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WORKSHOP MANUAL

HFC7151MV/HFC7151MTV-S3

Chassis

Version No：JAC-201511030415002

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FOREWORD CONTENT

This Manual is helpful for technical maintenance

staff for JAC and provides effective and correct

maintenance and service for JAC vehicle. To ensure

the customer satisfaction of the JAC products, it is

extremely essential that the professional maintenance

technicians for JAC have the friendly service and the

capability of proper operation; therefore, the

maintenance technicians must fully understand the

contents in this Manual. This Manual shall be

accessible for reference at any time.

All contents in this Manual, including pictures,

technical parameters are the latest. But if product

modification affects maintenance, JAC will provide

technical bulletin or supplementary volume. Therefore,

please obtain the latest information about this Manual.

JAC reserves the right to make change in design,

addition or improvement for the product.

This manual is a guide for vehicle maintenance, maintenance personnel must be strictly in

accordance with the maintenance manual operation. This product is a product that has precise

requirements, maintenance personnel must be professional with relevant skills, and

non-professional personnel are forbidden to disassemble vehicle privately. Due to complexity of

actual problem, for items not contained in the manual, please contact with company's customer

service, and operate under its guidance.

During the process of maintaining JAC vehicle, if genuine parts that are not from JAC or

disqualified oil, the vehicle may be damaged.

Overview & maintenance

Engine

Chassis

Body structure& electrical

Circuit

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of this manual.

Tel：0086-551-62296644

Fax：0086-551-62296633

JAC International Customer Service Depart.

2015.11

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I Warning and precautions

(I) Warning and precautions

Definition of “Warning”, “Important precautions” and “Caution”

The diagnosis and repair procedure in this maintenance manual consist of general and specific

“Warning”, “Important precautions” and “Caution”. Jianghuai Automobile Co., Ltd is committed to provide

maintenance information to after- sales service technician for diagnosing and repairing the system and

making the vehicle work normally. However, if the technician does not operate according to the

recommended ways, some procedure may cause danger to the technician.

The “Warning”, “Important precautions” and “Caution” are complied to prevent above risk but not all

risks can be predicted. These information lie at the conspicuous position of the manual and are complied to

prevent the occurrence of the following circumstances:

·

Cause severe injury to personnel

·

Damage the vehicle

·

Unnecessary vehicle repair

·

Unnecessary replacement of parts

·

Improper repair or replacement of parts

Definition of “Warning”

A “Warning” request you to strictly follow these dos and don’ts. It may cause following result if you

ignore the “Warning”:

·

Cause severe injury to personnel

·

Cause severe injury to driver or passenger if repaired improperly

Definition of “Important precautions”

“Important precautions” means you need pay attention to these dos and don’ts. It may cause following

result if you ignore the “important precautions”:

· Vehicle damage

·

Unnecessary vehicle repair

·

Unnecessary replacement of parts

·

Abnormal state of the repaired system or parts’ operation or performance

·

Damage to relevant system or parts

·

Damage to fasteners, general tools or special tools

·

Leakage of the engine coolant, lubricant or other important oil liquid

Definition of “Caution”

“Caution” emphasizes the necessity of diagnosing or repairing some procedure and for below purposes:

·

Definite procedure

·

Add information for completing a procedure

·

Clarify the reason for operating according to recommended procedure

·

Provide information to help complete the procedure in a more efficient way

·

Provide previous experience to technician so as to complete the procedure more easily

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Warning on lifting the vehicle

△

Warning: In order to avoid damage to vehicle, severe personnel injury or fatalities, when you remove

main parts from the vehicle and use a lifting machine to support the vehicle, use a lifting jack to sustain the

parts relative to the parts to be removed.

Warning on handling the anti-lock braking system components

△

Warning: Some parts of the ABS system cannot be repaired individually. Removing or disconnecting

some system component can cause personnel injury or make the system run abnormally. Only these

components with license to be removed and installed can be repaired.

Warning on colliding and repairing the permitted equipment

△

Warning: In order to avoid injury caused by exposure in welding arc or plating (Zinc Oxide) metal toxic

smoke when grinding or cutting metal or flake molded part of any type, you must work in good ventilation

environment and wear licensed respirator, goggles, ear plugs, protective gloves and protective clothes.

Warning on assistant driving

△

Warning: When the technician is inspecting the failure parts, the vehicle must be operated by the

assistant, or it may cause personnel injury.

Warning on disconnecting the battery

△

Warning: Before repairing the electrical components, make sure the ignition key is at “OFF” or “LOCK”

and all the electrical load are “OFF”(closed) unless otherwise specified in the operation program. If the

tools or equipment are easy to be contacted with the exposed live electrical terminals, you need disconnect

the battery negative electricity. Violating these safety instructions may cause personnel injury or damage to

the vehicle and components.

△

Warning: When repairing the airbag, you must disconnect the battery negative electricity for at least

90seconds and then take other operation.

Warning on brake dust

When repairing the wheel brake components, please avoid following operation:

·

Do not repair or wear the brake friction lining.

·

Do not sand the brake friction lining.

·

Do not use a dry brush or compressed air to clean the wheel brake parts.

△

Warning: Some models or after-sales installation of braking components may contain fiber which will be

mixed with the dust. Inhalation of the dust containing fiber will do severe harm to health. Please use a wet

cloth to clean any dust on the brake components.

Warning on braking fluid

·

△

Warning: Braking fluid is extremely easy to absorb moisture and wetness. Do not use the braking fluid in

the open container which may be polluted by water. Using improper or polluted braking fluid may cause

system failure, losing control of the vehicle and personnel injury.

