leakage, etc.

Are the terminals and connector OK? Are there

brake fluid, damages or rusting in the cab?

Go to

Step 6

Go to

Step 12

6 Connect an ohmmeter between Terminals 1 and 2

of HCU.

Is the resistance reading of pump motor within the

specified range?

Below 2Ω Go to

Step 7

Go to

Step 13

7 Replace ECU.

Do you complete the repair?

Go to

Step 14

8 Check the diagnostic circuit.

9 Find out the cause for short-circuit of Terminal 31

grounded circuit voltage, and repair it.

Do you complete the repair?

Go to

Step 14

10 Find out the cause for high resistance between the

grounded circuit of ECU terminal 31 and body

Go to

Step 14

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-28

C0018-short-circuit of pump motor and battery or open-circuit to ground/high

resistance of motor

Step Diagnostic actions Expected value Yes No

ground, and repair it.

Do you complete the repair?

11 If necessary, repair any poor grounded connection.

Do you complete the repair?

Go to

Step 14

12 1.If any damage and/or rusting exists, replace ECU

and/or HCU if necessary.

2.If the brake fluid leaks, replace ECU and HCU.

Do you complete the repair?

Go to

Step 14

13 Hydraulic control unit(HCU).

Do you complete the repair?

Go to

Step 14

14 1.Remove the diagnostic trouble code with a

scanning tool.

Is this diagnostic trouble code reset?

Go to

Step 1

System

is OK

C0021-Input signal of left front wheel speed sensor=0

Description of circuit

During the rotation of wheels, the speed sensor produces an AC voltage, which is

increased with the increase of wheel speed. ECU adopts the frequency of AC signal to

calculate the wheel speed. The speed sensor is connected to ECU with a “twisted

pair” cable. Its twisting can reduce the noise to avoid any possible interference on

setting the diagnostic trouble code.

Conditions for setting the diagnostic trouble code

In order to set C0021, the following conditions must appear:

1. C0032, C0033, C000034 or C0035 can’t appear at present.

2. Failure of ABS.

3. Disconnection of brake switch.

The speed of left front wheel is 0, and all other wheel speed sensors: up to 8km/hour

within at least 2.5s.

Conditions for removing the diagnostic trouble code

1. If no conditions for setting DTC C0021 exist, remove this diagnostic trouble

code with a proper scanning tool.

2. Remove the diagnostic trouble code not produced within 100 ignition cycles

from the historic data.

Diagnostic help

In case of diagnosing the intermittent diagnostic trouble code, please check the lines

and connectors thoroughly, including:

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-29

1. Remove the protective guide tube, and check the lines for damages, short-circuit

or pollutions.

2. Check the terminals for deformations or damages.

3. Check the contact maintaining capacity of terminal with a standby male/female

terminal.

4. Remove the terminal from the connector, and check whether the terminal

press-connected by the conductor is correct.

If the driver reflects that ABS warning lamp can go on only in case of wet

environment changes (rain, snow or vehicle flushing), check the possibility of water

entry into any wheel speed sensor. If this diagnostic trouble code is not current one,

simulate the influences of water entry. Perform the following steps: spray the area in

doubt with 5％salt solution, and then test the vehicle on various road surfaces (jarring

or turning, etc) at the speed more than 24km/hour (15 mile/hour). If any diagnostic

trouble code appear, replace the suspected harness and/or sensor.

Measure the resistance of wheel speed sensor, and ensure the vehicle is under the

room-temperature conditions because its resistance is increased with the rise of

temperature at room.

The failure to perform the above steps carefully and fully, may cause the wrong

diagnosis, unnecessary part replacement or regeneration of DTC C0021.

C0021-input signal of left front wheel speed sensor=0

Step Diagnostic actions Expected value Yes No

1 Do you complete the check of diagnostic

circuit?

Go to

Step 2

Go to

Step 12

2 1. Flame breaking.

2. Check left front wheel speed sensor,

harness and toothed ring for physical

damages.

Do you check any physical damage?

Go to

Step 13

Go to

Step 3

3 Do you set the diagnostic trouble code-C0032

as current or historic code?

Go to

Step 14

Go to

Step 4

4 1. Connect it to the scanning tool, and select

the data list.

2. Monitor the wheel speed sensor.

3. Test the vehicle at a speed of 24km/hour

(15 mile/hour), and then reduce the

vehicle speed slowly to zero, and repeat

this operation several times.

Is C0021 reset or left front wheel speed

suddenly reduced to zero before stopping the

vehicle fully?

Go to

Step 5

Go to

Step 15

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-30

C0021-input signal of left front wheel speed sensor=0

Step Diagnostic actions Expected value Yes No

5 1. Flame breaking.

2. Lift and support the vehicle properly.

3. Disconnect ECU harness from ECU.

4. Connect the voltmeter to Terminals 28

and 27

of ECU harness.

5. Select AC mV scale.

6. Turn left front wheel, and observe the

voltmeter. (when the wheel speed is

increased, the voltage shall be increased).

Is its AC voltage within the specified range?

At least 100mV Go to

Step 16

Go to

Step 6

6 1. Disconnect left front jumper wire from left

front wheel speed sensor.

2. Connect an ohmmeter between both

terminals of left front wheel speed sensor.

Is its resistance within the specified range?

800-1600Ω

(The resistance

will be changed

with the

changes of

temperature and

customer’s

requirements)

Go to

Step 7

Go to

Step 17

7 1. Still disconnect left front jumper wire from

left front speed sensor.

2. Connect a voltmeter between both

terminals of left front wheel speed sensor.

3. Select AC mV scale.

4. Turn left front wheel, and observe the

voltmeter. (when the wheel speed is

increased, the voltage shall be increased).

Is its AC voltage within the specified range?

At least 100mV Go to

Step 8

Go to

Step 17

8 1. Disconnect left front jumper wire from

ABS module harness.

2. Still disconnect ECU harness from ECU.

3. Connect the ohmmeter to Terminals 28

and 27 of ECU harness.

Is its resistance within the specified range?

(Open-circuit)

Go to

Step 9

Go to

Step 18

9 1. Still disconnect ECU harness from ECU.

2. Still disconnect left front jumper wire from

ABS module harness.

3. Connect the ohmmeter to Terminal 27 of

ECU harness, and then connect it to

Terminal A

of ABS module harness.

Is its resistance within the specified range?

Below 2Ω Go to

Step 10

Go to

Step 19

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-31

C0021-input signal of left front wheel speed sensor=0

Step Diagnostic actions Expected value Yes No

10 1. Still disconnect ECU harness from ECU.

2. Still disconnect left front jumper wire from

ABS module harness.

3. Connect the ohmmeter to Terminal 28 of

ECU harness, and then connect it to

Terminal B of ABS module harness.

Is its resistance within the specified range?

Below 2Ω Go to

Step 11

Go to

Step 20

11 1. Replace left front wheel speed jumper

wire.

2. Test the vehicle on various road surfaces at

different speeds.

Is it reset?

Go to

Step 16

System is

12 Check the diagnostic circuit before making the

diagnostic trouble code diagram.

13 Repair the damaged left front wheel speed

sensor, jumper wire and/or toothed ring.

Do you complete the repair?

Go to

Step 21

14 Diagnose the diagnostic trouble code-C0032

before performing this step of this table.

15 The diagnostic trouble code-C0021 is

intermittent. Refer to “Diagnostic Help”.

16 Replace ECU.

Do you complete the repair?

Go to

Step 21

17 Replace the left front wheel speed sensor.

Do you complete the repair?

Go to

Step 21

18 Check and repair the short-circuit fault

between two circuits.

Do you complete the repair?

Go to

Step 21

19 Repair the open-circuit or high resistance

between Terminals 27

and A.

Do you complete the repair?

Go to

Step 21

20 Repair the open-circuit or high resistance

between Terminals 28

and B.

Do you complete the repair?

Go to

Step 21

21 Remove the diagnostic trouble code with a

scanning tool.

Do you reset the diagnostic trouble code when

the conditions for setting the diagnostic

trouble code exist?

Go to

Step 1

System is

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-32

C0022-Input signal of right front wheel speed sensor=0

Description of circuit

During the rotation of wheels, the speed sensor produces an AC voltage, which is

increased with the increase of wheel speed. ECU adopts the frequency of AC signal to

calculate the wheel speed. The speed sensor is connected to ECU with a “twisted

pair” cable. Its twisting can reduce the noise to avoid any possible interference on

setting the diagnostic trouble code.

Conditions for setting the diagnostic trouble code

In order to set C0022, the following conditions must appear:

C0032, C0033, C0034 or C0035 is not current one.

1. Failure of ABS.

2. Disconnection of brake switch.

3. The speed of right front wheel is 0, and all other wheel speed sensors: more than

8km/hour (5 miles/hour)within at least 2.5s.

Measures taken when setting the diagnostic trouble code

1. Store DTC C0022.

2. Failure of ABS.

3. Activation of ABS warning lamp.

Conditions for removing the diagnostic trouble code

1. If no conditions for setting DTC C0022 exist, remove this diagnostic trouble

code with a proper scanning tool.

2. Remove the diagnostic trouble code not produced within 100 ignition cycles

from the historic data.

Diagnostic help

In case of diagnosing the intermittent diagnostic trouble code, please check the lines

and connectors thoroughly, including:

1. Remove the protective guide tube, and check the lines for damages, short-circuit

or pollutions.

2. Check the terminals for deformations and/or damages.

3. Check the contact (maintaining capacity) of terminal with a standby male/female

terminal.

4. Remove the terminal from the connector, and check the press-connected

conductor terminal.

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-33

C0022-input signal of right front wheel speed sensor=0

Step Diagnostic actions Expected value Yes No

1 Do you complete the check of diagnostic

circuit?

Go to

Step 2

Go to

Step 12

2 3. Flame breaking.

4. Check right front wheel speed sensor,

harness and toothed ring for physical

damages.

Do you check any physical damage?

Go to

Step 13

Go to

Step 3

3 Do you set the diagnostic trouble code-C0033

as current or historic code?

Go to

Step 14

Go to

Step 4

4 4. Connect it to the scanning tool, and select

the data list.

5. Monitor the wheel speed sensor.

6. Test the vehicle at a speed of 24km/hour

(15 mile/hour), and then reduce the vehicle

speed slowly to zero, and repeat this

operation several times.

Is C0021 reset or right front wheel speed

suddenly reduced to zero before stopping the

vehicle fully?

Go to

Step 5

Go to

Step 15

5 7. Flame breaking.

8. Lift and support the vehicle properly.

9. Disconnect ECU harness from ECU.

10. Connect the voltmeter to Terminals 24 and

39 of ECU harness.

11. Select AC mV scale.

12. Turn right front wheel, and observe the

voltmeter. (when the wheel speed is

increased, the voltage shall be increased).

Is its AC voltage within the specified range?

At least 100mV Go to

Step 16

Go to

Step 6

6 3. Disconnect right front jumper wire from

right front wheel speed sensor.

4. Connect the ohmmeter to both terminals of

right front wheel speed sensor.

Is its resistance within the specified range?

800-1600Ω

(The resistance

will be changed

with the

changes of

temperature and

customer’s

requirements)

Go to

Step 7

Go to

Step 17

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-34

C0022-input signal of right front wheel speed sensor=0

Step Diagnostic actions Expected value Yes No

7 5. Still disconnect right front jumper wire

from right front speed sensor.

6. Connect the voltmeter to both terminals of

right front wheel speed sensor.

7. Select AC mV scale.

8. Turn right front wheel, and observe the

voltmeter. (when the wheel speed is

increased, the voltage shall be increased).

Is its AC voltage within the specified range?

At least 100mV Go to

Step 8

Go to

Step 17

8 4. Disconnect right front jumper wire from

ABS module harness.

5. Still disconnect ECU harness from ECU.

6. Connect the ohmmeter to Terminals 24

and 39

of ECU harness.

Is its resistance within the specified range?

(Open-circuit)

Go to

Step 9

Go to

Step 18

9 4. Still disconnect ECU harness from ECU.

5. Still disconnect right front jumper wire from

ABS module harness.

6. Connect the ohmmeter to Terminal 39

ECU harness, and then connect it to

Terminal A

of ABS module harness.

Is its resistance within the specified range?

Below 2Ω Go to

Step 10

Go to

Step 19

10 4. Still disconnect ECU harness from ECU.

5. Still disconnect right front jumper wire

from ABS module harness.

6. Connect the ohmmeter to Terminal 24 of

ECU harness, and then connect it to

Terminal B

of ABS module harness.

Is its resistance within the specified range?

Below 2Ω Go to

Step 11

Go to

Step 20

11 3. Replace right front wheel speed jumper

wire.

4. Test the vehicle on various road surfaces at

different speeds.

Is C0022 reset?

Go to

Step 16

System is

12 Check the diagnostic circuit before making the

diagnostic trouble code diagram.

13 Repair the damaged right front wheel speed

sensor, jumper wire and/or toothed ring.

Do you complete the repair?

Go to

Step 21

14 Diagnose the diagnostic trouble code-C0033

before performing this step of this table.

15 The diagnostic trouble code-C0022 is

intermittent. Refer to “Diagnostic Help”.

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-35

C0022-input signal of right front wheel speed sensor=0

Step Diagnostic actions Expected value Yes No

16 Replace ECU.

Do you complete the repair?

Go to

Step 21

17 Replace the right front wheel speed sensor.

Do you complete the repair?

Go to

Step 21

18 Check and repair the short-circuit fault

between two circuits.

Do you complete the repair?

Go to

Step 21

19 Repair the open-circuit or high resistance

between Terminals 39

and A.

Do you complete the repair?

Go to

Step 21

20 Repair the open-circuit or high resistance

between Terminals 24

and B.

Do you complete the repair?

Go to

Step 21

21 Remove the diagnostic trouble code with a

scanning tool.

Do you reset the diagnostic trouble code when

the conditions for setting the diagnostic

trouble code exist?

Go to

Step 1

System is

C0023-input signal of left rear wheel speed sensor=0

Description of circuit

During the rotation of wheels, the speed sensor produces an AC voltage, which is

increased with the increase of wheel speed. ECU adopts the frequency of AC signal to

calculate the wheel speed. The speed sensor is connected to ECU with a “twisted

pair” cable. Its twisting can reduce the noise to avoid any possible interference on

setting the diagnostic trouble code.

Conditions for setting the diagnostic trouble code

In order to set C0023, the following conditions must exist:

1. C0032, C0033 or C0034 is not current one.

2. Failure of ABS.

3. Disconnection of brake switch.

4. The speed of left rear wheel is 0, and all other wheel speed sensors: more than

8km/hour (5 miles/hour)within at least 2.5s.

Measures taken when setting the diagnostic trouble code

1. Store DTC C0023.

2. Failure of ABS.

3. Activation of ABS warning lamp.

Conditions for removing the diagnostic trouble code

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-36

1. If no conditions for setting DTC C0023 exist, remove this diagnostic trouble

code with a proper scanning tool.

2. Remove the diagnostic trouble code not produced within 100 ignition cycles

from the historic data.

Diagnostic help

In case of diagnosing the intermittent diagnostic trouble code, please check the lines

and connectors thoroughly, including:

1. Remove the protective guide tube, and check the lines for damages, short-circuit

or pollutions.

2. Check the terminals for deformations and/or damages.

3. Check the contact (maintaining capacity) of terminal with a standby male/female

terminal.

4. Remove the terminal from the connector, and check whether the press-connected

conductor terminal is falsely connected.

C0023-input signal of left rear wheel speed sensor=0

Step Diagnostic actions Expected value Yes No

1 Do you complete the check of diagnostic

circuit?

Go to

Step 2

Go to

Step 12

2 5. Flame breaking.

6. Check left rear wheel speed sensor,

harness and toothed ring for physical

damages.

Do you check any physical damage?

Go to

Step 13

Go to

Step 3

3 Do you set the diagnostic trouble code-C0034

as current or historic code?

Go to

Step 14

Go to

Step 4

4 7. Connect it to the scanning tool, and select

the data list.

8. Monitor the wheel speed sensor.

9. Test the vehicle at a speed of 24km/hour

(15 mile/hour), and then reduce the vehicle

speed slowly to zero, and repeat this

operation several times.

Is C0023 reset or right front wheel speed

suddenly reduced to zero before stopping the

vehicle fully?

Go to

Step 5

Go to

Step 15

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-37

C0023-input signal of left rear wheel speed sensor=0

Step Diagnostic actions Expected value Yes No

5 13. Flame breaking.

14. Lift and support the vehicle properly.

15. Disconnect ECU harness from ECU.

16. Connect the voltmeter between Terminals

13 and 12 of ECU harness.

17. Select AC mV scale.

18. Turn left rear wheel, and observe the

voltmeter. (when the wheel speed is

increased, the voltage shall be increased).

Is its AC voltage within the specified range?

At least 100mV Go to

Step 16

Go to

Step 6

6 5. Disconnect left rear jumper wire from left

rear wheel speed sensor.

6. Connect an ohmmeter between both

terminals of left rear wheel speed sensor.

Is its resistance within the specified range?

800-1600Ω

(The resistance

will be changed

with the

changes of

temperature and

customer’s

requirements)

Go to

Step 7

Go to

Step 17

7 9. Still disconnect left rear jumper wire from

left rear speed sensor.

10. Connect a voltmeter to both terminals of

left rear wheel speed sensor.

11. Select AC mV scale.

12. Turn left rear wheel, and observe the

voltmeter. (when the wheel speed is

increased, the voltage shall be increased).

Is its AC voltage within the specified range?

At least 100mV Go to

Step 8

Go to

Step 17

8 7. Disconnect left rear jumper wire from

ABS module harness.

8. Still disconnect ECU harness from ECU.

9. Connect the ohmmeter to Terminals 13

and 12 of ECU harness.

Is its resistance within the specified range?

(Open-circuit)

Go to

Step 9

Go to

Step 18

9 7. Still disconnect ECU harness from ECU.

8. Still disconnect left rear jumper wire from

ABS module harness.

9. Connect the ohmmeter to Terminal 12 of

ECU harness, and then connect it to

Terminal A

of ABS module harness.

Is its resistance within the specified range?

Below 2Ω Go to

Step 10

Go to

Step 19

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-38

C0023-input signal of left rear wheel speed sensor=0

Step Diagnostic actions Expected value Yes No

10 7. Still disconnect ECU harness from ECU.

8. Still disconnect left rear jumper wire from

ABS module harness.

