B-ClassSedanServiceManualForeword

Foreword

ForewordMaster

Master

MasterTable

Table

Tableof

ofContents

Contents

Thismanualisintendedtohelptheprofessional

maintenancetechniciansauthorizedby

JianghuaiPassengerCarSalesCompany

provideeffectiveandcorrectmaintenanceand

serviceforJACB-Classseriesmodels.The

warmserviceandproperoperationfromthe

professionalmaintenancetechniciansofJAC

passengercarsareessentialforensuring

customersatisfactiontoJACpassengercar

products.Therefore,themaintenance

techniciansmustunderstandthismanualfully.

Thismanualshouldbeplacedinahandyplace

foryourconvenientreference.

Allcontentsofthismanualincludingpictures

andtechnicalparametersarelatest.Incase

maintenanceworksareaffectedduetoproduct

improvement,JianghuaiPassengerCarSales

Companywillprovidetechnicalbulletinsor

supplementaryvolumes.Therefore,youshould

usethismanualandpaycloseattentionto

obtaininglatestupdaterelevantinformation.

JianghuaiPassengerCarSalesCompany

reservestherightstochange,addorimprove

designsofitsproducts.

Nopartofthismanualisallowedtobe

reproducedormodifiedinanyform,including

butnotlimitedtoelectronicmedia,paper,

soundandimage,andmechanicalmedia,

withoutwrittenauthorizationfromJianghuai

PassengerCarSalesCompany.

UseofnongenuinesparepartsforJAC

passengercarsornonconformingoilsduring

maintenanceandserviceprocessesofJAC

passengercarproductsmaycausevehicle

damage.

Engine

General

GeneralDescription

Description

Description&

&Maintenance

Maintenance

Engine

Chassis

Clutch

Clutch&

&Manual

Manual

ManualTransmission

Transmission

Driveline/Axles

Suspensions

Brakes

Steering

Body

BodyElectrical

Electrical

Electrical&

&Structure

Structure

Body

BodyElectrical

Electrical

Body

BodyStructure

Structure

Body

BodyDimension

Dimension

DimensionData

Data

Circuit

CircuitTroubleshooting

Troubleshooting

J5 AT Sedan Service Manual

Chassis Contents

Chassis

Clutch & Manual Transmission ·························

CL-1

CL Clutch ························································

CL-1

Precautions ·································································

CL-1

Preparation ·································································

CL-1

System Description ·······················································

CL-2

Disassembly and Installation ············································

CL-3

Inspection and Maintenance·············································

CL-5

Clutch Hydraulic Fluid ···················································

CL-7

Trouble Diagnosis ························································

CL-7

Service Data and Specifications ········································

CL-10

MT Manual Transmission ·····································

MT-1

Precautions ·································································

MT-1

Preparation ·································································

MT-1

Gear Select and Shift Control Mechanism ····························

MT-4

Selector Lever ·····························································

MT-7

Control Shaft Assembly ··················································

MT-7

Transmission Assembly ··················································

MT-10

Input Shaft ·································································

MT-19

Output Shaft ·······························································

MT-26

Vehicle Speed Sensor Gear ··············································

MT-32

Clutch Housing ····························································

MT-33

Transmission Housing ···················································

MT-36

J5 AT Sedan Service Manual

Chassis Contents

Differential ·································································

MT-37

Trouble Diagnosis ························································

MT-40

Service Data and Specifications ········································

MT-41

Drive Train/Axle ············································

FAX-1

FAX Front Axle ··················································

FAX-1

Precautions ·································································

FAX-1

Preparation ·································································

FAX-1

Front Wheel Hub and Steering Knuckle ·······························

FAX-2

Front Drive Shaft ·························································

FAX-7

Trouble Diagnosis ························································

FAX-14

Service Data and Specification ·········································

FAX-15

RAX Rear Axle ··················································

RAX-1

Precautions ·································································

RAX-1

Preparation ·································································

RAX-1

Rear Wheel Hub and Steering Knuckle ·······························

RAX-1

Service Data and Specification ·········································

RAX-4

Suspension ···················································

FSU-1

FSU-Front Suspension ·········································

FSU-1

Precautions ·································································

FSU-1

Preparation ·································································

FSU-1

Front Suspension Assembly ·············································

FSU-2

Front Shock Absorber ····················································

FSU-4

Lower Swing Arm ························································

FSU-7

J5 AT Sedan Service Manual

Chassis Contents

Transverse Stabilizer Bar ················································

FSU-8

Transverse Stabilizer Bar Tie Rod ······································

FSU-9

Front Sub Frame Assembly ·············································

FSU-10

Trouble Diagnosis ························································

FSU-12

Service Data and Specification ·········································

FSU-13

RSU Rear Suspension ··········································

RSU-1

Precautions ·································································

RSU-1

Preparation ·································································

RSU-1

Rear Suspension Assembly ··············································

RSU-2

Rear Shock Absorber ·····················································

RSU-4

Rear Suspension Front Transverse Tie Rod, Rear Suspension

Rear Tie Rod ·······························································

RSU-8

Longitudinal Track Bar Assembly ······································

RSU-9

Rear Stabilizer Bar Connecting Rod ···································

RSU-9

Rear Transverse Stabilizer Bar ··········································

RSU-10

Rear Sub Frame Assembly ··············································

RSU-11

Trouble Diagnosis ························································

RSU-12

Service Data and Specification ·········································

RSU-12

WT Wheel And Tire ············································

WT-1

Precautions ·································································

WT-1

Tire ··········································································

WT-1

Wheel and Tire Assembly ···············································

WT-3

Trouble Diagnosis ························································

WT-5

Service Data and Specification ·········································

WT-6

J5 AT Sedan Service Manual

Chassis Contents

Brake ··························································

BR-1

BR Brake System ···············································

BR-1

Precautions ·································································

BR-1

Preparation ·································································

BR-2

Brake Pedal ································································

BR-2

Brake Master Cylinder ···················································

BR-4

Brake Fluid ································································

BR-6

Brake Pipe ·································································

BR-6

Brake Vacuum Booster ···················································

BR-10

Front Disc Brake Caliper ················································

BR-12

Rear Disc Brake Caliper ·················································

BR-18

Trouble Diagnosis ························································

BR-20

Service Data and Specification ·········································

BR-21

PB Parking Brake System ·····································

PB-1

Precautions ·································································

PB-1

Parking Brake Control ···················································

PB-1

Trouble Diagnosis ························································

PB-4

Anti-Lock Brake System (ABS) ······························

ABS-1

Precautions ·································································

ABS-1

Preparation ·································································

ABS-2

System Description ·······················································

ABS-2

Wheel Speed Sensor ······················································

ABS-5

ABS Hydraulic Assembly ···············································

ABS-7

J5 AT Sedan Service Manual

Chassis Contents

ABS Control Module ·····················································

ABS-8

Air Bleeding of ABS System············································

ABS-12

Trouble Diagnosis ························································

ABS-17

Analysis of ABS Trouble Codes ········································

ABS-25

Steering ·······················································

PS-1

Power Steering System ·········································

PS-1

Precautions ·································································

PS-1

Preparation ·································································

PS-1

Overview of Power Steering System ··································

PS-2

Power Steering Fluid ·····················································

PS-4

Steering Wheel ····························································

PS-7

Steering Column ··························································

PS-11

Power Steering Gear······················································

PS-14

Power Steering Pump ····················································

PS-21

Hydraulic Pipeline ························································

PS-23

Trouble Diagnosis ························································

PS-24

Service Data and Specification ·········································

PS-33

CL005

B-ClassSedanServiceManualCLClutch

CL-1

Clutch

Clutch&

&Manual

Manual

ManualTransmission

Transmission

CLClutch

Clutch

Precautions

�Recommendedclutchhydraulicfluidis“DOT4”.Pleasedonotusemineraloils

suchasgasolineorkerosene;otherwise,therubberpartsofthehydraulicsystem

willbecorroded.

�Pleasedonotreusedrainedclutchhydraulicfluid.

�Becarefulnottosplashclutchhydraulicfluidonbodypaintwork.

�Donotcleanclutchpressureplateusinggasoline!

�Releasebearingisfilledwithgrease.Pleasedonotcleanitusingoilsorliquids.

Warning:

�Whencleaningclutchfrictionplate,pleaseuseadustcollector.Neveruse

compressedairtocleanitup!

Preparation

Thespecialtoolusedisshownbelow:

ListofSpecialTools

SNToolOutlinedrawingNumberDescription

1Flywheelstopper

JAC-T1F011Fixingflywheel

Descriptionofsymbolsinpictures:

Applyandfillgrease

Applybrakefluid

B-ClassSedanServiceManualCLClutch

CL-2

System

Systemdescription

description

System

Systemdiagram:

diagram:

ClutchControlSystemDiagram

1-Clutch2-Clutchreleasecylinder3-Releasefork4-Releasebearing5-Clutchline

6-Clutchmastercylinder7-Clutchpedal8-Reservoir

ClutchControlSchematicDiagram

1-Clutchpedal2-Clutchmastercylinder3-Clutchhydraulicline4-Clutchreleasecylinder

5-Releasefork6-Pressureplate7-Drivenplate8-Flywheel

Brief

Briefprinciple:

principle:

Clutchcontrolreferstoenablingpowertransmissionandcutbetweenengineand

transmissionbycontrollingclutchengagementanddisengagementbymeansof

remotehydrauliccontrol.Thespecificimplementationisasfollows:

Disengagement:Afterthedriverdepressesclutchpedal1,thepushrodsonthepedal

andclutchmastercylinder2willpushthespecialclutchhydraulicoilstoredinmaster

cylinder2intoreleasecylinder4throughline3composedofclutchtubeandhoseto

pushthereleasebearingaxiallyforwardthroughfork5.Thenthediaphragmspringof

clutchpressureplate6ispushedtodisengage,sothedistancebetweenpressureplate

B-ClassSedanServiceManualCLClutch

CL-3

6andflywheel8willincreaseandsowillthecavitygapformedbydrivenplate7,

flywheel8,andpressureplate6andthuspoweriscutasdrivenplate7graduallycan

nottransmitpowertothetransmissioninputshaftduetoreducedfrictionalforce.

Engagement:Whenthedriverreleasesclutchpedal1slowly,thediaphragmspring

releasefingerofpressureplate6willreturnautomaticallylittlebylittlebecausethe

pressureonitisreduced,sotheleveragewillreducetheliquidchamberoftheslave

cylinderandincreasethatofthemastercylinderandthustheclutchpedalisraised

slowly.Atthesametime,thedistancebetweenpressureplate6andflywheel8will

decreaseandsowillthecavitygapformedbydrivenplate7,flywheel8,andpressure

plate6andthuspowerisengagedasdrivenplate7graduallycantransmitpowerto

thetransmissioninputshaftduetoincreasedfrictionalforce.

Disassembly

Disassemblyand

and

andInstallation

Installation

Clutch:

ExplodedViewofClutchAssembly

1-Clutchfluidlinebracket2-Insulator3-Washer4-Clutchpipe5-Unionbolt

6-Pipeunion7-Gasket8-Clutchreleasecylinder9-Clutchpressureplate

10-Clutchdrivenplate11-Returnspring12-Clutchreleaserearing13-Releasefork

14-Releaseforkguard15-Releasepin

B-ClassSedanServiceManualCLClutch

CL-4

Orders

Ordersof

ofremoval

removal

removaland

and

andinstallation:

installation:

RemoveandinstallaccordingtotheSNsin

theexplodedview.

Release

Releasefork

fork

forkremoval:

removal:

Movethereleaseforkinthedirectionof

arrowshowninthefigureatrighttoremove

theclipfromtherestpin.

CL001

Release

Releasefork

fork

forkinstallation:

installation:

Applyandfillgreasetotheplacesonthe

releaseforkasshowninthefigureand

installinthereverseorderofremoval.

CL002

Releasefork

(Coating)

(Filling)

B-ClassSedanServiceManualCLClutch

CL-5

Clutch

Clutchrelease

release

releasecylinder:

cylinder:

ExplodedViewofClutchReleaseCylinder

1-Nutcap2-Bleederplug3-Pushrod4-Guard5-Pistoncup6-Piston

7-Conicalspring8-Releasecylinder

Removal

Removaland

and

andinstallation:

installation:

RemoveandinstallaccordingtotheSNsintheexplodedview.

Piston

Pistoncup/piston

cup/piston

cup/pistonremoval:

removal:

Usingcompressedair,removepistonfrom

releasecylinder.

Caution:

�Coverwithcleaningclothinorderto

preventpistonejection.

�Blowcompressedairslowlyinorderto

preventbrakefluidspill.

CL003

Piston/piston

Piston/pistoncup

cup

cupinstallation:

installation:

Applybrakefluidtoinnersurfaceofreleasecylinderandwholecircumferencesof

pistonandcup,andtheninsertpistonandpistoncupintocylinder.

Inspection

Inspectionand

and

andmaintenance

maintenance

Clutch:

1)Clutchpressureplate

①

Checkendofdiaphragmspringforwearanddifferenceinheight.Ifnoticeable

wearisfoundordifferenceinheightisoutoflimit,replaceclutchpressureplate.

Limitvalue:0.5mm

②Checksurfaceofpressureplateforwear,cracks,anddiscoloration.

B-ClassSedanServiceManualCLClutch

CL-6

③Checkpressureplaterivetsforlooseness.Ifloose,replaceclutchpressureplate.

2)Clutchdrivenplate

Note:

�

�Donotcleanclutchdrivenplateusing

gasoline!

Checksurfacefordeteriorationand

greaseadhesion,etc.resultedfrom

looseness,single-sidedcontact,orburns

ofrivets.Ifanyproblemisfound,

replaceclutchdrivenplate.

2Checkrivetsinkdepth.Ifoutoflimit,

replaceclutchdrivenplate.

Limitvalue:0.3mm

CL004

③

Checktorsionspringforloosenessandbreakage.Ifanytroubleisfound,replace

clutchdrivenplate.

④Installclutchdrivenplateontoinputshaftandcheckitsslidinganddirectionof

rotationforlooseness.Inthecaseofpoorsliding,cleanandthencheckafter

installation.Inthecaseofnoticeablelooseness,replaceclutchdrivenplateor

inputshaft,orreplacethebothatthesametime.

3)Clutchreleaserearing

Note:

�Checkbearingforburns,damage,abnormalnoise,orunsmoothrotation,etc.

�Checkreleasebearinganddiaphragmspringorcontactsurfaceofreleaseforkfor

abnormalwear.Ifany,replace.

4)Releasefork

Ifreleaseforktobearingcontactsurfacehasabnormalwear,replace.

Clutch

Clutchrelease

release

releasecylinder:

cylinder:

Releasecylinder:

1)Checkinnersurfaceofreleasecylinderforrustanddamage.

2)Usingboregauge,measureboreofreleasecylinderat3places(bottom,middle,

andtop).Ifboretoexternalpistoncircleclearanceisoutoflimit,replacerelease

cylinderassembly.

Limitvalue:0.15mm

B-ClassSedanServiceManualCLClutch

CL-7

Clutch

Clutchhydraulic

hydraulic

hydraulicfluid

fluid

Note:

�Pleasedonotoperatethissystemusingvacuumpumporemptyingpowerunitof

anytype.

�Checkclutchhydraulicfluidlevel.Pleaseensureanormallevel.

Bleeding

Bleedinga

aline:

line:

Note:

�Afterclutchline,clutchmaster

cylinder,clutchslavecylinder,or

hydraulicreleasebearingisremoved

orwhenclutchpedalbecomessoft,

bleedthesystem.

1)Loosenbleederboltofclutchrelease

cylinder.

CL005

2)Depressclutchpedalslowlytillairiscompletelybled.

3)Depresspedaltothefloorandhold,andtightenbleederbolt.

4)Refillclutchhydraulicsystemwithhydraulicoil.

Note:

�BesuretoalwayskeepliquidlevelinreservoirbetweenMINandMAX.

5)Repeatabovestepstillclutchhydraulicfluiddischargedfromthesystemisclean

withoutbubbles.

6)Makesureclutchisinworkingorder.

①Starttheengine,depressclutchpedal,andshiftintoreversegear(R)carefully

afterapprox.2seconds.Ifloudnoiseisheardduringgearselection,depress

clutchpedaltothefloorfor5timestobleedthesystem.

②

Waitabout30seconds,andthencheckclutchoperation.Ifloudnoiseremains,

pleasebleedrepeatedly.

Trouble

TroubleDiagnosis

Diagnosis

Performancediagnosisofclutchassemblyandclutchcontrolsystemshouldbecarried

outbyskilledautoservicetechnicians.

Afteranappropriatediagnosis,youcanadjustorreplacepartsasrequiredaccording

tothecorrespondingsolutionsinthediagnostictableortheappropriateitemsinthe

servicemanualcorrespondingtoeachspecificprocedure.Allpartsandcomponents

requiringreplacementmustbegenuineJACpartsandcomponents.Whenclutch

pressureplateorclutchdrivenplateisdamaged,donotrepairit.Instead,theassembly

mustbereplaced.

B-ClassSedanServiceManualCLClutch

CL-8

Thefiguresinthisdiagnostictabledonotmeancheckorders.Thereareno

precedencerelationshipsbetweenpossiblecauses

DiagnosticTableforCommonFaults

CheckPossiblecauseSolution

Disengagement

failure

Disengagementfailuremeansclutch

cannotfunctionandcutpower

transmittedfromengine.

Checkthefollowing:

1.Clutchreleaseleverfor

deformation.

2.Diaphragmspringfor

deformation.

3.Diaphragmspringsupportringfor

fracture.

4.Clutchpedalcontrolsystemfor

improperadjustment.

5.Clutchfrictionplateforbinding

withflywheelorclutchpressure

plate.

Replacedeformed,worn,orbroken

parts.

Adjustclutchpedalcontrolsystem.

Drag

Clutchdragwillresultinfailuretocut

powertransmittedfromengine

normallyanddifficultytooperateshift

leverduetocontinuedrotationof

clutchfrictionplateandtransmission

inputshaft.

Checkthefollowing:

1.Clutchfrictionplatefor

deformation(shimmywilloccur

whenitrotates).

2.Clutchfrictionplatefordamage.

3.Clutchfrictionplatesplinefor

mismatchwithtransmissioninput

shaftspline,orsplinefacingfor

damage.

4.Clutchfrictionplateforpartial

bindingwithflywheelorseizure

withclutchpressureplate.

5.Ifthicknessofflywheel/clutch

pressureplate/clutchfrictionplate

exceedsgivensize.

6.Clutchpedalcontrolsystemfor

mechanicalbreakdownor

improperadjustment.

Replacedeformed,worn,broken,or

out-of-sizeparts.Ifclutchfrictionplate

doesnotworkwellwithtransmission

inputshaftspline,replacetheformer;if

necessary,replacetransmissioninput

shaft.

Ifclutchfrictionplateexceedsgiven

sizeorisdamaged,replaceit.

Replaceunsuitableclutchthrust

bearing.

Adjustclutchsysteminorderto

removeunnecessaryclearanceand

eliminatemechanicalbreakdown.

Reinstallimproperlyassembledparts.

Halfway

engagement

Halfwayclutchengagementwillresult

infailuretotransmitenginepowerto

transmissioninputshaftnormallyand

clutchfrictionplateslipping.

Replacedeformed,worn,andbroken

parts.

Replaceclutchfrictionplateor

B-ClassSedanServiceManualCLClutch

CL-9

CheckPossiblecauseSolution

Checkthefollowing:

1.Clutchfrictionplateforoilor

greasestains.

2.Clutchfrictionplatefordamage.

3.Clutchpedalforzerofreeplay.

4.Diaphragmspring/clutchpressure

plate/clutchreleaselever/clutch

frictionplatesplinefor

deformationordamage.

5.Clutchpedalcontrolsystemfor

mechanicalbreakdownor

improperadjustment.

defectiveclutchassembly.

Adjustfreeplayofclutchpedal

correctly.

Adjustclutchsysteminorderto

removeunnecessaryclearanceand

eliminatemechanicalbreakdown.

Reinstallimproperlyassembledparts.

Slipping

Clutchfrictionplateslippingwillresult

infailuretotransferenginepower

normally.

Checkthefollowing:

1.Clutchfrictionplateforwear.

2.Clutchfrictionplateforoilor

greasecontamination.

3.Clutchforhalfwayengagement.

4.Ifthicknessofflywheel/clutch

pressureplate/clutchfrictionplate

exceedsgivensizeandfriction

surfaceisbeyondspecification.

5.Interiorofclutchhousingfor

excesstemperaturecausedby

improperdriving.

6.Forunsuitableclutchinstalled.

Replacedeformed,worn,broken,and

out-of-size-and-specificationparts.

Sameascorrespondingsolutionsfor

“Drag”and“Halfwayengagement”.

Shutdownengine,coolinteriorof

clutchhousing(inthecaseofexcess

temperature),andthengotofurther

diagnosis.

Installdesignatedclutchcorrectly.

Adjustclutchpedalcontrolsystemin

ordertoremoveunnecessaryclearance

andeliminatemechanicalbreakdown.

Reinstallimproperlyassembledparts.

Donotallowdrivertoalwayskeep

his/herfootonclutchpedal.

Noise

Checkthefollowing:

1.Incorrectclutchfrictionplate.

2.Poorbalance.

3.Clutchthrustbearingfor

malfunction.

4.Torsiondampingspringofclutch

frictionplatefordamage.

Replacedeformed,worn,andbroken

parts.

Installdesignatedclutchfrictionplate.

Ifapartispoorlybalanced,replace

clutchassembly.

Adjustclutchpedalcontrolsystem.

Reinstallimproperlyassembledparts.

Jitter

Thiswilloccurswhenclutchfriction

platecannotengagewithflywheel

softly.

Checkthefollowing:

1.Dampingspringofclutchfriction

plateoutofspecification.

2.Clutchfrictionplateoutof

specification.

3.Clutchfrictionplateforoilor

greasecontamination.

Replaceclutchassembly.

B-ClassSedanServiceManualCLClutch

CL-10

Service

ServiceData

Data

Dataand

and

andSpecifications

Specifications

ClutchSpecificationTable

ClutchtypeDry,singleplate,diaphragmspring

Pressureplate

assembly

Assemblingandclampingload

(N)

4170±300

Leverratioofdiaphragmspring2.833(51/18)

Heightofdiaphragmspringlever

(mm)

31.5±1.0

Drivenplate

assembly

Outsidediameterxinside

diameter(mm)

Φ200×Φ130

Area(mm

)181

Splinesize

24/48-30

20NT

Clutchcontrol

mechanism

ControlmodeHydraulic

Leverratioofreleasefork1.726

Sizeofhydrauliccylinder(slave

cylinder)(mm)

20.64

ReleasebearingSelf-aligningtype

TechnicalDataSheet

Clutchpedalfreeplay

6～13mm

GreaseTable

PedalkingpinSAEJ310,NLGINO.2

TighteningTorqueTable

SNNameQuantityTighteningtorque(N·m)

1Fixingnutofmastercylinder2

18∼25

2Installingboltofclutchhosesupportassembly2

18∼25

3Connectingnutonclutchtube2

18∼22

4Bleederboltofclutchreleasecylinder1

7∼13

5Installingboltonclutchpedal1

18∼25

GENERAL INFORMATION 23A-0-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1. SPECIFICATIONS 23A-1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TRANSMISSION MODEL TABLE 23A-1-1. . . . . . . . . . . . . . . . . . . . . . . .

GENERAL SPECIFICATIONS 23A-1-2c. . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE SPECIFICATIONS 23A-1-2d. . . . . . . . . . . . . . . . . . . . . . . . . . . .

VALVE BODY SPRING IDENTIFICATION TABLE 23A-1-3. . . . . . . . .

SNAP RING, SPACER, THRUST WASHER, THRUST RACE

AND PRESSURE PLATE FOR ADJUSTMENT 23A-1-4. . . . . . . . . . . .

TORQUE SPECIFICATIONS 23A-1-9. . . . . . . . . . . . . . . . . . . . . . . . . . . .

SEALANTS 23A-1-10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2. SPECIAL TOOLS 23A-2-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3. TRANSMISSION 23A-3-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4. OIL PUMP 23A-4-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5. UNDERDRIVE CLUTCH AND INPUT SHAFT 23A-5-1. . . . . . . . . . . . . . .

6. REVERSE CLUTCH AND OVERDRIVE CLUTCH 23A-6-1. . . . . . . . . . . .

7. OVERDRIVE PLANETARY CARRIER

<F4A41, F4A42 without ONE-WAY CLUTCH> 23A-7-1. . . . . . . . . . . . . .

7a. PLANETARY CARRIER ASSEMBLY

<F4A42 with ONE-WAY CLUTCH, F4A51> 23A-7a-1. . . . . . . . . . . . . . . . .

8. LOW-REVERSE BRAKE 23A-8-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9. SECOND BRAKE 23A-9-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10. OUTPUT SHAFT 23A-10-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11. TRANSFER DRIVE GEAR

<F4A41 up to Dec. 1997, F4A42 up to Dec. 1997> 23A-11-1. . . . . . . . . .

12. DIFFERENTIAL 23A-12-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13. VALVE BODY 23A-13-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14. SPEEDOMETER GEAR 23A-14-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15. DRIVE SHAFT OIL SEAL 23A-15-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23A-0-1

AUTOMATIC

TRANSMISSION

F4A41, F4A42, F4A51

CONTENTS

RevisedPWEE9514-I

May 2002Mitsubishi Motors Corporation

23A-0-2

PWEE9514

May 1995Mitsubishi Motors Corporation

NOTES

AUTOMATIC TRANSMISSION (E- W) -

General Information

23A-0-3

GENERAL INFORMATION

(1) The combination of highest-precision electronic and mechanical technology heralds a new era in

automatic transmission performance.

(2) The gear shifting clutches use a hydraulic balancing mechanism to enable gear shifting at extra-high

engine speeds.

(3) The number of shafts has been decreased to two, increased use has been made of metal plates

and the one-way clutch has been abolished, which all contribute to reduce the weight.

(4) Increased meshing ratios and improved rigidity of the gear supports and casing result in less noise.

(5) The number of oil cooler feed tubes is increased to two.

3-DIMENSIONAL CROSS-SECTION

RevisedPWEE9514-F

Jun. 2000Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E- W) -

General Information

23A-0-4

SECTIONAL VIEW

RevisedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E- W) -

General Information

23A-0-5

RevisedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E- W) -

General Information

23A-0-6

<F4A42-1 up to Dec. 1997>

RevisedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E- W) -

General Information

23A-0-6a

<F4A42-1 from Jan. 1998>

AddedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E- W) -

General Information

23A-0-6b

<F4A42-2 without one-way clutch>

TFA1504

AddedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E- W) -

General Information

23A-0-6c

<F4A42-2 with one-way clutch>

AddedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E- W) -

General Information

23A-0-6d

AddedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation

Intentionally blank

AUTOMATIC TRANSMISSION (E- W) -

General Information

23A-0-7

<F4A51>

TFA1995

AddedPWEE9514-B

Feb. 1997Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E- W) -

General Information

23A-0-8

HYDRAULIC CIRCUIT

Type with external oil filter

15 16

25 26

RND

TFA1598

1. Reverse clutch

2. Low-reverse brake

3. Second brake

4. Underdrive clutch

5. Overdrive clutch

6. Low-reverse accumulator

7. Second accumulator

8. Underdrive accumulator

9. Overdrive accumulator

10. Damper clutch

11. Fail-safe valve A

12. Fail-safe valve B

13. Damper clutch control valve

14. Switching valve

15. Low-reverse pressure control valve

16. Second pressure control valve

17. Underdrive pressure control valve

18. Overdrive pressure control valve

19. Damper clutch control solenoid

valve

20. Low-reverse solenoid valve

21. Second solenoid valve

22. Underdrive solenoid valve

23. Overdrive solenoid valve

24. Torque converter pressure control

valve

25. Regulator valve

26. Manual valve

27. Oil filter

28. Oil filter

29. Oil pan

30. Oil pump

31. Relief valve

32. Oil strainer

RevisedPWEE9514-F

Jun. 2000Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E- W) -

General Information

23A-0-9

HYDRAULIC CIRCUIT

Type without external oil filter

12 3 4 5

678

16 17 18

25 26

RND

TFA2394

1. Reverse clutch

2. Low-reverse brake

3. Second brake

4. Underdrive clutch

5. Overdrive clutch

6. Low-reverse accumulator

7. Second accumulator

8. Underdrive accumulator

9. Overdrive accumulator

10. Damper clutch

11. Fail-safe valve A

12. Fail-safe valve B

13. Damper clutch control valve

14. Switching valve

15. Low-reverse pressure control valve

16. Second pressure control valve

17. Underdrive pressure control valve

18. Overdrive pressure control valve

19. Damper clutch control solenoid

valve

20. Low-reverse solenoid valve

21. Second solenoid valve

22. Underdrive solenoid valve

23. Overdrive solenoid valve

24. Torque converter pressure control

valve

25. Regulator valve

26. Manual valve

27. Oil filter

28. Oil pan

29. Oil pump

30. Relief valve

31. Oil strainer

AddedPWEE9514-F

Jun. 2000Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E- W) -

Specifications

23A-1-1

1. SPECIFICATIONS

TRANSMISSION MODEL TABLE

MODEL 1996

Transmission model

Speedometer

gear ratio

Final gear ratio Vehicle model Engine model

F4A41-1-MRA 31/36 4.042 DA1A 4G92

F4A41-1-M8A1 31/36 4.042 CJ4A, CK4A 4G92

EUR

F4A41-1-M8A2 31/36 4.042 CJ1A 4G13

F4A42-1-MRA 31/36 4.042 DA2A 4G93

F4A41-1-M8A 31/36 4.042 CJ2A 4G15

F4A41-1-M8A1 31/36 4.042 CJ4A 4G92

EXP

F4A41-1-M8A4 31/36 4.042 CK2A 4G15

F4A41-1-M8A5 31/36 4.042 CK1A 4G13

MODEL 1997

Transmission model

Speedometer

gear ratio

Final gear ratio Vehicle model Engine model

F4A42-1-M7A 30/36 4.042 EA2A, EA2W 4G63

EUR

F4A42-2-E6A 29/36 3.770 EA5A, EA5W 6A13

F4A42-1-M6A 29/36 4.042 EA1A 4G93

F4A42-1-M6A2 29/36 4.042 EA2A 4G63

F4A42-1-M7A 30/36 4.042 EA2A 4G63

EXP

F4A42-1-U6A1 29/36 4.407 EA4A 6A12

F4A42-2-E6A 29/36 3.770 EA5A 6A13

F4A51-2-E5B 28/36 3.735 F36A 6G72

MODEL 1998

Transmission model

Speedometer

gear ratio

Final gear ratio Vehicle model Engine model

F4A41-1-M8A1 31/36 4.042 CJ4A 4G92

F4A41-1-M8A5 31/36 4.042 CJ1A, CK1A 4G13

F4A41-1-M8A6 31/36 4.042 DA1A 4G92

EUR

F4A42-1-E8A 31/36 3.770 DA2A 4G93-GDI

F4A42-1-M7A 30/36 4.042 EA2A, EA2W 4G63

F4A42-1-M8A3 31/36 4.042 DA2A 4G93

F4A42-2-E6A 29/36 3.770 EA5A, EA5W 6A13

RevisedPWEE9514-D

Jun. 1998Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E–W) –

Specifications

23A-1-2

F4A41-1-M8A1 31/36 4.042 CJ4A, CK4A 4G92

F4A41-1-M8A4 31/36 4.042 CJ2A, CK2A 4G15

F4A41-1-M8A5 31/36 4.042 CK1A 4G13

EXP F4A42-1-M6A 29/36 4.042 EA1A 4G93

F4A42-1-M6A2 29/36 4.042 EA2A 4G63

F4A42-2-E6A 29/36 3.770 EA5A 6A13

F4A51-2-E5B 28/36 3.735 F36A 6G72

MODEL 1999

Transmission model

Speedometer

gear ratio

Final gear ratio Vehicle model Engine model

F4A42-1-U5A1 28/36 4.407 N61W 4G93-GDI

EUR

F4A42-2-E6B 29/36 3.770 EA3A, EA3W 4G64-GDI

EUR

F4A42-2-E6B1 29/36 3.770 EA5A, EA5W 6A13

F4A42-2-M5B1 28/36 4.042 N84W 4G64-GDI

EXP

F4A42-2-E6B1 29/36 3.770 EA5A 6A13

EXP

F4A42-2-M5B 28/36 4.042 N84W 4G64-S4

MODEL 2000

Transmission model

Speedometer

gear ratio

Final gear ratio Vehicle model Engine model

F4A41-1-M8A1 31/36 4.042 CJ4A 4G92

F4A41-1-M8A5 31/36 4.042 CJ1A 4G13

EUR

F4A41-1-U8A2 31/36 4.407 DA1A 4G92

EUR

F4A42-1-M7A1 30/36 4.042 DA2A 4G93

F4A42-1-U5A2 28/36 4.407 N63W 4G63

F4A42-2-M5B1 28/36 4.042 N64W, N84W 4G64

F4A41-1-M8A1 31/36 4.042 CJ4A, CK4A 4G92

F4A41-1-M8A4 31/36 4.042 CJ2A, CK2A 4G15

F4A41-1-M8A5 31/36 4.042 CJ1A, CK1A 4G13

EXP F4A42-1-M6A 29/36 4.042 EA1A 4G93

F4A42-1-M6A2 29/36 4.042 EA2A 4G63

F4A42-2-E6B1 29/36 3.770 EA5A 6A13

F4A42-2-M5B 28/36 4.042 N84W 4G64

AUS F4A42-2-M5B 28/36 4.042 N84W 4G64

RevisedPWEE9514-J

Jun. 2003Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E–W) –

Specifications

23A-1-2a

MODEL 2001

Transmission model

Speedometer

gear ratio

Final gear ratio Vehicle model Engine model

F4A42-1-NZA1 – 4.406 N63W 4G63

F4A42-2-JZB2 – 4.041 N64W 4G64

F4A42-2-JZB2 – 4.041 N84W 4G64

F4A41-1-J8A 31/36 4.041 CJ4A 4G92

EUR

F4A42-1-J8A 31/36 4.041 DG5A 4G93

EUR

F4A41-1-N7A 30/36 4.406 DA1A 4G92

F4A42-1-J7A 30/36 4.041 DA2A 4G93

F4A42-1-J6A 29/36 4.041 EA2A, W 4G63

F4A42-2-F6B 29/36 3.769 EA3A, W 4G64

F4A42-2-F6B1 29/36 3.769 EA5A, W 6A13

F4A42-1-JZA – 4.041 EA2W 4G63

F4A42-2-JZB1 – 4.041 N84W 4G64

F4A42-2-FZB2 – 3.769 N84W 4G64

F4A41-1-NZB1 – 4.406 CS3A 4G18

EXP

F4A41-1-NZB2 – 4.406 CS1A 4G13

EXP

F4A41-1-J8A 31/36 4.041 CJ4A 4G92

F4A41-1-J8A1 31/36 4.041 CJ2A 4G15

F4A42-1-JZA2 – 4.041 EA1A 4G93

F4A42-1-JZA – 4.041 EA2A 4G63

F4A42-1-FZB – 3.769 EA5A 6A13

F4A41-1-M8A1 31/36 4.042 CJ2A 4G15

AUS F4A42-1-J8A1 31/36 4.041 CJ5A 4G93

F4A42-2-JZB1 – 4.041 N84W 4G64

RevisedPWEE9514-J

Jun. 2003Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E–W) –

Specifications

23A-1-2b

MODEL 2002

Transmission model

Speedometer

gear ratio

Final gear ratio Vehicle model Engine model

F4A42-2-JZB2 – 4.041 N84W 4G64

F4A42-1-J7A 30/36 4.041 DA3A 4G93

F4A41-1-NZA – 4.406 DA1A 4G92

EUR F4A42-1-JZA3 – 4.041 DA2A 4G93

F4A41-1-J8A 31/36 4.041 CJ4A 4G92

F4A41-1-NZA2 – 4.406 DG3A 4G18

F4A42-1-JZA3 – 4.041 DG5A 4G93

F4A42-2-JZB1 – 4.041 N84W 4G64

F4A42-2-FZB2 – 3.769 N84W 4G64

F4A41-1-NZB1 – 4.406 CS3A 4G18

F4A41-1-NZB2 – 4.406 CS1A 4G13

EXP

F4A42-1-JZA – 4.041 EA2A, W 4G63

EXP

F4A42-1-JZA2 – 4.041 EA1A 4G93

F4A42-1-JZA1 – 4.041 EA7A 4G94

F4A42-2-FZB – 3.769 EA5A 6A13

F4A41-1-J8A 31/36 4.041 CJ4A 4G92

F4A41-1-J8A1 31/36 4.041 CJ2A 4G15

F4A42-2-JZB1 – 4.041 N84W 4G64

AUS

F4A42-1-JZB3 – 4.041 CJ6A 4G93

AUS

F4A41-1-J8A1 31/36 4.041 CJ2A 4G15

F4A42-1-J8A1 31/36 4.041 CJ5A, CK5A 4G93

RevisedPWEE9514-J

Jun. 2003Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E–W) –

Specifications

23A-1-2c

MODEL 2003

Transmission model

Speedometer

gear ratio

Final gear ratio Vehicle model Engine model

F4A41-1-NZA – 4.406 DA1A 4G92-S4

F4A42-1-JZA3 – 4.041 DA2A 4G93-GDI

F4A41-1-J8A 31/36 4.041 CJ4A 4G92-S4

F4A42-1-J6A 29/36 4.041 EA2A, W 4G63-S4

EUR F4A42-2-F6B 29/36 3.769 EA3A, W 4G64-GDI

F4A42-2-F6B1 29/36 3.769 EA5A, W 6G13-S4

F4A41-1-NZA2 – 4.406 DG3A 4G18-S4

F4A42-1-NZA2 – 4.406 DG5A 4G93-S4

F4A42-2-JZB2 – 4.041 N84W 4G64-GDI

F4A42-2-JZB1 – 4.041 N84W 4G64-S4

F4A42-2-FZB2 – 3.769 N84W 4G64-GDI

F4A4A-1-N1Z – 4.406 CS1A 4G13-S4

F4A4A-1-NZB2 – 4.406 CS1A 4G13-S4

EXP F4A42-2-FZB1 – 3.769 CS5W 4G93-GDI

F4A41-1-J8A 31/36 4.041 CJ4A 4G92-S4

F4A42-1-JZA – 4.041 EA2A, W 4G63-S4

F4A42-1-JZA1 – 4.041 EA7A 4G94-GDI

F4A42-2-FZB – 3.769 EA5A 6A13-S4

F4A42-2-JZB1 – 4.041 N84W 4G64-S4

AUS

F4A42-1-JZB3 – 4.041 CS6A 4G94-S4

AUS

F4A41-1-J8A1 31/36 4.041 CJ2A 4G15-S3

F4A42-1-J8A1 31/36 4.041 CJ5A, CK5A 4G93-S4

RevisedPWEE9514-J

Jun. 2003Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E–W) –

Specifications

23A-1-2d

MODEL 2004

Transmission model

Speedometer

gear ratio

Final gear ratio Vehicle model Engine model

F4A41-1-NZA2 – 4.406 DG3A 4G18-S4

EUR F4A42-1-NZA2 – 4.406 DG5A 4G93-S4

F4A42-2-JZB2 – 4.041 N84W 4G64-GDI

F4A42-2-JZB1 – 4.041 N84W 4G64-S4

F4A42-2-FZB2 – 3.769 N84W 4G64-GDI

EXP

F4A4A-1-N1Z – 4.406 CS1A 4G13-S4

EXP

F4A42-1-JZA – 4.041 EA2A 4G63-S4

F4A42-1-JZA1 – 4.041 EA7A 4G94-GDI

F4A42-2-FZB – 3.769 EA5A 6A13-S4

AUS

F4A42-2-JZB1 – 4.041 N84W 4G64-S4

AUS

F4A4B-1-J1Z – 4.041 CS6A 4G94-S4

GENERAL SPECIFICATIONS

Items F4A41 F4A42-1 F4A42-2 F4A51

Torque converter type 3-element,

1-stage, 2-phase

type

3-element,

1-stage, 2-phase

type

3-element,

1-stage, 2-phase

type

3-element,

1-stage, 2-phase

type

Transmission type 4-speed forward,

1-speed reverse

4-speed forward,

1-speed reverse

4-speed forward,

1-speed reverse

4-speed forward,

1-speed reverse

1st 2.842 2.842 2.842 2.842

2nd 1.529 1.529 1.529 1.495

Gear ratio 3rd 1.000 1.000 1.000 1.000

4th 0.712 0.712 0.712 0.731

Reverse 2.480 2.480 2.480 2.720

Number of underdrive clutch

disc

3 4 4 4

Number of overdrive clutch

disc

3 4 4 4

Number of reverse clutch

disc

2 2 2 2

Number of low-reverse

brake disc

4 5 6 6

Number of second brake

disc

2 3 3 4

RevisedPWEE9514-J

Jun. 2003Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E–W) –

Specifications

23A-1-2e

SERVICE SPECIFICATIONS

Items Standard value

Output shaft preload mm 0.01 – 0.09

Brake reaction plate end play mm 0 – 0.16

F4A41 1.05 – 1.51

Low-reverse brake end play mm F4A42-1 1.35 – 1.81

F4A51, F4A42-2 1.65 – 2.11

F4A41 0.49 – 0.95

Second brake end play mm F4A42 0.79 – 1.25

F4A51 1.09 – 1.55

Underdrive sun gear end play mm 0.25 – 0.45

Input shaft end play mm 0.70 – 1.45

Differential case end play mm F4A41 0.045 – 0.165

Differential case preload mm F4A42, F4A51 0.045 – 0.105

Underdrive clutch end play mm

F4A41 1.2 – 1.4

ve c

ay mm

F4A42, F4A51 1.6 – 1.8

Reverse and overdrive clutch return spring retainer end play mm 0 – 0.09

Overdrive clutch end play mm

F4A41 1.2 – 1.4

ver

ve c

ay mm

F4A42, F4A51 1.6 – 1.8

Reverse clutch end play mm 1.5 – 1.7

Backlash between differential side gear and pinion mm 0.025 – 0.150

AddedPWEE9514-J

Jun. 2003Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E–W) –

Specifications

23A-1-2f

AddedPWEE9514-J

Jun. 2003Mitsubishi Motors Corporation

Intentionally blank

AUTOMATIC TRANSMISSION (E- W) -

Specifications

23A-1-3

VALVE BODY SPRING IDENTIFICATION TABLE

Spring

Wire diameter Outside diameter Free length Number of loops

Regulator valve spring 1.8 15.7 86.7 24

Underdrive pressure control valve

spring

0.7 7.6 37.7 25

Overdrive pressure control valve

spring

0.7 7.6 37.7 25

Low-reverse pressure control

valve spring

0.7 7.6 37.7 25

Second pressure control valve

spring

0.7 7.6 37.7 25

Torque converter spring 1.6 11.2 34.4 12.5

Damper clutch control valve spring 0.7 5.9 28.1 19

Fail-safe valve A spring 0.7 8.9 21.9 9.5

Damping valve spring 1.0 7.7 35.8 17

Line relief valve spring 1.0 7.0 17.3 10

Orifice check ball spring 0.5 4.5 17.2 15

RevisedPWEE9514-A

Nov. 1995Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E- W) -

Specifications

23A-1-4

SNAP RING, SPACER, THRUST WASHER, THRUST RACE AND PRESSURE PLATE

FOR ADJUSTMENT

Part name Thickness mm Identification symbol Part No.

