J4 Service Manual.
Foreword
J4 Service Manual
Foreword
General Catalogue
This Manual is helpful for technical
maintenance staff for JAC and provides
effective and correct maintenance and
service for an electric vehicle of JAC RS
series. To ensure the customer
satisfaction of the JAC's car products, it
is extremely essential that the
professional maintenance technicians for
JAC's car have the friendly service and
the capability of proper operation;
therefore, the maintenance technicians
must fully understand the contents in this
Manual. This Manual shall be accessible
for reference at any time.
All contents in this Manual, including
pictures, technical parameters are the
latest. But if product modification affects
maintenance, JAC will provide technical
bulletin or supplementary volume.
Therefore, please obtain the latest
information about this Manual. JAC
reserves the right to make change in
design, addition or improvement for the
product.
This Manual shall not be copied or
modified without written authorization
from JAC in any form including, but not
limited to electronic, paper, video and
mechanical form.
During the process of maintaining
JAC car, if genuine parts that are not
from JAC or disqualified oil, the
vehicle may be damaged.
Circuit Maintenance Manual
Chapter III Body Data
Chapter II Body Structure
Chapter I Body Electrical
Sub-volume of Body Electrical
and Body Structure
Chapter VI Steering System
Chapter V Brake System
Chapter IV Suspension System
Chapter III Drive System
Chapter II Clutch System
Chapter I Transmission System
Chassis Manual
Chapter III Engine Electronic Control
System
Chapter II Engine Electrical Equipment
Chapter I Engine Machine
Engine Sub-volume
Chapter II Maintenance
Chapter I Overview
Overview and Maintenance
J4 Service Manual
Contents of Chassis
Sub-volume Workshop
Chassis Sub-volume Workshop
Chassis - Transmission System .......................................................... MT-1
Overview ....................................................................................................... MT-1
Precautions ............................................................................................................... MT-1
Preparation work ...................................................................................................... MT-1
Common fault diagnostic ......................................................................................... MT-3
System specification ................................................................................................ MT-4
Manual transmission gearbox oil ............................................................................. MT-5
Oil real...................................................................................................................... MT-6
Control mechanism of selecting gear ....................................................................... MT-7
Manual transmission assembly ................................................................................ MT-9
Disassembly and assembly..................................................................................... MT-11
Maintenance data and specification ....................................................................... MT-29
Maintenance ........................................................................................................... MT-30
Chassis - Clutch System ....................................................................... CL-1
Precautions ................................................................................................................ CL-1
Preparation work ....................................................................................................... CL-1
Common fault diagnostic .......................................................................................... CL-1
Hydraulic oil of clutch .............................................................................................. CL-3
Clutch master cylinder .............................................................................................. CL-4
Clutch pedal .............................................................................................................. CL-6
Clutch pressure plate, friction plate of clutch and flywheel ..................................... CL-8
Hydraulic pipeline ................................................................................................... CL-11
Service parameters .................................................................................................. CL-12
Chassis - Drive System ......................................................................... DS-1
Precautions ................................................................................................................ DS-1
Preparation work ....................................................................................................... DS-1
Common fault diagnostic .......................................................................................... DS-2
Front wheel hub and steering knuckle ...................................................................... DS-2
Front drive shaft ........................................................................................................ DS-8
J4 Service Manual
Contents of Chassis
Sub-volume Workshop
Service parameters .................................................................................................. DS-17
Chassis - Suspension System ............................................................. FSU-1
Front suspension system ........................................................................... FSU-1
Precautions ............................................................................................................. FSU-1
Preparation work .................................................................................................... FSU-2
Front suspension assembly..................................................................................... FSU-2
Front shock absorber .............................................................................................. FSU-4
Lower swing arm ................................................................................................... FSU-7
Lateral stabilizer bar ............................................................................................... FSU-8
Front sub-frame assembly ...................................................................................... FSU-9
Fault diagnosis ..................................................................................................... FSU-10
Maintenance data and specification ...................................................................... FSU-11
Rear suspension system ........................................................................... FSU-12
Precautions ........................................................................................................... FSU-12
Preparation work .................................................................................................. FSU-12
Rear suspension assembly .................................................................................... FSU-13
Rear shock absorber ............................................................................................. FSU-14
Rear coil spring .................................................................................................... FSU-15
Rear torsional girder assembly ............................................................................. FSU-16
Fault diagnosis ..................................................................................................... FSU-17
Maintenance data and specification ..................................................................... FSU-18
Chassis - Brake System ........................................................................ BR-1
Wheel & Tire ................................................................................................ BR-1
Precautions ............................................................................................................... BR-1
Tire ........................................................................................................................... BR-1
Wheel tire assembly ................................................................................................. BR-3
Tire pressure monitoring .......................................................................................... BR-5
Fault diagnosis ......................................................................................................... BR-8
Maintenance data and specification ......................................................................... BR-9
Service braking ............................................................................................ BR-9
Precautions ............................................................................................................... BR-9
Preparation work .................................................................................................... BR-10
J4 Service Manual
Contents of Chassis
Sub-volume Workshop
Brake pedal ............................................................................................................ BR-10
Brake master pump ................................................................................................ BR-12
Brake fluid.............................................................................................................. BR-13
Brake pipeline ........................................................................................................ BR-13
Brake vacuum booster assembly component ......................................................... BR-16
Front disc brake caliper .......................................................................................... BR-19
Rear parking brake ................................................................................................. BR-24
Fault diagnosis ....................................................................................................... BR-29
Maintenance data and specification ....................................................................... BR-32
Parking brake control ............................................................................................. BR-33
Fault diagnosis ....................................................................................................... BR-36
Anti-lock braking system (ABS) .............................................................. BR-37
Precautions ............................................................................................................. BR-37
Preparation work .................................................................................................... BR-38
System specification .............................................................................................. BR-38
ABS mode .............................................................................................................. BR-40
Speed sensor ........................................................................................................... BR-40
ABS hydraulic assembly ...................................................................................... BR-42
ABS control module............................................................................................... BR-43
Exhaust of ABS system .......................................................................................... BR-46
Fault diagnosis ....................................................................................................... BR-54
Chassis - Steering System .....................................................................PS-1
Precautions ................................................................................................................ PS-1
Preparation work ....................................................................................................... PS-1
Electric power steering system overview .................................................................. PS-1
Steering wheel ........................................................................................................... PS-3
Steering wheel assembly ........................................................................................... PS-5
Steering column assembly ........................................................................................ PS-7
Power steering gear assembly ................................................................................. PS-10
Solutions to common faults ..................................................................................... PS-12
Maintenance data and specification ........................................................................ PS-13
J4 Service Manual
Transmission System
MT-1
Chassis - Transmission system
Overview
Precautions
■ Do not reuse the discharged gear oil of M/T
■ When inspecting or replacing manual transmission gear oil, keep the vehicle level.
■ When dismantling and installing transmission, keep the interior free from any dust and
foreign matter.
■ Before dismantling or disassembling, check and confirm correct installation position. If
installing mark is needed, the function of the part bearing such a mark after that shall not be
affected adversely.
■ Tighten the middle and then the other bolts and nuts in a diagonal order step by step as
required. If the tightening sequence is defined, please follow it.
■ Do not damage sliding and fitting surfaces.
Preparation work
Special tools to be used are shown in following table:
Special Tool Table
No.
Tools
Overall Diagram
Instructions
1
Bearing remover
Installation and dismounting of
each gear, bearing and shaft
sleeve
2
Bearing remover
Installation and dismounting of
each gear, bearing and shaft
sleeve
3
Installer cover
Installer should be combined
with installer joint.
J4 Service Manual
Transmission System
MT-2
No.
Tools
Overall Diagram
Instructions
4
Installer-100
Installer cover should be
combined with installer joint.
5
Installer-100
Installer cover should be
combined with installer joint.
6
Install connector
When combined with installer,
it is necessary to install
bearings of middle shaft and
input shaft as well as bushing
of gear 1, gear 2 and gear 4.
7
Mounting handle
Mounting bearing used with
relevant installer.
8
Shift gears oil
seal Installer
Install transmission shift shaft
oil seal
9
Differential oil
seal installer
Install differential oil seal
10
Transmission
spring pin
remover
Dismantle transmission gear
shift fork spring pin.
11
Right bearing
installer of
intermediate
shaft
Install transmission Housing
intermediate shaft right bearing
J4 Service Manual
Transmission System
MT-3
Common fault diagnostic
Table of common failure diagnosis
Failure Mode
Cause
Countermeasures
Slipping and
out-of-mesh
Shifting fork shaft worn
Replace
Shifting fork or synchronizer sleeve worn
Replace
Shifting fork shaft position spring weaken or damaged
Replace
Synchronizer sleeve and chamfered teeth damaged
Replace synchronizer gear
sleeve and gear
Gear shifted
difficultly
Transmission gear oil insufficient
Added
Clutch pedal free stroke incorrect
Adjust
Clutch friction plate distorted or damaged
Replace
Clutch pressure plate damaged
Replace the pressure plate
Synchronizer gear ring worn
Replace
Synchronizer gear bushing and gear chamfered teeth worn
Replace synchronizer gear
sleeve or gear
Shifting fork shaft deformed
Replace
The cable isn't installed to proper position.
Adjusting cable
Noisy
Transmission gear oil insufficient
Added
Bearing damaged or worn
Replace
Gear damaged and worn
Replace
Synchronizer part damaged and worn
Replace
Oil leakage
Oil seal of input shaft is worn or damaged.
Replace
Oil seal of differential is worn or damaged (bad quality of the
surface of transmission shaft causes the abrasion of oil seal).
Replace
Oil leakage in the oil plug
Replace
Sealant of lock bolts of 1
st
gear and 2
nd
gear is fail.
Replace
Sealant of lock bolts of 5
th
gear and reverse gear is fail.
Replace
J4 Service Manual
Transmission System
MT-4
System specification
1. Structure schematic diagram
Transmission Structure Schematic Diagram
2. Principle of movement:
1
st
gear: Engine → Clutch → Input shaft spline 1 → Input 1
st
gear 3 → Output 1
st
gear 18 → 1/2
gear synchronizer 17 → Output shaft 2 → Differential 19
2
nd
gear: Engine → Clutch → Input shaft spline 1 → Input 2
nd
gear 6 → Input 2
nd
gear 16 →
1/2 gear synchronizer 17 → Output shaft 2 → Differential 19
3
rd
gear: Engine → Clutch → Input shaft spline 1 → 3/4 gear synchronizer8 → Input 3
th
gear
7 → Output 3
th
gear 15 → Output shaft 2 → Differential 19
4
th
gear: Engine → Clutch → Input shaft spline 1 → 3/4 gear synchronizer8 → Input 4
th
gear
teeth 9 → Output 4
th
gear teeth 14 → Output shaft 2 → Differential 19
5
th
gear: Engine →Clutch →Input shaft spline 1 → 5/R gear synchronizer 11 → Input 5
th
gear
10 → Output 5
th
gear 13 → Output shaft 2 → Differential 19
Reverse gear: Engine → Clutch → Input shaft spline 1 → 5/R gear synchronizer10, Reverse gear
synchronizing ring 12 → Reverse gear 5 → Input reverse gear 4 → 1/2 gear synchronizer17 →
Output shaft 2 → Differential 19
J4 Service Manual
Transmission System
MT-5
3. Shift principle
When the vehicle is going forward, gear shifting of transmission shall be as follows: gear shifting
for speeding shall be made level by level from Gear 1 to 5, and vice versa; Do not use rotating
speeders when the vehicle is going forward. Under the condition that the complete vehicle has
gear shifting operation, to avoid misoperation, the transmission is set with a function that 5
th
gear
reversing is not allowed. In principle, the reverse shall be turn on a 3s pause later after the clutch
is pressed when the vehicle is stationary; do not switch to the gear when the vehicle is running
forward; do not turn on any forward gear when the vehicle is rotating speedersing.
Caution:
■ It's allowed not to observe the gear shifting principle of transmission in emergency when the
vehicle is working.
Manual transmission gearbox oil
1. Replace manual transmission gear oil
1) Displacement
① Remove oil drain plug, drain gear oil.
■ Tightening torque: 10-17 N•m
② Check if the surface of oil drain plug has iron scraps.
If yes, remove them.
2) Fill
① Remove filling plug. Refill new gear oil until the oil
level reaches to the specified limit near mounting
hole.
② Gear oil model and oil filling capacity:
75W/90 GL-4gear oil.
Oil filling capacity: 2.0 L
③ Check fuel level after filling.
④ Tighten filling plug.
■ Tightening torque: 10-17 N•m
MT002
MT001
J4 Service Manual
Transmission System
MT-6
2. Check MT gear oil
■ Make sure that there is no gear oil leakage on or
around manual transmission.
① Remove filling plug.
As shown in figure 1.2.002 and 1.2.003, Check oil
level through mounting hole of filling plug.
② Tighten filling plug
Caution:
■ Do not start the engine during inspection for oil level.
Oil real
1. Removal and installation
1. Removal
① Drain transmission gear oil. Please see “Manual
transmission gear oil".
② Remove the front drive shaft from the axle. Please see
“Front drive shaft".
③ Remove the oil seal on differential side with a slotted
screwdriver.
Caution:
■ Do not breakout transmission housing.
2) Installation
① Use a special tool to install oil seal on differential side onto the clutch housing and
transmission housing.
Caution:
■ Apply proper amount of grease to the lip of new oil seal.
② Install all dismantled parts according to reverse order of dismantling.
③ Fill manual transmission gear oil, and check fluid level. Please see “Check manual
transmission gear oil “.
3) Check if drive shaft is flexible after installed.
MT004
MT003
J4 Service Manual
Transmission System
MT-7
Control mechanism of selecting gear
1. Components
Control mechanism of selecting gear drawing
1
st
select gear wire drawing
2
nd
shift control device
3
nd
selecting gear handle
2. Removal and installation
1) Removal
① Remove battery. Please see “Battery".
② Remove the air filter assembly. Please see "Air filter
assembly".
③ Select gear handle located at the neutral gear.
④ Remove select gear handle
⑤ Remove rear section of auxiliary fascia console.
Please refer to “Auxiliary Fascia Console".
⑥ Remove the selector & shift gear lock pin and spring
retainer (internals & externals)
Please refer to Fig. MT005 to Fig. MT008.
MT007
MT006
MT005
3
1
2
J4 Service Manual
Transmission System
MT-8
⑦ Unscrew off the fixing bolts of selector gear wire on
front engine compartment plate side.
■ Tightening torque: 20-30 N•m
⑧ Remove fixing bolt of select gear operating device.
■ Tightening torque: 20-30 N•m
⑨ Remove the selector gear mechanism assembly from
the inside vehicle.
MT011
MT010
MT009
MT008
J4 Service Manual
Transmission System
MT-9
2) Installation
Pay attention to the following considerations and
install in the order opposite to dismantling.
■ Properly install the gear selector or shifter pull-wire.
■ Pay attention to mount direction of spring disc.
■ When gear shifting lever is placed to 1
st
gear – 2
nd
gear and 5
th
gear- reversing side, make sure the lever
can be shifted to neutral position smoothly.
■ When the gear shifting lever is shifted to a gear,
make sure that the gear shifting is smooth.
Manual transmission assembly
Removal and installation:
1) Removal
① Disconnect negative battery cable.
② Remove battery and support of battery. Please see
“Battery".
③ Dismantle old air filter assembly. Please see "Air
filter assembly".
④ Discharge hydraulic oil from the clutch, and
disconnect oil pipe of the clutch from quick coupler
of hydraulic release bearing of the clutch. Please see
“Clutch pipeline".
Caution:
■ Please do not depress the clutch pedal during removal.
⑤ Disconnect speed sensor, reverse light switch and crankshaft position sensor wire harness
connector on the transmission.
⑥ Remove the crankshaft position sensor. Please see “Crankshaft position sensor”.
■ Tightening torque: 8-12 N•m
⑦ Dismantle oil pipe clamp of the clutch from fixing bracket of left suspension of manual
transmission and disconnect oil pipe of clutch master cylinder.
⑧ Disconnect transmission select gear wire drawing. Please see “control mechanism of
selecting gear".
⑨ Install the lifting frame onto the engine hook.
⑩ Remove the starter. Please see “Starter".
⑪ Drain the gear oil. Please see “Replace manual transmission gear oil".
MT013
MT012
J4 Service Manual
Transmission System
MT-10
⑫ Remove front drive shaft. Please see "Drive shaft".
Caution:
■ After dismantling of front drive shaft, please insert a suitable plug into side oil seal.
⑬ Remove the engine deflector.
⑭ Remove the engine support beam. Please see "Engine supporting beam".
⑮ Remove the lower support and lower clapboard of transmission.
■ Tightening torque: M6 5-6 N•m M8 12-15 N•m
⑯ Remove left suspension holder of transmission.
⑰ Use a jack to lift transmission assembly, and dismantle fixing bolts between transmission and
engine.
⑱ Remove the transmission assembly from vehicle.
2) Install
Pay attention to the following cautions and install it in the reverse order of removal.
■ When installing transmission assembly onto the engine, first pretighten the fixing bolts and
then tighten fixing bolts according to the following standards.
Screw-in direction: 1: transmission side → engine side (1, 3, 5, 6, 7)
2: Engine side → transmission side (2, 4)
Tightening torque: 1 50-70 N•m
2 50-70 N•m
3 50-70 N•m
4 50-70 N•m
5 50-70 N•m
6 50-70 N•m
7 50-70 N•m
■ Fill hydraulic oil of clutch, and exhaust gas in clutch hydraulic pipeline. Please see “Clutch
pipeline".
■ After installation, check gear oil level of manual transmission, and then check if there is any
gear oil of transmission leakage and whether the mechanical installation is loose. Please see
“Check manual transmission gear oil”.
1
2
3
4
5
6
7
MT014
J4 Service Manual
Transmission System
MT-11
Disassembly and assembly
1. Disassembly of transmission gearbox assembly
(1) Drain oil
Caution:
■ Remove the oil drain screw plug with wrench, and
drain oil from the oil drain screw plug. It is not
allowed to drain oil from other positions.
(2) Disassemble the rear cover screws.
(3) Disassemble the input & output shaft lock nuts.
(4) Remove the reverse cone shock insulator, reverse
cone and reverse synchronization ring.
(5) Disassemble the 5/R gear fork spring pin.
MT018
MT017
MT016
MT015
J4 Service Manual
Transmission System
MT-12
(6) Disassemble the 5/R gear fork and 5/R gear
synchronizer. Synchronizer gear sleeve and gear hub.
(7) Remove the 5
th
gear synchronization ring and input
5
th
gear fitting
(8) Remove the output 5
th
gear.
(9) Remove the ball plug, reverse gear shaft bolts and
clutch case joint bolts.
MT022
MT021
MT020
MT019
J4 Service Manual
Transmission System
MT-13
(10) Use a magnet to suck steel ball out of lock ball plug
hole.
(11) Remove the casing.
MT026
MT025
MT024
MT023
J4 Service Manual
Transmission System
MT-14
Caution:
■ If the housing adheres to the clutch housing tightly,
knock the edge of the housing gently with rubber
hammer or copper rod to loosen it.
(12) Remove the reverse gear and reverse gear shaft.
(13) Disassemble the mounting bolt of reverse gear shift
mechanism.
(14) Remove the reverse gear shift mechanism fitting.
(15) Disassemble the fork spring pin of 1/2 gear and
3/4.gear.
MT031
MT030
MT028
MT027
J4 Service Manual
Transmission System
MT-15
(16) Remove the fork shaft fitting and fork.
Caution:
■ Before removing shift shaft components and shift
fork, Rotate the fork block to separate it from
interlock plate.
(17) Disassemble the bearing pressure plate of input shaft.
(18) Remove the input shaft assembly, output shaft
assembly and differential assembly.
(19) Disassemble the interlock plate screws.
MT035
MT034
MT033
MT032
J4 Service Manual
Transmission System
MT-16
(20) Disassemble the gear selector shaft fitting.
Caution:
■ Punch the slot pin of shift shaft from the bolt hole of
interlock plate.
2. Input shaft assembly disassembly
(1) Disassemble the input 5
th
gear lining.
(2) Disassemble the ball bearing (behind the input shaft),
input 4
th
gear lining, and 3/4 gear synchronizer
assembly.
Caution:
■ Use clip forceps to remove the clip (on the rear of
input shaft) and install special drawing tool on the 3
rd
combination gear. Meanwhile dismantle 3/4 gear
synchronizer assembly, input 4
th
gear lining, ball
bearing (on the rear of input shaft) at the same time.
And then take out 3
rd
speed synchronizer and input
3
rd
gear components.
MT037
MT036
MT036
J4 Service Manual
Transmission System
MT-17
3. Output shaft assembly disassembly
(1) Disassemble the tapered roller bearing (behind the
output shaft) and output 4
th
gears.
Caution:
■ Install a special puller on the output 4
th
gear, and
dismantle taper roller bearing (on the rear of output
shaft) and output 4
th
gear at the same time.
(2) Disassemble the output 3
rd
gear, output 2
nd
gear
lining, output 2
nd
gear assembly, 1/2 gear
synchronizer assembly and output 1
st
gear assembly.
4. Disassembly of differential assembly
(1) Disassemble the main reduction gear
(2) Disassemble the groove pin.
(3) Remove the planet gear shaft, planet gear, planet gear
thrust pad, half-axle gear and its thrust ring.
MT041
MT040
MT039
MT038
J4 Service Manual
Transmission System
MT-18
5. Inspection of Key Parts
(1) Check input shaft assembly
1) Check if the teeth of input shaft gear are broken, tooth surface has pitting corrosion, serious
abrasion and gluing condition. If any of the above conditions occurs, it is necessary to
replace input shaft.
2) Check if the spline of input shaft has serious abrasion and damage. If yes, it is necessary to
replace input shaft.
3) “Feel” the bearing with hand for flexible rotation and stagnation. If the bearing rotates
inflexibly or has stagnation, the bearing must be replaced.
Caution:
■ Front ball bearing of input shaft can't be dismantled. If replacing output shaft or front bearing
of output shaft, these two parts must be replaced together at the same time.
(2) Check output shaft assembly
Check if the teeth of output shaft gear are broken, tooth surface has pitting corrosion, serious
abrasion and gluing condition. If any of the above conditions occurs, it is necessary to
replace output shaft.
Caution:
■ Inner ring of front bearing of output shaft can't be dismantled. If replacing output shaft or
inner ring of front bearing of output shaft, these two parts must be replaced together at the
same time.
■ “Feel” the bearing with hand for flexible rotation and stagnation. If the bearing rotates
inflexibly or has stagnation, the bearing must be replaced.
(3) Check the differential assembly
1) Check if the teeth of main reduction gear are broken, tooth surface has pitting corrosion,
serious abrasion and gluing condition. If any of the above conditions occurs, it is necessary
to replace main reduction gear.
2) Check if the planetary gear and half gear as well as spline have serious abrasion and damage.
If yes, it is necessary to replace them.
3) Check if the outer ring of taper roller bearing and the roller have serious abrasion. If yes, it is
necessary to replace bearing.