Warning on braking fluid irritant

Braking fluid is irritant to skin and eyes. Please take following measure if contacted: Eyes contact--use clean water

to wash thoroughly

· Eyes contact—use clean water to wash thoroughly

· Skin contact—use soap and clean water to wash thoroughly

· Warning on braking pipe replacement

·

△

Warning: Carefully install and fix it when replacing the braking pipe. Make sure you use the correct

fastener, or it may cause damage to the braking pipe and braking system which lead to personnel injury.

Warning on clutch dust

△

Warning: When repairing the clutch, do not polish or sand the clutch disc nor use dry brush or

compressed air to clean components because these operations will produce dust. You should use a wet cloth

dipped in the water (but not soaked). The clutch may contain fiber. If dust produced during repairing, the

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fiber will be mixed in the air. Inhalation of dust containing fiber will do severe harm to human health.

Warning on collision and cutting

△

Warning: Only cut the recommended parts, or it will damage the vehicle integrity and cause injury

during a crush.

Warning on eye protection

△

Warning: When you execute this program, you should wear approved safety goggles and gloves to

reduce the risk of getting injured.

Warning on moving parts and heat surface

△

Warning: When working beside the running engine, you should avoid contact with the moving parts and

hot surface to prevent injury.

Warning on goggles and gloves

·

△

Warning: Make sure to wear goggles and gloves when removing exhaust emission parts, otherwise the

rust and sharp edges from the worn exhaust system pats will do severe harm to human health.

Warning on removing the reservoir lid

△

Warning: In order to prevent being scalded, do not remove the reservoir lid before the engine cooled. If

you remove the reservoir lid before the engine and the radiator cooled, the cooling system will release boiling high

pressure liquid and steam.

Warning on cooling system repair

△

Warning: If the cooling system is with pressure, even though the solution in the radiator is not boiling, the

solution temperature will much higher than the boiling temperature. If you open the reservoir lid and repair

the cooling system with the engine uncooled and with high pressure, the engine coolant will boil immediately

and burst to personnel to cause severe scald.

Warning on road test

△

Warning: Operate road test of vehicle in the premise of safety and obey all traffic laws and regulation. Do

not try any operation to endanger the control of the vehicle. Violating above safety instruction will do severe

harm to human health and damage the vehicle.

Warning on goggles and fuel

△

Warning: Do wear goggles when handling fuel in order to prevent the fuel splashing into eyes.

Important precaution on fulfilling braking fluid in braking system

△

Important precaution: When adding braking fluid to brake master cylinder reservoir, you can only use the

braking fluid in clean and sealed braking fluid container and meet DOT4 standard.

Important precaution on brake caliper

△

Important precaution: When removing the brake caliper, use a steel wire to hang the brake caliper to avoid

damage to the brake pipe.

Special precaution on brake fluid’s impact on paint and electrical components

△

Important precaution: Avoid the brake fluid to splash on paint, electrical connector, wire or cable. The

brake fluid will damage the paint and lead to electrical components corrosion. If the brake fluid is exposed

to paint, rinse the contacted position immediately. If the brake fluid is exposed to electrical connector, wire

or cable, use a clean cloth to wipe the brake fluid.

Important precaution on fastener

△

Important precaution: Use correct fastener in correct position. The part NO of fastener replacement must

be correct. The fastener need to be replaced or need to be used with thread lock adhesive or sealants are

specially noted in the maintenance program. It is prohibited to use oil, paint, lubricant, or rust inhibitor on

fastener or fastener connector surface unless stated otherwise.

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These pigmentum will impact the fastener’s torque and clamping force and will damage the fastener. When

fixing the fastener, make sure to follow correct fastening order and torque so as to avoid damage to system and

components.

Important precaution on not twisting or bending the soft pipe during installing

△

Important precaution: It is prohibited to twist the entrance and exit of the soft pipe during installing. It is

prohibited to bend or deform the soft pipe for easier installation or it will damage the components.

Important precaution on machined surface damage

△

Important precaution: Do not cut, scratch or damage the sealed surface. The sealed surface is machined

surface. The machined surface damage will cause leakage.

Important precaution on removing ring gear

△

Important precaution: Do not remove the ring gear from the differential housing, or it will damage the ring

gear or differential housing.

Important precaution on sealant

△

Important precaution: Do not let the room temperature hardening sealant get into the tapped blind hole, or

the fastener will generate hydraulic locking effect when fastened which will damage the fastener or other

components. It will also make the fastener unable to get correct clamping force when fastened that make the

components to be sealed incorrectly and lead leakage. When the fastener is not fastened correctly, it will

make the components loose or separate that will cause severe damage to the engine.

Important note about the steer turning to the limited position

△

Important note: Do not keep the steer at the limited position for more than five seconds, or it will damage

the motor.

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II Vehicle inspection

(I)

Inspection list when operating the vehicle

Vehicle and positioning operation

Keep vigilant when the steering wheel or seat vibrates at normal driving speed. This situation shows there

might be a need to balance the wheel, besides, running on left and right deviation on a flat straight road means it

may need to adjust pressure or align the wheels.

Steering system operation

Keep vigilant at changes of steering action. It requests inspection when it is hard to rotate the steering wheel

or the free travel is too long or there is abnormal sound when turning or parking.

(II)

Inspection list for at least once per month

Wheel and pressure check

Check the wheel whether there is abnormal wear or damage. Check the pressure in cold state. Check the

spare tire and keep the pressure recommended on the label.

Oil leakage inspection

When the vehicle is parked for a period of time, regularly check the ground under the vehicle if there is

water, engine oil, fuel or other liquid. It is a normal phenomenon that the air conditioner system drips after using. If

you find fuel leakage or smoke, you should find out the reason and handle the failure.