Thrust washer 1.8 18 MD754509

(For adjustment of input shaft end play)

2.0 20 MD754508

2.2 22 MD754507

2.4 24 MD753793

2.6 26 MD753794

2.8 28 MD753795

Snap ring: F4A41, F4A42 1.6 None MD759666

(For adjustment of underdrive clutch and overdrive

1.7 Blue MD759667

clutch en d plays)

1.8 Brown MD759668

1.9 None MD752124

2.0 Blue MD752125

2.1 Brown MD752126

2.2 None MD752127

2.3 Blue MD752128

2.4 Brown MD752129

2.5 None MD752130

2.6 Blue MD752131

2.7 Brown MD752132

2.8 None MD752133

2.9 Blue MD752134

3.0 Brown MD754680

Snap ring: F4A51 1.6 Brown MD759960

(For adjustment of underdrive clutch and overdrive

1.7 None MD759961

clutch en d plays)

1.8 Blue MD759962

1.9 Brown MD759963

2.0 None MD750841

2.1 Blue MD750842

2.2 Brown MD750843

2.3 None MD750844

2.4 Blue MD750845

2.5 Brown MD750846

2.6 None MD750847

2.7 Blue MD750848

2.8 Brown MD750849

2.9 None MD750850

3.0 Blue MD750851

Snap ring: F4A41, F4A42 2.2 Blue MD754786

(For adjustment of low-reverse brake and second

2.3 Brown MD754787

brake reaction plates end plays)

2.4 None MD758240

2.5 Blue MD758241

RevisedPWEE9514-B

Feb. 1997Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E- W) -

Specifications

23A-1-5

Part name Part No.Identification symbolThickness mm

Snap ring: F4A51 2.2 None MD756784

(For adjustment of low-reverse brake and second

2.3 Blue MD756785

brake reaction plates end plays)

2.4 Brown MD758552

2.5 None MD758553

Pressure plate: F4A41, F4A42 1.6 L MD759567

(For adjustment of low-reverse brake and second

1.8 1 MD759414

brake end play)

2.0 0 MD759415

2.2 2 MD759416

2.4 4 MD759417

2.6 6 MD759418

2.8 8 MD759419

3.0 D MD759420

Pressure plate: F4A51 1.6 F MD759568

(For adjustment of low-reverse brake and second

1.8 E MD759425

brake end play)

2.0 D MD759426

2.2 C MD759427

2.4 B MD759428

2.6 A MD759429

2.8 0 MD759430

3.0 1 MD759431

Snap ring: F4A41, F4A42 1.6 None MD761085

(For adjustment of reverse clutch end play)

1.7 Blue MD761086

1.8 Brown MD761087

1.9 None MD752137

2.0 Blue MD752138

2.1 Brown MD752139

2.2 None MD752140

2.3 Blue MD752141

2.4 Brown MD752142

2.5 None MD752143

2.6 Blue MD752144

2.7 Brown MD752145

2.8 None MD752146

RevisedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E- W) -

Specifications

23A-1-6

Part name Part No.Identification symbolThickness mm

Snap ring: F4A51 1.6 None MD761008

(For adjustment of reverse clutch end play)

1.7 Blue MD761089

1.8 Brown MD761090

1.9 None MD758947

2.0 Blue MD756690

2.1 Brown MD756691

2.2 None MD756692

2.3 Blue MD756693

2.4 Brown MD756694

2.5 None MD756695

2.6 Blue MD756696

2.7 Brown MD756697

2.8 None MD756698

Snap ring 1.48 Brown MD755600

(For adjustment of reverse clutch and overdrive

1.53 None MD755601

clutch spring retainers end plays)

1.58 Blue MD755602

1.63 Brown MD755603

Thrust race 1.6 - MD707267

(For adjustment of underdrive sun gear end play)

1.7 - MD759681

1.8 - MD723064

1.9 - MD754794

2.0 - MD707268

2.1 - MD754795

2.2 - MD723065

2.3 - MD754796

2.4 - MD724358

2.5 - MD754797

2.6 - MD754798

RevisedPWEE9514-B

Feb. 1997Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E- W) -

Specifications

23A-1-7

Part name Part No.Identification symbolThickness mm

Spacer 1.88 88 MD756579

(For adjustment of output shaft preload)

1.92 92 MD756580

1.96 96 MD756581

2.00 00 MD756582

2.04 04 MD756583

2.08 08 MD756584

2.12 12 MD756585

2.16 16 MD756586

2.20 20 MD756587

2.24 24 MD756588

2.28 28 MD756589

2.32 32 MD756590

2.36 36 MD756591

2.40 40 MD756592

2.44 44 MD756593

2.48 48 MD756594

2.52 52 MD756595

2.56 56 MD756596

2.60 60 MD756597

2.64 64 MD756598

2.68 68 MD756599

2.72 72 MD760685

2.76 76 MD760686

Spacer: F4A41 1.28 N MD710458

(For adjustment of differential case end play)

1.37 P MD710460

1.46 R MD710462

1.55 T MD710464

1.64 V MD710466

1.73 X MD710468

1.82 Z MD710470

RevisedPWEE9514-B

Feb. 1997Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E- W) -

Specifications

23A-1-8

Part name Part No.Identification symbolThickness mm

Spacer: F4A42, F4A51 0.71 71 MD754475

(For adjustment of differential case preload)

0.74 74 MD727660

0.77 77 MD754476

0.80 80 MD727661

0.83 83 MD720937

0.86 86 MD720938

0.89 89 MD720939

0.92 92 MD720940

0.95 95 MD720941

0.98 98 MD720942

1.01 01 MD720943

1.04 04 MD720944

1.07 07 MD720945

1.10 J MD710454

1.13 D MD700270

1.16 K MD710455

1.19 L MD710456

1.22 G MD700271

1.25 M MD710457

1.28 N MD710458

1.31 E MD706574

1.34 O MD710459

1.37 P MD710460

Spacer 0.75 - 0.82 - MD722986

(For adjustment of backlash between differential

0.83 - 0.92 - MD722985

side gear and pinion)

0.93 - 1.00 - MD722984

1.01 - 1.08 - MD722982

1.09 - 1.16 - MD722983

RevisedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E–W) –

Specifications

23A-1-9

TORQUE SPECIFICATIONS

Items Nm

Transmission Roll stopper bracket 70

Wiring harness bracket 23

Control cable bracket 23

Eye bolt 31

Oil cooler feed tube (to transmission case) 10

Oil cooler feed tube (to roll stopper bracket) 11

Oil filter <Externally mounted> 12

Input shaft speed sensor 11

Output shaft speed sensor 11

Manual control lever 22

Inhibitor switch 11

Speedometer gear <If equipped> 5

Sealing cap <Type without speedometer gear> 5

Valve body cover 11

Valve body mounting bolt 11

Fluid temperature sensor 11

Manual control shaft detent 6

Rear cover 23

Torque converter housing 48

Oil pump <up to Mar. 2000> 23

Oil pump <from Apr. 2000> 29

Transfer drive gear bearing

Transfer drive gear bearing <F4A41 from Jan. 1998, F4A42-1

from Jan. 1998, F4A42-2 with one-way clutch, F4A51>

Output shaft lock nut 170

Output shaft bearing retainer <F4A41 up to Mar. 2000, F4A42

up to Mar. 2000>

Output shaft bearing retainer <F4A41 from Apr. 2000, F4A42

from Apr. 2000>

Output shaft bearing retainer <F4A51> 54

RevisedPWEE9514-I

May 2002Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E–W) –

Specifications

23A-1-10

Items Nm

Components Transfer drive gear lock nut

195

Differential drive gear 135

Valve body 11

Solenoid valve support 6

Plate 6

SEALANTS

Items Specified sealant

Rear cover Mitsubishi genuine sealant Part No. MD974421 or equivalent

Torque converter housing Mitsubishi genuine sealant Part No. MD974421 or equivalent

Valve body cover Mitsubishi genuine sealant Part No. MD974421 or equivalent

RevisedPWEE9514-I

May 2002Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E- W) -

Special Tools

AUTOMATIC TRANSMISSION (E- W) -

Special Tools

23A-2-1

2. SPECIAL TOOLS

Tool Number Name Use

MB990607 Torque wrench

socket

Removal and installation of output shaft lock

nut

MB990928 Installer adapter Removal of transfer drive gear bearing

<F4A41, F4A42>

MB990930 Installer adapter Installation of output shaft taper roller bearing

outer race

MB990931 Installer adapter Installation of cap

MB990935 Installer adapter Installation of differential taper roller bearing

outer race <F4A42>

MB990936 Installer adapter Installation of differential taper roller bearing

outer race <F4A51>

Installation of output shaft taper roller bearing

<F4A41, F4A42>

MB990937 Installer adapter Installation of output shaft taper roller bearing

<F4A51>

MB990938 Handle D Installation of input shaft rear bearing

D Use with installer adapter

MB991625 Special socket (41) Removal and installation of output shaft lock

nut

RevisedPWEE9514-B

Feb. 1997Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E- W) -

Special Tools

23A-2-2

Tool UseNameNumber

MB991626 Socket (60) Removal and installation of transfer drive gear

lock nut <F4A41, F4A42>

MB991628 Spring compressor D Removal and installation of low-reverse

brake snap ring <F4A41, F4A42>

D Measurement of underdrive clutch and

overdrive clutch end plays <F4A41,

F4A42>

MB991629 Spring compressor Measurement of underdrive clutch and over-

drive clutch en d plays <F4A51>

MB991631 Clearance dummy

plate

Measurement of low-reverse brake and

second brake end plays <F4A41, F4A42>

MB991632 Clearance dummy

plate

Measurement of low-reverse brake and

second brake end plays <F4A51>

MB991789 Spring compressor Measurement of reverse clutch end play

<F4A51>

MB991790 Spring compressor Measurement of reverse clutch end play

<F4A41, F4A42>

MD998333 Oil pump remover Removal of oil pump

MD998334 Oil seal installer Installation of oil pump oil seal

RevisedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E- W) -

Special Tools

23A-2-3

Tool UseNameNumber

MD998338 Spring comopres-

sor

Removal and installation of low-reverse brake

snap ring <F4A51>

MD998348 Bearing and gear

puller

Removal of transfer drive gear bearing

MD998350 Bearing installer Installation of output shaft, collar, bearing

MD998412 Guide Installation of oil pump and transfer drive gear

MD998800 Oil seal installer Installation of drive shaft oil seal

MD998801 Bearing remover Removal of each bearing

MD998812 Installer cap Use with installer an d installer adapter.

MD998813 Installer - 100 Use with installer cap and installer adapter.

MD998814 Installer - 200 Use with installer cap and installer adapter.

RevisedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E- W) -

Special Tools

23A-2-4

Tool UseNameNumber

MD998819 Installer adapter

(40)

Installation of differential ball bearing <F4A41>

MD998820 Installer adapter

(42)

Installation of differential taper roller bearing

<F4A42>

MD998823 Installer adapter

(48)

Installation of output shaft taper roller bearing

<F4A41, F4A42>, transfer drive gear <F4A41,

F4A42>

MD998824 Installer adapter

(50)

Installation of transfer drive gear <F4A51>,

differential taper roller bearing <F4A51>

MD998827 Installer adapter

(56)

Installation of output shaft taper roller bearing

<F4A51>

MD998829 Installer adapter

(60)

Installation of transfer drive gear bearing

<F4A41, F4A42>

MD998903 Spring compressor Removal and installation of one-way clutch

inner race snap ring <F4A42>

MD998907 Spring compressor Removal and installation of underdrive clutch

snap ring

MD998913 Dial gauge

extension

Measurement of low-reverse brake and

second brake end plays

RevisedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E–W) –

Special Tools

23A-2-5

Tool Number Name Use

MD998917 Bearing remover Removal of output shaft taper roller bearing

(except F4A51)

MD998924 Spring compressor

retainer

D Removal and installation of low-reverse

brake snap ring

D Measurement of underdrive clutch and

overdrive clutch end plays

MD999590 Spring compressor Removal and installation of overdrive clutch

snap ring

RevisedPWEE9514-G

Feb. 2001Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E- W) -

Transmission

23A-3-1

3. TRANSMISSION

DISASSEMBLY AND REASSEMBLY <F4A41 up to Dec. 1997, F4A42-1 up to Dec.

1997 and F4A42-2 without one-way clutch>

11 Nm

22 Nm

11 Nm

12 Nm

31 Nm

5Nm

70 Nm

6Nm

70 Nm

11 Nm

<F4A41-1-MRA,

F4A42- Model

1996>

<F4A41-1-M8A, M8A1,

M8A2, M8A4, M8A5,

F4A42- Model 1997>

31 Nm

10 Nm

11 Nm

31 Nm

Apply automatic

transmission fluid to

all moving parts

before installation.

TFA1996

23 Nm

1. Torque converter

2. Roll stopper bracket

3. Harness bracket

4. Control cable support bracket

5. Oil level gauge

6. Eye bolt

7. Oil cooler feed tube

8. Oil filter

9. Oil filter gasket

10. Input shaft speed sensor

11. Output shaft speed sensor

12. Manual control lever

13. Inhibitor switch

14. Speedometer gear

15. Valve body cover

16. Manual control shaft detent spring

17. Manual control shaft detent

RevisedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E- W) -

Transmission

23A-3-2

11 Nm

Apply automatic

transmission fluid to

all moving parts

before installation.

18. Fluid temperature sensor

19. Valve body

20. Steel ball

21. Gasket

22. Snap ring

23. Solenoid valve harness

24. Strainer

25. Second brake retainer oil seal

26. Accumulator piston

27. Accumulator spring

28. Accumulator spring

29. Manual control lever shaft roller

30. Manual control lever shaft

31. Parking pawl rod

RevisedPWEE9514-B

Feb. 1997Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E- W) -

Transmission

23A-3-3

48 Nm

23 Nm

Apply automatic

transmission fluid to

all moving parts

before installation.

32. Torque converter housing

33. Differential <F4A41>

34. Spacer <F4A41>

35. Spacer <F4A41-1-MRA only>

36. Differential <F4A42>

37. Oil filter

38. Oil pump

39. Gasket

40. Thrust washer #1

41. Underdrive clutch and input shaft

42. Thrust bearing #2

43. Underdrive clutch hub

44. Outer race <F4A42>

45. Spacer <F4A42>

RevisedPWEE9514-B

Feb. 1997Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E- W) -

Transmission

23A-3-4

No. of Brake Discs and Plates

Brake Model Brake Disc Brake Plate

Low-reverse F4A41 4 3

brake

F4A42-1 5 4

F4A42-2 6 5

Second F4A41 2 1

brake

F4A42-1

F4A42-2

3 2

170 Nm

23 Nm

19 Nm

Apply automatic

transmission fluid to

all moving parts

before installation.

RevisedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E- W) -

Transmission

23A-3-5

46. Rear cover

47. Thrust race #8

48. Seal ring

49. Input shaft rear bearing

50. Thrust bearing #7

51. Reverse and overdrive clutch

52. Thrust bearing #6

53. Overdrive clutch hub

54. Thrust bearing #5

55. Planetary reverse sun gear

56. Snap ring

57. Second brake piston

58. Return spring

59. Pressure plate

60. Second brake disc

61. Second brake plate

62. Overdrive planetary carrier

63. Thrust bearing #4

64. Output planetary carrier

65. Underdrive sun gear

66. Thrust bearing #3

67. Snap ring

68. Reaction plate

69. Snap ring

70. Low-reverse brake disc

71. Low-reverse brake plate

72. Pressure plate

73. Wave spring

74. Parking pawl shaft

75. Spacer

76. Parking pawl spring

77. Parking roller support shaft

78. Parking pawl

79. Parking roller support

80. Snap ring

81. Spring retainer

82. Return spring

83. Low-reverse brake piston

84. T ransfer drive gear

85. Cap

86. Lock nut

87. Output shaft

88. Taper roller bearing

89. Collar

90. Outer race

91. Spacer

92. Snap ring

93. Outer race

94. Transmission case

RevisedPWEE9514-B

Feb. 1997Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E–W) –

Transmission

23A-3-5a

DISASSEMBLY AND REASSEMBLY <F4A41 from Jan. 1998 and F4A42-1 from

Jan. 1998>

11 Nm

12 Nm

23 Nm

5 Nm

70 Nm

22 Nm

70 Nm

11 Nm

31 Nm

11 Nm

5 Nm

Apply automatic

transmission fluid to

all moving parts

before installation.

31 Nm

11 Nm

10 Nm

6 Nm

1. Torque converter

2. Roll stopper bracket

3. Harness bracket

4. Control cable support bracket

5. Oil level gauge

6. Eye bolt

7. Oil cooler feed tube

8. Oil filter <Externally mounted type>

Air breather <Air breather type>

9. Oil filter gasket <Externally

mounted type>

10. Input shaft speed sensor

11. Output shaft speed sensor

12. Manual control lever

13. Inhibitor switch

14. Speedometer gear <If equipped>

Sealing cap <Type without

speedometer gear>

15. Valve body cover

16. Manual control shaft detent

RevisedPWEE9514-J

Jun. 2003Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E–W) –

Transmission

23A-3-5b

11 Nm

Apply automatic

transmission fluid to

all moving parts

before installation.

17. Fluid temperature sensor*

18. Valve body

19. Steel ball

20. Gasket

21. Snap ring

22. Solenoid valve harness

23. Strainer

*: Not applicable to type with solenoid

valve harness incorporating fluid

temperature sensor

24. Second brake retainer oil seal

25. Accumulator piston

26. Accumulator spring

27. Accumulator spring

28. Manual control lever shaft roller

29. Manual control lever shaft

30. Parking pawl rod

RevisedPWEE9514-G

Feb. 2001Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E–W) –

Transmission

23A-3-5c

48 Nm

23 Nm <up to Mar. 2000>

29 Nm <from Apr. 2000>

Apply automatic

transmission fluid to

all moving parts

before installation.

31. Torque converter housing

32. Differential <F4A41>

33. Spacer <F4A41>

34. Differential <F4A42-1>

35. Oil filter

36. Oil pump

37. Gasket

38. Thrust washer #1

39. Underdrive clutch and input shaft

40. Thrust bearing #2

41. Underdrive clutch hub

42. Outer race <F4A42-1>

43. Spacer <F4A42-1>

RevisedPWEE9514-I

May 2002Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E–W) –

Transmission

23A-3-5d

No. of Brake Discs and Plates

Brake Model Brake Disc Brake Plate

Low-reverse

brake

F4A41 4 3

F4A42-1 5 4

Second

brake

F4A41 2 1

F4A42-1 3 2

34 Nm

170 Nm

23 Nm

Apply automatic

transmission fluid to

all moving parts

before installation.

23 Nm <up to Mar. 2000>

29 Nm <from Apr. 2000>

RevisedPWEE9514-I

May 2002Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E- W) -

Transmission

23A-3-5e

44. Rear cover

45. Thrust race #8

46. Seal ring

47. Input shaft rear bearing

48. Thrust bearing #7

49. Reverse and overdrive clutch

50. Thrust bearing #6

51. Overdrive clutch hub

52. Thrust bearing #5

53. Planetary reverse sun gear

54. Snap ring

55. Second brake piston

56. Return spring

57. Pressure plate

58. Second brake disc

59. Second brake plate

60. Overdrive planetary carrier

61. Thrust bearing #4

62. Output planetary carrier

63. Underdrive sun gear

64. Thrust bearing #3

65. Snap ring

66. Reaction plate

67. Snap ring

68. Low-reverse brake disc

69. Low-reverse brake plate

70. Pressure plate

71. Wave spring

72. Parking pawl shaft

73. Spacer

74. Parking pawl spring

75. Parking roller support shaft

76. Parking pawl

77. Parking roller support

78. Snap ring

79. Spring retainer

80. Return spring

81. Low-reverse brake piston

82. T ransfer drive gear

83. Cap

84. Lock nut

85. Output shaft

86. Taper roller bearing

87. Collar

88. Outer race

89. Spacer

90. Snap ring

91. Outer race

92. Transmission case

RevisedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E–W) –

Transmission

23A-3-5f

DISASSEMBLY AND REASSEMBLY <F4A42-2 with one-way clutch>

11 Nm

12 Nm

23 Nm

5 Nm

70 Nm

22 Nm

70 Nm

11 Nm

31 Nm

11 Nm

5 Nm

Apply automatic

transmission fluid to

all moving parts

before installation.

31 Nm

11 Nm

10 Nm

6 Nm

1. Torque converter

2. Roll stopper bracket

3. Harness bracket

4. Control cable support bracket

5. Oil level gauge

6. Eye bolt

7. Oil cooler feed tube

8. Oil filter <Externally mounted type>

Air breather <Air breather type>

9. Oil filter gasket <Externally

mounted type>

10. Input shaft speed sensor

11. Output shaft speed sensor

12. Manual control lever

13. Inhibitor switch

14. Speedometer gear <If equipped>

Sealing cap <Type without

speedometer gear>

15. Valve body cover

16. Manual control shaft detent

RevisedPWEE9514-J

Jun. 2003Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E–W) –

Transmission

23A-3-5g

11 Nm

Apply automatic

transmission fluid to

all moving parts

before installation.

17. Fluid temperature sensor*

18. Valve body

19. Steel ball

20. Gasket

21. Snap ring

22. Solenoid valve harness

23. Strainer

*: Not applicable to type with solenoid

valve harness incorporating fluid

temperature sensor

24. Second brake retainer oil seal

25. Accumulator piston

26. Accumulator spring

27. Accumulator spring

28. Manual control lever shaft roller

29. Manual control lever shaft

30. Parking pawl rod

RevisedPWEE9514-G

Feb. 2001Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E–W) –

Transmission

23A-3-5h

48 Nm

Apply automatic

transmission fluid to

all moving parts

before installation.

23 Nm <up to Mar. 2000>

29 Nm <from Apr. 2000>

31. Torque converter housing

32. Differential

33. Oil filter

34. Oil pump

35. Gasket

36. Thrust washer #1

37. Underdrive clutch and input shaft

38. Thrust bearing #2

39. Underdrive clutch hub

40. Outer race

41. Spacer

RevisedPWEE9514-I

May 2002Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E–W) –

Transmission

23A-3-5i

23 Nm

170 Nm

34 Nm

Apply automatic

transmission fluid to

all moving parts

before installation.

TFA2048

23 Nm <up to Mar. 2000>

29 Nm <from Apr. 2000>

42. Rear cover

43. Thrust race #8

44. Seal ring

45. Input shaft rear bearing

46. Thrust bearing #7

47. Reverse and overdrive clutch

48. Thrust bearing #6

49. Overdrive clutch hub

50. Thrust bearing #5

51. Planetary reverse sun gear

52. Snap ring

53. Second brake piston

54. Return spring

55. Pressure plate

56. Second brake disc

57. Second brake plate

58. Planetary carrier assembly

59. Snap ring

60. Reaction plate

61. Snap ring

62. Low-reverse brake disc

63. Low-reverse brake plate

64. Pressure plate

65. Wave spring

66. Parking pawl shaft

67. Spacer

68. Parking pawl spring

69. Parking roller support shaft

70. Parking pawl

71. Parking roller support

72. Snap ring

73. One-way clutch inner race

74. O-ring

75. Spring retainer

76. Return spring

77. Low-reverse brake piston

78. Transfer drive gear

79. Cap

80. Lock nut

81. Output shaft

82. Taper roller bearing

83. Collar

84. Outer race

85. Spacer

86. Snap ring

87. Outer race

88. Transmission case

RevisedPWEE9514-I

May 2002Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E- W) -

Transmission

23A-3-5j

DISASSEMBLY AND REASSEMBLY <F4A51>

11 Nm

22 Nm

11 Nm

23 Nm

5Nm

70 Nm

6Nm

70 Nm

11 Nm

Apply automatic

transmission fluid to

all moving parts

before installation.

12 Nm

TFA1980

1. Torque converter

2. Roll stopper bracket

3. Harness bracket

4. Control cable support bracket

5. Oil level gauge

6. Oil filter <Externally mounted type>

7. Oil filter gasket <Externally

mounted type>

8. Input shaft speed sensor

9. Output shaft speed sensor

10. Manual control lever

11. Inhibitor switch

12. Speedometer gear

13. Valve body cover

14. Manual control shaft detent

RevisedPWEE9514-F

Jun. 2000Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E–W) –

Transmission

23A-3-5k

11 Nm

Apply automatic

transmission fluid to

all moving parts

before installation.

TFA1981

15. Fluid temperature sensor*

16. Valve body

17. Steel ball

18. Gasket

19. Snap ring

20. Solenoid valve harness

21. Strainer

*: Not applicable to type with solenoid

valve harness incorporating fluid

temperature sensor

22. Second brake retainer oil seal

23. Accumulator piston

24. Accumulator spring

25. Accumulator spring

26. Manual control lever shaft roller

27. Manual control lever shaft

28. Parking pawl rod

RevisedPWEE9514-G

Feb. 2001Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E–W) –

Transmission

23A-3-5l

48 Nm

Apply automatic

transmission fluid to

all moving parts

before installation.

23 Nm <up to Mar. 2000>

29 Nm <from Apr. 2000>

29. Torque converter housing

30. Differential

31. Oil filter

32. Oil pump

33. Gasket

34. Thrust washer #1

35. Underdrive clutch and input shaft

36. Thrust bearing #2

37. Underdrive clutch hub

38. Outer race

39. Spacer

RevisedPWEE9514-I

May 2002Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E- W) -

Transmission

23A-3-5m

34 Nm

23 Nm

54 Nm

170 Nm

Apply automatic

transmission fluid to

all moving parts

before installation.

40. Rear cover

41. Thrust race #8

42. Seal ring

43. Input shaft rear bearing

44. Thrust bearing #7

45. Rear and overdrive clutch

46. Thrust bearing #6

47. Overdrive clutch hub

48. Thrust bearing #5

49. Planetary reverse sun gear

50. Snap ring

51. Second brake piston

52. Return spring

53. Pressure plate

54. Second brake disc

55. Second brake plate

56. Planetary carrier assembly

57. Snap ring

58. Reaction plate

59. Snap ring

60. Low-reverse brake disc

61. Low-reverse brake plate

62. Pressure plate

63. Wave spring

64. Parking pawl shaft

65. Spacer

66. Parking pawl spring

67. Parking roller support shaft

68. Parking pawl

69. Parking roller support

70. Snap ring

71. One-way clutch inner race

72. O-ring

73. Spring retainer

74. Return spring

75. Low-reverse brake piston

76. T ransfer drive gear

77. Cap

78. Lock nut

79. Output shaft

80. Taper roller bearing

81. Collar

82. Outer race

83. Spacer

84. Snap ring

85. Outer race

86. Transmission case

AddedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation AddedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E–W) –

Transmission

23A-3-5n

DISASSEMBLY

Caution

1. Because the automatic transmission is manufactured

from high-precision parts, sufficient care must be

taken not to scratch or damage these parts during

disassembly and reassembly.

2. The working area should be covered with a rubber

mat to keep it clean at all times.

3. Do not wear any cloth gloves and do not use any

rags during disassembly. Use nylon cloth or paper

towels if you need to use something.

4. Parts which have been disassembled should all be

cleaned. Metal parts can be cleaned with normal

detergent, but they should be dried completely using

compressed air.

5. Clutch discs, plastic thrust plates and rubber parts

should be cleaned with automatic transmission fluid

(ATF) so that they do not become dirty.

6. If the transmission body has been damaged,

disassemble and clean the cooler system also.

RevisedPWEE9514-J

Jun. 2003Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E–W) –

Transmission

23A-3-6

(1) Remove the torque converter.

(2) Use the dial gauge to measure the input shaft end play.

(3) Remove each bracket.

(4) Remove the oil level gauge.

(5) Remove the eye bolt, gasket and the oil cooler feed tube.

(6) Remove the oil filter. <Externally mounted type>

(6a)Remove the air breather by jabbing a screwdriver into

the air breather and prying it up. <Air breather type>

(7) Remove the input shaft speed sensor and output shaft

speed sensor.

(8) Remove the manual control lever, and then remove the

inhibitor switch.

Caution

Make sure that the valve body is installed before

removing the manual control lever installation nut.

RevisedPWEE9514-J

Jun. 2003Mitsubishi Motors Corporation

Input shaft speed

sensor

Output shaft

speed sensor

Manual control lever

Inhibitor

switch

AUTOMATIC TRANSMISSION (E–W) –

Transmission

AUTOMATIC TRANSMISSION (E–W) –

Transmission

23A-3-7

(9) Remove the speedometer gear or sealing cap.

(10)Remove the valve body cover.

(11)Remove the manual control shaft detent spring and the

manual control shaft detent. <Model 1996>

Remove the manual control shaft detent. <from Model

1997>

(12)Disconnect the solenoid valve harness from the valve

body by undoing the fluid temperature sensor (only in

the harness that incorporates the sensor) and all the

connectors.

RevisedPWEE9514-G

Feb. 2001Mitsubishi Motors Corporation

Manual control

shaft detent

Manual control shaft

detent spring

Manual control

shaft detent

TFA1877

AUTOMATIC TRANSMISSION (E–W) –

Transmission

23A-3-8

(13)Remove the valve body mounting bolts (28 pieces).

(14)Remove the fluid temperature sensor. (This step is

unnecessary if the sensor is incorporated in the solenoid

valve harness).

Caution

Make sure that the manual control lever and the inhibitor

switch are removed.

(15)Remove the valve body, gasket and the steel balls (2

pieces).

Caution

Do not lose the steel balls (2 pieces).

(16)Remove the snap ring, and then remove the solenoid

valve harness.

(17)Remove the strainer and the second brake retainer oil

seal.

(18)Remove each accumulator piston and spring.

No. Name

1 For low-reverse brake

2 For underdrive clutch

3 For second brake

4 For overdrive clutch

RevisedPWEE9514-G

Feb. 2001Mitsubishi Motors Corporation

TFA1387

Fluid temper-

ature sensor

Steel balls

Second brake

retainer oil seal

Strainer

AUTOMATIC TRANSMISSION (E- W) -

Transmission

23A-3-9

(19) Remove the manual control lever shaft roller.

(20) Remove the manual control lever shaft and the parking

pawl rod.

(21)Remove the torque converter housing mounting bolts

(18 pieces), and then remove the torque converter

housing.

(22)Remove the O-rings (2 pieces).

(23)Remove the differential and the spacer(s) (3 pieces

F4A41-1-MRA only). <F4A41>....

(24) Remove the differential. <F4A42, F4A51>

RevisedPWEE9514-B

Feb. 1997Mitsubishi Motors Corporation

Parking

pawl rod

Manual control

lever shaft

O-rings

Spacers

AUTOMATIC TRANSMISSION (E- W) -

Transmission

23A-3-10

(25)Remove the oil filter.

(26)Remove the oil pump mounting bolts (6 pieces).

(27) Install the special tool (MD998333) in the hole A.

(28)Screw the special tool to remove the oil pump.

(29)Remove the oil pump gasket.

(30)Remove the thrust washer #1.

(31)Hold the input shaft, and then remove the underdrive

clutch.

RevisedPWEE9514-B

Feb. 1997Mitsubishi Motors Corporation

MD998333

Thrust

washer #1

AUTOMATIC TRANSMISSION (E- W) -

Transmission

23A-3-11

(32) Remove the thrust bearing #2.

(33) Remove the underdrive clutch hub.

(34)Remove the rear cover.

(35)Remove the thrust race #8.

(36)Remove the seal rings (4 pieces).

(37) Remove the input shaft rear bearing.

(38)Remove the O-rings (3 pieces).

(39)Remove the reverse and overdrive clutch and the thrust

bearing #7.

RevisedPWEE9514-B

Feb. 1997Mitsubishi Motors Corporation

Thrust bearing #2

O-rings

Thrust

bearing #7

AUTOMATIC TRANSMISSION (E- W) -

Transmission

23A-3-12

(40)Remove the overdrive clutch hub and th e thrust bearing

#6.

(41) Remove the thrust bearing #5.

(42)Remove the planetary reverse sun gear.

(43) Remove the snap ring.

(44) Remove the second brake piston and the return spring.

RevisedPWEE9514-B

Feb. 1997Mitsubishi Motors Corporation

Thrust

bearing #6

Thrust bearing #5

AUTOMATIC TRANSMISSION (E- W) -

Transmission

23A-3-13

(45)Remove the pressure plate, brake discs and brake

plate(s).

No. of brake discs and plates

Model Brake disc Brake plate Pressure

plate

F4A41 2 1 1

F4A42 3 2 1

F4A51 4 3 1

(46) Remove the overdrive planetary carrier <F4A41, F4A42-1

and F4A42-2 without one-way clutch> or planetary carrier

assembly <F4A42-2 with one-way clutch and F4A51>.

(47)Remove the output planetary carrier and the thrust bearing

#4. <F4A41, F4A42-1 and F4A42-2 without one-way

clutch>

(48) Remove the underdrive sun gear and the thrust bearing

#3 from the output planetary carrier. <F4A41, F4A42-1

and F4A42-2 without one-way clutch>

(49) Remove the snap ring.

RevisedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation

Thrust

bearing #3

AUTOMATIC TRANSMISSION (E- W) -

Transmission

23A-3-14

(50) Remove the reaction plate and the brake disc.

(51) Remove the snap ring.

(52) Remove the brake plates, brake discs and pressure plate.

No. of brake discs and plates

Model Brake disc Brake plate Pressure

plate

F4A41 4 3 1

F4A42-1 5 4 1

F4A42-2, F4A51 6 5 1

(53)Remove the wave spring.

(54)Remove the parking pawl shaft, and then remove the

spacer and spring.

RevisedPWEE9514-B

Feb. 1997Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E- W) -

Transmission

23A-3-15

(55)Remove the two parking roller support shafts, and then

remove th e parking pawl case and parking roller support.

(56) Use the special tool to remove the snap ring.

(57) Remove the one-way clutch inner race <F4A42-2 with

one-way clutch a nd F4A51>, O-ring <F4A42-2 with

one-way clutch and F4A51>, spring retainer, return spring

and t he low-reverse brake piston.

(58) Remove th e transfer drive gear bearing mounting bolts

as follows:

F4A41, F4A42-1 and F4A42-2 without one-way clutch:

Remove all 4 mounting bolts.

F4A42-2 with one-way clutch: First remove 4 or 3 bolts,

then turn the gear

turn (45_) and remove the

remaining 3 or 4 bolts (7 bolts in total).

F4A51: First remove 4 bolts, then turn the gear

turn

(45_) and remove the remaining 4 bolts (8 bolts in

total).

RevisedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation

MB991628

<F4A41, F4A42-1 and F4A42-2 without

one-way clutch>

MD998924

MD998903

<F4A42-2 with one-way clutch>

MD998924

<F4A51>

MD998338

MD998924

AUTOMATIC TRANSMISSION (E- W) -

Transmission

23A-3-16

(59)Remove the transfer drive gear.

(60) Remove the cap.

(61)Straighten the locking tab of the output shaft lock nut.

(62) Use the special tool to remove the output shaft lock nut.

Caution

The lock nut is a left-handed screw.

<F4A41, F4A42-1 and F4A42-2 without

one-way clutch>

<F4A42-2 with one-way clutch and F4A51>

RevisedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation

MB991625

MB990607

AUTOMATIC TRANSMISSION (E- W) -

Transmission

23A-3-16a

(63) Remove the bearing retainer mounting bolt.

(64)Tap on the rear of the output shaft to remove the output

shaft, taper roller bearing and the collar.

(65)Remove the spacer and the outer race.

(66) Remove the snap ring.

(67) Remove th e differential bearing outer race and spacer

from the torque converter hosing. <F4A42, F4A51>

(68) Remove the differential bearing outer race from the

transmission case. <F4A42, F4A51>

RevisedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E- W) -

Transmission

23A-3-16b

AddedPWEE9514-B

Feb. 1997Mitsubishi Motors Corporation

Intentionally blank

AUTOMATIC TRANSMISSION (E- W) -

Transmission

23A-3-17

REASSEMBLY

Caution

1. Never reuse the gasket, O-ring, oil seal, etc. Always

replace with a new one when reassembling.

2. Never use grease other than blue petrolatum jelly

and white Vaseline.

3. Apply ATF to friction components, rotating parts, and

sliding parts before installation. Immerse a new clutch

disc or brake disc in ATF for at least two hours before

assembling them.

4. Never apply sealant or adhesive to gaskets.

5. When replacing a bushing, replace the assembly

which it belongs to.

6. Never use any cloth gloves or any rags during

reassembly. Use nylon cloth or paper towels if you

need to use something.

7. Change the oil in the cooler system.

(1) Use t he special tools to tap the differential bearing outer

race in the transmission case. <F4A42, F4A51>

Model Special tools No.

F4A42 MB990935, MB990938

F4A51 MB990936, MB990938

(2) Use the special tools to tap the output shaft bearing outer

race in th e transmission case.

(3) Install the used spacer and snap ring.

(4) Use the special tool to install th e transfer drive gear.

<F4A41 from Jan. 1998, F4A42-1 from Jan. 1998,

F4A42-2 with one-way clutch an d F4A51>

RevisedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation

MB990938

MB990935 or

MB990936

MB990938

MB990930

MB998412

AUTOMATIC TRANSMISSION (E- W) -

Transmission

23A-3-18

(4a) Tighten the mounting bolts of the transfer drive gear

bearing to the specified torque. <F4A41 from Jan. 1998,

F4A42-1 from Jan. 1998, F4A42-2 with one-way clutch

and F4A51>

F4A41 and F4A42-1 = 4 mounting bolts

F4A42-2 with one-way clutch = 7 mounting bolts

F4A51 = 8 mounting bolts

(5) Install the low-reverse brake piston, return spring and

spring retainer.

(5a)Check the placement of the identification notches in the

one-way clutch inner race. Install the one-way clutch inner

race with O-ring to the transfer drive gear bearing so

that the notches fall along the A - A line. <F4A42-2 with

one-way clutch an d F4A51>

(5b) Use the special tools to install the snap ring.

RevisedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation

<F4A42-2 with one-way clutch an d F4A51>

Identification

notches

Transmission

case

MB991628

<F4A41, F4A42-1 and F4A42-2 without

one-way clutch>

MB998924

MD998924

MD998903

<F4A42-2 with one-way clutch>

AUTOMATIC TRANSMISSION (E- W) -

Transmission

23A-3-19

(6) Install the wave spring.

(7) Install t he brake disc, brake plate and special tool and

snap ring as shown in the figure.

Caution

If necessary, take the measurements in steps 9 to

18 after replacing the pressure plate, brake plate and

brake disc.

NOTE

Do not install the pressure plate at this time.

Number of brake discs and plates

Model Brake disc Brake plate Special tool

F4A41 4 3 1

F4A42-1 5 4 1

F4A42-2, F4A51 6 5 1

(8) Install the reaction plate and the used snap ring.

(9) Move the special tool to measure the end play, and then

replace the snap ring installed in step (8) to adjust the

end play to standard value.

Standard value: 0 - 0.16 mm

RevisedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation

MD998924

<F4A51>

MD998338

Snap ring

MB991631

<F4A41 up to Dec. 1997, F4A42-1 up to Dec. 1997

Reaction

plate

TFA1777

and F4A42-2 without

one-way clutch>

Snap ring

MB991631

<F4A41 from

Jan. 1998>

Reaction plate

MB991631

<F4A42-1 from

Jan. 1998>

Snap ring

Reaction plate

AUTOMATIC TRANSMISSION (E- W) -

Transmission

23A-3-19a

(10)Install the brake disc, brake plate and special tool

MB991631 <F4A41, F4A42> or MB991632 <F4A51> as

shown in the figure.

Number of brake discs and plates

Model Brake disc Brake plate

F4A41 2 1

F4A42 3 2

F4A51 4 3

(11)Install the return spring, second brake piston an d snap

ring.

RevisedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation

<F4A42-2 with

one-way clutch>

Snap ring

Reaction plate

MB991631

Snap ring

<F4A51>

Reaction plate

MB991632

Snap ring

MB991631

<F4A41 up to Dec. 1997, F4A42-1 up to Dec. 1997

and F4A42-2 without one-way clutch>

Second brake

piston

Return spring

TFA1778

Snap ring

MB991631

Second brake

piston

Return

spring

Snap ring

MB991631

Second brake piston

Return

spring

<F4A42-1 from Jan. 1998>

AUTOMATIC TRANSMISSION (E- W) -

Transmission

23A-3-19b

(12) Move the special tool and measure its movement.

Select a pressure plate whose thickness corresponds

to the measured amount of movement from the following

table.

Standard value of end play (Reference):

0.49 - 0.95 mm <F4A41>

0.79 - 1.25 mm <F4A42>

1.09 - 1.55 mm <F4A51>

Pressure plate for F4A41 and F4A42

Movement amount mm

Thickness ID symbol Part No.

F4A41 F4A42

0.3 - 0.5 0.6 - 0.8 1.6 L MD759567

0.5 - 0.7 0.8 - 1.0 1.8 1 MD759414

0.7 - 0.9 1.0 - 1.2 2.0 0 MD759415

0.9 - 1.1 1.2 - 1.4 2.2 2 MD759416

1.1 - 1.3 1.4 - 1.6 2.4 4 MD759417

1.3 - 1.5 1.6 - 1.8 2.6 6 MD759418

RevisedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation

<F4A42-2 with one-way clutch>

Snap ring

MB991631

Second brake piston

Return

spring

MB991632

<F4A51>

Snap ring

Second brake piston

Return

spring

MB991631 or

MB991632

MB991631

TFA1779

<F4A41 up to Dec. 1997, F4A42-1 up to Dec.

1997 and F4A42-2 without

one-way clutch>

Movement

amount

Movement

amount

AUTOMATIC TRANSMISSION (E- W) -

Transmission

23A-3-19c

Pressure plate for F4A51

Movement amount mm Thickness

ID symbol Part No.

1.1 - 1.3 1.8 E MD759425

1.3 - 1.5 2.0 D MD759426

1.5 - 1.7 2.2 C MD759427

1.7 - 1.9 2.4 B MD759428

1.9 - 2.1 2.6 A MD759429

2.1 - 2.3 2.8 0 MD759430

(13)Reverse the transmission.

(14) Install the special tool (MD998913) in a dial gauge, and

then move the special tool (MB991631 or MB991632)

and measure its movement.

Select a pressure plate whose thickness corresponds

to the measured amount of movement from the following

table.

Standard value of end play (Reference):

1.05 - 1.51 mm <F4A41>

1.35 - 1.81 mm <F4A42-1>

1.65 - 2.11 mm <F4A42-2 and F4A51>

AddedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation

<F4A42-1 from Jan. 1998>

Movement

amount

<F4A42-2 with one-way clutch>

Movement

amount

<F4A51>

Movement

amount

MD998913

MB991631 or

MB991632

MD998913

MB991631

TFA1780

<F4A41 up to Dec. 1997,

F4A42-1 up to Dec. 1997

and F4A42-2 without

one-way clutch>

Movement

amount

AUTOMATIC TRANSMISSION (E-W) -

Transmission

23A-3-19d

Pressure plate for F4A41 and F4A42

Movement amount mm

Thick- ID Part No.

F4A41 F4A42-1 F4A42-2

ness

symbol

0.7 - 0.9 1.0 - 1.2 1.3 - 1.5 1.6 L MD759567

0.9 - 1.1 1.2 - 1.4 1.5 - 1.7 1.8 1 MD759414

1.1 - 1.3 1.4 - 1.6 1.7 - 1.9 2.0 0 MD759415

1.3 - 1.5 1.6 - 1.8 1.9 - 2.1 2.2 2 MD759416

1.5 - 1.7 1.8 - 2.0 2.1 - 2.3 2.4 4 MD759417

1.7 - 1.9 2.0 - 2.2 2.3 - 2.5 2.6 6 MD759418

1.9 - 2.1 2.2 - 2.4 2.5 - 2.7 2.8 8 MD759419

2.1 - 2.3 2.4 - 2.6 2.7 - 2.9 3.0 D MD759420

Pressure plate for F4A51

Movement amount mm Thickness

ID symbol Part No.

1.0 - 1.2 1.6 F MD759568

1.2 - 1.4 1.8 E MD759425

1.4 - 1.6 2.0 D MD759426

1.6 - 1.8 2.2 C MD759427

1.8 - 2.0 2.4 B MD759428

2.0 - 2.2 2.6 A MD759429

2.2 - 2.4 2.8 0 MD759430

2.4 - 2.6 3.0 1 MD759431

(15)Remove the parts installed from steps (6) to (14).

(16) Install the output shaft in the transmission case and tighten

the mounting bolts of the output shaft bearing retainer

to the specified torque.

AddedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation

MD998913

Movement

amount

MB991631

<F4A42-1 from Jan. 1998>

Movement

amount

MD998913

MB991631

Movement

amount

MD998913

<F4A42-2 with one-way

clutch>

MB991631

<F4A51>

Movement

amount

MD998913

MB991632

AUTOMATIC TRANSMISSION (E-W) -

Transmission

23A-3-20

(17)Use the special tool to install the collar and taper roller

bearing in the output shaft.

(18)Apply ATF to a new lock nut, and use the special tool

to tighten the lock nut to the specified torque. Then turn

back one turn, and tighten to the specified torque again.

Caution

The lock nut is a left-hand screw.

(19)Move the output shaft to measure operating amount (A),

and then replace the spacer installed in step (3) with

a new one which thickness is within the following value.

[A (operating amount) + B (thickness of the old spacer)

+ 0.01 mm) to [A (operating amount) + B (thickness

of the old spacer) + 0.09 mm]

(20) Stake the lock nut with a punch (two pleces).

(21) Install the cap as shown in the figure.

RevisedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation

MD998350

MB991625

MB990607

MB990938

2.5 - 3.0

MB990931

AUTOMATIC TRANSMISSION (E-W) -

Transmission

23A-3-21

(22)Use the special tool to install the transfer drive gear.

<F4A41 up to Dec. 1997, F4A42-1 up to Dec. 1997 and

F4A42-2 without one-way clutch>

(23) Tighten the four mounting bouts of the transfer drive gear

to the specified torque. <F4A41 up to Dec. 1997, F4A42-1

up to Dec. 1997 and F4A42-2 without one-way clutch>

(24) Install the parking pawl, spacer, a nd spring. Then install

the parking pawl shaft.

(25)Install the parking roller support, and then the two parking

roller support shafts.

(26) Install the underdrive sun gear and thrust bearing #3

to the output planetary carrier. <F4A41, F4A42-1 and

F4A42-2 without one-way clutch>

Caution

Be careful about the installation direction of the thrust

bearing.

RevisedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation

MB998412

Parking pawl shaft

Parking roller

support shaft

Thrust bearing #3

AUTOMATIC TRANSMISSION (E-W) -

Transmission

23A-3-22

#8 #7 #6 #5 #4 #3 #2 #1

<F4A41, F4A42>

IDENTIFICATION OF THRUST BEARINGS, THRUST RACES, AND THRUST WASHERS

Sym-

bol

O.D. I.D.

Thick-

ness

Part number

Sym-

bol

O.D. I.D.

Thick-

ness

Part number

1.8 MD754509 1.6 MD707267

2.0 MD754508 1.7 MD759681

2.2 MD754507 1.8 MD723064

#1 59 47

2.4 MD753793 1.9 MD754794

2.6 MD753794 2.0 MD707268

2.8 MD753795 2.1 MD754795

#2 49 36 3.6 MD756846

#8 48.9 37

2.2 MD723065

#3 49 36 3.6 MD756846 2.3 MD754796

#4 45.3 31 3.3 MD757647 2.4 MD724358

#5 49 36 3.6 MD756846 2.5 MD754797

#6 49 36 3.6 MD756846

#7 59 37 2.8 MD754595

2.6 MD754798

RevisedPWEE9514-B

Feb. 1997Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E-W) -

Transmission

23A-3-22a

#8 #7

<F4A51>

TFA1989

IDENTIFICATION OF THRUST BEARINGS, THRUST RACES, AND THRUST WASHERS

Sym-

bol

O.D. I.D.

Thick-

ness

Part number

Sym-

bol

O.D. I.D.

Thick-

ness

Part number

1.8 MD754509 1.6 MD707267

2.0 MD754508 1.7 MD759681

2.2 MD754507 1.8 MD723064

#1 59 47

2.4 MD753793 1.9 MD754794

2.6 MD753794 2.0 MD707268

2.8 MD753795 2.1 MD754795

#2 49 36 3.6 MD756846

#8 48.9 37

2.2 MD723065

#3 49 36 3.6 MD756846 2.3 MD754796

#4 55.4 38.5 3.3 MD761683 2.4 MD724358

#5 57 38.5 4.1 MD758556 2.5 MD754797

#6 57 38.5 4.1 MD758556

#7 59 37 2.8 MD754595

2.6 MD754798

AddedPWEE9514-B

Feb. 1997Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E-W) -

Transmission

23A-3-22b

AddedPWEE9514-B

Feb. 1997Mitsubishi Motors Corporation

Intentionally blank

AUTOMATIC TRANSMISSION (E-W) -

Transmission

23A-3-23

(27)Install the output planetary carrier and thrust bearing #4.

<F4A41, F4A42-1 a n d F4A42-2 without one-way clutch>

Caution

Be careful about the installation direction of the thrust

bearing.

(28) Install the overdrive planetary carrier <F4A41, F4A42-1

and F4A42-2 without one-way clutch> or planetary carrier

assembly <F4A42-2 with one-way clutch and F4A51>.

(29)Install t he planetary reverse sun gear.

(30)Install the wave spring.

(31) Install the pressure plate, brake disc, and brake plate.

Number of brake discs and plates

Model Brake disc Brake plate Pressure

plate

F4A41 4 3 1

F4A42-1 5 4 1

F4A42-2, F4A51 6 5 1

RevisedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation

Thrust

bearing #4

AUTOMATIC TRANSMISSION (E-W) -

Transmission

23A-3-24

(32) Install the snap ring.

(33) Install the reaction plate.

(34) Install the snap ring.

(35) Install the brake disc, brake plate, and pressure plate.

(36) Install the return spring and second brake piston.

PWEE9514

May 1995Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E-W) -

Transmission

23A-3-25

(37) Install the snap ring.

(38)Install t he thrust bearing #5.

Caution

Be careful about the installation direction of the thrust

bearing.

(39)Install the overdrive clutch hub an d thrust bearing #6

to the reverse and overdrive clutch.

Caution

Be careful about the installation direction of the thrust

bearing

(40)Install the reverse and overdrive clutch, and thrust bearing

#7.

Caution

Be careful about the installation direction of the thrust

bearing

(41)Install t he three O-rings.

PWEE9514

May 1995Mitsubishi Motors Corporation

Thrust bearing #5

Thrust bearing #7

O-rings

AUTOMATIC TRANSMISSION (E-W) -

Transmission

23A-3-26

(42)Use special tool an d tap the input shaft bearing in the

rear cover.