Caution:
■ Inner ring of taper roller bearing can't be dismantled.
■ If the inner ring of taper roller bearing is damaged, it is necessary to replace differential case
and inner ring of taper roller bearing at the same time. After replacement, it requires to
re-select upper adjusting shim of differential. The magnitude of interference is 0.15-0.20
mm.
(4) Inspect the synchronous ring
1) Inspect the surface of the synchronous ring gear for damage or scratch.
J4 Service Manual
Transmission System
MT-19
2) Inspect the conical part for damage or abrasion, and inspect the threads for damage by
compression.
3) Under the condition of pressing the synchronous ring towards gear, inspect the clearance “A”.
If “A” is less than the limit value, replace it.
Limiting value: 0.5 mm
(5) Inspect the synchronizer gear sleeve and gear hub
1) Assemble the synchronizer gear sleeve together with the gear hub, and inspect if they slide
smoothly with stagnation or not.
2) Inspect the front and rear ends on the inner surface of gear sleeve for damage.
Caution:
■ When it is necessary to replace the synchronizer gear sleeve or gear hub, replace them
together as a set.
6. Input shaft assembly
(1) Install input 3rd speed roller bearing, input 3
rd
gear
components, synchronizing spring and 3
rd
gear
synchronizer.
Caution:
■ Install the synchronizing spring on the position of synchronizer as shown in figure.
MT042
Synchronous
ring
Gear
J4 Service Manual
Transmission System
MT-20
(2) Install the 3
rd
and 4
th
gears synchronizer assembly.
Caution:
■ Install the 3/4 gear synchronizer gear hub according to the direction shown in figure.
This face is toward 3
rd
gear.
This face is toward 4
th
gear.
When installing synchronizer hub, confirm whether synchronizing ring clipped.
■ Synchronizer gear sleeve installation
MT043
Synchronizing
spring
Speed synchronizer
gear hub
Speed synchronizer
gear sleeve
J4 Service Manual
Transmission System
MT-21
When installing synchronizer gear sleeve, make sure that two deep gear groove of synchronizer
gear hub meets two high racks of gear sleeve.
(3) Install the input 2
nd
gear lining.
(4) Install the synchronization spring, 4
th
gear
synchronization ring, input 4
th
gear needle bearing,
input 4
th
gear fitting and input 4
th
gear thrust pad.
(5) Fit in the ball bearing behind the input shaft.
(6) Fit in the snap ring behind the input shaft.
Caution:
■ Snap ring thickness shall be so selected that axial
clearance of input shaft bearing will be satisfactory.
Standard value: 0-0.09 mm
MT046
MT045
MT044
J4 Service Manual
Transmission System
MT-22
(7) Fit in input speed V lining.
7. Output shaft assembly
(1) Install output 1
st
and 2
nd
gear roller bearing, output 1
st
gear components, 1
st
and 2
nd
gear synchronizer
components.
Caution:
■ Install the 3/4 synchronizing spring onto the synchronizer according to the direction shown
in figure.
(2) Install the 1
st
and 2
nd
gears synchronizer assembly.
MT049
MT048
MT047
Synchronizing
spring
J4 Service Manual
Transmission System
MT-23
Caution:
■ Install the 1/2 gear synchronizer gear hub in the direction shown in the Figure.
This surface faces to 1
st
gear.
This face is toward 2
nd
gear
When install synchronizer hub, confirm whether synchronizing ring clipped.
■ When installing synchronizer gear sleeve, make sure that two deep gear groove of
synchronizer gear hub meets two high racks of gear sleeve.
■ Install the 1/2 gear synchronizer gear sleeve according to graphical direction.
2
nd
gear
1
st
gear
(3) Install the 1/2 gear synchronization ring elements and
output 2
nd
gear lining
MT050
Speed synchronizer
gear sleeve
Speed synchronizer
gear hub
J4 Service Manual
Transmission System
MT-24
Caution:
■ Oil hole on the gear sleeve should be aligned with oil
hole on the output shaft.
(4) Fit in output 1
st
and 2
nd
gears needle bearings, output
2
nd
gear fitting and output 3
rd
gear
(5) Fit in the spacer bush and output 4
th
gear
(6) Install the tapered roller bearing behind the output
shaft
8. Differential assembly
(1) Install planetary gear, thrust cushion of planetary gear,
half gear, thrust ring of half gear.
Caution:
■ First install the thrush ring of half gear on the back of
half gear, and then install half gear onto the
differential.
After installing a thrust cushion of planetary gear onto the
back of planetary gear, make sure that the two planetary
gears engage with half gear at the same time. And then
rotate planetary gear to install it onto proper position.
MT054
MT053
MT052
MT051
J4 Service Manual
Transmission System
MT-25
(2) Insert the planet gear shaft.
(3) Install the groove pin.
(4) Fit in the main reduction gear.
9. Transmission assembly
(1) Input gear shift rock arm components, bolts of
interlock plate, reversing lock chip and torsion spring.
Caution:
■ Correct mounting position of torsion spring, as shown
in the below Figure:
MT057
MT056
MT055
MT054
J4 Service Manual
Transmission System
MT-26
(2) Fit in the differential assembly, input shaft assembly
and output shaft assembly.
(3) Install the 1/2 gear fork shaft assembly, 3/4 gear fork
shaft assembly, 5/R gear fork shaft assembly, 1/2 gear
fork, and 3/4 gear fork and spring pin.
Caution:
■ Elastic pin must be replaced with a new one.
(4) Install the pressure plate and its screws
MT061
MT060
MT059
MT058
J4 Service Manual
Transmission System
MT-27
(5) Fit in the reverse shift mechanism fitting
(6) Install the reverse gear and reverse shaft
(7) Fit in the magnet and oil chute and then close the box
Caution:
■ Gluing shall be made evenly. Ungluing is prohibited.
(8) Fit in steel ball, ball spring, ball plug, clutch case joint
bolts and reverse shaft bolts.
MT064
MT063
MT062
J4 Service Manual
Transmission System
MT-28
(9) Install input 5
th
gear.
(10) Install input 5
th
gear roller bearing, input 5
th
gear
components and 5
th
gear synchronizer.
(11) Fit in 5/R gear synchronizer assembly and 5/R gear
fork
(12) Fit in reverse synchronization ring, cone, cone shock
insulator and input & output shaft lock nut
Caution:
■ It has not to pull out after locking nut was tighter.
MT069
MT068
MT067
MT066
J4 Service Manual
Transmission System
MT-29
(13) Fit in rear cover.
Caution:
■ Gluing shall be made evenly. Ungluing is prohibited.
Maintenance data and specification
Tightening Torque
No.
Name
N•m
1
Bolt connecting reversing gear shifting mechanism and clutch body
14.7-21.6
2
Oil drain plug
40-60
3
Pressure plate and clutch housing connecting bolt
14.7-21.6
4
Connecting bolt of clutch and housing
34.3-41.2
5
Front cover bolt
6-8
6
Odometer fixing bolt
4-6
7
Reverse axle bolt
42.2-53.9
8
Rear cover bolt
14.7-21.6
9
Lock ball screw plug
29.4-41.2
10
Lock nut
137.2-156.8
11
Oil filler screw
30-40
12
Selecting gear position
40-50
13
Interlock plate guide bolt
19.6-26.5
14
Reversing light switch
29.4-34.3
15
Release fork and separation rocker arm connecting nut
30-42
16
Mounting bolt of main reduction gear
75-85
17
Selecting gear support and clutch housing connecting bolt
14.7-21.6
MT070
J4 Service Manual
Transmission System
MT-30
Main Technical Parameters
Type
5th forward gears, 1st reverse gear
Operation method
Telecontrol
Rated input torque
180 N•m
Mass of assembly
About 36.5Kg
Maintenance
The transmission gearbox shall be used and maintained according to the requirements for use and
maintenance of commercial vehicles, generally classified as technical maintenance of three levels.
Regularly check and replace (or add) lubricant of transmission gearbox.
List of Regular Inspection and Maintenance for Gearbox
Distance and time (in months) are indicated for the items, perform inspection as required,
whichever comes first.
○ Check position, tighten or adjust; ★ Replace lubricant
Item
Interval of Overhaul (by the reading of Odometer and number of months, whichever comes
first)
Months
－
3
6
12
18
24
30
36
42
48
54
Odometer reading × 1,000 km
1
5
10
20
30
40
50
60
70
80
90
Internal inspection of gearbox
Inspect the level of gear oil in the gearbox
○
○
○
○
○
Replace the gear oil
in the gearbox
General service conditions
★
★
★
★
★
Severe service conditions
★
★
★
★
★
★
★
★
Other inspection items
Caution: The “Severe service conditions” include the following items.
Running in dusty area or always exposed to salty air or salty water.
Running on uneven road or mountain road with accumulated water.
Running in cold area.
In cold seasons, engine kept idling for long or always running in short distance.
Have to use brake frequently and emergency brake for many times.
Towing vehicle.
It is for the vehicle which is used to be a taxi or rent car.
Under the high temperature above 32°C , the time of driving slowly in jammed urban area
exceeds 50% of total driving time.
J4 Service Manual
Transmission System
MT-31
Under the high temperature above 30°C , the time of driving at the high speed above 120km/h
exceeds 50% of total driving time.
Overloaded driving.
Lubrication and Sealing
Item
Lubricant and sealant
Quantity
Gear oil for transmission gearbox
Gear oil 75W/90 GL-4
2.0L
Transmission spline
Lubricating grease
Appropriate amount
Transmission gearbox oil seal
Lubricating grease
Appropriate amount
Adjoining surface between transmission gearbox
housing and clutch housing
KESAIXIN®1596F
Appropriate amount
Adjoining surface between transmission gearbox
housing and rear cover
KESAIXIN®1596F
Contents of Quick-wear Parts
No.
Code
Name
Quantity
1
D-1701251-00-00
Lock nut
2
2
D-1701551-00-00
Oil seal (input shaft)
1
3
D-1702201-00-00
Oil seal (shiftgear shaft)
1
4
D-2303011-00-00
Oil seal (differential)
2
5
Q5280525
Elastic pin
3
6
H-1701516-79-00
Gasket (oil drain screw plug)
1
7
Q2580820S
Pressure plate screw
3
J4 Service Manual
Clutch System
CL-1
Chassis - Clutch System
Precautions
■ Recommended clutch hydraulic oil is a brake liquid “DOT4”.
■ Do not reuse the drained clutch hydraulic oil.
■ Pay attention not to spray vehicle hydraulic oil of the clutch onto the paint of vehicle body.
■ Please do not use mineral oil such as gasoline or kerosene, to avoid corrosion of rubber part
in hydraulic system.
■ Please do not decompose master pump, hydraulic release bearing.
Warnings:
■ Please use a dust aspirator to clean clutch friction plate. Do not use compressed air to clean
it.
Preparation work
Special tools to be used are as below:
Special Tool Table
No.
Tools
Overall Diagram
Code
Instructions
1
Flywheel stop dog
JAC-T1F011
Fixing fly wheel
Common fault diagnostic
The performance diagnosis of clutch assembly and clutch control system should be performed by
experienced driver or skillful repair technician.
The following (fault) diagnosis involves common problems and possible causes. After conducting
proper diagnosis, adjust or replace parts according to corresponding Countermeasures and proper
sections of detailed procedures specified in Manual.
When repairing vehicle, clutch disc and clutch friction plate can't be repaired. If any of them is
damaged, it is necessary to replace the complete assembly.
If the rivet of clutch friction plate is worn or clutch friction plate is stained by engine oil or grease,
this clutch friction plate can't be reused.
If a part is required to be replaced, use a qualified new part to replace it.
This diagnosis table is helpful to diagnose faults of clutch system caused by the following
conditions: clutch can't be released, can't be released completely, can't be engaged completely,
skidding, noise, vibration.
The digit on this diagnosis sheet does refer to the order of inspection. There is no precedence
relationship among potential causes.
J4 Service Manual
Clutch System
CL-2
Diagnosis Table of Clutch System
Items
Potential Cause
Countermeasures
No
disengagement
If clutch can't be disengaged, it means the clutch
can't operate or cut off the power transmitted from
the engine.
Check the following conditions
1. Clutch release rod deformed.
2. Diaphragm spring deformation.
3. Support ring of diaphragm spring is
fractured.
4. Clutch pedal control system and clutch cable
are adjusted wrongly.
5. Clutch friction plate sticks to flywheel or
clutch cover.
Replace the deformed, worn or cracked
parts.
Adjusted clutch system.
Incomplete
separation
Incomplete disengagement of clutch may make it
impossible to cut off the power transmitted from
the engine and it is difficult to operate the
gearshift because clutch friction plate and
transmission input shaft continue running.
Check the following conditions:
1. Clutch friction plate is deformed. It may rock
when rotated.
2. Clutch friction plate is damaged.
3. Clutch friction plate spline doesn't match
transmission input-shaft spline, or spline
tooth face is damaged.
4. Clutch friction plate sticks partially to
flywheel or bites clutch cover.
5. The thickness of flywheel/clutch
cover/clutch friction plate exceeds the size as
required.
6. Clutch pedal control system and clutch cable
have mechanical fault or improper
adjustment.
Replace the deformed, worn, cracked or
over-size parts. If clutch friction plate
can't cooperate with the spline of the input
shaft of transmission, replace the plate; if
necessary, replace the input shaft.
If the friction plate of clutch exceeds the
size as specified or is damaged, replace it.
Replace does not apply clutch thrust
bearing.
Adjust clutch system to eliminate
unnecessary clearance and mechanical
faults.
Reinstall the parts that were assembled
incorrectly.
Incomplete
engagement
Incomplete engagement of clutch may make it
impossible to transmit engine power to
transmission input shaft. Meanwhile, clutch
friction plate may slip.
Check the following conditions:
1. Clutch friction plate is contaminated by
engine oil or grease.
2. Clutch friction plate is damaged.
3. Clutch pedal has no free travel.
4. Diaphragm spring/ clutch disc/ clutch release
lever/ spline of clutch friction plate is
deformed or damaged.
5. Clutch pedal control system and clutch cable
have mechanical fault or improper
adjustment.
Replace the deformed, worn or cracked
parts.
Replace clutch friction plate or defective
clutch assembly.
Adjust the free stroke of clutch pedal
correctly.
Adjust clutch system to eliminate
unnecessary clearance and mechanical
faults.
Reinstall the parts that were assembled
incorrectly.
J4 Service Manual
Clutch System
CL-3
Items
Potential Cause
Countermeasures
Slipping
Clutch friction plate slips, may make it impossible
to transfer engine power as normal.
Check the following conditions:
1. Clutch friction plate is worn.
2. Clutch friction plate is contaminated by
engine oil or grease.
3. Clutch is engaged incompletely.
4. Both thickness of flywheel/clutch
cover/clutch friction plate and frictional
surface exceed the size as required.
5. Over-temperature in clutch housing is caused
by improper driving.
6. Install unsuitable clutch.
Replace the deformed, worn or cracked
parts, those beyond the size or
specification.
Countermeasures to "incomplete
separation" and "incomplete engagement".
Stop engine, lower the temperature in the
housing of clutch (if too high), and make
further diagnosis.
Install the clutch correctly that is
designated.
Adjust clutch system and clutch cable, to
remove unnecessary clearance and
eliminate mechanical fault.
Reinstall the parts that were assembled
incorrectly.
Do not leave your foot on the clutch pedal
all the time.
Noise
Check the following conditions:
1. Improper clutch friction plate.
2. Poor balance.
3. Clutch thrust bearing fault.
4. Clutch friction plate is subjected to torsional
force vibration attenuation, and the spring is
damaged.
Replace the deformed, worn or cracked
parts.
Install clutch friction plate as designated.
If some part is poorly balanced, replace
the clutch assembly.
Adjusted clutch wiredrawing.
Reinstall the parts that were assembled
incorrectly.
Shaking
This situation will occur when clutch friction
plate can't engage with flywheel softly.
Check the following conditions:
1. Damper spring of clutch friction plate fails to
meet the specification.
2. Clutch friction plate fails to meet the
specification.
3. Clutch friction plate is contaminated by
engine oil or grease.
Replace clutch assembly.
Hydraulic oil of clutch
1. Overhaul key points
Caution:
■ Please do not use vacuum pump or any other type of air discharger power device for this
system.
■ Check the height of clutch hydraulic oil level. Ensure the level is right.
■ Do not spray hydraulic oil of the clutch onto the vehicle body paint and other parts. If
hydraulic oil of the clutch sprays onto the paint of vehicle body and other parts, immediately
wipe it with dry cloth.
J4 Service Manual
Clutch System
CL-4
2. Discharge the air in the pipeline:
Caution: When dismantling clutch pipeline, clutch master cylinder, hydraulic release bearing, if
clutch pedal is soft, it is necessary to discharge air from the system.
1) Loosen the bleed screw of clutch cylinder.
2) Press clutch pedal slowly until air is exhausted.
3) Completely step on the pedal and keep it and then tighten the bleed screw.
4) Supplement hydraulic fluid to the clutch hydraulic system.
Caution:
■ Always keep the reservoir level between the MIN and MAX.
5) Repeat the above steps until the clutch hydraulic oil discharged from the system is clean
without any blister.
6) Ensure clutch works soundly.
① Start the engine, press clutch pedal and switch carefully to Reverse about 2s later. If there is
large noise when choosing a gear, press the clutch pedal to the end 5 times to discharge air
from the system.
② Check the clutch performance about 30s later. If there is large noise still, please discharge air
again.
Clutch master cylinder
1. Components
Exploded View of Clutch Master pump
1-Fluid reservoir 2-Clamp 3-Piston 4-Snap ring 5-Pushing rod 6-Master pump body
7-Locking pin
6
3
4
5
7
2
1
J4 Service Manual
Clutch System
CL-5
2. Removal and installation
1) Removal
① Drain hydraulic oil from clutch air exhaust bolt in
front of clutch.
② Disconnect the lock pin of clutch master cylinder push
rod with clutch pedal.
③ Disconnect the hose from clutch master cylinder to
brake master cylinder.
④ Disassemble the clutch master cylinder oil pipe and
unscrew off the fixing bolts of the cylinder.
⑤ Take out master pump of clutch.
2) Inspection after removal
■ Check if clutch pipeline is blocked.
■ Check if clutch hose and pipe are damaged or rusted.
3) Installation
Pay attention to the following cautions and install it in the reverse order of removal.
■ Apply the specified hydraulic oil onto the inner wall of pump and the surface of piston
assembly (brake hydraulic oil DOT4).
■ Make system bleed air. Please see “Hydraulic oil of clutch “.
■ Adjust clutch free stroke. Please see “Inspection and adjustment on vehicle".
■ Tightening torque refers to “tightening torque table”.
CL003
CL002
CL001
J4 Service Manual
Clutch System
CL-6
Clutch pedal
1. Personalized inspection and adjustment
Free stroke inspection:
■ Press clutch pedal by hands until you feel some
resistance, and then use a scale to measure whether
the free stroke is within the specified range.
Pedal free stroke: 6-13 mm
2. Removal and installation
1. Components
Diagram of Clutch Pedal
2. Removal
① Remove clutch pedal lock pin, disconnect pushing rod
connecting with master pump of clutch.
② Remove clutch pedal fixing bolt, take out clutch
pedal.
CL006
CL005
CL004
J4 Service Manual
Clutch System
CL-7
3) Inspection after removal
Check if clutch pedal is distorted, damaged or there is
a crack welding cut. If any of the above conditions
occurs, please replace clutch pedal assembly.
4) Installation
Install in the order opposite to that of dismantling.
■ Tightening torque: 20-30 N•m
Caution:
■ When adjusted clutch pedal height, do not push pulling rod into the master pump of clutch.
■ After adjustment, check if the stroke and free stroke of clutch pedal are within specified
range.
■ If the free stroke of clutch isn't within the specified range, there must have air in hydraulic
pipe of the clutch and fault in clutch master cylinder. It is necessary to discharge air from the
system, and dismantle and check master cylinder or clutch.
CL007
J4 Service Manual
Clutch System
CL-8
Clutch pressure plate, friction plate of clutch and flywheel
1. Removal and installation
1) Components
Clutch Exploded View
1-Flywheel 2-Clutchfriction plate 3- Clutch pressure plate 4- Fixing bolt
Caution:
■ Do not make the surface of clutch friction plate, disc and flywheel stained with any grease.
2. Dismantle
① Remove manual transmission assembly on the vehicle. Please see “manual transmission
assembly".
② Uniformly release fixing bolts of clutch disc. And then dismantle clutch disc and clutch
friction plate.
Caution:
■ Loosen 1 to 2 cycles of each bolt each time, to avoid damage of flange of clutch housing.
③ Dismantle fixing bolts of flywheel from the rear of cylinder block, and then remove
flywheel.
④ Remove hydraulic release bearing on the transmission housing.
3) Inspection after removal
① Friction plate of clutch
■ Check if the surface has degradation and grease stain caused by rivet loosing, single surface
contact and burning. If yes, please replace clutch friction plate.
④
J4 Service Manual
Clutch System
CL-9
■ Measure the sinking depth of rivet. If it exceeds limit
value, please replace clutch friction plate.
Limiting value: 0.3 mm
■ Check if return spring is loosened or damaged; if so,
please replace clutch friction plate.
■ Install clutch friction plate onto the input shaft, and
Check sliding condition and loosening of rotation. If
the sliding operation is bad, clean it. If the fault still
exists after assembly, please replace it. If the
loosening is obvious, please replace clutch friction
plate or input shaft, or replace both of them at the
same time.
② Clutch pressure plate
■ Check if the end of diaphragm spring is worn and if there is any height difference. If there is
obvious abrasion or the height exceeds limit value, replace clutch friction plate.
Limiting value: 0.5 mm
② Check if pressure plate surface is worn, cracked or discolored.
■ Check if clutch cover rivets are loose. If so, replace the plate.
③ Hydraulic separate bearing
Check if bearing is burnt or damaged, has abnormal sound, or rotates unsmoothly, etc.
■ Check if the diaphragm spring of hydraulic bearing has abrasion. Replace it if any.
④ Flywheel
■ Use a dial indicator to measure the levelness of the
contact surface between flywheel and clutch friction
plate. If it doesn't meet requirement, please replace
flywheel.
■ If the contact surface between clutch disc and clutch
friction plate has burning or discolor sign, please
grind it with sand paper.
Caution:
■ Please measure the levelness on the exterior surface of flywheel (do not measure it on the
fixing pin).
4) Installation
① Clean clutch friction plate and the spline slot of input shaft, and remove grease and worn
metal scraps.
② Apply grease onto the spline slot of input shaft.
Caution:
■ Recommended grease: SAE J310 or equivalent.
CL009
CL008
Dial indicator
J4 Service Manual
Clutch System
CL-10
■ Make sure that the grease is applied to the specified position; otherwise, it may cause clutch
producing noise, bad release effect or damage. Excessive grease may also cause sliding or
vibration.
③ Install flywheel and tighten it with specified tightening torque. Use a special tool to install
clutch friction plate and clutch disc.
④ Perform it by steps in the order shown as in the figure
and evenly tighten the fixing screws of clutch in turn.