(III)

Inspection list for at least twice per year

Liquid level of brake master pump storage tank

Check the oil liquid and ensure it is at correct level. When the level is too low, it may indicate the pad

of the brake disc is worn and need to be repaired. Check the ventilation hole on the lid of the liquid storage

tank and ensure no dirt and airway to be patent.

Clutch pedal free travel

Check the clutch pedal free travel and adjust it if necessary. Refer to clutch pedal free travel adjustment.

Lubrication of the doors and windows sealing strip

Use a clean cloth to coat the sealing strip with a layer of silicon grease film.

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III Vehicle lifting

(I)

Lifting the vehicle

Refer to “Warning on lifting the vehicle” in “Warning and Important precautions”. To

avoid getting injured, when performing any work on or under the vehicle which is

only supported by a jack, make sure to use jack seat.

Vehicle lifting point

△

Caution: The rear lifting padding block cannot touch the outside of the sill plate and frame rail and

floor.

Put the rear lifting padding block at below position:

Under the connector between the rear frame rail and side frame rail.

△

Caution: The front lifting padding block cannot touch the outside of the sill plate and frame rail and

floor.

Put the front lifting padding block at below position:

Under the connector between the front frame rail and side frame rail.

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IV Maintenance

(I) Specification

Main liquid parameters

Name

Trade mark

Volume

Unleaded gasoline

Above 93# unleaded gasoline

45L

Engine cooling liquid

Ethylene glycol antifreeze concentration of 50%

5.5 L

Manual transmission

lubricant

75W/90 GL-4 gear oil

2.2 L

CVT transmission

lubricant

MOBIL,ESSO EZL 799 or Idemistu CVTF-EX1

4.2±0.05L

Engine oil

SAE10W-30 SJ or grade above

4 L

Air conditioner

compressor lubricant

PAG56

0.12 L

Braking liquid

DOT4

650ml±50ml

Power index

Item

Unit

1.5 6MT

1.5 CVT

Continuous acceleration time (0-100km/h)

S

≤ 14

≤ 15

Direct gear acceleration performance(80-

120Km/h)

S

≤ 15

≤ 11

Maximum speed

Km/h

≥ 175

≥ 170

Maximum gradability

%

≥ 30

Fuel consumption index

Item

1.5 6MT

1.5 CVT

Comprehensive (L/km)

≤ 5.9

≤ 7.2

90km/h constant speed (L/km)

≤ 5.6

≤ 6.1

Transmission gear ratio

Item

Reference value

Shift type

6MT

CVT

Maximum torque

N·m

/

rpm

180/4000

190

First

3.769

Manual 1st

2.28~2.41

Second

2.053

Manual 2

nd

1.51

Third

1.393

Manual 3

rd

1.10

Automatic model

ratio range

Gear ratio

Gear position

Fourth

1.031

Manual 4

th

0.83

0.443~2.416

Fifth

0.778

Manual 5

th

0.65

Sixth

0.681

Manual 6

th

0.52

Reverse

3.583

Manual reverse

2.68

Final ratio

4.056

5.76

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Item

Alignment

paramter

Reference value

（

°

）

Camber angle

0°±30′ (Difference value between left and right is

within 30′)

Kingpin

inclination angle

12.3°±30′(Difference value between left and right is

within 30′)

Front wheel

Kingpin camber

angle

3.8°±30′(Difference value between left and right is

within 30′)

Total toe-in

-1°±30′

Single wheel toe-

in

0±5′

Camber angle

-1°±15′ (two side angle difference is not bigger

than 20′)

Rear wheel

Total toe-in

24′±20

Single wheel toe-

in

12′±10

Tyre specification and cold inflation

pressure

Item

Parameter

Tyre specification 1

205/55R16 94V

Cold inflation pressure 1

(kpa)

220±10

Tyre specification 2

185/65R15 88H

Cold inflation pressure 2

(kpa)

240±10

Spare tyre

205/55R16 94V

(II)

Regular maintenance instructions

Normal use of the vehicle

The maintenance projects listed in the maintenance plan is on the supposition that the vehicle is used for

below purposes:

Carry passengers and goods under the limited condition instructed by the label on the edge of the

driver’s door.

Drive on proper road and abide by traffic laws and regulations.

Description of planned maintenance programs

Details for maintenance projects listed in the maintenance plan are as follows. Before proceeding below

maintenance projects, make sure to finish all components replacement and all necessary repair. After that,

you can drive on the way and make sure to use proper oil and lubricant.

Wheel inspection and transposition

Check the wheel to see whether it is worn or damaged abnormally. In order to get uniform abrasion and

extend service life, you should take transposition. If abnormal or premature wear occurs, please check the

wheel positioning first and then check if it is damaged.

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V

Maintenance information system

(I)

Instruction for arrows and symbols used in the manual

VI

Health and safety

(I)

Instruction

Many operations related to vehicle maintenance and repair will impact human safety and health. This

section lists some of the related dangerous operation, material and equipment. Besides, it also lists the safety

rules to avoid those hazards.

This section does not contain all instructions related to safety and health, so all work, program and

material handling should be operated in the premise of safety and health. Before using any product, you

should consult the product instruction provided by the manufacturer or supplier.

(II)

Acid and soda

For example, corrosive sodium carbonate and sulfate.

Used in battery and other materials cleaning.

Having stimulus and erosion impact to eyes, skin, smell and throat, and may cause burns to human body

and damage general protective clothes.

Avoid splashing in eyes, skin and clothing. Wear proper protective clothes, gloves and goggles. Avoid

inhalation of spray.

Make sure to allocate cleaning equipment around such as eye washing bottle, showerhead and soap etc.