(43)Install the four seal rings in the grooves of the rear cover.

(44)Install the thinnest thrust race #8 (thickness 1.6 mm: part

No. MD707267) on thrust bearing #7, then install the

rear cover and tighten the bolts to the specified torque.

(45) Measure end play of the underdrive sun gear and record

the measurement value.

NOTE

Installing the underdrive clutch hub makes it easy to

measure the end play of the underdrive sun gear.

Standard value: 0.25 - 0.45 mm

Select a thrust race #8 whose thickness corresponds

to the measured value from th e table below, and replace

the thrust race installed in step (44) with the selected

one.

Measurement value mm Thickness mm Part No.

0.3 - 0.4 1.6 MD707267

0.4 - 0.5 1.7 MD759681

0.5 - 0.6 1.8 MD723064

0.6 - 0.7 1.9 MD754794

0.7 - 0.8 2.0 MD707268

0.8 - 0.9 2.1 MD754795

0.9 - 1.0 2.2 MD723065

1.0 - 1.1 2.3 MD754796

1.1 - 1.2 2.4 MD724358

1.2 - 1.3 2.5 MD754797

1.3 - 1.4 2.6 MD754798

(46)Squeeze out the liquid gasket of 1.6 mm in diameter

and apply it to the shown points of the rear cover.

Liquid gasket:

MITSUBISHI genuine sealant Part No. MD974421

or equivalent

RevisedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation

MB990938

Underdrive

clutch hub

AUTOMATIC TRANSMISSION (E-W) -

Transmission

23A-3-27

(47) Install the rear cover, and tighten its mounting bolts to

the specified torque.

(48) Install the underdrive clutch hub.

(49)Install t he thrust bearing #2.

Caution

Install the thrust bearing in correct direction.

(50) Hold the input shaft, and install the underdrive clutch.

(50a) Place two beads of solder [each 10 mm in length, 3.5

mm in diameter] on the underdrive clutch retainer as shown

in the illustration.

RevisedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation

Thrust bearing #2

Underdrive

clutch retainer

Two beads

of solder

Input shaft

AUTOMATIC TRANSMISSION (E-W) -

Transmission

23A-3-27a

(50b) Install special tool in the illustrated place.

(50c) Install the oil pump to the transaxle case.

NOTE

Do not install the oil pump gasket at this time.

(50d) Tighten the oil pump mounting bolts (6 pieces) to the

specified torque.

(50e) Remove the oil pump mounting bolts.

(50f) Using special tool, remove the oil pump, and then take

out the crushed solders.

(50g) Use a micrometer to measure the thickness of the

crushed solder beads a n d record the measured value.

(50h) Select a thrust washer # 1 whose thickness corresponds

to the measured value from table below.

Measurement

value mm

Thickness

ID symbol Part No.

2.25 - 2.45 1.8 18 MD754509

2.45 - 2.65 2.0 20 MD754508

2.65 - 2.85 2.2 22 MD754507

2.85 - 3.05 2.4 24 MD753793

3.05 - 3.25 2.6 26 MD753794

3.25 - 3.45 2.8 28 MD753795

(51) Install the used thrust washer #1 that was selected in

step (50h) on the underdrive clutch retainer.

MD998412

MD998333

AddedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation

Thrust

washer #1

AUTOMATIC TRANSMISSION (E-W) -

Transmission

23A-3-27b

AddedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation

Intentionally blank

AUTOMATIC TRANSMISSION (E-W) -

Transmission

23A-3-28

(52)Use the special tool to install a new oil pump gasket

and oil pump.

Caution

Never reuse the old gasket.

(53)Tighten the oil pump mounting bolts to the specified torque.

(54) Make sure that the input shaft end play meets the standard

value.

Standard value: 0.70 - 1.45 mm

(55)Install the oil filter.

(56) Install the spacer (F4A41-1-MRA only), and then the

differential. <F4A41>

(57) Install the differential. <F4A42, F4A51>

RevisedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation

MD998412

<F4A41>

<F4A42, F4A51>

AUTOMATIC TRANSMISSION (E-W) -

Transmission

23A-3-29

(58)Install the 1.25-mm-thick spacer. <F4A41-1-MRA only>

(59)Place a solder (approx. 10 mm in length, 3 mm in diameter)

on the differential as shown in the figure. <F4A41>

(60)Place a solder (approx. 10 mm in length, 3 mm in diameter)

and outer race on the torque converter housing as shown

in the figure. <F4A42, F4A51>

(61)Install the torque converter housing to the transmission

case without applying sealant. Tighten its mounting bolts

to the specified torque.

(62)Loosen the bolts, and remove the outer race <F4A42,

F4A51> and solder.

(63)Use a micrometer to measure the thickness (T) of the

pressed solder. Select a spacer which thickness is within

the following value.

F4A41

(T - 0.045 mm) to (T - 0.165 mm)

F4A42, F4A51

(T + 0.045 mm) to (T + 0.105 mm)

(64)Place the spacer selected in the above step. <F4A41>

RevisedPWEE9514-F

Jun. 2000Mitsubishi Motors Corporation

Solders

Spacers

AUTOMATIC TRANSMISSION (E-W) -

Transmission

23A-3-30

(65)Set the spacer selected in step (63) and install the outer

race to the torque converter housing. Use the special

tools to press in the outer race. <F4A42, F4A51>

Model Special tools No.

F4A42 MB990935, MB990938

F4A51 MB990936, MB990938

(66)Squeeze out the liquid gasket of 1.6 mm in diameter

and apply it to the shown points of torque converter.

Liquid gasket:

MITSUBISHI genuine sealant Part No. MD974421

or equivalent

(67)Install the two O-rings.

(68)Install the torque converter, and then tighten its 18

mounting bolts to the specified torque.

(69)Install the manual control lever shaft and parking pawl

rod.

(70)Install the manual control lever shaft roller.

RevisedPWEE9514-F

Jun. 2000Mitsubishi Motors Corporation

MB990938

MB990935 or

MB990936

O-rings

Parking

pawl rod

Manual control

lever shaft

AUTOMATIC TRANSMISSION (E-W) -

Transmission

23A-3-31

(71) Install the accumulator pistons, new seal rings, and

springs.

NOTE

The accumulator springs are identified as shown in the

figure.

No. Name

1 For low-reverse brake

2 For underdrive clutch

3 For second brake

4 For overdrive clutch

(72) Install the strainer a nd second brake retainer oil seal.

(73) Install the solenoid valve harness, and then secure the

snap ring to the connector groove.

(74) Install the valve body, gasket, and two steel balls.

RevisedPWEE9514-B

Feb. 1997Mitsubishi Motors Corporation

1234

Strainer

Second brake

retainer oil seal

Steel balls

AUTOMATIC TRANSMISSION (E–W) –

Transmission

23A-3-32

(75)Install the fluid temperature sensor. (This step is

unnecessary if the sensor is incorporated in the solenoid

valve harness).

(76)Install the 28 mounting bolts of the valve body.

(77)Attach the solenoid valve harness to the valve body by

connecting the fluid temperature sensor (only in the

harness that incorporates the sensor) and all the

connectors.

No. Parts to be

connected

Cable colour Connector

housing

colour

1 Underdrive

solenoid valve

White, red, red Black

2 Overdrive

solenoid valve

Orange, red Black

3 Low-reverse

solenoid valve

Brown, yellow Milky white

4 Second solenoid

valve

Green, red, red

Blue, red, red

Milky white

5 Damper clutch

control solenoid

valve

Blue,

yellow, yellow

Black

6* Fluid temperature

sensor

Black, red Black

*: Not applicable to type with solenoid valve harness incorporating

fluid temperature sensor

(78)Install the manual control shaft detent spring and detent.

RevisedPWEE9514-J

Jun. 2003Mitsubishi Motors Corporation

TFA1387

Fluid temper-

ature sensor

Manual control

shaft detent

Manual control

shaft detent spring

AUTOMATIC TRANSMISSION (E–W) –

Transmission

23A-3-33

Install the manual control shaft detent. <from Model 1997>

(79)Apply the liquid gasket to the valve body cover.

Liquid gasket:

MITSUBISHI genuine sealant Part No. MD974421

or equivalent

(80)Install the valve body cover, and then tighten its mounting

bolts to the specified torque.

(81)Install the speedometer gear or sealing cap.

(82)Install the inhibitor switch and manual control lever.

RevisedPWEE9514-J

Jun. 2003Mitsubishi Motors Corporation

TFA1877

Manual control

shaft detent

Manual control lever

Inhibitor

switch

AUTOMATIC TRANSMISSION (E–W) –

Transmission

23A-3-34

(83)Install the input shaft speed sensor and output shaft speed

sensor.

(83a) Press in the air breather (A) until it becomes flush with

the transmission case (B) as shown in the drawing. <Air

breather type>

(84)Apply a small amount of ATF to the oil filter gasket. Tighten

the filter to the specified torque. <Externally mounted

type>

(85)Install the eye bolt, a new gasket, and the oil cooler feed

tube.

(86)Install the oil dipstick.

(87)Install the brackets.

(88)Install the torque converter, and secure it so that the

shown dimension (A) meets the reference value.

Reference value: approx.12.2 mm <F4A41, F4A42>

approx. 9.4 mm <F4A51>

Caution

Apply ATF to the oil pump drive hub before installing

the torque converter. Be careful not to damage the

oil seal lip when installing the torque converter.

RevisedPWEE9514-J

Jun. 2003Mitsubishi Motors Corporation

Input shaft

speed sensor

Output shaft

speed sensor

AUTOMATIC TRANSMISSION (E-W) -

Oil Pump

23A-4-1

4. OIL PUMP

DISASSEMBLY AND REASSEMBLY

Apply automatic

transmission fluid to

all moving parts

before installation.

Disassembly steps

A 1. O-ring

2. Seal ring

A 3. Oil seal

4. Oil pump assembly

REASSEMBLY SERVICE POINTS

OIL SEAL INSTALLATION

O-RING INSTALLATION

Install a new O-ring to the outer groove of th e oil pump,

and apply ATF to th e O-ring.

RevisedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation

MD998334

AUTOMATIC TRANSMISSION (E-W) -

Underdrive Clutch and Input Shaft

23A-5-1

5. UNDERDRIVE CLUTCH AND INPUT SHAFT

23302090019

DISASSEMBLY AND REASSEMBLY

Apply automatic

transmission fluid to

all moving parts

before installation.

Number of clutch discs and plates

Model Clutch disc Clutch plate Clutch reaction

plate

F4A41 3 3 1

F4A42,

F4A51

4 4 1

Disassembly steps

1. Snap ring

2. Input shaft

3. Seal ring

A 4. Snap ring

A 5. Clutch reaction plate

A 6. Clutch disc

A 7. Clutch plate

A 8. Snap ring

9. Spring retainer

A 10. D-ring

11. Return spring

12. Underdrive clutch piston

A 13. D-ring

A 14. D-ring

15. Underdrive clutch retainer

RevisedPWEE9514-B

Feb. 1997Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E-W) -

Underdrive Clutch and Input Shaft

23A-5-2

DISASSEMBLY SERVICE POINTS

SNAP RING REMOVAL

REASSEMBLY SERVICE POINTS

D-RING INSTALLATION

Apply ATF, blue petrolatum jelly or white Vaseline to D-ring,

and install carefully.

SNAP RING INSTALLATION

CLUTCH PLATE/CLUTCH DISC/CLUTCH

REACTION PLATE INSTALLATION

(1) Align each teeth missing part (part A) of the clutch plate,

clutch disc and clutch reaction plate to the outer

circumference hole (part B) of the underdrive clutch

retainer.

Caution

Immerse the clutch disc in ATF before assembling

it.

(2) Install the clutch reaction plate in th e shown direction.

Number of clutch discs and plates

Model Clutch disc Clutch plate Clutch reaction

plate

F4A41 3 3 1

F4A42,

F4A51

4 4 1

RevisedPWEE9514-B

Feb. 1997Mitsubishi Motors Corporation

MD998924

MD998907

MD998924

MD998907

Clutch plates

Shear droop

Clutch

reaction

plate

“R” or “W”

Clutch discs

AUTOMATIC TRANSMISSION (E-W) -

Underdrive Clutch and Input Shaft

23A-5-3

SNAP RING INSTALLATION

Check that the clearance between the snap ring and the

clutch reaction plate is within the standard value. When

measuring the clearance, use th e special tool to press the

clutch reaction plate evenly. If not within the standard value,

select a snap ring to adjust.

Standard value:

1.2 - 1.4 mm <F4A41>

1.6 - 1.8 mm <F4A42, F4A51>

Model Special tools No.

F4A41, F4A42 MB991628, MD998924

F4A51 MB991629, MD998924

RevisedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation

MD998924

MB991628 or

MB991629

AUTOMATIC TRANSMISSION (E-W) -

Reverse and Overdrive Clutch

23A-6-1

6. REVERSE AND OVERDRIVE CLUTCH

DISASSEMBLY AND REASSEMBLY

<F4A42> or

<F4A51>

<F4A42> or

<F4A51>

Apply automatic

transmission fluid to

all moving parts

before installation.

Number of clutch discs and plates

Model Pressure

plate

Clutch

disc

Clutch

plate

Clutch

reaction plate

Over- F4A41 - 3 3 1

drive

F4A42 - 4 4 1

clutch

F4A51 1 4 3 1

Reverse clutch - 2 2 1

Disassembly steps

1. Snap ring

2. Clutch reaction plate

3. Clutch disc

4. Clutch plate

5. Snap ring

6. Clutch reaction plate

7. Clutch disc

8. Clutch plate

9. Pressure plate <F4A51>

10. Snap ring

11. Spring retainer

12. D-ring

13. Return spring

14. Overdrive clutch piston

15. D-ring

16. Reverse clutch piston

17. D-ring

18. Reverse clutch retainer

19. D-ring

20. D-ring

RevisedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E-W) -

Reverse and Overdrive Clutch

23A-6-2

DISASSEMBLY SERVICE POINT

SNAP RING REMOVAL

REASSEMBLY SERVICE POINTS

D-RING INSTALLATION

Apply ATF, blue petrolatum jelly or white Vaseline to D-ring,

and install carefully.

REVERSE CLUTCH PISTON INSTALLATION

Align the outer circumference holes (parts A and B) of the

reverse clutch piston an d the reverse clutch retainer to

assemble them.

SNAP RING INSTALLATION

(1) Set special tools as shown in the illustration.

(2) Tighten the nut on the special tool to press down on

the spring retainer and reverse clutch retainer, and then

install the snap ring.

(3) Check that the clearance between the snap ring and

the return spring retainer is within the standard value.

If not within the standard value, select a snap ring to

adjust.

Standard value: 0 - 0.09 mm

PRESSURE PLATE / CLUTCH PLATE / CLUTCH

DISC / CLUTCH REACTION PLATE

INSTALLATION

Install the clutch reaction plate in t he shown direction.

Caution

Immerse the clutch disc in ATF before assembling the

clutch disc.

RevisedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation

MD998924

MD999590

MD998924

MD999590

Clutch plates Shear droop

Clutch discs

Clutch

reaction

plate

<F4A41>

AUTOMATIC TRANSMISSION (E-W) -

Reverse and Overdrive Clutch

23A-6-3

SNAP RING INSTALLATION

Check that the clearance between the snap ring and the

clutch reaction plate is within the standard value. When

measuring the clearance, use th e special tool to press the

clutch reaction plate evenly. If not within the standard value,

select a snap ring to adjust.

Standard value:

1.2 - 1.4 mm <F4A41>

1.6 - 1.8 mm <F4A42, F4A51>

Model Special tools No.

F4A41, F4A42 MB991628, MD998924

F4A51 MB991629, MD998924

CLUTCH PLATE / CLUTCH DISC / CLUTCH

REACTION PLATE INSTALLATION

(1) Align each teeth missing part (part A) of the clutch plate,

clutch disc and clutch reaction plate to the outer

circumference hole (part B) of the reverse clutch retainer.

Caution

Immerse the clutch disc in ATF.

RevisedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation

Clutch plates

Shear droop

Clutch discs

Clutch

reaction

plate

<F4A42>

Clutch

plates

Shear droop

Clutch discs

Clutch

reaction

plate

<F4A51>

Pressure

plate

MD998924

MB991628 or

MB991629

AUTOMATIC TRANSMISSION (E-W) -

Reverse and Overdrive Clutch

23A-6-4

(2) Install the clutch reaction plate in th e shown direction.

SNAP RING INSTALLATION

(1) Install the snap ring into the groove of reverse clutch

retainer.

(2) Set special tools MB991790 <F4A4> or MB991789

<F4A5> a n d MD998924 as shown in the illustration, and

compress the clutch element.

(3) Check that the clearance between the snap ring and

the clutch reaction plate is within th e standard value.

If not within the standard value, select a snap ring to

adjust.

Standard value: 1.5 - 1.7 mm

Clutch plates

Shear droop

Clutch

reaction plate

“R” or “W”

Clutch discs

RevisedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation

MD998924

MB991790 <F4A4> or

MB991789 <F4A5>

Clearance

AUTOMATIC TRANSMISSION (E-W) -

Overdrive Planetary Carrier <F4A41,

F4A42 without One-way Clutch>

23A-7-1

7. OVERDRIVE PLANETARY CARRIER

<F4A41, F4A42 without ONE-WAY CLUTCH>

DISASSEMBLY AND REASSEMBLY

Apply automatic

transmission fluid to

all moving parts

before installation.

Disassembly steps

1. Snap ring

2. Overdrive planetary carrier

3. Overdrive annulus gear

RevisedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E-W) -

Planetary Carrier Assembly <F4A42

with One-way Clutch, F4A51>

23A-7a-1

7a.PLANETARY CARRIER ASSEMBLY

DISASSEMBLY AND REASSEMBLY

Apply automatic

transmission fluid to

all moving parts

before installation.

Disassembly steps

1. Stopper plate

A 2. One-way clutch

3. Snap ring

4. Output planetary carrier

A 5. Thrust bearing #3

6. Underdrive sun gear

A 7. Thrust bearing #4

8. Snap ring

9. Overdrive planetary carrier

10. Overdrive annulus gear

REASSEMBLY SERVICE POINTS

THRUST BEARING #3 / THRUST BEARING #4

INSTALLATION

Check the installation direction of thrust bearings number

3 and 4, an d install them as shown.

Caution

Be careful about the installation direction of the thrust

bearings.

AddedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation

Thrust bearing #4

Thrust bearing #3

AUTOMATIC TRANSMISSION (E–W) –

Planetary Carrier Assembly <F4A42

with One-way Clutch, F4A51>

23A-7a-2

"BA ONE-WAY CLUTCH INSTALLATION

Insert the one-way clutch into the overdrive annulus gear

so that the arrow points to the output planetary carrier side.

RevisedPWEE9514-G

Feb. 2001Mitsubishi Motors Corporation

One-way clutch

Output

planetary

carrier

Overdrive

annulus

gear

AUTOMATIC TRANSMISSION (E-W) -

Low-reverse Brake

23A-8-1

PWEE9514

May 1995Mitsubishi Motors Corporation

8. LOW-REVERSE BRAKE

23300370047

DISASSEMBLY AND REASSEMBLY

Lubricate all internal

parts with automatic

transmission fluid during

reassembly.

Disassembly steps

1. D-ring

2. D-ring

3. Low-reverse brake piston

REASSEMBLY SERVICE POINT

D-RING INSTALLATION

Apply ATF, blue petrolatum jelly or white Vaseline to D-ring,

and install carefully.

AUTOMATIC TRANSMISSION (E-W) -

Second Brake

23A-9-1

PWEE9514

May 1995Mitsubishi Motors Corporation

9. SECOND BRAKE

23302180013

DISASSEMBLY AND REASSEMBLY

Lubricate all internal

parts with automatic

transmission fluid during

reassembly.

Disassembly steps

1. Second brake retainer

2. D-ring

3. Second brake piston

4. D-ring

REASSEMBLY SERVICE POINT

D-RING INSTALLATION

Apply ATF, blue petrolatum jelly or white Vaseline to D-ring,

and install carefully.

AUTOMATIC TRANSMISSION (E–W) –

Output Shaft

23A-10-1

PWEE9514-G

Feb. 2001Mitsubishi Motors Corporation

Revised

10. OUTPUT SHAFT

23302210019

DISASSEMBLY AND REASSEMBLY

Lubricate all internal

parts with automatic

transmission fluid during

reassembly.

Disassembly steps

AA""CA 1. Transfer driven gear

2. Bearing retainer

"BA 3. Outer race

AB""AA 4. Taper roller bearing

5. Output shaft

DISASSEMBLY SERVICE POINTS

AA" TRANSFER DRIVEN GEAR REMOVAL

MD998917

(except F4A51)

AUTOMATIC TRANSMISSION (E-W) -

Output Shaft

23A-10-2

TAPER ROLLER BEARING REMOVAL

REASSEMBLY SERVICE POINTS

TAPER ROLLER BEARING INSTALLATION

Model Special tools No.

F4A41, F4A42 MD998812, MD998814, MD998823

F4A51 MD998812, MD998814, MD998827

OUTER RACE INSTALLATION

Model Special tools No.

F4A41, F4A42 MB990936, MB990938

F4A51 MB990937, MB990938

TRANSFER DRIVEN GEAR INSTALLATION

Model Special tools No.

F4A41, F4A42 MD998812, MD998813, MB998823

F4A51 MD998812, MD998813, MB998824

RevisedPWEE9514-B

Feb. 1997Mitsubishi Motors Corporation

MD998801

MD998812

MD998823 or

MD998827

MD998814

MB990938

MB990936 or

MB990937

MD998812

MD998813

MD998823 or

MD998824

AUTOMATIC TRANSMISSION (E- W) -

Transfer Drive Gear <F4A41 up to

Dec. 1997, F4A42 up to Dec. 1997>

23A-11-1

11. TRANSFER DRIVE GEAR

DISASSEMBLY AND REASSEMBLY

195 Nm

Apply automatic

transmission fluid to

all moving parts

before installation.

Disassembly steps

A 1. Lock nut

A 2. Transfer drive gear bearing

3. Transfer drive gear

DISASSEMBLY SERVICE POINTS

LOCK NUT REMOVAL

(1) Pull up the turning stopper of the lock nut.

RevisedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E- W) -

Transfer Drive Gear <F4A41 up to

Dec. 1997, F4A42 up to Dec. 1997>

23A-11-2

(2) Use the special tool to remove the lock nut.

TRANSFER DRIVE GEAR BEARING REMOVAL

REASSEMBLY SERVICE POINTS

TRANSFER DRIVE GEAR BEARING INSTALLATION

LOCK NUT INSTALLATION

(1) Apply ATF to a new lock nut, and tighten it to the specified

torque. Then turn back one turn, and tighten to the

specified torque again.

(2) Use a punch or other to prevent the nut from turning

(two points).

RevisedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation

MB991626

MD998348

MB990928

MD998812

MD998829

MB991626

AUTOMATIC TRANSMISSION (E-W) -

Differential

23A-12-1

12. DIFFERENTIAL

DISASSEMBLY AND REASSEMBLY

135 Nm

Apply automatic

transmission fluid to

all moving parts

before installation.

Disassembly steps

A 1. Differential drive gear

A 2. Ball bearings <F4A41>

A 3. Taper roller bearings

<F4A42, F4A51>

A 4. Lock pin

A 5. Pinion shaft

A 6. Pinions

A 7. Washers

A 8. Side gears

A 9. Spacers

10. Differential case

DISASSEMBLY SERVICE POINTS

BALL BEARING REMOVAL

RevisedPWEE9514-B

Feb. 1997Mitsubishi Motors Corporation

MD998801

AUTOMATIC TRANSMISSION (E-W) -

Differential

23A-12-2

PWEE9514

May 1995Mitsubishi Motors Corporation

TAPER ROLLER BEARING REMOVAL

REASSEMBLY SERVICE POINTS

SPACER, SIDE GEAR, WASHER, PINION, PINION

SHAFT INSTALLATION

(1) Install the spacers to the back side of the side gears,

and then assemble the side gears into the differential

case.

NOTE

Select the medium size spacer (0.93 - 1.00 mm) when

assembling a new side gear.

(2) Attach the washers to the back side of the pinions, engage

the pinions simultaneously to the side gears, and settle

the gears by turning.

(3) Insert the pinion shaft.

(4) Measure the backlash between the side gears and pinions.

Standard value: 0.025 - 0.150 mm

(5) If not within the standard value, change a spacer and

measure the backlash again.

NOTE

Adjust so that both backlashes are equal.

LOCK PIN INSTALLATION

Install the lock pin in the shown direction.

MD998801

Differential

case

Lock pin

Pinion shaft

AUTOMATIC TRANSMISSION (E-W) -

Differential

23A-12-3

TAPER ROLLER BEARING INSTALLATION

Model Special tools No.

F4A42 MD998812, MD998820

F4A51 MD998812, MD998824

BALL BEARING INSTALLATION

DIFFERENTIAL DRIVE GEAR INSTALLATION

Apply ATF to the bolt, tighten the bolts to the specified torque

in the shown sequence.

RevisedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation

MD998812

MD998820 or

MD998824

Taper roller

bearing

MD998812

MD998819

Bearing

<F4A41>

TFA2259

<F4A42>

<F4A51>

AUTOMATIC TRANSMISSION (E-W) -

Valve Body

23A-13-1

PWEE9514

May 1995Mitsubishi Motors Corporation

13. VALVE BODY

23300550045

DISASSEMBLY AND REASSEMBLY

6Nm

11 Nm

6Nm

Lubricate all internal

parts with automatic

transmission fluid during

reassembly.

Disassembly steps

1. Solenoid valve support

2. Underdrive solenoid valve

3. Second solenoid valve

4. Damper clutch control solenoid

valve

5. Overdrive solenoid valve

6. Low-reverse solenoid valve

7. Manual valve

8. Cover

9. Plate

10. Outside valve body assembly

11. Steel ball (orifice check ball)

12. Spring

13. Plate

14. Damping valve

15. Damping valve spring

16. Steel ball (line relief)

17. Spring

18. Steel ball (orifice check ball)

19. Spring

20. Inside valve body assembly

AUTOMATIC TRANSMISSION (E-W) -

Valve Body

23A-13-2

PWEE9514

May 1995Mitsubishi Motors Corporation

Lubricate all internal

parts with automatic

transmission fluid during

reassembly.

21. Roller

22. Damper clutch control valve sleeve

23. Damper clutch control valve

24. Damper clutch control valve spring

25. Plate

26. Screw

27. Regulator valve spring

28. Regulator valve

29. Plate

30. Fail-safe valve A sleeve

31. Fail-safe valve A2

32. Fail-safe valve A spring

33. Fail-safe valve A1

34. Plate

35. Plug

36. Torque converter valve

37. Torque converter valve spring

38. Plate

39. Fail-safe valve B sleeve

40. Fail-safe valve B

41. Inside valve body

AUTOMATIC TRANSMISSION (E-W) -

Valve Body

23A-13-3

PWEE9514

May 1995Mitsubishi Motors Corporation

Lubricate all internal

parts with automatic

transmission fluid during

reassembly.

42. Roller

43. Overdrive pressure control valve

sleeve

44. Overdrive pressure control valve

45. Overdrive pressure control valve

spring

46. Roller

47. Low-reverse pressure control valve

sleeve

48. Low-reverse pressure control valve

49. Low-reverse pressure control valve

spring

50. Plate

51. Plug

52. Switching valve

53. Roller

54. Underdrive pressure control valve

sleeve

55. Underdrive pressure control valve

56. Underdrive pressure control valve

spring

57. Roller

58. Second pressure control valve

sleeve

59. Second pressure control valve

60. Second pressure control valve

spring

61. Outside valve body

AUTOMATIC TRANSMISSION (E-W) -

Valve Body

23A-13-4

PWEE9514

May 1995Mitsubishi Motors Corporation

DISASSEMBLY SERVICE POINT

SOLENOID VALVES REMOVAL

Mark solenoid valves by white paint to make reassembly

easier.

REASSEMBLY SERVICE POINTS

SPRING/STEEL BALL/DAMPING VALVE/DAMPING

VALVE SPRING INSTALLATION

SPRING/STEEL BALL INSTALLATION

SOLENOID VALVES INSTALLATION

(1) Apply ATF, blue petrolatum jelly or white Vaseline to O-ring,

and install carefully.

(2) Install the solenoid valves by referring to the marks during

disassembly.

No. Name

1 Underdrive solenoid valve

2 Second solenoid valve

3 Damper clutch control solenoid valve

4 Overdrive solenoid valve

5 Low- reverse solenoid valve

Steel ball

and spring

Damping valve

Steel ball and spring

Steel ball

and spring

Steel

ball

AUTOMATIC TRANSMISSION (E-W) -

Speedometer Gear

23A-14-1

14. SPEEDOMETER GEAR

DISASSEMBLY AND REASSEMBLY

Apply automatic

transmission fluid to

all moving parts

before installation.

Disassembly steps

1. e-clip

2. Speedometer driven gear

3. O-ring

4. Sleeve

RevisedPWEE9514-E

Aug. 1999Mitsubishi Motors Corporation

AUTOMATIC TRANSMISSION (E-W) -

Drive Shaft Oil Seal

23A-15-1

PWEE9514

May 1995Mitsubishi Motors Corporation

15. DRIVE SHAFT OIL SEAL

23300430035

DISASSEMBLY AND REASSEMBLY

Lubricate all internal

parts with automatic

transmission fluid during

reassembly.

Disassembly steps

1. Oil seal

2. Torque converter housing

3. Oil seal

4. Transmission case

REASSEMBLY SERVICE POINT

OIL SEAL INSTALLATION

MD998800

AUTOMATIC TRANSMISSION (E-W) -

Drive Shaft Oil Seal

23A-15-2

PWEE9514

May 1995Mitsubishi Motors Corporation

OIL SEAL INSTALLATION

MD998800

Service Bulletins

Click on the applicable bookmark to select the Service Bulletin.

SERVICE BULLETIN

QUALITY INFORMATION ANALYSIS

OVERSEAS SERVICE DEPT. MITSUBISHI MOTORS CORPORATION

SERVICE BULLETIN

No.:

MSB-99E23-002

Date

1999-12-15

Subject:

CHANGE IN TRANSFER DRIVE GEAR

DISASSEMBLY/REASSEMBLY PROCEDURE

Group:

AUTOMATIC

TRANSAXLE

Draft No.:

99TA532414

INFORMATION

INTERNATIONAL

CAR

ADMINISTRATION

OFFICE

T.NITTA - PROJECT LEADER

AFTER SALES SERVICE & CS PROMOTION

(EC) COLT (CJ0A)

(EC) LANCER (CK0A)

(EC) CARISMA

(EC) GALANTE (EA0)

(EC) SPACE RUNNER

(N61W)

(EC) SPACE WAGON

(N84W)

98-10

1. Description:

With change in shape of the lock nut, the transfer drive gear has been changed to that which

cannot be disassembled. Accordingly, the applicable transfer drive gear service procedure has

been added.

2. Applicable Manuals:

Manual Pub. No. Language Page(s)

PWEE9514-D (English)

PWES9515-D (Spanish)

PWEF9516-D (French)

PWEG9517-D (German)

PWED9518-D (Dutch)

Front Wheel Drive Automatic

Transmission (E-W)

Workshop Manual

PWEW9519-D (Swedish)

23A-11-1

3. Effective Date:

From January 1998

Effective Model: GM6015

4. Details:

Shape of lock nut

Old

New

11. TRANSFER DRIVE GEAR <F4A41, F4A42>

DISASSEMBLY AND REASSEMBLY

Disassembly steps

1. Lock nut

2. Transfer drive gear bearing

3. Transfer drive gear

DISSASEMBLY SERVICE POINTS

LOCK NUT REMOVAL

(1) Pull up the turning stopper of the lock nut.

23A-11-1

AUTOMATIC TRANSMISSION

(

E-W

)

–

rans

ear

<F4A41, F4A42>

Apply automatic

transmission fluid

to all moving parts

before installation.

Hexagonal lock nut type only

<Added>

TFA1376

TFA1539

SERVICE BULLETIN

QUALITY INFORMATION ANALYSIS

OVERSEAS SERVICE DEPT. MITSUBISHI MOTORS CORPORATION

SERVICE BULLETIN

No.:

MSB-99E23-003REV

2000-05-31

Subject:

DELETION OF AUTOMATIC TRANSMISSION

EXTERNAL OIL FILTER

ALL MODELS 99-99

Group:

AUTOMATIC

TRANSMISSION

Draft No.:

99AT610110

INFORMATION

INTERNATIONAL

CAR

ADMINISTRATIO

OFFICE

T.NITTA - PROJECT LEADER

AFTER SALES SERVICE & CS PROMOTION

1. Description:

On the front engine front wheel drive (E-W) cars, the external oil filter for the automatic

transmission has been deleted.

Deletion of the external oil filter makes it unnecessary to regularly replace the oil filter.

2. Applicable Models:

F4A41, F4A42, F4A51, F5A42, F5A51

W4A41, W4A42, W4A51, W5A42, W5A51

3. Effective Date:

From October 5, 1999 (KN0310)

SERVICE BULLETIN

QUALITY INFORMATION ANALYSIS

OVERSEAS SERVICE DEPT. MITSUBISHI MOTORS CORPORATION

SERVICE BULLETIN

No.:

MSB-99E23-503

Date

1999-12-15

Subject:

CHANGES IN AND CORRECTION TO FRONT

WHEEL DRIVE A/T WORKSHOP MANUAL

(EC) SPACE

WAGON (N84W)

99-10

Group:

AUTOMATIC

TRANSAXLE

Draft No.:

99TA532317 (EC) GALANT

(EA0)

CORRECTION

INTERNATIONAL

CAR

ADMINISTRATION

OFFICE

T.NITTA - PROJECT LEADER

AFTER SALES SERVICE & CS

PROMOTION

1. Description:

On the cars equipped with automatic transmission with one-way clutch, the following modifications

have been made.

Modification A: The 1999 transmission models (F4A42 with one way clutch for 2.4-liter and 2.5

liter engine equipped cars) have been added.

Modification B: On some models equipped with the F4A42 transmission, the service

procedures for the low-reverse brake have been changed due to addition of the

one-way clutch.

(1) The special tool has been added.

(2) The transmission diasassembly/reassembly procedures have been

changed.

(3) The overdrive planetary carrier disassembly/reassembly procedures have

been changed to the planetary carrier assembly reassembly/disassembly

procedures

Modification C: On all the models equipped with the F4A51 transmission, the service

procedures for the low-reverse brake have been corrected due to addition of the

one-way clutch.

(1) The transmission disassembly/ reassembly procedures have been

corrected.

(2) The overdrive planetary carrier disassembly/reassembly procedures have

been corrected to the planetary carrier assembly reassembly/disassembly

procedures

Modification D: On some models equipped with the F4A42 transmission, the number of the

transfer drive gear mounting bolts has been changed from 4 to 7.

Modification E: On all the models equipped with the F4A51 transmission, the four bolts for

mounting the transfer drive gear have been corrected to the eight bolts.

Modification F: On some models equipped with the F4A42 transmission, the transfer drive gear

tightening torque has been changed from 19 Nm to 34 Nm.

2. Applicable Manuals:

Manual Pub. No. Language Page(s)

Front Wheel Drive Automatic PWEE9514-D (English) 23A-1-2, 23A-1-9,

Transmission (E-W) PWES9515-D (Spanish) 23A-2-4, 23A-3-4,

Workshop Manual PWEF9516-D (French) 23A-3-5d,23A-3-13,

PWEG9517-D (German) 23A-3-15, 23A-3-17,

PWED9518-D (Dutch) 23A-3-21, 23A-3-23,

PWEW9519-D (Swedish) 23A-7-1

3. Effective Date:

• All models of Space Wagon (N84W):

From the first production car for Modifications B, D and F.

• From December 1, 1998 for Modifications B.

Effective Model: JD2563

From January 1, 1998 for Modifications D and F.

Effective Model: GM6015

4. Details:

Front Wheel Drive Automatic Transmission (E-W) Workshop Manual, page 1-14

Modification B: On some models equipped with the F4A42 transmission, the service procedures for the low-

reverse brake have been changed due to addition of the one-way clutch.

•

The special tool has been added.

Tool Number Name Use

MD998823 Installer adapter (48) Installation of output shaft tape roller

bearing <F4A41, F4A42>, transfer

drive gear <F4A41, F4A42>.

MD998824 Installer adapter (50) Installation of transfer drive gear

<F4A51>, differential taper roller

bearing <F4A51>.

MD998827 Installer adapter (56) Installation of output shaft tape roller

bearing <F4A51>.

MD998829 Installer adapter (60) Installation of transfer drive gear

<F4A41, F4A42>.

MD998907 Spring compressor Removal and installation of

underdrive clutch snap ring.

MD998913 Dial gauge extension Measurement of low-reverse brake

and second brake end plays.

MD998917 Bearing remover

Removal of output shaft taper roller

bearing.

MD998924 Spring compressor retainer

•

Removal and installation of low-

reverse brake snap ring.

•

Measurement of underdrive

clutch and overdrive clutch end

plays.

MD999590 Spring compressor Removal and installation of overdrive

clutch snap ring.

MD998903 Spring compressor Removal and installation of

one-way clutch inner race snap

ring <F4A42>.

<Added>

23A-2-4

AUTOMATIC TRANSMISSION (E-W) – Special Tools

Modification B: On some models equipped with the

F4A42 transmission, the service procedures for the

low-reverse brake have been changed due to

addition of the one-way clutch.

Modification F: On some models equipped with the

F4A42 transmission, the transfer drive gear

tightening torque has been changed from 19 Nm to

34 Nm.

23A-3-4

AUTOMATIC TRANSMISSION (E-W) – Transmission

No. of Brake Discs and Plates

Brake Model Brake disc Brake plate

F4A41 4 3Low-reverse

F4A42 5 4

F4A41 2 1Second brake

F4A42 3 2

<Added>

Planetary

carrier

assembly

Apply automatic

transmission fluid

to all moving parts

before installation.

TFA1979

One way

clutch inner

race

O-Ring

34 Nm

AUTOMATIC TRANSMISSION (E-W) – Transmission

23A-3-5d

TFA1997

Modification C: On all the models equipped with the F4A51

transmission, the service procedures for the low-reverse brake

have been corrected due to addition of the one-way clutch.

•

The transmission disassembly/reassembly procedures

•

have been corrected.

•

The overdrive planetary carrier disassembly/reassembly

procedures have been corrected to the planetary carrier

assembly reassembly/disassembly procedures.

Planetary carrier

assembly

Apply automatic

transmission fluid

to all moving parts

before installation.

Modification B: On some models equipped with the F4A42 transmission, the service procedures for the low-

reverse brake have been changed due to addition of the one-way clutch.

Modification C: On some models equipped with the F4A51 transmission, the service procedures for the low-

reverse brake have been changed due to addition of the one-way clutch.

(45) Remove the pressure plate, brake discs and brake plate(s).

(46) Remove the overdrive planetary carrier.

(47) Remove the output planetary carrier and the thrust bearing #4.

(48) Remove the underdrive sun gear and the thrust bearing #3 from the

output planetary carrier.

(49) Remove the snap ring.

AUTOMATIC TRANSMISSION (E-W) – Transmission

23A-3-13

TFA1402

TFA1403

TFA1404

TFA1405

TFA1406

Thrust bearing #3

Planetary carrier assembly

No. of brake discs and plates

Model Brake disc Brake plate Pressure plate

F4A41211

F4A42321

F4A51431

Modification B: On some models equipped with the F4A42 transmission, the service procedures for the low-

reverse brake have been changed due to addition of the one-way clutch.

Modification D: On some models equipped with the F4A42 transmission, the number of the transfer drive

gear mounting bolts has been changed from 4 to 7.

(55) Remove the two parking roller support shaft, and then remove the

parking pawl case and parking roller support.

(56) Use the special tool to remove the snap ring.

(57) Remove the one-way clutch inner race <F4A51>, O-ring <F4A51>,

spring retainer, return spring and the low-reverse brake piston.

(58) Remove the transfer drive gear mounting bolts (4 pieces – F4A41

•

F4A42, 8 pieces – F4A51).

NOTE <F4A51>

Remove four mounting bolts. Then, turn the gear 1/8 turn (45

) and

remove the remaining four bolts.

(59) Remove the transfer drive gear.

AUTOMATIC TRANSMISSION (E-W) – Transmission

23A-3-15

TFA1422

TFA1423

TFA1983

TFA1424

TFA1425

Four or three

TFA2242

Modification B: On some models equipped with the F4A42 transmission, the service procedures for the low-

reverse brake have been changed due to addition of the one-way clutch.

REASSEMBLY

Caution

1. Never reuse the gasket, O-ring, oil seal etc. Always replace with

a new one when reassembling.

2. Never use grease other than blue petrolatum jelly and white

Vaseline.

3. Apply ATF to friction components, rotating parts, and sliding

parts before installation. Immerse a new clutch disc or brake

disc in ATF for at least two hours before assembling them.

4. Never apply sealant or adhesive to gaskets.

5. When replacing a bushing, replace the assembly which it

belongs to.

6. Never use any cloth gloves or any rags during reassembly. Use

nylon cloth or paper towels if you need to use something.

7. Change the oil in the cooler system.

(1) Use the special tool to tap the differential bearing outer race in the

transmission case. <F4A42, F4A51>

(2) Use the special tool to tap the differential bearing outer race in the

transmission case.

(3) Install the used spacer and snap ring.

(4) Install the low-reverse brake piston, return spring and one-way

clutch inner race <F4A51>, transfer drive gear <F4A51> , O-ring

<F4A51>

, spring retainer.

(5) Use the special tools to install the snap ring.

AUTOMATIC TRANSMISSION (E-W) – Transmission

23A-3-17

TFA1422

TFA1506

TFA1507

TFA1423

Model Special tools No.

F4A42 MB990935, MB990938

F4A51 MB990936, MB990938

TFA2242

Modification B: On some models equipped with the F4A42 transmission, the service procedures for the low-reverse

brake have been changed due to addition of the one-way clutch.

Modification C: On all the models equipped with the F4A51 transmission, the service procedures for the low-reverse

brake have been changed due to addition of the one-way clutch.

Modification D: On some models equipped with the F4A42 transmission, the number of the transfer drive gear

mounting bolts has been changed from 4 to 7.

Modification E: On some models equipped with the F4A51 transmission, the four bolts for mounting the transfer drive

gear have been corrected to the eight bolts.

(22) Use the special tool to install the transfer drive gear.

(23) Tighten the four mounting bouts of the transfer drive gear to the

specified torque.

(24) Install the parking pawl, spacer, and spring. Then install the parking

pawl shaft.

(25) Install the parking roller support, and then the two parking roller

support shafts.

(26) Install the underdrive sun gear and thrust bearing #3 to the output

planetary carrier.

Caution

Be careful about the installation direction of the thrust bearing.

AUTOMATIC TRANSMISSION (E-W) – Transmission

23A-3-21

TFA1561

TFA1424

TFA1513

TFA1514

TFA1543

Seven mounting bolts (F4A42) and

eight mounting bolts (F4A51)

Thrust bearing #3

Parking pawl shaft

Parking roller support

shaft

Modification B: On some models equipped with the F4A42 transmission, the service procedures for the low-

reverse brake have been changed due to addition of the one-way clutch.

Modification C: On all the models equipped with the F4A51 transmission, the service procedures for the low-

reverse brake have been changed due to addition of the one-way clutch.

(27) Install the output planetary carrier and thrust bearing #4.

Caution

Be careful about the installation direction of the thrust bearing.

(28) Install the overdrive planetary drive.

(29) Install the planetary reverse sun gear.

(30) Install the wave spring.

(31) Install the pressure plate, brake disc, and brake plate.

AUTOMATIC TRANSMISSION (E-W) – Transmission

23A-3-23

TFA1544

TFA1403

TFA1399

TFA1410

TFA1536

Planetary carrier assembly

Number of brake discs and plates

Model Brake disc Brake plate Pressure plate

F4A41431

F4A42-1 5 4 1

F4A42-2, F4A51 6 5 1

Thrust bearing#4

Modification B: On some models equipped with the F4A42 transmission, the service procedures for the low-

reverse brake have been changed due to addition of the one-way clutch.

Modification C: On all the models equipped with the F4A51 transmission, the service procedures for the low-

reverse brake have been changed due to addition of the one-way clutch.

7. OVERDRIVE PLANETARY CARRIER

DISASSEMBLY AND REASSEMBLY

Disassembly steps

1. Snap ring

2. Overdrive planetary carrier

3. Overdrive annulus gear

23A-7-1

AUTOMATIC TRANSMISSION (E-W) – Overdrive Planetary Carrier

Lubricate all internal

parts with automatic

transmission fluid

during reassembly

TFA1372

23302150014

1999 transmission models (F4A42 with one-way clutch for 2.4-liter and 2.5-liter engine equipped cars)

added.

7. PLANETARY CARRIER ASSEMBLY

DISASSEMBLY AND REASSEMBLY

Disassembly steps

1. Stopper plate

2. One-way clutch

3. Snap ring

4. Output planetary carrier

5. Thrust bearing #3

6. Under drive sun gear

7. Thrust bearing #4

8. Snap ring

9. Over drive planetary carrier

10. Over drive annulus gear

REASSEMBLY SERVICE POINT

THRUST BEARING #3 AND THRUST BEARING #4

INSTALLATION

Check the installation direction of thrust bearings number 3 and 4, and

install them as shown.

Caution

Be careful about the installation direction of the thrust bearings

ONE-WAY CLUTCH INSTALLATION

Insert the one-way clutch into the over drive annulus gear so that the

arrow points to the output planetary carrier side.

AUTOMATIC TRANSMISSION (E-W) – Planetary carrier assembly

Lubricate all internal

parts with automatic

transmission fluid

during reassembly

TFA2042

TFA2043

TFA2044

Installation direction

Thrust bearing #3

Thrust bearing #4

SERVICE BULLETIN

QUALITY INFORMATION ANALYSIS

OVERSEAS SERVICE DEPT. MITSUBISHI MOTORS CORPORATION

SERVICE BULLETIN

No.: MSB-00E23-002

Date

2001-02-28 <Model> <M/Y>

Subject:

ADOPTION OF SOLENOID VALVE HARNESS

WITH INTEGRAL TYPE OIL TEMPERATURE

SENSOR

ALL 01-01

Group:

AUTOMATIC

TRANSMISSION

Draft No.: 00AT600310

INFORMATION

INTERNATIONAL

CAR

ADMINISTRATION

OFFICE

T.MASAKI – MANAGER

TECHNICAL SERVICE PLANNING

1. Description:

For the automatic transmission on the front-engine front-wheel (E-W) drive cars, the solenoid

valve harness with a separate type oil temperature sensor has been changed to that with an

integral type oil temperature.

2. Applicable Automatic Transmission Models:

F4A41, F4A42, F4A51, F5A42, F5A51,

W4A41, W4A42, W4A51, W5A42, W5A51

3. Interchangeability:

Not interchangeable

4. Effective Date (Effective Model):

From September 10, 2000

5. Change Details:

Oil temperature sensor

Old

New

J5 AT Sedan Service Manual

FAX Front Axle

FAX-1

Drive Train/Axle

FAX Front Axle

Precautions

 The parts not for overhaul such as steering knuckle cannot be removed.