9. Connect the ohmmeter to Terminal 13 of

ECU harness, and then connect it to

Terminal B

of ABS module harness.

Is its resistance within the specified range?

Below 2Ω Go to

Step 11

Go to

Step 20

11 5. Replace left rear wheel speed jumper wire.

6. Test the vehicle on various road surfaces at

different speeds.

Is C0023 reset?

Go to

Step 16

System is

12 Check the diagnostic circuit before making the

diagnostic trouble code diagram.

13 Repair the damaged left rear wheel speed

sensor, jumper wire and/or toothed ring.

Do you complete the repair?

Go to

Step 21

14 Diagnose the diagnostic trouble code-C0034

before performing this step of this table.

15 The diagnostic trouble code-C0023 is

intermittent. Refer to “Diagnostic Help”.

16 Replace ECU.

Do you complete the repair?

Go to

Step 21

17 Replace the left right wheel speed sensor.

Do you complete the repair?

Go to

Step 21

18 Check and repair the short-circuit fault

between two circuits.

Do you complete the repair?

Go to

Step 21

19 Repair the open-circuit or high resistance

between Terminals 12

and A.

Do you complete the repair?

Go to

Step 21

20 Repair the open-circuit or high resistance

between Terminals 13

and B.

Do you complete the repair?

Go to

Step 21

21 Remove the diagnostic trouble code with a

scanning tool.

Do you reset the diagnostic trouble code when

the conditions for setting the diagnostic

trouble code exist?

Go to

Step 1

System is

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-39

C0024-input signal of right rear wheel speed sensor=0

Description of circuit

During the rotation of wheels, the speed sensor produces an AC voltage, which is

increased with the increase of wheel speed. ECU adopts the frequency of AC signal to

calculate the wheel speed. The speed sensor is connected to ECU with a “twisted

pair” cable. Its twisting can reduce the noise to avoid any possible interference on

setting the diagnostic trouble code.

Conditions for setting the diagnostic trouble code

In order to set C0024, the following conditions must exist:

1. C0032, C0033, C0034 or C0035 is not current one.

2. Failure of ABS.

3. Disconnection of brake switch.

4. The speed of right rear wheel is 0, and all other wheel speed sensors: more than

8km/hour (5 miles/hour)within at least 2.5s.

Measures taken when setting the diagnostic trouble code

1. Store DTC C0024.

2. Failure of ABS.

3. Activation of ABS warning lamp.

Conditions for removing the trouble code

1. If no conditions for setting DTC C0024 exist, remove this diagnostic trouble

code with a proper scanning tool.

2. Remove the diagnostic trouble code not produced within 100 ignition cycles

from the historic data.

Diagnostic help

In case of diagnosing the intermittent diagnostic trouble code, please check the lines

and connectors thoroughly, including:

1. Remove the protective guide tube, and check the lines for damages, short-circuit

or pollutions.

2. Check the terminals for deformations and/or damages.

3. Check whether the press-connected conductor terminal is falsely connected with

a standby male/female terminal.

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-40

C0024-input signal of right rear wheel speed sensor=0

Step Diagnostic actions Expected value Yes No

1 Do you complete the check of diagnostic

circuit?

Go to

Step 2

Go to

Step 12

2 7. Flame breaking.

8. Check right rear wheel speed sensor,

harness and toothed ring for physical

damages.

Do you check any physical damage?

Go to

Step 13

Go to

Step 3

3 Do you set the diagnostic trouble code-C0033

as current or historic code?

Go to

Step 14

Go to

Step 4

4 10. Connect it to the scanning tool, and select

the data list.

11. Monitor the wheel speed sensor.

12. Test the vehicle at a speed of 24km/hour

(15 mile/hour), and then reduce the vehicle

speed slowly to zero, and repeat this

operation several times.

Is C0024 reset or right front wheel speed

suddenly reduced to zero before stopping the

vehicle fully?

Go to

Step 5

Go to

Step 15

5 19. Flame breaking.

20. Lift and support the vehicle properly.

21. Disconnect ECU harness from ECU.

22. Connect the voltmeter between Terminals

42 and 43 of ECU harness.

23. Select AC mV scale.

24. Turn right rear wheel, and observe the

voltmeter. (when the wheel speed is

increased, the voltage shall be increased).

Is its AC voltage within the specified range?

At least 100mV Go to

Step 16

Go to

Step 6

6 7. Disconnect right rear jumper wire from

right rear wheel speed sensor.

8. Connect an ohmmeter to both terminals of

right rear wheel speed sensor.

Is its resistance within the specified range?

800-1600Ω

(The resistance

will be changed

with the

changes of

temperature and

customer’s

requirements)

Go to

Step 7

Go to

Step 17

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-41

C0024-input signal of right rear wheel speed sensor=0

Step Diagnostic actions Expected value Yes No

7 13. Still disconnect right rear jumper wire

from right rear speed sensor.

14. Connect a voltmeter to both terminals of

right rear wheel speed sensor.

15. Select AC mV scale.

16. Turn right rear wheel, and observe the

voltmeter. (when the wheel speed is

increased, the voltage shall be increased).

Is its AC voltage within the specified range?

At least 100mV Go to

Step 8

Go to

Step 17

8 10. Disconnect right rear jumper wire from

ABS module harness.

11. Still disconnect ECU harness from ECU.

12. Connect the ohmmeter to Terminals 42

and 43 of ECU harness.

Is its resistance within the specified range?

(Open-circuit)

Go to

Step 9

Go to

Step 18

9 10. Still disconnect ECU harness from ECU.

11. Still disconnect right rear jumper wire

from ABS module harness.

12. Connect the ohmmeter to Terminal 43

ECU harness, and then connect it to

Terminal A

of ABS module harness.

Is its resistance within the specified range?

Below 2Ω Go to

Step 10

Go to

Step 19

10 10. Still disconnect ECU harness from ECU.

11. Still disconnect right rear jumper wire

from ABS module harness.

12. Connect the ohmmeter to Terminal 42 of

ECU harness, and then connect it to

Terminal B

of ABS module harness.

Is its resistance within the specified range?

Below 2Ω Go to

Step 11

Go to

Step 20

11 7. Replace right rear wheel speed jumper

wire.

8. Test the vehicle on various road surfaces at

different speeds.

Is C0024 reset?

Go to

Step 16

System is

12 Check the diagnostic circuit before making the

diagnostic trouble code diagram.

13 Repair the damaged right rear wheel speed

sensor, jumper wire and/or toothed ring.

Do you complete the repair?

Go to

Step 21

14 Diagnose the diagnostic trouble code-C0035

before performing this step of this table.

15 The diagnostic trouble code-C0024 is

intermittent. Refer to “Diagnostic Help”.

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-42

C0024-input signal of right rear wheel speed sensor=0

Step Diagnostic actions Expected value Yes No

16 Replace ECU.

Do you complete the repair?

Go to

Step 21

17 Replace the left right wheel speed sensor.

Do you complete the repair?

Go to

Step 21

18 Check and repair the short-circuit fault

between two circuits.

Do you complete the repair?

Go to

Step 21

19 Repair the open-circuit or high resistance

between Terminals 43

and A.

Do you complete the repair?

Go to

Step 21

20 Repair the open-circuit or high resistance

between Terminals 42

and B.

Do you complete the repair?

Go to

Step 21

21 Remove the diagnostic trouble code with a

scanning tool.

Do you reset the diagnostic trouble code when

the conditions for setting the diagnostic

trouble code exist?

Go to

Step 1

System is

C0025-Change fault of left front wheel speed

Description of circuit

During the rotation of wheels, the speed sensor produces an AC voltage, which is

increased with the increase of wheel speed. ECU adopts the frequency of AC signal to

calculate the wheel speed. The speed sensor is connected to ECU with a “twisted

pair” cable. Its twisting can reduce the noise to avoid any possible interference on

setting the diagnostic trouble code.

Conditions for setting the diagnostic trouble code

In order to set C0025, the following conditions must exist:

1. C0032, C0033, C0034 or C0035 is not current one.

2. Disconnection of brake switch.

3. The acceleration or deceleration of left front wheel exceeds the reasonable limit.

Measures taken when setting the diagnostic trouble code

1. Store DTC C0025.

2. Failure of ABS.

3. Activation of ABS warning lamp.

Conditions for removing the diagnostic trouble code

1. If no conditions for setting DTC C0025 exist, remove this diagnostic trouble

code with a proper scanning tool.

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-43

2. Remove the diagnostic trouble code not produced within 100 ignition cycles

from the historic data.1.

Diagnostic help

In case of diagnosing the intermittent diagnostic trouble code, please check the lines

and connectors thoroughly, including:

1. Remove the protective guide tube, and check the lines for damages, short-circuit

or pollutions.

2. Check the terminals for deformations and damages.

3. Check the contact (maintaining capacity) of terminal with a standby male/female

terminal.

4. Remove the terminal from the connector, and check whether the press-connected

conductor terminal is falsely connected.

C0025-Change fault of left front wheel speed

Step Diagnostic actions Expected value Yes No

1 Do you complete the check of diagnostic

circuit?

Go to

Step 2

Go to

Step 12

2 Do you set DTC-C0032 as current or

historic code?

Go to

Step 13

Go to

Step 3

3 1. Flame breaking.

2. Check left front wheel speed sensor and

jumper wire for damages.

3. Check left front toothed ring fully and

thoroughly to know its damages (cracks,

tooth missing or loosening).

Do you check any physical damage?

Go to

Step 14

Go to

Step 4

4 1. Stop the vehicle.

2. Connect to the scanning tool, and select

the data list.

3. Monitor the wheel speed sensor.

4. Start the vehicle, and monitor the wheel

speed sensor in the event that the engine

runs but the vehicle doesn’t move.

5. Step on the accelerator pedal lightly to

increase the engine idle speed.

Is C0025 reset or does the reading of left

front wheel speed exceed 0 mile/hour if the

engine runs but the vehicle parks.

Go to

Step 15

Go to

Step 5

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-44

C0025-Change fault of left front wheel speed

Step Diagnostic actions Expected value Yes No

5 1. Still connect to the scanning tool.

2. Monitor the wheel speed sensor.

3. Test the vehicle up to the maximum

limit speed, and then reduce the speed to

zero. Repeat this operation several times.

Is C0025 reset or the change of left front

wheel speed more than 5 km/hour(3

mile/hour) in case of comparing with any

other wheel speed during the driving

operation?

Go to

Step 6

Go to

Step 16

6 1. Stop the vehicle, and stall.

2. Lift and support the vehicle properly.

3. Disconnect left front jumper wire from

left front wheel speed sensor.

4. Connect the ohmmeter to both terminals

of left front wheel speed sensor.

Is its resistance within the specified range?

800-1600Ω

(The resistance

will be changed

with the changes

of temperature and

customer’s

requirements)

Go to

Step 7

Go to

Step 17

7 1. Still disconnect the vehicle speed sensor

from the jumper wire.

2. Connect a voltmeter to both terminals of

left front wheel speed sensor.

3. Select AC mV scale.

4. Turn left front wheel, while observing

the voltmeter voltage.

Is its AC voltage within the specified range?

At least 100mV Go to

Step 8

Go to

Step 17

8 1. Disconnect ECU harness from ECU.

2. Disconnect left front jumper wire from

ABS module harness.

3. Connect the ohmmeter to Terminal 28 of

ECU harness, and then connect it to

Terminal B

of ABS module harness.

Is its resistance within the specified range?

Below 2Ω Go to

Step 9

Go to

Step 18

9 1. Still disconnect ECU harness from ECU.

2. Still disconnect the jumper wire from

ABS module harness.

3. Connect the ohmmeter to Terminal 27 of

ECU harness, and then connect it to

Terminal A

of ABS module harness.

Is its resistance within the specified range?

Below 2Ω Go to

Step 10

Go to

Step 19

10 1. Still disconnect ECU harness from ECU.

2. Still disconnect the jumper wire from

ABS module harness.

3. Connect the ohmmeter to Terminals 28

and 27 of ECU harness.

Is its resistance within the specified range?

(Open-circuit)

Go to

Step 11

Go to

Step 20

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-45

C0025-Change fault of left front wheel speed

Step Diagnostic actions Expected value Yes No

11 1. Replace left front jumper wire.

2. Test the vehicle on various road surfaces

at different speeds.

Is C0025 reset?

Go to

Step 21

System

is OK

12 Check the diagnostic circuit before making

the diagnostic trouble code-C0025 diagram.

13 Prepare the diagnostic diagram of C0032

before making the diagnostic trouble

code-C0025 diagram.

14 Repair the damaged left front wheel speed

sensor, jumper wire and/or toothed ring.

Do you complete the repair?

Go to

Step 22

15 C0025 is caused by the sensing of ignition

noise coupling to the circuit of left front

wheel speed sensor.

Check left front ABS module and/or jumper

wire for potential ignition noise sources, e.g.

spark plug conductor. Re-lay the conductor

as per the demands.

Do you complete the repair?

Go to

Step 22

16 The diagnostic trouble code-C0025 is

intermittent. Refer to “Diagnostic Help”.

17 Replace left front wheel speed sensor.

Do you complete the repair?

Go to

Step 22

18 Repair the open circuit or high resistance

between Terminals 28

and B.

Do you complete the repair?

Go to

Step 22

19 Repair the open circuit or high resistance

between Terminals 27

and A.

Do you complete the repair?

Go to

Step 22

20 Repair the short-circuit between two

conductors.

Do you complete the repair?

Go to

Step 22

21 Replace ECU.

Do you complete the repair?

Go to

Step 22

22 Remove the diagnostic trouble code with a

scanning tool.

Do you reset the diagnostic trouble code

when the conditions for setting the

diagnostic trouble code exist?

Go to

Step 1

System

is OK

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-46

C0026-Change fault of right front wheel speed

Description of circuit

During the rotation of wheels, the speed sensor produces an AC voltage, which is

increased with the increase of wheel speed. ECU adopts the frequency of AC signal to

calculate the wheel speed. The speed sensor is connected to ECU with a “twisted

pair” cable. Its twisting can reduce the noise to avoid any possible interference on

setting the diagnostic trouble code.

Conditions for setting the diagnostic trouble code

In order to set C0026, the following conditions must exist:

1. C0032, C0033, C0034 or C0035 is not current one.

2. Disconnection of brake switch.

3. The acceleration or deceleration of right front wheel exceeds the reasonable

limit.

Measures taken when setting the diagnostic trouble code

4. Store DTC C0026.

5. Failure of ABS.

6. Activation of ABS warning lamp.

Conditions for removing the diagnostic trouble code

1. If no conditions for setting DTC C0026 exist, remove this diagnostic trouble

code with a proper scanning tool.

2. Remove the diagnostic trouble code not produced within 100 ignition cycles

from the historic data.

Diagnostic help

In case of diagnosing the intermittent diagnostic trouble code, please check the lines

and connectors thoroughly, including:

1. Remove the protective guide tube, and check the lines for damages, short-circuit

or pollutions.

2. Check the terminals for deformations and damages.

3. Check the contact maintaining capacity of terminal with a standby male/female

terminal.

4. Remove the terminal from the connector, and check whether the press-connected

conductor terminal is falsely connected.

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-47

C0026-Change fault of right front wheel speed

Step Diagnostic actions Expected value Yes No

1 Do you complete the check of diagnostic

circuit?

Go to

Step 2

Go to

Step 12

2 Do you set C0026 as current or historic code?

Go to

Step 13

Go to

Step 3

3 1. Flame breaking.

2. Check right front wheel speed sensor and

jumper wire for damages.

3. Check right front toothed ring fully and

thoroughly to know its damages (cracks,

tooth missing or loosening).

Do you check any physical damage?

Go to

Step 14

Go to

Step 4

4 1. Stop the vehicle.

2. Connect to the scanning tool, and select

the data list.

3. Monitor the wheel speed sensor.

4. Start the vehicle, and monitor the wheel

speed sensor in the event that the engine

runs but the vehicle doesn’t move.

5. Step on the accelerator pedal lightly to

increase the engine idle speed.

Is C0026 reset or does the reading of right

front wheel speed exceed 0 mile/hour if the

engine runs but the vehicle parks.

Go to

Step 15

Go to

Step 5

5 1. Still connect to the scanning tool.

2. Monitor the wheel speed sensor.

3. Test the vehicle up to the maximum limit

speed, and then reduce the speed to zero.

Repeat this operation several times.

Is C0026 reset or the change of right front

wheel speed more than 5 km/hour(3

mile/hour) in case of comparing with any

other wheel speed during the driving

operation?

Go to

Step 6

Go to

Step 16

6 1. Stop the vehicle, and stall.

2. Lift and support the vehicle properly.

3. Disconnect right front jumper wire from

right front wheel speed sensor.

4. Connect the ohmmeter to both terminals

of right front wheel speed sensor.

Is its resistance within the specified range?

800-1600Ω

(The resistance

will be changed

with the changes

of temperature

and customer’s

requirements)

Go to

Step 7

Go to

Step 17

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-48

C0026-Change fault of right front wheel speed

Step Diagnostic actions Expected value Yes No

7 1. Still disconnect the vehicle speed sensor

from the jumper wire.

2. Connect a voltmeter to both terminals of

right front wheel speed sensor.

3. Select AC mV scale.

4. Turn right front wheel, while observing

the voltmeter voltage.

Is its AC voltage within the specified range?

At least 100mV Go to

Step 8

Go to

Step 17

8 1. Disconnect ECU harness from ECU.

2. Disconnect right front jumper wire from

ABS module harness.

3. Connect the ohmmeter to Terminal 24

ECU harness, and then connect it to

Terminal B

of ABS module harness.

Is its resistance within the specified range?

Below 2Ω Go to

Step 9

Go to

Step 18

9 1. Still disconnect ECU harness from ECU.

2. Still disconnect the jumper wire from

ABS module harness.

3. Connect the ohmmeter to Terminal 39 of

ECU harness, and then connect it to

Terminal A of ABS module harness.

Is its resistance within the specified range?

Below 2Ω Go to

Step 10

Go to

Step 19

10 1. Still disconnect ECU harness from ECU.

2. Still disconnect the jumper wire from

ABS module harness.

3. Connect the ohmmeter to Terminals 24

and 39 of ECU harness.

Is its resistance within the specified range?

(Open-circuit)

Go to

Step 11

Go to

Step 20

11 1. Replace right front jumper wire.

2. Test the vehicle on various road surfaces

at different speeds.

Is C0026 reset?