It can provide first aid when spray or spill occurs.

Mark a signal of “DANGER OF EYES” in an eye-catching position.

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(III)

Braking fluid

You may feel a light irritation if the braking fluid sprays into skin or eyes, so try to avoid the braking

fluid to contact your skin and eyes. The risk of inhaling braking fluid vapor at room temperature is not high

because the vapor pressure is very low.

(IV)

Chemical material

Take special attention when using, storing and handling chemical material like solvent, sealant, binder,

paint, resin foam, battery acid, engine coolant, braking fluid, fuel, lubricant, lubricating grease and etc. They

may be poisonous, harmful, erosive, irritant, high combustible and contain severe dangerous smell and dust.

The impact of long-term excessive exposure to environment with chemical substances may be instant or

chronic, transient or eternal, accumulative, exterior, fatal or may possibly affect longevity.

Chemical material—operations you should take are as following

·

Read carefully and follow the warnings and precautions on the material container, any enclosed

leaflets, posters or other product instructions. You can get the safety and health information about the

raw material from the manufacturer.

·

If you get touched with chemical material, remove it from your skin or clothes as quick as you can,

take off the seriously immersed clothes immediately and rinse it thoroughly.

·

Strictly follow the working procedure instruction and wear protective clothes to avoid direct touch

with your skin and eyes.

·

During chemical material handling process, you must wash before you rest, eat and drink, smoke or

use toilet facilities.

·

Keep the working area clean and tidy. Do not make the chemical material spray out.

Chemical material—operations you should not take are as following

·

Do not mix the chemical material together except there is instruction provided by the manufacturer.

Substance of some chemical material may contain other poisonous or harmful substance which may

release other poisonous or harmful substance when mixed or cause explosion or other accident.

·

Do not spray chemical material in a closed environment.

·

Do not heat chemical material except there is instruction provided by the manufacturer because some

chemical materials are high combustible and some may release poisonous and harmful gas.

·

Do not keep the chemical material container open because the emitted gas may accumulate to be

poisonous, harmful or explosive. Some gas is heavier than air so they can be accumulated in a closed

space.

·

Do not put chemical material in a container without a mark.

·

Do not use chemical material to clean your hands or clothes. Chemicals, especially solvent and fuel

will make skin dry. They also may cause skin allergy, skin inflammation or absorb poisonous and

harmful substance through skin to affect your health.

·

Do not put other chemical material in an empty container unless the container is cleaned under

supervision.

·

Do not smell chemical material at will. A short exposure to gas of high density may get poisoned or

harmed.

·

(V) Dust

Powder and dust may be irritated, poisonous and harmful. Try to avoid inhalation of powder chemical

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material or dust caused by operation friction in dry temperature. If ventilation is poor, you should wear

protective device such as breathing mask to avoid inhalation of dust.

Small dusts of combustible matter may lead to explode. Please avoid explosion and fire.

(VI) Electric shock

It may cause electric shock if you use electrical devices wrongly without following instructions or abuse

equipment in good condition.

Do arrange maintenance for electrical devices within required time and test it regularly. Those failed

electrical devices should be marked or it will be better to remove them out of working area.

It is prohibited to make the wire, cable, plug and socket to be worn, twisted, cut off or damaged in other

way. Do not make the electrical devices and wire to be in contact with water.

Make sure that the electrical devices are under protection of proper fuse.

It is prohibited to misuse electrical devices and use these electrical devices with failure, or it will risk

your safety.

Make sure the cables for mobile electrical device are not pressed or damaged.

Arrange general aid training for special electrical devices operator.

If electric shock happens:

·

Turn off the power before contacting with the victim.

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·

If the power cannot be turned off, use dry insulating material to remove the electric devices from the

victim.

·

Arrange first aid immediately if you have been trained.

·

Ask for medical assistance.

(VII)

Exhaust

Exhaust contains poisonous and harmful substance such as carbon oxides, nitrogen oxides, aldehyde,

lead, aromatic hydrocarbons and etc. The engine can only run when there is proper exhaust equipment or

general ventilation equipment and in an open space.

(VIII)

Fiber isolation

To be used for isolation of noise and sound.

The fibrous nature or sharp edge of the surface may cause skin irritated.

During operation, strictly follow working procedure instructions and wear gloves to avoid the skin from

excessive exposure to fiber.

(IX)

Fire

Many materials related to vehicle repair are extremely combustible. Some material will release

poisonous and harmful gas after burning.

Do follow fire safety instructions when storing or handling combustible material or solvent especially

when you are around electrical devices or there is welding.

Ensure there is no fire risk before using electrical devices or welding equipment.

Prepare a proper fire extinguisher around the working area before using welding or heating equipment.

(X)

First aid

It is better to be with personnel with first aid training in the working place and confirm to laws and

regulations.

If the eye gets sprayed, rinse it with clean water for at least ten minutes.

If the skin gets polluted, rinse the polluted area with soap and clean water.

If the skin gets frostbite, rinse the frostbite part into icy or cold water.

If poisonous gas is inhaled, remove the victim to fresh air. If the adverse reaction phenomenon

persists, send the victim to hospital immediately for medical aid.

If liquid is swallowed accidentally,

tell the information marked on the container or volume label to the doctor. Do not guide the victim to

split blindly unless there is instruction on the volume label.

(XI)

Foam -polyurethane

Curing foam is a buffer pad for seat and decoration.

Follow the instructions provided by manufacturer.

The components without chemical effect are irritated and may be harmful to eyes and

skin. Wear gloves and goggles for operation. Those who have chronic breathing disease,

asthma, bronchi or hereditary allergy should not handle or approach the uncured material.