 It is better to operate on work bench which is dust free.

 Please clean the surface of part and component before disassembly and assembly.

 Be careful not dirt the parts during operating process, and prevent foreign

material from entering.

 The disassembled parts must be reinstalled in correct order carefully. If the

working process is broken, the parts must be covered with cleaning outer cover.

 The cover must be paper cloth; such prevent roving cloth chips from attaching on

the parts.

 The disassembled part and component (except the rubber part) should be cleaned

with kerosene and blown off, or mop up with paper cloth.

 After installation the fastener must be checked as specified torque.

 After installation, apply necessary alignment inspection to the system.

 All the non-reusable part or components cannot be used again.

 The part and component should be checked thoroughly before repair or

replacement.

Preparation

Remove and install with suitable servicing tools.

Common tool:

Table of Common Service Tool

Tool

Outline drawing

Description

Power tool

Install and remove the bolts, nuts

J5 AT Sedan Service Manual

FAX Front Axle

FAX-2

Special tool:

Table of Special Tool

Tool

Outline drawing

Number

Description

The steering drive rod

pull tool

JAC-T1D003

Remove linkage ball

head.

Front Wheel Hub and Steering Knuckle

On board inspection:

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

1) Wheel bearing check

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

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

bearing or reinstall it.

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

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

Removal and installation:

1) Part

Figure of Front Wheel Hub and Steering Knuckle Part

1- Left front steering knuckle 2- Left front mud guard 3- Front steering knuckle snap spring

J5 AT Sedan Service Manual

FAX Front Axle

FAX-3

4- Front hub bearing 5- Retaining ring 6- Nut protecting cover 7-Nut

8-Front flange disc bolt 9-Front flange disc assembly

2) Removal

① Lift up the vehicle, remove front tires.

② Remove the wheel speed sensor from

steering knuckle.

 Tightening torque: 8～10N·m

Caution:

 Do not pull wire harness of wheel speed sensor.

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

 Standard clearance: 0.8±0.4mm

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

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

for fixation.

 Tightening torque: 70～90N·m

Caution:

 After removal of the brake clipper, the

brake pedal must not be depressed.

⑤ Remove the brake disc stopper bolts

from wheel hub, and take off the brake

disc.

 Tightening torque: 10～15N·m

⑥ Remove the split pin, release the wheel

hub lock nut

 Tightening torque: 260～300N·m

⑦ Knock the drive shaft with rubber

hammer (or other suitable tool) and

wood block, to separate wheel hub and

steering knuckle, then remove the

wheel hub lock nut.

Caution:

FAX001

FAX002

FAX003

J5 AT Sedan Service Manual

FAX Front Axle

FAX-4

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

supported as the drive shaft is put down.

 If the above operation still cannot detach the wheel hub from drive shaft, the

puller (or other suitable tools) may be used.

⑧ Remove steering tie rod ball joint from

the steering knuckle.

Caution:

 The special or suitable tools should be

used so as to avoid ball joint boot

damage.

⑨ Remove the securing bolt of shock

absorber and steering knuckle.

 Tightening torque: 130～150N·m

⑩ Remove drive shaft form wheel hub.

Caution:

 The located angle of drive shaft

universal joint should not be too large.

 Avoid excessive stretching, so as to

prevent ball joint falling off.

⑪ Remove lower swing arm lock nut from

the steering knuckle.

 Tightening torque: 60～72N·m

Caution:

 Special tool should be applied to avoid

ball joint boot damage.

⑫ Take off the wheel hub and steering

knuckle.

FAX004

FAX005

FAX006

FAX007

J5 AT Sedan Service Manual

FAX Front Axle

FAX-5

3) Check after removal

Caution:

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

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

distortion.

4) Installation

 Installation is the reverse order of removal. Please do not use damaged parts or

components.

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

and then tighten the nut.

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

steering knuckle removal with no load.

 Check the wheel alignment.

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

Disassembly and assembly:

1) Disassembly

① Remove the snap clip with inner snap

ring pliers.

② Remove wheel hub and dust deflector

from steering knuckle.

③ Remove inner race of wheel bearing

from wheel hub.

④ Remove outer race of wheel bearing

from steering knuckle.

Caution:

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

may lead to personal injury.

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

many times attempt, please replace the steering knuckle.

2) Check after disassembly

① Steering knuckle

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

crack or other damage, if any, please repair or replace it according to the

condition.

② Brake disc

FAX008

J5 AT Sedan Service Manual

FAX Front Axle

FAX-6

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

③ Snap clip

 Check the snap clip for crack or other damage.

④ Wheel hub

 Check whether the wheel hub bolt is elongated.

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

damage.

 If any, please repair or replace it.

3) Assembly

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

contact surface.

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

Caution:

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

bearing assembly.

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

③ Install dust deflector

④ Press wheel hub into the steering knuckle.

Caution:

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

bearing assembly.

4) Check after assembly

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

 Measure the axial play of the bearing.

Limit value: 0.064～0.088mm

Caution:

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

The wheel bearing replacement:

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

steering knuckle".

Caution:

 Please do not use damaged parts and components.

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

J5 AT Sedan Service Manual

FAX Front Axle

FAX-7

 Perform necessary road test.

Front drive shaft

On board inspection and service:

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

2) Check the boot for crack or other damage.

Caution:

 If there is noise or vibration on the drive shaft, please replace the drive shaft

assembly.

Propeller shaft boots replacement:

1) As to front wheel and steering knuckle removal, please refer to "Front wheel and

steering knuckle removal”.

2) Remove clamps of the boot.

3) Screw the drive shaft puller (or

other suitable tool) into the

universal joint sub assembly screw

hole; pull the universal joint

sub-assembly from the shaft.

Caution:

 If the universal joint sub assembly

cannot be pulled out, remove the

drive shaft assembly firstly and then

try it again.

4) Remove the snap clip from drive shaft, and take off the boot.

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

6) Apply appropriate quantity of grease

to the universal joint sub-assembly

dentoid hole, until the grease flow out

from the circular groove and dentoid

hole. After the grease has been

applied, wipe off the effluent old

grease with towel.

7) Wrap the spline with adhesive tape to

avoid damage to boot. Install new boot

and clamps on the drive shaft.

Caution:

 The boot and clamps cannot be reused.

8) Remove adhesive tape wrapped on the shaft.

FAX010

Sub-assembly

FAX009

J5 AT Sedan Service Manual

FAX Front Axle

FAX-8

9) Put snap clip into groove at edge of the

shaft, align the intermediate shaft at

shaft edge to the universal joint

sub-assembly, then secure the shaft to

universal joint sub-assembly with snap

clip.

Caution:

 The clips cannot be reused.

 It is recommended that use special

tools to install the snap clip.

10) Fit the universal joint sub-assembly to drive shaft with rubber hammer.

Caution:

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

rotating the drive shaft.

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

12) Fit boot into the groove as figure below.

Caution:

 If there is grease adhere to fixing

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

may fall off. Clean off all the grease on

boot surface.

13) Put a slotted screwdriver into the boot

from large diameter end, bleed the

boot, and adjust the installation length

of boot, prevent the boot from

deformation.

Caution:

 If the boot installation length is too

excessive, it may cause boot damage.

 Be careful to use the flat screwdriver;

do not touch inside of the boot.

14) Fix the new boot clamp with tools.

Caution:

 The boot clamp cannot be reused.

FAX013

FAX012

Sub-assembly

FAX011

Prevent the boot from deformation

Flat screwdriver

J5 AT Sedan Service Manual

FAX Front Axle

FAX-9

15) Fix the universal joint sub-assembly and drive shaft, and then determine correct

location when rotating the boot.

Caution:

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

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

17) Insert drive shaft into the wheel hub and bearing assembly, and then tighten the

wheel hub lock nut.

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

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

Caution:

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

nut.

20) Install brake clipper and fix the brake hose.

21) Install wheel speed sensor to the steering knuckle.

22) Tighten the lock nut to standard torque.

 Tightening torque: 260～300N·m

23) Install the cotter pin

Caution:

 The cotter pin may not be reused.

24) Install the tire and tighten as standard torque.

Removal and installation:

1) Removal

① As to the removal of front wheel and steering knuckle, please refer to "Front

wheel and steering knuckle removal”.

② Remove the drive shaft from the transmission side.

Caution:

 The location angle of drive shaft universal joint should not be too large when

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

2) Check after removal

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

badly loose.

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

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

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

J5 AT Sedan Service Manual

FAX Front Axle

FAX-10

2) Installation

Caution:

 When installing drive shaft, the oil seal at transmission side should be replaced

with new one.

① Install the removable end firstly, and then apply gear oil on the drive shaft spline.

Turn the snap clip open downward before installing the drive shaft.

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

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

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

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

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

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

Caution:

 The special structure of lower swing arm and drive shaft is likely lead to the boot

damage. After the drive shaft has been installed on power train, the boot of fixed

section may run into edge of lower swing arm, (please refer to the figure below),

which may impact the boot and shorten its service life greatly, even worse will

damage it directly. So the drive shaft installed must be protected or the steering

knuckle should be installed immediately, or take other measures to assure that the

drive shaft fixed section will not contact the lower swing arm.

Boot and Lower Swing Arm Collision Figure

④ Install end of fixed section

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

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

the washer, nut, cotter pin.

FAX014

J5 AT Sedan Service Manual

FAX Front Axle

FAX-11

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

installing. Install the nut, the tightening torque is 260～300N·m; Install the cotter

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

Disassembly and assembly:

1) Disassembly

① Transmission side

a. Secure the drive shaft in pliers.

Caution:

 Protect the drive shaft with aluminum or copper plate as it is fixed in the pliers.

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

c. Make marks on the case and drive

shaft, and then pull the case out of

the drive shaft.

Caution:

 Make marks with paint or similar

materials.

Do not scratch the surface.

d. Remove the snap clip, and then

remove the trident assembly from

the drive shaft.

e. Remove the boot from drive shaft.

f. Wipe off the old grease on case with

paper towel.

② Wheel side

a. Secure the drive shaft in pliers.

Caution:

 Protect the drive shaft with aluminum or copper plate as it is fixed in the pliers.

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

assembly.

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

assembly screw hole; pull the universal joint sub assembly from the drive shaft.

FAX016

FAX015

Fitting mark

Snap clip

J5 AT Sedan Service Manual

FAX Front Axle

FAX-12

Caution:

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

please replace the drive shaft assembly.

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

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

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

turning the ball joint.

2) Check after disassembly

① Drive shaft

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

drive shaft assembly.

a. Universal joint sub-assembly (wheel side)

Check the following item:

 Check if the universal joint sub-assembly turning excessively and the drive shaft

is loose excessively.

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

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

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

universal joint sub-assembly.

b. Case and trident assembly (transmission side)

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

replace the case or trident assembly.

Caution:

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

② Boot and wheel speed sensor

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

2) Assembly

① Transmission side

a. Wrap the spline on drive shaft with

adhesive tape to avoid boot damage.

Install new boot and clamps on the

drive shaft.

Caution:

 The boot and clamps cannot be reused

FAX017

Adhesive tap

J5 AT Sedan Service Manual

FAX Front Axle

FAX-13

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

c. The paint marks should be aligned

when installing the trident assembly.

Make the chamfer towards shaft to

install the trident assembly

d. Secure trident assembly to the case

with clamps.

e. Apply the recommended grease to

trident assembly and the sliding

surface.

f. Install the case to trident assembly,

and then apply the recommended

grease.

g. Install clamps in the groove as the figure below.

Caution:

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

Clean off all the grease on boot surface.

h. Put a flat screwdriver into the boot

from the large diameter end, bleed the

boot, and adjust the installation length

of boot, prevent the boot from

deformation

Caution:

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

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

i. Fix the new boot clamps with special tool.

Caution:

 The boot clamp cannot be reused.

FAX020

FAX019

FAX018

Snap clip

Drive shaft

Fitting mark

Spline

Fitting mark

Cross shaft component

Flat screwdriver

Prevent the boot from deformation

J5 AT Sedan Service Manual

FAX Front Axle

FAX-14

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

boot.

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

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

② Wheel side

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

Caution:

 The universal joint sub-assembly and drive shaft must be in one line when

installing.

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

engaged.

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

pressed in.

Trouble Diagnosis

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

1) Abnormal sound.

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

abnormal sound when driving or turning the steering wheel.

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

when the vehicle driving.

2) The boot rupture lead to ball joint damage.

① The outer ball joint boot early aging and chap.

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

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

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

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

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

Trouble diagnosis steps and requirements:

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

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

or falling off.

2) Check the fastened bolt for loose.

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

chassis abnormal sound brought by other system trouble.

J5 AT Sedan Service Manual

FAX Front Axle

FAX-15

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

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

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

travelling smoothly.

① Appearance check:

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

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

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

others are connected by fitting.

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

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

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

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

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

② Check with hand:

Clearance check

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

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

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

normal condition)

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

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

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

condition)

The outer ball joint rotation check:

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

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

Inner ball joint move check:

 Set the drive shaft in perpendicular direction, catch hold of the inner ball joint

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

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

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

Solution proposal for the check result:

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

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

and installation standard steps and requirements.

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

keep on function. It is suggested to check other parts for loose, sealed off or

other failures.

J5 AT Sedan Service Manual

FAX Front Axle

FAX-16

Service Data and Specification

Tightening Torque Table

Item

Tightening torque (N·m)

Drive shaft lock nut

260～300

Wheel nut

100～120

Connecting bolt of front steering knuckle and

front shock absorber assembly

130～150

Connecting nut of lower swing arm ball joint and

steering knuckle

60～72

Lower swing arm front installing bolt

130～150

Lower swing arm rear installing bolt

130～150

J5 AT Sedan Service Manual

RAX Rear Axle

RAX-1

RAX Rear Axle

Precautions

 After installation, all the fasteners must be inspected for specified torques.

 After installation, the system must be inspected for necessary alignment.

 All the non-reusable parts or components can not be reused.

 Please inspect the parts completely before repair or replacement.

Preparation

Remove and install with suitable service tools.

Table of Service Tools

Number

Tool

Outline drawing

Description

Power tool

Installing and removing bolts and

nuts

Rear wheel hub and steering knuckle

On board inspection:

Judge whether each part is in normal fixing (clearance) and worn conditions.

1) Wheel bearing inspection

 Push the wheel hub and bearing assembly along axial direction by hand to judge

whether the bearing is loose. If any, it is recommended that you replace the

bearing or reinstall it.

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

condition. If any, it is recommended that the bearing be replaced.

J5 AT Sedan Service Manual

RAX Rear Axle

RAX-2

Removal and Installation:

Rear Axle Exploded View

1-Rear shock absorber assembly 2-Longitudinal rod assembly

3-Rear wheel hub assembly 4-Rear suspension front tie rod 5-Rear suspension rear tie rod

6-Rear sub-frame 7-Rear antiroll bar

1) Removal

① Wheel hub and bearing assembly

a. Lift up the vehicle, remove the wheel

and tire.

b. Release the parking brake.

c. Remove the rear wheel brake caliper assembly.

 Tightening torque: 56～70N·m

d. Remove the wheel hub dust cover.

e. Remove the axle head nut and washer.

 Tightening torque: 260～330 N·m

f. Remove the brake disc stopper bolt and take off the brake disc.

 Tightening torque: 10～15 N·m

g. Remove the rear wheel bearing assembly from the rear steering knuckle.

RAX001

J5 AT Sedan Service Manual

RAX Rear Axle

RAX-3

Caution:

 The wheel bearing assembly should be taken off along the axial direction slowly.

② Rear steering knuckle

a. Remove the wheel hub and bearing assembly from the rear steering knuckle.

b. Remove the wheel speed sensor.

Caution:

 Please do not pull wire harness of the wheel speed sensor.

c. Remove the parking brake cable.

d. Remove rear brake tube.

Caution:

 The brake fluid must be collected as specified to avoid environmental pollution.

 If brake fluid adheres to any brake component, mop up with paper cloth.

e. Remove the bolts securing brake

bottom plate and rear steering

knuckle.

f. Remove bolts of rear suspension

front and rear tie rods.

 Tightening torque: 160～180N·m

g. Remove bolts connecting

longitudinal rod with rear steering

knuckle.

 Tightening torque: 100～120N·m

h. Remove bolts and nuts securing rear

shock absorber and rear steering

knuckle as well as oil pipe clips.

 Tightening torque: 110～130N·m

i. Remove rear steering knuckle.

2） Inspection after removal

① Inspect the part for deformation, crack or other damages. If any, please replace

the part.

② Inspect the rear wheel hub bearing for abrasion, noise or other damages.

③ Inspect the wheel hub inner surface for abrasion, scratch and crack.

3) Installation

① Rear wheel hub

RAX003

RAX002

J5 AT Sedan Service Manual

RAX Rear Axle

RAX-4

Caution:

 The grease for rear wheel hub is conforming to the requirement (designation:

LIG-2 MS511-7 or SUN LIGHT # 2).

a. Press the wheel hub bolts into the rear wheel hub (pay attention to the direction)

without loosening or coming off; the pressed direction of wheel hub bolt should

be perpendicular to the surface of rear wheel hub.

b. Press the bearing into the fixing bracket of rear wheel hub. In this process, the

bearing should go in axial direction; when pressing in, only apply force to

bearing outer race.

c. Put the wheel hub bearing into the rear steering knuckle, then put the washer in

the knuckle, and fasten with lock nut.

② Rear steering knuckle

Caution:

 Installation is the reverse order of removal.

Note: Please do not use damaged parts or components.

 Determine the installation direction of bumper block.

 Perform final tightening to each part removed during rear steering knuckle

removal with on load.

 Inspect the wheel alignment.

 Bleed the brake system.

Service Data and Specification

Table of Tightening Torques

Item

Tightening torque (N·m)

Rear wheel hub bearing lock nut

260～330

Bolts connecting rear shock absorber with rear steering knuckle

110～130

J5 AT Sedan Service Manual

FSU Front Suspension

FSU-1

Suspension

FSU-Front Suspension

Precautions

 To install the suspension or rubber sleeve, the final tightening must be performed

with tires on ground and in unloaded condition.

 Wheel alignment must be inspected after suspension components have been

repaired.

 Oil may shorten service life of rubber sleeve. So the oil spilled must be cleaned

off.

 The unloaded condition means that the fuel, engine coolant and oil all have been

filled, the spare tire, lifting jack, attachment tools and foot pad have been in

specified position.

 The lock nut must not be used again. New nuts should always be used for

installation. The anticorrosive oil on lock nut should not be cleaned off before the

nuts are tightened.

Preparation

The special tool used is shown below:

List of Special Tools

Tool

Outline drawing

Number

Description

Steering drive

rod pull tool

JAC-T1D003

To remove linkage

ball joint

Damping spring

puller

JAC-T1D004

Remove and install

damping spring

J5 AT Sedan Service Manual

FSU Front Suspension

FSU-2

Front suspension assembly

On board inspection:

Confirm each part for the tightening (clearance) and abrasion condition is normal or

not.

1) Inspect the tie rod clearance.

① Stop the vehicle with front wheel face straightly forward.

② Put the pull bar (or similar tools) between the tie rod and steering knuckle.

③ Pull up and down to inspect the clearance.

Caution:

 Do not damage the ball joint boot.

 Do not damage the installation position with too excessive force.

2) Shock absorber check.

Check the installation position for oil leakage, damage or breakage.

Front wheel alignment check:

1) Instruction

Test the wheel alignment in unloaded condition.

2) Pre-check

Check the following item:

① Check whether the tire pressure is normal, and the tire is worn.

② Test run-out of the wheel.

③ Check axial clearance of wheel bearing.

④ Check end clearance of tie rod.

⑤ Check each anchor point on axle and suspension for loose or deformation.

⑥ Check each suspension part, steering knuckle, shock absorber and tie rod for

crack, deformation and other damage.

⑦ Height of vehicle body.

Front wheel toe-in inspection:

Caution:

 The wheel alignment must be conducted on horizontal ground and with no load.

 Front wheel toe-in: 0±1mm

If the toe-in is out of the standard range, please adjust as following steps:

J5 AT Sedan Service Manual

FSU Front Suspension

FSU-3

1) Inspect the set of toe-in on four-wheel

alignment instrument.

2) Set the steer wheel in origin position

and fixed it.

3) Loosen the lock nut on toe rod end.

4) Rotate the left and right tie rod in

clockwise direction or

counterclockwise direction, set the

toe-in to standard value.

Notice:

 The turns of left and right tie rod

should be equal.

5) Fasten the lock nut on tie rod end.

Inspection of camber, kingpin caster angle and kingpin inclination angle:

Front wheel camber: 6′±30′

Kingpin caster angle: 2°54′±30′

Kingpin inclination angle: 12°12′±30′

Notice:

 The camber, kingpin caster angle and kingpin inclination angle have been set

before delivery, do not adjust them.

 If the camber, kingpin caster angle and kingpin inclination angle are not in the

standard range, please check the front suspension, steering knuckle, shock

absorber and tie rod for abrasion or damage. If any, please replace the suspected

part.

FSU002

FSU001

J5 AT Sedan Service Manual

FSU Front Suspension

FSU-4

Front Shock Absorber

Part:

Part Drawing of Front Shock Absorber Assembly

Removal and installation:

1) Removal

① Remove the front wheel tire.

② Disconnect the wheel speed sensor connector.

Caution:

 Do not pull wire harness of the wheel

speed sensor.

③ Remove clips of brake hose, and

disconnect the brake hose.

④ Remove the shock absorber and body

lock nut, take off the clips.

 Tightening torque: 45～60N·m

⑤ Remove the securing bolts and nuts to

shock absorber and steering knuckle.

 Tightening torque: 90～110N·m

⑥ Take out the shock absorber assembly.

2) Installation

Installation is the reverse order of removal.

FSU003

FSU004

FSU003

J5 AT Sedan Service Manual

FSU Front Suspension

FSU-5

Caution:

 Please do not use damaged parts.

 Perform final tightening to each part removed during shock absorber removal

with no load.

 Inspect the wheel alignment.

Disassembly and assembly:

1) Part

Exploded View of Front Shock Absorber

1-Upper spring seat 2-Vibration isolator 3-Bumper 4-Helical spring 5-Dust deflector

6-Upper support assembly 7-Shock absorber

2) Disassembly

Caution:

 Please do not damage the shock

absorber piston pull rod when removing

the absorber.

① Remove the trim cover with slotted

screwdriver.

② Press the coil spring with the spring compressor until the spring is completely

released.

FSU005

J5 AT Sedan Service Manual

FSU Front Suspension

FSU-6

Notice:

 Make sure that the compressor has been installed in position before starting to

press the spring.

 As fastening the bolts to spring compressor, no pneumatic tool should be used.

③ Secure end of the piston push rod, and remove the locking nut of piston push rod.

 Tightening torque: 60～70N·m

Caution:

 Make sure the compressed helical spring is relaxed.

④ Remove the helical spring upper seat, spring upper insulator, dust deflector,

bumper block.

⑤ Remove the helical spring with compressor, and then release the compressor

slowly.

⑥ Remove the spring lower insulator, and take off the shock absorber body.

3) Check after disassembly

① Shock absorber

Caution:

 Check the shock absorber for deformation, crack and damage. if any, please

replace it.

 Check the piston push rod for damage, abrasion and deformation. If any, please

replace it.

 Check the piston for oil leakage. If any, please replace it.

② Spring insulator, bumper block and dust deflector.

Check for crack, and check rubber parts and components for abrasion. If any, please

replace it.

③ Helical spring

Check the helical spring for crack, abrasion and damage. If any, please replace it.

④ Spring upper seat

Check for crack, abrasion, deformation and other damage. If any, please replace it.

J5 AT Sedan Service Manual

FSU Front Suspension

FSU-7

4) Assembly

Assembly is the reverse order of

disassembly.

Caution:

 Please do not damage the piston push

rod as fitting parts and components to

shock absorber.

 Put the larger diameter end of helical

spring downwards, and align to spring

lower seat.

 Make sure that the compressor has been installed to the helical spring completely

before pressing the helical spring.

 The installation position of helical spring should be inspected as the compressor

is released.

 Whether the assembly mark is correct.

Lower Swing Arm

Removal and installation:

1) Removal

① Lift up the vehicle, remove wheels and

tires.

② Remove the bolts to lower swing arm

and fixed support.

 Tightening torque: 60～80N·m

③ Remove bolts to lower swing arm rear

fixed support.

 Tightening torque: 60～80N·m

④ Remove the lock nut of lower swing

arm ball joint.

 Tightening torque: 60～72N·m

Note: The lower swing arm ball joint should

be fixed firstly when removing before

unscrewing the lock nut so as to avoid

rotation of ball joint.

⑤ Remove the lower swing arm assembly.

FSU006

FSU007

FSU008

Helical spring

Lower spring seat

Put the spring in position

J5 AT Sedan Service Manual

FSU Front Suspension

FSU-8

⑥ Remove the assembling bolt of lower swing arm bush and pivot pin.

 Tightening torque: 90～110N.m

⑦ Take off the fixing bracket.

2) Check after removal

① Visual Check

 Check the bush for abrasion or damage. If any, please replace it.

 Check the lower swing arm for deformation or other damages. If any, please

replace it.

 Check the lower swing arm ball head dust deflector for cracks. If any, please

replace it.

 Check all the fixing bolts and nuts for damage. If any, please replace it.

3) Installation

Installation is the reverse order of removal.

Caution:

 Please do not use damaged parts and components.

 The bolts of lower swing arm front rubber sleeve and fixed support should be

pre-tightened, so as to avoid distortion or deformation.

 Perform final tightening to each part removed during lower swing arm removal

with no load.

 Inspect the wheel alignment.

Transverse stabilizer bar

Removal and installation:

1) Removal

① Remove the ball joint of left and right

front stabilizer bar.

 Tightening torque: 35～45N·m

FSU009

J5 AT Sedan Service Manual

FSU Front Suspension

FSU-9

② Remove the securing bolts of left and

right stabilizer bar fixing bracket, take

off the fixing bracket and bush.

 Tightening torque: 30～45N·m

③ Remove the stabilizer bar assembly.

2) Check after removal

Check the stabilizer bar, stabilizer bar connecting ball joint, fixing bracket and bush

for deformation or abrasion. If any, please replace it.

3) Installation

Installation is the reverse order of removal.

Caution:

 Please do not use parts and components that can not be used again.

 Pay attention to the installation direction as installing stabilizer bar bush and

stabilizer bar fixing bracket.

 Perform final tightening to each part removed during front stabilizer removal with

no load.

Transverse Stabilizer Bar Tie Rod

Removal and installation:

1) Removal

① Remove lock nut at one end of

transverse stabilizer bar tie rod from

front swing arm.

 Tightening torque: 35～45N·m

② Remove lock nut at another end of

transverse stabilizer bar tie rod from

transverse stabilizer bar.

 Tightening torque: 35～45N·m

2) Check after removal

① Tie rod check

 Move the ball joint bolt by hand to judge whether it is easy to move.

② Visual check

FSU011

FSU010

J5 AT Sedan Service Manual

FSU Front Suspension

FSU-10

 Check the dust deflector of transverse stabilizer bar for crack or other damage. If

any, please replace it.

3) Installation

 Installation is the reverse order of removal.

 The bolt of transverse stabilizer bar tie rod should be fixed before tightening of

lock nut so as to avoid rotation.

Front Sub Frame Assembly

Part:

Diagram of Front Sub Frame

1-Front sub frame assembly.

2-Front sub frame left connecting plate (the right one is symmetrical to this part)

Removal and installation:

1) Removal

① Support the engine oil pan with jack.

Caution:

 A soft pad should be put between the engine oil pan and the jack.

② Remove the securing bolts of engine support member.

③ Remove the securing bolts and nuts of engine suspension fixing bracket and front,

rear suspension bracket.

④ Take off the front sub frame assembly.

⑤ Remove the front and rear engine suspension soft pad.

2) Check after removal

 Check the soft pad and bush for crack, abrasion or ageing.

 Check the fixing bracket for deformation or damage.

J5 AT Sedan Service Manual

FSU Front Suspension

FSU-11

3) Engine suspension

①Rear suspension ② Front suspension ③Right suspension ④ Left suspension

1-Rear suspension soft pad assembly 2-bolt 3-Rear suspension bracket

4-Right suspension soft pad assembly 5-Right suspension stopping block assembly

6-Right suspension bracket 7-Front suspension soft pad assembly 8-bolt

9-Front suspension bracket 10-Left suspension bracket assembly

11-Left suspension soft pad assembly 12-bolt

J5 AT Sedan Service Manual

FSU Front Suspension

FSU-12

Trouble Diagnosis

Diagnostic Table for Common Faults

Check

Possible cause

Solution

Heavy steering

Front wheel improper alignment

Adjust

Rotate to exceed the lower swing arm ball joint

Replace

Tire air pressure too low

Inflate

Non-power steering

Repair or replace

Return badly

Front wheel improper alignment

Adjust

Shock absorber fault

Repair or replace

Transverse stabilizer bar abrasion or damage

Replace

Helical spring abrasion or damage

Replace

Lower swing arm bush abrasion

Replace

Tire abnormal abrasion

Front wheel improper alignment

Adjust

Tire air pressure too low or too high

Adjust air pressure

Shock absorber fault

Repair or replace

Vehicle running

deviation

Front wheel improper alignment

Adjust

Insufficient lower swing arm ball joint linkage

steering resistance force

Replace

Lower swing arm bush loose or abrasion

Replace

Vehicle running

deviation in one side

Front wheel improper alignment

Adjust

Insufficient lower swing arm ball joint linkage

steering resistance force

Replace

Lower swing arm bending

Replace

Helical spring abrasion or damage

Replace

The steering wheel

wobbling

Front wheel improper alignment

Adjust

Insufficient lower swing arm ball joint linkage

steering resistance force

Replace

Lower swing arm bush loose or abrasion

Replace

Shock absorber fault

Repair or replace

Transverse stabilizer bar abrasion or damage

Replace

Helical spring abrasion or damage

Replace

Vehicle sinkage

Helical spring abrasion or damage

Replace

Shock absorber fault

Repair or replace

J5 AT Sedan Service Manual

FSU Front Suspension

FSU-13

Service Data and Specification

Technical Specification Table

Item

Parameter and specification

Type of front suspension

McPherson independent suspension with helical spring

Shock absorber

Type

Two-way hydraulic cylinder

Travel

160mm

Damping force

Extended

845±130N·m

Compressed

240±40N·m

Helical spring

Free height 395±5mm

Color mark: White-wire 1

Wheel alignment

Wheel toe-in (front)

0±1

Camber angle

6′±30′

Kingpin inclination angle

12°12′±30′

Kingpin caster angle

2°54′±30′

Kingpin offset distance

5.8mm

Tightening Torque Table

Item

Torque (N·m)

Front transverse stabilizer bar bracket securing bolt

30～45

Front transverse stabilizer bar and transverse stabilizer bar tie rod connecting nut

35～45

Nut fastening front absorber to body

45～60

Self lock nut on front shock absorber

50～70

Lock nut of front lower swing arm ball joint

60～72

Front lower swing arm bush and pivot pin installing bolt

90～110

Bolt to front shock absorber and steering knuckle

90～110

Front transverse stabilizer bar ball joint and lock nut

35～45

Steering tie rod adjusting lock nut

50～60

Front fixing bolt of Front Sub Frame

160-180

Rear fixing nut of Front Sub Frame

130-150

Bolt to left and right suspension soft pad and body (M10)

60±5

Bolt to front and rear suspension soft pad and sub Frame (M10)

60±5

Bolt to transmission and front/rear suspension bracket (M12)

70±5

J5 AT Sedan Service Manual

FSU Front Suspension

FSU-14

Item

Torque (N·m)

Nut to transmission and left suspension bracket (M12)

70±5

Nut to engine and right suspension bracket (M10)

60±5

Bolt to right suspension soft pad and bracket (engine) (M12)

80±5

Bolt to left suspension soft pad and bracket (engine) (M12)

80±5

Bolt to front and rear suspension soft pad and bracket(M10)

70±5

J5 AT Sedan Service Manual

RSU Rear Suspension

RSU-1

RSU Rear Suspension

Precautions

 When installing the suspension, the final tightening must be performed with tires

on ground and in unloaded condition.

 The wheel alignment must be checked after suspension components have been

repaired.

 When installing the rubber sleeve, the final tightening must be performed with

tires on ground and in unloaded condition.

 The oil may shorten service life of rubber sleeve. So the oil spilled must be

cleaned off.

 The unloaded condition means that the fuel, engine coolant and oil all have been

filled, the spare tire, lifting jack, attachment tools and foot pad have been in

specified position.

 The lock nut must not be used again. New nuts should always be used as

installation. The anticorrosive oil on lock nut should not be cleaned off before the

nuts are tightened.

Preparation

The common and special service tools used are listed in the table below:

List of Common Tools

Tool

Outline drawing

Description

Power tool

Install and remove the bolts, nuts

List of Special Tools

Tool

Outline drawing

Number

Description

The steering

drive rod pull

tool

JAC-T1D003

Remove linkage

ball head.

Damping spring

puller

JAC-T1D004

Remove and install

damping spring

J5 AT Sedan Service Manual

RSU Rear Suspension

RSU-2

Rear Suspension Assembly

Part:

Part Drawing of Rear Suspension Assembly

1-Shock absorber assembly 2-Longitudinal track bar fixing bracket

3-Longitudinal track bar assembly

4- Connecting nut of rear shock absorber and stabilizer bar drag rod

5- Rear transverse stabilizer bar tie rod 6-Rear suspension front tie rod

7- Rear suspension rear tie rod 8- Rear transverse stabilizer bar

9- Rear transverse stabilizer bar fixing bracket, installing bush 10--Nut

On board inspection:

Check each part for tightening condition (clearance, loose) and other conditions

(abrasion, damage).

1) Shock absorber check

Check the installing region for oil leakage or damage.

2) Check the axial clearance of wheel bearing

① Jack up the vehicle, check the axial clearance while the vehicle is stationary, if

there is axial clearance, remove the wheel hub cover and release the park brake

handle, to continue the steps below.

② Check the axial clearance of wheel bearing end.

a. Put the micrometer on surface of wheel hub; turn the hub to check the axial

clearance.

 Standard clearance: 0～0.22mm

J5 AT Sedan Service Manual

RSU Rear Suspension

RSU-3

b. If axial clearance is out of the specified range, tighten the wheel bearing nut as

specified torque, then check the axial clearance again.

c. If the axial clearance can not be adjusted to specified range, please replace the

rear wheel bearing.

Rear wheel alignment check:

Caution:

 If the parts of rear suspension is worn or changed, the rear wheel alignment

parameters should be checked according to the requirements, if any inconformity

is found, please adjust in time as following steps:

 If it is impossible to get standard parameter by adjustment, please replace the

deformed or worn part and component.

 Standard value:

Rear wheel toe-in: 4±1mm

Rear wheel camber angle: -66′±30′

1) Instruction

Test the wheel alignment in unloaded condition.

2) Pre-check

Check the following item:

① Test whether the tire pressure is normal, and check the tire for abrasion.

② Test run-out of the wheel

③ Test axial clearance of wheel bearing.

④ Check clearance between parts of the suspension, whether the fixed point is

loose.

⑤ Maneuverability of shock absorber.

⑥ Check each cantilever for crack, deformation and other damages.

⑦ Body height.

3) Adjustment

Park the vehicle on four-wheel alignment instruments, if the toe-in of rear wheel is

excess of the standard value, unscrew the tie rod adjusting nut (which can not be

removed), turn the tie rod adjusting bolt to change the rear wheel toe-in to standard

value, then fasten the adjusting nut. The rear wheel camber will change along with

toe-in increasing or decreasing.

J5 AT Sedan Service Manual

RSU Rear Suspension

RSU-4

 The variation of toe-in by tie rod turn

one round: about 6mm (0.6°)

 Tightening torque 50～60 N·m

Rear Shock Absorber

Part:

Part Drawing of Rear Shock Absorber Assembly

Removal and installation:

1) Removal

① Lift up the vehicle, remove the wheel and tire.

② Remove the clips of brake tube and

move the brake tube away.

③ Remove the upper trim plate of pillar

④ Remove the self lock nut on shock

absorber.

 Tightening torque: 30～40N·m

RSU002

RSU001

J5 AT Sedan Service Manual

RSU Rear Suspension

RSU-5

⑤ Remove the securing bolts and nuts of

shock absorber and rear steering

knuckle.

 Tightening torque: 110～130N·m

Warning:

 Pay attention to sudden falling of shock absorber assembly when removing so as

to avoid personal injury!

⑥ Remove oil pipes on shock absorber.

⑦ Remove rear shock absorber assembly.

2) Check after removal

Check for oil leakage, deformation, crack or other damages. If any, please replace it.

3) Installation

Installation is the reverse order of removal.

Caution:

 Please do not use damaged parts or components.

 Tighten each part that has been removed when removing the shock absorber with

no load.

 Check the wheel alignment.

 Bleed the brake system.

RSU003

J5 AT Sedan Service Manual

RSU Rear Suspension

RSU-6

Disassembly and installation:

1) Disassembly

Caution:

 Please don't damage the shock absorber piston push rod when removing the shock

absorber part and component.

① Remove the trim cover with flat

screwdriver.

② Press the helical spring with special

tool spring compressor until the

helical spring is released.

Caution:

 Make sure that the special tool compressor has been installed in position, and

then begin to press the helical spring.

 The bolts of compressor must not be tightened by pneumatic tool.

③ Fix the end of piston push rod, and remove the 3 self lock nuts of shock absorber.

 Tightening torque: 45～55N·m

Caution:

 Make sure that the compressed helical spring is relaxed.

④ Remove the helical spring upper mount, spring upper insulator, dust deflector,

bumper block.

⑤ Remove the helical spring with compressor, and then release the compressor

slowly.

⑥ Remove the spring lower insulator, and take off the shock absorber body.

2) Check after disassembly

① Shock absorber

 Check the shock absorber for oil leakage. If any, please replace it.

 Check the piston push rod for damage, abrasion and deformation. If any, please

replace it.

 Check the helical spring lower mount for crack or deformation. If any, please

replace it.

② Bumper block, dust deflector, insulator

RSU004

J5 AT Sedan Service Manual

RSU Rear Suspension

RSU-7

 Check the bumper block, dust deflector, spring upper insulator, spring lower

insulator for abrasion or damage. If any, please replace it.

③ Helical spring

 Test free travel of helical spring. If it does not meet the following value, please

replace the spring.

 Free travel: 193mm

④ Helical spring upper mount

 Check whether there is crack, abrasion, deformation and other damage. If any,

please replace it.

3) Assembly

Assembly is the reverse order of removal.

Caution:

 Please do not use damaged parts or

components.

 Please do not damage the piston push

rod as installing parts and

components to shock absorber.

 When installing the spring lower

insulator, the projection of insulator

must be aligned to spring mount hole

on shock absorber and installed in

position.

 The large diameter end of helical

spring should be downward, and

align to spring lower mount.

 Make sure that the compressor has

been installed to the helical spring

completely, and then start to press the

helical spring.

 The installing position of helical

spring should be checked when the

compressor is relaxed.

 Whether the assembly mark is

correct.

RSU006

RSU005

Lower spring

mount

Hole (3 point)

Projection (3 point)

J5 AT Sedan Service Manual

RSU Rear Suspension

RSU-8

Rear Suspension Front Transverse Tie Rod, Rear Suspension Rear Tie Rod

Part:

Removal and installation:

1) Removal

① Remove the securing bolts of rear

suspension front transverse tie rod,

rear suspension rear tie rod and rear

wheel steering knuckle.

 Tightening torque: 160～180N·m

② Remove the connecting bolts of rear

suspension front tie rod, rear

suspension rear tie rod and rear sub

frame, rear mounting plate.

 Tightening torque: 160～180N·m

③ Take off the rear suspension front tie rod and rear suspension rear tie rod.

2) Check after removal

 Check rear suspension front tie rod, rear suspension rear tie rod for deformation,

the bush for abrasion or other damage. If any, please replace it.

 Check the link mechanism thread for distortion. If any, please replace it.

3) Installation

Installation is the reverse order of removal.

Caution:

 Perform final tightening to each part removed during rear suspension tie rod, rear

suspension rear tie rod removal with no load.

 Check the vehicle for rear wheel alignment.

RSU008

RSU007

J5 AT Sedan Service Manual

RSU Rear Suspension

RSU-9

Longitudinal Track Bar Assembly

Removal and installation:

1) Removal

① Remove the securing bolt at front and

rear end of longitudinal track bar.

 Tightening torque: 100～120N·m

② Remove the connecting bolts of

longitudinal track bar and rear

steering knuckle.

 Tightening torque: 100～120N·m

2) Check after removal

 Check the longitudinal track bar for deformation, the bush for abrasion or other

damages. If any, please replace it.

3) Installation

Installation is the reverse order of removal.

Caution:

 The connecting bolt should be pre-tightened.

 Perform final tightening to each part removed during longitudinal track bar

removal with no load.

RSU010

RSU009

J5 AT Sedan Service Manual

RSU Rear Suspension

RSU-10

Rear Stabilizer Bar Connecting Rod

Removal and installation:

1) Removal

Remove self lock nut of connecting rod,

and take off the rear stabilizer bar

connecting bar.

 Tightening torque: 35～45N·m

2) Installation

Installation is the reverse order of removal.

Caution:

 Please do not use damaged parts or components.

Rear Transverse Stabilizer Bar

Removal and installation:

1) Removal

① Remove self lock nut of rear

transverse stabilizer bar.

 Tightening torque: 35～45N·m

② Remove bolt of rear stabilizer bar

fixing bracket, take off the bracket

and bush, bilateral symmetry.

 Tightening torque: 17～26N·m

③ Remove the rear transverse stabilizer

bar.

RSU013

RSU012

RSU011

J5 AT Sedan Service Manual

RSU Rear Suspension

RSU-11

2) Check after removal

Check rear transverse stabilizer bar and rear transverse stabilizer bar anchorage for

deformation, crack and abrasion, if any, please replace it.

3) Installation

Installation is the reverse order of removal.

Caution:

 Please do not use damaged parts and components.

Rear Sub Frame Assembly

Part:

Part Diagram of Rear Sub Frame

Removal and installation:

1) Removal

① Remove connecting bolts of rear

suspension front tie rod, rear

suspension rear tie rod to rear sub

frame.

 Tightening torque: 160～180N·m

② Jack the rear sub frame assembly up.

Caution:

 The jack must not slide off when

removing.

③ Remove the securing bolts on left and

right sides of rear sub frame.

 Tightening torque: 100～120N·m

2) Installation

Installation is the reverse order of removal.

RSU015

RSU014

J5 AT Sedan Service Manual

RSU Rear Suspension

RSU-12

Caution:

 Please do not use damaged parts and components.

 Pay attention to installing direction when installing rear sub frame.

Trouble Diagnosis

Diagnostic Table for Common Faults

Check

Possible cause

Solution

Abnormal sound

Loose installation

Fasten

Fatigue or damage of wheel bearing

Replace

Shock absorber assembly damage

Replace the damaged component

Tire defects

Replace

Vibration

Excessive tire air pressure

Adjust the pressure

Shock absorber assembly damage

Replace the damaged component

Tire nut loose

Tighten

Helical spring is shortened or broken

Replace

Tire defects

Replace

Body incline

Helical spring is shortened or broken

Replace

Service Data and Specification

Technical Specification Table

Item

Parameter and specification

Type of rear suspension

Dual link

Shock absorber

Type

Two-way hydraulic cylinder

Travel

193mm

Damping force

Pull

775±130N

Compress

235±40N

Helical spring

Type

Standard

Free height

385±5mm

Color mark

White wire

Wheel alignment

Wheel toe-in (rear)

4±1mm

Camber angle

-66′±30′

J5 AT Sedan Service Manual

RSU Rear Suspension

RSU-13

Tightening Torque Table

Item

Tightening torque (N·m)

Installing nut of rear absorber to body

30～40

Self lock nut of rear absorber

40～50

Connecting nut of rear transverse stabilizer bar to tie rod

35～45

Rear transverse stabilizer bar bracket securing bolt

17～26

Rear suspension rear tie rod adjusting nut

50～60

Longitudinal track bar bracket securing bolt

40～50

Longitudinal track bar and steering nut fitting nut

100～120

Rear sub frame fitting bolt

100～120

Longitudinal track bar and longitudinal track bar bracket fitting nut

100～120

Rear suspension front and rear tie rod fitting bolt

160～180

Bolt to rear shock absorber and steering knuckle

110～130

J5 AT Sedan Service Manual

WT Wheel and Tire

WT-1

WT Wheel and Tire

Precautions

 Please use the original manufactured wheel.

 In the run-in period of new tires, quick start, sharp turn and emergency brake

should be avoided in bad working condition, to prevent the new tire untimely

damage.

 The new tire should be balanced before usage.

Tire

Inspection:

1) Air pressure inspection

① Inspect the tire for inflation pressure. If the pressure is not in standard pressure

range, please adjust it.

Standard value: 220±10KPa

Notice:

 Test tire pressure with good tire pressure gauge.

 Determine whether the wheel is worn, improper inflation, with cracks or other

damages.

 As the ambient temperature fluctuate violently, the tire pressure should be

inspected frequently.

② The incorrect tire pressure may

result:

a. The insufficient inflation will lead

tire shoulder to wear rapidly, tire

deflection, as well as rolling

resistance increasing.

b. The excessive air pressure will make

the tire crown worn quickly, and

decrease the tire buffering capacity.

WT001

WT002

J5 AT Sedan Service Manual

WT Wheel and Tire

WT-2

2) Incorrect alignment inspection

Too large or small toe-in of rear wheel

and front wheel will cause the tire

feathered worn as shown in the figure.

3) Tire tread inspection

① Measure depth of tire treads.

Note: Tire specification 205/55R16 91V

 As the depth of tire tread is worn to

limit or smaller, the worn marks

should appear on the tire tread. If the

worn marks appear, please replace

the tire.

② Inspect whether there are foreign materials in the tire tread. If any, please clear

them off.

4) Inspect the wheel to see whether there are cracks or other damages.

If there is deformation, please test the wheel run-out.

① Remove the tire from the wheel, and

install it on the tire balancing

machine.

② Set micrometer gauge as the figure

below.

As wheel run-out value, please refer to

"service data and specification". If the tire

run-out has exceed the limit, please

replace it.

WT006

WT005

WT004

WT003

Worn for too large front toe-in

Inside

Worn for too small front toe-in

Radial run-out

Lateral run-out

J5 AT Sedan Service Manual

WT Wheel and Tire

WT-3

Interchange:

 The tires should be interchanged as

the vehicle has driven for 8000km.

The tires should also be interchanged as

new tires are applied.

Note: It is recommended that tires are

interchanged as shown in the figure.

Replace:

① The tires should be replaced if the vehicle has driven normally for 50000km.

② The tires should also be replaced if one of the symptoms below is found:

 More than 3 worn marks appear on the tire tread.

 The cord or cord wire was exposed on the tire rubber.

 Cracks on tire tread or tire shoulder, the cord layer is uncovered.