Caution:
■ Tight 1-2 cycles for each bolt and gradually tighten it
well.
Tightening torque: 15-2 N•m
⑤ Install hydraulic release bearing.
⑥ Install manual transmission on the vehicle. Installing
process, Please see “Manual transmission".
CL010
J4 Service Manual
Clutch System
CL-11
Hydraulic pipeline
Hydraulic Pipeline Diagram
1-Clutch pressure plate and clutch drive plate 2-Rocker arm 3-Pushing rod
4-Clutch work cylinder and hose assembly 5-Spring clip disc 6-Support 7-Hard pipe
8- Clutch master cylinder 9- Clutch pedal
Pay attention to the following precautions when dismantling and installation of hydraulic pipe of
clutch.
Caution:
■ Do not spray hydraulic oil of the clutch onto the vehicle body paint and other parts. If
hydraulic oil of the clutch sprays onto the paint of vehicle body and other parts, immediately
wipe it with dry cloth.
■ When installing clutch pipe on the hydraulic release bearing, three-way valve, clutch pipe,
please insert it completely to the bottom and Check if the clamp is installed to proper
position.
■ Use oil pipe wrench to tighten the pipe joints.
■ After installation, please discharge air from clutch hydraulic system. Please see “Air
exhaust".
1
2
3
4
5
6
7
8
9
J4 Service Manual
Clutch System
CL-12
Service Parameters
1. Technical parameters
Technical Parameter Table
Clutch free stroke
6-20 mm
2. Grease
Lubricating Grease Table
Master pin of main pump
Kunlun no.2 low temperature grease
3. Tightening torque
Fastening Torque Table
Item
Torque (N•m)
Master pump of clutch fixing bolt
20-28
Master pump of clutch fixing nut
20-28
Oil pipe fixing support
20-28
Air exhaust bolt
8-12
Clutch pressure plate mounting bolt
20-28
J4 Service Manual
Drive System
DS-1
Chassis - Drive System
Precautions
1. Instruction for maintenance of drive shaft
1) Do not remove the components that need overhaul like steering knuckle.
2) Be sure to operate on a dust-free work platform as much as possible.
3) Please clean the components surface before removal and installation.
4) During working, pay attention not to stain parts, and avoid foreign matters entering into the
parts.
5) Be sure to re-assemble carefully the disassembled parts in the correct order. If the operation
is interrupted, be sure to shield the parts with clean cover.
6) Be sure to use paper type cloth instead of fiber cloth to prevent cloth cuttings from attaching
the parts.
7) The disassembled parts (except for rubber parts) should be cleaned with kerosene, and blown
to dry or dried with paper or cloth.
2. Instruction for inspection, maintenance or replacement of components
1) Check the specified torque of fastener after the assembly.
2) After assembly of system, it is necessary to conduct necessary positioning inspection.
3) Disposable parts can't be reused.
4) Before Repair or Replace component, and completely inspect.
Preparation work
Use appropriate maintenance tools to remove and install.
1. General Tools
Table of Common Repair Tools
No.
Tools
Overall Diagram
Instructions
1
Power tool
Install and remove bolt and screw
J4 Service Manual
Drive System
DS-2
2. Special tool
Special Tool Table
No.
Tools
Overall Diagram
Code
Instructions
1
Move drawplate of drive link
JAC-T1D003
Remove connected bulb
Common fault diagnostic
Table of Common Failure Diagnosis
Fault Symptom
Fault Possible Cause
Countermeasures
Vehicle deviation
Knuckle of the drive shaft is worn-out
Replace
Wheel bearings are worn-out, frictional and make abnormal noise
Replace
Front suspension and steering are defective
Adjust or replace
Vibration
Drive shaft is worn-out, damaged or bent
Replace
Drive shaft and spline of the hub make abnormal noise
Replace
Wheel bearings are worn-out, frictional and make abnormal noise
Replace
Runout
Wheel unbalance
Adjust or replace
Front axle steering knuckle is defective
Adjust or replace
Noise is too big
Drive shaft is worn-out, damaged or bent
Replace
Spline of the drive axle hub is worn-out
Replace
Spline of the drive axle hub is worn-out
Replace
Wheel bearings are worn-out, burnt and make abnormal noise
Replace
Nut in the hub is loose
Adjust or replace
Front suspension and steering are defective
Adjust or replace
Front wheel hub and steering knuckle
1. Inspection in the car
Confirm whether each component is fixed (clearance) and worn properly and normally.
1) Inspection of wheel bearings
■ Push the wheel hub and bearing assembly along axial direction by hand to confirm the
wheel-hub bearing is not loosen. If any, please replace or reinstall bearings.
■ Rotate the wheel hub to confirm that no abnormal noise or any other abnormalities. If any,
please replace bearings.
J4 Service Manual
Drive System
DS-3
2. Removal and installation
1) Components
Disassembly diagram of front axle
1-Lower swing arm 2-Ball head 3-Brake caliper Fixing bolt 4-Dustproof cover 5-Hub assembly
6- Lock nut 7, 8, 9-Brake disc 10-Brake caliper 11-Steering knuckle 12-Shock absorber 13-Nut
14-Snap ring 15-Wheel bearing 16-Lower swing arm locking nut
2) Removal
① Lift the vehicle and remove the front tire. Please
refer to "Wheels and Tires".
② Remove the wheel speed sensor from the knuckle.
Please refer to "Wheel Speed Sensor".
■ Tightening torque: 8-10 N•m
Caution:
■ Do not pull the wire harness of wheel speed sensor.
■ While installing, check the gap between the wheel
speed sensor and the hub.
Clearance standard value: 0.5 mm
③ Release the set bolts of the brake hose and remove
the brake hose. Please refer to "Brake Line".
DS001
J4 Service Manual
Drive System
DS-4
④ Remove the front brake caliper assembly from the
knuckle, and hang and fix it. Please refer to “Front
Brake Caliper “.
■ Tightening torque: 65-75 N•m
Caution:
■ Do not depress the brake pedal after removing the
brake caliper.
⑤ Remove the brake disc stop screw from the hub and
take off the disc.
■ Tightening torque: 10-15 N•m
⑥ Loosen hub locking nut.
■ Tightening torque: 220-260 N•m
⑦ Hit the drive shaft gently with the hammer (or other
appropriate tool) and wooden block to disengage the
wheel hub from the steering knuckle assembly, and
then remove the lock nuts from the wheel hub.
Caution:
■ Support housing (universal joint group), shafts and
other components after putting down the drive shaft.
■ If you still cannot disengage the wheel hub from the
drive shaft after performing these operations, you can
use the puller (or other appropriate tool).
⑧ Remove the bulb of steering tie rod from the
knuckle.
Caution:
■ Special tools or right tools should be used to avoid
damaging the bulb dust cover.
⑨ Remove the shock absorbers from the knuckle and its
set bolts.
■ Tightening torque: 75-90 N•m
DS005
DS004
DS002
DS003
J4 Service Manual
Drive System
DS-5
⑩ Remove the drive shaft from the wheel hub.
Caution:
■ The angle to place the universal joints of the drive
shaft should not be too wide. Avoid overstretching
and prevent the gate from falling off.
⑪ Remove the lower swing arm bulb from the steering
knuckle. Please refer to "Lower swing arm".
■ Tightening torque: 60-72 N•m
Caution:
■ Special tools should be used to avoid damaging the
bulb dust cover.
⑫ Remove the wheel hub and steering knuckle assembly.
3) Inspection after removal
Caution:
■ Check the component for deformation, crack and other damages. Replace if any of the
above.
Check the dust cover of the tie-rod outer ball for damage, oversized axial clearance and
twisting. Please refer to the "Tie Rod".
4) Installation
■ Installation is in the reverse order of removal. Please refer to "Maintenance Parameters" for
information about the tightening torque.
Caution: do not use the damaged components.
■ When installing the tie-rod bulb, be sure to fix the bolt to avoid its rotation and then tighten
its nut.
■ In the case of no load, tighten each part removed when removing the front wheel hub and
steering knuckle to its final torque.
■ Check the wheel alignment. Please refer to "Inspection of front wheel alignment ".
■ Check if the wiring harness of the wheel speed sensor is connected correctly. Please refer to
"Wheel speed sensor".
DS007
DS006
J4 Service Manual
Drive System
DS-6
3. Disassembly and assembly
1) Disassembly
① Use internal snap ring pliers to remove the snap ring.
② Remove the hub and the dust helmet from the
knuckle.
③ Remove the wheel bearing inner ring from the hub.
④ Remove the wheel bearing outer ring from the
knuckle.
Caution:
■ To avoid personal injuries due to bearing slipping
off, be sure to operate as standardized.
■ Tightening torque: 80-100 N•m
■ If you still cannot disengage the steering knuckle
from the wheel bearing after several attempts,
replace the steering knuckle assembly.
2) Inspection after disassembly
① Steering knuckle
■ Check the contact surfaces between the steering knuckle and wheel bearing for scratch, crack
or other damage.
■ If any of these conditions, repair or replace it depending on the actual conditions.
② Brake disc
Check the brake disc surface for cracks and other damages.
③ Snap ring
■ Check the snap ring for crack or other damage.
Caution:
■ Do not use any damaged part.
④ The hub
■ Check if the hub bolts are elongated.
DS008
J4 Service Manual
Drive System
DS-7
■ Check the contact surfaces between the wheel hub and wheel bearing for scratch, crack or
other damage.
■ Replace or change if any of the above.
3) Assembly
① Apply moderate grease to the contact surface of the knuckle and wheel bearing.
② Press new wheel bearings into the knuckle and install a new snap ring.
Caution:
■ Do not press the wheel bearing inner ring, in case the wheel bearing assembly should be
damaged.
■ Model of left and right wheel bearing must be consistent.
■ Do not reuse the damaged components.
③ Install the dust cover.
④ Press the hub into the knuckle.
Caution:
■ Do not press the wheel bearing outer ring to avoid the wheel bearing assembly.
4) Inspection after assembly
■ Check if the hub and wheel bearing are installed in the right place.
■ Measure the bearing axial clearance.
Limiting value: 0.064-0.088 mm
Caution:
■ If the axial clearance exceeds the limit, please reassemble it.
4. Replacement of the wheel bearing
For information about removal and installation, please refer to the steps of “Front wheel hub
and knuckle”.
Caution:
■ Do not use any damaged part.
■ Check the left and right wheel bearing models for consistency.
■ Carry out necessary road test.
J4 Service Manual
Drive System
DS-8
Front drive shaft
1. Inspection and maintenance in the car
1) Check the drive shaft and universal joint for looseness and other damage.
2) Check the dust cover for crack and other damage.
Caution:
■ If the drive shaft produces noise or vibration, replace the drive shaft assembly.
2. Replacement of the drive shaft dust cover
1) Lift the vehicle and remove the front tire of vehicle. Please refer to "Wheels and tires".
■ Tightening torque: 90-110 N•m
2) Remove the wheel speed sensor from the steering knuckle. Please refer to "Wheel speed
sensor".
Caution:
■ Do not pull the wire harness of wheel speed sensor.
■ Tightening torque: 8-10 N•m
3) Remove the front brake caliper assembly from the knuckle, and hang and fix it. Please refer
to “Front brake caliper “.
Caution:
■ Do not depress the brake pedal after removing the brake caliper.
■ Tightening torque: 65-75 N•m
4) Remove the cotter pin and release the hub locknut.
■ Tightening torque: 220-260 N•m
5) Hit the drive shaft gently with the hammer (or other appropriate tool) and wooden block to
disengage the wheel hub from the steering knuckle assembly, and then remove the lock nuts
from the wheel hub.
Caution:
■ Support housing (universal joint group), shafts and other components after putting down the
drive shaft.
■ If you still cannot disengage the wheel hub from the drive shaft after performing these
operations, you can use the puller (or other appropriate tool).
6) Remove the bulb of steering tie rod from the knuckle.
Caution:
■ Special tools should be used to avoid damaging the bulb dust cover.
■ Tightening torque: 15-34 N•m
7) Loosen the set bolts and nuts of the shock absorbers and knuckle.
■ Tightening torque: 75-90 N•m
J4 Service Manual
Drive System
DS-9
8) Separate the drive shaft from the hub and bearing assembly.
Caution:
■ The angle to place the universal joints of the drive shaft should not be too wide. Avoid
overstretching and prevent the gate from falling off.
9) Remove the dust cover clamp.
10) Screw the drive shaft puller (or other appropriate
tool) into the screw hole of the universal joint
sub-assembly to pull out the universal joint
sub-assembly from the shaft.
Caution:
■ If you cannot pull out the universal joint
sub-assembly, remove the drive shaft assembly from
the car and then try it again.
11) Remove the snap ring from the drive shaft and the
dust cover.
12) Dry the grease on the universal joint sub-assembly
with paper towels.
13) Apply suitable amount of lubricating grease into the
tooth hole of universal joint until the lubricating
grease flows out of round slot and tooth hole. After
greasing, wipe off the outflow of the used grease
with clean cloth.
14) Wrap around the spline in tape to avoid damaging the
dust cover. Install the new dust cover and dust cover
clamp in the drive shaft.
Caution:
■ Do not reuse dust cover and dust cover clamp.
15) Remove the tape on the shaft.
16) Place the snap ring on the grooves along the edges of
the shaft. Make sure that the intermediate shaft at the
axis edge is in alignment with the universal joint
sub-assembly. And then, re-install the shaft to the
universal joint sub-assembly with the snap ring.
Caution:
■ Do not reuse the snap ring.
■ Special tools are recommended to install the snap
ring.
DS010
Sub-assembly
DS009
J4 Service Manual
Drive System
DS-10
17) Use a plastic hammer to mount the universal joint
sub-assembly on the drive shaft.
Caution:
■ Verify that the universal joint sub-assembly has been
properly engaged when rotating the drive shaft.
18) Apply a right amount of grease evenly to the dust
cover inside from its large-diameter side.
19) Mount the dust cover in the tank as illustrated in the
figure.
Caution:
■ If any grease sticks to dust cover mounting surface
(indicated by *), the boot can fall off. Wipe all the
grease on the surface of the dust cover.
20) Insert the flat-blade screwdriver into the dust cover
from the large diameter side to make its internal air
bleed out, and adjust its mounting length to avoid
deformation.
Caution:
■ If the mounting length of the dust cover is overlong,
it may damage the dust cover.
■ Use the flat-blade screwdriver with care, do not
touch the inside of the dust cover.
21) Fix the new dust cover clamp with a tool.
Caution:
■ Do not reuse the dust cover clamp.
22) Fix the universal joint sub-assembly and the drive shaft, and then confirm the correct
position in the case of the dust cover rotation.
Caution: if the dust cover has been installed improperly, please use a new boot clamp to reinstall
it.
23) Make sure that the snap ring at the transaxle side has been fully engaged.
24) Insert the drive shaft into the wheel hub and bearing assembly, and then tighten the lock nuts
of wheel hub.
25) Install the set bolts and nuts of the shock absorbers and knuckle.
26) Install the bulb of the steering tie rod and tighten the locknut according to the standard
tighten torque.
DS013
DS012
avoid Transformation of
dirt-proof boot
Slotted screwdriver
DS011
Sub-ass
embly
J4 Service Manual
Drive System
DS-11
Caution:
■ When installing, fix the bolt to prevent rotation before tightening the nut.
27) Install the brake caliper component and fasten the brake hose. Please refer to "Front brake”
and “Brake line".
28) Install the wheel speed sensor to the knuckle. Please refer to "Wheel speed sensor".
29) Tighten the locknut to standard torque.
■ Tightening torque: 220-260 N•m
30) Install the cotter pin.
Caution:
■ Do not reuse the cotter pin.
31) Install the tire and tighten it in accordance with standard torque. Please refer to “Service
Parameter “.
3. Removal and installation
1) Components
Diagram of Drive Shaft Assembly
2) Removal
① Lift the vehicle and remove the front tire. Please refer to "Wheels and Tires".
② Remove the wheel speed sensor from the knuckle. Please refer to "Wheel Speed Sensor".
Caution:
■ Do not pull the wire harness of wheel speed sensor.
③ Remove the front brake caliper assembly from the knuckle, and hang and fix it. Please refer
to “Front brake caliper “.
Caution:
■ Do not depress the brake pedal after removing the brake caliper.
④ Remove the brake disc.
⑤ Remove the cotter pin and release the hub locknut.
⑥ Hit the drive shaft gently with the hammer (or other appropriate tool) and wooden block to
disengage the wheel hub from the steering knuckle assembly, and then remove the lock nuts
from the wheel hub.
J4 Service Manual
Drive System
DS-12
Caution:
■ Support housing (universal joint group), shafts and other components after putting down the
drive shaft.
■ If you still cannot disengage the wheel hub from the drive shaft after performing these
operations, you can use the puller (or other appropriate tool).
⑦ Remove the bulb of steering tie rod from the knuckle.
Caution:
■ Special tools should be used to avoid damaging the bulb dust cover.
⑧ Loosen the set bolts and nuts of the shock absorbers and knuckle.
⑨ Remove drive shaft from the wheel hub and bearing assembly.
⑩ Remove drive shaft from the transmission side.
Caution:
■ When removing the drive shaft do not place the drive shaft universal joints in an excessive
angle. Do not stretching the slip joint excessively.
3. Inspection after disassembly
① Rotate the universal joint to check if it can move smoothly and for any serious loose.
② Check the dust cover for cracks, damage and grease leakage.
③ If any non-compliance occurs, disassemble the drive shaft and replace the faulty parts.
4) Installation
Caution:
■ When installing the drive shaft, replace the transmission side oil seal.
① Front drive shaft
■ Installation is in the reverse order of removal. For tightening torque, please refer to “Service
parameters”.
Caution: do not reuse non-reusable components.
■ Avoid damaging the oil seal when inserting the drive shaft into the transmission side.
Caution:
■ Confirm the snap ring of this side has been fully engaged.
■ Apply gear oil on to the drive shaft splines.
■ The opening of the snap ring should face down before installing the drive shaft.
J4 Service Manual
Drive System
DS-13
4. Disassembly and assembly
1) Components
Exploded view of drive shaft
1-Snap spring 2-Housing 3-Snap ring 4-Three-fork assembly 5-Anti-dust boot
6- Dust cover clamp. 7- Lock nut 8-Anti-dust cover 9-Wheel speed sensor gear ring
2) Disassembly
① Transmission side
a. Fix the drive shaft in the caliper.
Caution:
■ When fixing the drive axle in a vise, be sure to use
aluminum or copper plates to protect the drive shaft.
b. Remove the dust cover from the housing after removing the dust cover clamp.
c. Mark the housing and the drive shaft with assembly marks, respectively, and then pull the
drive shaft out from the housing.
DS014
Matching mark
5
6
7
2
3
4
5
6
2
9
8
1
J4 Service Manual
Drive System
DS-14
Caution:
■ Use paint or similar materials to mark. Please do not scratch the surface.
d. Remove the trigeminal assembly from the drive shaft
after removing the snap ring.
e. Remove the dust cover from the drive shaft.
f. Use paper towels to dry the old grease on the housing.
② Wheel side
a. Fix the drive shaft in the caliper.
Caution:
■ When fixing the drive shaft in a vise, be sure to use aluminum or copper plates to protect the
drive shaft.
b. Remove the dust cover clamp, then install the dust cover from the universal joint
sub-assembly.
c. Screw the drive shaft puller (or a suitable tool) into the thread of the universal joint
sub-assembly, and then pull away the universal joint sub-assembly from the drive shaft.
Caution:
■ If you fail to remove the universal joint sub-assembly even if trying several times, replace
the drive shaft assembly.
d. Remove the snap ring from the drive shaft and the dust cover.
e. Remove the dust cover from the drive shaft and the wheel speed sensor.
f. Turn the ball-and-cage, and wipe off the used grease on the universal joint sub-assembly
with paper towel.
3) Inspection after disassembly
① Drive shaft
Check the drive shaft for jumpiness, cracks and other damage. In case of any of the said
conditions, replace the drive shaft assembly.
a. The Universal Joint Sub-assembly (Wheel side)
Check the following item:
■ Check the universal joint sub-assembly for excessive rotation and check the drive shaft for
excessive loose.
■ Check the universal joint sub-assembly inside for entry of foreign matter.
DS015
Snap ring
J4 Service Manual
Drive System
DS-15
■ Check the universal joint sub-assembly for signs of press, crack and internal damage.
If you find any non-compliance, replace the universal joint sub-assembly.
b. Housing and trigeminal assembly (transmission side)
If you find any scratch or wear on the housing rolling contact surface or tri-yoke rolling
contact surface, be sure to replace the housing and tri-yoke assembly.
Caution:
Housing and trigeminal assembly are used in the same device.
② Dust cover and wheel speed sensor
■ Check for crack and other damage. Replace if any of the above.
4) Assembly
① Transmission side
a. Wrap the splines in the drive shaft with adhesive tapes to avoid damage to the dust cover.
Install the new dust cover and dust cover clamp in the shaft.
Caution: Do not reuse dust cover and dust cover clamp.
b. Remove the tape around the axle shaft spline.
c. When installing the trigeminal assembly, mark the
paint mark. Install the reversed shaft on the trigeminal
assembly
d. Fix the trigeminal assembly to the housing with the
snap ring.
DS018
Snap ring
DS017
Cross-shaft componentTo
Matching
mark
Matching
mark
Spline
Drive shaft
DS016
Adhesive
tape
J4 Service Manual
Drive System
DS-16
e. Coat the tri-yoke assembly and the sliding surface
with the recommended lubricant.
f. Install the housing to the tri-yoke assembly, and then
apply the recommended grease.
g. Mount clamps to the tank as illustrated in the figure.
Caution:
■ If the grease sticks to the fixed surface of the dust
cover, dust cover may fall off. Dry all grease on the
surface.
h. Hinder the flat-blade screwdriver into the dust cover
from the large diameter side to make its internal air
bleed out, and adjust its mounting length to avoid
deformation.
Caution:
■ If the mounting length of the dust cover is overlong, it
may damage the dust cover.
■ Use the flat-blade screwdriver with care, do not touch
the inside of the dust cover.
i. Use special tools to fix the new dust cover clamp.
Caution:
■ Do not reuse the dust cover clamp.
j. Fix the housing and the drive shaft, and then confirm the correct position when rotating the
dust cover.
Caution: If the dust cover has been installed improperly, please use a new boot clamp to reinstall
it.
k. Install the wheel speed sensor and the dust cover to the housing.
② Wheel side
Assemble in accordance with the Steps 14-23 of "Replacement of drive shaft dust cover".
Caution:
■ When installing, make sure that the universal joint sub-assembly and the drive shaft are
located at the same line.
■ When installing, make sure the wheel speed sensor and the housing have been fully engaged.
■ Press the boot before installing the wheel speed sensor.
DS019
To avoid Transformation
of dirt-proof boot
Slotted screwdriver
J4 Service Manual
Drive System
DS-17
Service Parameters
Fastening Torque Table
Item
Fastening Torque
(N·m)
Item
Fastening Torque
(N·m)
Drive shaft locknut
220-260
Connecting nut of rear cantilever
and rear steering knuckle
130-150
Connecting nut of steering knuckle
and shock absorber assembly
75-90
Bolts of retaining bracket roll bar
17-26
Bulb of down swing arm and
connect nut of knuckle.