The spare parts, vapor and sprayer of fiber will cause direct irritation and allergic reactions and may be

poisonous and harmful.

Do not inhale vapor and sprayer which can only be handled in good ventilation and with breathing

protective devices equipped. You cannot put the gauze mask off immediately after finish spraying unless the

vapor and sprayer disperse completely.

The combustion of the uncured assembly and cured foam will release poisonous and harmful gas.

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During bubble operation, it is prohibited to smoke, use open flame and electrical devices unless the vapor

and sprayer are removed completely. Any thermal cutting of foamed material or special foamed material

should be operated in good ventilation environment.

(XII)

Fuel

Try to avoid the skin from direct contact with fuel. If contacted, rinse the contacted skin with soap and

clean water.

Gasoline

Easily combustibles should follow no-smoking ban.

If gasoline is carelessly swallowed, it will cause irritation to mouth and throat. When absorbed by the

stomach, it will cause general weakness and confusion. A little of gasoline will threaten a child’s life. Thus, it

is very dangerous if liquid enters into lungs.

Gasoline will make skin dry. Long-term or regular contact will cause skin allergy and skin inflammation.

It will cause severe pain in the eyes if liquid enters into eyes.

Gasoline used in vehicle may contain large amount of benzene. Inflation of gasoline will get poisoned.

Thus, the density of gasoline vapor must be kept at a very low stage. Gasoline vapor of high density will

cause irritation to eyes, nose and throat, nausea, headache, depression, drunkenness and etc uncomfortable

phenomenon. Gasoline vapor of extreme high density will cause quick loss of consciousness.

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Gasoline must be handled in good ventilation environment. Take care to avoid inflation of gasoline

vapor by spilling when operates in a closed space.

Pay special attention when cleaning and maintaining gasoline container.

It is absolutely prohibited to use gasoline as detergent and suck it with mouth.

(XIII)

Gas cylinder bottle

Gases such as oxygen, acetylene, argon and propane are usually stored in cylinder bottles with pressure

of 13.8Mp (2001psi). Take special attention when handling these cylinders. Try to avoid mechanical damage

to the cylinders and valves. The filled gas in the cylinders should be marked clearly and properly.

Cylinder bottles should be stored in good ventilation environment and avoid to be put in snow, ice, or

environment with direct sunlight. Fuel gases such as acetylene and propane should not be stored together

with oxygen cylinder.

Take special attention and try to avoid leakage of gas cylinders and piping and fire source.

Only these trained personnel can take operations related to cylinders.

(XIV)

General workshop tools and equipment

It is very important to keep good working condition of all tools and equipment and operate them

correctly during using process.

The tools and equipment should not be used against the function designed. Do not make the equipment

such as crane, lifting jack, axle and chassis frame, sling to bear the load that exceed its maximum limit. The

damage caused by overloading may not emerge immediately but it can cause severe accident when used next

time.

Do not use the equipment which are damaged or in poor condition especially high-speed equipment like

grinding wheel. The damaged grinding wheel will break without warning and cause serious injury.

Wear eyes protective equipment when using grinding wheel, a chisel or sand blasting equipment.

Wear proper breathing mask when using sand blasting equipment or spraying equipment , or handling

materials containing asbestos.

Make sure there is ventilation equipment that can control the content of dust, sprayer and soot.

(XV)

Lubricant and grease

Try to avoid long-term and repeated contact with mineral oil. All lubricant and grease will cause

irritation to skin and eyes.

·

Try to avoid long-term and repeated contact with engine oil especially the used one.

·

Wear protective clothing including impermeable gloves.

·

Do not put the wiping cloth stained with engine oil into the pocket.

·

Try to prevent the clothing from being contaminated by engine oil especially the underwear.

·

Do not wear the clothes and shoes contaminated by dense engine oil. The working clothes should be

rinsed regularly and kept clean.

·

Take first aid for open wounds timely.

·

During working process, smear sun cream on the skin so as to avoid direct contact with engine oil.

·

Use soap and clean water to rinse and remove all engine oil. Smearing protective agent containing

lanolin will help to replace natural oil removed on the skin.

·

If the skin occurs lesion, go to seek medical assistance.

·

Try to remove the residual oil on the components before working.

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·

Wear goggles such as chemical goggles or mask if the oil may possibly get direct contact with eyes.

In addition, devices for eyes flushing should be equipped with.

Precautions on environmental protection

The engine oil and oil filter used should be handled by authorized or licensed waste disposal business or

waste engine oil recyclers. If you have any query, please contact the relevant department of local authorities.

It is illegal to pour the used engine oil into ground, sewer or draining equipment.

(XVI) Noise

Some operations can cause high decibel noise and may do harm to your hearing, so appropriate hearing

protective devices should be worn.

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Overview

VII

Fastener specification

(I)

Fastener specification chart

In order to reduce the number of fasteners size, Jianghuai Automobile Co., Ltd engineering standard has

already adopted a part of the standard metric fasteners size defined by ISO and keeps each thread size the

best thread quality. As shown in the above metric bolt, the strength grade increases by the digital.