Go to

Step 21

System is

12 Check the diagnostic circuit before making

the diagnostic trouble code-C0026 diagram.

13 Prepare the diagnostic diagram of

C0033 before making the diagnostic trouble

code-C0026 diagram.

14 Repair the damaged right front wheel speed

sensor, jumper wire and/or toothed ring.

Do you complete the repair?

Go to

Step 22

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-49

C0026-Change fault of right front wheel speed

Step Diagnostic actions Expected value Yes No

15 C0026 is caused by the sensing of ignition

noise coupling to the circuit of right front

wheel speed sensor.

Check right front ABS module and/or jumper

wire for potential ignition noise sources, e.g.

spark plug conductor. Re-lay the conductor as

per the demands.

Do you complete the repair?

Go to

Step 22

16 The diagnostic trouble code-C0026 is

intermittent. Refer to “Diagnostic Help”.

17 Replace right front wheel speed sensor.

Do you complete the repair?

Go to

Step 22

18 Repair the open circuit or high resistance

between Terminals 24

and B.

Do you complete the repair?

Go to

Step 22

19 Repair the open circuit or high resistance

between Terminals 39

and A.

Do you complete the repair?

Go to

Step 22

20 Repair the short-circuit between two

conductors.

Do you complete the repair?

Go to

Step 22

21 Replace ECU.

Do you complete the repair?

Go to

Step 22

22 Remove the diagnostic trouble code with a

scanning tool.

Do you reset the diagnostic trouble code

when the conditions for setting the diagnostic

trouble code exist?

Go to

Step 1

System is

C0027-Change fault of left rear wheel speed

Description of circuit

During the rotation of wheels, the speed sensor produces an AC voltage, which is

increased with the increase of wheel speed. ECU adopts the frequency of AC signal to

calculate the wheel speed. The speed sensor is connected to ECU with a “twisted

pair” cable. Its twisting can reduce the noise to avoid any possible interference on

setting the diagnostic trouble code.

Conditions for setting the diagnostic trouble code

In order to set C0027, the following conditions must exist:

1. C0032, C0033, C0034 or C0035 is not current one.

2. Disconnection of brake switch.

3. The acceleration or deceleration of left rear wheel exceeds the reasonable limit.

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-50

Measures taken when setting the diagnostic trouble code

4. Store DTC C0027.

5. Failure of ABS.

6. Activation of ABS warning lamp.

Conditions for removing the diagnostic trouble code

1. If no conditions for setting DTC C0027 exist, remove this diagnostic trouble

code with a proper scanning tool.

2. Remove the diagnostic trouble code not produced within 100 ignition cycles

from the historic data.

Diagnostic help

In case of diagnosing the intermittent diagnostic trouble code, please check the lines

and connectors thoroughly, including:

1. Remove the protective guide tube, and check the lines for damages, short-circuit

or pollutions.

2. Check the terminals for deformations and damages.

3. Check the contact maintaining capacity of terminal with a standby male/female

terminal.

4. Remove the terminal from the connector, and check whether the press-connected

conductor terminal is falsely connected.

C0027-Change fault of left rear wheel speed

Step Diagnostic actions Expected value Yes No

1 Do you complete the check of diagnostic

circuit?

Go to

Step 2

Go to

Step 12

2 Do you set C0034 as current or historic code?

Go to

Step 13

Go to

Step 3

3 4. Flame breaking.

5. Check left rear wheel speed sensor and

jumper wire for damages.

6. Check left rear toothed ring fully and

thoroughly to know its damages (cracks,

tooth missing or loosening).

Do you check any physical damage?

Go to

Step 14

Go to

Step 4

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-51

C0027-Change fault of left rear wheel speed

Step Diagnostic actions Expected value Yes No

4 6. Stop the vehicle.

7. Connect to the scanning tool, and select the

data list.

8. Monitor the wheel speed sensor.

9. Start the vehicle, and monitor the wheel

speed sensor in the event that the engine

runs but the vehicle doesn’t move.

10. Step on the accelerator pedal lightly to

increase the engine idle speed.

Is C0027 reset or does the reading of left rear

wheel speed exceed 0 mile/hour if the engine

runs but the vehicle parks.

Go to

Step 15

Go to

Step 5

5 4. Still connect to the scanning tool.

5. Monitor the wheel speed sensor.

6. Test the vehicle up to the maximum limit

speed, and then reduce the speed to zero.

Repeat this operation several times.

Is C0027 reset or the change of left rear wheel

speed more than 5 km/hour(3 mile/hour) in

case of comparing with any other wheel speed

during the driving operation?

Go to

Step 6

Go to

Step 16

6 5. Stop the vehicle, and stall.

6. Lift and support the vehicle properly.

7. Disconnect left rear jumper wire from left

rear wheel speed sensor.

8. Connect the ohmmeter to both terminals of

left rear wheel speed sensor.

Is its resistance within the specified range?

800-1600Ω

(The resistance

will be changed

with the

changes of

temperature and

customer’s

requirements)

Go to

Step 7

Go to

Step 17

7 5. Still disconnect the vehicle speed sensor

from the jumper wire.

6. Connect a voltmeter to both terminals of

left rear wheel speed sensor.

7. Select AC mV scale.

8. Turn left rear wheel, while observing the

voltmeter voltage.

Is its AC voltage within the specified range?

At least 100mV Go to

Step 8

Go to

Step 17

8 4. Disconnect ECU harness from ECU.

5. Disconnect left rear jumper wire from ABS

module harness.

6. Connect the ohmmeter to Terminal 12 of

ECU harness, and then connect it to

Terminal B

of ABS module harness.

Is its resistance within the specified range?

Below 2Ω Go to

Step 9

Go to

Step 18

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-52

C0027-Change fault of left rear wheel speed

Step Diagnostic actions Expected value Yes No

9 4. Still disconnect ECU harness from ECU.

5. Still disconnect the jumper wire from ABS

module harness.

6. Connect the ohmmeter to Terminal 13 of

ECU harness, and then connect it to

Terminal A of ABS module harness.

Is its resistance within the specified range?

Below 2Ω Go to

Step 10

Go to

Step 19

10 4. Still disconnect ECU harness from ECU.

5. Still disconnect the jumper wire from ABS

module harness.

6. Connect the ohmmeter to Terminals 12 and

13 of ECU harness.

Is its resistance within the specified range?

(Open-circuit)

Go to

Step 11

Go to

Step 20

11 3. Replace left rear jumper wire.

4. Test the vehicle on various road surfaces at

different speeds.

Is C0027 reset?

Go to

Step 21

System is

12 Check the diagnostic circuit before making the

diagnostic trouble code-C0027 diagram.

13 Prepare the diagnostic diagram of

C0034 before making the diagnostic trouble

code-C0027 diagram.

14 Repair the damaged left rear wheel speed

sensor, jumper wire and/or toothed ring.

Do you complete the repair?

Go to

Step 22

15 C0027 is caused by the sensing of ignition

noise coupling to the circuit of left rear wheel

speed sensor.

Check left rear ABS module and/or jumper

wire for potential ignition noise sources, e.g.

spark plug conductor. Re-lay the conductor as

per the demands.

Do you complete the repair?

Go to

Step 22

16 The diagnostic trouble code-C0027 is

intermittent. Refer to “Diagnostic Help”.

17 Replace left rear wheel speed sensor.

Do you complete the repair?

Go to

Step 22

18 Repair the open circuit or high resistance

between Terminals 12

and B.

Do you complete the repair?

Go to

Step 22

19 Repair the open circuit or high resistance

between Terminals 13

and A.

Do you complete the repair?

Go to

Step 22

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-53

C0027-Change fault of left rear wheel speed

Step Diagnostic actions Expected value Yes No

20 Repair the short-circuit between two

conductors.

Do you complete the repair?

Go to

Step 22

21 Replace ECU.

Do you complete the repair?

Go to

Step 22

22 Remove the diagnostic trouble code with a

scanning tool.

Do you reset the diagnostic trouble code when

the conditions for setting the diagnostic trouble

code exist?

Go to

Step 1

System is

C0028-Change fault of right rear wheel speed

Description of circuit

During the rotation of wheels, the speed sensor produces an AC voltage, which is

increased with the increase of wheel speed. ECU adopts the frequency of AC signal to

calculate the wheel speed. The speed sensor is connected to ECU with a “twisted

pair” cable. Its twisting can reduce the noise to avoid any possible interference on

setting the diagnostic trouble code.

Conditions for setting the diagnostic trouble code

In order to set C0028, all the following conditions must exist:

1. C0032, C0033, C0034 or C0035 is not current one.

2. Disconnection of brake switch.

3. The acceleration or deceleration of right rear wheel exceeds the reasonable limit.

Measures taken when setting the diagnostic trouble code

1. Store DTC C0028.

2. Failure of ABS.

3. Turn on ABS warning lamp.

Conditions for removing the diagnostic trouble code

1. If no conditions for setting DTC C0028 exist, remove this diagnostic trouble

code with a proper scanning tool.

2. Remove the diagnostic trouble code not produced within 100 ignition cycles

from the historic data.

Diagnostic help

In case of diagnosing the intermittent diagnostic trouble code, please check the lines

and connectors thoroughly, including:

1. Remove the protective guide tube, and check the lines for damages, short-circuit

or pollutions.

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-54

2. Check the terminals for deformations and damages.

3. Check the contact (maintaining capacity) of terminal with a standby male/female

terminal.

4. Remove the terminal from the connector, and check whether the press-connected

conductor terminal is falsely connected.

C0028- Change fault of right rear wheel speed

Step Diagnostic actions Expected value Yes No

1 Do you complete the check of diagnostic

circuit?

Go to

Step 2

Go to

Step 12

2 Do you set C0035 as current or historic code?

Go to

Step 13

Go to

Step 3

3 1. Flame breaking.

2. Check right rear wheel speed sensor and

jumper wire for damages.

3. Check right rear toothed ring fully and

thoroughly to know its damages (cracks,

tooth missing or loosening).

Do you check any physical damage?

Go to

Step 14

Go to

Step 4

4 11. Stop the vehicle.

12. Connect to the scanning tool, and select the

data list.

13. Monitor the wheel speed sensor.

14. Start the vehicle, and monitor the wheel

speed sensor in the event that the engine

runs but the vehicle doesn’t move.

15. Step on the accelerator pedal lightly to

increase the engine idle speed.

Is C0028 reset or does the reading of right rear

wheel speed exceed 0 mile/hour if the engine

runs but the vehicle parks.

Go to

Step 15

Go to

Step 5

5 7. Still connect to the scanning tool.

8. Monitor the wheel speed sensor.

9. Test the vehicle up to the maximum limit

speed, and then reduce the speed to zero.

Repeat this operation several times.

Is C0028 reset or the change of right rear wheel

speed more than 5 km/hour(3 mile/hour) in

case of comparing with any other wheel speed

during the driving operation?

Go to

Step 6

Go to

Step 16

6 9. Stop the vehicle, and stall.

10. Lift and support the vehicle properly.

11. Disconnect right rear jumper wire from

right rear wheel speed sensor.

12. Connect the ohmmeter to both terminals

of right rear wheel speed sensor.

Is its resistance within the specified range?

800-1600Ω

(The resistance

will be changed

with the

changes of

temperature and

customer’s

requirements)

Go to

Step 7

Go to

Step 17

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-55

C0028- Change fault of right rear wheel speed

Step Diagnostic actions Expected value Yes No

7 9. Still disconnect the vehicle speed sensor

from the jumper wire.

10. Connect a voltmeter to both terminals of

right rear wheel speed sensor.

11. Select AC mV scale.

12. Turn right rear wheel, while observing the

voltmeter voltage.

Is its AC voltage within the specified range?

At least 100mV Go to

Step 8

Go to

Step 17

8 7. Disconnect ECU harness from ECU.

8. Disconnect right rear jumper wire from

ABS module harness.

9. Connect the ohmmeter to Terminal 43 of

ECU harness, and then connect it to

Terminal B

of ABS module harness.

Is its resistance within the specified range?

Below 2Ω Go to

Step 9

Go to

Step 18

9 7. Still disconnect ECU harness from ECU.

8. Still disconnect the jumper wire from ABS

module harness.

9. Connect the ohmmeter to Terminal 42

ECU harness, and then connect it to

Terminal A

of ABS module harness.

Is its resistance within the specified range?

Below 2Ω Go to

Step 10

Go to

Step 19

10 7. Still disconnect ECU harness from ECU.

8. Still disconnect the jumper wire from ABS

module harness.

9. Connect the ohmmeter to Terminals 43 and

of ECU harness.

Is its resistance within the specified range?

(Open-circuit)

Go to

Step 11

Go to

Step 20

11 5. Replace right rear jumper wire.

6. Test the vehicle on various road surfaces at

different speeds.

Is C0028 reset?

Go to

Step 21

System is

12 Check the diagnostic circuit before making the

diagnostic trouble code-C0028 diagram.

13 Prepare the diagnostic diagram of

C0035 before making the diagnostic trouble

code-C0028 diagram.

14 Repair the damaged right rear wheel speed

sensor, jumper wire and/or toothed ring.

Do you complete the repair?

Go to

Step 22

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-56

C0028- Change fault of right rear wheel speed

Step Diagnostic actions Expected value Yes No

15 C0028 is caused by the sensing of ignition

noise coupling to the circuit of right rear wheel

speed sensor.

Check right rear ABS module and/or jumper

wire for potential ignition noise sources, e.g.

spark plug conductor. Re-lay the conductor as

per the demands.

Do you complete the repair?

Go to

Step 22

16 The diagnostic trouble code-C0028 is

intermittent. Refer to “Diagnostic Help”.

17 Replace right rear wheel speed sensor.

Do you complete the repair?

Go to

Step 22

18 Repair the open circuit or high resistance

between Terminals 43

and B.

Do you complete the repair?

Go to

Step 22

19 Repair the open circuit or high resistance

between Terminals 42

and A.

Do you complete the repair?

Go to

Step 22

20 Repair the short-circuit between two

conductors.

Do you complete the repair?

Go to

Step 22

21 Replace ECU.

Do you complete the repair?

Go to

Step 22

22 Remove the diagnostic trouble code with a

scanning tool.

Do you reset the diagnostic trouble code when

the conditions for setting the diagnostic trouble

code exist?

Go to

Step 1

System is

C0032-Open-circuit or short-circuit of left front wheel speed sensor

Description of circuit

During the rotation of wheels, the speed sensor produces an AC voltage, which is

increased with the increase of wheel speed. ECU adopts the frequency of AC signal to

calculate the wheel speed. The speed sensor is connected to ECU with a “twisted

pair” cable. Its twisting can reduce the noise to avoid any possible interference on

setting the diagnostic trouble code.

Conditions for setting the diagnostic trouble code

In case of ignition, DTC C0032 can be set when ECU checks the open-circuit,

short-circuit to ground or short-circuit to battery of left front wheel speed circuit at

any time.

Measures taken when setting the diagnostic trouble code

1. Store DTC C0032.

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-57

2. Failure of ABS.

3. Turn on ABS warning lamp.

Conditions for removing the diagnostic trouble code

1. If no conditions for setting DTC C0032 exist, remove this diagnostic trouble

code with a proper scanning tool.

2. Remove the diagnostic trouble code not produced within 100 ignition cycles from

the historic data.

Diagnostic help

In case of diagnosing the intermittent diagnostic trouble code, please check the lines

and connectors thoroughly, including:

1. Remove the protective guide tube, and check the lines for damages, short-circuit

or pollutions.

2. Check the terminals for deformations and damages.

3. Check the contact (maintaining capacity) of terminal with a standby male/female

terminal.

4. Remove the terminal from the connector, and check whether the press-connected

conductor terminal is falsely connected.

C0032- open-circuit or short-circuit of left front wheel speed sensor

Step Diagnostic actions Expected value Yes No

1 Do you complete the check of diagnostic

circuit?

Go to

Step 2

Go to

Step 14

2 1. Flame breaking.

2. Check left front wheel speed sensor,

harness and toothed ring for physical

damages.

Do you check any physical damage?

Go to

Step 15

Go to

Step 3

3 Test the vehicle on various road surfaces at

different speeds.

Is C0032 reset?

Go to

Step 4

Go to

Step 16

4 1. Stall and stop the vehicle.

2. Lift and support the vehicle properly.

3. Disconnect left front jumper wire from

left front wheel speed sensor.

4. Connect the ohmmeter to Terminals A

and B

of left front wheel speed sensor.

Is its resistance within the specified range?

800-1600Ω

(The resistance

will be changed

with the changes

of temperature

and customer’s

requirements)

Go to

Step 5

Go to

Step 17

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-58

C0032- open-circuit or short-circuit of left front wheel speed sensor

Step Diagnostic actions Expected value Yes No

5 1. Still disconnect the left front jumper

wire from the speed sensor.

2. Connect the ohmmeter to Terminal A of

left front wheel speed sensor, and then

connect it to body ground.

Is its resistance within the specified range?

(Open-circuit)

Go to

Step 6

Go to

Step 17

6 1. Still disconnect ECU harness from ECU.

2. Still disconnect left front jumper wire

from ABS module harness.

3. Connect the ohmmeter to Terminal 28 of

ECU harness, and then connect it to

Terminal B of ABS module harness.

Is its resistance within the specified range?

Below 2Ω Go to

Step 7

Go to

Step 18

7 1. Still disconnect ECU harness from ECU.

2. Still disconnect left front jumper wire

from ABS module harness.

3. Connect the ohmmeter to Terminal 27 of

ECU harness, and then connect it to

Terminal A

of ABS module harness.

Is its resistance within the specified range?

Below 2Ω Go to

Step 8

Go to

Step 19

8 1. Still disconnect ECU harness from ECU.

2. Left front cross-wiring harness

disconnects the harness of anti-lock

brake system module.

3. Connect the voltmeter to Terminal 28 of

left front wheel speed sensor, and then

connect it to body ground.

Is its voltage within the specified range?

Below 1V Go to

Step 9

Go to

Step 20

9 1. Still disconnect ECU harness from ECU.

2. Still disconnect left front jumper wire

from ABS module harness.

3. Connect the voltmeter to Terminal 27

ECU harness, and then connect it to

body ground.

Is its voltage within the specified range?

Below 1V Go to

Step 10

Go to

Step 21

10 1. Still disconnect ECU harness from ECU.

2. Still disconnect the left front jumper

wire from ABS module harness.

3. Connect the ohmmeter to Terminal 28 of

ECU harness, and then connect it to

body ground.