60-72
The connect nut of stabilizer rod
and lever
35-45
Wheel nuts
90-110
Connecting nut between rear
cantilever and vehicle body
100-120
Rear-wheel hub bearing locknut
180-220
Rear cantilever eccentric nut
80-100
Connecting nut of rear shock
absorber and rear steering knuckle
75-90
Limit bolt of brake disc
10-15
J4 Service Manual
Suspension System
FSU-1
Chassis - Suspension system
Front suspension system
Schematic Diagram of Front Suspension Assembly
Precautions
■ When installing suspension or rubber bushing, it can be tightened finally only when the tires
shall be on the ground, without load.
■ After maintenance of suspension components, be sure to check the wheel alignment.
■ Oil has to shorten service life of rubber bushing. The flowed oil must be wiped away.
■ Idle condition means that fuel, engine coolant and lubricant has been filled, spare tire, jack,
driver's tool and foot pad are at specified position.
■ Do not reuse lock nut. Always use a new nut when installing. When replacing, before
tightening lock nut, do not wipe anti-rusting oil from lock nut.
Front stabilizer bar
assembly
Front hub bearing
assembly
Front stabilizer bar
mounting support
Front stabilizer bar
bushing
Front sub-frame
assembly
Front lower
swing arm
assembly
Front post assembly
Front stabilizer bar pulling
assembly
Front
steering
knuckle
assembly
J4 Service Manual
Suspension System
FSU-2
Preparation work
Special tools to be used are shown in following table:
Special Tool Table
No.
Tools
Overall Diagram
Code
Instructions
1
Move drawplate of
drive link.
JAC-T1D003
Removal of connected bulb
2
Removal machine of
damping spring
JAC-T1D004
Removal and installation of
damping spring
Front suspension assembly
1. Inspection in the car
Confirm whether each component is fixed (clearance) and worn properly and normally.
1) Check clearance of track rod
① Park the front wheel straight ahead.
② Place a crowbar (or similar tools) between track rod and knuckle.
③ Lever to check the clearance.
Caution:
■ Do not destroy dust cover of bulb.
■ Do not use excessive force to destroy the assembly part.
2) Inspection of shock absorber
Check if the assembly part is leaking, destroyed or worn-out.
2. Front wheel alignment check
1) Specification
Measure the wheel alignment in idle load.
2) Pre-inspection
Check the following item:
① Check if the tire pressure is normal and tire is worn-out.
② Check if the wheel jumps.
J4 Service Manual
Suspension System
FSU-3
③ The clearance of wheel bearing.
④ The clearance of track rod.
⑤ Check if the fixed points of axle and suspension are loose or out of shape.
⑥ Check if each suspending part, steering knuckle, shock absorber and tie rod are cracked,
deformed or damaged.
⑦ The height of vehicle body.
3. Check the toe-in of the front wheel
Caution:
■ Locate the wheel in level and idle condition.
■ The toe-in value of the front wheel: 0°±10′
If the above value is not within the standard, please adjust according to the following steps:
1) Check the above value on the four-wheel aligner.
2) Adjust and fix the steering wheel.
3) Loose the locknut at the end of track rod.
4) Rotate the left/right tie rod in clockwise/counter clockwise, and adjust the value of toe-in to
the standard value.
Caution:
■ The amount of rotating the tie rod shall be proper.
5) Lock the locknut at the end of track rod.
4. Check camber angle, rear caster angle and kingpin inclination.
Front-wheel camber: 0°±30′
Rear caster angle: 4°±30′
Kingpin inclination angle: 13°±30′
FSU002
FSU001
J4 Service Manual
Suspension System
FSU-4
Caution:
■ Camber angle, caster angle and toe-in angle of main pin are set before leaving factory, so do
not adjust them.
■ If camber angle, kingpin caster angle and kingpin inclination angle are out of standard range,
please check if front suspension, steering knuckle, shock absorber and tie rod are worn or
damaged. If any, replace any suspected components.
Front shock absorber
1. Components
Diagram of Front Shock Absorber Assembly
2. Removal and installation
1) Removal
① Remove the front tire.
② Disconnect the connector of wheel speed sensor.
Caution:
■ Do not pull the wire harness of wheel speed sensor.
③ Remove flexible brake hose card and cut off flexible
brake hose.
④ Remove self-locking nut of shock absorber and body.
■ Tightening torque: 21 -25 N•m
⑤ Remove set bolts and nuts of absorber and steering
knuckle.
■ Tightening torque: 110-130 N•m
FSU004
FSU003
J4 Service Manual
Suspension System
FSU-5
⑥ Take out shock absorber assembly.
2) Installation
Install it in the reverse order of removal
Caution:
■ Do not use any damaged part.
■ Under idle condition, completely tighten each part removed at the time of dismantling shock
absorber.
■ Check the wheel alignment.
3. Disassembly and assembly
1) Components
Front shock absorber stand column assembly exploded view
1-Self-locking nut 2-Upper support assembly 3-Plane bearing
4- Upper support saddle of the coil spring 5-Coil spring upper vibration isolation cushion
6-Dustproof cover 7-Shock absorber buffer block 8-Front coil spring
9-Coil spring lower vibration isolation cushion 10-Front shock absorber body
1
2
3
4
5
6
7
8
9
10
FSU005
J4 Service Manual
Suspension System
FSU-6
2) Disassembly
Caution:
■ Do not destroy piston push rod of shock absorber when removing components of shock
absorber
① Use spring compressor to compress coil spring until it is loose completely.
Caution:
■ Confirm the compressor is installed in the right position, and then compress coil spring.
■ When tightening spring compressor bolts, do not use pneumatic tools.
③ Fix the end of piston push rod and remove the locknut of piston push rod.
■ Tightening torque: 49-68.6 N•m
Caution:
■ Confirm compressed coil spring is slack.
④ Remove upper support saddle, vibration cushion of the coil spring, dust helmet and buffer
block.
⑤ Remove coil spring with a compressor, and then release the compressor slowly.
⑥ Remove down vibration cushion of the coil spring and remove the shock absorber.
3) Inspection after disassembly
① Shock absorber
Caution:
■ Whether the shock absorber has deformation, crack and damage. Replace it if any.
■ Check the piston push rod for damage, wear and deformation. Replace it if any of the above.
■ Check the piston for oil leakage. Replace it if any.
② Vibration cushion of the coil spring, buffer block and dust helmet.
Check if there is crackle and if the rubber components are worn-out. Replace it if any.
③ Coil spring
Check the coil spring for crack, wear and damage. Replace it if any.
④ Upper support saddle of the coil spring
Check for cracks, wear, deformation and other damage. Replace it if any.
⑤ Plane bearing
Check for cracks, wear, deformation and other damage. Replace it if any.
⑥ Upper support assembly
Check for cracks, wear, deformation and other damage. Replace it if any.
J4 Service Manual
Suspension System
FSU-7
4) Assembly
Installation is in the reverse order of removal.
Caution:
■ Do not destroy the piston push rod when assembling
the components on shock absorber.
■ Adown the larger diameter end and direct down
support saddle of the spring.
■ Be sure that compressor has assembled on the coil
spring before pressing coil spring.
■ Before releasing compressor, check if the mounting
position of the coil spring is correct.
■ Check if the auxiliary aiming mark is correct.
Lower swing arm
Removal and installation:
1) Removal
① Lift the vehicle and remove the wheel tire.
② Unplug cotter pin, and dismantle slot type nut fixing
lower swing arm ball pin and lower swing arm.
■ Tightening torque: 100-120 N•m
③ Unscrew off the fixing screws of lower swing arm
and sub-frame rear point.
■ Tightening torque: 100 -120 N•m
④ Dismantle fixing bolt of rear fixing point of lower
swing arm and auxiliary frame.
■ Tightening torque: 170-190 N•m
Caution: fix the lower swing arm ball joint and then
unscrew the locking nut to avoid rotation during removal.
⑤ Remove the lower swing arm assembly.
2) Inspection after disassembly
① Visual inspection
■ Check the bushing for wear or damage. Replace it if any.
■ Check if rear swing arm is deformed or destroyed. Replace it if any.
■ Check if dust cover of bulb or down swing arm cracks. Replace it if any.
■ Check all the set bolt and nut. Replace it if any damage.
FSU007
FSU006
Coil spring
Lower spring seat
Place spring onto
proper position.
J4 Service Manual
Suspension System
FSU-8
3) Installation
Install it in the reverse order of removal
Caution:
■ Do not use any damaged part.
■ Pre-tighten the bolt between front rubber sleeve of lower swing arm and set bracket to avoid
the rubber sleeve from deforming.
■ Under idle condition, tighten each part removed at the time of dismantling lower swing arm.
■ Check the wheel alignment.
Lateral stabilizer bar
Removal and installation:
1) Removal
① Disassemble the fixing nut of front left & right
stabilizer bar link connecting ball and front pillar
assembly.
■ Tightening torque: 55-65 N•m
② Disassemble the fixing nut on front left & right
stabilizer bar link connecting ball and front stabilizer
bar assembly.
■ Tightening torque: 55-65 N•m
③ Remove the set screw bolt of left and right stabilizer
rod and dissemble fixed frame and bush.
■ Tightening torque: 45-55 N•m
④ Remove the stabilizer rod assembly.
2) Inspection after disassembly
Check if stabilizer bar, connection ball of stabilizer bar, support structure of stabilizer bar
and stabilizer bar bushing are deformed and worn. Replace it if any.
■ Move the bulb stud manually to see if it is flexible.
■ Check if the dustproof shield of stabilizer rod has crack and grease leakage. Replace it if any.
3) Installation
■ Install it according to the reverse order of dismantling.
■ When tightening lock nut, first fix bolts of horizontal stabilizer rod and avoid rotating it.
Caution:
FSU009
FSU008
J4 Service Manual
Suspension System
FSU-9
■ Do not reuse non-reusable components.
■ When assembling bush and fixed frame of stabilizer rod, note the direction.
■ Under idle condition, tighten each part removed at the time of removing front stabilizer rod.
Front sub-frame assembly
1. Components
Front sub-frame component diagram
2. Removal and installation
1) Removal
① Lift the vehicle and remove the tires.
② Disassemble the steering column assembly and steering shaft U-joint screws.
③ Unscrew off the fixing bolts of engine rear mounting with the front sub-frame.
④ Fixing bolts of sub-frame with front vehicle body point.
■ Tightening torque: 170-190 N•m
⑤ Fixing bolts of sub-frame with rear vehicle body point.
■ Tightening torque: 170-190 N•m
Take down front sub-frame assembly.
2) Inspection after disassembly
■ Check if sub-frame has clack
J4 Service Manual
Suspension System
FSU-10
Fault diagnosis
Table of Common Failure Diagnosis
Fault Symptoms
Fault Possible Cause
Countermeasures
Steering heaviness
Wheel alignment is improper
Adjust
Rotation beyond the ball joint of lower arm
Replace
Tire pressure is too low
Inflation
W/O power steering
Repair or replace
Return is poor
Wheel alignment is improper
Adjust
The absorber is faulty.
Repair or replace
Wear or damage to stabilizer bar
Replace
Coil spring is worn-out or destroyed.
Replace
Worn lower swing arm bushing
Replace
The tire is worn out abnormally.
Wheel alignment is improper
Adjust
The air pressure is lower or higher.
Adjust the air
pressure
The absorber is faulty.
Repair or replace
Vehicle deviation
Wheel alignment is improper
Adjust
Lack of resistance for bulb connection of down swing
arm.
Replace
Bush of down lower swing arm loose or worn-out.
Replace
The vehicle runs biased to a single
side
Wheel alignment is improper
Adjust
Lack of resistance for bulb connection of down swing
arm.
Replace
lower swing arm is bent
Replace
Coil spring is worn-out or destroyed.
Replace
Steered wheel vibration
Wheel alignment is improper
Adjust
Lack of resistance for bulb connection of down swing
arm.
Replace
Bush of down lower swing arm loose or worn-out.
Replace
The absorber is faulty.
Repair or replace
Wear or damage to stabilizer bar
Replace
Coil spring is worn-out or destroyed.
Replace
Vehicle declines.
Coil spring is worn-out or destroyed.
Replace
The absorber is faulty.
Repair or replace
J4 Service Manual
Suspension System
FSU-11
Maintenance data and specification
Technical Specification Table
Items
Parameter and Specification
Front suspension from
Coil spring with independent suspension in Mac Pherson style.
Shock absorber
Type
Two-way hydraulic drum
Stroke
168 mm
Damping
force
Stretch
1115 N ± 165 N (0.3 m/s)
Compression
355 N ± 77 N (0.3 m/s)
Coil spring
Free height: 329±5 mm
Color mark: a white line with a
yellow line.
Wheel
alignment
Toe in (Front)
0°±10′
Camber angle of wheel
0°±30′
Inner caster angle
13°±30′
Rear caster angle
4°±30′
Kingpin offset
9.7mm
Fastening torque table
Item
Torque (N·m)
Fixing bolt of front lateral stabilizer bar mounting support and sub-frame
45-55
Front lateral stabilizer bar and lateral stabilizer bar pulling rod
connecting nut
55-65
Connecting nut of front lateral stabilizer bar pulling rod and front post
assembly
55-65
Nut of front shock absorber and body assembly
21-25
Front shock absorber upper self-locking nut
49-68.6
Front shock absorber and steering knuckle connecting bolt
100-120
Lower swing arm ball pin and steering knuckle connecting bolt
100-120
Lower swing arm ball pin and lower swing arm connecting nut
100-120
Lower swing arm front bushing and sub-frame connecting bolt
170-190
Lower swing arm rear bushing and sub-frame connecting bolt
100-120
Front sub-frame front fixing nut
170-190
Front sub-frame rear fixing bolt
170-190
J4 Service Manual
Suspension System
FSU-12
Rear suspension system
Precautions
■ When installing the suspension, it can be tightened finally only when the tires shall be on the
ground, without load.
■ After maintenance of suspension components, be sure to check the wheel alignment.
■ When installing rubber bushing, it can be tightened finally only when the tires shall be on the
ground, without load.
■ Oil has to shorten service life of rubber bushing. The flowed oil must be wiped away.
■ Idle condition means that fuel, engine coolant and lubricant has been filled, spare tire, jack,
driver's tool and foot pad are at specified position.
■ Do not reuse lock nut. Always use a new nut when installing. When replacing, before
tightening lock nut, do not wipe anti-rusting oil from lock nut.
Preparation work
Common and special repair tools are shown in table below:
General Tools Table
No.
Tools
Overall Diagram
Instructions
1
Power tool
Installation and removal of bolt and screw
J4 Service Manual
Suspension System
FSU-13
Rear suspension assembly
1. Component
Diagram of Rear Suspension Assembly
2. Inspection in the car
Confirm whether every component is fixed (clearance and looseness) and its condition (be
worn-out or damaged).
Check if shock absorber and mounting position has oil leakage or damage.
3. Inspection of rear wheel alignment
Caution:
■ Toe-in angle and camber angle are set before leaving factory, so do not adjust them.
■ After the abrasion and loosening of relevant parts of rear suspension, it is necessary to Check
if the rear wheel alignment parameters meet requirement. If no, please replace relevant
deformed and worn parts.
■ Standard value:
Toe-in of rear wheel: 19′±10′
Rear-wheel camber: -1°±30′
1) Specification
Measure the wheel alignment in idle load.
2) Pretest
Check the following contents:
① Check if the tire pressure complies with standards and whether the tire is worn-out.
② Check if the wheel jumps.
Rear torsional
girder assembly
Rear absorber
assembly
Rear coil
spring
Lower rubber
cushion of
rear-spring
Rear hub unit
assembly
Upper rubber
cushion of
rear-spring
J4 Service Manual
Suspension System
FSU-14
③ The clearance of wheel bearing.
④ Check if all the components as well as fixed points are loose.
⑤ Control the performance of shock absorbers.
⑥ Check if each cantilever is flawed, deformed and damaged.
⑦ Vehicle height.
Rear shock absorber
1. Components
Rear shock absorber assembly component diagram
1-Self-locking nut 2-Upper mounting vibration isolation pressure pad
3-Upper mounting plate of rear reducer 4-Limiting seat 5-Buffer block 6-Dustproof cover
7-Rear shock absorber body
2. Removal and installation
1) Removal
① Lift the vehicle and remove the wheel tire.
② Remove connecting bolt of shock absorber and body.
■ Tightening torque: 45-55 N•m
③ Remove shock absorber and rear torsional girder.
■ Tightening torque: 100-120 N•m
FSU009
1
2
3
5
7
6
4
J4 Service Manual
Suspension System
FSU-15
2) Inspection after removal
① Shock absorber
■ Check if the shock absorber is leaking. Replace it if
any.
■ Check if the piston push rod is damaged, worn-out or
deformed. Replace it if any.
② buffer block, dust helmet
Check the buffer block and dust cover for abrasions
and damages. Replace it if any.
③ Upper mounting plate of rear reducer
■ Check rear shock absorber upper mounting plate for
abrasions or damages. Replace it if any.
④ Limiting seat, upper mounting vibration isolation
pressure pad
■ Check if limit seat, upper mounting shock absorption
cushion have abrasion or damage. Replace it if any.
3) Installation
Install it in the reverse order of removal
Caution:
■ Do not use any damaged part.
■ Under idle condition, completely tighten each part removed at the time of dismantling shock
absorber.
■ Check the wheel alignment.
Rear coil spring
1) Removal
① Remove the connecting screw of rear shock absorber
with rear torsion beam.
Tightening torque: 100-120 N•m
② Remove upper rubber soft cushion of rear spring, rear
spiral spring and lower rubber soft cushion of rear
spring.
FSU011
FSU010
J4 Service Manual
Suspension System
FSU-16
Caution:
During dismantling, pay attention to sudden falling of
spring, and avoid personnel injuries!
2) Inspection after disassembly
① Upper rubber cushion of rear spring, Lower rubber
cushion of rear spring
■ Check if the upper support cushion of rear spring and
lower support cushion of rear spring have abrasion or
damage. Replace it if any.
② Coil spring
■ Check if spiral spring has abrasion or damage.
Replace it if any.
3) Installation
Install it in the reverse order of removal
Caution:
■ Do not use any damaged part.
■ When installing lower support cushion of spring, it is necessary to align rubber round
cylinder of lower support cushion with corresponding support plate hole of spring on the rear
torsion beam, and install them on proper positions.
■ Adown the larger diameter end and direct down support plate of the spring.
■ Check if the auxiliary aiming mark is correct.
■ On no-load condition, conduct final tightening to each part.
■ Check the wheel alignment.
Rear torsional girder assembly
1. Components
Diagram of Rear Torsional Girder Component
FSU012
J4 Service Manual
Suspension System
FSU-17
2. Removal and installation
1) Removal
① Remove connecting bolt of rear torsional girder and shock absorber.
■ Tightening torque: 100-120 N•m
② Use a jack to support rear torsion beam assembly.
Caution:
■ During dismantling, it is not allowed to let the jack slide.
③ Remove fixing bolt between rear torsional girder and body.
■ Tightening torque: 100 -120 N•m
2) Installation
Install it in the reverse order of removal
Caution:
■ Do not use any damaged part.
Fault diagnosis
Table of Common Failure Diagnosis
Fault Symptom
Fault Possible Cause
Countermeasures
Abnormal sound
Loose assembly
Fasten
Fatigued or damaged wheel bearing
Replace
Damaged shock absorber assembly
Replace damaged component
Defective tire quality
Replace
Vibration
Excessive tire pressure
Adjust the pressure
Damaged shock absorber assembly
Replace damaged component
Loosen tire nut
Tighten
Shortened or broken coil spring
Replace
Defective tire quality
Replace
Body inclination
Shortened or broken coil spring
Replace
J4 Service Manual
Suspension System
FSU-18
Maintenance data and specification
Technical Specification Table
Item
Parameter and Specification
Rear suspension form
Torsion beam type
Shock absorber
Type
Two-way hydraulic drum
Stroke
223mm
Damping force
Stretch
635N±102.5N (0.3m/s)
Compression
265N±62.5N (0.3m/s)
Coil spring
Type
Spiral straight spring
Free height
335±5mm
Color mark
One write or one yellow
Wheel alignment
Toe in (Rear)
19′±10′
Camber angle of wheel
-1°±30＇
Fastening torque table
Item
Tightening torque (N·m)
Bolt of rear shock absorber and body assembly
45-55
Upper self-locking nut of rear shock absorber
24.5-34.3
Connecting bolt of rear shock absorber and rear torsional girder
100-110
Bolt of rear torsional girder and body assembly
100-110
J4 Service Manual
Brake System
BR-1
Chassis - Brake system
Wheel & Tire
Precautions
■ Please use the original wheel.
■ During the period of new tires, a sudden starting, turning and braking shall be avoided to
prevent new tires from early damage under severe working conditions.
■ A new tire shall be subject to wheel balancing before use.
Tire
1) Inspection
1. Check air pressure.
① Check the tire inflation pressure. Adjust if not within
the standard range.
Standard value: 240±10 KPa
Caution:
■ Use a tire pressure gage of excellent quality to check
tire pressure.
■ Check if wheels are worn, aerated incorrectly, cracked
or otherwise damaged.
■ When ambient temperature varies largely, check tire
pressure frequently.
② Incorrect tire pressure may cause:
a. Insufficient pressure will cause quick wear to tire
shoulder, tire deflection and increase rolling
resistance.
b. Excessive pressure will cause quick wear to tire crown
and decreased tire buffer capability.
BR002
BR001
J4 Service Manual
Brake System
BR-2
2) Check incorrect positioning.
If the front wheel toe-in or the rear wheel toe-in is too large
or too small, it will affect the feather-like wear of tires.
3. Tire tread check.
① Check the tire tread depth.
Caution: Tire specification 185/65R15 88H
■ When the tire tread depth reaches the limit or less, the
wear indicator will appear on the tire tread pattern.
When the wear indicator appears, please replace the
tire.
② Check the tire tread pattern for foreign matters. Please
clear away if any.
4) Check the wheel for cracks and other damages. If
deformed, please check the wheel run-out.
① Remove the tire from the wheel, and install on the tire
balancer.
② Set the micrometer in the position as shown in the
figure.
For wheel runout, please refer to the "Maintenance data
and specification". If the total runout exceeds limit value
(see "repair data and specification" in wheel and tire),
please replace it.
BR006
Transverse run
out
Radial
runout
mount
BR005
BR004
Inner side
Toe-in is too slightly worn
Toe-in is too slightly worn
BR003
Inner side
Toe-in is too badly worn
J4 Service Manual
Brake System
BR-3
2) Rotation
■ The tire rotation shall be carried out when the vehicle
travels every 8,000 km. Perform tire rotation when
replacement a new tire.
Caution: Please refer to the table for tire rotation
recommended.
3. Replacement
① When the vehicle travels 50,000 km, the tires shall be replaced.
② If there is one of the following conditions, the tire shall be replaced as well:
■ The wear indicator appears at 3 or more positions on the tire tread pattern.