 There are surface bulging, protrusion or delamination on the tire.

 The tire is punctured, cut or with other damages that can not be repaired.

Wheel and tire assembly

Remove and install:

1) Remove

① Remove the wheel nut.

 Tightening torque: 100～120N·m

② Remove the wheel and tire assembly.

2) Install

Install the wheel and tire assembly as well

as tire nut.

Notice:

 If it is installed by hand, please

pre-tighten in turn firstly, and then

tighten the nut in diagonal sequence.

 If it is tighten automatically, the

tightening torque should be adjusted

and tightened at one time.

 All wheel nuts should be fastened according to the sequence shown in the figure.

WT009

WT008

WT007

J5 AT Sedan Service Manual

WT Wheel and Tire

WT-4

Wheel balance:

1) Remove

① Remove tires which need adjustment.

② Remove old balance weight on both sides of wheel, and clear the objects on tire

tread.

Notice:

 Be careful not to hurt the wheel as removing.

 The adhesive tapes on new tires should be removed.

2) Adjustment of wheel balance

① Take the center hole as alignment surface, mount the wheel on wheel balancing

machine, and start the machine.

② As the imbalance value of both side displayed on screen of balancing machine,

the outside imbalance value should be multiplied with 5/3 to determine the actual

balance weight used. Then choose outside balance weight which is most close to

the calculated value, and mount it to specified outside position, or to angle

position specified relative to the wheel.

Notice:

 The inside balance weight should be mounted after the outside balance weight

has been mounted.

 The matched surface must be clean off before the balance weights are mounted.

a. Mount the balance weight as

shown in the figure.

b. As the balance weight is mounted

on the wheel, the weight should be

put on inside of wheel with

grooves, make the center of weight

alignment to specified position on

wheel balancing machine (or

angle).

c. If the calculated balance weight is

more than 50g, mount the two

balance weights in one line.

Notice:

 The balance weights may not be

used again, please replace with new

ones.

 The balance weights mounted

should not be more than three parts.

WT010

WT011

Position indicated by the balancing

machine (angle)

Weight pasted

Align to

groove

Gravity center

Position indicated by the

balancing machine (angle)

J5 AT Sedan Service Manual

WT Wheel and Tire

WT-5

 The origin balance weights should always be used.

 The balance weight can't be put on another.

③ Start the wheel balancing machine again.

④ Strike the balance weight into inner side of wheel according to position (or angle)

pointed by the balance machine.

⑤ Start the balancing machine, make sure that remain imbalance weight of inside

and outside is 5g or smaller, if imbalance weight of either side is more than 5g,

repeat the steps above.

Trouble Diagnosis

Table of Common Malfunction Diagnosis

Fault symptom

Possible cause

Solution

The steering wheel

vibration in

circumference

The tire and wheel run-out is excessive

The wheel nut is loose

tire imbalance

The tire is worn unevenly

Insufficient tire pressure

Front wheel bearing is damaged or worn

Steering system fault

Suspension system fault

Replace

Fasten

Adjust

Adjust or replace

Adjust

Adjust or replace

Tire is worn in advance

Incorrect tire pressure

Adjust

Tire noise

Incorrect tire pressure

Tire degenerate

Adjust

Replace

Road noise or the body

vibration

Insufficient tire pressure

Tire imbalance

Deformation of wheel rim or tire

Tire is worn unevenly

Adjust

Repair or replace

Adjust or replace

The steering wheel

vibrates up and down

The tire and wheel run-out is excessive

The wheel nut is loose

Tire imbalance

The engine support rubber is broken or worn

The transmission support rubber is broken or worn

Replace

Fasten

Adjust

Replace

The steering wheel is

deflected

Incorrect tire pressure

The tire is worn excessively or unevenly

Steering system fault

Brake system fault

Suspension system fault

Adjust

Adjust or replace

Driving unstable

The tire pressure on both side is different

Adjust

J5 AT Sedan Service Manual

WT Wheel and Tire

WT-6

Fault symptom

Possible cause

Solution

Deformation of wheel rim or tire

The wheel nut is loose

Steering system fault

Suspension system fault

Repair or replace

Fasten

Adjust or replace

Brake deflected

The tire pressure on both side is different

Brake system fault

Adjust

Adjust or replace

Steering wheel is hard

to move

Insufficient tire pressure

Steering system fault

Suspension system fault

Adjust

Adjust or replace

Steering wheel return

ability is bad

Insufficient tire pressure

Steering system fault

Suspension system fault

Adjust

Adjust or replace

Service Data and Specification

Technical Specification Table

Item

Parameter

Wheel run-out

Radial

Steel wheel

0.6mm

Aluminum wheel

0.3mm

Axial

Steel wheel

1.0mm

Aluminum wheel

0.3mm

Tire pressure (cooled)

220±10KPa

Tire specification

205/55R16 91V

Table of Tightening Torque

Item

Tightening torque

Wheel nut

100～120N·m

J5 AT Sedan Service Manual

BR Brake System

BR-1

Brake

BR Brake System

Precautions

 Recommended brake fluid is “DOT 4”;

 Please don not reuse the drained brake fluid

 Be careful not splash brake fluid on paintwork, avoid paintwork damage. If it is

splashed on paintwork, please clean it off with water.

 Clean all parts of brake wheel cylinder with cleaning brake fluid.

 Please do not use mineral oil such as gasoline and kerosene, otherwise, the rubber

parts of hydraulic system will be corroded.

 Please use special oil tube wrench when removing and installing oil tube.

 When installing the brake tube, the fastening torque must be checked.

 The brake contact surface must be run in after repair or replacement of brake disc,

brake shoe, or when the braking became soft after a very short distance driving.

 The brake wheel cylinder and brake shoe must be cleaned thoroughly, such the

damage caused by particles in air and other matters will be minimum.

 When removing the brake wheel cylinder, the brake pedal must not be depressed,

prevent the piston from being bounced out, which may lead to the piston boot

damage.

 The bolts on brake wheel cylinder fixing support and brake hose must not be

removed unless disassemble or replace the brake wheel cylinder. After being

removed, the brake wheel cylinder can be hung up with rope to avoid pulling the

brake hose.

 If the brake shoe shim or the shim retainer ring is corroded seriously, please

replace the brake shoe shim and shim retainer ring with new ones.

 The brake shoe shim and shim retainer ring must be replaced either every time

the brake shoe is replaced.

 Make sure that no brake fluid on brake disc, please do not splash brake fluid on

the brake disc, otherwise will cause brake failure.

J5 AT Sedan Service Manual

BR Brake System

BR-2

Preparation

Apply special service tool to remove and install as necessary.

Table of Service Tool

Tool

Outline drawing

Description

Oil pipe

wrench

Remove and install the

brake tube

Power tool

Remove and install the

bolts, nuts

Brake Pedal

Check and adjustment:

Adjustment of clearance between brake

pedal and brake limit switch bolt:

1) Remove the lower protecting panel

assembly on driver side.

2) Disconnect the brake lamp connector,

Unscrew the brake limit switch nut,

release the brake pedal, turn the

switch bolt to get the clearance

between switch bolt and brake pedal

is 0.5～1mm.

 Tightening torque: 8～10N·m

BR001

Locking nut

Brake pedal retainer

J5 AT Sedan Service Manual

BR Brake System

BR-3

Brake pedal free travel:

1) Depress the brake pedal for 2～ 3

times with the engine switched off.

2) Make sure that vacuum in vacuum

booster is eliminated, depress the

pedal by hand.

3) Check whether the pedal free travel is

in standard range before any

resistance force arising.

 Standard value: 3～8mm

4) If the free travel is out of standard

range, please adjust.

Caution:

 If the free travel can not be adjusted to the standard range, please replace the

damaged part and components.

Removal and installation:

1) Removal

① Remove the lower protect panel

assembly on driver side.

② Disconnect the brake lamp connector.

③ Remove the locking pin to brake

vacuum booster, disconnect link to

brake vacuum booster.

④ Remove the fixing bolt of brake

pedal to body, and fixing nut to brake

vacuum booster.

 Tightening torque: 17～26N·m

⑤ Take out the brake pedal.

2) Check after removal

① Brake pedal

 Check the movable pin of brake pedal for abrasion or deformation.

BR004

BR003

BR002

J5 AT Sedan Service Manual

BR Brake System

BR-4

 Check the brake pedal for crack, twist or other damages.

② Locking pin and bush

 Check locking pin and bush for damage or deformation, if any, please replace.

③ Brake lamp switch

a. Test the 2 terminals of brake lamp

with multimeter, press and release

the brake lamp switch to check

whether it is in connection

b. As shown in the figure, if the switch

is depressed for more than 4mm, the

two terminals being not in

connection, and being in connection

as released, thus the brake lamp

switch function normally.

3) Installation

Install is the reverse order of removal.

Caution:

 Check whether the brake pedal can travel freely.

 Check the brake pedal free travel.

 Check the clearance between brake pedal and brake lamp.

Brake master cylinder

On board inspection:

Check the fitting surface of master cylinder, oil pot and whether there is leakage from

brake tube connector.

Removal and installation:

1) Removal

① Drain off the brake fluid.

② Remove the air filter assembly.

③ Remove the plug of brake fluid level

switch.

BR006

BR005

In connection

Not in connection

J5 AT Sedan Service Manual

BR Brake System

BR-5

④ Disconnect the master cylinder brake

tube with pipe wrench.

 Tightening torque: 13～17N·m

⑤ Remove the fixing nut of brake

master cylinder and clutch master

cylinder connecting pipe to master

cylinder, and then remove the master

cylinder assembly.

Caution:

 Do not bend or damage the brake

pipe.

2) Installation

Caution:

 Apply grease to the axis pin before installation: SAE J310 or similar products.

① Install the master cylinder component to brake vacuum booster, and fasten the

nut.

Caution:

 Do not damage the sliding surface of piston push rod, no foreign matters should

on the surface.

② Install the brake tube on master cylinder component, and pre-tighten it.

③ Tighten the brake pipe nut with oil pipe wrench or similar tool.

④ Install brake fluid level switch connector.

⑤ Fill new brake fluid and bleed.

BR008

BR007

J5 AT Sedan Service Manual

BR Brake System

BR-6

Brake Fluid

Check position of brake fluid level:

1) Confirm whether level of brake fluid

in oil pot is in specified range

(between MAX and MIN marks), if

the fluid level is too low, please

check whether there is leakage

around the oil pot and brake system.

2) Start the vehicle, release brake handle to observe whether the brake warning

lamp turn off. If it does not turn off, please check the parking brake switch, brake

fluid level switch for faults.

Brake pipe

Hydraulic pipe diagram:

Hydraulic pipe instruction drawing

1-Master cylinder 2-ABS actuator

Caution:

 All the brake pipes can not be bent, twisted and pulled.

 Make sure that all brake pipe will not interfere with other parts whenever the

vehicle is parked or steering.

 The brake pipe is important security part, if there is brake fluid leakage, tighten it

to fixing position all the time. If there are damaged part and component, please

replace suitable new parts.

BR009

J5 AT Sedan Service Manual

BR Brake System

BR-7

 If the brake pipe is disconnected, please plug both ends of the pipe to avoid the

dust ingress.

Front brake pipe and hose:

1) Removal

① Remove the wheel tire.

② Remove the brake hose bolt.

Caution:

 Pay attention the bolt washer not to

fall off.

 Tightening torque: 25～30N·m

③ Remove the joint of brake hose and

brake tube with oil pipe wrench, take

off the snap clip.

 Tightening torque: 13～17N·m

④ Take off the brake hose and brake

tube.

2) Installation

Installation is the reverse order of

removal.

Caution:

 Please reuse the shim and oil pipe clip.

 Pay attention to the installing direction of brake hose.

 Refill brake fluid and bleed.

Rear brake pipe and brake hose:

1) Removal

① Remove the fixing bolt to rear brake

wheel cylinder hose.

 Tightening torque: 25～30N·m

BR012

BR011

BR010

J5 AT Sedan Service Manual

BR Brake System

BR-8

② Remove the joint of rear brake hose

and brake tube, take off the snap clip.

 Tightening torque: 13～17N·m

③ Take off the brake hose and brake

tube.

2) Installation

Installation is the reverse order of removal.

Brake Master Cylinder and Brake Tube of ABS Hydraulic Adjuster:

1) Removal

① Remove the air filter assembly.

② Remove oil pipes joint of brake

master cylinder.

 Tightening torque: 13～17 N·m

③ Firstly disconnect the joint of brake

master cylinder oil pipe to ABS

hydraulic adjuster assembly, and then

disconnect the other joints in turn.

 Tightening torque: 13～17 N·m

Caution:

 The brake fluid in ABS hydraulic

adjuster assembly must not be drained

off or disassemble the ABS hydraulic

adjuster.

2) Installation

BR015

BR014

BR013

J5 AT Sedan Service Manual

BR Brake System

BR-9

Caution:

 Install the ABS hydraulic adjuster

bracket firstly, and then fasten it with

bolt, fix the hydraulic adjuster

assembly to ABS bracket, the

installation sequence of hydraulic

adjuster assembly is as SN in the right

figure:

 The brake pipes may not be changed due to installation difficulty; all the fixing

clips and casing must be installed in position when installing each pipe

assemblies.

① Attach left front brake hose assembly to left front brake caliper, pass the whole

pipes through the shock absorber bracket and body bracket to connect with left

front brake tube and fit the snap clip, fit snap clip on the shock absorber bracket

at last. The installation of right side is identical to that of left side.

② Fix the rear brake master pipe assembly to underside of the body with bolt.

③ Install the air filter assembly.

④ Refill brake fluid and bleed.

3) Check after installation

Caution:

 If there is leakage from joint of brake tube and brake hose, please tighten it again,

if there are damaged part, please replace it.

① Check the brake hose, brake pipes and joint for fluid leakage, damage, twist,

deformation, interference with other part and loose.

② When the engine is running, apply a definite brake force and keep for several

seconds, check each part for fluid leakage.

BR016

J5 AT Sedan Service Manual

BR Brake System

BR-10

Brake Vacuum Booster

Part:

Schematic Drawing of Brake Vacuum Booster

1-Cacuum booster assembly 2-Brake master cylinder 3-Brake oil pot 4-Brake pedal assembly

On board inspection:

1) Operation check

Turn the engine off; depress the brake

pedal for several times, make the vacuum

in brake vacuum booster is equal to

atmosphere. Depress the brake pedal to

limitation, start the engine, confirm

whether the clearance between brake

pedal and the floor has decrease when the

vacuum arrives at standard value.

Caution:

 The interval time between brake

pedal depressing is 5 seconds.

2) Air-tightness check

 Start the engine and keep it on idle

running for 1 minute, turn it off when

the brake vacuum booster is in

vacuum condition. Depress the brake

pedal normally, to eliminate the

vacuum. Make sure whether the

distance between brake pedal and

floor is increasing slowly.

BR018

BR017

Good

Bad

First

Second

Third

J5 AT Sedan Service Manual

BR Brake System

BR-11

 Depress the brake pedal when the engine is running, and hold the brake pedal

until the engine turns off. Hold the pedal for 30 seconds; make sure that the pedal

travel does not change.

Removal and installation:

Caution:

 Do not bend the brake pipe when removing the brake vacuum booster.

 Please replace the damaged locking pin.

 Please do not damage thread of fixing bolt to brake vacuum booster.

1) Removal

① Remove the air filter assembly.

② Take off the clamp on vacuum hose,

remove vacuum hose from the brake

vacuum booster

③ Remove locking pin and washer from

the brake pedal.

④ Remove the union nut of brake pedal

and brake vacuum booster.

 Tightening torque: 17～26N·m

⑤ Remove brake vacuum booster from

the engine compartment.

2) Check after removal

① Check the push rod length.

a. Apply a vacuum pressure of

-66.7KPa to the brake vacuum

booster with manual vacuum pump.

b. Check length of the push rod.

 Length of the push rod: 203～228mm

② Vacuum hose

BR021

BR020

BR019

Preload

Push rod length

J5 AT Sedan Service Manual

BR Brake System

BR-12

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

3) Installation

① Install the brake master cylinder and vacuum booster assembly on the body, pass

brake pedal assembly through the vacuum booster push rod to install on the

vacuum booster bolt, fasten the installing nut.

② Install the brake pedal and vacuum booster push rod axis pin, apply SAE J310,

NLGI No.0 grease on the axis pin surface .If the axis pin can not be installed

normally, adjust the length of pedal adjusting bolt to assure that the axis pin may

be installed in natural condition, but the length of vacuum booster push rod must

not be adjusted, or the vacuum booster push rod is in pressed condition.

③ Fix the brake pedal upper bracket with hexagon combination bolt.

 Tightening torque: 17～26N.m.

④ Fix the vacuum hose assembly and clamp to correct position on vacuum booster.

Caution:

 The vacuum hose should be inserted at least 20mm as installation.

 No lubricating oil should be applied when installing.

⑤ Adjust the brake pedal free travel.

⑥ Tighten the push rod locking nut as specified torque.

⑦ Install the air filter assembly.

⑧ Refill brake fluid and bleed.

Front disc brake caliper

On board inspection:

1) Brake shoe abrasion check

Caution:

 Standard thickness: 11mm

 Abrasion limit thickness: 2mm

Brake shoe removal and installation:

1) Removal

① Remove the wheel tire.

 Tightening torque: 100～120N·m

② Remove brake caliper assembly

sliding pin.

BR023

BR022

J5 AT Sedan Service Manual

BR Brake System

BR-13

 Tightening torque: 22～32N·m

③ Hang the brake caliper assembly up with ropes, remove the brake shoe etc.

2) Installation

① Install the brake shoe shim and shim retainer ring to respective brake shoe.

Caution:

 Install as the silencer fixing direction.

② Press the piston when installing the

brake shoe, and then install the brake

wheel cylinder on its fixing support.

③ Install the brake shoe to brake wheel

cylinder fixing support.

Caution:

 Pay attention to brake fluid level in

oil pot.

④ Install the brake wheel cylinder

sliding pin and tighten it.

⑤ Fix the brake disc, depress brake

pedal until the brake force arises.

⑥ Check the rotating resistance of

brake.

⑦ Install the wheel tire.

BR025

BR024

BR026

J5 AT Sedan Service Manual

BR Brake System

BR-14

Brake caliper component removal and installation:

1) Removal

① Remove the wheel tire.

② Remove brake hose bolt and

disconnect the brake hose.

 Tightening torque: 25～30 N·m

Caution:

 Pay attention bolt washer not to fall off.

③ Remove the brake caliper assembly

fixing support bolt, and remove the

brake caliper component.

 Tightening torque: 70～90 N·m

2) Installation

Installation is the reverse order of removal.

Disassembly and assembly:

1) Disassembly

① Remove the brake wheel cylinder sliding pin, and remove brake wheel cylinder

from its fixing support. If necessary, remove the brake shoe, brake shoe silencer

from brake wheel cylinder fixing support.

Caution:

 The brake shoe, brake shoe silencer must not fall off.

② Remove pump sliding pin and sliding

pin boot from brake pump fixing

support.

③ As shown in the figure, put a suitable

wood block, and blow evenly to the

brake hose fixing bolt hole, to

remove the piston and piston boot.

Caution:

BR029

BR028

BR027

J5 AT Sedan Service Manual

BR Brake System

BR-15

 Be careful that the finger being clamped by piston.

④ Remove the piston seal ring from

brake wheel piston with flat

screwdriver.

Caution:

 Be careful not damage inner surface

of the brake wheel cylinder.

2) Check after disassembly

① Brake wheel cylinder block

Caution:

 Clean the cylinder block with new brake fluid. Do not use gasoline or kerosene

etc.

 Check the cylinder block inner surface for abrasion or damage. If any, please

replace the brake wheel cylinder.

② Brake wheel cylinder fixing support

 Check fixing support for abrasion, crack or damage. If any, please replace it.

③ Piston

 Check surface of piston for corrosion, abrasion or damage. If any, please replace

it.

 Do not use abrasive paper to polish surface of the piston.

④ Sliding pin, pin bolt and pin boot

 Check the sliding pin, pin bolt and pin boot for abrasion and crack. If any, please

replace it.

3) Assembly

Caution:

 Apply the specified rubber grease

when assembling.

 Please do not reuse the piston seal

ring and piston boot.

① Apply rubber grease to piston seal

ring, and install it in the cylinder

block.

BR031

BR030

Piston seal ring

Piston sealing collar

J5 AT Sedan Service Manual

BR Brake System

BR-16

② Apply brake fluid to the piston, and

rubber grease to piston boot. Plug the

piston port with piston boot, and fix

the cylinder block side of piston boot

slowly into groove on cylinder block.

③ Put hand in the cylinder block and insert the cylinder block side of piston boot in

the piston groove.

Caution:

 Press the piston down evenly, avoid friction to cylinder inner surface.

④ Install the sliding pin and the boot to

brake wheel cylinder fixing support.

⑤ Install the brake shoe silencer to

brake shoe.

Caution:

 Install as the silencer fixing direction.

⑥ Install brake shoe component to brake wheel cylinder fixing support.

⑦ Hold the piston to install the brake shoe, and install the brake wheel cylinder to

its fixing support.

⑧ Tighten the pin bolt.

Check brake disc:

1) Visual check

 Check surface of the brake disc for uneven abrasion, crack or serious damage. If

any, please replace it.

BR033

BR032

Piston boot

Piston

J5 AT Sedan Service Manual

BR Brake System

BR-17

2) Run-out check

① Fix the brake disc to wheel hub.

Caution:

Before measurement, make sure that the

axial clearance of wheel bearing is not

too large.

② Measure run-out with micrometer. (measure at 10mm away from edge of brake

disc inner side)

 Limit value of run-out: 0.05mm

③ If the run-out is more than the specified value, please replace it or process as

necessary.

3) Thickness check

 Check brake disc thickness with

micrometer. If the thickness is less

than abrasion limit, please replace

the brake disc.

Standard thickness: 25mm

Abrasion limit: 23mm

Brake run-in steps:

Repair or replace the brake disc, if there is insufficient brake force symptom after

brake shoe replacement or driving a short distance, please run in the contact surface of

brake disc and brake shoe as following steps.

 The brake effect is bad before running-in, so take care to control the vehicle

speed.

 Perform this step on safe road and traffic condition, take care of the safety.

1) Drive the vehicle on smooth and straight road.

2) Control the force on brake pedal, brake the vehicle in 3～5 second.

3) Stop the vehicle for 3 minutes after driving a stretch to cool the brake system.

4) Repeat the step 1～3 until the brake shoe and brake disc run in well.

BR035

BR034

J5 AT Sedan Service Manual

BR Brake System

BR-18

Rear disc brake caliper

Brake shoe abrasion check:

Caution:

 Please check with graduated scale.

 Standard thickness: 9mm

 Abrasion limit thickness: 2mm

Removal and installation:

1) Removal

① Remove the wheel tire.

② Remove the parking brake, and

remove the pulling wire of parking

brake.

③ Remove bolt of brake wheel cylinder.

 Tightening torque: 22～32N·m

④ Hang the brake wheel cylinder up

with ropes, and remove the brake

shoe, brake shoe shim and shim

retainer ring.

2) Installation

① Install brake shoe shim and its

retainer ring on the specific brake

shoe.

Caution:

 Install as the fixing direction of brake

shoe shim and brake shoe retainer

ring.

② Hold the piston to install the brake

shoe, and then install the brake wheel

cylinder to its fixing support

③ Install the brake shoe to brake wheel

cylinder fixing support.

BR039

BR038

BR037

BR036

J5 AT Sedan Service Manual

BR Brake System

BR-19

Caution:

 The brake fluid level in oil pot.

④ Install the brake wheel cylinder sliding pin and tighten it.

⑤ Fix the brake disc with tire nuts, depress brake pedal until the brake force arises.

⑥ Check the rotating resistance of brake.

⑦ Install the wheel tire.

Rear brake installation:

Rear brake assembly instruction drawing

1- Rear brake caliper assembly 2- Rear brake hose assembly 3- Rear wheel hub assembly

4-Rear brake disc

① Install the rear brake disc firstly, and fix it with a crosshead screw.

② Install rear brake caliper, fix the brake caliper bracket to respective hole on rear

steering knuckle with rear brake caliper bolt and spring washer.

 Tightening torque: 56～70 N·m

③ Install the rear brake hose assembly and brake pipes punched bolt, washer at last.

 The caution during installation is same to that of the front brake.

④ After brake system installation, depress the brake pedal for several times to make

the brake shoe in position correctly.

J5 AT Sedan Service Manual

BR Brake System

BR-20

Brake disc check:

The specific steps please refer to front disc brake caliper.

1) Thickness check

■ Check the brake disc thickness with

micrometer. If the thickness is less

than abrasion limit, please replace the

brake disc.

Standard thickness: 10mm

Abrasion limit: 9mm

2) Run-out check

① Fix the brake disc to wheel hub.

② Measure run-out with micrometer.

(Measure at 10mm away from edge of

brake disc inner side)

 Limit value of run-out: 0.05 mm

Trouble Diagnosis

Table of Common Trouble Diagnosis

Check

Possible cause

Solution

The vehicle running

deviation in one side as

brake

Under-inflation for left and right tires

Adjust

Front wheel adjustment incorrect

Adjust

The brake shoe contact badly

Adjust

There is grease or oil on brake shoe surface

Replace

The brake wheel cylinder is installed incorrectly

Adjust

Fault of self-adjusting mechanism

Adjust

Insufficient brake force

Brake fluid insufficient or polluted

Add or replace the

brake fluid

Air in brake system

Bleed the system

Brake vacuum booster fault

Adjust

The brake shoe contact badly

Adjust

There is grease or oil on brake shoe surface

Replace

BR041

BR040

J5 AT Sedan Service Manual

BR Brake System

BR-21

Check

Possible cause

Solution

Fault of self-adjusting mechanism

Adjust

The brake rotating part overheat due to the brake

shoe sluggish

Adjust

Brake pipe limit

Adjust

The brake pedal travel

increase (the distance

between brake pedal and

floor decrease)

Air in brake system

Bleed the system

Brake fluid leakage

Adjust

Fault of self-adjusting mechanism

Adjust

The clearance between push rod and brake master

cylinder is too large

Adjust

Brake retard

The parking brake has not been released

completely

Release

The parking brake adjustment incorrect

Adjust

Brake pedal return spring abrasion

Replace

Brake master cylinder oil return limit

Adjust

Sliding part lubrication insufficient

Lubricate

Brake master cylinder check valve or piston return

spring defect

Replace

The clearance between push rod and brake master

cylinder is too small.

Adjust

The parking brake

function insufficient

Rear brake shoe damage

Adjust

There is grease or oil on rear brake shoe surface

Replace

The parking brake pulling wire is clamped

Adjust

Fault of self-adjusting mechanism

Adjust

The travel of parking brake handle is too excessive

Adjust

Service Data and Specification

Table of Technical Specification

Item

Specification

Brake master

cylinder

Type

In series

Bore diameter

25.4mm

Brake booster

Type

Vacuum

Effective diameter

203～228mm

Booster ratio

7:01

Front brake

Type

Floating plier /Ventilated disc

Brake disc diameter

282mm

J5 AT Sedan Service Manual

BR Brake System

BR-22

Brake disc thickness

25mm

Friction block

thickness

11mm

Bore diameter

57mm

Rear brake

Type

Integrated of service brake and parking

brake/ventilated disc

Brake disc diameter

285mm

Brake disc thickness

10mm

Friction block

thickness

9mm

Bore diameter

38mm

J5 AT Sedan Service Manual

BR Brake System

BR-23

Tightening Torque Table

Item

Torque (N·m)

Bolt to front brake pliers and steering knuckle

70～90

Bolt to rear brake pliers and steering knuckle

56～70

Front and rear brake pliers bleeding bolt

7～13

Fixing bolt of brake pedal upper bracket

17～26

Fixing nut of brake pedal

13～16

Bolt of brake hose and brake caliper

25～30

Brake tube joint

13～17

J5 AT Sedan Service Manual

PB Parking Brake

PB-1

PB Parking Brake

Precautions

 The parking brake should be checked and adjusted while service brake function

normally.

 The vehicle should be parked on level ground, and the wheel be blocked with

triangle wood for brake system check.

Parking Brake Control

On board inspection:

1) Travel of parking handle

 Pull the parking brake handle up with

the force of 200N, make sure that the

pawl is in specified groove (one click

sound may be heard as the pawl

passing through each tooth, check by

listening to the click sounds of pawl).

 Standard value: 8～9 teeth

2) Part check

① Confirm each part for the tightening (clearance) is normal or not.

② Check the parking brake handle assembly for bending, damage or crack. If any,

please replace it.

③ Check the parking brake pulling wire for abrasion or damage. If any, please

replace it.

④ Check whether the warning lamp of parking brake function normally or not. If it

can not function well, please check or replace it.

⑤ Remove the connector of parking brake switch so as to check the connection of

positive terminal and body.

 It should be in connection as the parking handle upward.

 It should not be in connection as the parking handle downward.

3) Adjustment

① Insert left and right parking brake pulling wire joint into the installing hole on

parking brake handle balancing plate. As the figure below, after the pulling wire

has been installed, tighten the adjusting nut to assure that the distance L between

adjusting nut and pulling wire end is 8±2mm.

PB001

J5 AT Sedan Service Manual

PB Parking Brake

PB-2

Schematic Diagram of Parking Brake

1-Parking brake handle assembly 2-Adjusting nut 3- Thread tie rod

4-Joint of parking wire assembly

② After finishing the adjustment, pull parking brake handle up by the force of

200N·m which is perpendicular to the handle, the handle may be pulled up by

8～9 teeth, otherwise the distance L should be adjusted by the adjusting nut. The

specific method is: If the number of pulled teeth is less than 8, L should be

decreased; if the number of pulled teeth is more than 8, the L should be

increased;

Part:

System Diagram of Parking Brake Pulling Wire

1-Parking brake handle assembly 2-The union clamp fixing left and right wires

3-Right parking brake pulling wire assembly 4-Left parking brake pulling wire assembly

5- Clip

J5 AT Sedan Service Manual

PB Parking Brake

PB-3

1) Removal and installation

① Removal

a. Remove the auxiliary instrument

panel rear segment assembly.

b. Unscrew the adjusting nut; remove

the left and right parking brake

pulling wire assembly from the

pulling wire clips.

c. Disconnect wire of parking brake

switch; remove the securing bolt of

parking brake handle, and take out

the parking brake assembly.

 Tightening torque: 20～25N·m

d. Unscrew adjusting nut; remove the

parking brake pulling wire

assembly from wire clips.

PB003

PB004

PB002

PB005

J5 AT Sedan Service Manual

PB Parking Brake

PB-4

e. Take out parking brake pulling wire

from the installing hole at bottom of

body.

② Check after removal

 Check whether the button mechanism may operate flexibly. If the button can not

reset normally, please replace it.

 Check the pawl of parking brake handle for abrasion.

 Check the parking brake pulling wire for deformation, abrasion, bend or loose. If

any, please replace it.

③ Installation

Installation is the reverse order of removal.

Trouble Diagnosis

The indicator light normally ON or OFF:

① Check the indicator light for function fault.

② Check bolt to indicator light and tooth plate support for loose.

Servicing:

If any fault found, please replace the indicator light or install it again.

The braking force is insufficient or deteriorated:

① Check the connection of wire connecting plate to brake pulling wire.

② Check the lock nut for distorted thread.

③ Check whether the current brake distance is the same as the brake distance

specified by the vehicle or not.

Servicing:

① First symptom: Connect the wire connecting plate to the brake pulling wire.

② Second symptom: Please replace the lock nut.

③ Third symptom: Please adjust the lock nut distance.

PB006

PB005

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-1

Anti-Lock Brake System (ABS)

Precautions

 While driving on rough, gritty, or sloppy (Such as snowy) roads, the braking

distance of the vehicle may be longer than that of the vehicle without ABS.

 When the ABS or other warning lamp indicates the presence of fault, before

starting the repair, collect all necessary information (Which symptoms occur

under which conditions) from the customers to find out the simple causes.

Besides the check of electric system, further check the operation of vacuum

booster and the level and quality of brake fluid for leakage.

 If the tire size and type fail to meet the requirements or the brake shoe plate is

other than the JAC genuine parts, the braking distance or the steering stability

may be deteriorated.

 If the vehicle is installed with the components purchased from the market (such

as automotive stereo audio device, CD player, and others), check the electric

harness for being clamped, open-circuit, short-circuit, or incorrect wiring.

 Before conducting the electric welding, disconnect the connectors from the ABS

control module.

 As the components of the anti-lock brake system (ABS) are extremely sensitive

to electromagnetic interference (EMI), carefully caution the arrangement,

location, installation and positioning of all components and eliminate all

interferences from the wiring arrangement, connectors, clamps, and supports.

 Do not start the engine nor charge the battery still being connected with rapid

charger, otherwise it may lead to battery failure or damage of ABS components.

 During the repair, make sure to turn off the ignition switch, disconnect the battery

negative, and then disconnect the connector of ABS control module assembly,

otherwise it may damage the control module.

 Do not try to repair any components of anti-lock brake system. The faults for all

components of ABS can only be resolved by replacement.

 Do not hang the components of suspension part onto the wheel speed sensor

harness, in order to prevent damaging the sensor harness.

 Do not place the ABS control module in the environment with above 105ºC

temperature.

 Do not use the fluid with petroleum-based content in the brake master pump, as

the petroleum will lead to the expansion and deformation of rubber components

in the hydraulic brake system.

 When turning the ignition switch to ―ON‖ position to start the vehicle, the brake

pedal may vibrate or the operating noise of the motor may be heard from the ABS

hydraulic assembly, which is the normal status of check.

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-2

Preparations

The common repair tool and special tool will be used in the repair.

List of Special Tools

Tool

Outline drawing

No.

Description

X-431

diagnosis

instrument

JAC-T1Z001

ABS System

Fault

Diagnosis

System Description

System Diagram:

ABS System Diagram

1- Left front brake assembly 2- Brake master cylinder assembly 3- Vacuum booster

4- Right front brake assembly 5- ABS control module with hydraulic assembly

6- Brake pipeline 7- Left rear brake assembly 8- Right rear brake assembly

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-3

ABS function:

The anti-lock brake system (ABS) controls the hydraulic brake devices of four wheels

to prevent wheel locking in event of emergency braking or braking on hazardous

roads. The main advantages of the ABS are as below:

(1) Capable of reliable steering in event of confrontation of obstacles during the

emergency braking.

(2) Capable of maintaining the stable and controllable stop during the emergency

braking on bends.

Notice:

 If the electric system is interrupted, the failure protection mode will be activated

so that the ABS enters into inactive status and the ABS warning lamp lights up.

 The JAC-provided special diagnosis instrument may be used for diagnosis of

ABS electric system.

During the braking, the brake pedal may vibrate slightly and some mechanical noise

may be heard. This is the normal operating condition of ABS.

EBD function:

The electronic brake-force distribution (EBD) is one proportional system used to

maintain the vehicle stability during the braking. Under the normal braking conditions,

it effectively balances the equal wheel speed required by the braking. Under difficult

braking condition, as the vehicle weight conveys onto the front wheels and the rear

wheels requires relatively lower braking force, the EBD maintains the braking

pressure required by the rear wheels via the ABS pressure increasing valve and

reducing valve, in order to provide the effective braking and vehicle stability.

Emergency protection function:

The ABS warning lamp lights up in event of electric fault of ABS system. In event of

EBD electric fault, the braking warning lamp and ABS warning lamp will both light

up.

At the same time, the ABS system will turn to one of the following emergency

protection functions:

1) For ABS fault, only the EBD is activated and the vehicle status is same with that

of the vehicle without ABS system.

2) For EBD fault, both EBD and ABS are inactive and the vehicle status is same

with that of the vehicle without both ABS and EBD systems.

Anti-lock braking mode:

Upon the detection of wheel slip during the braking, the ABS will enter into anti-lock

braking mode. During the anti-lock braking, the pressures of hydraulic circuit for

various wheels are under control, in order to prevent the wheel slip. Each wheel is

equipped with individual hydraulic pipeline and valve. ABS can reduce, maintain or

increase the hydraulic braking pressure for various wheels. However, the ABS can’t

increase the hydraulic pressure to a pressure in excess of the pressure conveyed by the

master cylinder during the braking. During the anti-lock braking, one series of rapid

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-4

vibration can be felt on the brake pedal. The pedal vibration occurs during the

anti-lock braking and stops during the normal braking or when the vehicle completely

stops. Due to the rapid recirculated operation of the solenoid valve, the operation

noise can be heard. While activating the anti-lock braking on dry roads, the tires will

generate intermittent and sharp noise when the tires close to slip. This noise and the

pedal vibration are normal during the operation of the anti-lock braking. The

operation of brake pedal shall be same with that of vehicle without ABS system

during the normal braking. Maintaining the equal stepping force of pedal can

guarantee the shortest stopping distance while maintaining the vehicle stability.

1. Pressure maintaining

When the ABS control module detects the wheel slip, it will close the inlet valve and

close the outlet valve of hydraulic assembly to isolate the system. This can maintain

the stable pressure of the brake and prevent the hydraulic pressure from increasing or

reducing.

2. Pressure reducing

If the ABS control module still can detect the wheel slip under the pressure

maintaining mode, it will reduce the pressure of the wheel being influenced. By

keeping the inlet valve closed and opening the outlet valve, the excessive

fluid/pressure will be temporarily stored in the accumulator of the hydraulic assembly,

till the pump motor can convey the brake fluid back to the oil reservoir of the master

cylinder.

3. Pressure increasing

If the ABS control module detects the reduced wheel slip under the pressure

maintaining or pressure reducing mode, the ABS control module will increase the

pressure of the wheel being influenced via the pressure of master cylinder. By

opening the inlet valve and closing the outlet valve, all pressure or partial pressure

from the brake master pump will be applied to the wheel.

4. Operating process of ABS

During the driving of the vehicle, each wheel speed sensor generates one voltage

signal in proportional to the wheel speed. The ABS control module receives the wheel

speed data and judges the presence of excessive deceleration of one or more wheels

(compared with the reference vehicle speed), which is referred to as slip. Depending

on the needs, the ABS control module will activate the module and the module will

control the braking pressure of each wheel to realize the best optimization.

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-5

Hydraulic Schematic Diagram of ABS System:

Hydraulic Schematic Diagram of ABS System

1- Master pump 2- Inlet valve/LF 3- Outlet valve/LF 4- Inlet valve/RR 5- Outlet valve/RR

6- Damper 7- Reflux pump 8- Accumulator 9- Inlet valve/RF 10- Outlet valve/RF

11- Inlet valve/LR 12- Outlet valve/LR

Wheel speed sensor

Consisted of the sensor itself and the gear ring, one set for each wheel. This vehicle

model adopts the active wheel speed sensor, which requires the external power supply

(12V) for operating. It can provide one constant amplitude signal, no matter what the

size of the wheel speed is.

Component:

Consisted of the sensor itself and the gear ring, one set for each wheel.

Removal:

1) Front wheels

① Lift the vehicle.

② Remove the fender and disconnect the

sensor connector.

③ Loosen the fixing bolts of sensor and

slowly take out the sensor.

 Tightening torque: 8~10N.m

ABS001

Right front/RF

Left front/LF

Right rear/RR

Left rear/LR

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-6

Notice:

 Do not pull the wheel speed sensor harness with force.

 Notice the clearance between wheel speed sensor and the signal gear ring during

the installation.

Standard value: 0.8±0.4mm

2) Rear wheels

① Lift the vehicle and remove the rear

tires.

② Remove the lower trim panel of pillar

③ Disconnect the sensor connector.

④ Loosen the fixing bolts of wheel

speed sensor and slowly take out the

wheel speed sensor.

Notice:

 Do not pull the wheel speed sensor harness with force.

 Notice the clearance between wheel speed sensor and the signal gear ring during

the installation.

Standard value: 0.8±0.4mm

Check after removal:

1) Check the installation hole of sensor for presence of foreign matters and check

the surface of brake plate for presence of foreign matters (such as metal chips).

2) Before installation, clean the sensor installing hole and surface of brake plate.

Installation

Installation is the reverse order of removal and tighten the bolts to specified torque.

Notice:

 The harness shall be free of torsion after the installation.

ABS002

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-7

ABS hydraulic assembly

Removal and Installation:

1) Removal

① Turn off the ignition switch and

disconnect the negative wiring post

of the battery.

② Remove the connector of ABS

control module.

③ Step down the pedal by >60mm and

secure the pedal bracket.

 Close the central valve of hydraulic assembly so that the brake fluid will not flow

out from the outlet while the system is opened.

④ Remove from the hydraulic assembly the brake tubing that connected to the

master pump, add the marking, and plug the outlet with plug immediately.

⑤ Remove the brake tubing that connected to various wheels, add the marking, and

plug the outlet with plug immediately.

⑥ Remove the bolts from the fixing bracket of ABS hydraulic assembly.

2) Installation

Notice:

 The connectors of the brake pipeline that connected to the ABS hydraulic

assembly shall be tightened to the specified torque.

Tightening torque: 13~17N.m

 The plug at the hydraulic outlet of the ABS hydraulic assembly shall be removed

only right before the installation of brake tubing, in order to prevent the ingress of

foreign matters.

 Replace the ABS hydraulic assembly in event of fault of ABS hydraulic

assembly.

① Install the ABS hydraulic assembly onto the bracket and tighten to specified

torque.

② Remove the plug from the hydraulic outlet, install the brake tubing, and confirm

the correct connection of the tubing.

③ Connect the brake tubing from hydraulic assembly to the master pump.

ABS003

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-8

④ Install the brake tubing and tighten to

the specified torque.

⑤ Add new brake fluid to the oil

reservoir, till the fluid level reaches

to marking MAX, and bleed the air

according to the specified method.

⑥ Turn the ignition switch to ―ON‖

position. The ABS warning lamp

lights up and then goes out.

⑦ Clear the trouble codes from the memory and re-read the memory for the

presence of trouble code.

⑧ Test run the vehicle to determine whether the ABS functions normally.

ABS control module

Component:

This vehicle model adopts the BOSCH

ABS 8 FDD—X anti-lock brake system.

The ABS control module is integrated

with the hydraulic assembly.

Description of pins of ABS control module:

Pin Diagram of ABS Control Module

Description Table of pins of ABS Control Module:

Pin No.

Description

Pin No.

Description

Power terminal of motor

(Positive)

Signal terminal of wheel speed sensor

(Left rear)

Vacant pin

ABS005

ABS004

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-9

Pin No.

Description

Pin No.

Description

Output of wheel speed sensor

(Right rear wheel)

Signal terminal of wheel speed sensor

(Left front)

Active ABS warning lamp

Vacant pin

Signal terminal of wheel speed

sensor (Right front)

Power terminal of valve relay

Vacant pin

CAN - High

Vacant pin

Output of wheel speed sensor (Right

front wheel)

Vacant pin

Input of brake lamp switch

Vacant pin

Signal terminal of wheel speed sensor

(Right rear)

Grounding terminal of motor

Power terminal of ABS control

module (Ignition power wire)

CAN - Low

Power terminal of wheel speed sensor

(Left rear)

Vacant pin

Power terminal of wheel speed sensor

(Left front)

Active EBD warning lamp

Vacant pin

Diagnosis K-wire

Vacant pin

Power terminal of wheel speed

sensor (Right front)

Vacant pin

Power terminal of wheel speed

sensor (Right rear)

Grounding wire of ABS control

module

ABS control module check:

Notice:

 Without special needs, do not disassemble the ABS hydraulic assembly (inclusive

of control module).

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-10

1) Basic check of brake system

① Check the level of brake fluid. If the fluid level is low, add brake fluid.

② Check the surrounding area of brake pipeline and ABS hydraulic assembly for

leakage. Upon the detection of leakage, conduct the following check:

a. If the connector of ABS hydraulic assembly is loose, tighten the oil pipe nuts of

the pipeline to the specified torque (13~17N.m). Re-check the leakage and

confirm there is no leakage of brake fluid.

b. If oil pipe nut at the connector and the threaded part of actuator are damaged,

replace the damaged components. Re-check the leakage and confirm there is no

leakage of brake fluid.

c. If the leakage is detected in the location other than the actuator connectors,

please wipe with clean cloth and re-check. If the leakage still exists, replace the

damaged components.

d. If the leakage is detected on the hydraulic assembly, wipe with clean cloth and

re-check. If the leakage still exists, replace the hydraulic assembly.

③ Check the brake shoe plate for wear.

④ Check the power supply terminals and the positive/negative terminals of the

battery for looseness and abnormal voltage.

2) Check of ABS warning lamp and brake warning lamp

① Make sure that, when turning the ignition switch to ―ON‖ position, the ABS

warning lamp lights up for about 1s and the brake warning lamp lights up. If not,

please refer to the ―Fault diagnosis‖.

② Check whether the ABS warning lamp goes out about 1s after the ignition switch

is turned to ―ON‖ position and whether the brake warning lamp goes out after the

engine is started. If not, please refer to ―Fault diagnosis‖.

③ If the ABS warning lamp fails to go out 10s after the engine is started, please

refer to ―Fault diagnosis‖.

Notice:

The brake warning lamp lights up when the parking brake is applied (when the switch

is at ―ON‖ position) and when the brake fluid sensor functions (insufficient brake

fluid).

3) Check the ABS control module with diagnosis instrument

Check the control data of the control module and the stored trouble codes with the

diagnosis instrument. In event of any abnormal conditions, repair according to the

fault tips.

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-11

List of ABS Trouble Codes

Trouble code

Description

C1101

Excessive voltage of ABS control module

C1102

Insufficient voltage of ABS control module

C1200

Front left wheel speed sensor: Open-circuit/short-circuit

C1201

Front left wheel speed sensor: Overturn, performance error, and intermittent

signal

C1202

Front left wheel speed sensor: Invalid signal/no signal

C1203

Front right wheel speed sensor: Open-circuit/short-circuit

C1204

Front right wheel speed sensor: Overturn, performance error, and intermittent

signal

C1205

Front right wheel speed sensor: Invalid signal/no signal

C1206

Rear left wheel speed sensor: Open-circuit/short-circuit

C1207

Rear left wheel speed sensor: Overturn, performance error, and intermittent

signal

C1208

Rear left wheel speed sensor: Invalid signal/no signal

C1209

Rear right wheel speed sensor: Open-circuit/short-circuit

C1210

Rear right wheel speed sensor: Overturn, performance error, and intermittent

signal

C1211

Rear right wheel speed sensor: Invalid signal/no signal

C1213

Wheel speed sensor frequency error (common wheel speed sensor fault,

missing tooth, or tooth quantity error)

C1604

ECU hardware fault

C1605

CAN hardware fault

C1616

CAN bus OFF fault

C2112

Valve relay fault

C2308

Front left inlet valve fault

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-12

Trouble code

Description

C2312

Front left outlet valve fault

C2316

Front right inlet valve fault

C2320

Front right outlet valve fault

C2324

Rear left inlet valve fault

C2328

Rear left outlet valve fault

C2332

Rear right inlet valve fault

C2336

Rear right outlet valve fault

C2402

Reflux pump fault (motor electric fault)

C0072

Overall valve fault (overheating protection)

Air Bleeding of ABS System

Air bleeding conditions of ABS system:

The air bleeding procedure shall be taken for the ABS system following whichever

the following conditions:

1) When the traditional air-bleeding method for the brake pipeline can’t realize the

required pedal height or feeling.