(II)

Main fastener tightening torque chart

SN

Name

Tightening torque (N·m)

1

Connecting nut between front shock absorber and vehicle body

21~25

2

Connecting bolt(nut) between front shock absorber and steering

knuckle

110±10

3

Connecting bolt between steering knuckle and ball head of lower

sway arm

110±10

4

Connecting bolt between steering gear and steering knuckle

50~55

5

Connecting bolt between left suspension and vehicle body

55±5

6

Connecting bolt between left suspension and gear box

70±10

7

Connecting bolt between right suspension bracket and right

suspension

70±10

8

Connecting bolt between right suspension bracket and vehicle

body

55±5

9

Connecting nut between right suspension and engine

55±5

10

Connecting bolt between rear suspension bracket and gear box

70±10

11

Connecting bolt(nut) between rear suspension and rear suspension

bracket

130±15

12

Connecting bolt between rear suspension and side frame

130±15

13

Front connecting nut between sub-frame and vehicle body

180±10

14

Rear connecting bolt between sub-frame and vehicle body

180±10

15

Connecting bolt between steering gear and sub-frame

Main: 100~110 Auxiliary :110~120

16

Connecting bolt between stabilizer bar and sub-frame

60±5

17

Connecting nut between stabilizer bar and stability pulling rod

60±5

18

Connecting nut between stability pulling rod and vibration damper

cylinder

50±5

19

Connecting bolt between brake hose and brake caliper(piercing

bolt)

25~30

20

Front connection bolt between lower sway arm and side frame

180±10

21

Rear connection bolt between lower sway arm and side frame

110±10

22

Connecting bolt between brake caliper and steering knuckle

65~75

23

Connecting bolt between rear shock absorber and vehicle body

50±5

24

Connecting bolt between rear shock absorber and rear torsion

beam assembly

140±10

25

Connecting bolt between rear suspension and brake

70±10

26

Connecting bolt between rear torsion beam assembly and vehicle

body

110±10

27

Driving shaft mounting nut

240~260

28

Mounting bolt

90~110

29

Mounting bolt between gear box and engine

35~45

30

Clutch mounting bolt(bracket bolt)

20~28

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31

Mounting bolt between oil tank and vehicle body

60~70

32

Mounting bolt between universal joint and steering

30~35

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SN

Name

Tightening torque (N·m)

33

Connecting bolt between direction pipe column and universal joint

30~35

34

Connecting bolt between direction pipe column and dashboard

framework

上：

20~25

下：

20~30

35

Mounting bolt for clutch pedal and brake pedal

20~28

36

Steering wheel mounting nut

42~52

VIII

Vehicle identification

(I)

Vehicle identification number

Vehicle Identification Number (VIN) is legal mark of

the vehicle.

Carving position of VIN

The VIN is engraved on the installing cross beam of the

right front seat.

Plate position

The VIN label is located in the upper left corner of the

instrument panel and can be seen through the front

window glass out of the vehicle.

(II) Label

Label-vehicle certification

Information label

The label is permanently posted side down of the

driver’s door. You can refer to the content for tire

information. The label marks the maximum load of the

vehicle, tire size(include spare tire) and cold inflation

pressure（include spare tire).

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Transmission identification number and location

Carving position of manual transmission identification number

IX

Noise, vibration and abnormal noise

(I)

Diagnosis information and steps

Wind noise and air sound

△

Warning Refer to “Warning on assistant driving” in “Warning and Precautions”.

△

Caution The vehicle should be driven by assistant when the technician is inspecting the failure part

or it may cause accidents.

In order to accurately confirm the location of the wind noise, you must drive the car by yourself for a

test. Generally, there are main leakage and secondary leakage in wind noise. If you cannot repair all leakage

during maintaining process, you can only reduce the wind noise but cannot eliminate it completely. During

testing driving, in order to confirm the location of wind noise, the repairman must take below tools:

·

Stethoscope

·

Masking tape

·

Caulking strip

·

Sharpie

·

Screwdriver

·

Take a road test

according to below

procedures:

·

Choose a road path with straight streets in four different directions of east, south, west and north.

·

Choose the street with less traffic flows and less noise to avoid the detection being impacted.

·

Make the road test at a speed which the customer thinks the noise is most

obvious and will occur. It is prohibited to drive over the legally limited speed. The

wind noises occurring in below case are external noises:

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·

You can hear wind noise immediately after you lower the window glass and drive the vehicle.

·

The wind noise will appear when you stick a tape on all decoration

seal and gap. Internal wind noise is caused when the air escapes out of

the vehicle. You should follow below approaches for repair:

·

Tape the pressure relief valve of the door lock pillar when you confirm the leakage location. The

inside pressure will be formed and make wind noise enhanced.

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·

Use a stethoscope to confirm the leaking location.

·

Use a masking tape to repair the leaking location temporarily.

·

Continue the road test and check if wind noise is eliminated completely or there is other leakage

location.

·

After confirmation of all leakage location by road test, return to the repair workshop and repair them

permanently with professional and reasonable method as well as sealing material.

Vibration

Most high speed vibrations are caused by dynamic imbalance of the wheel. The reasons for vibration

after dynamic balance are as follows:

·

Tires are out of round

·

Wheel hubs are out of round

·

Tires have

hardness deviation

Not all causes of vibration can be detected by measuring tire and wheel free runout. The three reasons

above are called load radical runout. Repair the vehicle by replacing the original tire and wheel assembly

with good tire and wheel assembly you know.

Low speed vibration which occurs when the vehicle speed is under 64km/h is generally caused by beat.

High speed vibration which occurs when the vehicle speed is above 64hk/h is generally caused by imbalance

or beat.

Correcting uneven tire

Generally, there are two ways to correct the tires which still vibrate after being balanced. One is to use

automatic machines. Install the tire on the machine tool and rub a small amount of rubber from the high

point of the tire thread on the left and right sides. Correcting tires in this way is permanent. It will not cause

significant impact on the tire appearance and tire thread life if operate by following instructions. Do not use

edge-type machine tool to repair tires during correction because it will shorten the tire using life and cannot

solve the problem fundamentally.

Another way is to disassemble the tire and turn the tire for one hundred and eighty degree on the rim.