■ The cord or cord line appears in the tire rubber.
■ The tire tread or shoulder is cracked, and the cord ply appears.
■ The tire is bulged, swelled or layered.
■ The tire has punctures, scratches or other damages, and its damage degree is difficult to
repair.
Wheel tire assembly
1. Removal and installation
1) Dismantle
① Remove wheel nuts.
■ Tightening torque: 90-110 N•m
② Remove wheel tire assembly.
2) Install
Install wheel tire assembly and tire nuts.
Caution:
■ Pre-tighten orderly and tighten evenly in a diagonal
order for manual installation.
■ In case of automatic tightening, adjust the tightening
torque and tighten once.
■ Tighten all wheel nuts faithfully in the order shown in
the drawing.
BR009
BR008
BR007
J4 Service Manual
Brake System
BR-4
2. Wheel Balance
1) Dismantle
① Remove the wheel tire needed to be adjusted.
② Remove the old balance weights of the wheel at both side, and remove foreign matters from
the tire tread pattern.
Caution:
■ Be careful not to scratch the wheel during disassembly and installation.
■ Remove the tape from the tires if they are new.
2) Adjustment of wheel balance
① Install the wheel onto a balancing machine oriented to the central hole and then start the tire
balancing machine.
② When the imbalance value on both sides is displayed on display screen of wheel balancer,
select balance weight with weight of near displayed value to install on both sides of the
specified wheel.
Caution:
■ Install the outside balance weight first, and then the inside balance weight.
■ Clear the fitting surface of wheel before installing balance weight.
a. Install balance weights in the positions as shown in the
figure.
b. When installing balance weight to wheels as shown on
the right figure, it shall be put in the slot area on the
inner wall so that the center of balance weight is
aligned to the position (or angle) shown on wheel
balancer.
c. If the calculated weight of balance weights exceeds 50g, install two balance weights on a
straight line.
Caution:
■ Balance weight can't be used repeatedly. It shall be replaced every time.
BR011
Indicator position of vehicle
balancing machine (angle)
Indicator position of
vehicle balancing
machine (angle)
BR010
40g Adhesive
weight
Align with
groove
Indicator position of wheel
balance weights (angle)
Center of gravity
J4 Service Manual
Brake System
BR-5
■ Number of installed balance weights is no more than three.
■ Always use the original balance weights.
■ Do not put one balance weight on another.
③ Start the wheel balancer again.
④ Hammer balance weight in the inside of wheel according to the position (or angle) indicated
by wheel balancer.
⑤ Start the balancer, and make sure that the rest imbalance value on both sides is only 5g or
less. If the rest imbalance value on any side exceeds 5g, repeat the installation procedures of
balance block.
Tire pressure monitoring
System warning mode
High voltage alarm mode
If tire pressure value is higher than 125% of standard value, system will send high pressure
warning information. Warning mark lamp
on the instrument will light up constantly, while
TPMS warning light will go out constantly. If no operation is conducted, the system will keep
warning. If recovering normal pressure value, after the controller receives normal data meeting
required package, warning mark lamp on the instrument goes out, while TPMS warning light
lights up constantly.
Low voltage alarm mode
If tire pressure value is lower than 75% of standard value, system will send high pressure warning
information. Warning mark lamp on the instrument will light up constantly, while TPMS
warning light will go out constantly. If no operation is conducted, the system will keep warning. If
recovering normal pressure value, after the controller receives normal data meeting required
package, warning mark lamp on the instrument goes out, while TPMS warning light lights up
constantly.
High temperature alarm mode
If tire temperature value is higher than high-temp standard value 85°C , system will send high
temperature warning information. Warning mark lamp on the instrument will light up
constantly, while TPMS warning light will go out constantly. If no operation is conducted, the
system will keep warning. If recovering normal tire temperature value, after the controller
receives normal data meeting required package, warning mark lamp on the instrument goes
out, while TPMS warning light lights up constantly.
For quick air leakage warning mode, when pressure of some tire lowers to more than 30KPa
within 1min, the system will treat quick air leakage warning information. Warning mark lamp on
the instrument will periodically light up or go out, while TPMS warning light goes out
constantly. If no operation is conducted, the system will keep warning. If at this moment, the tire
pressure doesn't change or pressure rises up, after the controller receives normal data meeting
specified package, warning mark lamp on the instrument goes out, while TPMS warning light
goes out constantly. For low electricity warning mode, when sensor battery has low amount of
electricity, the system will treat the low electricity warning information, and warning mark lamp
J4 Service Manual
Brake System
BR-6
on the instrument goes out constantly; while TPMS warning light lights up constantly. If no
operation is conducted, the system will keep warning. If at this moment, after pressure sensor of
tire sends normal data frame to the controller and the controller receives normal data meeting
specified package, warning mark lamp on the instrument goes out constantly; while TPMS
warning light goes out.
For sensor losing mode, under normal traveling condition, if the information is not received
from one or more sensors (within two) of the system within 5min while other sensors are normal,
the system will judge the sensor which doesn't send information is losing or damaged, and the
system will treat the sensor losing warning information. Warning mark lamp on the instrument
goes out constantly; while TPMS warning light lights up constantly. If no operation is conducted,
the system will keep warning. If at this moment, the controller receives normal data frame from
the pressure sensor of relevant losing tire, after the controller receives normal data meeting
specified package, warning mark lamp on the instrument goes out constantly, while TPMS
warning light goes out. Alarm indicator light
After the vehicle is switched on and started and under the condition that tire pressure is normal,
the warning indicator lamp of tire pressure monitoring system
and TPMS will go out
constantly. When there is any fault or specified operation is conducted, indicator lamp will light
up to indicate current condition and indication of detailed warning indicator lamp.
Significance as following table:
TPMS Condition
Condition
Alarm
Level
Status of ω and PMS
Remarks
The system has no
fault currently.
During driving
/
TPMS warning light goes out,
ω warning light goes out.
Quick leakage
alarm
Vehicle during
driving
Primary
TPMS warning light goes out,
ω warning light is flashing
rapidly (frequency of 2Hz).
High pressure
alarm, Low
pressure alarm,
High temperature
alarm
Vehicle during
driving
Secondary
TPMS warning light goes
out, ωwarning light lights
up constantly.
Sensor failure,
alarm of low
electric quantity
for sensor
Vehicle during
driving
Three-level
TPMS warning light goes out,
ω warning light goes out.
Tire pressure
controller and
instrument
communication are
switched off.
When is energized
to start
Three-level
TPMS warning light goes out,
ω warning light goes out.
TPMS do not
complete sensor
study
When is energized
to start
/
TPMS and ω light up for 2 s
at the same time and then go
out.
TPMS complete
sensor study
When is energized
to start
/
TPMS warning light goes out,
ω warning light goes out after
2s.
J4 Service Manual
Brake System
BR-7
TPMS Condition
Condition
Alarm
Level
Status of ω and PMS
Remarks
TPMS goes into
the sensor study
mode
After the switching
on of vehicle's
ACC
/
Ω and TPMS lights light up
constantly.
Go into sensor study
mode handed with tool
uniformly
TPMS completes
sensor study and
exits study mode
After the switching
on of vehicle's
ACC
/
TPMS and ω warning lights
go out at the same time.
Complete study
uniformly handed with
tool
J4 Service Manual
Brake System
BR-8
Operating instructions
Learning TPMS sensor
This function is used when sensor and controller equipment are required to be combined, such as
offline study, replacement of new sensor, loss of communication between sensor and display
screen, etc.
Operation steps
Step 1: park the combined vehicle to the specified position, and power up vehicle ACC.
Step 2: use a hand tool to select "uniform combination" under "sensor combination" mode, and
then press "confirm" key to send it. The controller receives command and enters into combination
mode. warning light and TPMS light up constantly.
Step 3: Under the condition the hand tool is in "TPMS offline distribution" mode, In sequence
activate them and read tire sensor ID on relevant vehicle position according to the sequence of
(left front → right front → right rear → left rear) shown in screen.
Step 4: operator enters into the vehicle and close the door.
Step 5: hand tool points at tire pressure controller (Caution: different tire pressure controller has
different installation positions on actual vehicle. When combining or deleting sensor ID, it is
necessary to point at different position of the controller on the vehicle), and press "confirm" key
to combine them. the system will finish combination within 10s. After successful combination,
warning light and TPMS will go out.
Step 6: switch off vehicle's ACC and then power up it again. At this moment, after successful
combination, vehicle warning light will light up for 2 s and go out, and TPMS will go out
constantly.
Caution: if the study doesn't finish within 10s after pressing "confirm" key in step 5 and warning
light doesn't go out, please repeat step 4 and 5 to finish combination.
Precautions
■ The operator must finish deleting and combination operation inside vehicle, and the door
must be closed (use the shield of vehicle body to reduce outer radiation).
■ Hand tool should point at tire pressure controller, and keep 1m away from controller.
■ Make sure that all vehicles except for current vehicle stop (ACC stop), or keep other vehicle
at least 2m away from current vehicle (distance of two window glass).
■ It is forbidden to use hand tool except for combination of tire pressure, to avoid misoperation
(such as misoperation of deleting some sensor). Emission distance of hand tool is easy to be
affected by battery power and barrier shield. Please timely charge power. During
combination, make sure that there is no other object between hand tool and tire pressure
controller.
J4 Service Manual
Brake System
BR-9
Fault diagnosis
Table of Common Failure Diagnosis
Fault Symptom
Fault Possible Cause
Countermeasure
Circular vibration of steering wheel
Over-deflection of tire and rim
Wheel nuts loosened
Tire unbalance
Tires worn unevenly
Short tire pressure
Front wheel bearing damaged or worn
Fault of steering system
Fault of suspension system
Replace
Locking
Adjust
Adjust or replace
Adjust
Adjust or replace
Adjust or replace
Adjust or replace
Early wear to tires
Incorrect tire pressure
Adjust
Tire noise
Incorrect tire pressure
Tire deterioration
Adjust
Replace
Road noise or body vibration
Short tire pressure
Tire unbalance
Rim or tire deformation
Tires worn unevenly
Adjust
Adjust
Repair or replace
Adjust or replace
Vertical vibration of steering wheel
Over-deflection of tire and rim
Wheel nuts loosened
Tire unbalance
Engine foot rubber worn or fractured
Rubber of transmission bracket is fractured or worn.
Replace
Locking
Adjust
Replace
Replace
Steering wheel biased to one side
Incorrect tire pressure
Tire worn excessively or unevenly
Fault of steering system
Fault of braking system
Fault of suspension system
Adjust
Adjust or replace
Adjust or replace
Adjust or replace
Adjust or replace
Instable service of vehicle
The tire pressure on both sides is uneven.
Rim or tire deformation
Wheel nuts loosened
Fault of steering system
Fault of suspension system
Adjust
Repair or replace
Locking
Adjust or replace
Adjust or replace
Braking biased to a side
The tire pressure on both sides is uneven.
Fault of braking system
Adjust
Adjust or replace
Steering wheel feels heavy
Short tire pressure
Fault of steering system
Fault of suspension system
Adjust
Adjust or replace
Adjust or replace
Steering wheel returning incorrectly
Short tire pressure
Fault of steering system
Fault of suspension system
Adjust
Adjust or replace
Adjust or replace
J4 Service Manual
Brake System
BR-10
Maintenance data and specification
Technical Specification Table
Item
Parameters
Wheel pulsation
Radial
The steel wheel
0.6 mm
The aluminum wheel
0.3 mm
Axial
The steel wheel
1.0 mm
The aluminum wheel
0.3 mm
Tire pressure (cold state)
240±10 KPa
Tire specification
185/65R15 88H
Fastening torque table
Item
Tightening torque
Wheel nuts
90-110 N•m
Service braking
Precautions
■ It is recommended to use “DOT4” brake fluid.
■ Do not reuse the brake fluid discharged.
■ Do not spray brake fluid on the paint surface, so as to protect paint. If it is splashed on the
paint surface, wash with clean water immediately.
■ Wash all brake cylinder components with clean brake liquid.
■ Please do not use mineral oil such as gasoline or kerosene, to avoid damage of rubber part in
hydraulic system.
■ When removing and installing oil pipe, please use special oil pipe wrench.
■ When installing the brake oil pipe, make sure to check the tightening torque.
■ If the brake is soft after repairing or replacing the brake disc and brake shoe, or when
traveling for a short distance, it is necessary to grind brake combination surface.
■ Make sure that there is no brake fluid on the brake disc. Please do not spray brake fluid onto
the brake disc; otherwise, it may cause brake failure.
J4 Service Manual
Brake System
BR-11
Preparation work
Use special service tools to remove and install if necessary.
Maintenance tool list
No.
Tools
Overall Diagram
Instructions
1
Oil pipe wrench
Remove and install the brake oil pipe
2
Power tool
Remove and install the bolts and nuts
Brake pedal
1. Inspection and adjustment
Adjustment of clearance between brake pedal and brake
limit switch bolt:
1) Remove driver side lower guard board assembly.
2) Disconnect brake lamp switch connector and loosen
nut of brake limit switch and release brake pedal, and
rotate switch bolt to keep the clearance between
switch bolt and brake pedal 0.5mm-1mm.
■ Tightening torque: 8-10 N•m
2. Brake pedal free stroke
1) Under the condition that the engine stops, step brake
pedal for 2-3 times.
2) Confirm that the vacuum of the brake vacuum booster
is eliminated, and press the pedal with hand.
3) Confirm that the free travel of the pedal is within the
standard range before the resistance appears.
■ Standard value: 3mm-8mm
4) If the free travel exceeds the standard range, adjust.
Caution:
■ If the free travel cannot be adjusted within the range, replace the damage parts.
BR013
BR012
Lock nut
Brake pedal gear
J4 Service Manual
Brake System
BR-12
3. Removal and installation
1) Removal
① Remove driver side lower guard board assembly.
② Disconnect the brake light switch connector.
③ Remove the lock pin connected with the brake
vacuum booster, and disconnect from the brake
vacuum booster.
④ Remove the set bolts of the brake pedal and body, and
the set screw nuts of the brake pedal and brake
vacuum booster.
■ Tightening torque: 20-25 N•m
⑤ Take the brake pedal out.
2) Inspection after removal
① Brake pedal
■ Check the movable pin of the brake pedal for wear or deformation.
■ Check the brake pedal for cracks, twisting or other damages.
② Lock pin and bush
■ Check the lock pin and bush is damaged or deformed, and replace it if any.
③ Brake light switch
a. Use the multimeter to measure whether 2 terminals of the brake light switch are on while
pressing and releasing the brake light column.
b. As shown in figure, the terminals are off when the
column is pressed more than 4 mm and they are on
when releasing, so that the brake light switch is in
working order.
BR016
Non-conducting
Conducted
BR015
BR014
J4 Service Manual
Brake System
BR-13
3) Installation
Install it according to the reverse order of removal.
Caution:
■ Check if the brake pedal works smoothly.
■ Check brake pedal free stroke.
■ Check the clearance between the brake pedal and
brake light switch.
Brake master pump
1. Inspection in the car
Check if master pump installing face, oiler installing face
and brake pipe joint leak.
2. Removal and installation
1) Dismantle
① Drain the brake fluid.
② Remove brake fluid level switching connector.
③ Disconnect the master cylinder brake pipe with an oil
pipe wrench.
■ Tightening torque: 16-18 N•m
④ Remove the brake master cylinder to clutch master
cylinder connecting pipe and the master cylinder set
screw nut, and then remove the master cylinder
assembly.
Caution:
■ Do not bend or damaged brake pipeline.
2) Installation
Caution:
■ Before installation, apply grease on the master cylinder: -SAE J31 0, NLGI No2 or
equivalent.
BR019
BR01
8
BR017
J4 Service Manual
Brake System
BR-14
① Install the master cylinder assembly on the brake vacuum booster, and tighten the nut.
Caution:
■ Do not damage the sliding surface of the piston push rod. Do not make foreign matters fall
on the surface.
② Install the brake pipe on the master cylinder assembly, and pre-tighten.
③ Tighten the brake pipe nut with oil pipe wrench or equivalent.
④ Install the brake fluid level switch connector.
⑤ Add Fresh brake fluid and emit air.
Brake fluid
1. Check the height of brake fluid level
Check if brake fluid level in the oiler is between MIN and
MAX. If the level is too low, check if the oiler and brake
system leak.
2) Start the vehicle, release parking handle and see if brake warning light goes out. If it doesn't
go out, check if parking brake switch or brake fluid level switch is faulty.
Brake pipeline
Hydraulic pipeline diagram
Schematic Diagram of Hydraulic Pipe
1- Brake master pump 2- ABS module assembly
Caution:
■ All braking oil pipes must not be excessively bent, twisted and tensioned.
■ Make sure that all brake pipes will not clash with other parts when the vehicle is stationary
or turning.
■ The brake oil pipes are the most important safety parts. If there is brake fluid leakage, always
BR020
J4 Service Manual
Brake System
BR-15
tighten the retaining device. If any damaged parts found, please replace it with new
appropriate parts.
■ When disconnecting brake pipe, please seal the joint end to avoid dust entering.
Front brake pipe and hose
1) Removal
① Remove the tire.
② Remove the bolts from brake hose.
Caution:
■ Pay attention to the falling of copper washer.
■ Tightening torque: 25-30 N•m
③ Remove the brake hose and brake pipe joint with oil
pipe wrench, and take down the clamping plate.
■ Tightening torque: 16-17 N•m
④ Remove from the front shock absorber the fixing bolts
in the middle of brake hose.
⑤ Take the brake hose and brake pipe down.
2) Installation
Install it in the reverse order of removal.
Caution:
■ Do not reuse the gasket and oil pipe washer.
■ Note the installation direction of the brake hose joint.
■ Refill the braking liquid and release air.
BR024
BR023
J4 Service Manual
Brake System
BR-16
Rear brake pipeline and brake hose
1) Removal
① Disassemble the joint of rear braking hose with
both-end braking tube, and take the pad off.
■ Tightening torque: 16-18 N•m
② Remove the braking tube joint on rear brake end.
■ Tightening torque: 16-18 N•m
③ Remove brake hose and brake pipe.
2) Installation
Install it in the reverse order of removal.
Brake pipe of master brake cylinder and ABS module assembly
1) Dismantle
① Remove two oil pipe connector of master brake
cylinder end.
② Remove two oil pipe connector of ABS module
assembly end.
③ Unscrew off two fixing nuts in the middle of braking
tube.
■ Tightening torque
Oil pipe connector 16-18 N•m;
Fixing nut 10-15 N•m
④ Disconnect ABS module assembly and oil pipe
connector again.
■ Tightening torque: 16-18 N•m
BR028
BR027
BR026
BR025
J4 Service Manual
Brake System
BR-17
Caution:
■ Drain brake fluid from ABS module assembly or dismantle ABS module assembly.
2) Install
Caution:
■ First install fixing bracket of ABS module assembly. And then tighten bolt. Clip ABS module
assembly to ABS fixing bracket. Installation sequence of ABS module assembly is shown in
figure BR028:
■ Do not make the brake pipe bend due to installation difficulty. When installing pipe assembly,
make sure that fixing pipe clips and sleeve are installed to proper position.
① Connect left front brake hose assembly and left front brake caliper, and then let the complete
pipe smoothly pass through shock absorber bracket and body bracket, and install it with left
front brake pipe and install clamp. At last, fix it on the steering knuckle with bolts. The
installation in right side is the same as that of in right side.
② Fix the rear brake pipe assembly under the body with bolts or nuts.
③ Refill the braking liquid and release air.
3) Inspection after installation
Caution:
■ Retighten the adapter between the brake pipe and the brake hose if it leaks, or replace the
parts if any damaged.
① Check if the brake hose, the brake pipe and the adapter leak fluid, contact with the other
parts and loose or they are damaged, twisted and deformed.
② When the engine runs, exert some brake force and keep for several seconds, and then Check
if each part has liquid leakage.
Brake vacuum booster assembly component
Diagram of Brake Vacuum Booster Assembly
1- Vacuum booster 2- Main brake cylinder 3- Oil brake can
J4 Service Manual
Brake System
BR-18
1. Inspection in the car
1) Operation inspection
Start the engine and press the brake pedal a few times, so
that the vacuum inside brake vacuum booster is equal to
the atmosphere. Press brake pedal to the end and start
engine. When vacuity is up to standard, ensure if the
clearance between brake pedal and floor is shortened.
Caution:
■ The interval of pressing the brake pedal is 5s.
2) Inspect air tightness
■ Start engine, let it idle 1min, and stop when brake
vacuum booster turns vacuum. Eliminate vacuum by
pressing the brake pedal as normal. Check if the
clearance between the brake pedal and the floor
increases gradually.
■ When the engine is working, press and hold brake
pedal to shut it down. Ensure no change occurs to
pedal travel 30 s after the pedal is pressed.
2. Removal and installation
Caution:
■ Do not bend the brake pipe when removing the brake
vacuum booster.
■ Please replace the damage lock pin.
■ Do not damage the thread of fixing bolts on the
vacuum booster.
1) Removal
① Dismantle old air filter assembly
② Remove clamp from vacuum hose, and then dismantle
vacuum hose from brake vacuum booster.
③ Dismantle lock pins and washers from brake pedal.
④ Remove the connecting nut of the brake pedal and
brake vacuum booster.
⑤ Remove connecting bolt of brake pedal and body.
■ Tightening torque: 20-25 N•m
⑥ Remove the brake vacuum booster from the engine compartment.
BR032
BR031
BR030
Good
Badly
1st
2nd
3rd
BR029
J4 Service Manual
Brake System
BR-19
2) Inspection after removal
① Inspection of the length of the push rod
a. Apply a vacuum pressure of -66.7KPa to the brake
vacuum booster with a manual vacuum pump.
b. Check the length of the push rod
■ Pulling rod length: 116.7-117.3 mm
② Vacuum hose
Check if it damaged or cracked. Replace it if any.
3) Installation
① Install brake master cylinder and vacuum booster assembly onto relevant positions of vehicle
body, make the brake pedal assembly pass through the middle of push rod of vacuum booster
and install it on the vacuum booster bolts, and then tighten four mounting nuts.
② Install brake pedal and pin shaft of push rod of vacuum booster; meanwhile, apply -SAE J31
0, NLGI No2 lubricating grease on the surface of pin shaft. When the pin shaft isn't installed
normally, adjust the length of adjusting bolt of the pedal to ensure that the pin shaft can be
installed naturally. But it is not allowed to adjust the length of push rod of vacuum booster or
let the push rod of vacuum booster on compression condition.
③ Fix the brake pedal upper-support with combined screw.
■ Tightening torque: 20-25 N•m
④ Fix the vacuum hose assembly onto proper position of vacuum booster.
Caution:
■ When installing, insert vacuum hose into proper position.
■ Do not use lubricant during installation.
⑤ Adjust the free travel of the brake pedal.
⑥ Tighten the push rod locking nut to the specified torque.
⑦ Install air filter assembly.
⑧ Refill brake fluid and brake fluid, and then air exhaust.