Is its resistance within the specified range?

(Open-circuit)

Go to

Step 11

Go to

Step 22

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-59

C0032- open-circuit or short-circuit of left front wheel speed sensor

Step Diagnostic actions Expected value Yes No

11 1. Still disconnect ECU harness from ECU.

2. Still disconnect the left front jumper

wire from ABS module harness.

3. Connect the ohmmeter to Terminal 27 of

ECU harness, and then connect it to

body ground.

Is its resistance within the specified range?

(Open-circuit)

Go to

Step 12

Go to

Step 23

12 1. Still disconnect ECU harness from ECU.

2. Still disconnect the left front jumper

wire from ABS module harness.

3. Connect the ohmmeter to

Terminals 28 and 27 of ECU harness.

Is its resistance within the specified range?

(Open-circuit)

Go to

Step 13

Go to

Step 24

13 1. Replace left front jumper wire.

2. Test the vehicle on various road surfaces

at different speeds.

Is C0032 reset?

Go to

Step 25

System is

14 Check the diagnostic circuit.

15 Repair the damaged left front wheel speed

sensor, jumper wire and/or toothed ring.

Do you complete the repair?

Go to

Step 26

16 The diagnostic trouble code-C0028 is

intermittent. Refer to “Diagnostic Help”.

17 Replace left front wheel speed sensor.

Do you complete the repair?

Go to

Step 26

18 Repair the open circuit or high resistance

between Terminals 28

and B.

Do you complete the repair?

Go to

Step 26

19 Repair the open circuit or high resistance

between Terminals 27

and A.

Do you complete the repair?

Go to

Step 26

20 Repair the short-circuit to voltage between

Terminals 28

and B.

Do you complete the repair?

Go to

Step 26

21 Repair the short-circuit to voltage between

Terminals 27

and A.

Do you complete the repair?

Go to

Step 26

22 Repair the short-circuit to ground between

Terminals 28

and B.

Do you complete the repair?

Go to

Step 26

23 Repair the short-circuit to ground between

Terminals 27

and A.

Do you complete the repair?

Go to

Step 26

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-60

C0032- open-circuit or short-circuit of left front wheel speed sensor

Step Diagnostic actions Expected value Yes No

24 Repair the short-circuit between two

conductors.

Do you complete the repair?

Go to

Step 26

25 Replace ECU.

Do you complete the repair?

Go to

Step 26

26 Remove the diagnostic trouble code with a

scanning tool.

Do you reset the diagnostic trouble code

when the conditions for setting the

diagnostic trouble code exist?

Go to

Step 1

System is

C0033-open-circuit or short-circuit of right front wheel speed sensor

Description of circuit

During the rotation of wheels, the speed sensor produces an AC voltage, which is

increased with the increase of wheel speed. ECU adopts the frequency of AC signal to

calculate the wheel speed. The speed sensor is connected to ECU with a “twisted

pair” cable. Its twisting can reduce the noise to avoid any possible interference on

setting the diagnostic trouble code.

Conditions for setting the diagnostic trouble code

In case of ignition, DTC C0033 can be set when ECU checks the open-circuit,

short-circuit to ground or short-circuit to battery of right front wheel speed circuit at

any time.

Measures taken when setting the diagnostic trouble code

1. Store DTC C0033.

2. Failure of ABS.

3. Turn on ABS warning lamp.

Conditions for removing the diagnostic trouble code

1. If no conditions for setting DTC C0033 exist, remove this diagnostic trouble

code with a proper scanning tool.

2. Remove the diagnostic trouble code not produced within 100 ignition cycles

from the historic data.

Diagnostic help

In case of diagnosing the intermittent diagnostic trouble code, please check the lines

and connectors thoroughly, including:

1. Remove the protective guide tube, and check the lines for damages, short-circuit

or pollutions.

2. Check the terminals for deformations and damages.

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-61

3. Check the contact (maintaining capacity) of terminal with a standby male/female

terminal.

4. Remove the terminal from the connector, and check whether the press-connected

conductor terminal is falsely connected.

C0033- open-circuit or short-circuit of right front wheel speed sensor

Step Diagnostic actions Expected value Yes No

1 Do you complete the check of diagnostic

circuit?

Go to

Step 2

Go to

Step 14

2 1. Flame breaking.

2. Check right front wheel speed sensor,

harness and toothed ring for physical

damages.

Do you check any physical damage?

Go to

Step 15

Go to

Step 3

3 Test the vehicle on various road surfaces at

different speeds.

Is C0033 reset?

Go to

Step 4

Go to

Step 16

4 1. Stall and stop the vehicle.

2. Lift and support the vehicle properly.

3. Disconnect right front jumper wire from

right front wheel speed sensor.

4. Connect the ohmmeter to Terminals A

and B of right front wheel speed sensor.

Is its resistance within the specified range?

800-1600Ω

(The resistance

will be changed

with the changes

of temperature

and customer’s

requirements)

Go to

Step 5

Go to

Step 17

5 1. Still disconnect the right front jumper

wire from the speed sensor.

2. Connect the ohmmeter to Terminal A of

right front wheel speed sensor, and then

connect it to body ground.

Is its resistance within the specified range?

(Open-circuit)

Go to

Step 6

Go to

Step 17

6 1. Still disconnect ECU harness from ECU.

2. Still disconnect right front jumper wire

from ABS module harness.

3. Connect the ohmmeter to Terminal 24 of

ECU harness, and then connect it to

Terminal B

of ABS module harness.

Is its resistance within the specified range?

Below 2Ω Go to

Step 7

Go to

Step 18

7 1. Still disconnect ECU harness from ECU.

2. Still disconnect right front jumper wire

from ABS module harness.

3. Connect the ohmmeter to Terminal 39 of

ECU harness, and then connect it to

Terminal A of ABS module harness.

Is its resistance within the specified range?

Below 2Ω Go to

Step 8

Go to

Step 19

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-62

C0033- open-circuit or short-circuit of right front wheel speed sensor

Step Diagnostic actions Expected value Yes No

8 1. Still disconnect ECU harness from ECU.

2. Right front cross-wiring harness

disconnects the harness of ABS module.

3. Connect the voltmeter to Terminal 24 of

right front wheel speed sensor, and then

connect it to body ground.

Is its voltage within the specified range?

Below 1V Go to

Step 9

Go to

Step 20

9 1. Still disconnect ECU harness from ECU.

2. Still disconnect right front jumper wire

from ABS module harness.

3. Connect the voltmeter to Terminal 39 of

ECU harness, and then connect it to body

ground.

Is its voltage within the specified range?

Below 1V Go to

Step 10

Go to

Step 21

10 1. Still disconnect ECU harness from ECU.

2. Still disconnect the right front jumper

wire from ABS module harness.

3. Connect the ohmmeter to Terminal 24 of

ECU harness, and then connect it to body

ground.

Is its resistance within the specified range?

(Open-circuit)

Go to

Step 11

Go to

Step 22

11 1. Still disconnect ECU harness from ECU.

2. Still disconnect the right front jumper

wire from ABS module harness.

3. Connect the ohmmeter to Terminal 39

ECU harness, and then connect it to body

ground.

Is its resistance within the specified range?

(Open-circuit)

Go to

Step 12

Go to

Step 23

12 1. Still disconnect ECU harness from ECU.

2. Still disconnect the right front jumper

wire from ABS module harness.

3. Connect the ohmmeter to

Terminals 24

and 39 of ECU harness.

Is its resistance within the specified range?

(Open-circuit)

Go to

Step 13

Go to

Step 24

13 1.Replace right front jumper wire.

2.Test the vehicle on various road surfaces at

different speeds.

Is C0033 reset?

Go to

Step 25

System is

14 Check the diagnostic circuit.

15 Repair the damaged right front wheel speed

sensor, jumper wire and/or toothed ring.

Do you complete the repair?

Go to

Step 26

16 The diagnostic trouble code-C0033 is

intermittent. Refer to “Diagnostic Help”.

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-63

C0033- open-circuit or short-circuit of right front wheel speed sensor

Step Diagnostic actions Expected value Yes No

17 Replace right front wheel speed sensor.

Do you complete the repair?

Go to

Step 26

18 Repair the open circuit or high resistance

between Terminals 24

and B.

Do you complete the repair?

Go to

Step 26

19 Repair the open circuit or high resistance

between Terminals 39

and A.

Do you complete the repair?

Go to

Step 26

20 Repair the short-circuit to voltage between

Terminals 24

and B.

Do you complete the repair?

Go to

Step 26

21 Repair the short-circuit to voltage between

Terminals 39

and A.

Do you complete the repair?

Go to

Step 26

22 Repair the short-circuit to ground between

Terminals 24

and B.

Do you complete the repair?

Go to

Step 26

23 Repair the short-circuit to ground between

Terminals 39

and A.

Do you complete the repair?

Go to

Step 26

24 Repair the short-circuit between two

conductors.

Do you complete the repair?

Go to

Step 26

25 Replace ECU.

Do you complete the repair?

Go to

Step 26

26 Remove the diagnostic trouble code with a

scanning tool.

Do you reset the diagnostic trouble code

when the conditions for setting the diagnostic

trouble code exist?

Go to

Step 1

System is

C0034-open-circuit or short-circuit of left rear wheel speed sensor

Description of circuit

During the rotation of wheels, the speed sensor produces an AC voltage, which is

increased with the increase of wheel speed. ECU adopts the frequency of AC signal to

calculate the wheel speed. The speed sensor is connected to ECU with a “twisted

pair” cable. Its twisting can reduce the noise to avoid any possible interference on

setting the diagnostic trouble code.

Conditions for setting the diagnostic trouble code

In case of ignition, DTC C0034 can be set when ECU checks the open-circuit,

short-circuit to ground or short-circuit to battery of left rear wheel speed circuit at any

time.

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-64

Measures taken when setting the diagnostic trouble code

1. Store DTC C0034.

2. Failure of ABS.

3. Turn on ABS warning lamp.

Conditions for removing the diagnostic trouble code

1. If no conditions for setting DTC C0034 exist, remove this diagnostic trouble

code with a proper scanning tool.

2. Remove the diagnostic trouble code not produced within 100 ignition cycles

from the historic data.

C0034- open-circuit or short-circuit of left rear wheel speed sensor

Step Diagnostic actions Expected value Yes No

1 Do you complete the check of diagnostic

circuit?

Go to

Step 2

Go to

Step 14

2 1. Flame breaking.

2. Check left rear wheel speed sensor,

harness and toothed ring for physical

damages.

Do you check any physical damage?

Go to

Step 15

Go to

Step 3

3 Test the vehicle on various road surfaces at

different speeds.

Is C0034 reset?

Go to

Step 14

Go to

Step 4

4 1. Stall and stop the vehicle.

2. Lift and support the vehicle properly.

3. Disconnect left rear jumper wire from

left rear wheel speed sensor.

4. Connect the ohmmeter to Terminals A

and B

of left rear wheel speed sensor.

Is its resistance within the specified range?

800-1600Ω

(The resistance

will be changed

with the changes

of temperature and

customer’s

requirements)

Go to

Step 5

Go to

Step 17

5 1. Still disconnect the left rear jumper wire

from the speed sensor.

2. Connect the ohmmeter to Terminal A of

left rear wheel speed sensor, and then

connect it to body ground.

Is its resistance within the specified range?

(Open-circuit)

Go to

Step 6

Go to

Step 17

6 1. Still disconnect ECU harness from ECU.

2. Still disconnect left rear jumper wire

from ABS module harness.

3. Connect the ohmmeter to Terminal 12

ECU harness, and then connect it to

Terminal B

of ABS module harness.

Is its resistance within the specified range?

Below 2Ω Go to

Step 7

Go to

Step 18

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-65

C0034- open-circuit or short-circuit of left rear wheel speed sensor

Step Diagnostic actions Expected value Yes No

7 1. Still disconnect ECU harness from ECU.

2. Still disconnect left rear jumper wire

from ABS module harness.

3. Connect the ohmmeter to Terminal 13

ECU harness, and then connect it to

Terminal A

of ABS module harness.

Is its resistance within the specified range?

Below 2Ω Go to

Step 8

Go to

Step 19

8 1. Still disconnect ECU harness from ECU.

2. Left rear cross-wiring harness still

disconnects the harness of ABS module.

3. Connect the voltmeter to Terminal 12 of

left rear wheel speed sensor, and then

connect it to body ground.

Is its voltage within the specified range?

Below 1V Go to

Step 9

Go to

Step 20

9 1. Still disconnect ECU harness from ECU.

2. Still disconnect left rear jumper wire

from ABS module harness.

3. Connect the voltmeter to Terminal 13

ECU harness, and then connect it to

body ground.

Is its voltage within the specified range?

Below 1V Go to

Step 10

Go to

Step 21

10 1. Still disconnect ECU harness from ECU.

2. Still disconnect the left rear jumper wire

from ABS module harness.

3. Connect the ohmmeter to Terminal 12

ECU harness, and then connect it to

body ground.

Is its resistance within the specified range?

(Open-circuit)

Go to

Step 11

Go to

Step 22

11 1. Still disconnect ECU harness from ECU.

2. Still disconnect the left rear jumper wire

from ABS module harness.

3. Connect the ohmmeter to Terminal 13

ECU harness, and then connect it to

body ground.

Is its resistance within the specified range?

(Open-circuit)

Go to

Step 12

Go to

Step 23

12 1. Still disconnect ECU harness from ECU.

2. Still disconnect the left rear jumper wire

from ABS module harness.

3. Connect the ohmmeter to

Terminals 12

and 13 of ECU harness.

Is its resistance within the specified range?

(Open-circuit)

Go to

Step 13

Go to

Step 24

13 1. Replace left rear jumper wire.

2. Test the vehicle on various road surfaces

at different speeds.

Is C0034 reset?

Go to

Step 25

System is

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-66

C0034- open-circuit or short-circuit of left rear wheel speed sensor

Step Diagnostic actions Expected value Yes No

14 Check the diagnostic circuit.

15 Repair the damaged left rear wheel speed

sensor, jumper wire and/or toothed ring.

Do you complete the repair?

Go to

Step 26

16 The diagnostic trouble code-C0034 is

intermittent. Refer to “Diagnostic Help”.

17 Replace left rear wheel speed sensor.

Do you complete the repair?

Go to

Step 26

18 Repair the open circuit or high resistance

between Terminals 12

and B.

Do you complete the repair?

Go to

Step 26

19 Repair the open circuit or high resistance

between Terminals 13

and A.

Do you complete the repair?

Go to

Step 26

20 Repair the short-circuit to voltage between

Terminals 12

and B.

Do you complete the repair?

Go to

Step 26

21 Repair the short-circuit to voltage between

Terminals 13

and A.

Do you complete the repair?

Go to

Step 26

22 Repair the short-circuit to ground between

Terminals 12

and B.

Do you complete the repair?

Go to

Step 26

23 Repair the short-circuit to ground between

Terminals 13

and A.

Do you complete the repair?

Go to

Step 26

24 Repair the short-circuit between two

conductors.

Do you complete the repair?

Go to

Step 26

25 Replace ECU.

Do you complete the repair?

Go to

Step 26

26 Remove the diagnostic trouble code with a

scanning tool.

Do you reset the diagnostic trouble code

when the conditions for setting the

diagnostic trouble code exist?

Go to

Step 1

System is

C0035-open-circuit or short-circuit of right rear wheel speed sensor

Description of circuit

During the rotation of wheels, the speed sensor produces an AC voltage, which is

increased with the increase of wheel speed. ECU adopts the frequency of AC signal to

calculate the wheel speed. The speed sensor is connected to ECU with a “twisted

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-67

pair” cable. Its twisting can reduce the noise to avoid any possible interference on

setting the diagnostic trouble code.

Conditions for setting the diagnostic trouble code

In case of ignition, DTC C0035 can be set when ECU checks the open-circuit,

short-circuit to ground or short-circuit to battery of right rear wheel speed circuit at

any time.

Measures taken when setting the diagnostic trouble code

1. Store DTC C0035.

2. Failure of ABS.

3. Turn on ABS warning lamp.

Conditions for removing the diagnostic trouble code

1. If no conditions for setting DTC C0035 exist, remove this diagnostic trouble

code with a proper scanning tool.

2. Remove the diagnostic trouble code not produced within 100 ignition cycles

from the historic data.

C0035- open-circuit or short-circuit of right rear wheel speed sensor

Step Diagnostic actions Expected value Yes No

1 Do you complete the check of diagnostic

circuit?

Go to

Step 2

Go to

Step 14

2 3. Flame breaking.

4. Check right rear wheel speed sensor,

harness and toothed ring for physical

damages.

Do you check any physical damage?

Go to

Step 15

Go to

Step 3

3 Test the vehicle on various road surfaces at

different speeds.

Is C0035 reset?

Go to

Step 4

Go to

Step 16

4 5. Stall and stop the vehicle.

6. Lift and support the vehicle properly.

7. Disconnect right rear jumper wire from

right rear wheel speed sensor.

8. Connect the ohmmeter to Terminals A

and B

of right rear wheel speed sensor.

Is its resistance within the specified range?

800-1600Ω

(The resistance

will be changed

with the changes

of temperature and

customer’s

requirements)

Go to

Step 5

Go to

Step 17

5 3. Still disconnect the right rear jumper

wire from the speed sensor.

4. Connect the ohmmeter to Terminal A of

right rear wheel speed sensor, and then

connect it to body ground.

Is its resistance within the specified range?

(Open-circuit)

Go to

Step 6

Go to

Step 17

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-68

C0035- open-circuit or short-circuit of right rear wheel speed sensor

Step Diagnostic actions Expected value Yes No

6 4. Still disconnect ECU harness from ECU.

5. Still disconnect right rear jumper wire

from ABS module harness.

6. Connect the ohmmeter to Terminal 43

ECU harness, and then connect it to

Terminal B

of ABS module harness.

Is its resistance within the specified range?

Below 2Ω Go to

Step 7

Go to

Step 18

7 4. Still disconnect ECU harness from ECU.

5. Still disconnect right rear jumper wire

from ABS module harness.

6. Connect the ohmmeter to Terminal 42

ECU harness, and then connect it to

Terminal A

of ABS module harness.

Is its resistance within the specified range?

Below 2Ω Go to

Step 8

Go to

Step 19

8 4.Still disconnect ECU harness from ECU.

5. Right rear cross-wiring harness still

disconnects the harness of ABS module.