This method can only be used when the vibration is confirmed to be caused by the tire and wheel assembly

because it may also cause intact wheel assembly to vibrate.

Abnormal sound

Check the heating shield if contacted with the bottom of the vehicle body when there is creak while the

vehicle engine is at a high speed.

·

Lift the vehicle and inspect visually.

·

Bent the heating shied slightly to produce a gap with the bottom of the vehicle body.

Squeak occurs in front of the vehicle in cold weather

Check the isolation pouches of the front balance bar

-

Make a road test when the vehicle is not heated and pass over potholes to make the front

suspension to reach its maximum stroke.

-

Remove the isolation pouch and wrap the front balancing bar with tape and then re-install

the isolation pouch on the tape.

Dull and abnormal sound occurs in the rear part of the vehicle when bumps

Check the spare tire in the trunk to be correctly secured.

-

Open the trunk and check the spare tire and vehicle tools.

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Re-fix the spare tire and vehicle tools.

-

Make a road test to see if the abnormal sound disappears.

Glass percussion sound occurs in the rear part of the vehicle when driving on a bumpy road.

Check the rear door lock to be properly adjusted.

-

Make a road test to confirm the rear door lock state.

-

Loosen the lock nut and adjust the latch.

Creaks on the vehicle door

Check the wiring harness connector inside the door trim panel if creaks.

-

Tap the interior trimming panel and observe carefully if there is creak.

-

Remove the door interior trimming panel and wrap the harness connector with foamed pad

based on real cases.

Squeak occurs when using the vehicle door

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Check the door hinge if it is lack of lubricant.

-

Operate the door back and forth and listen carefully whether the door squeaks.

-

Use rust remover to lubricate the door hinges and apply grease on it.

Squeak occurs when shifting gear in manual transmission (occurs in cold weather and during cold start).

Check the sheath under the manual shift devices assembly.

-

Switch the shift lever and observe if there is squeak.

-

Remove the floor console and change the shift lever sheath or coat it with gypsum powder.

(II)

Maintenance instruction

Wind noise and air sound

External wind noise

The repairing method for wind noise is very close to the repairing method for liquid leakage. You can

refer to “diagnosis information and steps”. The actual repairing program depends on the type of sealing

material maintained.

Vibration

Wheels and tires balance on the vehicle

Use electric vehicle wheel balancing machine to get dynamic balance. The dynamic balancing machine

is easy to be used for both static and dynamic balance. Different from balancing on the vehicle, the

balancing machine under the vehicle cannot correct imbalance of the braking disc. However, the accuracy of

the balancing machine under the vehicle overcomes this shortcoming. Fix the wheel on the balancing

machine, and then use a cone to pass through the back side of the central hole but through the wheel nut

hole.

Wheels and tires balance under the vehicle

Wheels and tires balance on the vehicle can correct the vibration caused by imbalance of the braking

disc.

△

Warning Make the lower controlling arm to support in normal position in order to avoid damage to the driving

axle. Do not shift into gear when the wheel is sank to its maximum trip.

·

When operate dynamic balancing on the vehicle, it is forbidden to remove the balancing block

installed on the wheel during dynamic balancing under the vehicle.

·

If you need to increase the balancing block for more than 25g in dynamic balancing, divide the

counterweight into two pieces and put them respectively on the inside rim and outside rim.

·

Use the engine to rotate the driven wheel and wheel assembly.

Directional allocation of wheels and tires

Wheels and tires are packed in the factory. Equipment is matching the thicker part of the radial tire(high

point) with the minimum radius(low point) of the wheel.

When the tires leave from the factory, the high point of the tire is marked with a red paint mark

originally or a label is attached to the outer wall of the wheel.

The low pint position of the wheel is the valve core.

Before removing the tires from the wheel, mark the valve core position to ensure it can be installed to

the original position.

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Abnormal sound

Repair for abnormal sound

Abnormal sound mainly comes from relative movement between the components which should not exist.

There are three ways to repair the abnormal sound:

·

Strongly fasten the components to avoid any relative movement in the driving process.

·

Separate the components to avoid any contact during working.

·

Isolate the components to avoid any abnormal sound during moving. Uniform surfaces with low

friction can be used to eliminate the viscous sliding among components

.

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Clutch

I．Overview

(I) Structure overview

Structure description

The clutch assembly is located between engine and transmission. The clutch pressure plate is mounted on the back plate of

flywheel through bolts. The clutch driven disk is connected with transmission input shaft through spline, rolls in axial direction, and

transmits torque circumferentially. During driving a vehicle, the driver can press or release clutch pedal to realize temporary

separation and gradual junction between engine and transmission, so as to cut off or transmit the power from engine to transmission.

The clutch system mainly consists of following components:

· Driving part: clutch pressure plate

assembly. The clutch pressure plate

assembly is mounted on the flywheel

through bolts.

· Driven part: clutch driven disk. The clutch driven disk is connected with transmission input shaft through spline. The

driving part and driven part keeps connection through spring pressure, which is imposed by diaphragm spring in the

pressure plate assembly.

· Controls: clutch operating system consists of clutch pedal, master cylinder, oil pump, wheel cylinder, release fork, and

release bearing. When pressing clutch pedal, the main cylinder pushes wheel cylinder and release fork through hydraulic

pressure, and then pushes diaphragm spring disengaging pawl through release bearing, release pressure plate, so as to

release the clutch.

Clutch operating system

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Clutch pressure plate & Clutch driven disk、

1.

Engine flywheel

3. Clutch pressure

plate assembly

2.