BR033
Output rod length
Pre-load
J4 Service Manual
Brake System
BR-20
Front disc brake caliper
1. Inspection in the car
1) Check brake shoe breaking-in
Caution:
■ Standard thickness: 11 mm
■ Wear limit thickness: 2 mm
2. Components
Exploded View of Brake Caliper Assembly
1- Dustproof cover of bleed screw 2- Bleed screw 3- Hex bolt with flange surface
4- Caliper body 5-Position 6-Rectangular sealing ring 7-Dustproof cover pin of pin
8-Inner brake block with sound absorbing disc assembly 9-Leaf spring
10-Outer brake block with silent blade assembly 11-Guide pin 12-Piston
13-Piston dust proof cover 14-Rubber sleeve 15-Support
Caution:
■ It is necessary to completely clean brake wheel cylinder and brake shoe, to minimize damage
caused by particles and other matters in the air.
■ When removing the brake wheel cylinder, please do not press the brake pedal, so as to avoid
ejecting the piston.
■ Please do not damage piston dust cover.
■ Unless dismantling or replacing brake wheel cylinder, do not dismantle fixing brake of brake
wheel cylinder and bolts on the brake hose. Here, lift the brake wheel cylinder by rope, and
avoid pulling the brake hose.
■ If the brake shoe shim is corroded seriously, please replace with a new one.
■ Replace the shim whenever replacing the brake shoe.
BR034
J4 Service Manual
Brake System
BR-21
■ Confirm no brake fluid on brake disc.
3. Remove and install brake show
1) Removal
① Remove the tire.
■ Tightening torque: 90-110 N•m
② Remove fixing bolt of brake caliper assembly
position.
■ Tightening torque: 35-45 N•m
③ Lift up the brake caliper assembly with a rope and
then remove internal & external brake shoes and etc.
2) Installation
① Install shoe spring onto the brake shoe.
Caution:
■ Install according to shim retaining direction.
② Press the piston when installing the brake shoe, and
install the brake wheel cylinder on the brake wheel
cylinder retaining bracket.
③ Install the brake shoe on the brake wheel cylinder
retaining bracket.
Caution:
■ Pay attention to brake fluid level in the brake oil can.
④ Install the fixing screw of cylinder position pin and
tighten it.
⑤ Fix brake disc, step brake shoe straightly until the
brake has reaction.
⑥ Check the rotation resistance of brake.
⑦ Install the tire of vehicle.
BR036
BR035
J4 Service Manual
Brake System
BR-22
Remove and install brake caliper component
1. Removal and installation
1) Dismantle
① Remove the tire.
② Remove the brake hose bolt, and then disconnect the
brake hose.
■ Tightening torque: 25-30 N•m
Caution:
■ Pay attention to the falling of copper washer.
③ Remove retaining bracket bolt of brake caplier
assembly, and remove brake caplier assembly.
■ Tightening torque: 65-75 N•m
2) Install
Install it in the reverse order of removal.
2. Disassembly and assembly
1) Disassembly
① Dismantle fixing bolts of positioning pins of brake
wheel cylinder, and dismantle brake wheel cylinder
from fixing bracket of brake wheel cylinder. If
necessary, remove the brake shoe and brake shoe
shim from the brake wheel cylinder retaining bracket.
Caution:
■ Do not fall the brake shoe and brake shoe shim.
② Dismantle positioning pin of wheel cylinder and
dustproof cover of positioning pin from fixing
bracket of brake wheel cylinder.
③ Shown as figure. Place a proper wood block, blow air
into the set bolt hole of the brake hose evenly, and
remove the piston and piston dust cover.
Caution:
■ Be careful that finger couldn't be clamped by piston.
BR039
BR038
BR037
J4 Service Manual
Brake System
BR-23
④ Remove the piston seal ring from the brake wheel
cylinder with slotted screwdriver.
Caution:
■ Do not damage the inner wall of brake wheel
cylinder.
2) Inspection after disassembly
① Brake wheel cylinder
Caution:
■ Clean up cylinder with new brake fluid. Please do not use gasoline or paraffin.
■ Check if the inner wall of cylinder is damaged or worn. If any, please replace brake wheel
cylinder.
② Brake wheel holder
■ Check if retaining bracket is worn, cracked or damaged. Replace it if any.
③ Piston
■ Check if piston surface is corrodent, worn or damaged. Replace it if any.
■ Do not sand the piston surface with abrasive paper.
④ Sliding pin, pin bolt and pin dust cover
■ Check the sliding pin, pin bolt and pin dust cover for
wear and cracks. Replace it if any.
3) Assembly
Caution:
■ Use the specified rubber grease during assembly.
■ Do not reuse the piston sealing ring and dust cover.
① Apply rubber grease on the piston seal ring, and install it into the cylinder block.
BR041
Piston seal ring
BR040
Piston seal ring
J4 Service Manual
Brake System
BR-24
② Apply brake fluid on the piston, and apply rubber
grease on the piston dust cover. Cover the piston end
port with the piston boot and then fix the cylinder
body side on the piston dust cover into the groove on
the cylinder body slowly.
③ Extend the hand into the cylinder block, and insert
the piston side edge of the piston dust cover into the
piston groove.
Caution:
■ Evenly press the piston, and avoid friction with the
inner wall of the cylinder block.
④ Install the sliding pin and sliding pin dust cover on
the brake wheel cylinder retaining bracket.
⑤ Install the brake shoe shim on the brake shoe.
Caution:
■ Install according to shim retaining direction.
⑥ Install the brake shoe assembly on the brake wheel
cylinder retaining bracket.
⑦ Press the piston while installing the brake shoe and
then install the brake cylinder on the brake cylinder
mount.
⑧ Tighten pin bolt.
Inspection of brake disc
1) Visual inspection
■ Check the brake disc surface for uneven ear, cracks and serious damage. Replace it if any.
2) Runout check
① Fix the brake disc to wheel hub.
Caution:
Ensure the axial clearance of wheel bearing is not too large before measurement.
② Check the jerk value with micrometer. (Measure it about 10mm of brake disc edge).
■ Runout limit value: 0.05 mm
③ If the runout exceeds the specified value, please replace or perform necessary machining.
BR044
BR043
BR042
Piston dustproof cover
Piston
J4 Service Manual
Brake System
BR-25
3) Thickness inspection
■ Check the thickness of the brake disc with a
micrometer. If the thickness is less than the wear
limit, please replace the brake disc.
Standard thickness: 26 mm
Wear limit: 24.4 mm
Brake breaking-in steps :
Repair or replace brake disc. Soft braking occurs after replacing brake shoe or after a short
distance. Please observe the following procedures to run in contact surface between brake disc
and brake shoe.
■ Before running-in, pay attention to control the vehicle speed if the brake effect is poor.
■ Only execute the step on the safe road surface and in safe traffic condition, pay attention to
safety.
1) Drive the vehicle on the straight road.
2) Push the brake pedal down without proper efforts to brake the vehicle within 3-5s.
3) After driving vehicle a distance, park the vehicle for 3min to cool brake system.
4) Repeat steps 1 to 3 until the brake shoe and the brake disc are run in completely.
Rear parking brake
1. Inspection in the car
1) Check brake shoe breaking-in
■ Check the thickness of the brake shoe from the
inspection hole of the brake bottom plate.
2. Removal and installation
1) Removal
① Remove the tire.
② Remove the rear brake drum stop bolt, and take down
the brake disc.
■ Tightening torque: 10-15 N•m
BR046
BR046
BR045
J4 Service Manual
Brake System
BR-26
③ Release parking brake and dismantle clamp spring on
the parking brake cable and the head of parking brake
cable.
④ Remove rear brake pipe connector.
■ Tightening torque: 16-18 N•m
⑤ Remove head fixing bolt of wheel speed sensor.
Caution:
■ Do not pull the wire harness of wheel speed sensor.
■ Tightening torque: 10-15 N•m
⑥ Remove four fixing bolts of rear hub assembly, take
down rear hub assembly and cushion block.
■ Tightening torque: 65-85 N•m
⑦ Take down rear brake assembly
3. Inspection after disassembly
① Brake drum
■ Check if the inside diameter and circular runout of
the brake drum are within the standard value. Process
and Replacement should be carried out if
non-conformance.
Standard value: 204 mm
Circumferential runout: < 0.05 mm
BR050
Inner diameter (ID)
BR049
BR048
BR047
J4 Service Manual
Brake System
BR-27
② Brake shoe
■ Check the thickness of the brake shoe and the contact
condition with the brake drum. If non-conformance,
please replace it.
Standard thickness of brake shoe (A): 4mm
Allowable limit thickness(A): 1mm
③ Brake bottom plate
Check if the brake bottom plate is worn or damaged.
Installation
■ Install it according to the reverse order of dismantling.
■ Four fixing bolts on the rear wheel hub assembly should be tightened according to diagonal
sequence.
■ Before installing, the diameter of the brake shoe shall be adjusted in Φ203.35±0.15 mm so as
to install the brake drum.
■ Clean the inner surface of the brake drum during installation, and prevent the contact surface
of the brake shoe and brake drum from touching grease. Wash by acetone if contacting and
replace the same type of brake shoe assembly if it is serious.
■ After installing the brake drum, press the brake pedal several times to seat the brake shoe.
Caution:
■ The brake is equipped with a self-regulation mechanism for clearance. The shoe clearance
shall be automatically adjusted to the normal use value in the above braking process.
■ Adjust parking brake cable. Please refer to "Parking Brake System".
■ Bleed the air of brake system. Please refer to "Brake Fluid".
BR051
J4 Service Manual
Brake System
BR-28
4. Disassembly and assembly
1) Components
Exploded View of Rear Brake Assembly
1-Observe blocked 1 2-Observe blocked 2 3-Pick tension spring
4-Self-adjustment mechanism assembly 5-Brake cylinder assembly 6. Hexagon flange bolt
7- Bleed screw 8-Air drain screw dustproof cover 9-Upper tension spring
10-Pick with axis pin assembly 11-Brake shoe assembly 12-Lower tension spring
13-Base plate assembly 14-Brake shoe pressure spring 15-Limiting pin
16-Brake shoe with parking pull rod assembly
2) Removal
① Dismantle pick drag spring.
BR052
J4 Service Manual
Brake System
BR-29
② Remove shoe pressure spring and handle of pressure
spring.
③ Open the shoes, remove the upper & lower springs
and self-regulating mechanism assembly.
④ Remove the parking wire from the brake shoe with
parking lever assembly and take off the shoes.
⑤ Remove the set bolt of the brake wheel cylinder, and
take down the brake wheel cylinder from the brake
bottom plate.
3) Inspection after disassembly
① Brake wheel cylinder
Check if the outside of the brake cylinder is worn or
damaged by others, whether the piston is flexible, whether
the contact surface of the piston and the shoe is worn and
whether there is oil leaked. Please replace brake wheel
cylinder if the above situation occurs.
② For pick dray spring, upper drag spring, lower drag spring, self-adjusting mechanism
assembly and brake shoe with parking pull rod assembly, Check the elasticity of springs and
Check if self-adjusting mechanism assembly and brake shoe with parking pull rod assembly
have deformation or other damage.
BR056
BR05
5
BR054
BR053
J4 Service Manual
Brake System
BR-30
4) Assembly
Pay attention to the following cautions and install it in the reverse order of removal.
■ First install the upper tension spring, and then lower
tension spring.
■ Pay attention to mounting direction of self-adjustment
mechanism assembly.
Fault diagnosis
Common Troubleshooting Table for Rear Brake System
Fault
Possible Cause
Countermeasures
Brake
insufficiently
1 Fluid leakage at pipe joint or rear brake
wheel cylinder cup
2. Residual air in pipeline
3. Too big clearance between brake shoe and
brake drum
4. Greasy or hardened shoe surface
5. Overheated brake drum, air resistance in
pipeline
1. Tighten up or replace after rub-up.
2. Bleed air
3. Readjust
4. Rub or replace
5. Replace, cooling and bleed air
Difficult
release of brake
1. Blocked rear brake wheel cylinder oil
return hole or swelled cup
2. Clearance of shoe drum is to small
3. The power of shoe pull-off spring weaken
or breakage
4. Shoe or bottom plate deform, return is
blocked
1. Clean up or replace
2. Readjust
3. Replacement
4. Revise or replace
Noisy
1. Rear brake shoe severely worn
2. Brake drum is out of round
3. Frictional noise may be caused during the
slipping of the smooth surface when the
surface of the rear brake shoe is too
smooth, the friction coefficient is low but
the brake pressure is high, or when the
foreign matter is plugged between the
friction pair to squeeze the friction
surface.
1. Replacement
2. Cut and need to balance performance
check
3. Remove foreign matters, and sand the
rear brake shoe with coarse abrasive
paper.
BR057
Tighten
forward
J4 Service Manual
Brake System
BR-31
Fault
Possible Cause
Countermeasures
Brake drum
fever caused by
brake drag
1. The brake clearance is too little and the
free stroke of the brake is too short; the
braking force is not released completely
when releasing the brake pedal, so that the
friction pair is in the friction condition for
a long time; thus, it is difficult to drive off,
it is weak to drive, and you will feel hot if
you touch the surface of the wheel hub by
hands.
2. The brake handle is not released
completely. It may be caused by
misalignment or operational negligence.
As a result, the friction pair is in the
friction condition for a long time to heat
up.
3. The heat caused by braking makes the
return spring heated and deformed and
little elastic or even inelastic, so that the
brake shoe assembly shall not be returned
timely after braking; thus, the braking
cannot be released thoroughly in time to
heat the brake drum.
1. Readjust brake clearance in accordance
with specification in this situation
2. Adjust in accordance with specification
if necessary
3. Repair or replace pull-off spring to
troubleshoot
Parking brake
fail
The parking brake control wire drawing or the
brake drawing is not drawn flexibly in their
coat due to common wire drawing or coat rust,
as well as broken, dropped or inelastic drag
spring; therefore, the parking brake could not
be released to be ineffective.
Check if the surface of the brake control wire
drawing (drawbench) and the brake system
component is damaged, whether the handle is
operated flexibly without clamping
stagnation, and whether the drawing
connector and the fixed part are loosened and
damaged, and repair or replace them if
necessary.
Common Troubleshooting Table for Brake Master Cylinder
Fault
Possible Cause
Countermeasures
Vehicle deviation when braking
Insufficient air pressure for left and right
tires
Adjust
Adjust front wheel improperly
Adjust
Brake shoe is in poor contact
Adjust
Grease or oil on brake shoe surface
Replace
Eccentric or unevenly worn brake drum
Replace
Brake cylinder assemblies incorrectly
Adjust
Faulty self-adjusting mechanism
Adjust
J4 Service Manual
Brake System
BR-32
Fault
Possible Cause
Countermeasures
Brake insufficiently
Low or polluted brake fluid
Supply or replace
There is air in brake system
System exhaust
Brake booster is faulty
Adjust
Brake shoe is in poor contact
Adjust
Grease or oil on brake shoe surface
Replace
Faulty self-adjusting mechanism
Adjust
Overheated rotating parts due to drag of the
brake shoe
Adjust
Brake line limitation
Adjust
Increase pedal travel (decrease
distance between pedal and floor)
There is air in brake system System exhaust
Brake fluid is leaking Adjust
Faulty self-adjusting mechanism Adjust
There is an excessive clearance between the
push rod to the brake master cylinder.
Adjust
Brake lag
Parking brake do not open enough Open
Parking brake adjust improperly Adjust
Pull-off spring of brake system is worn Replace
Return opening of brake master cylinder
limits
Adjust
Rear drum brake pull-off spring is damaged
Replace
Sliding part lubricate insufficiently
Grease
One-way valve of brake master cylinder or
pull-off spring of piston is faulty
Replace
Too small clearance between the push rod
and brake master cylinder
Adjust
Insufficient parking brake function
Rear brake shoe is damaged
Adjust
There is lubricating grease or oil in rear
brake shoe surface
Replace
Parking brake cable is stuck
Adjust
Faulty self-adjusting mechanism
Adjust
The travel of parking brake handle is too
large
Adjust
J4 Service Manual
Brake System
BR-33
Maintenance data and specification
Technical Specification Table
Item
Specifications
Brake master pump
Type
In series
Cylinder bore
22.22mm
Brake booster
Type
Vacuum
Specification (dimension)
10 inch
Boost ratio
7.3: 1
Front brake
Type
Caliper/ ventilated disc
Brake disc diameter
256mm
Brake disc thickness
11mm
Thickness of clutch block
10.8mm
Cylinder bore
54mm
Rear parking brake
Type
Drum brake
Diameter of wheel cylinder
17.46mm
Brake hub diameter
204mm
Thickness of clutch block
4mm
Fastening torque table
Item
Torque (N·m)
Front brake caliper and steering knuckle connecting
bolt
65-75
Connecting bolt of rear brake and rear hub
65-85
Front/rear brake caliper air exhaust bolt
7-13
Brake pedal upper support fixing bolt
20-25
Brake pedal fixing nut
20-25
Brake hose and brake caliper connecting bolt
25-30
Brake pipe connector
16-18
J4 Service Manual
Brake System
BR-34
Parking brake control
1. Inspection in the car
1) Stroke of parking brake handle
■ Pull up parking brake handle with a force of 200N,
and make sure that the pawl is in specified groove
(there is a click sound when passing through a tooth.
Check it by listening to and counting the sound of
pawl).
■ Standard value: 7 - 9 gear
2) Inspection of elements:
① Verify whether the fixing of each element is normal.
② Whether parking brake handle assembly is bent, damaged, cracked.
Replace if any of the above.
③ Check the parking brake cable for wear and damage. Replace it if any.
④ Is parking brake warning light switch work normal. If it doesn't work normally, please Check
or replace it.
⑤ Disassemble the parking brake switch connectors and check the continuity between the
positive terminal and vehicle body.
■ When parking brake pedal is upward, it should be conducted.
■ When parking brake pedal is downward, it should not be conducted.
3) Adjustment
① When parking brake operation handle is on release condition, insert left and right parking
brake cable joints into the mounting hole of balance plate of parking operation handle. As
shown in figure After the installation of cable, tighten adjusting nut and make sure that the
distance L between adjusting nut and the end of cable is 31-34 mm.
Parking handle assembly
Adjusting nut
Adjusting screw rod
BR058
J4 Service Manual
Brake System
BR-35
② After the commissioning, pull up parking hand along the vertical direction of handle with a
force of about 200 N at a distance of 25 mm from handle button. And then adjust adjusting
nut to let the handle locked at teeth No.7-9. Or, adjust the adjusting nut to adjust the L value.
Detailed adjusting method: if the number of pulling up teeth is less than 7, the distance L
should be reduced. If it is more than 9, the distance L should be increased.
Caution:
■ After adjusting completely, check if the rear wheels are dragged under the condition that the
parking brake handle is released.
2. Components
Parking brake cable system drawing
1- Parking handle assembly 2. Left parking brake wire drawing assembly
3. Right parking brake wire drawing assembly 4- Snap spring
1) Removal and installation
① Removal
a. Remove auxiliary fascia console rear section
assemblies.
BR059
BR059
J4 Service Manual
Brake System
BR-36
b. Unscrew adjusting nut and dismantle the head of left
and right parking brake cable assembly from cable
buckles.
c. Disconnect wire harness of parking brake switch,
dismantle four fixing bolts of parking brake handle,
and take out parking brake handle assembly.
■ Tightening torque: 20-25 N•m
d. Release clamp spring, and then dismantle the head of
parking brake cable assembly from brake shoe with
parking brake pull rod assembly.
e. Dismantle fixing bolts from fixing brackets on the
parking brake cable.
■ Tightening torque: 20-25 N•m
BR063
BR06
2
BR061
BR060
J4 Service Manual
Brake System
BR-37
f. Take parking brake cable from the mounting pipe
hole at the bottom of the vehicle body.
② Inspection after dismantling
■ Check if button mechanism work flexibly. If it can't return normally, please replace it.
■ Check parking brake handle pawl is worn.
■ Check the parking brake cable for deformation, wear, bending and looseness. Replace it if
any.
③ Installation
Install it in the reverse order of removal.
Fault diagnosis
Indicator lamp steadily burns or not burn at all;
① Check if the performance of indicator lamp is damaged.
② Check if the screw between indicator lamp and teeth plate seat is loose.
Maintenance
If any of the above conditions occurs, please replace or reinstall indicator lamp.
Brake force is not enough and or lose efficacy:
① Check if connecting plate of cable is connected with brake cable.
② Check if locking nut loosed
③ Check if parking brake shoe was worn.
Maintenance
① First condition: please connect connecting plate of cable and brake cable.
② Second condition: please replace lock nut.
③ Third condition: please adjust the distance of lock nut.
④ 4th condition: please adjust parking brake shoe clearance
BR064
J4 Service Manual
Brake System
BR-38
Anti-lock braking system (ABS)
Precautions
When maintaining anti-lock braking system (ABS), please observe the following items.
Otherwise, anti-lock brake system may be damaged.
1. Disconnect the connector from the ABS control module before electric welding operation.
2. The ABS parts are particularly sensitive to EMI (Electro-Magnetic Interference), pay care
attention to the routing, position, installation and position of all ABS parts as well as whether
the wiring, adapter, the clamp and the support are intervened.
3. Do not charge the battery that is still connected during engine starting by the rapid charger
because it may make the battery invalid or damage the ABS parts.
4. Make sure to turn off the ignition switch, then disconnect the battery negative, and
disconnect the connector of the ABS control module assembly.
5. Do not attempt to repair any ABS parts; all ABS parts can be serviced by replacement.
6. Do not hang suspension parts on the wheel sensor harness, to prevent damage to the sensor
harness.
7. The ABS control module shall not be placed in the environment at above 105°C .
8. Brake loop should neither contain inorganic substances such as chlorine and sulphur, nor
mineral oil or ester group plasticizer/ softener (including parts possibly producing these
substances dissolving).
9. In ABS operation, the brake pedal will vibrate slightly, and mechanical noise may be heard;
this is normal.
10. Start up the vehicle after the ignition switch is turned to ON, the brake pedal may be shocked,
or there is working noise heard from the motor of the ABS hydraulic assembly. This is the
normal condition during operation inspection.
11. The braking distance for vehicles equipped with the ABS may be longer than for those
without it on uneven, gravel, rough or snow-covered (deeper fresh snow) roads.
12. When the brake system is broken down, first, differentiate it is due to either the ABS or the
common brake system, for example, differentiating whether the vacuum booster, the brake
hydraulic system, the brake and other parts are broken down.
13. If the size and the type of the tire are not used as per the correct compound, or the brake shoe
is not JAC’s original part, the braking distance or the steering stability may be deteriorated.
J4 Service Manual
Brake System
BR-39
Preparation work
General maintenance tools and specified tools maybe used in service.
Special tool table
No.
Tools
Overall Diagram
Code
Instructions
1
Diagnostic unit
ABS system fault
diagnostic
System specification
1. Brake system diagram
2. ABS function
The ABS controls the hydraulic brake pressure of the four wheels during emergency brake or the
brake on the dangerous road surface to prevent the wheels from locking. The advantages in using
ABS are as follows.
(1) Allowing the vehicle to steer reliably when meeting obstacles in emergency braking.