6. Connect the voltmeter to Terminal 43 of

right rear wheel speed sensor, and then

connect it to body ground.

Is its voltage within the specified range?

Below 1V Go to

Step 9

Go to

Step 20

9 4. Still disconnect ECU harness from ECU.

5. Still disconnect right rear jumper wire

from ABS module harness.

6. Connect the voltmeter to Terminal 42

ECU harness, and then connect it to

body ground.

Is its voltage within the specified range?

Below 1V Go to

Step 10

Go to

Step 21

10 4. Still disconnect ECU harness from ECU.

5. Still disconnect the right rear jumper

wire from ABS module harness.

6. Connect the ohmmeter to Terminal 43

ECU harness, and then connect it to

body ground.

Is its resistance within the specified range?

(Open-circuit)

Go to

Step 11

Go to

Step 22

11 4. Still disconnect ECU harness from ECU.

5. Still disconnect the right rear jumper

wire from ABS module harness.

6. Connect the ohmmeter to Terminal 42

ECU harness, and then connect it to

body ground.

Is its resistance within the specified range?

(Open-circuit)

Go to

Step 12

Go to

Step 23

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-69

C0035- open-circuit or short-circuit of right rear wheel speed sensor

Step Diagnostic actions Expected value Yes No

12 4. Still disconnect ECU harness from ECU.

5. Still disconnect the right rear jumper

wire from ABS module harness.

6. Connect the ohmmeter to

Terminals 43

and 42 of ECU harness.

Is its resistance within the specified range?

(Open-circuit)

Go to

Step 13

Go to

Step 24

13 3. Replace right rear jumper wire.

4. Test the vehicle on various road surfaces

at different speeds.

Is C0035 reset?

Go to

Step 25

System is

14 Check the diagnostic circuit.

15 Repair the damaged right rear wheel speed

sensor, jumper wire and/or toothed ring.

Do you complete the repair?

Go to

Step 26

16 The diagnostic trouble code-C0035 is

intermittent. Refer to “Diagnostic Help”.

17 Replace right rear wheel speed sensor.

Do you complete the repair?

Go to

Step 26

18 Repair the open circuit or high resistance

between Terminals 43

and B.

Do you complete the repair?

Go to

Step 26

19 Repair the open circuit or high resistance

between Terminals 42

and A.

Do you complete the repair?

Go to

Step 26

20 Repair the short-circuit to voltage between

Terminals 43

and B.

Do you complete the repair?

Go to

Step 26

21 Repair the short-circuit to voltage between

Terminals 42

and A.

Do you complete the repair?

Go to

Step 26

22 Repair the short-circuit to ground between

Terminals 43

and B.

Do you complete the repair?

Go to

Step 26

23 Repair the short-circuit to ground between

Terminals 42

and A.

Do you complete the repair?

Go to

Step 26

24 Repair the short-circuit between two

conductors.

Do you complete the repair?

Go to

Step 26

25 Replace ECU.

Do you complete the repair?

Go to

Step 26

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-70

C0035- open-circuit or short-circuit of right rear wheel speed sensor

Step Diagnostic actions Expected value Yes No

26 Remove the diagnostic trouble code with a

scanning tool.

Do you reset the diagnostic trouble code

when the conditions for setting the

diagnostic trouble code exist?

Go to

Step 1

System is

C0036- Low system voltage fault

Description of circuit

This circuit is used to monitor the voltage and electric level supplied to ECU. If the

voltage is reduced to a certain level, all the performances of system can’t be ensured.

As several common conditions will cause the voltage drop of battery during the

operation of ABS, please monitor the voltage before activating ABS to indicate the

good charging conditions, and such conditions will also occur during the operation of

ABS in case of any possible great voltage drop.

Conditions for setting the diagnostic trouble code

If the voltage of ignition terminal 16 and battery terminal 46 is below 10.5V without

ABS or during its initialization period, C0036 can be set only when the vehicle speed

is more than 8km/hour. When ABS is available, C0036 can be set if the ignition

voltage is below 10.5V and battery voltage is below 9.0V.

Measures taken when setting the diagnostic trouble code

1. Store DTC C0036.

2. Failure of ABS.

3. Turn on ABS warning lamp.

Conditions for removing the diagnostic trouble code

1. If no conditions for setting DTC C0036 exist, remove this diagnostic trouble

code with a proper scanning tool.

2. Remove the diagnostic trouble code not produced within 100 ignition cycles

from the historic data.

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-71

C0036-low system voltage fault

Step Diagnostic actions Expected value Yes No

1 Do you complete the check of diagnostic

circuit?

Go to

Step 2

Go to

Step 6

2 1. Battery load test. Refer to the Battery

Maintenance Manual.

2. Check the charging system. Refer to the

Maintenance Manual for Starter and

Charging System.

3. Perform the additional load test.

Do you pass the tests of battery, charging

system and additional load?

The battery must

be capable of

maintaining at

least 9.6V for

10s.

Not more than

30mA.

Go to

Step 3

Go to

Step 7

3 1. Flame breaking.

2. Disconnect the positive and negative

poles of battery.

3. Disconnect the harness from ECU.

4. Check the following harness for poor

contacts.

• Battery terminal wiring.

• Negative cable to engine block and/or

chassis.

• Positive cable to starter coil and/or wiring

box.

• ECU terminals 16,46 and 1.

• EBCM/ECU grounded wire to chassis

ground.

Are all the above connections good?

Go to

Step 4

Go to

Step 8

4 1. Still disconnect ECU.

2. Still disconnect ECU harness.

3. Connect an ohmmeter between Terminal

1 of ECU harness and negative cable of

battery.

Is its resistance within the specified range?

Below 2 Ohm Go to

Step 5

Go to

Step 9

5 1. Reconnect the battery cable.

2. Still disconnect ECU.

3. Ignition.

4. Measure the voltage between Terminals

16 and 46 of ECU harness with a

voltmeter.

Is the voltage between both terminals within

the specified range?

Battery voltage Go to

Step 11

Go to

Step 10

6 Check the diagnostic circuit.

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-72

C0036-low system voltage fault

Step Diagnostic actions Expected value Yes No

7 Repair the charging system.

And/or

Recharge/replace the battery.

And/or

Find out the causes for excessive leakage, and

repair it.

Do you complete the repair?

Go to

Step 12

8 If necessary, repair the terminals and/or

connectors.

Do you complete the repair?

Go to

Step 12

9 Check the cause for high resistance between

negative cable of battery and ECU harness

connector, and repair it.

Do you complete the repair?

Go to

Step 12

10 Check the cause for low voltage of ECU

terminal, and repair it.

Do you complete the repair?

Go to

Step 12

11 Replace ECU.

Do you complete the repair?

Go to

Step 12

12 Remove the diagnostic trouble code with a

scanning tool.

Do you reset the diagnostic trouble code

when the conditions for setting the diagnostic

trouble code exist?

Go to

Step 1

System is

OK.

C0037- High system voltage fault

Description of circuit

This circuit is used to monitor the level of voltage supplied to ECU. If the voltage is

increased to a certain level, the system may be damaged.

Conditions for setting the diagnostic trouble code

If the voltage supplied to Terminal 46 is more than 17V for 1s, DTC C0037 can be set

only when the vehicle speed is more than 8km/hour(5 mile/hour).

Measures taken when setting the diagnostic trouble code

1. Store DTC C0037.

2. Failure of ABS.

3. Turn on ABS warning lamp.

Conditions for removing the diagnostic trouble code

1. If no conditions for setting DTC C0037 exist, remove this diagnostic trouble

code with a proper scanning tool.

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-73

2. Remove the diagnostic trouble code not produced within 100 ignition cycles

from the historic data.

Diagnostic help

Typical causes for setting DTC C0037:

1. Fault of charging system.

2. Poor connection.

3. ECU faults.

C0037-high system voltage fault

Step Diagnostic actions Expected value Yes No

1 Do you complete the check of diagnostic

circuit?

Go to

Step 2

Go to

Step 6

2 1. Connect a voltmeter between positive and

negative poles of battery.

2. Turn off all the accessories.

3. Start the engine.

4. Monitor the voltage of voltmeter when

the engine runs at 2000rpm for several

seconds.

Is its voltage within the specified range?

Below 17.0V

Go to

Step 3

Go to

Step 5

3 1. Connect the scanning tool, and select

ABS data list.

2. Monitor the battery voltage in the list of

ABS data when the engine runs at

2000rpm for several seconds.

Is its voltage within the specified range?

Below 17.0V

Go to

Step 6

Go to

Step 7

4 Check the diagnostic circuit.

5 Refer to the diagnosis of starter and charging

system.

6 If intermittent, refer to Diagnostic Help, the

diagnosis of starter and charging system.

7 Replace ECU.

Do you complete the repair?

Go to

Step 8

8 Remove the diagnostic trouble code with a

scanning tool.

Do you reset the diagnostic trouble code

when the conditions for setting the diagnostic

trouble code exist?

Go to

Step 1

System is

OK.

C0042-Open-circuit of pump motor circuit

Description of circuit

The pump motor is included in hydraulic control unit (HCU). The voltage of pump

motor is supplied by Terminal 46 of ECU, which is controlled by a high-voltage solid

drive. The pump motor is grounded through Terminal 31 of ECU.

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-74

Conditions for setting the diagnostic trouble code

C0042 can be set only when the ignition switch is in connected (ON) position, pump

motor is stopped, and ECU detects the high resistance or open-circuit of motor circuit.

Measures taken when setting the diagnostic trouble code

1. Store DTC C0042.

2. Failure of ABS.

3. Turn on ABS warning lamp.

Conditions for removing the diagnostic trouble code

1. If no conditions for setting DTC C0042 exist, remove this diagnostic trouble

code with a proper scanning tool.

2. Remove the diagnostic trouble code not produced within 100 ignition cycles from

the historic data.

Diagnostic help

Typical causes for setting DTC C0042:

1. Open-circuit or high resistance of the circuit from pump motor to ECU connector.

2. Open-circuit of pump motor circuit.

3. ECU faults.

C0036-low voltage of system

Step Diagnostic actions Expected value Yes No

1 Do you complete the check of diagnostic

circuit?

Go to

Step 2

Go to

Step 4

2 1. Flame breaking.

2. Disconnect ECU.

3. Remove ECU from HCU.

4. Check the connector from ECU to HCU

for damages, corrosion, poor terminal

contacts or brake fluid leakage, etc.

Are the terminal and connector OK, brake

fluid, damages or corrosion exist in hollow

space?

Go to

Step 3

Go to

Step 5

3 Connect the ohmmeter to Terminals 1 and 2

of HCU.

Is the reading of pump motor resistance

within the specified range?

Below 2Ω Go to

Step 6

Go to

Step 7

4 Perform the diagnostic circuit check.

5 1. If damages and/or corrosion exist, replace

ECU and/or HCU if necessary.

2. If the brake fluid leaks, replace ECU and

HCU.

Do you complete the repair?

Go to Step

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-75

C0036-low voltage of system

Step Diagnostic actions Expected value Yes No

6 Replace ECU.

Do you complete the repair?

Go to Step

7 Replace HCU.

Do you complete the repair?

Go to

Step 8

8 Remove the diagnostic trouble code with a

scanning tool.

Do you reset the diagnostic trouble code

when the conditions for setting the diagnostic

trouble code exist?

Go to

Step 1

System is

OK.

C0055- ECU malfunction detected

Description of circuit

This diagnostic trouble code is determined as a possible trouble in ECU.

Conditions for setting the diagnostic trouble code

Set DTC C0055 when any trouble may occur to internal part/microprocessor.

Measures taken when setting the diagnostic trouble code

1. Disconnect the electromagnetic relay, and disconnect the power supply of pump

motor and solenoid.

2. Failure of ABS.

3. Store DTC C0055.

4. Turn on ABS warning lamp and brake warning lamp.

Conditions for removing the diagnostic trouble code

1. If no conditions for setting DTC C0055 exist, remove this diagnostic trouble

code with a proper scanning tool.

2. Remove the diagnostic trouble code not produced within 100 ignition cycles

from the historic data.

Diagnostic help

1. When C0055 is shown in the scanning tool, it should be followed by two digits

(XX),and record these two digits with other shown DTCs.

2. Before analyzing the fault tree of C0055, first repair the faults of low-voltage,

driving performance or other electric faults.

3. Ensure the whole connection of ECU and HCU is reliable, tight, corrosion-free,

leak-free and/or non-destructive.

C0055- ECU malfunction detected

Step Diagnostic actions Expected value Yes No

1 Do you complete the check of diagnostic

Go to Go to

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-76

circuit?

Step 2 Step 5

2 1. Install the scanning tool.

2. Ignition in case of stopping the engine.

3. Observe the information of diagnostic

trouble code with a scanning tool.

Do you set any diagnostic fault code in

current or historic data except C0055XX?

Go to

Step 6

Go to

Step 3

3 1.Flame breaking.

2. Disconnect ECU harness from ECU.

3.Check the connector for damages, corrosion

and mutual terminal contacts.

Do you find out any problem?

Below 2Ω Go to

Step 7

Go to

Step 4

4 Replace ECU.

Do you complete the repair?

Go to

Step 8

5 Check the diagnostic circuit.

6 Perform the relevant diagnosis for other

diagnostic trouble codes..

7 Repair as per the demands.

Do you complete the repair?

Go to

Step 8

8 Remove the diagnostic trouble code with a

scanning tool.

Do you reset the diagnostic trouble code

when the conditions for setting the diagnostic

trouble code exist?

Go to

Step 1

System is

OK.

C0056-System relay always connected

Description of circuit

This diagnostic trouble code is determined as a possible fault in ECU. Activate ECU

relay(ON); power the coil of solenoid valve and pump motor.

Conditions for setting the diagnostic trouble code

When the internal fault may exist, set DTC C0056.

Measures taken when setting the diagnostic trouble code

1. Deactivation of ABS warning lamp.

2. Store DTC C0056.

3. ABS still functions.

Conditions for removing the diagnostic trouble code

1. If no conditions for setting DTC C0056 exist, remove this diagnostic trouble

code with a proper scanning tool.

2. Remove the diagnostic trouble code not produced within 100 ignition cycles

from the historic data.

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-77

Diagnostic help

1. Before analyzing the fault tree of C0056, first repair the faults of low-voltage,

driving performance or other electric faults.

2. Ensure the whole connection of ECU and HCU is reliable, tight, corrosion-free,

leak-free and/or non-destructive.

3. The possible cause for setting DTC C0056 is trouble of relay in ECU.

C0056- System relay always connected

Step Diagnostic actions Expected value Yes No

1 Do you complete the check of diagnostic

circuit?

Go to

Step 2

Go to

Step 5

2 1. Install the scanning tool.

2. Ignition in case of stopping the engine.

3. Observe the information of diagnostic

trouble code with a scanning tool.

Do you set any diagnostic fault code in

current or historic data except C0056?

Go to

Step 6

Go to

Step 3

3 1. Key off.

2. Disconnect ECU harness from ECU.

3. Check the connector for damages,

corrosion and mutual terminal contacts.

Do you find out any problem?

Go to

Step 7

Go to

Step 4

4 Replace ECU.

Do you complete the repair?

Go to

Step 8

5 Check the diagnostic circuit.

6 Perform the relevant diagnosis for other

diagnostic trouble codes.

7 Repair as per the demands.

Do you complete the repair?

Go to

Step 8

8 Remove the diagnostic trouble code with a

scanning tool.

Do you reset the diagnostic trouble code

when the conditions for setting the diagnostic

trouble code exist?

Go to

Step 1

System is

OK.

C0061, C0062, C0063, C0064, C0065, C0066, C0067, C0068-open-circuit or

short-circuit of apply or release solenoid valve

Description of circuit

The apply or release coil is a necessary part of ECU. Power the coil with a battery

when the ignition switch is in connected position, and the solenoid relay is closed. If

necessary, ECU controls the solenoid valve by grounding the corresponding coil

circuit.

Conditions for setting the diagnostic trouble code

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-78

When ECU sensor is open-circuited to ground, short-circuited, or any apply or release

coil is short-circuited to power supply, set the corresponding diagnostic trouble code.

Measures taken when setting the diagnostic trouble code

1. Activate the electromagnetic relay, and disconnect the power supply of solenoid

valve.

2. Store the corresponding DTC.

3. Failure of ABS, and turn on ABS warning lamp.

4. Failure of EBD, and turn on brake warning lamp (only for COO65 and C0067).

Conditions for removing the diagnostic trouble code

1. If no conditions for setting DTC C0061 via C0068 exist, remove the diagnostic

trouble code with a proper scanning tool.

2. Remove the diagnostic trouble code not produced within 100 ignition cycles

from the historic data.

Diagnostic help

Ensure the whole connection of ECU and HCU is reliable, tight and corrosion-free.

As the coil of solenoid valve is an integral part of ECU, any diagnostic trouble code is

usually set to indicate the internal fault of ECU.

C0061, C0062, C0063, C0064, C0065, C0066, C0067, C0068-open-circuit or

short-circuit of apply or release solenoid valve

Step Diagnostic actions Expected

value

Yes No

1 Do you complete the check of diagnostic circuit?

Go to

Step 2

Go to

Step 5

2 1. Flame breaking.

2. Check right rear wheel speed sensor, harness

and toothed ring for physical damages.

Do you check any physical damage?

Go to

Step 6

Go to

Step 3

3 1. Disconnect ECU harness from ECU.

2. Remove ECU from HCU.

3. Check the inner chamber of ECU and HCU

for fluid leakage, corrosion and/or damages.

Do you check any fluid leakage, corrosion and/or

damage in its inner chamber?

Go to

Step 7

Go to

Step 4

4 1. Install the scanning tool.

2. Ignition in case of stopping the engine.

3. Remove the diagnostic trouble code with a

scanning tool.

4. Drive the vehicle in case of running the

diagnostic trouble code.

5. Is the diagnostic fault code reset as current

fault code?

Go to

Step 8

Intermitt

ent

problem

Go to

Step 5

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-79

C0061, C0062, C0063, C0064, C0065, C0066, C0067, C0068-open-circuit or

short-circuit of apply or release solenoid valve

Step Diagnostic actions Expected

value

Yes No

5 Check the diagnostic circuit.

Do you find out any problem?

Go to the

correspon

ding

procedure

System is

6 Replace the damaged parts.

Do you complete the repair?

Go to

Step 9

7 Replace ECU and HCU.

Do you complete the repair?

Go to

Step 9

8 Replace ECU.

Do you complete the repair?