2) When the ABS hydraulic assembly is replaced.

3) When extremely high fluid loss occurs.

4) When in suspect of air suction.

This procedure adopts the diagnosis instrument to drive the system valve and run the

pump motor to bleed the air from the secondary circuits. These secondary circuits are

normally close and are opened only during the initialization at the vehicle startup and

during the ABS operations. The automatic air-bleeding procedure opens these

secondary circuits, bleeds and collects all the air in the hydraulic assembly, in which

the air can be bled from the system.

Air bleeding procedure of ABS system:

1) Required items

① Diagnosis instrument, with correct software.

② Brake fluid.

③ Lifter

④ Air bleeding tank, equipped with hose for recovery of automotive brake fluid.

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-13

⑤ Proper safety equipment, including the safety goggles.

⑥ Two repair operators are required: One operator steps down the brake pedal and

controls the diagnosis instrument and another operator maintains the hydraulic

oil level of brake master pump main chamber and opens/closes the air bleeding

bolt according to the instruction of the diagnosis instrument.

2) Initial check

① Check the charging status of the battery and repair the battery and the charging

system based on the needs.

② Connect the diagnosis instrument and select the current and historic diagnosis

trouble codes. Before conducting the ABS air bleeding procedure, clear all

diagnosis trouble codes. If the diagnosis trouble codes can’t be cleared, resolve

the faults first.

③ Check the appearance for damage and leakage. Repair when necessary.

3) Actions before air bleeding

① Start the engine.

② Connect the diagnosis instrument and establish the communication with ABS

control module.

③ Lift the vehicle and support properly.

4) Bleed the air on the vehicle.

Notice:

 By pressing the EXIT button on the diagnosis instrument, the automatic air

bleeding procedure can be terminated at any time.

① Select ―Automatic air bleeding function‖ on the diagnosis instrument and operate

according to the instructions.

② During the basic air bleeding and automatic air bleeding, it’s necessary To step

down the brake pedal and maintain the brake fluid level of the brake master

pump.

③ When bleeding the air for one wheel, make sure to connect the hose to the air

bleeding bolt and drain to a container with brake fluid. This container must be

higher by 30mm than the bolt with the hose fully filled with brake fluid. This is

intended to prevent the air from ingress into the brake pipeline.

④ The first step is the basic air bleeding. This step must be taken before the

automatic air bleeding, in order to obtain good pedal height and pedal feeling and

guarantee the best performance of ABS.

⑤ During the next step, the diagnosis instrument will require the repair operator to

open one air bleeding bolt. Then, the diagnosis instrument will check repeatedly

the pressurizing valve and the pump motor for about 30s. During the entire

process, the brake pedal shall be always pressurized and released.

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-14

⑥ For remaining air bleeding bolts, the diagnosis instrument will repeat step ⑤ for

air bleeding.

⑦ When the automatic air bleeding procedure is complete, the diagnosis instrument

will display the relevant information.

⑧ Step down the brake pedal and measure the pedal height and feeling. Repeat step

① to ⑦, till the pedal restores to normal height.

Warning:

 When repeating certain step or the entire air bleeding procedure, make sure to

wait for 5min to cool down the solenoid valve, or the solenoid valve may be

damaged due to overheating.

5) Automatic air bleeding procedure

Onboard diagnosis procedure:

① Enter into the JAC special fault diagnosis system.

② Select the JAC special V13.00 system.

Select the diagnosis software version

JAC special V13.00 system

This procedure can diagnose all

electric… for JAC commercial

vehicles and cars before 2009.

page

Back

Help

(Start)

③ Select the anti-lock brake system.

Select the diagnosis software version

Engine system

Anti-lock brake system

Airbag system

Automatic transmission system

page

Back

Help

(Start)

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-15

④ Enter into the automatic air bleeding function. To bleed the air, click ―Yes‖.

Warning:

 Warning from the diagnosis instrument!

Air bleeding function

To fully bleed the air, make sure To

step down the brake pedal repeatedly

during the entire process.

The sequence for air bleeding must be:

Left rear – Left front – Right front –

Right rear

When repeating certain step or the

entire air bleeding procedure, make

sure to wait for 5min to cool down the

solenoid valve, or the solenoid valve

may be damaged due to overheating.

Please click ―OK‖ to start the air

bleeding function.

Yes

(Start)

⑤ Prepare the air bleeding for left rear wheel. To start the air bleeding, please click

―OK‖.

Air bleeding function

Please open the air bleeding bolt of

the left rear wheel and click ―OK" to

conduct the air bleeding for left rear

wheel.

(Start)

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-16

⑥ The air bleeding for left rear wheel is under the way.

Air bleeding function

The air bleeding for left rear wheel is

under the way. Please step down the

brake pedal repeatedly…..

Diagnosis home

(Start)

⑦ The air bleeding for left rear wheel is complete. To conduct the air bleeding for

next wheel, please click ―OK‖.

Air bleeding function

The air bleeding for left rear wheel is

complete. Please close the air bleeding

bolt for left rear wheel.

(Start)

⑧ Prepare the air bleeding for left front wheel. To start the air bleeding, please click

―OK‖.

Air bleeding function

Please open the air bleeding bolt of

the left front wheel and click ―OK" to

conduct the air bleeding for left front

wheel.

(Start)

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-17

⑨ The air bleeding for left front wheel is under the way.

Air bleeding function

The air bleeding for left front wheel is

under the way. Please step down the

brake pedal repeatedly at a frequency

of 3s/time…..

Diagnosis home

(Start)

⑩ The air bleeding for left front wheel is complete. To conduct the air bleeding for

next wheel, please click ―OK‖.

Air bleeding function

The air bleeding for left front wheel is

complete. Please close the air bleeding

bolt for left front wheel.

(Start)

⑪ Prepare the air bleeding for right front wheel. To start the air bleeding, please

click ―OK‖.

Air bleeding function

Please open the air bleeding bolt of

the right front wheel and click ―OK"

to conduct the air bleeding for right

front wheel.

(Start)

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-18

⑫ The air bleeding for right front wheel is under the way.

Air bleeding function

The air bleeding for right front wheel

is under the way. Please step down the

brake pedal repeatedly at a frequency

of holding for 3s + releasing for 0.5s.

Diagnosis home

(Start)

⑬ The air bleeding for right front wheel is complete. To conduct the air bleeding

for next wheel, please click ―OK‖.

Air bleeding function

The air bleeding for right front wheel

is complete. Please close the air

bleeding bolt for right front wheel.

(Start)

⑭ Prepare the air bleeding for right rear wheel. To start the air bleeding, please

click ―OK‖.

Air bleeding function

Please open the air bleeding bolt of

the right rear wheel and click ―OK" to

conduct the air bleeding for right rear

wheel.

(Start)

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-19

⑮ The air bleeding for right rear wheel is under the way.

Air bleeding function

The air bleeding for right rear wheel is

under the way. Please always and

continuously step down the brake

pedal.

Diagnosis home

(Start)

⑯ The air bleeding for right rear wheel is complete. In such case, click ―OK‖ to

complete the entire air bleeding procedure.

Air bleeding function

The air bleeding for right rear wheel is

complete. Please close the air bleeding

bolt for right rear wheel.

(Start)

Trouble Diagnosis

Brief of Fault Diagnosis:

1) Conduct the fault diagnosis and completely understand various systems of the

vehicle.

2) Understand the complaints of the customers before check. After fully

understanding the symptom, carefully inquire the dissatisfaction of the

customers.

3) Make sure to conduct the symptom check from the initial stage, in order to

completely repair the fault. For intermittent fault, it’s of extreme importance to

reproduce the symptom based on the discussion with the customers and the

previous cases. Do not check based on some special cases. Most of the

intermittent faults are caused by the poor contact. In such case, shaking the

suspected harness or connectors with hand is one effective way.

4) At completion of the diagnosis, make sure to conduct ―Clear trouble code‖.

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-20

Diagnosis flowchart:

The diagnosis procedure is as below:

Clear self-diagnosis result and drive the vehicle

at a speed of 30km/h or above for more than

1min.

Determine fault

symptom

Understand ―Precautions‖ and how to

conduct rapid diagnosis and rapidly find out

fault

Conduct initial check

Does ABS warning lamp

light up?

Does diagnosis instrument display

trouble code?

Conduct self-diagnosis

Check and repair faulty components

Re-conduct self-diagnosis

Check result

Check ABS actuator, electric

components and data connector harness

Conduct symptom diagnosis

procedure

Confirm symptom

Normal

Abnormal

Yes

Normal

Abnormal

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-21

Diagnosis Information and Procedure:

1) Self-diagnosis

The ABS control module conducts the self-diagnosis to the system and is capable of

the detection of system faults. Upon the detection of system faults, it sets up the

diagnosis trouble code (DTC), lights up the ABS warning lamp, and at the same time

turns off the ABS system.

2) Display diagnosis trouble code (DTC)

By means of the special diagnosis instrument, the diagnosis trouble code can be

displayed.

3) Clear diagnosis trouble code (DTC)

The diagnosis trouble codes in the memory of the ABS control module can be cleared

by means of the diagnosis instrument.

Notice:

 After clearing the diagnosis trouble codes, make sure to verify the system for

normal functioning and confirm that the diagnosis trouble codes never reoccur.

 The diagnosis trouble codes can’t be cleared by disconnecting the ABS control

module connector, disconnecting the battery wiring, or stopping the engine.

4) The intermittent fault or poor contact is mostly caused by any condition as

below:

① Error of electric wiring.

② Error of electric connection.

③ Stagnation of relay or solenoid valve.

5) Initialization procedure

The ABS control module conducts the initialization testing at the beginning of each

ignition period.

The initialization procedure is as below: Check the components of the solenoid valve

and pump motor for normal functioning. Upon the detection of fault, the ABS control

module will set up corresponding diagnosis trouble code. During the initialization

procedure, some actions may be heard and felt, which are the constituent parts of the

normal system functioning. If the ABS control module detects no signal input of the

brake switch (namely the foot is released from the brake pedal), the initialization

starts immediately. If the brake switch has signal input (namely the foot is put onto

the brake pedal), the initialization will not start, till the brake switch has no signal

input (namely the foot is released from the brake pedal) or the vehicle speed reaches

16km/h.

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-22

Check of Diagnosis Circuit:

1) System description

The diagnosis circuit can detect the problems arising from the fault of ABS system.

The check of diagnosis circuit will guide the repair technicians to conduct the next

step of fault diagnosis.

2) Diagnosis procedure

The procedure for repair of ABS system is as below:

① Check the vehicle for brake system related mechanical faults.

 Check the brake oil reservoir for correct level.

 Check the brake fluid of master cylinder for contamination.

 Check the brake master pump/ABS hydraulic assembly for leakage.

 Check the brake components of all wheels.

 Verify the presence of braking stagnation.

 Verify the stable braking (Without rear pulling or forward rushing).

 Check the brake shoe plate for wearing/damage.

 Check the wheel bearings for damage.

 Check the wheel speed sensors and harness.

 Check the wheel speed sensor connector/gear ring for damage and check the tread

depth/wear of tires.

 Conduct the road test, verify the status, and correct accordingly.

② Conduct check of diagnosis circuit and operate according to the appropriate fault

diagnosis procedure. After all system faults are resolved, clear the ABS

diagnosis trouble codes.

Table of Fault Diagnosis

Step

Diagnosis

Yes

1. If possible, connect or install all components

disconnected or removed before.

2. Shift the ignition switch to ON position and stop the

engine.

3. Install appropriate diagnosis instrument to DLC and

enable it to communicate with ABS control module.

To step 2

To step 4

Is there any current or old trouble code?

To step 3

To step 7

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-23

Step

Diagnosis

Yes

1. Record current trouble code.

2. Record old diagnosis trouble code.

3. Record the history data, such as the number of setup for

each diagnosis trouble code; number of first setup for

each trouble code; number of previous setup for each

trouble code; the vehicle speed when the diagnosis

trouble code is set; other reinforced data helping the

diagnosis.

4. Before recording the information from diagnosis

instrument, do not clear diagnosis trouble codes.

Can the diagnosis instrument communicate with other

modules in same data line?

To step 5

To step 6

To ―No communication with ABS control module‖ in

diagnosis procedure of ABS control module.

To other electric control modules for diagnosis.

1. Stop the engine.

2. Wait for 10s.

3. Start the engine.

4. Observe ABS warning lamp after engine start.

To step 8

To step 9

Is there any lamp still ON?

To step 9

To step 10

To diagnosis procedure of ―ON‖ for corresponding lamp.

To diagnosis procedure of ―Inactive‖ for corresponding

lamp.

Common ABS Symptoms and Analysis Procedures:

2) No communication with ABS control module

The typical causes for communication failure of ABS control module are as below:

 Poor contact of diagnosis port.

 No grounding of ABS control module.

 No battery or ignition switch supplied voltage of ABS control module.

 Open-circuit/short-circuit/excessive resistance of data line.

2) No light-up of ABS warning lamp/No diagnosis trouble code

The typical causes for failure of ABS warning lamp and no setup of diagnosis trouble

code are as below:

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-24

 Failure of ABS warning lamp bulb/loose connector.

 Breakage of instrument panel fuse

 Fault of instrument warning lamp drive module.

 Fault of ABS control module.

 Open-circuit or short-circuit between ABS control module and instrument.

3) Light-up of ABS warning lamp/No diagnosis trouble code

The typical causes for light-up of ABS warning lamp without setup of diagnosis

trouble code are as below:

 Open-circuit between instrument and ABS control module.

 No grounding of ABS control module.

 Short-circuit between instrument and ABS control module.

 Fault of instrument warning lamp drive module.

 Fault of ABS control module.

4) Light-up of brake warning lamp

The typical causes for light-up of brake warning lamp without setup of diagnosis

trouble code are as below:

 Failure of parking brake switch.

 Low brake fluid level or failure of brake fluid switch.

 Open-circuit between instrument and ABS control module.

 Failure of warning lamp circuit.

 Instrument fault.

 Fault of ABS control module.

5) No light-up of brake warning lamp/without setup of diagnosis trouble code

The typical causes for failure of brake warning lamp and no setup of diagnosis trouble

code are as below:

 Bulb fault/loose connector.

 Breakage of instrument panel fuse

 Instrument fault.

 Fault of ABS control module.

 Circuit grounding between instrument and ABS control module.

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-25

Analysis of ABS Trouble Codes

C1101 – Excessive voltage of ABS control module

Circuit description:

This circuit is used to monitor the voltage level supplied to the ABS control module.

When the voltage raises to above certain level, it may lead to system damage.

Condition for setup of diagnosis trouble code:

If the voltage at terminal 32 of ABS control module exceeds 17V for 1s, the DTC

C1101 can be set only when the wheel speed exceeds 8km/h (5 miles/hour).

Action at setup of diagnosis trouble code:

1. Store DTC C1101.

2. Failure of ABS.

3. Light-up of ABS warning lamp.

Condition for clearing diagnosis trouble code:

1. If the condition for setup of DTC C1101 disappears, the diagnosis trouble code

can be cleared by means of appropriate diagnosis instrument.

2. The diagnosis trouble codes not occurred within 100 drive periods will be

cleared from the history data.

Diagnosis tips:

The typical causes for setup of DTC C1101 are as below:

1) Failure of charging system.

2) Poor connection.

3) Fault of ABS control module.

C1101 – Excessive voltage of ABS control module

Step

Diagnosis Action

Expected

Value

Yes

Is the check of diagnosis circuit completed?

To step 2

To step 4

1. Connect one voltmeter between

positive/negative terminals of battery.

2. Turn off all electric devices.

3. Start the engine.

4. Observe the voltage reading of voltmeter

when the engine runs at 2000r/m for several

seconds.

Is the voltage within the specified range?

<17V

To step 3

To step 5

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-26

Step

Diagnosis Action

Expected

Value

Yes

1. Connect the diagnosis instrument and select

ABS data list.

2. Observe the voltage value of battery in the

ABS data list when the engine runs at

2000r/m for several seconds.

Is the voltage within the specified range?

<17V

To step 6

To step 7

Conduct the check of diagnosis circuit

Refer to diagnosis of starter system and charging

system

The status is intermittent.

Replace ABS control module.

Is the repair completed?

To step 8

Clear diagnosis trouble code with the diagnosis

instrument.

Under the condition for setup of diagnosis trouble

code, is the diagnosis trouble code reset?

System

To step 1

C1102 – Insufficient voltage of ABS control module

Circuit description:

This circuit is used to monitor the voltage level supplied to the ABS control module.

When the voltage drops to certain level, it can’t guarantee all normal performances of

the system. There are several typical conditions leading to the voltage drop of the

battery during the operation of ABS. Therefore, monitor the voltage before the

operation of ABS to indicate the good charging status as well as during the operation

of the ABS that may lead to great drop of voltage. The condition for setup of

diagnosis trouble code is as below: Within the period of no ABS or initialization, if

the voltage at terminal 32 of ABS control module is below 10.5V, the DTC C1102

can be set only when the wheel speed exceeds 8km/h. Within the period of ABS, the

DTC C1102 can be set when the ignition voltage is below 10.5V and the battery

voltage is below 9.0V.

Action at setup of diagnosis trouble code:

1. Store DTC C1102.

2. Failure of ABS.

3. Light-up of ABS warning lamp.

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-27

Condition for clearing diagnosis trouble code:

1. If the condition for setup of DTC C1102 disappears, the diagnosis trouble code

can be cleared by means of appropriate diagnosis instrument.

2. The diagnosis trouble codes not occurred within 100 drive periods will be

cleared from the history data.

Diagnosis tips:

The typical causes for setup of DTC C1102 are as below:

 Low voltage or depletion of battery.

 Poor contact of battery terminals.

 The original electric devices or supplemented electric devices (supplemental

loads) split much voltage of the battery.

 Poor grounding of battery on engine cylinder block or chassis.

 Poor contact of terminal on ABS control module.

 Poor grounding of ABS control module.

For fault of charging system (engine), completely check the circuits and connectors.

The careless and incomplete check of wiring and connectors may lead to the

replacement of parts instead of the repair of fault.

C1102 – Insufficient voltage of ABS control module

Step

Diagnosis Action

Expected

Value

Yes

Is the check of diagnosis circuit completed?

To step 2

To step 6

1. Check the battery load.

2. Check the charging system.

3. Conduct the testing of supplemental

loads.

Are battery testing, charging system testing,

and testing of supplementary loads all

passed?

The battery

voltage must

maintain

at >9.6V for

10s.

Do not exceed

20mA

To step 3

To step 7

1. Stop the engine.

2. Disconnect positive/negative terminals

of battery.

3. Disconnect harness from ABS control

module.

4. Check following items for poor

contact:

To step 4

To step 8

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-28

Step

Diagnosis Action

Expected

Value

Yes

Terminal cable of battery negative cable to

engine or chassis positive cable to starter

coil or junction case. Terminal 32 and 38 of

ABS control module

Grounding wire of ABS control module to

chassis grounding.

Are all above connections good?

1. Keep the ABS control module

disconnected.

2. Keep the battery cable disconnected.

3. Connect one ohmmeter between

harness terminal 38 of ABS control

module and battery negative cable.

Is the resistance value within the specified

range?

<2Ω

To step 5

To step 9

1. Connect the battery cable.

2. Keep the ABS control module

disconnected.

3. Turn on ignition switch.

4. Measure voltage value between harness

terminal 32 and 38 of ABS control

module.

Is the measurement between two terminals

within the specified range?

Battery

voltage

To step 11

To step 10

Conduct the check of diagnosis circuit

Repair charging system, and/or recharge /

replace battery, and/or find out and repair

the cause with supplemental electric

leakage.

Is the repair completed?

To step 12

When necessary, repair terminals and/or

connectors.

Is the repair completed?

To step 12

Find out and repair the cause for high

resistance value between negative cable of

battery and harness connector of ABS

control module.

To step 12

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-29

Step

Diagnosis Action

Expected

Value

Yes

Is the repair completed?

Find out and repair cause for terminal

voltage of ABS control module.

Is the repair completed?

To step 12

Replace ABS control module.

Is the repair completed?

To step 12

Clear diagnosis trouble code with the

diagnosis instrument.

Under the conditions for setup of diagnosis

trouble code, is the diagnosis trouble code

reset?

System OK

To step 1

C1200 – Front left wheel speed sensor: Open-circuit/short-circuit

Circuit description:

While the wheel is rotating, the speed sensor generates one square wave signal

following the increasing of wheel speed. The ABS control module calculates the

wheel speed by means of the frequency of square wave signal. The speed sensor is

connected with the ABS control module via twisted pair cable.

Condition for setup of diagnosis trouble code:

The DTC C1200 can be set whenever the ABS control module detects the

open-circuit, short-circuit to ground or to battery on the front left wheel speed circuit.

Action at setup of diagnosis trouble code:

1. Store DTC C1200.

2. Failure of ABS.

3. Light-up of ABS warning lamp.

Condition for clearing diagnosis trouble code:

1. If the condition for setup of diagnosis trouble code DTC C1200 disappears, the

diagnosis trouble code can be cleared by means of appropriate diagnosis

instrument.

2. The diagnosis trouble codes not occurred within 100 ignition periods will be

cleared from the history data.

Diagnosis tips:

During the diagnosis of intermittent diagnosis trouble code, please completely check

the wiring and connectors. This shall include:

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-30

1. Remove the protective duct and check the circuits for damage, short-circuit and

contamination.

2. Check the terminals for deformation and damage.

3. Check the contact of terminals (retention force) by means the backup

positive/negative terminals.

4. Remove the terminals from connectors and check the terminals of crimped wires

for loose connection.

C1200 – Front left wheel speed sensor: Open-circuit/short-circuit

Step

Diagnosis Action

Expected

Value

Yes

Is the check of diagnosis circuit completed?

To step 2

To step 14

1. Stop the engine.

2. Check front left wheel speed sensor,

sensor harness, and gear ring for physical

damage?

Is there any physical damage detected?

To step 15

To step 3

Conduct the road test under various wheel

speeds on various roads.

Is C1200 reset?

Are all above connections good?

To step 4

To step 16

1. Stop the engine and park the vehicle.

2. Raise and properly support the vehicle.

3. Disconnect the harness of front left wheel

speed sensor.

4. Connect one ohmmeter between terminal

1 and 2 of front left wheel speed sensor.

Is the resistance value within the specified

range?

75Ω±1 %

To step 5

To step 17

1. Disconnect front left wheel jumper

harness from front left wheel speed

sensor.

2. Connect one ohmmeter between the body

grounding and terminal 1 of front left

wheel speed sensor.

Is the resistance value within the specified

range?

(Open-circuit)

To step 6

To step 17

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-31

Step

Diagnosis Action

Expected

Value

Yes

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of front left

wheel speed sensor.

3. Connect one ohmmeter between harness

terminal 22 of ABS control module and

terminal 2 of front left wheel speed

sensor.

Is the resistance value within the specified

range?

<2Ω

To step 7

To step 18

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of front left

wheel speed sensor.

3. Connect one ohmmeter between harness

terminal 34 of ABS control module and

connector 1 of front left wheel speed

sensor.

Is the resistance value within the specified

range?

<2Ω

To step 8

To step 19

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of front left

wheel speed sensor.

3. Connect one voltmeter between harness

terminal 22 of ABS control module and

the body grounding.

Is the voltage reading within the specified

range?

<1V

To step 9

To step 20

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of front left

wheel speed sensor.

3. Connect one voltmeter between harness

terminal 34 of ABS control module and

the body grounding.

Is the voltage reading within the specified

range?

<1V

To step 10

To step 21

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-32

Step

Diagnosis Action

Expected

Value

Yes

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of front left

wheel speed sensor.

3. Connect one ohmmeter between harness

terminal 22 of ABS control module and

the body grounding.

Is the resistance value within the specified

range?

(Open-circuit)

To step 11

To step 22

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of front left

wheel speed sensor.

3. Connect one ohmmeter between harness

terminal 34 of ABS control module and

the body grounding.

Is the resistance value within the specified

range?

(Open-circuit)

To step 12

To step 23

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of front left

wheel speed sensor.

3. Connect one ohmmeter between harness

terminal 22 and 34 of ABS control

module.

4. Is the resistance value within the

specified range?

(Open-circuit)

To step 13

To step 24

1. Replace the harness of front left wheel

speed sensor.

2. Conduct the road test under various wheel

speeds on various roads.

Is C1200 reset?

System Ok

To step 25

Conduct the check of diagnosis circuit

Repair the damaged front left wheel speed

sensor, harness and/or gear ring.

Is the repair completed?

To step 26

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-33

Step

Diagnosis Action

Expected

Value

Yes

Is DTC C1200 intermittent?

To step 26

Replace front left wheel speed sensor.

Is the repair completed?

To step 26

Open-circuit or high resistance between

repair terminal 34 and 1.

Is the repair completed?

To step 26

Open-circuit or high resistance between

repair terminal 22 and 2.

Is the repair completed?

To step 26

Short-circuit to voltage between repair

terminal 34 and 1.

Is the repair completed?

To step 26

Short-circuit to voltage between repair

terminal 22 and 2.

Is the repair completed?

To step 26

Short-circuit to ground between repair

terminal 34 and 1.

Is the repair completed?

To step 26

Short-circuit to ground between repair

terminal 22 and 2.

Is the repair completed?

To step 26

Repair short-circuit between 2 circuits.

Is the repair completed?

To step 26

Replace ABS control module.

Is the repair completed?

To step 26

Clear diagnosis trouble code with the

diagnosis instrument.

Under the conditions for setup of diagnosis

trouble code, is the diagnosis trouble code

reset?

System Ok

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-34

C1201 – Front left wheel speed sensor: Overturn, performance error, and

intermittent signal

Circuit description:

While the wheel is rotating, the speed sensor generates one square wave signal

following the increasing of wheel speed. The ABS control module calculates the

wheel speed by means of the frequency of square wave signal. The speed sensor is

connected with the ABS control module via twisted pair cable.

Condition for setup of diagnosis trouble code:

To setup the DTC C1201, the following conditions must be met:

1. DTC C1200 or C1203 or C1206 or C1209 is not the current trouble code.

2. The brake switch is turned off.

3. The acceleration or deceleration of front left wheel is out of the reasonable range.

Action at setup of diagnosis trouble code:

1. Store the diagnosis trouble code DTC C1201.

2. Failure of ABS.

3. Light-up of ABS warning lamp.

Condition for clearing diagnosis trouble code:

1. If the condition for setup of diagnosis trouble code DTC C1201 disappears, the

diagnosis trouble code can be cleared by means of appropriate diagnosis

instrument.

2. The diagnosis trouble codes not occurred within 100 ignition periods will be

cleared from the history data.

Diagnosis tips:

During the diagnosis of intermittent diagnosis trouble code, please completely check

the wiring and connectors. This shall include:

1. Remove the protective duct and check the circuits for damage, short-circuit and

contamination.

2. Check the terminals for deformation and damage.

3. Check the contact of terminals (retention force) by means the backup

positive/negative terminals.

4. Remove the terminals from connectors and check the terminals of crimped wires

for loose connection.

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-35

C1201 – Front left wheel speed sensor: Overturn, performance error, and intermittent

signal

Step

Diagnosis Action

Expected

Value

Yes

Is the check of diagnosis circuit completed?

To step 2

To step 12

Is the setup of DTC C1200 one current or

historic diagnosis trouble code?

To step 13

To step 3

1. Stop the engine and park the vehicle.

2. Check the front left wheel speed sensor

and sensor harness for damage.

3. Completely and thoroughly check the

front left gear ring and understand the

presence of damage (crack, tooth

breakage, or looseness).

Is there any physical damage detected?

To step 14

To step 5

1. Park the vehicle.

2. Connect the diagnosis instrument and

select the data list.

3. Monitor the wheel speed sensor.

4. Start the engine and monitor the wheel

speed sensor while the engine is running

but the vehicle is still.

5. Lightly step down the accelerator pedal

to increase the idling speed of the engine.

Is C1201 reset or does the reading of front left

vehicle speed exceed 0km/h while the engine

is running but the vehicle is still?

To step 15

To step 5

1. Keep the diagnosis instrument connected.

2. Monitor the wheel speed sensor.

3. Test run the vehicle to the maximum limit

speed and then slowly decelerate to zero.

Repeat above process for several times.

Is C1201 reset or does the speed variation of

front left wheel exceed 5km/h compared with

any other wheel during the driving?

To step 6

To step 16

1. Stop the engine and park the vehicle.

2. Raise and properly support the vehicle.

75 Ω ± 1 %

To step 7

To step 17

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-36

Step

Diagnosis Action

Expected

Value

Yes

3. Disconnect the harness of front left wheel

speed sensor.

4. Connect one ohmmeter between two

terminals of front left wheel speed sensor.

Is the resistance value within the specified

range?

1. Keep the wheel speed sensor

disconnected from the jumper cable.

2. Connect one voltmeter between two

terminals of front left wheel speed sensor.

3. Select the mv scale.

4. Observe the voltage reading on the

voltmeter while rotating the front left

wheel.

Min 100mV

To step 8

To step 17

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of front left

wheel speed sensor.

3. Connect one ohmmeter between harness

terminal 22 of ABS control module and

connector 2 of front left wheel speed

sensor.

Is the resistance value within the specified

range?

<2Ω

To step 9

To step 18

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of front left

wheel speed sensor.

3. Connect one ohmmeter between harness

terminal 34 of ABS control module and

connector 1 of front left wheel speed

sensor.

Is the resistance value within the specified

range?

<2Ω

To step 10

To step 19

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of front left

wheel speed sensor.

(Open-circuit)

To step 11

To step 20

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-37

Step

Diagnosis Action

Expected

Value

Yes

3. Connect one ohmmeter between harness

terminal 22 and 34 of ABS control

module.

4. Is the resistance value within the

specified range?

1. Replace the harness of front left wheel

speed sensor.

2. Conduct the road test under various

wheel speeds on various roads.

Is C1201 reset?

System

To step 21

Before preparing the fault diagram of

diagnosis trouble code C1201, conduct the

check of diagnosis circuit.

Prepare the C1201 diagnosis diagram before

preparing the fault diagram of diagnosis

trouble code C1201.

Repair the damaged front left wheel speed

sensor, sensor harness and/or gear ring.

Is the repair completed?

To step 22

The cause of C1201 is that the ignition noise

coupling is detected on the front left wheel

speed sensor circuit.

Check the front left ABS module harness

and/or sensor harness for presence of potential

ignition noise source, such as spark plug wire.

When necessary, re-arrange the wires.

Is the repair completed?

To step 22

The diagnosis trouble code C1201 is

intermittent.

Replace front left wheel speed sensor.

Is the repair completed?

To step 22

Open-circuit or high resistance between

repair terminal 22 and 2.

Is the repair completed?

To step 22

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-38

Step

Diagnosis Action

Expected

Value

Yes

Open-circuit or high resistance between repair

terminal 34 and 1.

Is the repair completed?

To step 22

Repair the short-circuit between 2 wires.

Is the repair completed?

To step 22

Replace ABS control module.

Is the repair completed?

To step 22

Clear diagnosis trouble code with the

diagnosis instrument.

Under the condition for setup of diagnosis

trouble code, is the diagnosis trouble code

reset?

System

To step 1

C1202 – Front left wheel speed sensor: Invalid signal/no signal

Circuit description:

While the wheel is rotating, the speed sensor generates one square wave signal

following the increasing of wheel speed. The ECU calculates the wheel speed by

means of the frequency of square wave signal. The speed sensor is connected with the

ECU via twisted pair cable.

Condition for setup of diagnosis trouble code:

To setup the DTC C1202, the following conditions must be met:

1. DTC C1200 or C1203 or C1206 or C1209 is not the current trouble code.

2. Failure of ABS.

3. The brake switch is turned off. The front left wheel speed equals to 0 and all

other wheel speed sensors are as below: Above 8km/h within at least 2.5s.

Condition for clearing diagnosis trouble code:

1. If the condition for setup of DTC C1202 disappears, the diagnosis trouble code

can be cleared by means of appropriate diagnosis instrument.

2. The diagnosis trouble codes not occurred within 100 ignition periods will be

cleared from the history data.

Diagnosis tips:

During the diagnosis of intermittent diagnosis trouble code, please completely check

the circuits and connectors.

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-39

This shall include:

1. Remove the protective duct and check the circuits for damage, short-circuit and

contamination.

2. Check the terminals for deformation and damage.

3. Check the contact retention force of terminals by means the backup

positive/negative terminals.

C1202 – Front left wheel speed sensor: Invalid signal/no signal

Step

Diagnosis Action

Expected

Value

Yes

Is the check of diagnosis circuit completed?

To step 2

To step 12

1. Stop the engine.

2. Check front left wheel speed sensor,

sensor harness, and gear ring for physical

damage?

Is there any physical damage detected?

To step 13

To step 3

Is the setup of diagnosis trouble code C1200

current or historic trouble code?

To step 14

To step 4

1. Connect the diagnosis instrument and

select the data list.

2. Monitor the wheel speed sensor.

3. Test run the vehicle at a speed of 24km/h

and then slowly decelerate the wheel

speed to zero. Repeat this process for

several times.

Is the C1202 reset or does the front left wheel

speed suddenly drop to zero before the vehicle

fully stops?

To step 5

To step 15

1. Stop the engine.

2. Raise and properly support the vehicle.

3. Disconnect harness from ABS control

module.

4. Connect one voltmeter between harness

terminal 22 and 34 of ABS control

module.

5. Select the AC mV scale.

Min 100mV

To step 16

To step 6

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-40

Step

Diagnosis Action

Expected

Value

Yes

6. Observe the voltmeter while rotating the

front left wheel. (The voltage shall

increase following the increasing of

wheel speed)

Is the value of square wave signal within the

specified range?

1. Disconnect the harness of front left

wheel speed sensor.

2. Connect one ohmmeter between two

terminals of front left wheel speed

sensor.

Is the resistance value within the specified

range?

75Ω±1 %

To step 7

To step 17

1. Disconnect the connector of front left

wheel speed sensor.

2. Connect one voltmeter between two

terminals of front left wheel speed

sensor.

3. Select the AC mV scale.

4. Observe the voltmeter while rotating the

front left wheel. (The voltage shall

increase following the increasing of

wheel speed)

Is the value of square wave signal within the

specified range?

Min 100mV

To step 8

To step 17

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of front left

wheel speed sensor.

3. Connect one ohmmeter between harness

terminal 22 and 34 of ABS control

module.

Is the resistance value within the specified

range?

(Open-circuit)

To step 9

To step 18

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of front left

wheel speed sensor.

3. Connect one ohmmeter between terminal

34 of ABS control module harness and

<2Ω

To step 10

To step 19

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-41

terminal 1 of sensor connector.

Step

Diagnosis Action

Expected

Value

Yes

Is the resistance value within the specified

range?

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of front left

wheel speed sensor.

3. Connect one ohmmeter between terminal

22 of ABS control module harness and

terminal 2 of sensor connector.

Is the resistance value within the specified

range?

<2Ω

To step 11

To step 20

1. Replace the connector of front left wheel

speed sensor.

2. Conduct the road test under various

wheel speeds on various roads.

Is the diagnosis trouble code reset?

System

To step 16

Conduct the check of diagnosis circuit before

diagnosing this fault.

Repair the damaged front left wheel speed

sensor, harness and/or gear ring.

Is the repair completed?

To step 21

Before taking the check procedure described

in this table, diagnose the diagnosis trouble

code C1200.

The diagnosis trouble code C1202 is

intermittent.

Replace ABS control module.

Is the repair completed?

To step 21

Replace front left wheel speed sensor.

Is the repair completed?

To step 21

Find out and repair the short-circuit between

two circuits.

Is the repair completed?

To step 21

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-42

Step

Diagnosis Action

Expected

Value

Yes

Open-circuit or high resistance between

repair terminal 34 and 1.

Is the repair completed?

To step 21

Open-circuit or high resistance between

repair terminal 22 and 2.

Is the repair completed?

To step 21

Clear diagnosis trouble code with the

diagnosis instrument.

Under the conditions for setup of diagnosis

trouble code, is the diagnosis trouble code

reset?

System

To step 1

C1203 – Front right wheel speed sensor: Open-circuit/short-circuit

Circuit description:

While the wheel is rotating, the speed sensor generates one square wave signal

following the increasing of wheel speed. The ABS control module calculates the

wheel speed by means of the frequency of square wave signal. The speed sensor is

connected with the ABS control module via twisted pair cable.

Condition for setup of diagnosis trouble code:

The DTC C1203 can be set whenever the ABS control module detects the

open-circuit, short-circuit to ground or to battery on the front right wheel speed

circuit.

Action at setup of diagnosis trouble code:

1. Store DTC C1203.

2. Failure of ABS.

3. Light-up of ABS warning lamp.

Condition for clearing diagnosis trouble code:

1. If the condition for setup of diagnosis trouble code DTC C1203 disappears, the

diagnosis trouble code can be cleared by means of appropriate diagnosis

instrument.

2. The diagnosis trouble codes not occurred within 100 ignition periods will be

cleared from the history data.

Diagnosis tips:

During the diagnosis of intermittent diagnosis trouble code, please completely check

the wiring and connectors. This shall include:

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-43

1. Remove the protective duct and check the circuits for damage, short-circuit and

contamination.

2. Check the terminals for deformation and damage.

3. Check the contact of terminals (retention force) by means the backup

positive/negative terminals.

4. Remove the terminals from connectors and check the terminals of crimped wires

for loose connection.

C1203 – Front right wheel speed sensor: Open-circuit/short-circuit

Step

Diagnosis Action

Expected

Value

Yes

Is the check of diagnosis circuit completed?

To step 2

To step 14

1. Stop the engine.

2. Check front right wheel speed sensor,

sensor harness, and gear ring for

physical damage?

Is there any physical damage detected?

To step 15

To step 3

Conduct the road test under various wheel

speeds on various roads.

Is C1203 reset?

Are all above connections good?

To step 4

To step 16

1. Stop the engine and park the vehicle.

2. Raise and properly support the vehicle.

3. Disconnect the harness of front right

wheel speed sensor.

4. Connect one ohmmeter between

terminal 1 and 2 of front right wheel

speed sensor.

Is the resistance value within the specified

range?

75 Ω ± 1 %

To step 5

To step 17

1. Disconnect front right wheel jumper

harness from front right wheel speed

sensor.

2. Connect one ohmmeter between the

body grounding and terminal 1 of front

right wheel speed sensor.

Is the resistance value within the specified

range?

(Open-circuit)

To step 6

To step 17

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-44

Step

Diagnosis Action

Expected

Value

Yes

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of front right

wheel speed sensor.

3. Connect one ohmmeter between harness

terminal 6 of ABS control module and

terminal 2 of front right wheel speed

sensor.

Is the resistance value within the specified

range?

<2 Ω

To step 7

To step 18

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of front right

wheel speed sensor.

3. Connect one ohmmeter between harness

terminal 18 of ABS control module and

connector 1 of front right wheel speed

sensor.

Is the resistance value within the specified

range?

<2 Ω

To step 8

To step 19

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of front right

wheel speed sensor.

3. Connect one voltmeter between harness

terminal 6 of ABS control module and

the body grounding.

Is the voltage reading within the specified

range?

<1V

To step 9

To step 20

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of front right

wheel speed sensor.

3. Connect one voltmeter between harness

terminal 18 of ABS control module and

the body grounding.

Is the voltage reading within the specified

range?

<1V

To step 10

To step 21

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-45

Step

Diagnosis Action

Expected

Value

Yes

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of front right

wheel speed sensor.

3. Connect one ohmmeter between harness

terminal 6 of ABS control module and

the body grounding.

Is the resistance value within the specified

range?

(Open-circuit)

To step 11

To step 22

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of front right

wheel speed sensor.

3. Connect one ohmmeter between harness

terminal 18 of ABS control module and

the body grounding.

Is the resistance value within the specified

range?

(Open-circuit)

To step 12

To step 23

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of front right

wheel speed sensor.

3. Connect one ohmmeter between harness

terminal 6 and 18 of ABS control

module.

4. Is the resistance value within the

specified range?

(Open-circuit)

To step 13

To step 24

1. Replace the harness of front right wheel

speed sensor.

2. Conduct the road test under various wheel

speeds on various roads.

Is C1203 reset?

System

To step 25

Conduct the check of diagnosis circuit

Repair the damaged front right wheel speed

sensor, harness and/or gear ring.

Is the repair completed?

To step 26

Is DTC C1203 intermittent?

To step 26

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-46

Step

Diagnosis Action

Expected

Value

Yes

Replace front right wheel speed sensor.

Is the repair completed?

To step 26

Open-circuit or high resistance between

repair terminal 18 and 1.

Is the repair completed?

To step 26

Open-circuit or high resistance between

repair terminal 6 and 2.

Is the repair completed?

To step 26

Short-circuit to voltage between repair

terminal 18 and 1.

Is the repair completed?

To step 26

Short-circuit to voltage between repair

terminal 6 and 2.

Is the repair completed?

To step 26

Short-circuit to ground between repair

terminal 18 and 1.

Is the repair completed?

To step 26

Short-circuit to ground between repair

terminal 6 and 2.

Is the repair completed?

To step 26

Repair short-circuit between 2 circuits.

Is the repair completed?

To step 26

Replace ABS control module.

Is the repair completed?

To step 26

Clear diagnosis trouble code with the

diagnosis instrument.

Under the conditions for setup of diagnosis

trouble code, is the diagnosis trouble code

reset?

System

To step 1

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-47

C1204 – Front right wheel speed sensor: Overturn, performance error, and

intermittent signal

Circuit description:

While the wheel is rotating, the speed sensor generates one square wave signal

following the increasing of wheel speed. The ABS control module calculates the

wheel speed by means of the frequency of square wave signal. The speed sensor is

connected with the ABS control module via twisted pair cable.

Condition for setup of diagnosis trouble code:

To setup the DTC C1204, the following conditions must be met:

1. DTC C1200 or C1203 or C1206 or C1209 is not the current trouble code.

2. The brake switch is turned off.

3. The acceleration or deceleration of front right wheel is out of the reasonable

range.

Action at setup of diagnosis trouble code:

1. Store the diagnosis trouble code DTC C1204.

2. Failure of ABS.

3. Light-up of ABS warning lamp.

Condition for clearing diagnosis trouble code:

1. If the condition for setup of diagnosis trouble code DTC C1204 disappears, the

diagnosis trouble code can be cleared by means of appropriate diagnosis

instrument.

2. The diagnosis trouble codes not occurred within 100 ignition periods will be

cleared from the history data.

Diagnosis tips:

During the diagnosis of intermittent diagnosis trouble code, please completely check

the wiring and connectors. This shall include:

1. Remove the protective duct and check the circuits for damage, short-circuit and

contamination.

2. Check the terminals for deformation and damage.

3. Check the contact of terminals (retention force) by means the backup

positive/negative terminals.

4. Remove the terminals from connectors and check the terminals of crimped wires

for loose connection.

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-48

C1204 – Front right wheel speed sensor: Overturn, performance error, and

intermittent signal

Step

Diagnosis Action

Expected

Value

Yes

Is the check of diagnosis circuit completed?

To step 2

To step 12

Is the setup of DTC C1203 one current or

historic diagnosis trouble code?

To step 13

To step 3

1. Stop the engine and park the vehicle.

2. Check the front right wheel speed sensor

and sensor harness for damage.

3. Completely and thoroughly check the

front right gear ring and understand the

presence of damage (crack, tooth

breakage, or looseness).

Is there any physical damage detected?

To step 14

To step 5

1. Park the vehicle.

2. Connect the diagnosis instrument and

select the data list.

3. Monitor the wheel speed sensor.

4. Start the engine and monitor the wheel

speed sensor while the engine is running

but the vehicle is still.

5. Lightly step down the accelerator pedal to

increase the idling speed of the engine.

Is C1204 reset or does the reading of front

right vehicle speed exceed 0km/h while the

engine is running but the vehicle is still?

To step 15

To step 5

1. Keep the diagnosis instrument connected.

2. Monitor the wheel speed sensor.

3. Test run the vehicle to the maximum limit

speed and then slowly decelerate to zero.

Repeat above process for several times.

Is C1204 reset or does the speed variation of

front right wheel exceed 5km/h compared with

any other wheel during the driving?

To step 6

To step 16

1. Stop the engine and park the vehicle.

2. Raise and properly support the vehicle.

75 Ω ± 1 %

To step 7

To step 17

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-49

Step

Diagnosis Action

Expected

Value

Yes

3. Disconnect the harness of front right

wheel speed sensor.

4. Connect one ohmmeter between two

terminals of front right wheel speed

sensor.

Is the resistance value within the specified

range?

1. Keep the wheel speed sensor

disconnected from the jumper cable.

2. Connect one voltmeter between two

terminals of front right wheel speed

sensor.

3. Select the AC mV scale.

4. Observe the voltage reading on the

voltmeter while rotating the front right

wheel.

Min 100mV

To step 8

To step 17

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of front right

wheel speed sensor.

3. Connect one ohmmeter between harness

terminal 6 of ABS control module and

connector 2 of front right wheel speed

sensor.

Is the resistance value within the specified

range?

<2 Ω

To step 9

To step 18

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of front right

wheel speed sensor.

3. Connect one ohmmeter between harness

terminal 18 of ABS control module and

connector 1 of front right wheel speed

sensor.

Is the resistance value within the specified

range?

<2 Ω

To step 10

To step 19

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of front right

wheel speed sensor.

(Open-circuit)

To step 11

To step 20

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-50

Step

Diagnosis Action

Expected

Value

Yes

3. Connect one ohmmeter between harness

terminal 6 and 18 of ABS control module.

4. Is the resistance value within the

specified range?

1. Replace the harness of front right wheel

speed sensor.

2. Conduct the road test under various

wheel speeds on various roads.

Is C1204 reset?

System

To step 21

Before preparing the fault diagram of

diagnosis trouble code C1204, conduct the

check of diagnosis circuit.

Prepare the C1204 diagnosis diagram before

preparing the fault diagram of diagnosis

trouble code C1203.

Repair the damaged front right wheel speed

sensor, sensor harness and/or gear ring.

Is the repair completed?

To step 22

The cause of C1204 is that the ignition noise

coupling is detected on the front right wheel

speed sensor circuit.

Check the front right ABS module harness

and/or sensor harness for presence of potential

ignition noise source, such as spark plug wire.

When necessary, re-arrange the wires.

Is the repair completed?

To step 22

The diagnosis trouble code C1204 is

intermittent.

Replace front right wheel speed sensor.

Is the repair completed?

To step 22

Open-circuit or high resistance between

repair terminal 6 and 2.

Is the repair completed?

To step 22

Open-circuit or high resistance between

repair terminal 18 and 1.

To step 22

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-51

Step

Diagnosis Action

Expected

Value

Yes

Is the repair completed?

Repair the short-circuit between 2 wires.

Is the repair completed?

To step 22

Replace ABS control module.

Is the repair completed?

To step 22

Clear diagnosis trouble code with the

diagnosis instrument.