(2) Keeping the vehicle stopping stably and controllably on a curve in emergency braking.
Caution:
1. Front left brake assembly 2. Vacuum booster with brake master cylinder and oil can assembly 3. Brake pedal assembly 4.
ABS module assembly 5. Front right brake assembly 6. Brake pipelines 7. Rear left brake assembly 8. Rear left wheel speed
sensor 9. Rear right brake assembly 10. Rear right wheel speed sensor 11. Front left wheel speed sensor 12. Front right wheel
speed sensor 13. Parking handle assembly 14. Left and right parking cable assembly
J4 Service Manual
Brake System
BR-40
■ If the electrical system is interrupted, the failure protection mode starts, ABS enters into the
disabled state, and the ABS warning light comes on.
■ The special can tool provided by JAC can be used for diagnosis of the ABS electrical system.
■ During braking, the brake pedal will vibrate slightly, and some mechanical noise may be
heard. This is normal working of ABS.
3. EBD function
Electronic brake distribution (EBD) can accurately control the brake force of each wheel and
ensure the stability of the vehicle during braking. It can effectively balance the equal wheel speed
required for braking under normal braking conditions. EBD can distribute brake pressure
necessary for each wheel by using oil inlet valve and outlet valve in ABS hydraulic adjusting
module, to provide effective brake and stability of vehicle.
4. Failure protection function
ABS system electric failure, ABS warning light will come on. If EBD has an electrical fault, the
brake warning light and ABS warning light will come on.
Meanwhile, ABS enters into one condition of the following failure protection functions.
1) For ABS failure, only EBD is activated, and the vehicle state is the same as the vehicle
without ABS.
2) For EBD failure, EBD and ABS are disabled, and the vehicle state is the same as the vehicle
without ABS or EBD.
5. Principle diagram of ABS system fluid pressure
FREV PR Air
inlet valve
Energy accumulator 2
(volume is 3 ml)
RLEV RL Air
inlet valve
RREV RR Air
inlet valve
FKEV PL Air
inlet valve
Energy
accumulator
(volume is 3
ml)
Motor
RP damper1
RFP2damper 2
FRAV Oil return
valve
RLAV RL Oil
return valve
RRAV RR Oil
return valve
FLAV FL Oil
return valve
J4 Service Manual
Brake System
BR-41
ABS mode
ABS will enter into the anti-lock brake mode if wheel slip happens in the brake period. During
antilock braking, the pressure of the hydraulic circuit of each wheel will be under control to
prevent wheel slippage. Each wheel is provided with an independent hydraulic pipe and valve.
ABS can decrease, hold and increase the braking hydraulic pressure of each wheel. But ABS
cannot increase the hydraulic pressure beyond the pressure value transferred by the master
cylinder during braking. When ABS is operating, the brake pedal feels a series of quick vibration.
Each valve position changes rapidly along with the required wheel speed to cause vibration. The
pedal vibration occurs when ABS is operating, and stops during normal braking or when the
vehicle stops fully. Due to rapid cyclic use of the solenoid valve, the motion noise can be heard. If
the ABS is used on the dry road surface, the tires will make intermittent sharp sound when it is
adjacent to slide. The noise and pedal vibration are normal when ABS is operating. The operation
of the brake pedal shall be identical with that of the system without during normal braking. The
equal force of pressing the pedal can keep the vehicle stability, and can ensure the shortest
stopping distance.
1. Pressure maintenance
When the ABS control module detects wheel slip, it will close the oil inlet valve, and also close
the oil outlet valve in the hydraulic assembly, so as to isolate the system. This can maintain the
stability of the pressure on the brakes so that the hydraulic pressure will not increase or decrease.
2. Pressure decrease
If the ABS control module still detects wheel slip in the pressure holding mode, it will decrease
the pressure of the affected wheel. The oil inlet valve keeps closed, and the oil outlet valve opens.
Excessive fluid/pressure is stored temporarily in the accumulator in the hydraulic assembly, until
the pump motor can transfer brake fluid to the reservoir of the master cylinder.
3. Pressure increase
If the ABS control module detects that the wheel slippage has been reduced under the mode of
keeping the pressure or reducing the pressure, it will increase the pressure of the wheel affected
by the master cylinder pressure. The oil inlet valve opens, and the oil outlet valve closes. Partial
or all pressure from the brake master cylinder will be applied to the wheel.
4. Working process of ABS
When the vehicle is traveling, each wheel speed sensor will generate a voltage signal proportional
to the wheel rotation speed. ABS controller receives the wheel speed data and judges whether
there is 1 or more wheels slowing down more thickly than the reference speed as slippage. It will
activate the module as required to control the brake pressure of each wheel to make it optimized.
Speed sensor
It consists of the sensor itself and ring gear, one group provided for each wheel. This vehicle
model uses the active wheel speed sensor, which needs an external power supply (12V) to work.
It can provide a constant amplitude signal regardless of speed value.
1. Components
It consists of the body and gear ring. A group contains one wheel.
J4 Service Manual
Brake System
BR-42
2. Removal
1) Front wheel
① Disconnect power supply of vehicle
② Lift the vehicle.
③ Disconnect the sensor connector.
④ Loosen the fixing bolt at the head of sensor and
slowly take out the sensor.
■ Tightening torque: 8-10 N•m
Caution:
■ Do not use hard force to draw the wire harness of
wheel speed sensor.
■ Pay attention to the clearance between the wheel
speed sensor and signal gear during installation.
Standard value: 0.2-1.1 mm
2) Rear wheel
① Disconnect power supply of vehicle
② Lift the vehicle and remove the rear wheel tire.
Caution:
■ Unscrew the set nut of the tire before lifting up the
vehicle.
③ Disconnect the sensor connector.
④ Unscrew the set bolt of the wheel speed sensor, and
take out the wheel speed sensor slowly.
■ Tightening torque: 8-10 N•m
Caution:
■ Do not use hard force to draw the wire harness of
wheel speed sensor.
■ Pay attention to the clearance between the wheel
speed sensor and signal gear during installation.
Standard value: 0.2-1.1 mm
3) Inspection after removal
1) Check if there is any foreign matter in sensor mounting hole and metal particles on brake
disc surface.
2) Check if the teeth number of teeth gear of wheel speed sensor is correct, whether there are no
foreign matters and rustiness.
BR067
BR065
J4 Service Manual
Brake System
BR-43
3) Clean the sensor mounting hole and brake disc surface before installation.
4. Install
Install it in the reverse order of removal, and tighten the bolt to the specified torque.
Caution:
■ The wire harness shall not be twisted after installation.
ABS hydraulic assembly
1. Removal and installation
1) Dismantle
① Turn off all ignition switches and disconnect the
negative cable of battery.
② Remove ABS control module connector.
③ Press the pedal above 60mm and fix by the pedal rack.
■ Close the center valve of the hydraulic assembly, so
brake fluid will not flow out from the outlet when
opening the system.
④ First, dismount the brake pipe on the hydraulic assembly to the master cylinder and mark,
and then block the outlet by the plug at once.
⑤ Dismount the brake pipes to various wheels and mark, and then block the outlet by the plug
at once.
⑥ Remove the bolt on the ABS hydraulic assembly retaining bracket.
⑦ Remove the whole ABS hydraulic assembly from the bracket.
2) Install
Install the ABS hydraulic assembly in the reverse order or removal.
Caution:
■ Tighten the brake pipe joint connected with the hydraulic assembly to the specified torque.
■ Tightening torque: 16-18 N•m
■ The plug of the hydraulic opening on the ABS hydraulic assembly can only be dismounted
when the brake pipe is to be installed in order to avoid the foreign matters from entering into
the brake system. Please refer to “Brake Pipeline” for the following steps.
① Install the ABS hydraulic assembly on the bracket and tighten to the specified torque.
② Remove the plug on the hydraulic port, install the brake pipe and confirm that the pipe is
connected correctly.
③ Connect the hydraulic assembly to the brake pipe of the master cylinder.
④ Install the brake pipe and tighten to the specified torque.
BR068
J4 Service Manual
Brake System
BR-44
⑤ Add new brake fluid into the fluid reservoir until the level is up to the MAX position and
exhaust according to the specified method.
⑥ When turning the ignition switch to ON position, the ABS warning light comes on and then
goes out.
⑦ Clear the stored DTCs, and read again whether there are DTCs.
⑧ Finally perform road test and confirm that the ABS function is normal.
Caution:
If the ABS hydraulic assembly has a fault, replace the assembly.
ABS control module
1. Components
The vehicle adopts BOSCH ABS 9 ABS. ABS control module and hydraulic assembly is
integrated.
2. ABS control module pin description
Definition table of ABS Control Module Pin
Pin No.
Definition
Pin No.
Definition
1
The power terminal of motor (positive)
20
N.C.
2
Output of wheel speed sensor (FRT/RH
wheel)
21
N.C.
3
Active EBD warning lamp
22
N.C.
4
Signal terminal of wheel speed sensor
(FRT/RH)
23
N.C.
5
N.C.
24
N.C.
6
Diagnostic K Line
25
Power terminal of valve relay
7
N.C.
26
CAN-HI
8
Signal terminal of wheel speed sensor
(FRT/LH)
27
Active ABS warning light
9
N.C.
28
The power terminal of ECU (Ignition
power wiring)
10
N.C.
29
Signal terminal of wheel speed sensor
(RR/RH)
11
N.C.
30
Brake Lamp Switch Input
12
N.C.
31
The power terminal of wheel speed sensor
(RR/LH)
13
The ground terminal motor
32
N.C.
14
CAN-Low
33
Vehicle speed signal output
15
N.C.
34
N.C.
16
The power terminal of wheel speed sensor
(FRT/RH)
35
N.C.
J4 Service Manual
Brake System
BR-45
Pin No.
Definition
Pin No.
Definition
17
The power terminal of wheel speed sensor
(RR/RH)
36
N.C.
18
Signal terminal of wheel speed sensor
(RR/LH)
37
N.C.
19
The power terminal of wheel speed sensor
(FRT/LH)
38
ECU cable
ABS control module pin location diagram
3. Check of ABS control module
Caution:
■ Please execute the basic check of brake system.
1) Basic check of brake system
① Check brake fluid level. If the level is low, fill brake fluid.
② Check the area near the brake pipeline and ABS hydraulic assembly for leakage. In case of
leakage, check the following:
a. If the ABS hydraulic assembly connecting part loosens, tighten the oil pipe nut of the
pipeline to the appointed torque (16-30 N•m). Check leakage again, and confirm no brake
fluid leakage.
b. If the oil pipe nut of the joint and the thread part of the actuator are damaged, replace the
damaged parts. Check leakage again, and confirm no brake fluid leakage.
c. If it leaks out of the actuator connecting part, wipe by the clean cloth and then re-check. If
there is leakage still, replace the damaged parts.
d. If there is leakage in the hydraulic assembly, wipe with clean cloth and check again. If there
is leakage still, replace the hydraulic assembly.
Caution:
■ If no special needs, do not disassemble the ABS hydraulic assembly (including control
module).
③ Check if brake shoe is worn.
④ Looseness of power circuit port and battery check.
J4 Service Manual
Brake System
BR-46
■ Check for loose battery positive/negative terminal. At the same time, confirm that the battery
voltage is normal.
2) ABS warning lamp and brake warning lamp check
① Confirm that the ABS warning light is on for about 3s and the brake warning light comes on
when turning the ignition switch to “ON” position. If they are not on, please refer to
“Common Symptoms and Analysis Procedure of ABS”.
② Check if the ABS warning light goes out after the ignition switch is turned to “ON” about 3s
and whether the brake warning light goes out after the engine starts up. If they are not off,
please refer to “Common Symptoms and Analysis Procedure of ABS”.
③ If the ABS warning light does not go out after 10s since the engine starts, please refer to
“Common Symptoms and Analysis Procedure of ABS”.
Caution:
■ The brake warning light comes during the parking brake operation (when the switch is in
position ON) and when the brake fluid level sensor is working (the brake fluid is
insufficient).
3) Check ABS control module by using diagnosis device.
Detect the control module control data and stored DTCs by the scan tool. If abnormal,
service according to the fault prompt. Please refer to "Failure diagnosis".
4) ABS failure code table
Fault Code
Description
C190004
ECU too high voltage
C190104
ECU too low voltage
C100004
ECU hardware fault
C101008
ECU software fault
C006B06
C003108
Front left wheel speed sensor signal fault
C003200
Open circuit of left front wheel speed sensor
C00A000
Front left wheel speed sensor short ground circuit fault
C00A100
Front left wheel speed sensor short circuit fault to power supply
C00A900
Left front wheel speed sensor has fault, but the cause isn't found.
C003408
Front right wheel speed sensor signal fault
C003500
Open circuit of right front wheel speed sensor
C00A200
Front right wheel speed sensor short circuit fault to ground
C00A300
Front right wheel speed sensor short circuit fault to power supply
C00AA00
Right front wheel speed sensor has fault, but the cause isn't found.
C003708
Left rear wheel speed sensor signal is fault.
C003800
Open circuit of left rear wheel speed sensor
C00A400
Rear left wheel speed sensor short to ground
J4 Service Manual
Brake System
BR-47
Fault Code
Description
C00A500
Rear left wheel speed sensor short to power supply
C00AB00
Left rear wheel speed sensor is fault, but the cause isn't found.
C003A08
Rear right wheel speed sensor signal fault
C003B00
Open circuit of right rear wheel speed sensor
C00A600
Rear right wheel speed sensor short circuit fault to ground
C00A700
Rear right wheel speed sensor short circuit fault to power supply
C00AC00
Right rear wheel speed sensor fails but its reason does not detected
C109904
Wheel speed sensor has other faults (such as: fault in left and right sequence, multiple
sensor error).
C001004
Front left oil inlet solenoid valve fault
C001104
Front left rear fluid outlet solenoid valve fault
C001404
Front right oil inlet solenoid valve fault
C001504
Front right fluid outlet solenoid valve fault
C001804
Left rear oil inlet solenoid valve fault
C001904
Left rear fluid outlet solenoid valve fault
C001C04
Rear right oil inlet solenoid valve fault
C001D04
Rear right fluid outlet solenoid valve fault
C109504
Valve relay fault
C002004
Motor faults
C007208
Other faults of valve (Overheat protection, signal failure or hardware fault)
Exhaust of ABS system
1. Exhaust condition of ABS system
It is necessary to perform the ABS bleeding procedure when one of the following conditions
occurs:
1) The braking line cannot realize the pedal height or feeling required according to the
traditional exhaust method.
2) Replace ABS hydraulic assembly.
3) Excessive fluid loss.
4) Possible air suction.
■ This procedure uses the scan tool to driver the system valve and operate the pump motor, so
as to remove air from the secondary circuit. These secondary loops are normally closed and
can only be opened during the initializing period and the ABS operating period while starting
the vehicle. Open these secondary loops by the automatic exhaust procedure, make all airs
flowed out and collect them in the hydraulic assembly to remove them out of the system.
2. Exhaust of ABS system
1) Items required
J4 Service Manual
Brake System
BR-48
① Diagnosis device with correct software
② Brake fluid
③ Lifter
④ Bleeding bottle with hose for receiving fluid from the vehicle
⑤ Suitable safety equipment, include safety goggles.
⑥ Two servicemen are needed: one pushes the brake pedal down and control the diagnostic unit
and the other keeps the hydraulic fluid of the main cavity of the brake master cylinder level
and switch on and off the exhaust screw according to the process of the diagnostic unit.
2) Initial inspection
① Check the charging state of the battery, and service the battery and charging system as
required.
② Connect the scan tool, and select current or past DTCs. Before carrying out ABS gas
exhausting, clear all failure diagnosis codes. Remove the fault first if DTCs cannot be
cleared.
③ Check the appearance for damage and leakage. Service as required.
3) Steps before exhaust
① Start the engine.
② Connect the scan tool, and establish communication with ABS.
③ Lift and support the vehicle properly.
4) Bleed on the vehicle.
Caution:
Press down the EXIT key on the diagnostic unit to stop the automatic exhaust procedure at any
time.
■ Select “Automatic Bleeding Procedure” from the scan tool and follow the instructions.
(Please refer to the actual scan tool procedure)
■ In the basic bleeding and automatic bleeding process, it is necessary to press the brake pedal
and hole the brake fluid level of the brake master cylinder.
■ When bleeding one wheel, ensure that the hose is connected with the bleed screw and empty
to the chamber containing brake fluid. This chamber must be 30mm higher than the bolt with
the hose filled with brake fluid. This is to prevent air from entering the brake pipeline again.
■ The first step is basic bleeding. This step must be performed before automatically exhausting
to obtain good pedal height and feeling as well as ensure the best performance of the ABS.
■ The first step of the automatic exhaust procedure is to rotate the pump and the reducing valve
for about 30 s. It is unnecessary to open and close the bleed screw in this step. The brake
pedal pressurizes or depressurizes continuously in the whole process.
J4 Service Manual
Brake System
BR-49
■ In the next step, the serviceman will be demanded to open one of the exhaust bolts for the
diagnostic unit. The scan tool then circularly checks the pressurizing valve and pump motor
for about 30s. The brake pedal needs to pressurize or depressurize continuously in the whole
process.
■ For the rest exhaust bolts, the step 6 will be repeated by the diagnostic unit to exhaust.
■ When the automatic bleeding procedure ends, the scan tool will display the corresponding
information.
■ Press the brake pedal to measure the pedal height and feeling. Repeat Steps 1 to 8, until the
pedal is acceptable.
Caution:
■ The automatic exhaust procedure may be stopped temporarily to access to the mode of “cool
down waiting” during repetitive operation.
5) Automatic exhaust
Do not proceed until the timer exceeds the time, and this process cannot be crossed.
Diagnosis steps in the vehicle
① Enter into the Special Fault Diagnosis System for JAC Car.
Special fault diagnosis
system for JAC car
Developed by LAUNCH Co. Ltd
Please login in time
Start
Exit
Original Info
Help
Start
② Select the Special V10.01 Full System for JAC Car.
Diagnostic software version selection
This program can diagnose all
electrically-controlled systems produced by JAC in
and before 2007.
Special V10.01 system for JAC car
PgUp PgDn Enter
Back Help
Start
J4 Service Manual
Brake System
BR-50
③ Enter into the automatic bleeding procedure. Follow the
prompts.
Yes
Air bleeding mode
1st step
Please tighten all bleed bolts,
step brake pedal, and then click
"YES" to continue
No
Start
④ The first step of system exhaust.
Yes
Air bleeding mode
Start air bleeding mode
Please strictly follow the in
structions
of system to operate
No
Start
⑤ Exhaust is ongoing.
Diagnosis front page
Air bleeding mode
The bleeding mode is processing,
pump is started and this process will
last for 20 s
Start
J4 Service Manual
Brake System
BR-51
⑥ The first step is finished.
1
st
step completed
Air bleeding mode
Enter
Start
⑦ The second step of exhaust.
Air bleeding mode
2nd step
The bleeding of right rear wheel is
processing. Please connect oil outlet
pipe, screw off right rear bleed bolt,
and then step brake pedal.
Enter
Start
⑧ Exhaust is ongoing.
Diagnosis front page
Air bleeding mode
The bleeding mode is processing,
pump is started and this process will
last for 20s.
Start
J4 Service Manual
Brake System
BR-52
⑨ The third step.
3
r
d
step:
Deflate the rear left wheel tire,
connect the oil drain pipe, open
left and right blee
d bolts, and
then depress the brake pedal
Air bleeding mode
Enter
Start
⑩ Exhaust is ongoing.
Diagnosis front page
Air bleeding mode
The bleeding mode is processing,
pump is started and
this process will
last for 20s
Start
⑪ The third step is finished.
3
rd
step completed
Air bleeding mode
Start
Enter
J4 Service Manual
Brake System
BR-53
⑫ The fourth step
Enter
Air bleeding mode
4
th
step:
First front right wheel blow
off,
please connect with oil drain pipe,
open front left bleed bolt, and depress
in brake pedal
Start
⑬ Exhaust is ongoing.
Diagnosis front page
Air bleeding mode
The bleeding mode is processing,
pump is started and this process will
last for 20s.
Start
⑭ The fourth step is finished.
Enter
Air bleeding mode
5
th
step:
First front right wheel blow
off,
please connect with oil drain pipe,
open front right bleed bolt, and
depress in brake pedal
Start
J4 Service Manual
Brake System
BR-54
⑮ The fifth step.
Enter
Air bleeding mode
第五步：
First front right wheel blow
off,
please connect with oil drain pipe,
open front right bleed bolt, and
depress in brake pedal
Start
⑯ Exhaust is ongoing.
Diagnosis front page
Air bleeding mode
The bleeding mode is processing,
pump is started and this process will
last for 20s.
Start
⑰ The process of exhaust is finished.
Enter
Air bleeding mode
Bleed processing is completed.
Start
J4 Service Manual
Brake System
BR-55
Fault diagnosis
1. Brief introduction of failure diagnosis
1) Do failure diagnosis to get a thorough understanding of various system (control and
mechanism) of the vehicle.
2) Know the customer’s complaints before check. After understanding the symptoms, carefully
ask to the client about the complaint.
3) The symptom check must start from the initial stage, so as to completely correct the fault. It
is very important to playback the symptom for intermittent fault according to the meeting
with the customer and the past cases. Do not check according to some special conditions.
Most of intermittent faults are caused by poor contact. It is effective to sway the suspicious
wire harness or the plug-in with hands under such circumstances.
4) After completing diagnosis, make sure to perform “Clear DTC”.
J4 Service Manual
Brake System
BR-56
2. Diagram of diagnosis process
Diagnosis process is as follows:
3. Diagnosis information and process
1) Self-diagnosis
The Abs control module performs self-diagnosis on the system, which can detect the system
fault. Once it is in trouble, set up the diagnostic trouble code (DTC), turn on the ABS
warning light, and shut down the ABS system at the same time.
2) Display of failure diagnosis
The special scan tool can display DTCs.
3) Clearing failure diagnosis
The DTCs in the ABS control module memory can be cleared by the scan tool.
Caution:
■ Check if the system operation is normal and DTC appears after the clearing step.
清除自诊断结果，以
30km/h
或更
高的车速驾驶一分钟以上
确定故障内容
了解
”
注意
事项
”
速诊断以最快找出故障
进行初步检查
ABS
故障灯是否亮
诊断仪是否显示故障码
进行自我诊断
检查与修理故障零件
再次进行自诊断
检查结果
检查
ABS
执行器和电气
单元与数据连接口线束
进行症状诊断程序
确认症状
正常
Determine fault contents
If diagnostic unit display DTCs
Do self-diagnosis again
Check and repair faulty parts
Do self-diagnosis again
Check the result
Confirm the symptoms
Abnormal
Familiar with “Caution items” and the
method to find faults soonest
Do primary inspection
Is ABS trouble light on?
Y
N
N
Y
Abnormal
Normal
Normal
Implement symptom diagnosis process
Check ABS actuator and the harness
of electrical unit and data connector
Clear self-diagnosis result, and drive the
car at the speed of 30 km/h or higher for
more than 1 min
J4 Service Manual
Brake System
BR-57
■ The DTC shall not be cleared away by dismantling the ABS control module plug-in,
disconnecting the battery wire or going out.