Go to

Step 9

9 Remove the diagnostic trouble code with a

scanning tool.

Do you reset the diagnostic trouble code when the

conditions for setting the diagnostic trouble code

exist?

Go to

Step 1

System is

OK.

C0091- Brake pedal not applied with deceleration

Description of circuit

ECU monitors the input conditions of brake switch for corresponding system

operation. The signals of brake switch are supplied by the vehicle. ECU identifies

three input conditions of brake switch: low, high and open.

Conditions for setting the diagnostic trouble code

If the following conditions occur, set DTC C0091:

1. Ignition.

2. Failure of brake pedal.

3. Failure of brake control during the movement.

4. Vehicle speed is more than 24km/hour.

5. Vehicle deceleration speed exceeds 11.5km/hour twice continually for 1s.

6. Second occurrence of above 5 conditions.

Measures taken when setting the diagnostic trouble code

ECU stores DTC C0091.

Conditions for removing the diagnostic trouble code

1. If no conditions for setting DTC C0091 exist, remove this diagnostic trouble

code with a proper scanning tool.

2. Remove the diagnostic trouble code not produced within 100 ignition cycles

from the historic data.

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-80

C0091-Brake pedal not applied with deceleration

Step Diagnostic actions Expected value Yes No

1 Do you complete the check of diagnostic

circuit?

Go to

Step 2

Go to

Step 5

2 Step down the brake pedal.

Does it fail to operate due to any fault of brake

lamp bulb? Including central high-mounted

brake lamp (CHMSL) or third brake lamp.

Go to

Step 6

Go to

Step 3

3 1. Flame breaking.

2. Disconnect ECU harness from ECU.

3. Mount a general commutator box between

ECU and ECU harness with a proper

adopter cable.

4. Attach a voltmeter to Terminal 41 of

commutator box, and then connect it to

Terminal 1 of general commutator box or

body ground.

Is its voltage within the specified range?

Below 2V Go to

Step 4

Go to

Step 7

4 Replace ECU.

Do you complete the repair?

Go to

Step 8

5 Check the brake circuit.

6 In case of stepping down the brake pedal,

remove and check the failed bulb/socket.

Replace the bulb/socket, or repair and ground it

if necessary.

Do you complete the repair?

Go to

Step 8

7 Check all the rear brake lamp

grounds/bulbs/sockets for poor contacts/high

resistance. It’s not allowed to connect 5V

reference voltage of ECU to low voltage (below

2V).

Do you complete the repair?

Go to

Step 8

8 Remove the diagnostic trouble code with a

scanning tool.

Do you reset the diagnostic trouble code when

the conditions for setting the diagnostic trouble

code exist?

Go to

Step 1

System

is OK.

C0093-Brake pedal not applied with deceleration on previous ignition cycle

Description of circuit

ECU monitors the input conditions of brake switch for corresponding system

operation. The signals of brake switch are supplied by the vehicle. ECU identifies

three input conditions of brake switch: low, high and open.

Conditions for setting the diagnostic trouble code

Fault of DTC C0091 or DTC C0093 at the end of previous ignition cycle.

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-81

Measures taken when setting the diagnostic trouble code

ECU stores DTC C0093.

Conditions for removing the diagnostic trouble code

1. If no conditions for setting DTC C0093 exist, remove this diagnostic trouble

code with a proper scanning tool.

2. Remove the diagnostic trouble code not produced within 100 ignition cycles

from the historic data.

C0093-Brake pedal not applied with deceleration on previous ignition cycle

Step Diagnostic actions Expected value Yes No

1 Do you complete the check of diagnostic

circuit?

Go to

Step 2

Go to

Step 5

2 Step down the brake pedal.

Does it fail to operate due to any fault of brake

lamp bulb? Including central high-mounted

brake lamp (CHMSL) or third brake lamp.

Go to

Step 6

Go to

Step 3

3 5. Flame breaking.

6. Disconnect ECU harness from ECU.

7. Mount a general commutator box between

ECU and ECU harness with a proper

adopter cable.

8. Attach a voltmeter to Terminal 41 of

commutator box, and then connect it to

Terminal 1 of general commutator box or

body ground.

Is its voltage within the specified range?

Below 2V Go to

Step 4

Go to

Step 7

4 Replace ECU.

Do you complete the repair?

Go to

Step 8

5 Check the brake circuit.

6 In case of stepping down the brake pedal,

remove and check the failed bulb/socket.

Replace the bulb/socket, or repair and ground it

if necessary.

Do you complete the repair?

Go to

Step 8

7 Check all the rear brake lamp

grounds/bulbs/sockets for poor contacts/high

resistance. It’s not allowed to connect 5V

reference voltage of ECU to low voltage (below

2V).

Do you complete the repair?

Go to

Step 8

8 Remove the diagnostic trouble code with a

scanning tool.

Do you reset the diagnostic trouble code when

the conditions for setting the diagnostic trouble

code exist?

Go to

Step 1

System is

OK.

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-82

C0094-Brake pedal always applied without deceleration

Description of circuit

ECU monitors the input conditions of brake switch for corresponding system

operation. The signals of brake switch are supplied by the vehicle. ECU identifies

three input conditions of brake switch: low, high and open.

Conditions for setting the diagnostic trouble code

Set DTC C0094 under the following conditions:

1. Brake pedal seems to be adopted.

2. Vehicle speed exceeds 40km/hour.

3. Vehicle acceleration exceeds 8km per hour/s.

4. Above three conditions last for 2s or longer time.

Measures taken when setting the diagnostic trouble code

ECU stores DTC C0094.

Conditions for removing the diagnostic trouble code

1. If no conditions for setting DTC C0094 exist, remove this diagnostic trouble

code with a proper scanning tool.

2. Remove the diagnostic trouble code not produced within 100 ignition cycles

from the historic data.

Diagnostic help

Typical causes for DTC C0094:

1. Output voltage of brake-applied sensor is below the brake requirements.

2. The driver steps on the pedal twice in case of liking the braking operation.

3. Internal faults of brake-applied sensor.

C0094-Brake pedal always applied without deceleration

Step Diagnostic actions Expected value Yes No

1 Do you complete the check of diagnostic

circuit?

Go to

Step 2

Go to

Step 5

2 Step down the brake pedal.

Does it fail to operate due to any fault of

brake lamp bulb? Including central

high-mounted brake lamp (CHMSL) or

third brake lamp.

Go to

Step 6

Go to

Step 3

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-83

C0094-Brake pedal always applied without deceleration

Step Diagnostic actions Expected value Yes No

3 1. Flame breaking.

2. Disconnect ECU harness from ECU.

3. Mount a general commutator box

between ECU and ECU harness with a

proper adopter cable.

4. Attach a voltmeter to Terminal 41 of

commutator box, and then connect it to

Terminal 1 of general commutator box

or body ground.

Is its voltage within the specified range?

Below 2V Go to

Step 4

Go to

Step 7

4 Replace ECU.

Do you complete the repair?

Go to

Step 8

5 Check the brake circuit.

6 In case of stepping down the brake pedal,

remove and check the failed bulb/socket.

Replace the bulb/socket, or repair and

ground it if necessary.

Do you complete the repair?

Go to

Step 8

7 Check all the rear brake lamp

grounds/bulbs/sockets for poor

contacts/high resistance. It’s not allowed to

connect 5V reference voltage of ECU to

low voltage (below 2V).

Do you complete the repair?

Go to

Step 8

8 Remove the diagnostic trouble code with a

scanning tool.

Do you reset the diagnostic trouble code

when the conditions for setting the

diagnostic trouble code exist?

Go to

Step 1

System is

OK.

C0095-Brake switch open-circuit fault (parking lamp open-circuit fault)

Description of circuit

This diagnostic trouble code is used to determine the open-circuit of parking lamp

switch circuit. In case of applying the brake, it prevents the switch of parking lamp

from inputting into ECU at its changed state. ECU sends low-current 5V sensing

voltage to rear brake lamp bulb on the input circuit of brake switch. If the circuit of

brake lamp is perfect, this voltage will be lowered to ground (below 1V) through rear

brake lamp bulb. When pressing the brake switch, the voltage of battery will be

supplied to rear brake lamp and ECU, which indicates the activation of brake lamp. If

the voltage is low (below 1V) or high (above the battery voltage), ECU will fail to

determine the conditions of brake switch, and then DTC C0095 will be set.

Conditions for setting the diagnostic trouble code

Set C0095 after its initialization. If the voltage of brake switch input terminal is 2 to

5V within 2s, set the diagnostic trouble code.

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-84

Measures taken when setting the diagnostic trouble code

ABS maintains its functions.

Conditions for removing the diagnostic trouble code

1. If no conditions for setting DTC C0095 exist, remove this diagnostic trouble

code with a proper scanning tool.

2. Remove the diagnostic trouble code not produced within 100 ignition cycles

from the historic data.

C0095-Brake switch open-circuit fault (parking lamp open-circuit fault)

Step Diagnostic actions Expected value Yes No

1 Do you complete the check of diagnostic

circuit?

Go to

Step 2

Go to

Step 5

2 Step down the brake pedal.

Does it fail to operate due to any fault of brake

lamp bulb? Including central high-mounted

brake lamp (CHMSL) or third brake lamp.

Go to

Step 6

Go to

Step 3

3 1. Flame breaking.

2. Disconnect ECU harness from ECU.

3. Mount a general commutator box between

ECU and ECU harness with a proper

adopter cable.

4. Attach a voltmeter to Terminal 41 of

commutator box, and then connect it to

Terminal 1 of general commutator box or

body ground.

Is its voltage within the specified range?

Below 2V Go to

Step 4

Go to

Step 7

4 Replace ECU.

Do you complete the repair?

Go to

Step 8

5 Check the brake circuit.

6 In case of stepping down the brake pedal,

remove and check the failed bulb/socket.

Replace the bulb/socket, or repair and ground it

if necessary.

Do you complete the repair?

Go to

Step 8

7 Check all the rear brake lamp

grounds/bulbs/sockets for poor contacts/high

resistance. It’s not allowed to connect 5V

reference voltage of ECU to low voltage (below

2V).

Do you complete the repair?

Go to

Step 8

8 Remove the diagnostic trouble code with a

scanning tool.

Do you reset the diagnostic trouble code when

the conditions for setting the diagnostic trouble

code exist?

Go to

Step 1

System

is OK.

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-85

C0118,C0121-Rear apply solenoid valve correlation fault

Description of circuit

The apply or release coil is a necessary part of ECU. Power the coil with a battery

when the ignition switch is in closed position and the solenoid relay is closed. If

necessary, ECU controls the solenoid valve by grounding the corresponding coil

circuit.

Conditions for setting the diagnostic trouble code

In case of sending a pulse width modulation (PWM)command to left rear apply

solenoid valve, and its relevant feedback input check proves that the hardware signal

is the same as software command, set DTC C0118. PWM command is a 2khz, 30%

duty ratio to last 1ms. In case of sending a pulse width modulation (PWM)command

to right rear apply solenoid valve, and its relevant feedback input check proves that

the hardware signal is the same as software command, set DTC C0118. PWM

command is a 2khz, 30% duty ratio to last 1ms.

Measures taken when setting the diagnostic trouble code

1. Store DTC C0118.

2. ECU makes ABS invalid.

3. ECU makes EBD invalid.

4. ECU stores DTC C0118.

5. Turn on ABS and brake warning lamp.

Conditions for removing the diagnostic trouble code

1. If no conditions for setting DTC C0118 exist, remove this diagnostic trouble

code with a proper scanning tool.

2. Remove the diagnostic trouble code not produced within 100 ignition cycles

from the historic data.

Diagnostic help

Typical causes for DTC C0091:

Internal faults of ECU.

C0118,C0121-Rear apply solenoid valve correlation fault

Step Diagnostic actions Expected value Yes No

1 Do you complete the check of diagnostic

circuit?

Go to

Step 2

Go to

Step 5

2 1. Flame breaking.

2. Check ECU and HCU for physical

damages.

Do you check any physical damage?

Go to

Step 6

Go to

Step 3

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-86

C0118,C0121-Rear apply solenoid valve correlation fault

Step Diagnostic actions Expected value Yes No

3 1. Disconnect ECU harness from ECU.

2. Remove ECU from HCU.

3. Check ECU and HCU for fluid leakage,

corrosion and/or damages.

Do you check any fluid leakage, corrosion

and/or damage?

Go to

Step 7

Go to

Step 4

4 6. Install the scanning tool.

7. Turn the ignition switch in ON position,

and stop the engine.

8. Remove DTC with a scanning tool.

9. Drive the vehicle when DTC exists.

10. Is DTC reset as current DTC?

Go to

Step 8

Intermitt

ent

problem

Go to

Step 5

5 Check the diagnostic circuit.

Do you find out any problem?

Go to the

correspon

ding

procedure

System is

6 Replace the damaged parts.

Do you complete the repair?

Go to

Step 9

7 Replace ECU and HCU.

Do you complete the repair?

Go to

Step 9

8 Replace ECU.

Do you complete the repair?

Go to

Step 9

9 Remove DTC with a scanning tool.

Do you reset DTC when the conditions for

setting DTC exist?

Go to

Step 1

System is

OK.

C0122-Release or front apply solenoid valve correlation fault

Description of circuit

The apply or release coil is a necessary part of ECU. Power the coil with a battery

when the ignition switch is in closed position and the solenoid relay is closed. If

necessary, ECU controls the solenoid valve by grounding the corresponding coil

circuit.

Conditions for setting the diagnostic trouble code

In case of sending a pulse width modulation (PWM)command to left rear apply

solenoid valve, and its relevant feedback input check proves that the hardware signal

is the same as software command, set DTC C0122. PWM command is a 2khz, 30%

duty ratio to last 1ms.

Measures taken when setting the diagnostic trouble code

1. ECU stores DTC C0122.

2. ECU makes ABS invalid.

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-87

3. ECU makes EBD invalid.

4. ECU stores DTC C0122.

5. Turn on ABS and brake warning lamp.

Conditions for removing the diagnostic trouble code

1. If no conditions for setting DTC C0122 exist, remove this diagnostic trouble

code with a proper scanning tool.

2. Remove the diagnostic trouble code not produced within 100 ignition cycles

from the historic data.

Diagnostic help

Typical causes for DTC C0091:

Internal faults of ECU.

C0122-Release or front apply solenoid valve correlation fault

Step Diagnostic actions Expected value Yes No

1 Do you complete the check of diagnostic

circuit?

Go to

Step 2

Go to

Step 5

2 1. Flame breaking.

2. Check ECU and HCU for physical

damages.

Do you check any physical damage?

Go to

Step 6

Go to

Step 3

3 7. Disconnect ECU harness from ECU.

8. Remove ECU from HCU.

9. Check ECU and HCU for fluid leakage,

corrosion and/or damages.

Do you check any fluid leakage, corrosion

and/or damage?

Go to

Step 7

Go to

Step 4

4 11. Install the scanning tool.

12. Turn the ignition switch in ON position,

and stop the engine.

13. Remove DTC with a scanning tool.

14. Drive the vehicle when DTC exists.

15. Is DTC reset as current DTC?

Go to

Step 8

Intermitt

ent

problem

Go to

Step 5

5 Check the diagnostic circuit.

Do you find out any problem?

Go to the

correspon

ding

procedure

System

is OK

6 Replace the damaged parts.

Do you complete the repair?

Go to

Step 9

7 Replace ECU and HCU.

Do you complete the repair?

Go to

Step 9

8 Replace ECU.

Do you complete the repair?

Go to

Step 9

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-88

C0122-Release or front apply solenoid valve correlation fault

Step Diagnostic actions Expected value Yes No

9 Remove DTC with a scanning tool.

Do you reset DTC when the conditions for

setting DTC exist?

Go to

Step 1

System

is OK.

C0127-Brake pedal always applied without deceleration on previous ignition

cycle

Description of circuit

ECU monitors the input conditions of brake switch for corresponding system

operations. The signals of brake switch are supplied by the vehicle. ECU identifies

three input conditions of brake switch: low, high and open.

Conditions for setting the diagnostic trouble code

When it fails to set the fault of “Brake pedal always applied without deceleration” at

the end of previous ignition cycle, set DTC C0127.

Measures taken when setting the diagnostic trouble code

ECU stores DTC C0127.

Conditions for removing the diagnostic trouble code

1. If no conditions for setting DTC C0127 exist, remove this diagnostic trouble

code with a proper scanning tool.

2. Remove the diagnostic trouble code not produced within 100 ignition cycles

from the historic data.

C0127-Brake pedal always applied without deceleration on previous ignition

cycle

Step Diagnostic actions Expected value Yes No

1 Do you complete the check of diagnostic

circuit?

Go to

Step 2

Go to

Step 5

2 Step down the brake pedal.

Does it fail to operate due to any fault of

brake lamp bulb? Including central

high-mounted brake lamp (CHMSL) or third

brake lamp.

Go to

Step 6

Go to

Step 3

3 5. Flame breaking.

6. Disconnect ECU harness from ECU.

7. Mount a general commutator box between

ECU and ECU harness with a proper

adopter cable.

8. Attach a voltmeter to Terminal 41 of

commutator box, and then connect it to

Terminal 1 of general commutator box or

body ground.

Is its voltage within the specified range?

Below 2V Go to

Step 4

Go to

Step 7

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-89

C0127-Brake pedal always applied without deceleration on previous ignition

cycle

Step Diagnostic actions Expected value Yes No

4 Replace ECU.

5 Check the brake circuit.

6 In case of stepping down the brake pedal,

remove and check the failed bulb/socket.

Replace the bulb/socket, or repair and ground

it if necessary.

7 Check all the rear brake lamp

grounds/bulbs/sockets for poor contacts/high

resistance. It’s not allowed to connect 5V

reference voltage of ECU to low voltage

(below 2V).

C0151,C0152,C0153,C0154-Too long release of wheels

Description of circuit

The apply or release coil is a necessary part of ECU. Power the coil with a battery

when the ignition switch is in closed position and the solenoid relay is closed. If

necessary, ECU controls the solenoid valve by grounding the corresponding coil

circuit.

ECU monitors ON/OFF state of each solenoid valve, and judges whether the release

time of ABS is too long. This fault means that ECU can’t reduce the pressure of a

certain wheel fully to avoid its side slip.

Conditions for setting the diagnostic trouble code

Set DTC CO151 in case of facing the following standards:

1. ABS command to reduce the pressure of left front wheel.

2. The speed of left front wheel is below 5km/hour for 1.00s. Set DTC C0152 in

case of facing the following standards.