Under the conditions for setup of diagnosis

trouble code, is the diagnosis trouble code

reset?

System

To step 1

C1205 – Front right wheel speed sensor: Invalid signal/no signal

Circuit description:

While the wheel is rotating, the speed sensor generates one square wave signal

following the increasing of wheel speed. The ECU calculates the wheel speed by

means of the frequency of square wave signal. The speed sensor is connected with the

ECU via twisted pair cable.

Condition for setup of diagnosis trouble code:

To setup the DTC C1205, the following conditions must be met:

1. DTC C1200 or C1203 or C1206 or C1209 is not the current trouble code.

2. Failure of ABS.

3. The brake switch is turned off. The front right wheel speed equals to 0 and all

other wheel speed sensors are as below: Above 8km/h within at least 2.5s.

Condition for clearing diagnosis trouble code:

1. If the condition for setup of DTC C1205 disappears, the diagnosis trouble code

can be cleared by means of appropriate diagnosis instrument.

2. The diagnosis trouble codes not occurred within 100 ignition periods will be

cleared from the history data.

Diagnosis tips:

During the diagnosis of intermittent diagnosis trouble code, please completely check

the circuits and connectors.

This shall include:

1. Remove the protective duct and check the circuits for damage, short-circuit and

contamination.

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-52

2. Check the terminals for deformation and damage.

3. Check the contact retention force of terminals by means the backup

positive/negative terminals.

C1205 – Front right wheel speed sensor: Invalid signal/no signal

Step

Diagnosis Action

Expected

Value

Yes

Is the check of diagnosis circuit completed?

To step 2

To step 12

1. Stop the engine.

2. Check front right wheel speed sensor,

sensor harness, and gear ring for

physical damage?

Is there any physical damage detected?

To step 13

To step 3

Is the setup of diagnosis trouble code C1203

current or historic trouble code?

To step 14

To step 4

1. Connect the diagnosis instrument and

select the data list.

2. Monitor the wheel speed sensor.

3. Test run the vehicle at a speed of

24km/h and then slowly decelerate the

wheel speed to zero. Repeat this process

for several times.

Is the C1205 reset or does the front right

wheel speed suddenly drop to zero before the

vehicle fully stops?

To step 5

To step 15

1. Stop the engine.

2. Raise and properly support the vehicle.

3. Disconnect harness from ABS control

module.

4. Connect one voltmeter between harness

terminal 6 and 18 of ABS control

module.

5. Select the AC mV scale.

6. Observe the voltmeter while rotating the

front right wheel. (The voltage shall

increase following the increasing of

wheel speed)

Is the value of square wave signal within the

specified range?

Min 100mV

To step 16

To step 6

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-53

Step

Diagnosis Action

Expected

Value

Yes

1. Disconnect the harness of front right

wheel speed sensor.

2. Connect one ohmmeter between two

terminals of front right wheel speed

sensor.

Is the resistance value within the specified

range?

75 Ω ± 1 %

To step 7

To step 17

1. Disconnect the connector of front right

wheel speed sensor.

2. Connect one voltmeter between two

terminals of front right wheel speed

sensor.

3. Select the mV voltage scale.

4. Observe the voltmeter while rotating the

front right wheel. (The voltage shall

increase following the increasing of

wheel speed)

Is the value of square wave signal within the

specified range?

Min 100mV

To step 8

To step 17

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of front right

wheel speed sensor.

3. Connect one ohmmeter between harness

terminal 6 and 18 of ABS control

module.

Is the resistance value within the specified

range?

(Open-circuit)

To step 9

To step 18

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of front right

wheel speed sensor.

3. Connect one ohmmeter between

terminal 18 of ABS control module

harness and terminal 1 of sensor

connector.

Is the resistance value within the specified

range?

<2 Ω

To step 10

To step 19

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-54

Step

Diagnosis Action

Expected

Value

Yes

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of front right

wheel speed sensor.

3. Connect one ohmmeter between

terminal 6 of ABS control module

harness and terminal 2 of sensor

connector.

Is the resistance value within the specified

range?

<2 Ω

To step 11

To step 20

1. Replace the connector of front right

wheel speed sensor.

2. Conduct the road test under various

wheel speeds on various roads.

Is the diagnosis trouble code reset?

System Ok

To step 16

Conduct the check of diagnosis circuit before

diagnosing this fault.

Repair the damaged front right wheel speed

sensor, harness and/or gear ring.

Is the repair completed?

To step 21

Before taking the check procedure described

in this table, diagnose the diagnosis trouble

code C1203.

The diagnosis trouble code C1205 is

intermittent.

Replace ABS control module.

Is the repair completed?

To step 21

Replace front right wheel speed sensor.

Is the repair completed?

To step 21

Find out and repair the short-circuit between

two circuits.

Is the repair completed?

To step 21

Open-circuit or high resistance between

repair terminal 18 and 1.

To step 21

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-55

Step

Diagnosis Action

Expected

Value

Yes

Is the repair completed?

Open-circuit or high resistance between

repair terminal 6 and 2.

Is the repair completed?

To step 21

Clear diagnosis trouble code with the

diagnosis instrument.

Under the conditions for setup of diagnosis

trouble code, is the diagnosis trouble code

reset?

System Ok

To step 1

C1206 – Rear left wheel speed sensor: Open-circuit/short-circuit

Circuit description:

While the wheel is rotating, the speed sensor generates one square wave signal

following the increasing of wheel speed. The ABS control module calculates the

wheel speed by means of the frequency of square wave signal. The speed sensor is

connected with the ABS control module via twisted pair cable.

Condition for setup of diagnosis trouble code:

The DTC C1206 can be set whenever the ABS control module detects the

open-circuit, short-circuit to ground or to battery on the rear left wheel speed circuit.

Action at setup of diagnosis trouble code:

1. Store DTC C1206.

2. Failure of ABS.

3. Light-up of ABS warning lamp.

Condition for clearing diagnosis trouble code:

1. If the condition for setup of diagnosis trouble code DTC C1206 disappears, the

diagnosis trouble code can be cleared by means of appropriate diagnosis

instrument.

2. The diagnosis trouble codes not occurred within 100 ignition periods will be

cleared from the history data.

Diagnosis tips:

During the diagnosis of intermittent diagnosis trouble code, please completely check

the wiring and connectors. This shall include:

1. Remove the protective duct and check the circuits for damage, short-circuit and

contamination.

2. Check the terminals for deformation and damage.

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-56

3. Check the contact of terminals (retention force) by means the backup

positive/negative terminals.

4. Remove the terminals from connectors and check the terminals of crimped wires

for loose connection.

C1206 – Rear left wheel speed sensor: Open-circuit/short-circuit

Step

Diagnosis Action

Expected

Value

Yes

Is the check of diagnosis circuit completed?

To step 2

To step 14

1. Stop the engine.

2. Check rear left wheel speed sensor,

sensor harness, and gear ring for physical

damage?

Is there any physical damage detected?

To step 15

To step 3

Conduct the road test under various wheel

speeds on various roads.

Is C1206 reset?

Are all above connections good?

To step 4

To step 16

1. Stop the engine and park the vehicle.

2. Raise and properly support the vehicle.

3. Disconnect the harness of rear left wheel

speed sensor.

4. Connect one ohmmeter between terminal

1 and 2 of rear left wheel speed sensor.

Is the resistance value within the specified

range?

75 Ω ±1 %

To step 5

To step 17

1. Disconnect rear left wheel jumper

harness from rear left wheel speed sensor.

2. Connect one ohmmeter between the body

grounding and terminal 1 of rear left

wheel speed sensor.

Is the resistance value within the specified

range?

(Open-circuit)

To step 6

To step 17

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of rear left

wheel speed sensor.

<2 Ω

To step 7

To step 18

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-57

Step

Diagnosis Action

Expected

Value

Yes

3. Connect one ohmmeter between harness

terminal 33 of ABS control module and

terminal 2 of rear left wheel speed sensor.

Is the resistance value within the specified

range?

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of rear left

wheel speed sensor.

3. Connect one ohmmeter between harness

terminal 20 of ABS control module and

connector 1 of rear left wheel speed

sensor.

Is the resistance value within the specified

range?

<2 Ω

To step 8

To step 19

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of rear left

wheel speed sensor.

3. Connect one voltmeter between harness

terminal 33 of ABS control module and

the body grounding.

Is the voltage reading within the specified

range?

<1V

To step 9

To step 20

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of rear left

wheel speed sensor.

3. Connect one voltmeter between harness

terminal 20 of ABS control module and

the body grounding.

Is the voltage reading within the specified

range?

<1V

To step 10

To step 21

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of rear left

wheel speed sensor.

3. Connect one ohmmeter between harness

terminal 33 of ABS control module and

the body grounding.

(Open-circuit)

To step 11

To step 22

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-58

Step

Diagnosis Action

Expected

Value

Yes

Is the resistance value within the specified

range?

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of rear left

wheel speed sensor.

3. Connect one ohmmeter between harness

terminal 20 of ABS control module and

the body grounding.

Is the resistance value within the specified

range?

(Open-circuit)

To step 12

To step 23

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of rear left

wheel speed sensor.

3. Connect one ohmmeter between harness

terminal 33 and 20 of ABS control

module.

4. Is the resistance value within the

specified range?

(Open-circuit)

To step 13

To step 24

1. Replace the harness of rear left wheel

speed sensor.

2. Conduct the road test under various

wheel speeds on various roads.

Is C1206 reset?

System

To step 25

Conduct the check of diagnosis circuit

Repair the damaged rear left wheel speed

sensor, harness and/or gear ring.

Is the repair completed?

To step 26

Is DTC C1206 intermittent?

To step 26

Replace rear left wheel speed sensor.

Is the repair completed?

To step 26

Open-circuit or high resistance between repair

terminal 20 and 1.

Is the repair completed?

To step 26

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-59

Step

Diagnosis Action

Expected

Value

Yes

Open-circuit or high resistance between repair

terminal 33 and 2.

Is the repair completed?

To step 26

Short-circuit to voltage between repair

terminal 20 and 1.

Is the repair completed?

To step 26

Short-circuit to voltage between repair

terminal 33 and 2.

Is the repair completed?

To step 26

Short-circuit to ground between repair

terminal 20 and 1.

Is the repair completed?

To step 26

Short-circuit to ground between repair

terminal 33 and 2.

Is the repair completed?

To step 26

Repair short-circuit between 2 circuits.

Is the repair completed?

To step 26

Replace ABS control module.

Is the repair completed?

To step 26

Clear diagnosis trouble code with the

diagnosis instrument.

Under the conditions for setup of diagnosis

trouble code, is the diagnosis trouble code

reset?

System

To step 1

C1207 – Rear left wheel speed sensor: Overturn, performance error, and

intermittent signal

Circuit description:

While the wheel is rotating, the speed sensor generates one square wave signal

following the increasing of wheel speed. The ABS control module calculates the

wheel speed by means of the frequency of square wave signal. The speed sensor is

connected with the ABS control module via twisted pair cable.

Condition for setup of diagnosis trouble code:

To setup the DTC C1207, the following conditions must be met:

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-60

1. DTC C1200 or C1203 or C1206 or C1209 is not the current trouble code.

2. The brake switch is turned off.

3. The acceleration or deceleration of rear left wheel is out of the reasonable range.

Action at setup of diagnosis trouble code:

1. Store the diagnosis trouble code C1207.

2. Failure of ABS.

3. Light-up of ABS warning lamp.

Condition for clearing diagnosis trouble code:

1. If the condition for setup of diagnosis trouble code DTC C1207 disappears, the

diagnosis trouble code can be cleared by means of appropriate diagnosis

instrument.

2. The diagnosis trouble codes not occurred within 100 ignition periods will be

cleared from the history data.

Diagnosis tips:

During the diagnosis of intermittent diagnosis trouble code, please completely check

the wiring and connectors. This shall include:

1. Remove the protective duct and check the circuits for damage, short-circuit and

contamination.

2. Check the terminals for deformation and damage.

3. Check the contact of terminals (retention force) by means the backup

positive/negative terminals.

4. Remove the terminals from connectors and check the terminals of crimped wires

for loose connection.

C1207 – Rear left wheel speed sensor: Overturn, performance error, and intermittent

signal

Step

Diagnosis Action

Expected

Value

Yes

Is the check of diagnosis circuit completed?

To step 2

To step 12

Is the setup of DTC C1206 one current or

historic diagnosis trouble code?

To step 13

To step 3

1. Stop the engine and park the vehicle.

2. Check the rear left wheel speed sensor and

sensor harness for damage.

To step 14

To step 5

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-61

Step

Diagnosis Action

Expected

Value

Yes

3. Completely and thoroughly check the rear

left gear ring and understand the presence

of damage (crack, tooth breakage, or

looseness).

Is there any physical damage detected?

1. Park the vehicle.

2. Connect the diagnosis instrument and

select the data list.

3. Monitor the wheel speed sensor.

4. Start the engine and monitor the wheel

speed sensor while the engine is running

but the vehicle is still.

5. Lightly step down the accelerator pedal to

increase the idling speed of the engine.

Is C1207 reset or does the reading of rear left

vehicle speed exceed 0km/h while the engine is

running but the vehicle is still?

To step 15

To step 5

1. Keep the diagnosis instrument connected.

2. Monitor the wheel speed sensor.

3. Test run the vehicle to the maximum limit

speed and then slowly decelerate to zero.

Repeat above process for several times.

Is C1207 reset or does the speed variation of

rear left wheel exceed 5km/h compared with

any other wheel during the driving?

To step 6

To step 16

1. Stop the engine and park the vehicle.

2. Raise and properly support the vehicle.

3. Disconnect the harness of rear left wheel

speed sensor.

4. Connect one ohmmeter between two

terminals of rear left wheel speed sensor.

Is the resistance value within the specified

range?

75 Ω ±1 %

To step 7

To step 17

1. Keep the wheel speed sensor disconnected

from the jumper cable.

2. Connect one voltmeter between two

terminals of rear left wheel speed sensor.

3. Select the AC mV scale.

Min 100mV

To step 8

To step 17

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-62

Step

Diagnosis Action

Expected

Value

Yes

4. Observe the voltage reading on the

voltmeter while rotating the rear left

wheel.

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of rear left

wheel speed sensor.

3. Connect one ohmmeter between harness

terminal 33 of ABS control module and

connector 2 of rear left wheel speed

sensor.

Is the resistance value within the specified

range?

<2 Ω

To step 9

To step 18

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of rear left

wheel speed sensor.

3. Connect one ohmmeter between harness

terminal 20 of ABS control module and

connector 1 of rear left wheel speed

sensor.

Is the resistance value within the specified

range?

<2 Ω

To step 10

To step 19

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of rear left

wheel speed sensor.

3. Connect one ohmmeter between harness

terminal 33 and 20 of ABS control

module.

4. Is the resistance value within the specified

range?

Open-circuit

To step 11

To step 20

1. Replace the harness of rear left wheel

speed sensor.

2. Conduct the road test under various wheel

speeds on various roads.

Is C1207 reset?

System

To step 21

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-63

Step

Diagnosis Action

Expected

Value

Yes

Before preparing the fault diagram of diagnosis

trouble code C1207, conduct the check of

diagnosis circuit.

Prepare the C1207 diagnosis diagram before

preparing the fault diagram of diagnosis trouble

code C1206.

Repair the damaged rear left wheel speed

sensor, sensor harness and/or gear ring.

Is the repair completed?

To step 22

The cause of C1207 is that the ignition noise

coupling is detected on the rear left wheel

speed sensor circuit.

Check the rear left ABS module harness and/or

sensor harness for presence of potential ignition

noise source, such as spark plug wire. When

necessary, re-arrange the wires.

Is the repair completed?

To step 22

The diagnosis trouble code C1207 is

intermittent.

Replace rear left wheel speed sensor.

Is the repair completed?

To step 22

Open-circuit or high resistance between

repair terminal 33 and 2.

Is the repair completed?

To step 22

Open-circuit or high resistance between

repair terminal 20 and 1.

Is the repair completed?

To step 22

Repair the short-circuit between 2 wires.

Is the repair completed?

To step 22

Replace ABS control module.

Is the repair completed?

To step 22

Clear diagnosis trouble code with the diagnosis

instrument.

System

To step 1

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-64

Step

Diagnosis Action

Expected

Value

Yes

Under the conditions for setup of diagnosis

trouble code, is the diagnosis trouble code

reset?

C1208 – Rear left wheel speed sensor: Invalid signal/no signal

Circuit description:

While the wheel is rotating, the speed sensor generates one square wave signal

following the increasing of wheel speed. The ECU calculates the wheel speed by

means of the frequency of square wave signal. The speed sensor is connected with the

ECU via twisted pair cable.

Condition for setup of diagnosis trouble code:

To setup the DTC C1208, the following conditions must be met:

1. DTC C1200 or C1203 or C1206 or C1209 is not the current trouble code.

2. Failure of ABS.

3. The brake switch is turned off. The rear left wheel speed equals to 0 and all other

wheel speed sensors are as below: Above 8km/h within at least 2.5s.

Condition for clearing diagnosis trouble code:

1. If the condition for setup of DTC C1208 disappears, the diagnosis trouble code

can be cleared by means of appropriate diagnosis instrument.

2. The diagnosis trouble codes not occurred within 100 ignition periods will be

cleared from the history data.

Diagnosis tips:

During the diagnosis of intermittent diagnosis trouble code, please completely check

the circuits and connectors.

This shall include:

1. Remove the protective duct and check the circuits for damage, short-circuit and

contamination.

2. Check the terminals for deformation and damage.

3. Check the contact retention force of terminals by means the backup

positive/negative terminals.

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-65

C1208 – Rear left wheel speed sensor: Invalid signal/no signal

Step

Diagnosis Action

Expected

Value

Yes

Is the check of diagnosis circuit completed?

To step 2

To step 12

1. Stop the engine.

2. Check rear left wheel speed sensor,

sensor harness, and gear ring for physical

damage?

Is there any physical damage detected?

To step 13

To step 3

Is the setup of diagnosis trouble code C1206

current or historic trouble code?

To step 14

To step 4

1. Connect the diagnosis instrument and

select the data list.

2. Monitor the wheel speed sensor.

3. Test run the vehicle at a speed of 24km/h

and then slowly decelerate the wheel

speed to zero. Repeat this process for

several times.

Is the C1208 reset or does the rear left wheel

speed suddenly drop to zero before the vehicle

fully stops?

To step 5

To step 15

1. Stop the engine.

2. Raise and properly support the vehicle.

3. Disconnect harness from ABS control

module.

4. Connect one voltmeter between harness

terminal 33 and 20 of ABS control

module.

5. Select the AC mV scale.

6. Observe the voltmeter while rotating the

rear left wheel. (The voltage shall

increase following the increasing of

wheel speed)

Is the value of square wave signal within the

specified range?

Min 100mV

To step 16

To step 6

1. Disconnect the harness of rear left wheel

speed sensor.

2. Connect one ohmmeter between two

terminals of rear left wheel speed sensor.

75 Ω ±1 %

To step 7

To step 17

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-66

Step

Diagnosis Action

Expected

Value

Yes

Is the resistance value within the specified

range?

1. Disconnect the connector of rear left

wheel speed sensor.

2. Connect one voltmeter between two

terminals of rear left wheel speed sensor.

3. Select the AC mV scale.

4. Observe the voltmeter while rotating the

rear left wheel. (The voltage shall

increase following the increasing of

wheel speed)

Is the value of square wave signal within the

specified range?

Min 100mV

To step 8

To step 17

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of rear left

wheel speed sensor.

3. Connect one ohmmeter between harness

terminal 33 and 20 of ABS control

module.

Is the resistance value within the specified

range?

(Open-circuit)

To step 9

To step 18

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of rear left

wheel speed sensor.

3. Connect one ohmmeter between terminal

20 of ABS control module harness and

terminal 1 of sensor connector.

Is the resistance value within the specified

range?

<2 Ω

To step 10

To step 19

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of rear left

wheel speed sensor.

3. Connect one ohmmeter between terminal

33 of ABS control module harness and

terminal 2 of sensor connector.

<2 Ω

To step 11

To step 20

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-67

Step

Diagnosis Action

Expected

Value

Yes

Is the resistance value within the specified

range?

1. Replace the connector of rear left wheel

speed sensor.

2. Conduct the road test under various

wheel speeds on various roads.

Is the diagnosis trouble code reset?

System

To step 16

Conduct the check of diagnosis circuit before

diagnosing this fault.

Repair the damaged rear left wheel speed

sensor, harness and/or gear ring.

Is the repair completed?

To step 21

Before taking the check procedure described

in this table, diagnose the diagnosis trouble

code C1206.

The diagnosis trouble code C1208 is

intermittent.

Replace ABS control module.

Is the repair completed?

To step 21

Replace rear left wheel speed sensor.

Is the repair completed?

To step 21

Find out and repair the short-circuit between

two circuits.

Is the repair completed?

To step 21

Open-circuit or high resistance between

repair terminal 20 and 1.

Is the repair completed?

To step 21

Open-circuit or high resistance between

repair terminal 33 and 2.

Is the repair completed?

To step 21

Clear diagnosis trouble code with the

diagnosis instrument.

System

To step 1

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-68

Step

Diagnosis Action

Expected

Value

Yes

Under the conditions for setup of diagnosis

trouble code, is the diagnosis trouble code

reset?

C1209 – Rear right wheel speed sensor: Open-circuit/short-circuit

Circuit description:

While the wheel is rotating, the speed sensor generates one square wave signal

following the increasing of wheel speed. The ABS control module calculates the

wheel speed by means of the frequency of square wave signal. The speed sensor is

connected with the ABS control module via twisted pair cable.

Condition for setup of diagnosis trouble code:

The DTC C1209 can be set whenever the ABS control module detects the

open-circuit, short-circuit to ground or to battery on the rear right wheel speed circuit.

Action at setup of diagnosis trouble code:

1. Store DTC C1209.

2. Failure of ABS.

3. Light-up of ABS warning lamp.

Condition for clearing diagnosis trouble code:

1. If the condition for setup of diagnosis trouble code DTC C1209 disappears, the

diagnosis trouble code can be cleared by means of appropriate diagnosis

instrument.

2. The diagnosis trouble codes not occurred within 100 ignition periods will be

cleared from the history data.

Diagnosis tips:

During the diagnosis of intermittent diagnosis trouble code, please completely check

the wiring and connectors. This shall include:

1. Remove the protective duct and check the circuits for damage, short-circuit and

contamination.

2. Check the terminals for deformation and damage.

3. Check the contact of terminals (retention force) by means the backup

positive/negative terminals.

4. Remove the terminals from connectors and check the terminals of crimped wires

for loose connection.

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-69

C1206 – Rear right wheel speed sensor: Open-circuit/short-circuit

Step

Diagnosis Action

Expected

Value

Yes

Is the check of diagnosis circuit completed?

To step 2

To step 14

1. Stop the engine.

2. Check rear right wheel speed sensor,

sensor harness, and gear ring for

physical damage?

Is there any physical damage detected?

To step 15

To step 3

Conduct the road test under various wheel

speeds on various roads.

Is C1209 reset?

Are all above connections good?

To step 4

To step 16

1. Stop the engine and park the vehicle.

2. Raise and properly support the vehicle.

3. Disconnect the harness of rear right

wheel speed sensor.

4. Connect one ohmmeter between

terminal 1 and 2 of rear right wheel

speed sensor.

Is the resistance value within the specified

range?

75 Ω ±1 %

To step 5

To step 17

1. Disconnect rear right wheel jumper

harness from rear right wheel speed

sensor.

2. Connect one ohmmeter between the

body grounding and terminal 1 of rear

right wheel speed sensor.

Is the resistance value within the specified

range?

(Open-circuit)

To step 6

To step 17

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of rear right

wheel speed sensor.

3. Connect one ohmmeter between harness

terminal 19 of ABS control module and

terminal 2 of rear right wheel speed

sensor.

<2 Ω

To step 7

To step 18

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-70

Step

Diagnosis Action

Expected

Value

Yes

Is the resistance value within the specified

range?

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of rear right

wheel speed sensor.

3. Connect one ohmmeter between harness

terminal 31 of ABS control module and

connector 1 of rear right wheel speed

sensor.

Is the resistance value within the specified

range?

<2 Ω

To step 8

To step 19

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of rear right

wheel speed sensor.

3. Connect one voltmeter between harness

terminal 19 of ABS control module and

the body grounding.

Is the voltage reading within the specified

range?

<1V

To step 9

To step 20

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of rear right

wheel speed sensor.

3. Connect one voltmeter between harness

terminal 31 of ABS control module and

the body grounding.

Is the voltage reading within the specified

range?

<1V

To step 10

To step 21

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of rear right

wheel speed sensor.

3. Connect one ohmmeter between harness

terminal 19 of ABS control module and

the body grounding.

Is the resistance value within the specified

range?

(Open-circuit)

To step 11

To step 22

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-71

Step

Diagnosis Action

Expected

Value

Yes

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of rear right

wheel speed sensor.

3. Connect one ohmmeter between harness

terminal 31 of ABS control module and

the body grounding.

Is the resistance value within the specified

range?

(Open-circuit)

To step 12

To step 23

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of rear right

wheel speed sensor.

3. Connect one ohmmeter between harness

terminal 19 and 31 of ABS control

module.

4. Is the resistance value within the

specified range?

(Open-circuit)

To step 13

To step 24

1. Replace the harness of rear right wheel

speed sensor.

2. Conduct the road test under various

wheel speeds on various roads.

Is C1209 reset?

System Ok

To step 25

Conduct the check of diagnosis circuit

Repair the damaged rear right wheel speed

sensor, harness and/or gear ring.

Is the repair completed?

To step 26

Is DTC C1209 intermittent?

To step 26

Replace rear right wheel speed sensor.

Is the repair completed?

To step 26

Open-circuit or high resistance between

repair terminal 31 and 1.

Is the repair completed?

To step 26

Open-circuit or high resistance between

repair terminal 19 and 2.

To step 26

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-72

Step

Diagnosis Action

Expected

Value

Yes

Is the repair completed?

Short-circuit to voltage between repair

terminal 31 and 1.

Is the repair completed?

To step 26

Short-circuit to voltage between repair

terminal 19 and 2.

Is the repair completed?

To step 26

Short-circuit to ground between repair

terminal 31 and 1.

Is the repair completed?

To step 26

Short-circuit to ground between repair

terminal 19 and 2.

Is the repair completed?

To step 26

Repair short-circuit between 2 circuits.

Is the repair completed?

To step 26

Replace ABS control module.

Is the repair completed?

To step 26

Clear diagnosis trouble code with the

diagnosis instrument.

Under the conditions for setup of diagnosis

trouble code, is the diagnosis trouble code

reset?

System Ok

To step 1

C1210 – Rear right wheel speed sensor: Overturn, performance error, and

intermittent signal

Circuit description:

While the wheel is rotating, the speed sensor generates one square wave signal

following the increasing of wheel speed. The ABS control module calculates the

wheel speed by means of the frequency of square wave signal.

Condition for setup of diagnosis trouble code:

To setup the DTC C1210, the following conditions must be met:

1. DTC C1200 or C1203 or C1206 or C1209 is not the current trouble code.

2. The brake switch is turned off.

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-73

3. The acceleration or deceleration of rear right wheel is out of the reasonable

range.

Action at setup of diagnosis trouble code:

1. Store the diagnosis trouble code DTC C1210.

2. Failure of ABS.

3. Light-up of ABS warning lamp.

Condition for clearing diagnosis trouble code:

1. If the condition for setup of diagnosis trouble code DTC C1210 disappears, the

diagnosis trouble code can be cleared by means of appropriate diagnosis

instrument.

2. The diagnosis trouble codes not occurred within 100 ignition periods will be

cleared from the history data.

Diagnosis tips:

During the diagnosis of intermittent diagnosis trouble code, please completely check

the wiring and connectors. This shall include:

1. Remove the protective duct and check the circuits for damage, short-circuit and

contamination.

2. Check the terminals for deformation and damage.

3. Check the contact of terminals (retention force) by means the backup

positive/negative terminals.

4. Remove the terminals from connectors and check the terminals of crimped wires

for loose connection.

C1210 – Rear right wheel speed sensor: Overturn, performance error, and intermittent

signal

Step

Diagnosis Action

Expected

Value

Yes

Is the check of diagnosis circuit completed?

To step 2

To step 12

Is the setup of DTC C1209 one current or

historic diagnosis trouble code?

To step 13

To step 3

1. Stop the engine and park the vehicle.

2. Check the rear right wheel speed sensor

and sensor harness for damage.

3. Completely and thoroughly check the

rear right gear ring and understand the

presence of damage (crack, tooth

breakage, or looseness).

To step 14

To step 5

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-74

Step

Diagnosis Action

Expected

Value

Yes

Is there any physical damage detected?

1. Park the vehicle.

2. Connect the diagnosis instrument and

select the data list.

3. Monitor the wheel speed sensor.

4. Start the engine and monitor the wheel

speed sensor while the engine is running

but the vehicle is still.

5. Lightly step down the accelerator pedal

to increase the idling speed of the engine.

Is C1210 reset or does the reading of rear

right vehicle speed exceed 0km/h while the

engine is running but the vehicle is still?

To step 15

To step 5

1. Keep the diagnosis instrument

connected.

2. Monitor the wheel speed sensor.

3. Test run the vehicle to the maximum

limit speed and then slowly decelerate to

zero. Repeat above process for several

times.

Is C1210 reset or does the speed variation of

rear right wheel exceed 5km/h compared with

any other wheel during the driving?

To step 6

To step 16

1. Stop the engine and park the vehicle.

2. Raise and properly support the vehicle.

3. Disconnect the harness of rear right

wheel speed sensor.

4. Connect one ohmmeter between two

terminals of rear right wheel speed

sensor.

Is the resistance value within the specified

range?

75 Ω ±1 %

To step 7

To step 17

1. Keep the wheel speed sensor

disconnected from the jumper cable.

2. Connect one voltmeter between two

terminals of rear right wheel speed

sensor.

3. Select the AC mV scale.

Min 100mV

To step 8

To step 17

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-75

Step

Diagnosis Action

Expected

Value

Yes

4. Observe the voltage reading on the

voltmeter while rotating the rear right

wheel.

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of rear right

wheel speed sensor.

3. Connect one ohmmeter between harness

terminal 19 of ABS control module and

connector 2 of rear right wheel speed

sensor.

Is the resistance value within the specified

range?

<2 Ω

To step 9

To step 18

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of rear right

wheel speed sensor.

3. Connect one ohmmeter between harness

terminal 31 of ABS control module and

connector 1 of rear right wheel speed

sensor.

Is the resistance value within the specified

range?

<2 Ω

To step 10

To step 19

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of rear right

wheel speed sensor.

3. Connect one ohmmeter between harness

terminal 19 and 31 of ABS control

module.

4. Is the resistance value within the

specified range?

(Open-circuit)

To step 11

To step 20

1. Replace the harness of rear right wheel

speed sensor.

2. Conduct the road test under various

wheel speeds on various roads.

Is C1210 reset?

System Ok

To step 21

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-76

Step

Diagnosis Action

Expected

Value

Yes

Before preparing the fault diagram of

diagnosis trouble code C1210, conduct the

check of diagnosis circuit.

Prepare the C1210 diagnosis diagram before

preparing the fault diagram of diagnosis

trouble code C1209.

Repair the damaged rear right wheel speed

sensor, sensor harness and/or gear ring.

Is the repair completed?

To step 22

The cause of C1210 is that the ignition noise

coupling is detected on the rear right wheel

speed sensor circuit.

Check the rear right ABS module harness

and/or sensor harness for presence of potential

ignition noise source, such as spark plug wire.

When necessary, re-arrange the wires.

Is the repair completed?

To step 22

The diagnosis trouble code C1210 is

intermittent.

Replace rear right wheel speed sensor.

Is the repair completed?

To step 22

Open-circuit or high resistance between

repair terminal 19 and 2.

Is the repair completed?

To step 22

Open-circuit or high resistance between

repair terminal 31 and 1.

Is the repair completed?

To step 22

Repair the short-circuit between 2 wires.

Is the repair completed?

To step 22

Replace ABS control module.

Is the repair completed?

To step 22

Clear diagnosis trouble code with the

diagnosis instrument.

System Ok

To step 1

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-77

Step

Diagnosis Action

Expected

Value

Yes

Under the conditions for setup of diagnosis

trouble code, is the diagnosis trouble code

reset?

C1211 – Rear right wheel speed sensor: Invalid signal/no signal

Circuit description:

While the wheel is rotating, the speed sensor generates one square wave signal

following the increasing of wheel speed. The ECU calculates the wheel speed by

means of the frequency of square wave signal. The speed sensor is connected with the

ECU via twisted pair cable.

Condition for setup of diagnosis trouble code:

To setup the DTC C1211, the following conditions must be met:

1. DTC C1200 or C1203 or C1206 or C1209 is not the current trouble code.

2. Failure of ABS.

3. The brake switch is turned off. The rear right wheel speed equals to 0 and all

other wheel speed sensors are as below: Above 8km/h within at least 2.5s.

Condition for clearing diagnosis trouble code:

1. If the condition for setup of DTC C1211 disappears, the diagnosis trouble code

can be cleared by means of appropriate diagnosis instrument.

2. The diagnosis trouble codes not occurred within 100 ignition periods will be

cleared from the history data.

Diagnosis tips:

During the diagnosis of intermittent diagnosis trouble code, please completely check

the circuits and connectors.

This shall include:

1. Remove the protective duct and check the circuits for damage, short-circuit and

contamination.

2. Check the terminals for deformation and damage.

3. Check the contact retention force of terminals by means the backup

positive/negative terminals.

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-78

C1211 – Rear right wheel speed sensor: Invalid signal/no signal

Step

Diagnosis Action

Expected

Value

Yes

Is the check of diagnosis circuit completed?

To step 2

To step 12

1. Stop the engine.

2. Check rear right wheel speed sensor,

sensor harness, and gear ring for physical

damage?

Is there any physical damage detected?

To step 13

To step 3

Is the setup of diagnosis trouble code C1209

current or historic trouble code?

To step 14

To step 4

1. Connect the diagnosis instrument and

select the data list.

2. Monitor the wheel speed sensor.

3. Test run the vehicle at a speed of 24km/h

and then slowly decelerate the wheel

speed to zero. Repeat this process for

several times.

Is the C1211 reset or does the rear right wheel

speed suddenly drop to zero before the vehicle

fully stops?

To step 5

To step 15

1. Stop the engine.

2. Raise and properly support the vehicle.

3. Disconnect harness from ABS control

module.

4. Connect one voltmeter between harness

terminal 19 and 31 of ABS control

module.

5. Select the mV scale.

6. Observe the voltmeter while rotating the

rear right wheel. (The voltage shall

increase following the increasing of

wheel speed)

Is the voltage reading within the specified

range?

Min 100mV

To step 16

To step 6

1. Disconnect the harness of rear right

wheel speed sensor.

75 Ω ±1 %

To step 7

To step 17

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-79

Step

Diagnosis Action

Expected

Value

Yes

2. Connect one ohmmeter between two

terminals of rear right wheel speed

sensor.

Is the resistance value within the specified

range?

1. Disconnect the connector of rear right

wheel speed sensor.

2. Connect one voltmeter between two

terminals of rear right wheel speed

sensor.

3. Select the mV scale.

4. Observe the voltmeter while rotating the

rear right wheel. (The voltage shall

increase following the increasing of

wheel speed)

Is the voltage reading within the specified

range?

Min 100mV

To step 8

To step 17

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of rear right

wheel speed sensor.

3. Connect one ohmmeter between harness

terminal 19 and 31 of ABS control

module.

Is the resistance value within the specified

range?

(Open-circuit)

To step 9

To step 18

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of rear right

wheel speed sensor.

3. Connect one ohmmeter between terminal

31 of ABS control module harness and

terminal 1 of sensor connector.

Is the resistance value within the specified

range?

<2 Ω

To step 10

To step 19

1. Disconnect harness from ABS control

module.

2. Disconnect the connector of rear right

wheel speed sensor.

<2 Ω

To step 11

To step 20

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-80

Step

Diagnosis Action

Expected

Value

Yes

3. Connect one ohmmeter between terminal

19 of ABS control module harness and

terminal 2 of sensor connector.

Is the resistance value within the specified

range?

1. Replace the connector of rear right wheel

speed sensor.

2. Conduct the road test under various

wheel speeds on various roads.

Is the diagnosis trouble code reset?

System

To step 16

Conduct the check of diagnosis circuit before

diagnosing this fault.

Repair the damaged rear right wheel speed

sensor, harness and/or gear ring.

Is the repair completed?

To step 21

Before taking the check procedure described

in this table, diagnose the diagnosis trouble

code C1209.

The diagnosis trouble code C1211 is

intermittent.

Replace ABS control module.

Is the repair completed?

To step 21

Replace rear right wheel speed sensor.

Is the repair completed?

To step 21

Find out and repair the short-circuit between

two circuits.

Is the repair completed?

To step 21

Open-circuit or high resistance between

repair terminal 31 and 1.

Is the repair completed?

To step 21

Open-circuit or high resistance between

repair terminal 19 and 2.

Is the repair completed?

To step 21

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-81

Step

Diagnosis Action

Expected

Value

Yes

Clear diagnosis trouble code with the

diagnosis instrument.

Under the conditions for setup of diagnosis

trouble code, is the diagnosis trouble code

reset?

System

To step 1

C1213 – Wheel speed sensor frequency error (common wheel speed sensor fault,

missing tooth, or tooth quantity error)

Please refer to the fault check of C1202, C1205, C1208 and C1211 for this check

procedure.

C1604 – Hardware fault of ABS control module

Circuit description:

This diagnosis trouble code determines the possible faults in the ABS control module.

Condition for setup of diagnosis trouble code:

The DTC C1604 will be set in event of possible fault of internal

components/microprocessor.

Action at setup of diagnosis trouble code:

1. The solenoid relay is turned off to cut off the power of reflux pump and the

solenoid.

2. Failure of ABS.

3. Store DTC C1604.

4. Light-up of ABS warning lamp and brake warning lamp.

Condition for clearing diagnosis trouble code:

1. If the condition for setup of DTC C1604 disappears, the diagnosis trouble code

can be cleared by means of appropriate diagnosis instrument.

2. The diagnosis trouble codes not occurred within 100 drive periods will be

cleared from the history data.

Diagnosis tips:

1. While displaying the DTC C1604 on the diagnosis instrument, the trouble code

shall be succeeded with two numbers (XX), which shall be recorded along with

other DTCs capable of being displayed.

2. Before conducting the DTC C1604 fault tree analysis, firstly repair the low

voltage, driving performance or other electric faults.

3. Make sure that the overall connection between the ABS control module and ABS

hydraulic assembly is reliable and secure, without any corrosion, leakage and/or

damage.

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-82

C1604 – Hardware fault of ABS control module

Step

Diagnosis Action

Expected

Value

Yes

Is the check of diagnosis circuit completed?

To step 2

To step 5

1. Install the diagnosis instrument.

2. Turn off the ignition switch under the

condition that the engine is stopped.

3. Observe the information of diagnosis

trouble code by means of the diagnosis

instrument.

Is there the setup of any diagnosis trouble code

in the current or historic data other than C1604

XX?

To step 6

To step 3

1. Stop the engine.

2. Disconnect the ABS control module harness

from the ABS control module.

3. Check the connectors for damage and

corrosion and check the terminals for

mutual contact.

Is there problem detected?

To step 7

To step 4

Replace ABS control module.

Is the repair completed?

To step 8

Conduct the check of diagnosis circuit

For other diagnosis trouble codes, take

corresponding diagnosis for these trouble codes.

Repair when necessary.

Is the repair completed?

To step 8

Clear diagnosis trouble code with the diagnosis

instrument.

Under the conditions for setup of diagnosis

trouble code, is the diagnosis trouble code reset?

System OK

To step 1

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-83

C1212 – Valve relay fault

Circuit description:

This diagnosis trouble code determines the possible faults in the ABS control module.

Activate the ABS control module relay (actuation); power the coil of solenoid valve

and the reflux pump.

Condition for setup of diagnosis trouble code:

In event of possible internal faults, the DTC C2112 is set.

Action at setup of diagnosis trouble code:

1. The ABS warning lamp is not lighted up.

2. Store DTC C2112.

3. The ABS is still functionable.

Condition for clearing diagnosis trouble code:

1. If the condition for setup of DTC C2112 disappears, the diagnosis trouble code

can be cleared by means of appropriate diagnosis instrument.

2. The diagnosis trouble codes not occurred within 100 drive periods will be

cleared from the history data.

Diagnosis tips:

1. Before conducting the DTC C2112 fault tree analysis, firstly repair the low

voltage, driving performance or other electric faults.

2. Make sure that the overall connection between the ABS control module and ABS

hydraulic assembly is reliable and secure, without any corrosion, leakage and/or

damage.

3. The setup of DTC C2112 is possibly caused by the internal relay fault of the

ABS control module.

C1212 – Valve relay fault

Step

Diagnosis Action

Expected

Value

Yes

Is the check of diagnosis circuit completed?

To step 2

To step 5

1. Install the diagnosis instrument.

2. Turn off the ignition switch under the

condition that the engine is stopped.

3. Observe the information of diagnosis

trouble code by means of the diagnosis

instrument.

To step 6

To step 3

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-84

Step

Diagnosis Action

Expected

Value

Yes

Does the diagnosis instrument display any

diagnosis trouble code set in the current or

historic data at C2112?

1. Stop the engine.

2. Disconnect the ABS control module harness

from the ABS control module.

3. Check the connectors for damage and

corrosion and check the terminals for

mutual contact.

Is there problem detected?

To step 7

To step 4

Replace ABS control module.

Is the repair completed?

To step 8

Conduct the check of diagnosis circuit

Conduct relevant diagnosis for other diagnosis

trouble codes.

Repair when necessary.

Is the repair completed?

To step 8

Clear diagnosis trouble code with the diagnosis

instrument.

Under the conditions for setup of diagnosis

trouble code, is the diagnosis trouble code reset?

System Ok

To step 1

C2308, C2312, C2316, C2320, C2324, C2328, C2332, C2336 – Inlet valve or

outlet valve fault

Circuit description:

The inlet valve coil or the outlet valve coil is one inseparable part of the ABS control

module. When the ignition switch is turned on, the battery powers the coil so that the

solenoid relay is actuated. When necessary, the ABS control module controls the

solenoid valve by grounding the related coil circuit.

Condition for setup of diagnosis trouble code:

When the ABS control module sensor is short-circuited or open-circuited to the

ground or any inlet valve coil or outlet valve coil is short-circuited to the power

supply, the corresponding diagnosis trouble code will be set.

Action at setup of diagnosis trouble code:

1. The solenoid relay opens to cut off the power supply of solenoid valve.

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-85

2. Store corresponding DTC.

3. The ABS fails and the ABS warning lamp lights up.

Condition for clearing diagnosis trouble code:

1. If the condition for setup of DTC C2308 via DTC C2336 disappears, the

diagnosis trouble code can be cleared by means of appropriate diagnosis

instrument.

2. The diagnosis trouble codes not occurred within 100 drive periods will be

cleared from the history data.

Diagnosis tips:

Make sure that the overall connection between the ABS control module and ABS

hydraulic assembly is reliable and secure, without any corrosion. As the solenoid

valve coil is one integral part of the ABS control module, the setup of any diagnosis

trouble code is generally the internal fault of the ABS control module.

C2308, C2312, C2316, C2320, C2324, C2328, C2332, C2336 – Inlet valve or outlet

valve fault

Step

Diagnosis Action

Expected

Value

Yes

Is the check of diagnosis circuit

completed?

To step 2

To step 5

1. Stop the engine.

2. Check the ABS control module

and ABS hydraulic assembly for

physical damage.

Is there any physical damage detected?

To step 6

To step 3

1. Disconnect the ABS control

module harness from the ABS

control module.

2. Remove the ABS control module

from the ABS hydraulic assembly.

3. Check the internal chamber of

ABS control module and ABS

hydraulic assembly for liquid

leakage, corrosion and/or damage.

Does the internal chamber have any

liquid leakage, damage or corrosion?

To step 7

To step 4

1. Install the diagnosis instrument.

2. Under the condition that the

engine is stopped, start the engine.

To step 8

For intermittent

fault, to step 5

J5 AT Sedan Service Manual

Anti-Lock Brake System (ABS)

ABS-86

Step

Diagnosis Action

Expected

Value

Yes

3. Clear diagnosis trouble code with

the diagnosis instrument.

4. Drive the vehicle under the

condition that the diagnosis

trouble code is set.

5. Is the diagnosis trouble code reset

to current diagnosis trouble code?

Conduct the check of diagnosis circuit

Is there problem detected?

To corresponding

procedure

System OK

Replace damaged components.

Is the repair completed?

To step 9

Replace ABS control module and ABS

hydraulic assembly.

Is the repair completed?

To step 9

Replace ABS control module.

Is the repair completed?

To step 9

Clear diagnosis trouble code with the

diagnosis instrument.

Under the conditions for setup of

diagnosis trouble code, is the diagnosis

trouble code reset?

System Ok

To step 1

J5 AT Sedan Service Manual

Power Steering System

PS-1

Steering

Power Steering System

Precautions

 When checking the steering system, park the vehicle on level and dry ground.

 The bolts for various components of the steering system must be tightened to the

specified torque.

 At completion of checking and repair of steering gear and other steering

mechanism, check the wheel alignment.

 The maximum flow rate of the system shall not exceed 10L/min and the

maximum working pressure shall not exceed 8MPa.

 When one new steering gear drives for 2,500km, replace the hydraulic oil and

clean the filter in the oil reservoir. Afterwards, replace the hydraulic oil and clean

the oil reservoir once a year or every 50,000km.

 Frequently check the tire pressure and maintain within the specification.

 In event of any abnormal clearance, stagnation, or snaking, analyze in which

portion of the steering drive unit, power steering system or steering linkage

system this problem occurs and resolve accordingly.

 Carefully check whether the parts of the steering system are under the application

of abnormal impact frequently. The damaged parts or defective parts shall be

replaced timely.

 Never weld the parts of steering gear and system members by any means.

 Make sure that the pipeline is free of knocking and wear during the working and

various segments are in proper tension, without any dead bends.

 Once a month, check whether the quantity of hydraulic oil is reduced and check

the oil for deterioration and excessive impurities. In event of any abnormal status,

replace the oil timely. While adding the hydraulic oil, the new hydraulic oil added

shall be of same trademark of the old hydraulic oil of the power steering system

and the mixing of oils is strictly prohibited.

Preparations

List of Special Tools

Tool

Outline drawing

No.

Description

Puller of steering wheel

JAC-T1D002

For removal of steering

wheel

J5 AT Sedan Service Manual

Power Steering System

PS-2

List of Common Tools

Tool

Outline drawing

Description

Power tool

For removal and installation of bolts and nuts

Overview of Power Steering System

The power steering system is installed onto the vehicle with a purpose of reducing the

working strength of the driver. At the beginning, it’s mainly installed onto heavy-duty

vehicles. Following the high-speed trend of the cars and the increasing of load onto

the steering wheels, the power system has become one essential system and was

applied more widely. The power steering system features the advantages as below:

 Reduce the steering force applied onto the steering wheel, and especially provide

great assistance during pivot steering and wide-angle steering at low speed.