4) Intermittent faults or intermittent faults due to poor contact are mostly caused by the
following conditions:
① Incorrect electric wiring.
② Fault electric connecting.
③ Stuck relay or solenoid valve.
5) Initialization Order
The ABS control module performs initialization test at the beginning of the each ignition
cycle.
The initialization order is: solenoid valve and pump motor, to check if the part operation is
normal. If a fault is detected, the ABS control module will set the corresponding DTCs. You
can hear or feel some actions during initializing order and this is one part of the normal
operation of the system. If the ABS control module discovers no signal is input in the brake
switch (the foot releases the brake pedal), initialize immediately. If the signal is input into the
brake switch (the foot pushes down on the brake pedal), stop initializing until no signal is
input in the brake switch (the foot releases the brake pedal) or the speed is up to 16Km/h.
4. Diagnostic circuit inspection
1) System specification
The diagnostic circuit can detect the problems caused by faulty ABS/EBD system. The
diagnostic circuit check will guide the service technician to perform the next step of
diagnosing fault.
2) Diagnosis procedure
Maintenance steps of ABS/EBD system as follows:
① Check if the vehicle has mechanical faults related to the brake system.
■ The level of the brake fluid reservoir is correct.
■ Check the brake fluid of the master cylinder for pollution.
■ Check the brake master cylinder/ABS hydraulic assembly for leakage.
■ Check the brake parts of all wheels.
■ Verify whether brake drag exists.
■ Verify whether braking is stable (drag or rush-out).
■ Check the brake shoe for wear/damage.
■ Check the wheel bearing for damage.
■ Check the wheel (speed) sensor and harness.
■ Check the wheel speed sensor connector/ring gear for damage/check the tire tread
depth/wear degree.
■ Carry out road test, verify the condition and correct.
J4 Service Manual
Brake System
BR-58
② The check of diagnostic circuit must follow the applicable diagnostic fault procedure. All
system faults are removed, clear ABS DTCs.
Fault Diagnosis Table
Steps
Diagnostic
Yes
No
1
1. If possible, connect or install all parts disconnected or removed
previously.
2. Turn the ignition switch to ON position, and the engine stops.
3. Install the applicable scan tool on DLC, and make it communicate with
the ABS control module.
To steps 2
To steps 4
2
Are there current or past DTCs?
To steps 3
To steps 7
3
1. Record current DTCs
2. Record the past DTCs.
3. Record the historical data, for example, the time set by various DTCs,
the time firstly set from various DTCs, the time previously set from
various DTCs, the speed when setting the DTC, and other enhanced
data that are helpful to diagnosis.
4. Do not clear DTCs before recording the information from the scan tool.
4
Can the scan tool communicate with other modules on the same data line?
To steps 5
To steps 6
5
To "no communication with ABS control module" in ABS control module
fault procedures.
6
Go to the data link connector unit of the electrical end part.
7
1. Flameout.
2. Wait for 10 seconds.
3. Start the engine.
4. Observe the ABS warning light after starting.
To steps 8
To steps 9
8
Is any light always on?
To steps 9
To steps 10
9
Go to the “ON” fault procedure of the corresponding light.
10
Go to the “INOPERATIVE” fault procedure of the corresponding light.
5. Common Symptoms and Analysis Procedure of ABS
1) Lost communication with ABS control module
The typical causes of lost communication with ABS control module are:
■ Poor contact of diagnostic port.
■ ABS control module not grounded.
■ No voltage provided by battery to ABS control module
■ No voltage provided by ignition switch to ABS control module
■ Data line open/short circuit.
■ Data line resistance is too high.
J4 Service Manual
Brake System
BR-59
2) ABS warning light NOT ON/no DTCs
The typical causes of ABS warning light failed and no DTCs set are:
■ Fault-ABS warning light / loose socket.
■ Instrument panel fuse disconnecting.
■ Fault-instrument warning light drive module.
■ Fault-ABS control module.
■ Open or short line between ABS control module and instrument.
3) ABS warning light on/no DTCs
The typical causes of ABS warning light on with no DTCs set are:
■ Open circuit between instrument and ABS control module.
■ ABS control module is not grounded.
■ Short circuit between instrument and ABS control module.
■ Fault-instrument warning light drive module.
■ Fault-ABS control module.
4) Brake warning light ON
The typical causes of the brake warning light on with no DTCs set are:
■ Fault-parking brake switch.
■ Too low brake fluid level or faulty brake fluid switch.
■ EBD failure due to the following faults in ABS.
a. Failed two concentric wheel speed sensors.
b. Open circuit to battery or short circuit to ground.
c. Motor grounded or short circuit to battery.
e. ABS control module is open to ground wire or short to battery.
f. Open circuit to ignition switch or short circuit to ground.
■ Instrument and ABS control module open circuit.
■ Fault warning lamp circuit.
■ Instrument fault
■ Faulty ABS control module
5) Brake warning light not on/no DTCs set
The typical causes of brake warning light not on and no DTCs set are:
■ Fault-bulb/loose socket.
■ Instrument panel fuse disconnecting.
■ Instrument fault
J4 Service Manual
Brake System
BR-60
■ Faulty ABS control module
■ The circuit between ABS control module and instrument is grounded.
J4 Service Manual
Steering System
PS-1
Chassis - Steering system
Precautions
■ When inspecting steering system, place the vehicle on level and dry ground.
■ The bolts of the components in the steering system must be tightened to the specified torque.
■ After overhauling the steering column assembly, steering gear and other steering mechanism,
it is necessary to check wheel alignment.
■ Maximum voltage of system should not exceed 18V, and minimum voltage should not be
less than 9V.
■ Check frequently and keep the tire pressure at the specified value.
■ Once there is abnormal clearance, sticking, head swinging symptoms, it is necessary to find
out where is the fault position, steering drive transmission unit, power steering system or
steering pull rod system, and eliminate the fault.
■ Check with care the parts of the steering system for abnormal impact frequently. For
damaged parts or fault parts, it is necessary to timely replace it.
■ Do not weld the part of steering gear and system rods in any manner.
■ Regularly check if there is interference or abrasion of EPS wire harness, whether connector
is loose. If any abnormality is found, timely replace it.
Preparation work
General Tools Table
No.
Tools
Overall Diagram
Instructions
1
Power tool
Removal and Installation of Bolts
Nut
Electric Power Steering System Overview
Power steering system is designed to reduce driver's working intensity. As passenger cars need to
run fast and the load to steering wheel increases, power steering gear becomes indispensable and
is used very widely. Power steering system has such advantages:
It can reduce steering force on the steering wheel. It's especially obvious when taking a turning in
the original place or at a low speed but a large turn angle.
■ Steering sensitivity is improved.
■ The kickback of ground against the steering wheel is reduced.
■ This can protating speedent wheels from turning suddenly if a tire explodes, thus ensuring
service safety.
■ If the allowed load of steering wheel is larger, it may increase freedom of the entire setup.
J4 Service Manual
Steering System
PS-2
■ They are relatively more energy saving and environmental protection.
Composition of power steering system:
Power steering system consists of steering wheel assembly, steering pipe with intermediate shaft
assembly, mechanical steering gear assembly, etc. Of which, mechanical steering gear is the
actuating part of electric booster of steering system. Steering column motor is linked with the
complete vehicle power supply system, which provides power source for the system.
The structure of power steering system is diagrammed as follows:
Structure diagram of power steering system
1-Steering wheel assembly 2-Steering column with intermediate shaft assembly
3-Mechanical steering gear assembly
Steering process:
When rotating steering wheel, torque sensor detects the change of torque exerted on the steering
wheel, and instructs boosting motor to rotate through ECU control unit, so as to drive steering tie
rod assembly to move and achieve boosting steering function.
Returning process:
After steering, the force exerted on the steering wheel disappears. Torque sensor detects the
change of torque exerted on the steering wheel and instructs boosting motor stop rotates through
ECU control unit. Under the effect of self-aligning torque of front wheel, the vehicle will travel
straightly forward until the vehicle returns to straight traveling position.
Road feel effect:
Road feel effect refers to the ability of causing the steering feeling. When driver exerts force to
the steering wheel, it also acts on the torsion bar of steering gear simultaneously, so that it's
deformed torsionally. This deformation depends on wheel turning resistance; the deformation
increases as the resistance increases. So the driver can feel the change of steering resistance based
on the force he exerts to the steering wheel.
3
2
1
J4 Service Manual
Steering System
PS-3
Steer wheel
Inspection in the car:
1) Check installation conditions
① Check if steering device assembly, front suspension, axles and steering column are installed
correctly.
② Check if there is any moving clearance when steering wheel moves vertically, transversely
and axially.
③ Check if set nuts and bolts of steering device assembly are loose.
2) Check the free travel of the steering wheel
① Turn the steering wheel to keep the front wheels straight forward. Start engine and rotate
steering wheel leftwards or rightwards gently until front wheels begin to move. Measure the
movement of the steering wheel on the excircle.
■ Free stroke of the steering wheel: 30 mm
② When the measured value exceeds the standard value, check installation of each joint of
steering column and the steering mechanism. Correct or replace relevant parts as necessary.
③ If the idled travel exceeds 30mm still, shut off engine, make front wheels run in a line, exert
5 N along periphery of steering wheel and check the idled travel, which shall not exceed 10
mm. If it exceeds 10mm, check if the steering gear assembly is eligible.
④ If the travel is still at a limit, leave steering wheel in the middle when the engine is shut
down, exert 4±0.6 N to the periphery of steering wheel and check the free travel.
■ Standard value: < 15 mm
⑤ If it exceeds the standard value, remove the steering gear and check the total torque of the
pinion.
3) Check the middle.
① Ensure steering device assembly, steering column and steering wheel are installed correctly.
② After wheel alignment, perform the middle position inspection. Please refer to "Inspection of
front wheel alignment".
③ Stop the vehicle straight forward, and confirm that the steering wheel in the middle.
④ Release the tie rod lock nut and rotate the adjustment level left and right for fine tuning to
affirm whether the steering wheel is in the middle.
4) Check the static steering force of the steering wheel
① Stop the vehicle on a flat dry ground, and pull up the parking brake lever.
② Start the engine.
Caution:
■ The tire pressure value shall be within the standard value.
J4 Service Manual
Steering System
PS-4
③ Rotate the steering at wheel 360° from the middle position to check the steering effort of the
steering wheel and to check if there is obvious fluctuation.
■ Steering force of steering wheel: < 34 N Allowable fluctuation: < 5.9 N
④ If the steering force of the steering wheel exceeds the specified value, check or adjust the
following items:
a. The lower swing arm and steering tie rod end for damage.
b. The gear preload of steering gear and the rotating torque of steering tie rod end.
c. The rotating torque of lower swing arm ball joint.
5) Check self-return of steering wheel
Caution:
■ Turn slowly and sharply to confirm whether its acting force and the returning performance
have no difference along the left direction and the right direction by feeling.
■ Be sure to execute the step on the safe road surface and in safe traffic condition, pay
attention to safety.
Rotate the steering wheel at 90° and run at the speed of 35
km/h to hold for few seconds, and then release the steering
wheel to return at least more than 70%.
6) Inspection of front wheel steering angle
① Check the toe-in of the front wheel and then its
steering angle. Place the front wheel in the steering
angle measures (front wheel positioning steering
wheel) to check the maximum inner and outer wheel
steering angle of the left and right wheels.
■ Inner wheel: 36°±1.5°
Outer wheel : 30°±1.5°
② When engine idles, measure steering angle by rotating steering wheel left and right to the
end.
■ If the measured value is not within the standard range, adjust the tie rod.
The adjustment method of steering angle is as follows:
When the steering angle exceeds the standard value, release the lock nut of the left and right
steering tie rods, rotate the left and right tie rods with the wrench respectively to adjust the
steering angle to the standard value, and then lock the lock nut with the tightening torque of 50-55
PS002
PS001
J4 Service Manual
Steering System
PS-5
N•m. When adjusting the exposed length of the thread of left and right tie rod, pay attention to
make the length of left and right tie rods uniform.
Caution:
■ When the inner wheel steering angle exceeds standard, adjust the tie rod at this side to rotate
outward to increase the inner wheel steering angle; and when the outer wheel steering angle
exceeds standard, adjust the tie rod at this side to rotate outward to reduce the outer wheel
steering angle.
Caution:
■ The toe-in is related to other wheel alignment parameters and steering wheel adjustment.
7) Inspection of the tie rod end dust cover
① Press with finger, and check the dust cover for cracks or damage.
② If there are cracks or damage on the dust cover, replace the steering tie rod end.
Caution:
■ When the dust cover has cracks or damage, the tie rod end may be damaged jointly.
8) Check the rotating torque of the steering tie rod end
① Swing the tie rod 10 times quickly.
② Measure the swing resistance of the tie rod with a
spring scale.
■ Standard value: 0.5-3 N•m
■ If the measured value is not within the standard
value, replace.
Steering wheel assembly
Removal and installation:
1) Dismantle
① Disconnect the battery negative terminal, and wait for
above 3 minutes.
② Remove the driver’s airbag module from the steering
wheel.
③ Lock steering and remove the set screw nut of the
steering wheel.
■ Tightening torque: 42-52 N•m
④ Lift up the steering wheel from the steering shaft.
Caution: If it’s not easy to pull it out, please use the steering wheel puller.
2) Install
Install it according to the reverse order of dismantling.
PS004
PS003
J4 Service Manual
Steering System
PS-6
Horn cover assembly dismounting as following steps:
1. Connection area between steering wheel and DAB clamp (red circle)
2. Assembly drawing of steering wheel and DA
Schematic Diagram of DAB Dismantling on Complete Vehicle (total 3 steps). Use the flathead
screwdriver (15cm) as a special tool.
1. Dismantle 3H dismantling hole: rotate steering wheel for 90° counterclockwise, and use
screwdriver to pry the groove of 3H dismantling hole (for detailed structure, refer to right
above figure) to separate DAB claw from steering wheel bracket.
② Dismantle 6H dismantling hole: rotate steering wheel for 90° counterclockwise again, and
use screwdriver to pry the groove of 6H dismantling hole (for detailed structure, refer to right
above figure) to separate DAB claw from steering wheel bracket.
③ Dismantle 9H dismantling hole: turn steering wheel to middle position and rotate steering
wheel for 90° clockwise again, and use screwdriver to pry the groove of 9H dismantling hole
(for detailed structure, refer to right above figure) to separate DAB claw from steering wheel
bracket.
3. Horn cover assembly
Align the steering wheel with connection area of DAB and press them; meanwhile Check if the
clearance is uniform.
9H dismounting
hole
3H dismounting
hole
6H dismounting
hole
J4 Service Manual
Steering System
PS-7
Caution:
■ The installation can be performed only when wheels are in straight driving state and the
steering wheel is in the middle. Or, make marks on the steering wheel and set bolt in advance
before removal, and ensure that the marks are aligned during installation.
■ The steering column must rotate smoothly and do not make click sound or shall not be stuck
in the installing condition.
■ After installing the other parts on the steering wheel, adjust the gradient of the steering wheel
and the steering column 5-6 times; the maximum force applied for operating the locking
position of the steering column shall not exceed 60-100 N. When the locking position of the
steering column is in the free position, the maximum force applied for the gradient of the
steering wheel and the steering column shall not exceed 100 N.
■ Mounting position of clock spring (hair spring).
■ Do not distort timer spring after tightening it.
Steering column assembly
Diagram of Steering Column Assembly:
Schematic diagram of Steering Column Assembly:
1- Steering column assembly 2- Countershaft assembly
Caution:
■ Do not apply excessive axial force to the steering column assembly during removal and
installation.
■ Do not move the steering gear when removing the steering column.
Removal and installation:
1) Dismantle
① Park the vehicle straight.
② Disconnect the battery negative terminal, and wait for above 3 minutes.
1
2
J4 Service Manual
Steering System
PS-8
③ Remove the driver airbag module.
④ Remove the steering wheel.
⑤ Remove the steering column upper and lower covers and driver’s instrument panel lower.
⑥ Remove the combined switch assembly and clock spring from the steering column.
⑦ Disconnect all wire harness connectors on the steering column, and move away the wire
harness from the steering column assembly.
⑧ Unscrew off the connecting bolts of steering
column with lower shaft and separate the column
from the steering gear.
■ Tightening torque: 30-35 N•m
⑩ Unscrew off the fixing nut on the steering column
assembly, turn down the column and take out the
column assembly.
■ Tightening torque: 20-30 N•m
2) Inspection after disassembly
① Check if steering column is cracked, deformed or otherwise damaged. If so, replace it.
② Check the spline of the steering column shaft for wear or broken tooth, and replace if any.
3) Disassemble
① Disassembly
a. Unscrew connecting bolts of steering column and universal joint of connecting shaft, and
then dismantle universal joint.
b. Remove the steering lock if necessary.
Caution:
■ Make sure to replace the special bolts when re-installing the steering lock.
PS006
PS005
J4 Service Manual
Steering System
PS-9
c. Remove the adjustable steering column and bracket if
necessary.
② Key point of disassembly
Removal of special bolts:
a. Use an electric drill to make a hole on the special bolt,
which is big enough to receive the screw tap.
b. Use a negative screw tap to remove the special bolt.
4) Check after dismantling
① Check the adjusting bracket and spring for cracks and damage.
② Check if the steering lock mechanism is operated normally.
5) Assembly
Assemble steering lock assembly, bracket assembly and special bolt.
Caution:
■ When installing on the steering column assembly,
align the steering lock assembly and the steering lock
bracket with the lock notch of the steering column to
temporarily lock the steering lock.
■ After confirming the steering lock correctly operates,
lock the special bolt until the bolt head is locked off.
6) Installation
Install it according to the reverse order of dismantling.
Caution:
■ Do not reuse the unavailable part.
■ Keep the steering wheel in the middle and install the steering column assembly.
■ When installing the connecting shaft on the steering column, note the installation position.
7) Inspection after installation
When the vehicle stops straight, turn the steering wheel to the end several times, and confirm
that the steering wheel is operated flexibly.
Gap
PS008
Gap
PS007
Steering lock support
Special bolt
Cross bite screw tap
Steering lock body
J4 Service Manual
Steering System
PS-10
Power steering gear assembly
Component
Component Diagram of Steering Gear
Caution:
■ If rotating the steering wheel when separating the steering column from the steering gear
assembly, it may injure the clock spring. So you must fix the steering wheel first.
Removal and installation:
Caution:
① Stop the vehicle straight forward.
② Disconnect connecting bolts of intermediate shaft
assembly and mechanical steering gear from driver's
cab, and then separate steering column and steering
gear.
■ Tightening torque: 30-35 N•m
③ Remove the locking nut of the tie rod end.
■ Tightening torque: 50-55 N•m
④ As shown in the figure, remove the steering tie rod
end from the steering knuckle with special tool.
⑤ Remove the front sub-frame assembly and engine
mount.
Caution:
■ Please use jack to support.
PS011
PS010
Ball joint
Rope
Lock nut
PS009
J4 Service Manual
Steering System
PS-11
⑥ Remove fixing bolt of mechanical steering gear on
the sub-frame.
■ Tightening torque: 110-120 N•m
⑦ Take down power steering gear assembly on the
frame.
Caution:
■ Take out slowly with care, and do not damage the tie rod dust cover.
2) Inspection after removal
① Mechanical steering
■ Check the gear rack for smooth operation and wear.
■ Check the gear preload.
a. Rotate the gear at the speed of 4-6 s per turn and measure the pre-load of the gear within the
full range of the rack.
■ Standard value: 0.6-1.3 N•m
b. If the measured value exceeds the specified value, adjust the plug, and then re-check the gear
preload.
c. If it is still incapable of obtaining the specified pre-load of the gear by adjusting the blockage,
check or replace the blocking component.
② Steering tie rod
■ Check the rotating torque of steering tie rod.
a. Rotate the tie rod rapidly for 10 times.
b. Measure the swing resistance of the tie rod with a spring scale.
■ Standard value: 0.5-3 N•m
If the measured value is not within the standard value, replace.
Caution:
■ When the tie rod slowly swings without excessive clearance, it can be still used even if the
measuring value is lower than standard value. If the measured value is high than 4.3 N•m,
the tie rod must be replaced.
③ Tie rod dust cover
■ Check the dust cover for damage, and replace if any.
■ Check the dust cover for correct installation position.
3) Installation
Install it according to the reverse order of dismantling.
PS012
J4 Service Manual
Steering System
PS-12
Caution: Do not reuse non-reusable components.
Caution:
■ When machinery the power steering gear with the steering column, pay attention to the
installation position.
■ When machinery the power steering gear assembly, keep the tires on the level ground in an
idle condition to finally tighten the nut and the bolt.
■ Check the wheel alignment.
4) Inspection after installation
■ Turn the steering wheel to the end left and right several times, and confirm that the steering
wheel is operated flexibly.
EPS ECU DTC
Fault code
Description
C1111
Sensor main signal fault
C1115
Sensor sub-signal fault
C1114
Sensor power supply fault
C1113
Main and sub-fault of sensor
C1141
Motor and current open circuit
C1142
Motor and current is abnormal 1
C1145
Motor and current is abnormal 2
C1153
Power supply voltage is too low
C1112
Power supply voltage is too high
C1154
Abnormal relay
C1121
Speed signal fault 1
C1123
Speed signal fault 3
C1124
Speed signal fault 4
C1122
Engine revolving speed signal fault
C1155
Temperature is abnormal or ROM is error.
Countermeasures to common faults
Deviation (test the vehicle on a flat road from two directions);
Failure causes
1) Steered-wheel ball joint or front wheels are positioned incorrectly.
2) The steering lever system is twisted, deformed and over-worn.
3) Pretightening of rack inside steering gear is misadjusted.
4) Steering wheel vibrates, returns poorly or strikes driver's hand when .
Elimination of faults:
J4 Service Manual
Steering System
PS-13
1) Adjust front-wheel alignment and ball joint of steered wheel.
2) Adjust or repair pretension of steering gear rack.
3) Check and adjust each joint of steering system as required.
Maintenance data and specification
Specification Table
Item
Specifications
Diameter of steering wheel
φ375mm
Steering column and lower shaft
Three-class crumple
Operation torque of steering wheel
4.5±0.5 N•m
Power steering gear rack travel
130±2 mm
Wire drive ratio
45.3
Circle number of steering wheel
2.87±0.1
Mechanical steering gear type
Pinion and rack
Fastening Torque Table
Item
Quantity
Fastening torque (N•m)
Fixing nut of steering wheel
1
42-52
Steering column mounting nut
2
20-25
Steering column mounting bolt
1
20-30
Steering column assembly and intermediate shaft assembly
connecting bolt
1
30-35
Connecting bolt between intermediate shaft assembly and
mechanical steering gear
1
30-35
Main fixing bolt of mechanical steering gear
2
100-110
Fixing bolt of mechanical steering gear
2
110-120
Steering tie rod tie-in adjusting nut
2
50-55
Steering gear ball head slotted nut
2
50-55