3. ABS command to reduce the pressure of right front wheel.

4. The speed of right front wheel is below 5km/hour for 1.00s. Set DTC C0153 in

case of facing the following standards.

5. ABS command to reduce the pressure of left rear wheel.

6. The speed of left rear wheel is below 5km/hour for 1.00s. Set DTC C0154 in

case of facing the following standards.

7. ABS command to reduce the pressure of right rear wheel.

8. The speed of right rear wheel is below 5km/hour for 1.00s.

Measures taken when setting the diagnostic trouble code

1. Failure of ABS.

2. Turn on ABS warning lamp.

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-90

3. ECU stores C0151.

Conditions for removing the diagnostic trouble code

1. If no conditions for setting DTC C0151 exist, remove this diagnostic trouble

code with a proper scanning tool.

2. If the diagnostic trouble code is not produced within 100 ignition cycles, ECU

will remove its historic DTC.

Diagnostic help

Typical causes:

1. Pollution of hydraulic unit.

2. Signals of intermittent wheel speed sensor.

3. Sticking of solenoid valve.

4. Excessive brake towing force or resisting force of basic brake system.

5. Irregularity of suspension system.

C0151,C0152,C0153,C0154-Too long release of wheels

Step Diagnostic actions Expected value Yes No

1 Do you complete the check of

diagnostic circuit?

Go to Step 2 Go to Check

of Brake

System

2 1. Install the scanning tool.

2. Ignition, but the engine is

stopped.

3. Observe the parameters of

ABS diagnostic trouble code

with a scanning tool.

Does the scanning tool display

any other ABS diagnostic trouble

code regarding the actions of

wheel speed sensor or solenoid

valve.

Go to the

corresponding

DTC flow chart.

Go to Step 3

3 When the vehicle speed is

reduced from 56km/hour to

0km/hour, monitor the shown data

of ABS in all the wheel speed

sensors with a scanning tool.

Is any wheel speed unstable or

intermittent?

Go to the list of

diagnostic trouble

codes due to

excessive changes

of influenced

wheel speed.

Go to Step 4

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-91

C0151,C0152,C0153,C0154-Too long release of wheels

Step Diagnostic actions Expected value Yes No

4 Check the basic brake system as

per the following conditions:

• Pollution of brake fluid

• Excessive towing force of

brake

• Irregularity of suspension

system

Do you find out and correct the

above conditions?

Go to Step 7 Go to Step 5

5 1. Remove DTC with a scanning

tool.

2. Apply the pressure with a foot

brake pedal.

3. Activate the corresponding

release valve with a scanning

tool.

Does the brake pedal lower?

Intermittency-refer

to Diagnostic

Help.

Go to Step 6

6 Perform the appropriate

procedure:

• Replace HCU.

Do you complete this procedure?

Go to Step 7

7 1. Remove DTC with a scanning

tool.

2. Test the vehicle, and complete

one action of ABS brake.

Is DTC reset?

Go to Step 2 System is

C0166 DTC-Vertical acceleration outside the range

C0167 DTC-Deviation fault of vertical acceleration

Description of circuit

The single vertical acceleration meter is controlled by ignition. The acceleration is

described as the voltage for connection to ECU through Pin 10. Connect the grounded

pin of sensor to ECU sensor, and return to Pin 44.

Conditions for setting the diagnostic trouble code

If the switch is ON and ECU detects the open-circuit, short-circuit to ground or

battery when inputting the vertical acceleration speed, set DTC C0166.

Measures taken when setting the diagnostic trouble code

1. Store DTC C0166.

2. Failure of ABS.

3. Turn on ABS brake warning lamp.

Conditions for removing the trouble code

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-92

1. If no conditions for setting DTC C0166 exist, remove this diagnostic trouble

code with a proper scanning tool.

2. If the diagnostic trouble code is not produced within 100 ignition cycles, ECU

will remove its historic DTC.

Diagnostic help

In case of diagnosing the intermittent diagnostic trouble code, it’s required to check

the lines and connectors thoroughly, including:

1. Remove the protective guide tube, and check the lines for damages, short-circuit

or pollutions.

2. Check them for incorrect connections and/or damaged terminals.

3. Remove the terminals from the connector to check whether the coil terminals are

correctly connected.

C0166 DTC-Vertical acceleration outside the range

C0167 DTC-Deviation fault of vertical acceleration

Step Diagnostic actions Expected value Yes No

1 Do you complete the check of diagnostic

circuit?

Go to

Step 2

Go to

Check

Diagno

stic

System

2 1. Install the diagnostic unit.

2. Turn on ignition switch, and stop the

engine.

3. Check the input signals of vertical

acceleration sensor in the data list with a

diagnostic unit.

Are the shown data of diagnostic unit within the

specified range?

0.15-4.85V

Go to

Step 6

Go to

Step 3

3 1. Stop the engine.

2. Disconnect the connection of vertical

acceleration sensor.

3. Turn on ignition switch, and stop the

engine.

4. Observe the input parameters of vertical

acceleration with a diagnostic unit.

Is the voltage shown in diagnostic unit below

the specified range?

0.15V Go to

Step 4

Go to

Step 10

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-93

C0166 DTC-Vertical acceleration outside the range

C0167 DTC-Deviation fault of vertical acceleration

Step Diagnostic actions Expected value Yes No

4 1. Turn off the ignition switch.

2. Connect a 3A fuse jumper wire between the

vertical acceleration signal circuit and

vertical acceleration ignition line.

3. Turn on ignition switch, and stop the

engine.

4. Observe the input parameters of vertical

acceleration sensor with a diagnostic unit.

Is the voltage shown in diagnostic unit above

the specified range?

4.85V Go to

Step 5

Go to

Step 8

5 1. Disconnect the fuse jumper wire.

2. Measure the voltage between the reference

circuit and ignition circuit of vertical

acceleration sensor with a digital

multimeter.

Is the measured voltage below the specified

range?

9V Go to

Step 12

Go to

Step 7

6 Are the input parameters of vertical acceleration

sensor shown in diagnostic unit within the

specified range?

2.3 to 2.7V Go to

Diagno

stic

Help

Go to

Step 11

7 Measure a 5V vertical acceleration sensor

reference circuit to check whether it’s

short-circuited to voltage. Refer to the line

system for circuit test and line repair.

Do you find out and correct such trouble?

Go to

Step 16

Go to

Step 13

8 Test the ignition circuit of vertical acceleration

sensor to find out the following conditions:

• open-circuit

• short-circuit to ground

• high resistance

Refer to the line system for circuit test and line

repair.

Do you find out and correct such trouble?

Go to

Step 16

Go to

Step 9

9 Test the signal circuit of vertical acceleration

sensor to find out the following conditions:

• open-circuit

• short-circuit to ground

• high resistance

Refer to the line system for circuit test and line

repair.

Do you find out and correct such trouble?

Go to

Step 16

Go to

Step 13

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-94

C0166 DTC-Vertical acceleration outside the range

C0167 DTC-Deviation fault of vertical acceleration

Step Diagnostic actions Expected value Yes No

10 Measure the signal circuit of vertical

acceleration sensor to check whether it’s

short-circuited to voltage.

Do you find out and correct such trouble?

Go to

Step 16

Go to

Step 13

11 Test the low reference circuit of vertical

acceleration sensor to find out the following

conditions:

• open-circuit

• high resistance

Do you find out and correct such trouble?

Go to

Step 16

Go to

Step 12

12 Check the vertical acceleration sensor harness

connector for wrong connections.

Do you find out and correct such trouble?

Go to

Step 16

Go to

Step 14

13 Check the electronic brake control module

harness connector for wrong connections.

Do you find out and correct such trouble?

Go to

Step 16

Go to

Step 15

14 Replace the vertical acceleration sensor.

Do you complete the repair?

Go to

Step 16

15 Replace ECU of ABS. Refer to Replacement of

Electronic Control Unit (ECU).

Do you complete the repair?

Go to

Step 16

16 1. Remove the diagnostic trouble code with a

diagnostic unit.

2. Start the vehicle if the diagnostic trouble

code of drive is within the specified support

range.

Is the diagnostic trouble code reset?

Go to

Step 2

System

is OK

C0191- No pump motor starting current

Description of circuit

When the pump motor runs, ECU can detect the current above/below its fixed

threshold through the pump motor.

Conditions for setting the diagnostic trouble code

In case of not exceeding the current threshold after the pump motor runs within

100ms, set DTC C0191.

Measures taken when setting the diagnostic trouble code

1. Failure of ABS.

2. ECU stores DTC C0191.

3. Turn on ABS warning lamp.

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-95

Conditions for removing the diagnostic trouble code

1. If no conditions for setting DTC C0191 exist, remove this diagnostic trouble

code with a proper scanning tool.

2. Remove the diagnostic trouble code not produced within 100 ignition cycles

from the historic data.

Diagnostic help

Typical causes for DTC C0191:

1. High resistance of pump motor coil.

2. High resistance of pump motor ground.

C0191- No pump motor starting current

Step Diagnostic actions Expected value Yes No

1 Do you complete the check of diagnostic

circuit?

Go to

Step 2

Go to

Step 4

2 1. Flame breaking.

2. Disconnect the negative cable of

battery.

3. Disconnect ECU harness from ECU.

4. Connect an ohmmeter between

negative cable of battery and

Terminal 31 of ECU harness.

Is its resistance within the specified

range?

Below 2Ω Go to

Step 3

Go to

Step 7

3 1. Check the grounded connection of

engine block and/or chassis for

cleanness or firm connections, along

the negative cable of battery.

2. Find the position of circuit ground to

chassis along the wire from Terminal

31 of ECU harness. Check them for

cleanness and rigidity.

Are all the connections clean and firm?

Go to

Step 4

Go to

Step 8

4 1. Still disconnect ECU harness.

2. Remove ECU from HCU.

3. Check the connector from ECU to

HCU for damages, rusting, poor

contact or brake fluid leakage, etc.

Are the terminals and connector OK? Are

there brake fluid leakage, damages or

rusting in the space?

Go to

Step 5

Go to

Step 9

5 Connect an ohmmeter between Terminals

1 and 2 of HCU.

Is the resistance reading of pump motor

within the specified range?

Below 2Ω Go to

Step 10

Go to

Step 11

6 Check the diagnostic circuit.

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-96

C0191- No pump motor starting current

Step Diagnostic actions Expected value Yes No

7 Find out the cause for high resistance

between the grounded circuit of ECU and

chassis ground, and repair it.

Do you complete the repair?

Go to

Step 12

8 Repair the poor grounding.

Do you complete the repair?

Go to

Step 12

9 1. If any damage and/or rusting exists,

replace ECU and/or HCU if

necessary.

2. If the brake fluid leaks, replace ECU

and HCU.

Do you complete the repair?

Go to

Step 12

10 Replace ECU.

Do you complete the repair?

Go to

Step 12

11 Replace HCU.

Do you complete the repair?

Go to

Step 12

12 1.Remove DTC with a scanning tool.

Is DTC reset?

Go to

Step 2

System

is OK.

C0192-Overload of pump motor

Description of circuit

When the pump motor runs, ECU can detect the current above/below its fixed

threshold through a circuit of pump motor.

Conditions for setting the diagnostic trouble code

Set DTC C0192 in case of facing the following standards:

1. Pump motor runs.

2. After the motor runs, the current is more than its threshold for 100ms.

3. The current is above its threshold for 11ms.

Measures taken when setting the diagnostic trouble code

1. Failure of ABS.

2. ECU stores DTC C0192.

3. Turn on ABS warning lamp.

Conditions for removing the diagnostic trouble code

1. If no conditions for setting DTC C0192 exist, remove this diagnostic trouble

code with a proper scanning tool.

2. Remove the diagnostic trouble code not produced within 100 ignition cycles from

the historic data.

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-97

C0192-Overload of pump motor

Step Diagnostic actions Expected value Yes No

1 Do you complete the check of diagnostic

circuit?

Go to

Step 2

Go to

Step 5

2 Connect the diagnostic tool.

1.Make the pump motor running with a

scanning tool.

Do you hear any abnormal noise during the

test of motor?

Go to

Step 8

Go to

Step 3

3 1. Flame breaking.

2. Disconnect the negative cable of

battery.

3. Disconnect ECU harness from ECU.

4. Disassemble ECU and HCU.

5. Connect an ohmmeter between

Terminals 1 and 2 of HCU motor

connector.

Is its resistance within the specified range?

100-200 mΩ Go to

Step 4

Go to

Step 8

4 1. Connect an ohmmeter between

Terminal 1 and HCU motor housing.

2. Connect an ohmmeter between

Terminal 2 and HCU motor housing.

Is its resistance in each step within the

specified range?

Above 100 KΩ Go to

Step 6

Go to

Step 8

5 Check the diagnostic circuit.

6 Replace ECU.

Do you complete the repair?

Go to

Step 7

7 Remove DTC with a scanning tool.

Is DTC reset?

Go to

Step 8

System is

8 Replace HCU.

Do you complete the repair?

Go to

Step 9

9 Remove DTC with a scanning tool.

Is DTC reset?

Go to

Step 2

System is

OK.

C0194- Pump motor short circuit current

Description of circuit

ECU can detect the current above/below its fixed threshold through a circuit of pump

motor.

Conditions for setting the diagnostic trouble code

Set DTC C0194 in case of facing the following standards:

1. Pump motor runs.

2. The current is more than its threshold 0.15ms after the pump motor runs.

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-98

Measures taken when setting the diagnostic trouble code

Failure of ABS.

ECU stores DTC C0194。

Turn on ABS warning lamp.

Conditions for removing the diagnostic trouble code

1. If no conditions for setting DTC C0194 exist, remove this diagnostic trouble

code with a proper scanning tool.

2. Remove the diagnostic trouble code not produced within 100 ignition cycles

from the historic data.

Diagnostic help

Typical causes for DTC C0194:

1. Very low resistance of pump motor coil.

2. Short-circuit to ground of pump motor high potential end.

C0194- Pump motor short circuit current

Step Diagnostic actions Expected value Yes No

1 Do you complete the check of diagnostic

circuit?

Go to

Step 2

Go to

Step 5

2 1. Connect the scanning tool.

2. Make the pump motor running with a

scanning tool.

Do you hear any abnormal noise during the test

of motor?

Go to

Step 8

Go to

Step 3

3 6. Flame breaking.

7. Disconnect the negative cable of battery.

8. Disconnect ECU harness from ECU.

9. Disassemble ECU and HCU.

10. Connect an ohmmeter between Terminals 1

and 2 of HCU motor connector.

Is its resistance within the specified range?

100-200 mΩ Go to

Step 4

Go to

Step 8

4 3. Connect an ohmmeter between Terminal 1

and HCU motor housing.

4. Connect an ohmmeter between Terminal 2

and HCU motor housing.

Is its resistance in each step within the specified

range?

Above 100 KΩ Go to

Step 6

Go to

Step 8

5 Check the diagnostic circuit.

6 Replace ECU.

Do you complete the repair?

Go to

Step 7

7 Remove DTC with a scanning tool.

Is DTC reset?

Go to

Step 8

System

is OK

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-99

C0194- Pump motor short circuit current

Step Diagnostic actions Expected value Yes No

8 Replace HCU.

Do you complete the repair?

Go to

Step 9

9 Remove DTC with a scanning tool.

Is DTC reset?

Go to

Step 2

System

is OK.

C0198-Bumping road fire & pulse width modulation output errors

Description of circuit

The signal of bumping road fire & pulse width modulation supplies the data for

bumping road calculated via ABS controller, and sends these data to the power

assembly controller. The pulse width modulation signal is at Pin 38 of ECU.

Conditions for setting the diagnostic trouble code

When the switch is “ON” and ECU detects the open-circuit, short-circuit to ground or

battery of bumping road fire & pulse width modulation signal, set DTC C0198.

Measures taken when setting the diagnostic trouble code

Store DTC C0198.

Conditions for removing the diagnostic trouble code

1. If no conditions for setting DTC C0198 exist, remove this diagnostic trouble

code with a proper scanning tool.

2. Remove the diagnostic trouble code not produced within 100 ignition cycles

from the historic data.

Diagnostic help

In case of diagnosing any temporary diagnostic trouble code, check the lines and

connectors thoroughly, including:

1. Remove the protective guide tube, and check the lines for damages, short-circuit

or pollutions.

2. Check the terminals for deformations and damages.

3. Check the contact maintaining force of terminals.

4. Remove the terminals from the connector to check whether the press-connected

conductor terminals are falsely connected.

C0191- No pump motor starting current

Step Diagnostic actions Expected value Yes No

1 Do you complete the check of diagnostic

circuit?

Go to

Step 2

Go to

Check of

Diagnostic

system

2 1. Turn off the ignition switch. 5-95% Go to

Step 3

Go to Step

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-100

C0191- No pump motor starting current

Step Diagnostic actions Expected value Yes No

2. Disconnect the harness of ABS ECU.

3. Install a storage box capable of storing

the bumping road fire & pulse width

modulation signals.

4. Turn on the ignition switch.

5. Control the duty ratio within 5%-95%

with a diagnostic unit.

6. Measure DC duty ratio between the

signal circuit of bumping road fire and

good grounded circuit.

Is the duty ratio within the specified range?

3 Measure the frequency of DC current

between the signal circuit of bumping road

fire and good grounded circuit.

Is the measured frequency within the

specified range?

121-134Hz Go to

Step 6

Go to Step

4 1. Turn off the ignition switch.

2. Disconnect the storage box.

3. Turn on the ignition switch, and stop the

engine.

4. Measure the voltage between the signal

circuit of bumping road fire and good

grounded circuit.

Is the measured voltage near to the specified

value?

Battery Volt Go to

Step 8

Go to Step

5 1. Turn off the ignition switch.

2. Disconnect the harness of power

assembly control module.

3. Check the signal circuit of bumping road

fire under the following conditions:

• Short-circuit to battery

• Short-circuit to ground

Do you find out and change these conditions?

Go to

Step 11

Go to Step

6 1. Turn off the ignition switch.

2. Disconnect the harness of power

assembly control module.

3. Check the required torque signal circuit

under the following conditions:

• Open-circuit

• High resistance

Do you find out and change these conditions?

Go to

Step 11

Go to Step

7 Check the harness of power assembly control

module for poor connections.

Do you find out and correct such trouble?