 Promote the steering sensitivity.

 Reduce the impact onto the steering wheel under the kickback of the ground.

 In event of the burst of certain tire, better prevent the sudden steering of wheels

and thus improve the steering safety.

 Allow the higher load of steering wheels and increase the freedom degree of the

overall arrangement.

Composition of Power Steering System:

The automotive power steering system consists of the power steering gear, power

steering pump, power steering oil reservoir, and hydraulic pipeline. In which, the

power steering gear is the hydraulic power actuator of the steering system, the

steering oil pump is linked with the engine to provide hydraulic power source to the

system, and the steering oil reservoir exerts the functions of storage, cooling-down

and oil filtration.

The structure of the power steering system is shown in the figure below:

Structural Diagram of Power Steering System

1- Power steering pump 2- Power steering oil reservoir 3- Hydraulic pipeline 4- Power

steering gear

J5 AT Sedan Service Manual

Power Steering System

PS-3

Brief to structure of rack & pinion power steering gear

The rack & pinion power steering gear consists of the control valve, mechanical

steering gear, and power steering pump. The control valve is one rotary valve with

advanced structure and high sensitivity and the mechanical steering gear is of rack &

pinion type.

Control valve:

As shown in the figure below, the control valve is one normally open rotary valve

consisted of torsion rod 1, input shaft 2, and valve bush 3. Through the pre-fabricated

clearance between the input shaft 2 and the valve bush 3, the hydraulic oil is inputted

into the left and right oil chambers.

Structural Diagram of Control Valve

1- Torsion rod 2- Input shaft 3- Valve bush

Mechanical steering part:

The mechanical steering part is of rack & pinion type and consists of the gear shaft,

rack piston assembly, and steering tie rod.

Power steering pump:

The power steering pump has one metallic housing and its internal rack piston divides

it into left and right oil chambers, which are connected to two oil ports of the control

valve respectively.

Working Principle

Neutral position:

When the vehicle drives linearly (the steering wheel is still), the oil pump feeds in the

hydraulic oil through the oil inlet port. After flowing through the pre-fabricated

clearance of the rotary valve, as the rotary valve is still at that time, the hydraulic oil

returns to the oil reservoir through the oil return port. In such case, the pressures for

two working chambers of the steering gear are equal and no power assistance is

generated.

Steering process:

While rotating the steering wheel, the clearance between the valve bush and the input

shaft varies so that the hydraulic oil flowing to two working chambers forms the

pressure difference. This pressure difference is applied onto the piston and drives to

Oil return

Oil inlet

To right

chamber

J5 AT Sedan Service Manual

Power Steering System

PS-4

the piston to generate displacement by overcoming the steering resistance, which

drives the movement of steering tie rod assembly to realize the power steering.

Return process:

At completion of the steering, the force applied onto the steering wheel disappears.

Under the elastic force of the torsion rod, the input shaft returns to the balance

position relative to the valve bush so that the pressure difference between two

working chambers of the steering gear disappears accordingly. Therefore, under the

application of automatic aligning torque of the front wheels, the vehicle moves

towards the linear movement, till the vehicle returns to the linear driving.

Road feeling effect:

Road feeling effect is the capability generating the steering feeling. When the driver

applies the force onto the steering wheel, at the same time applies to the torsion rod of

the steering gear and enables to cause torsional deformation. The amount of this

deformation depends on the steering resistance of the wheels. When the steering

resistance increases, this deformation also increases. Therefore, the driver can judge

the variation of steering resistance based on the size of the force he applied onto the

steering wheel and thus obtain the “Road feeling” effect.

Power Steering Fluid

Check the fluid level:

1) Make sure to check the fluid level

when the engine is stopped.

2) Confirm that the fluid level is

between MIN and MAX.

Notice:

 The fluid level shall not exceed the maximum value (marking MAX) in order to

prevent the leakage of power steering fluid.

Recommended oil: ATF-Ⅲ

3) Never re-use the drained power steering fluid.

PS001

J5 AT Sedan Service Manual

Power Steering System

PS-5

Check the leakage of steering fluid:

1) Check the hydraulic connectors for oil

leakage, cracking, damage, looseness or

wear.

① Run the engine to heat up the

temperature of the fluid in the power

steering oil reservoir to 50~80ºC

(122~176ºF) and maintain the engine at

idling.

② Rotate the steering wheel leftward and rightward to limit position for several

times.

③ Hold the steering wheel at the locking point for 5s and at the same time check for

oil leakage.

④ In event of oil leakage at joints, loosen the nuts of oil pipes and re-tighten to the

specified torque.

 Tightening torque: 57~63N.m

Notice:

 Do not excessively tighten the connecting nuts, in order to prevent damaging the

O-rings, washers, and connectors.

⑤ In event of oil leakage from the power steering pump, please check the power

steering pump.

⑥ Check the dust cap of steering gear for oil accumulation.

Bleed the air from the hydraulic system:

It will lead to following phenomena if the air bleeding is not completed:

 Air bubble in the power steering oil reservoir.

 Noise in the power steering pump.

Notice:

 The power steering pump will have liquid noise during the functioning, which

will not impair the performance or durability of the system.

1) Stop the engine and rotate the steering wheel leftward or rightward to limit

position for several times.

Notice:

 While adding the oil to the power steering oil reservoir, rotate the steering wheel

to make sure that the oil level is not below the marking MIN.

PS002

Rupture of oil pipe

Oil pipe nut

Hose clamp

Hose rupture

Eyebolt

J5 AT Sedan Service Manual

Power Steering System

PS-6

2) Start the engine and run at idling. Then, hold the steering wheel at the locking

point for 3s and check for oil leakage.

3) Repeat above step 2) for several times at internals of 3s.

Notice:

 Do not hold the steering wheel at locking point for more than 10s in order to

prevent damaging the power steering pump.

4) Check the oil for air bubbles or white impurities.

5) If the air bubbles or white impurities are not fully bled, please stop the engine.

Conduct above step 2)~3) after the air bubbles or white impurities are fully bled.

6) Stop the engine and check the oil level.

Notice:

 Check whether the variation of oil level in the power steering oil reservoir is

within 5mm between the running status and stop status of the engine.

 If it’s out of the above range, repeat the air bleeding of the steering system.

Replacement of Power Steering Fluid:

1) Lift the front wheels of the vehicle.

Notice:

 Secure with rigid support.

2) Remove the oil return pipe from the power steering oil reservoir and plug the oil

return port of the power steering oil reservoir.

3) Connect the oil return pipe with the common oil pipe and drain the power

steering fluid into one container.

4) Start the engine and rotate the steering wheel leftward and rightward to drain the

power steering fluid.

Notice:

 Add the power steering fluid timely to maintain the fluid level between MIN and

MAX, in order to prevent the dry friction of the power steering pump.

 Do not run the engine for a long period. Stop the engine while the fluid level is

lowered to position MIN.

5) Connect the oil return pipe and add new power steering fluid to the specified

level.

6) If the quality of new power steering fluid added fails to meet the ideal

requirement, operate according to step 2)~5).

Notice:

 After the replacement, bleed the air from the system.

J5 AT Sedan Service Manual

Power Steering System

PS-7

Check of Tension of Power Steering Pump Pulley

When applying a 100N force onto the middle top of the V-belt between the power

steering pump and the engine crankshaft, the deflection of the V-belt shall be within

11.7~15.3mm. Otherwise, loosen the tensioner adjusting bolt and adjust the tension of

the belt to meet the specification.

Steering wheel

On board Checking:

1) Check the installation status

① Check the installation status of the steering gear assembly, front suspension, axle,

and the steering column.

② Check the steering wheel for movement clearance in vertical, lateral, and axial

directions.

③ Check the fixing nuts and bolts of the steering gear assembly for looseness.

2) Check the free stroke of the steering wheel.

① Rotate the steering wheel to position the front wheels to straight forward position.

Start the engine and slightly rotate the steering wheel leftward and rightward, till

the front wheels start movement. Measure the movement of steering wheel on

the circumcircle.

 Free stroke of steering wheel: 30mm

② If the measurement is out of above specification, check the installation status of

each connector of steering column and the steering mechanism. Depending on

the actual condition, correct or replace related components.

③ If the free stroke still exceeds 30mm, stop the engine, position the front wheels to

straight forward position, apply a 5N force along the circumference of the

steering wheel, and check the idle stroke. This idle stroke shall not exceed 10mm.

If the measurement exceeds 10mm, check whether the steering gear assembly

meets the requirement.

④ If this measurement is still at limit value, stop the engine, position the steering

wheel at neutral position, apply a 4±0.6N force on the circumcircle of the

steering wheel, and check the free stroke.

 Standard value: <15mm.

⑤ If the measurement exceeds the standard value, remove the steering gear and

check the overall torque of the pinion.

3) Check the neutral position.

① Confirm that the steering gear assembly, steering column, and steering wheel are

installed correctly.

② After the wheels are aligned, conduct the checking of neutral position. Please

refer to “Check of Alignment of Front Wheels”.

J5 AT Sedan Service Manual

Power Steering System

PS-8

③ Park the vehicle in straight forward position and make sure that the steering

wheel is at neutral position.

④ Loosen the lock nut of tie rod, rotate the adjusting lever leftward and rightward

for fine adjustment, and confirm whether the steering wheel is at neutral position.

4) Check the static steering force of the steering wheel

① Park the vehicle on level and dry ground and apply the parking brake lever.

② Start the engine.

③ Run the engine to head up the power steering fluid to working temperature.

Notice:

 The air pressure of the tires shall be within the specification.

④ Rotate the steering from the neutral position by 360º and check the rotating force

of the steering and check for obvious variation.

 Steering force of steering wheel: <34N Allowable variation: <5.9N

⑤ If the steering force of the steering wheel exceeds the specified value, please

check or adjust the following items:

a. Check the lower swing arm and steering tie rod ball joint for damage.

b. Check the gear preload of steering gear and the rotating torque of the steering tie

rod ball joint.

c. Check the rotating torque of lower swing arm ball joint.

5) Check the automatic return of steering wheel

Notice:

 Make slow and sudden turns and confirm by feeling whether there is difference

between left and right directions in terms of applied force and the return status.

 Make sure to conduct this step on safe roads and traffic conditions and take care.

① Rotate the steering wheel by 90º, drive

at a speed of 35km/h, and maintain for

several seconds. Then, release the

steering wheel. In such case, the return

amount of the steering wheel shall be

more than 70%.

Notice:

 If there is the temporary “Heavy”

feeling at the rapid rotation of the

steering wheel, this is caused by the

insufficient oil supply of the power

steering pump during the idling and is

not one fault.

PS003

J5 AT Sedan Service Manual

Power Steering System

PS-9

6) Check the front wheel steering angle

① Check the front wheel steering angle after checking the front wheel toe-in. Place

the front wheel at the steering angle measuring instrument (Front wheel aligned

steering wheel) and check the maximum internal/external steering angle of the

left and right wheels.

 Internal wheel: 38.3°±1°30’

External wheel: 32.5°±1°30’

② While the engine runs at idling, rotate the steering leftward or rightward to limit

position and measure the steering angle.

 If the measurement is out of the standard range, adjust the tie rod.

The adjusting method of the steering angle is as below:

When the steering angle is out of the standard range, loosen the lock nut of left and

right steering tie rods and rotate the left and right steering tie rods with wrench to

adjust the steering angle to standard range. Then, secure the lock nuts and tighten to

45~55N.m. While adjusting the length of left and right tie rods (the length shown in

figure below), notice to guarantee the consistence length of left and right tie rods

(208.7mm, in reverse direction).

Diagram of Tie Rod

Notice:

 When the internal wheel steering angle is out of tolerance, adjust the tie rod at

this side and rotate outward to increase the internal wheel steering angle. When

the external wheel steering angle is out of tolerance, adjust the tie rod at this side

and rotate outward to reduce the external wheel steering angle

Notice:

 The toe-in is directly related to other 4-wheel alignment parameters and the

adjustment of steering angle.

7) Check the ball joint dust cap.

PS004

J5 AT Sedan Service Manual

Power Steering System

PS-10

① Press with fingers to check the dust cap for cracking or damage.

② In event of cracking or damage of the dust cap, make sure to replace the tie rod

ball joint.

Notice:

 The cracked or damaged dust cap may lead to the damage of ball joint.

8) Check the rotating torque of steering

tie rod ball joint

① Rapidly swing the tie rod for 10 times.

② Measure the swing resistance of tie rod

with the spring balance.

 Standard value: 2~5 N·m

 If the measurement is out of the

standard value, please replace.

Removal and Installation:

1) Removal

① Disconnect the cathode terminal of

battery and wait for more than 3min.

② Remove the driver airbag module

from the steering wheel.

③ Remove the fixing nut of steering

wheel after the steering wheel is

locked.

 Tightening torque: 35～45 N·m

④ Lift the steering wheel from the steering column.

Note: If it’s difficult to lift, please use the steering wheel puller.

2) Installation

Installation is the reverse order of removal.

Notice:

 The installation must be fulfilled under the conditions that the wheels are at

straight forward position and the steering wheel is at neutral position.

Alternatively, add the markings to the steering wheel and fixing bolts before the

removal and make sure to align the markings during the installation.

 Under the installation status, the steering column must rotate smoothly, without

any click sound or viscous phenomenon.

 After other components are installed onto the steering wheel, adjust the

PS006

PS005

J5 AT Sedan Service Manual

Power Steering System

PS-11

inclination of steering wheel and steering column for 5~6 times. The maximum

force to operate the locking position of steering column shall not exceed

60~100N. When the locking position of steering column is at free position, the

maximum operating force for inclination of steering wheel and steering column

shall not exceed 100N.

 Installing location of clock spring (balance spring).

 Never distort excessive after tightening the clock spring.

Steering Column

Diagram of Steering Column Assembly:

Diagram of Steering Column Assembly

1- Horn cap, with airbag 2- Steering wheel 3- Steering column assembly

4- Connecting shaft, with universal joint 5- Housing

6 – Vertical freedom adjustment and locking device of steering wheel

Notice:

 Never apply excessive axial force to the steering column assembly during the

removal and installation.

 Never move the steering gear when removing the steering column.

Removal and Installation:

1) Removal

① Straightly park the vehicle.

② Disconnect the cathode terminal of battery and wait for more than 3min.

③ Remove the driver airbag module.

J5 AT Sedan Service Manual

Power Steering System

PS-12

④ Remove the steering wheel.

⑤ Remove the upper and lower guards of steering column and the lower portion of

driver instrument panel.

⑥ Remove the combined switch assembly and clock spring from the steering

column.

⑦ Disconnect every harness connector from the steering column and remove the

harness from the steering column assembly.

⑧Remove the connecting bolts between

steering column and lower shaft and

separate the steering column and

steering gear.

 Tightening torque: 25～30 N·m

⑨ Remove the fixing nuts of steering

column assembly, lower the steering

column, and remove the steering

column assembly.

 Tightening torque: 18~25N·m

2) Check after removal

① Check the steering column for crack, deformation and other damage and replace

in event of any above defect.

② Check the spline of steering column shaft for wear and tooth breakage and

replace in event of any above defect.

3) Disassembly

① Disassembly

a. Loosen the connecting bolts between steering column and connecting shaft

universal joint and remove the universal joint.

b. When necessary, remove the steering lock.

Notice:

 When reinstalling the steering lock, make sure to replace the special bolts.

PS008

PS007

J5 AT Sedan Service Manual

Power Steering System

PS-13

c. When necessary, remove the

adjustable steering column and

support.

② Disassembly essentials

Removal of special bolts:

a. Drill with the electric drill on the

special bolts one hole enough to

accommodate the screw tap.

b. Remove the special bolts with the

left-handed screw tap.

4) Check after disassembly

① Check the adjusting support and spring for crack and damage.

② Check the steering lock mechanism for normal functioning.

5) Assembly

Assemble the steering lock assembly, steering lock support and the special bolts.

Notice:

 When assembling the steering lock

assembly and the steering lock bracket

to the assembling column assembly,

align with the locking notch of the

steering column to temporarily lock

the steering lock.

 After confirming the correct action of the steering lock, lock the special bolts, till

the bolt heads are broken.

6) Installation

Installation is the reverse order of removal.

Notice:

 Never re-use the components not intended for re-use.

 Install the steering column assembly when maintaining the steering wheel at

neutral position.

 When installing the connecting shaft onto the steering column, pay attention to

the installing location.

7) Check after installation

PS010

PS009

Notch

Left-handed screw tap

Special bolt

Steering lock

bracket

Steering lock body

J5 AT Sedan Service Manual

Power Steering System

PS-14

Under the condition that the vehicle is straightly parked, rotate the steering wheel

leftward and rightward to limit point for several times to confirm the smooth

operation of the steering wheel.

Power Steering Gear

Components:

Component Diagram of Power Steering Gear

Notice:

 When separating the steering column and the steering gear assembly, the rotation

of steering wheel may damage the clock spring. Therefore, make sure to fix the

steering wheel to prevent rotation.

Removal and Installation:

1) Removal

Notice:

 Before removal, collect the oil from

the steering system.

① Straightly park the vehicle.

② Remove the connecting bolts between the steering column and lower shaft and lower shaft

power steering gear in the driver cab and separate the steering column and power steering

gear.

 Tightening torque: 25~30N·m

③ Remove the air filter assembly.

④ Remove the oil pipe of power steering

gear.

PS012

PS011

J5 AT Sedan Service Manual

Power Steering System

PS-15

⑤ Remove the lock nuts of tie rod ball

joint.

 Tightening torque: 50~60N·m

⑥ As shown in the figure, remove with

special tools the steering tie rod ball

joint from the steering knuckle.

⑦ Remove the front sub-frame assembly

and the engine suspension.

Notice:

 Support with jack.

⑧ Remove the fixing bolts of power

steering gear from the firewall.

 Tightening torque: 90~110N·m

⑨ Move rightward the power steering

gear assembly and remove from the

left side of the frame.

Notice:

Remove slowly and carefully and do not damage the tie rod dust cap.

2) Check after removal

① Power Steering Gear

 Check the oil pipe connector for looseness and damage.

 Check the power steering gear fixing bush for wear, crack or other damage.

 Check the rack and pinion for smooth functioning and for wear.

 Check the preload of gear.

a. Rotate the gear at a speed of 4~6s/turn and measure the gear preload within the

entire stroke range of the rack.

 Standard value: 0.6~1.3N·m

PS015

PS014

PS013

Rope

Ball joint

Lock nut

J5 AT Sedan Service Manual

Power Steering System

PS-16

b. If the measurement is out of the standard value, first adjust the blockage and

re-check the gear preload.

c. If the adjustment of blockage still can’t obtain the specified gear preload, check

or replace the blocked component.

② Steering tie rod

 Check the rotating torque of steering tie rod.

a. Rapidly swing the tie rod for 10 times.

b. Measure with spring balance the swing resistance of the tie rod.

 Standard value: 2~5N·m

 If the measurement is out of the standard value, please replace.

Notice:

 If the tie rod has no excessive clearance at the slow swing, it can be used even the

measurement is below the standard value. If the measurement is below 4.3N·m,

make sure to replace the tie rod.

③ Tie rod dust cap

 Check the dust cap for damage and replace in event of any damage.

 Check whether the dust cap is correctly installed.

3) Installation

Installation is the reverse order of removal.

Note: Never re-use the components not intended for re-use.

Notice:

 When connecting the power steering gear and the steering column, notice the

installing position.

 After the installation, bleed the air from the steering hydraulic system.

 When removing the power steering gear assembly, under the unloaded condition,

maintain the tires on level ground and finally tighten the nuts and bolts.

 Check the alignment of wheels.

4) Checking after installation

 Rotate the steering wheel leftward and rightward to limit point for several times

to confirm the smooth operation of the steering wheel.

Removal and Disassembly of Power Steering Gear:

Fix the power steering gear on vice and position the input shaft at level position.

Remove the plug from oil inlet port and oil outlet port to drain the oil. Rotate the input

shaft for several times to drain the oil from the steering gear.

1) Remove the left and right steering linkage assembly.

J5 AT Sedan Service Manual

Power Steering System

PS-17

Loosen the lock nuts of left and right steering linkage assembly and remove the outer

ball joint assembly.

2) Remove the left and right guards.

Remove the clamp. Remove single-ear

stepless clamp before removing the guard.

3) Remove the left and right oil pipe

assemblies.

Loosen the connecting nuts in the left oil

pipe assembly and right oil pipe assembly

and remove the left and right oil pipe

assemblies.

4) Remove the inner ball joint.

Remove the inner ball joint assembly.

5) Remove the support part of the rack.

After removing the lock nuts with special

wrench, remove the adjusting bolt and take

out the spring, rack support seat, and rack

support seat cushion in turn.

6) Remove the valve assembly.

Clamp the housing cylinder assembly in

the control valve assembly on the vice and

remove the valve core assembly with

special tool. Attach the protective bush

onto the gear shaft spline part of the valve

core assembly and remove the oil seal and

bearing (Pay attention not to damage the

lip part of the oil seal).

PS019

PS018

PS017

PS016

J5 AT Sedan Service Manual

Power Steering System

PS-18

7) Remove the limit collar assembly.

Remove the limit collar with special tool

and remove the O-ring.

8) Remove the rack assembly.

Press out the rack assembly with special

tool.

Check and Replacement of Steering Mechanism Components:

Check the rack piston assembly:

Check the straightness of the rack in the rack piston assembly. The maximum

deviation shall be 0.15mm. Check the tooth surface for peeling-off or press mark. In

addition, observe the working surface of the teeth for crack or damage and check the

tooth back for wear or damage. When necessary, replace the rack piston assembly.

Check the damage status of the piston ring in the piston and the damage status of the

O-ring. In event of any defect, replace them. During the replacement, remove the

piston ring and O-ring with flat screwdriver.

Notice:

 Cautions shall be taken to prevent

damaging the rack. Apply the power

steering hydraulic oil onto the new

O-ring and install the O-ring.

Notice:

 Cautions shall be taken not to excessively expand the piston ring. Attach the new

piston ring onto the piston of the rack piston assembly, apply the power steering

hydraulic oil onto the piston ring, and press tightly with fingers.

Check the valve assembly:

PS022

PS021

PS020

J5 AT Sedan Service Manual

Power Steering System

PS-19

Check the tooth surface of the gear shaft in the valve core assembly for crack, damage,

peeling-off and deformation. In addition, check for smooth rotation. In event of any

defect, replace the valve core assembly.

Installation of steering mechanism:

1) Preparations:

Before the installation, clean all parts in the clean organic solvent and blow dry.

Warning:

 The organic solvent is one flammable and explosive substance. Therefore,

extreme care shall be taken during the handling, as the minor spark will cause fire

or explosion, leading to injury or death.

 While using the compressed air, make sure to wear the protective goggles.

 Position the clean parts one by one, in order to prevent knocking or scratch.

 Replace all oil seal assemblies, O-rings, and sealing rings. During the installation,

apply lubricating grease onto the sealing parts of various sealing locations.

 Prepare the replacement parts: All components must pass the inspection and only

qualified components can be installed.

Warning: For all fixing bolts, adjusting screws, sealing parts, locking nuts and etc.,

the user must use those meeting our specified technical conditions and shall not

replace at will during the replacement.

 Prepare the clean molybdenum disulfide lithium-based lubricating grease or

equivalent for use during the installation.

Warning: The dirty lubricating grease will damage the sealing parts or scratch the

parts and thus impair the steering assistance and cause accidents.

2) Install the rack

Warning: During the installation, no torsion is allowed for all sealing parts.

① Apply the molybdenum disulfide

lithium-based lubricating grease to

the tooth area of the rack assembly.

② Protect the tooth area of the rack with

ethylene tape, install the rack piston

assembly into the cylinder housing,

pull out the tape, and check the tape

for intactness.

PS023

J5 AT Sedan Service Manual

Power Steering System

PS-20

3) Install the valve body and valve core

assembly

① Apply the molybdenum disulfide

lithium-based lubricating grease to

the tooth area of the pinion.

② Inject the molybdenum disulfide

lithium-based lubricating grease to

the needle portion of housing

cylinder assembly. Install the valve

body assembly and the valve core

assembly into the housing cylinder

assembly along the oblique tooth

direction.

③ Install the bearing, upper oil seal, and hole retainer.

4) Install the limit collar assembly

① Apply white special lubricating grease onto the inner surface of oil seal.

② Press the limit collar assembly into the cylinder block.

③ Tighten the limit collar assembly to 80~100N·m.

5) Install the support component of rack

① Install the rack support seat cushion into the rack support seat.

② Apply the molybdenum disulfide lithium-based lubricating grease onto the

grooves of rack support seat cushion and the rack support seat.

③ Install the rack support seat with rack support seat cushion into the housing

cylinder assembly.

④ Install the spring.

⑤ Apply 5242 sealant to the thread portion of the adjusting bolt and tighten the

adjusting bolt into the housing cylinder assembly with special tool.

⑥ Tighten the lock nut to the adjusting bolt.

6) Install the left and right oil pipe assemblies

① Install new taper connectors to the connecting portions of left oil pipe assembly

and right oil pipe assembly.

② Tighten the left and right oil pipe assemblies to 15~25N·m.

7) Installation adjustment

① Loosen the adjust bolt by 30~40º with special tool.

② Attach the crank onto the input shaft and rotate the input shaft. The hand feeling

shall be stable, without any stagnation.

PS024

J5 AT Sedan Service Manual

Power Steering System

PS-21

③ Tighten the lock nut to tighten the adjust bolt to 25~30N·m.

8) Install the inner ball joint assembly

Attach with special tool and tighten the inner ball joint assembly to 70~100N·m.

9) Install the guard, outer ball joint assembly, clamp, and single-ear stepless clamp

① Apply the lubricating grease onto the lip of guard and install the guard into the

housing cylinder assembly and inner ball joint assembly.

② Clamp two ends of the guard with clamp and single-ear stepless clamp.

③ Install the pull rod lock nut.

④ Screw the outer ball joint assembly into the inner ball joint.

Power steering pump

On board Check:

1) Check the release oil pressure

Notice:

 Confirm the belt tension before check.

① Remove the oil outlet pipe from the power steering pump and connect with

pressure gauge.

Diagram of Power Steering Pump Assembly

1- Thermometer 2- Power steering oil reservoir 3- Power steering pump 4- Pressure gauge

J5 AT Sedan Service Manual

Power Steering System

PS-22

5- Shut-off valve 6- Connector

② Open the valve and bleed the air from the hydraulic pipeline.

③ Run the engine and rotate the steering wheel for several times, till the oil

temperature reaches approximate 50ºC.

Notice:

 When starting the engine, make sure to maintain the cleanliness of belt and hose

of other components.

④ When the engine runs idle, completely close the pressure gauge and measure the

release oil pressure.

Notice:

 Do not close the valve for more than 10s.

⑤ After measurement, slowly open the valve. If the release oil pressure is out of the

standard range, replace the power steering pump.

⑥ After check, disconnect the pressure gauge from the hydraulic pipeline and then

add new oil and bleed the air from the pipeline.

Removal and Installation:

1) Removal

① Drain the power steering fluid from the

power steering oil reservoir.

② Remove the belt of power steering

pump.

③ Remove the high pressure oil inlet pipe

and oil outlet pipe from the power

steering pump and pull out the pressure

switch connector.

④ Remove the fixing bolts and then remove the power steering pump.

 Tightening torque: 50~60N·m

2) Installation

① Installation is the reverse order of removal.

② Conduct the following steps after installation.

 Adjust the tension of belt.

 Bleed the air from the pipeline.

PS025

J5 AT Sedan Service Manual

Power Steering System

PS-23

Hydraulic Pipeline

Diagram of Hydraulic Pipeline:

Diagram of Power Steering Hydraulic Pipeline

1- Oil return pipe 2- Power steering pump 3- High pressure pipe

4- Power steering oil reservoir 5- Oil outlet pipe 6- Oil return hose 7- Power steering gear

8- Steering tie rod 9- Radiator

Removal and Installation of Pipeline:

1) Fixing of power steering pump high pressure oil outlet pipe at the oil inlet port of

steering gear: Connect one end of power steering pump high pressure oil outlet

pipe (notice the direction) to the oil inlet port of the steering gear and tighten the

nut. This oil pipe is one high pressure resistance oil pipe.

2) Fixing of oil return pipe assembly: Connect one end of oil return pipe assembly

(notice the direction) to the oil outlet port of steering gear, tighten the nuts, and

fix with 4 bolts along the sub-frame right longitudinal beam and front crossbeam.

3) Check of oil pipe: Check the O-rings of high pressure oil pipe and oil return pipe

for intactness.

Installation of Power Steering Oil Reservoir:

1) Fixing of power steering oil reservoir bracket: Fix the power steering oil

reservoir bracket to corresponding location of engine compartment front

longitudinal beam with bolts and tighten the bolts to 18~24N·m.

J5 AT Sedan Service Manual

Power Steering System

PS-24

2) Installation of power steering oil reservoir and its hose assembly: Connect the

lower half hose of power steering oil reservoir to the oil return pipe assembly and

connect the oil reservoir oil return pipe to the power steering pump respectively

with pipe clamps and then fix the power steering oil reservoir onto the oil

reservoir bracket.

3) Fixing of power steering pump high pressure oil outlet pipe at the power steering

pump end: Connect another end of power steering pump high pressure oil outlet

pipe to the power steering pump and fix with perforated bolts and washers (with

copper washer at outside and plastic washer at inside. Do not install reversely).

The tightening torque for the perforated bolts shall be 55~65N·m.

Trouble diagnosis

Diagnostic Table for Common Troubles

Trouble

Trouble Phenomenon

Trouble Cause

Troubleshooting

Oil leakage

Oil leakage of power

steering pump

Damage of power steering

pump oil seal

Replace power steering pump

oil seal.

Oil leakage of oil pipe

and oil reservoir

High temperate aging of oil

pipes, poor connection, etc.

Replace oil reservoir and oil

pipes

Damage

Damage of power

steering pump

Damage of power steering

pump oil seal

Replace power steering pump

oil seal.

Damage of power steering

pump housing

Replace power steering pump

Stagnation

Insufficient system

pressure

Blockage of slide valve

Remove the slide valve for

grinding and cleaning to

enable smooth sliding.

Insufficient flow rate

of power steering

pump

Blockage of slide valve and

spring failure

Internal

pressure

release

No pressure in

steering system

Blockage of slide valve

component in steering pump,

serious wear of component

Check safety valve/pressure

release valve and replace oil

and steering pump

Power Steering Gear

Internal pressure release of

power steering gear

Check safety valve/pressure

release valve and replace oil

and power steering gear

Failure of oil seal in power

steering gear

Replace oil seal or power

steering gear

Earlier opening of steering

limitator.

Adjust limitator

Noise

Noise of power

steering pump

Air suction

Bleed air from steering

system

Damage of drive parts in power

steering pump

Replace power steering pump

J5 AT Sedan Service Manual

Power Steering System

PS-25

Trouble

Trouble Phenomenon

Trouble Cause

Troubleshooting

Noise in oil

pipes/power steering

oil reservoir

The oil pipes amplify the noise

of steering pump and

superpose, instead of

absorbing, the flowing noise of

fluid in the oil pipes, which

lead to the excessive noise in

the system.

This fault can be resolved

only by optimizing the

matching angle of steering

system. The individual

replacement of any part can’t

resolve this fault. The

resonating pipe may be added

into oil pipes.

Heavy

steering

Heavy steering at both

left and right

directions

Insufficient oil level in power

steering oil reservoir

Add oil

Air suction

Bleed the air

Blockage of steering column or

steering linkage

Adjust linkage

Blockage of filter core in power

steering oil reservoir.

Clean and replace power

steering oil reservoir and

steering fluid.

Damage of power steering

pump

Check working pressure

output of hydraulic pump with

pressure gage and check

pump for damage. In event of

insufficient pressure or flow

of power steering pump,

further check hydraulic oil

filter and pipeline for

blockage.

Poor power steering gear

Check power steering gear for

damage.

Check V-belt for skid or

looseness. For gear drive, check

the engagement status of gear

drive pair.

Check and adjust various

parts

Heavy steering at

rapid rotation of

steering wheel under

engine idling

Air in system

Check for leakage/bleed air

Insufficient pressure in power

steering system (such as

insufficient oil supply of power

steering pump), looseness and

skid of drive belt. Improper

adjustment of overflow valve,

excessive deformation of high

pressure oil pipes under

application of high pressure oil

(leading to pressure lag), air in

system, etc.

Check, adjust and repair

entire steering system

Internal wear of power steering

pump

Replace power steering pump

and clean entire steering

system

J5 AT Sedan Service Manual

Power Steering System

PS-26

Diagnostic Procedure of Common Faults:

Oil leakage

Check oil reservoir

and oil pipes

Check oil level

Check various sealing

portions of power

steering gear

Adjust, reconnect or

replace gasket

Adjust or add oil

Replace or adjust oil

reservoir and oil pipes

Leakage

Damage/looseness

/leakage

Rupture/looseness/

bending

Replace power steering gear

Replace power steering pump

Check various sealing

portions of pump body

Excessive or insufficient

Check high pressure

and low pressure pipe

connectors

J5 AT Sedan Service Manual

Power Steering System

PS-27

Heavy steering

Replace/adjust

Inflate and adjust to

specification

Replace/adjust/tighten

Insufficient air

pressure and

positioning deviation

Clean oil reservoir

and pump

Check and resolve

leakage/add oil

Check power steering oil reservoir

filtration device and vicinity of

steering pump.

Solution: The oil temperature is the main cause for rapid steering; add length of oil pipes to

reduce oil temperature and enhance radiation; reduce the time and frequency required to steer

to limit position and avoid excessive temperature of pump from causing damage; strictly

control cleanliness of internal parts of system.

Discoloration,

with impurity

It’s recommended to

replace steering fluid at

first 5000km mileage and

replace once every

2500km mileage

afterwards.

Replace all oil of system

and clean oil pipe, power

steering pump, and power

steering gear

For item 1), if the steering is completely

failed, the power steering pump or power

steering gear may be damaged for normal

functioning.

For item 2), it indicates that the power steering pump is not failed. The cause is: The excessive temperature

of oil in system influences and damages the oil film clearance formed between various parts of pump and

leads to internal leakage while steering the pump to limit position so that it can’t supply enough flow and

pressure required for steering. However, it resumes to normal status at slow steering. In addition, the poor

cleanliness in system increases wear of internal parts of pump and causes more internal leakage.

Connect one pressure gauge with one

Tee valve to measure pressure output of

pump or measure pressure at output end

of power steering gear.

Check cleanliness of steering system,

check oil for discoloration or

presence of minor grains, and check

pump valve core for blockage.

Currently it has two faults: 1) Complete

failure of steering; 2) normal functioning

at normal steering, but with sudden failure

of steering at rapid steering.

Blockage or

dirty

Check steering system for leakage

and check for low oil level

Leakage/insufficie

nt oil level

Check power components of

various linkage of steering system

Deformation/int

erference

Check tire pressure and front

wheel alignment

Check pulley/tensioner

pulley/installation bracket

Damage/looseness

J5 AT Sedan Service Manual

Power Steering System

PS-28

Check power steering oil reservoir

filtration device and vicinity of

steering pump.

Clean power steering

oil reservoir and pump

Check and resolve

leakage/add oil

Yes

Leakage

Bleed air and check oil level

and status under still condition.

It’s recommended to

replace steering fluid at

first 5000km mileage

and replace once every

2500km mileage

afterwards.

Replace and clean power steering oil reservoir,

oil pipes, pump or steering gear.

For power steering pump, it may

remove the large valve screw, pour

out control valve core component,

clean with clean oil, re-place into

valve bore, and guarantee smooth

and free movement.

Discoloration,

with impurity

Check cleanliness of steering

system and check oil for

discoloration or minor grains.

Replace all oil of system and

clean oil pipe, power steering

pump, and power steering gear

Check steering system for air

or milky foam

Blockage

or dirty

Check steering system for

leakage/check oil level

Check pulley/tensioner

pulley/installation bracket

Damage/looseness

Replace/adjust/ti

ghten

Noise

J5 AT Sedan Service Manual

Power Steering System

PS-29

Passed

Failed

Solution: Replace power steering oil reservoir, increase the

volume of oil reservoir and its internal structure, and restrain

the vortex phenomenon of oil; add length of oil pipes to

reduce oil temperature and enhance radiation; reduce the

time and frequency required to steer to limit position and

avoid excessive temperature of pump from causing damage.

Disassemble the pump for

checking and conduct

stand performance testing

after cleaning.

Solution: The poor cleanliness is the main cause for failure of pump. In addition, the special

application environment and poor system cleanliness will easily enhance the damage of pump and

internal parts and accelerate the damage. Therefore, it’s necessary to strictly enhance the control of

cleanliness of various parts in steering system.

The fault disappears after

refitting to vehicle

The fault still exists after

refitting to vehicle

Excluding the causes in terms of matching of

steering system, we attribute the noise faults to two

main causes as below:

1) Due to simple structure of power

steering oil reservoir, the oil easily

generates vortex in power steering oil

reservoir while steering to limit position

and thus the inhales the air into system,

which repeats the cycle of compression -

explosion – release – air intake during the

steering.

2) Observe the oil quality and check for grain

impurities and check the pump and system for

contamination – When the internal parts of

pump is seriously damaged, the pump will

easily lead to irregular pulse and abnormal

pressure release.

Occurrence status and phenomenon:

Generally when the temperature of the oil

in steering system increases to above 50ºC,

the air bubbles generate in the oil and the

noise of the system and the pump is really

high.

Occurrence status and phenomenon: Without

cleaning the pump and replacing the internal

parts, the noise re-occurs while refitting the

pump to vehicle for testing.

J5 AT Sedan Service Manual

Power Steering System

PS-30

Common Fault Solution

Oil leakage:

1) Oil penetration at various connections of oil pipes in steering system, power

steering oil reservoir, and power steering pump.

2) At the oil inlet port of power steering pump, if the oil inlet pipe loosens, the oil

penetration generally occurs at such location. Therefore, it’s required not to

knock the oil inlet pipe of power steering pump at all times (As the oil pipe is

pressed into the pump body by interference fit, please handle with care).

3) At the high pressure oil outlet port of oil pipes and power steering pump, if the

oil leakage occurs here, re-adjust or replace the O-ring and tighten the installing

bolts on the oil pipes. This oil leakage fault is not related to the quality of the

pump and it’s unnecessary to replace the oil pump.

4) For oil penetration of power steering oil reservoir, the oil penetration occurs at

the cap of power steering oil reservoir under rough road if the power steering oil

reservoir is excessively filled, or the connection of power steering oil reservoir is

not completely sealed, or the engine has high vibration. This phenomenon occurs

commonly and shall not be considered as the oil leakage of power steering pump

or power steering oil reservoir. In such case, clean the power steering pump and

power steering oil reservoir, re-install them, carefully observe and confirm the oil

leakage, notice the amount of oil added in the future, and demand the customers

to enhance the maintenance and regular cleaning.

Troubleshooting of oil leakage:

1) Carefully confirm and check the location with oil leakage, replace various

sealing parts and oil pipes, and tighten the bolts of various connectors. The

tightening torque for large nut of power steering pump high pressure oil outlet

port shall be 55~65N.m. It’s recommended that the torque for installing the high

pressure oil pipe shall not exceed 60N.m, or it may easily damage the internal

thread of aluminum housing of power steering pump.

2) Timely fill the power steering fluid while the oil level is below the specified

value. While adding the oil, the oil level shall not exceed the marking on the

power steering oil reservoir.

3) Clean the penetrated oil at the outer surface of power steering pump, power

steering oil reservoir, oil pipes and related connections, in order to correctly

judge the oil leakage or excessive filling of oil.

Noise:

1) Insufficient oil level in power steering oil reservoir, system oil leakage or air in

system, and dirty filter core in power steering oil reservoir leading to insufficient

oil suction of power steering pump.

2) Internal dirt of steering system, leading to excessive wear of stator, rotor, fuel

distributor, end cap, and input shaft.

3) The resonance arising from the design and installation types of oil pipes,

blocking, bending and excessive deformation during the installation and

connecting of oil pipes or the poor matching of system, the choked oil inlet and

J5 AT Sedan Service Manual

Power Steering System

PS-31

outlet of system, and etc.

4) Overloaded running of steering system, leading to excessive wear of internal

stator and rotor of the power steering pump, which causes the irregular oil

movement in the power steering pump and generates noise (It’s quite normal that

the “ChiChi” sound occurs while rotating the steering wheel to the limit position

within short period "<6s").

5) If the power steering pump works frequently and excessively long at the limit

steering position, a large amount of air bubbles may easily form in the steering

system. If the noise in the system is lowered after oil replacement, but re-occurs

with a large amount of air bubbles after the road test, this fault is unrelated to the

performance and function of power steering pump and the power steering gear.

In such case, replace the steering oil reservoir and oil. It’s preferable to have

steps or bent tracks in the oil reservoir.

6) Other V rotating components of the engine, such as the noise of bearings at water

pump, A/C compressor, tensioner, and pulley and similar “squeak” noise after the

belt is loose, which looks like being occurred at the front bearing of the power

steering pump. For instance: After driving for a certain period, some vehicles

may have noise while rotating the steering wheel to left or right limit position. In

such case, check the belt. As the required torque of the steering system varies at

the limit position, if there is the presence of belt looseness or skid, the belt will

generate noise on the pulley of the power steering pump.

7) The problems such as low installing location of power steering pump and poor

driving road conditions of the vehicle will easily lead to the accumulation of a

large amount of sediment and oil dirt on the housing of the oil pump and thus the

input shaft of the power steering pump and the needle bearing of the housing will

be damaged by external factors during the operation and thus be corroded by

water, acid and alkali. If the entire steering system is not maintained as scheduled,

the ball bearing of the power steering pump will easily be burnt or blocked and at

the same time will lead to noise and heavy steering at this area.

8) Loose installation of power steering gear and power steering pump on the

bracket, internal wear of power steering gear, and improper adjustment of pinion

and rack.

9) The improper matching between various components of the system before

delivery will easily lead to the suction failure of pipeline and lead to the system

faults such as noise and failure. For instance: If the pipeline is not equipped with

the noise reduction and corresponding matched shock absorption device, the

entire system will lead to noise and failure fault. In such case, replace with oil

pipes with different noise reduction effects. However, this requires high technical

requirements and the operations of professionals from the manufacturer. In such

case, this fault can be resolved excellently.

Troubleshooting of noise fault:

1) Clean the entire steering system, bleed the air from the system, adjust properly

the belt tension or replace belt, check and repair the oil pipes, power steering oil

reservoir, power steering pump, and power steering gear, and replace with new

power steering oil and power steering oil reservoir.

J5 AT Sedan Service Manual

Power Steering System

PS-32

2) Replace the steering high pressure oil pipes with shock absorption effects or with

well matched oil pipes.

3) Check other rotating parts and tensioner pulley and clean the power steering

pump and power steering gear. Under special conditions, replace the power

steering pump or power steering gear assembly.

Heavy Steering:

1) Dirty inside of power steering oil reservoir, blocked filter screen, or low lever of

power steering oil reservoir.

2) A large amount of air in the power steering system.

3) Foreign matters in the steering system lead to the blockage of steering pump

flow control valve, serious wear of internal components of power steering pump,

and internal leakage of pump.

4) Excessive wear of piston cylinder of power steering gear, poor sealing of oil seal,

and adhesion or damage of control valve.

5) Insufficient air pressure of tires, interference or loose connection of steering

column of power steering pump, loose belt or belt skid of power steering pump,

or loose installation of pump.

6) Loose bolts at various connections of oil pipes, leading to leakage of steering

fluid and insufficient flow in the system.

Troubleshooting of heavy steering:

1) Check the power steering gear, power steering pump control valve, oil reservoir

filter screen, and steering oil and clean the entire power steering system (Clean

with kerosene as far as possible. It’s disallowed to disassemble the pump body.

In such case, remove the bolts from the pump control valve chamber and drain

from the internal valve body for simple cleaning).

2) If the power steering pump is dirty, make sure to clean the inside and outside of

the power steering pump and oil pipes (clean with clean brush, instead of the

cotton gauze or other multi-fiber cloth). During the cleaning, pay attention to the

system cleanliness and prevent the visible foreign materials from ingress into

pump and the system.

3) Add oil to the specified level and check or replace the oil reservoir.

4) Adjust the belt tension as specified and tighten the connecting bolts of various

components.

5) Check various connections of the oil pipes and tighten various connecting nuts.

6) Replace the oil pipes, power steering pump or power steering gear.

Formation of Milky Foam in Power Steering Fluid:

Fault Cause:

1) Air in steering system.

2) Fluid leakage in steering system

J5 AT Sedan Service Manual

Power Steering System

PS-33

Troubleshooting:

1) Bleed the air, check for oil leakage and resolve accordingly.

2) Check the power steering oil reservoir and add oil to the oil reservoir.

Off-Tracking (Test the vehicle from two directions on the level road):

Fault Cause:

1) Loose ball joint of steering wheels or improper alignment of front wheels.

2) Torsion deformation or excessive wear of steering rod system.

3) Improper adjustment of rack pre-tension in power steering gear.

4) Improper return of steering wheel and vibration or beating of steering wheel.

Troubleshooting:

1) Adjust the alignment of front wheels and the ball joint of steering wheels.

2) Add the steering fluid and bleed the air.

3) Adjust or repair the rack pre-tension of power steering gear.

4) As specified, check and adjust various connections in the steering system.

Service Data and Specification

Specification Table

Item

Specification

Diameter of steering wheel

φ390mm

Steering column and lower shaft

4-level collapse

Operating torque of steering wheel

4±0.6N.m

Rack stroke of power steering gear

140±3mm

Operating pressure of power steering gear

8.5Mpa

Load output of power steering gear

8500N.m

Line angle drive ratio

44.3

Turns of steering wheel

3.16±0.1

Type of power steering gear

Rack & pinion

Power steering pump

Impeller type

Flow rate of power steering pump

8.5cm3/rev

Specification/capacity of power steering fluid

ATF-III/1.1L (Automatic transmission oil)

J5 AT Sedan Service Manual

Power Steering System

PS-34

Tightening Torque Table

Item

Quantity

Tightening torque

(N.m)

Fixing nut of steering wheel

35～40

Installing nuts of steering column

18～22

Installing bolts of steering column

18～25

Connecting bolt between steering column and lower shaft

25～30

Connecting bolt between lower shaft and power steering gear

25～30

Fixing bolts of power steering gear

90～110

Connecting nuts between steering tie rod ball joint and

steering knuckle

50～60

Bolts of oil pipes and fixing bracket

9～11

Fixing bolts of oil reservoir bracket

18～22

Installing bolt of power steering pump bracket Q1841035

30～50

Installing bolt of power steering pump bracket Q1461025

25～35

Fixing bolt of fastening bracket

30～50

Fixing torque of low pressure pipe and steering engine

30～40

Fixing torque of high pressure pipe and steering engine

30～40

Fixing torque of high pressure pipe and steering pump

30～40