Go to

Step 11

Go to Step

8 Check ABS ECU harness for poor

Go to Go to Step

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-101

C0191- No pump motor starting current

Step Diagnostic actions Expected value Yes No

connections.

Do you find out and correct such trouble?

Step 11 10

9 Replace the engine control module-power

assembly control module.

Do you complete the repair?

Go to

Step 11

10 Replace ABS ECU. Refer to Replacement of

Electronic Control Unit (ECU).

Do you complete the repair?

Go to

Step 11

11 1.Remove the diagnostic trouble code with a

diagnostic unit.

2.Start the vehicle if the diagnostic trouble

code of drive is within the specified support

range.

Is the diagnostic trouble code reset?

Go to

Step 2

System is

OK.

Basic check of ABS system

1. Check the level of liquid in a fluid reservoir.

Basic check 1:

Check the level or leakage of brake fluid and thickness of brake lining. If the fluid

level is low, refill the brake fluid.

2. Check the adjacent areas of brake pipe, ABS actuator and electric unit (control

unit)for leaks. In case of leakage, perform the following operations.

Check:

(1) If any connected part of ABS actuator and electric unit (control unit) is loosened,

tighten the oil pipe nut up to the specified torque (18-30N.m). Check their

leakage again, and confirm the leakage of no brake fluid.

(2) If the oil pipe nut and actuator threads of this connected part are damaged, please

replace the damaged parts. Check their leakage again, and confirm the leakage of

no brake fluid.

(3) If any leakage occurs in the areas outside the connected part of actuator, wipe

them with a clean cloth, and check them again. If the leakage still exists, replace

the damaged parts.

(4) If any leakage occurs on the body of actuator, wipe it with a clean cloth, and

check it again. If the leakage still exists, replace ABS actuator and electric unit

(control unit).

Note:

If no special demands, don’t disassemble ABS actuator and electric unit (control

unit).

3. Check the brake lining for wears(front and rear ones).

Basic check 2:

Maintenance Manual for J2 Sedan

Anti-Lock Brake System (ABS)

ABS-102

Loosening of power circuit port and check of battery

Check the positive/negative pole and grounded end of battery for loosening, while

confirming whether the voltage of battery is normal.

Basic check 3:

Check of ABS warning lamp and brake warning lamp

1. Confirm that ABS warning lamp lights up for ca.1s and the brake warning lamp

lights up when the ignition switch is turned to ON position. If they don’t light up,

check them with a diagnostic unit.

2. Check whether ABS warning lamp extinguishes about 1s after turning the

ignition switch to ON position, and whether the brake warning lamp extinguishes

after starting the engine. If they don’t extinguish, perform the self-diagnosis to

them.

3. If ABS warning lamp doesn’t extinguish 10s after starting the engine, perform

the self-diagnosis to ABS actuator and electric unit (control unit).

4. After completing the self-diagnosis, be sure to eliminate the self-diagnosis

results.

Note:

The brake warning lamp lights up during the operations of parking brake (when the

switch is in ON position) and brake fluid level sensor (insufficiency of brake fluid).

Maintenance Manual for J2 Sedan

Electric Power Steering (EPS)

EPS-1

Steering

Electric Power Steering (EPS)

Precautions

 When checking the steering system, park the vehicle on level and dry ground.

 The bolts for various components of the steering system must be tightened to the

specified torque.

 At completion of checking and repair of steering gear and other steering

mechanism, check the wheel alignment.

 Frequently check the tire pressure and maintain within the specification.

 In event of any abnormal clearance, stagnation, or snaking, analyze in which

portion of the steering drive unit, power steering system or steering linkage

system this problem occurs and resolve accordingly.

 Carefully check whether the parts of the steering system are under the application

of abnormal impact frequently. The damaged parts or defective parts shall be

replaced timely.

 Never weld the parts of steering gear and system members by any means.

 Make sure that the pipeline is free of knocking and wear during the working and

various segments are in proper tension, without any dead bends.

Preparations

List of Special Tools

SN Tool Outline drawing No. Description

1 Puller of steering wheel JAC-T1D002

For removal of steering

wheel

List of Common Tools

SN Tool Outline drawing Description

1 Power tool For removal and installation of bolts and nuts

Maintenance Manual for J2 Sedan

Electric Power Steering (EPS)

EPS-2

Overview of Electric Power Steering System

EPS is one power steering system that directly relies on the motor to provide the

assisting torque. Compared with traditional hydraulic power steering system (HPS),

the EPS system features many advantages: The motor is started only when the

steering is needed, which can save the fuel consumption of the engine; it can provide

the best assisting force under all kinds of driving conditions, reducing the interference

of power steering system through the action of drive device arising from the varying

torque output of the motor due to uneven road, improving the steering characteristic

of vehicle, and promoting the active safety of the vehicle; Without the adoption of

hydraulic circuits, it makes the adjustment and inspection easier, realizes higher

automation level, achieves rapid matching with different vehicle models through

different setup procedures, and shortens the production and development periods;

Without the risk of oil leakage, it reduces the environment contamination.

Composition of Electric Power Steering System

The EPS is mainly composed of torque sensor, vehicle speed sensor, motor, reducer

mechanism, and electronic control unit (ECU). The sensor detects the size and

direction or the torque or rotation angle generated by the steering wheel at the steering

operation of the driver and converts the required information into digital signals and

sends into control unit so that the control unit processes these signals and obtains one

torque adapting to the driving condition and finally sends commands to drive the

working of motor, of which the output torque is boosted by the action of drive device.

Therefore, the torque sensor is one of the most important components in the EPS

system.

The structure of the electric power steering system is shown in the figure below:

Structural Diagram of Electric Power Steering System

1 – Steering gear assembly 2 – Steering shaft assembly with universal joint

3 – Torque sensor 4 – EPS controller assembly 5 – Steering column assembly

6 – Motor

Maintenance Manual for J2 Sedan

Electric Power Steering (EPS)

EPS-3

Schematic diagram

转速信号

电子助力转向控制器(EPS)

P-2

064

P-6

080

P-6

081

MF8 30A

F/S11 10A

ME01

2.0 L/R

1.0 R/B

0.5 R/B

0.5 P

0.5 L/G

搭铁2

G06

2.0 B

0.5 O/G

车速信号

M34

Pin Definition

Pin Definition of Electric Power Steering System

Vehicle speed sensor

Engine speed sensor

Electric Power Steering (EPS) Controller

Grounding 2

Maintenance Manual for J2 Sedan

Electric Power Steering (EPS)

EPS-4

Port Definition of Controller

Port number Signal definition Port number Signal definition

A1 Clutch drive port B5 Vehicle speed signal

A2 Clutch drive port B6 Ignition signal

A3 Motor drive port C1 Power supply signal

(+)

A4 Motor drive port C2 Power supply signal

(-)

B1 Vacant D1 Vacant

B2 Vacant D2 Torque sensor power

supply

B3 EPS lamp output D3 Torque sensor (GND)

B4 Engine signal D4 Torque sensor (Sub)

D5 Torque sensor (Main)

Steering wheel

On board Checking:

1) Check the installation status

① Check the installation status of the steering gear assembly, front suspension, axle,

and the steering column.

② Check the steering wheel for movement clearance in vertical, lateral, and axial

directions.

③ Check the fixing nuts and bolts of the steering gear assembly for looseness.

2) Check the free stroke of the steering wheel.

① Rotate the steering wheel to position the front wheels to straight forward position.

Start the engine and slightly rotate the steering wheel leftward and rightward, till

the front wheels start movement. Measure the movement of steering wheel on

the circumcircle.

 Free stroke of steering wheel: 30mm

② If the measurement is out of above specification, check the installation status of

each connector of steering column and the steering mechanism. Depending on

the actual condition, correct or replace related components.

③ If the free stroke still exceeds 30mm, stop the engine, position the front wheels to

straight forward position, apply a 5N force along the circumference of the

steering wheel, and check the idle stroke. This idle stroke shall not exceed 10mm.

If the measurement exceeds 10mm, check whether the steering gear assembly

Maintenance Manual for J2 Sedan

Electric Power Steering (EPS)

EPS-5

meets the requirement.

④ If this measurement is still at limit value, stop the engine, position the steering

wheel at neutral position, apply a 4±0.6N force on the circumcircle of the

steering wheel, and check the free stroke.

 Standard value: <15mm.

⑤ If the measurement exceeds the standard value, remove the steering gear and

check the overall torque of the pinion.

3) Check the neutral position.

① Confirm that the steering gear assembly, steering column, and steering wheel are

installed correctly.

② After the wheels are aligned, conduct the checking of neutral position. Please

refer to “Check of Alignment of Front Wheels”.

③ Park the vehicle in straight forward position and make sure that the steering

wheel is at neutral position.

④ Loosen the lock nut of tie rod, rotate the adjusting lever leftward and rightward

for fine adjustment, and confirm whether the steering wheel is at neutral position.

4) Check the static steering force of the steering wheel

① Park the vehicle on level and dry ground and apply the parking brake lever.

② Start the engine.

③ Run the engine to head up the power steering fluid to working temperature.

Notice:

 The air pressure of the tires shall be within the specification.

④ Rotate the steering from the neutral position by 360º and check the rotating force

of the steering and check for obvious variation.

 Steering force of steering wheel: <34N Allowable variation: <5.9N

⑤ If the steering force of the steering wheel exceeds the specified value, please

check or adjust the following items:

a. Check the lower swing arm and steering tie rod ball joint for damage.

b. Check the gear preload of steering gear and the rotating torque of the steering tie

rod ball joint.

c. Check the rotating torque of lower swing arm ball joint.

5) Check the automatic return of steering wheel

Notice:

 Make slow and sudden turns and confirm by feeling whether there is difference

between left and right directions in terms of applied force and the return status.

Maintenance Manual for J2 Sedan

Electric Power Steering (EPS)

EPS-6

 Make sure to conduct this step on safe roads and traffic conditions and take care.

① Rotate the steering wheel by 90º, drive

at a speed of 35km/h, and maintain for

several seconds. Then, release the

steering wheel. In such case, the return

amount of the steering wheel shall be

more than 70%.

Notice:

 If there is the temporary “Heavy”

feeling at the rapid rotation of the

steering wheel, this is caused by the

insufficient oil supply of the power

steering pump during the idling and is

not one fault.

6) Check the front wheel steering angle

① Check the front wheel steering angle after checking the front wheel toe-in. Place

the front wheel at the steering angle measuring instrument (Front wheel aligned

steering wheel) and check the maximum internal/external steering angle of the

left and right wheels.

 Internal wheel: 38.3°±1.5°

External wheel: 32.5°±1.5°

② While the engine runs at idling, rotate the steering leftward or rightward to limit

position and measure the steering angle.

 If the measurement is out of the standard range, adjust the tie rod.

The adjusting method of the steering angle is as below:

When the steering angle is out of the standard range, loosen the lock nut of left and

right steering tie rods and rotate the left and right steering tie rods with wrench to

adjust the steering angle to standard range. Then, secure the lock nuts and tighten to

45~55N.m. While adjusting the length of left and right tie rods (the length shown in

figure below), notice to guarantee the consistence length of left and right tie rods (in

reverse direction).

EPS002

EPS001

Maintenance Manual for J2 Sedan

Electric Power Steering (EPS)

EPS-7

Diagram of Tie Rod

Notice:

 When the internal wheel steering angle is out of tolerance, adjust the tie rod at

this side and rotate outward to increase the internal wheel steering angle. When

the external wheel steering angle is out of tolerance, adjust the tie rod at this side

and rotate outward to reduce the external wheel steering angle

Notice:

 The toe-in is directly related to other 4-wheel alignment parameters and the

adjustment of steering angle.

7) Check the ball joint dust cap.

① Press with fingers to check the dust cap for cracking or damage.

② In event of cracking or damage of the dust cap, make sure to replace the tie rod

ball joint.

Notice:

 The cracked or damaged dust cap may lead to the damage of ball joint.

8) Check the rotating torque of steering

tie rod ball joint

① Rapidly swing the tie rod for 10 times.

② Measure the swing resistance of tie rod

with the spring balance.

 Standard value: 2~5 N·m

 If the measurement is out of the

standard value, please replace.

Removal and Installation:

1) Removal

① Disconnect the cathode terminal of

battery and wait for more than 3min.

② Remove the driver airbag module from

the steering wheel.

③ Remove the fixing nut of steering

wheel after the steering wheel is

locked.

EPS003

EPS004

Maintenance Manual for J2 Sedan

Electric Power Steering (EPS)

EPS-8

 Tightening torque: 35~45 N·m

④ Lift the steering wheel from the steering column.

Note: If it’s difficult to lift, please use the steering wheel puller.

2) Installation

Installation is the reverse order of removal.

Notice:

 The installation must be fulfilled under the conditions that the wheels are at

straight forward position and the steering wheel is at neutral position.

Alternatively, add the markings to the steering wheel and fixing bolts before the

removal and make sure to align the markings during the installation.

 Under the installation status, the steering column must rotate smoothly, without

any click sound or viscous phenomenon.

 After other components are installed onto the steering wheel, adjust the

inclination of steering wheel and steering column for 5~6 times. The maximum

force to operate the locking position of steering column shall not exceed

60~100N. When the locking position of steering column is at free position, the

maximum operating force for inclination of steering wheel and steering column

shall not exceed 100N.

 Installing location of clock spring (balance spring).

 Never distort excessive after tightening the clock spring.

Steering Column Assembly

Notice:

 Never apply excessive axial force to the steering column assembly during the

removal and installation.

 Never move the steering gear when removing the steering column.

Removal and Installation:

1) Removal

① Straightly park the vehicle.

② Disconnect the cathode terminal of battery and wait for more than 3min.

③ Remove the driver airbag module.

④ Remove the steering wheel.

⑤ Remove the upper and lower guards of steering column and the lower portion of

driver instrument panel.

⑥ Remove the combined switch assembly and clock spring from the steering

column.

⑦ Disconnect every harness connector from the steering column and remove the

harness from the steering column assembly.

Maintenance Manual for J2 Sedan

Electric Power Steering (EPS)

EPS-9

⑧Remove the connecting bolts between

steering column and lower shaft and

separate the steering column and

steering gear.

 Tightening torque: 20~30 N·m

⑨ Remove the fixing bolts of steering

column assembly and remove the

steering column assembly.

 Tightening torque: 20~30N·m

2) Check after removal

① Check the steering column for crack, deformation and other damage and replace

in event of any above defect.

② Check the spline of steering column shaft for wear and tooth breakage and

replace in event of any above defect.

3) Disassembly

① Disassembly

a. Loosen the connecting bolts between steering column and connecting shaft universal joint

and remove the universal joint.

b. When necessary, remove the steering lock.

Notice:

 When reinstalling the steering lock, make sure to replace the special bolts.

EPS005

EPS006

Maintenance Manual for J2 Sedan

Electric Power Steering (EPS)

EPS-10

c. When necessary, remove the

adjustable steering column and

support.

② Disassembly essentials

Removal of special bolts:

a. Drill with the electric drill on the

special bolts one hole enough to

accommodate the screw tap.

b. Remove the special bolts with the

left-handed screw tap.

4) Check after disassembly

① Check the adjusting support and spring for crack and damage.

② Check the steering lock mechanism for normal functioning.

5) Assembly

Assemble the steering lock assembly, steering lock support and the special bolts.

Notice:

 When assembling the steering lock assembly and the steering lock bracket to the

assembling column assembly, align with the locking notch of the steering column

to temporarily lock the steering lock.

 After confirming the correct action of the steering lock, lock the special bolts, till

the bolt heads are broken.

6) Installation

Installation is the reverse order of removal.

Notice:

 Never re-use the components not intended for re-use.

 Install the steering column assembly when maintaining the steering wheel at

neutral position.

 When installing the connecting shaft onto the steering column, pay attention to

the installing location.

7) Check after installation

Under the condition that the vehicle is straightly parked, rotate the steering wheel

leftward and rightward to limit point for several times to confirm the smooth

operation of the steering wheel.

EPS007

Left-handed screw tap

Special bolt

Steering lock

bracket

Steering lock body

Maintenance Manual for J2 Sedan

Electric Power Steering (EPS)

EPS-11

Trouble Diagnosis

Diagnosis of Main Faults

Faulty part Fault phenomenon Possible fault cause

Torque sensor Inconsistent left and right steering

forces

Off-tracking

Automatic steering

- Sensor is not in neutral position

- Insecure connection of connector

- Poor contact of connector

- Poor characteristic

Motor Low motor voltage

Heavy steering

- Short-circuit or grounding of

harness to battery

- FET short-circuit

Excessive measurement current

Light steering

- Harness grounding

- Harness short-circuit

- EFT short-circuit

Low measurement current

Heavy steering

- Poor contact of connector

- Insecure connection of harness

- FET open-circuit

- Motor short-circuit

ECU Constant light-up of EPS lamp - Insecure connection of connector

- Failure of integrated circuit

- Failure of central control unit

Speed sensor No power steering - Failure of vehicle speed sensor

Engine speed sensor - Failure of engine speed sensor

Maintenance Manual for J2 Sedan

Electric Power Steering (EPS)

EPS-12

Table of Fault Code

Repair Data and Specification

Specification

Item Standard

Remarks

Control mode Single chip

Working voltage (V) 10~16

Working current (A) 0~25 Matched with 25A motor

Torque output (N·m)

0~20 Matched with 25A motor

Working temperature (ºC) -40~+85

Static current (A) 0.1A

Steering angle

Inner wheel: 38.3°±1.5°

Outer wheel: 32.5°±1.5°

Diagnosis fault code

Diagnosis description

Normal

Main circuit fault of torque sensor

Open-circuit or short-circuit of auxiliary circuit of torque sensor

o engine speed signal input

High difference between branch circuit outputs of main circui

and torque sensor

High or low power supply voltage of torque sensor

High or low motor voltage

High difference between displayed current and actual

motor current

High motor current

Low motor current

Fault of ECU controller

Low battery voltage

No.

Flashing waveform of “EPS” lamp

Maintenance Manual for J2 Sedan

Electric Power Steering (EPS)

EPS-13

Table of Tightening Torque

Item Quantity

Tightening torque

(N.m)

Fixing nuts of steering wheel 1 35~40

Mounting bolts of steering column 3 20~30

Connecting bolts between steering column and

lower shaft

1 20~30

Connecting bolts between lower shaft and

steering gear

1 20~30

Motor fixing bolt 4 10~15

Steering gear fixing bolt 2 60~80