Clutch driven disk

(II) Maintenance parameters

Maintenance parameters

SN

Item

Parameter

1

Clutch free travel

6~20mm

Grease

SN

Item

Grease type

1

Master cylinder master pin

Kunlun No. low-temperature grease

(III) Torque

parameter

SN

Item

Torque (N.m) （N·m）

1

Clutch master cylinder mounting bolts

20~28

2

Clutch master cylinder mounting nuts

20~28

3

Oil pump mounting bracket

20~28

4

Exhaust bolts

8~12

5

Clutch pressure plate installation bolts

20~28

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(IV) Precautions for maintenance

Precautions

· The recommended clutch hydraulic fluid is brake fluid “DOT 4”. “DOT 4”

· Please do not repeatedly use the discharged clutch hydraulic fluid.

· Do not splash clutch hydraulic fluid onto vehicle body.

· Do not use mineral oil such as gasoline or kerosene. Otherwise, the rubber components in hydraulic system will be

corroded.

· Please do not disassemble master cylinder and hydraulic release bearing.

△

Warning: Please use cleaner to clean the clutch and do not use compressed air to clean.

Main points for maintenance

△ It is prohibited to use vacuum pump or any type of emptying power device to operate on this system. Check the level of

clutch hydraulic fluid and ensure the level is normal. Do not splash clutch hydraulic fluid on vehicle body or

other components. If clutch hydraulic fluid splashes on the vehicle body or other components, please use a dry

cloth to clean completely.

(V) Special tools

SN

No.

Tool

Outline drawing

Description

1

JAC-T1F011

Flywheel brake

Mounting flywheel

II. Malfunction Diagnosis

(I) Common malfunction diagnosis

The performance diagnosis of clutch assembly and clutch operating system should be conducted by a skilled driver or a

professional automotive repairing technician.

The following (malfunction) diagnosis consists of common problems and possible reasons. After conducting proper diagnosis,

please adjust or replace the parts as requested according to the respective solutions in the diagnosis chart and the proper chapters

corresponding with each specific procedure in the service manual.

During the maintenance, the clutch pressure plate and clutch driven disk cannot be repaired. If any one of them is broken, please

replace the whole assembly.

If the rivets of clutch driven disk are damaged or polluted by engine oil or grease, this clutch driven disk cannot be used.

If you need to replace a new part, please use a qualified new part to replace it.

This diagnosis chart helps to diagnose the malfunction of clutch system caused by the following situations: unreleased,

incomplete release, incomplete junction, slipping, noise, and vibration.

The numbers in the diagnosis chart does not represent the checking sequence, and there is no precedence relation among all

kinds of possible reasons.

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(II) Malfunction

Diagnosis chart

SN

Malfunction

phenomenon

Malfunction reason analysis

Solution

Remark

Clutch release lever deforms

Replace deformed part

diaphragm spring deforms

Replace deformed part

1

Unreleased

diaphragm spring support ring breaks

Replace deformed part

Clutch pedal spring breaks

Replace worn and damaged part

Clutch driven disk sticks with flywheel or

clutch pressure plate

Adjust clutch system

Clutch driven disk deforms, and swings when

it rotates

Replace deformed, worn, damaged

and exceed-fixed-parameter part

Clutch driven disk damages

Replace driven disk

If clutch driven disk cannot match

with transmission input spline,

replace clutch driven disk. If

necessary, replace transmission input

shaft.

Clutch driven spline does not match with

transmission input shaft spline, or spline tooth

damages

2

Incomplete

release

Clutch driven disk sticks with flywheel or

seizes clutch pressure plate

Replace undesirable part

Thickness of flywheel, clutch pressure plate,

clutch driven disk exceeds prescribed

parameter

Replace undesirable part

Clutch pedal control system and clutch wire

drawing have mechanical failure or improper

adjustment

Adjust clutch system to kill

unnecessary clearance and eliminate

mechanical failure

Reinstall improperly installed part

Clutch driven disk is polluted by engine oil or

grease

Clean grease or replace driven disk

Clutch driven disk damages

Replace deformed, worn, and

damaged part

Clutch pedal has no free travel

Correctly adjust clutch pedal free

travel

3

Incomplete

junction

Diaphragm spring/clutch pressure plate/clutch

release lever/clutch driven disk spline

deforms or damaged

Replace clutch driven disk or

problematic clutch assembly

Clutch pedal control system and clutch wire

drawing have mechanical failure or improper

adjustment

Adjust clutch system to kill

unnecessary clearance and eliminate

mechanical failure

Reinstall improperly installed part

Clutch driven disk damaged

Replace driven disk

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Clutch driven disk is polluted by engine oil or

grease

Clean grease or replace driven disk

Clutch incomplete junction

Same with the respective solution for

“incomplete release” and “incomplete

junction”

“ ” “

”

4

Slipping

Thickness of flywheel, clutch pressure plate,

clutch driven disk exceeds prescribed

parameter, friction surface exceeds specified

standard / ／

Replace undesirable part

，

Extreme high temperature in clutch due to

improper driving

Switch off the engine, cool down the

temperature of clutch (if temperature

is high), and then conduct further

diagnosis，

（），

Clutch installed improperly

Reinstall clutch

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SN

Malfunction

phenomenon

Malfunction reason analysis

Solution

Remark

Unfit clutch driven disk

Install prescribed clutch driven disk

Improper balance

If a part has improper balance, replace

clutch assembly，

5

Noise

Adjust clutch wire drawing

Reinstall improper installed part

Clutch thrust bearing fails

Clutch driven disk torsion shock absorber

spring damaged

Replace deformed, worn, and

damaged part、

Clutch driven disk shock absorber spring does

not conform parameter

Replace driven disk

6

Vibration

Clutch driven disk does not conform

parameter

Replace driven disk

Clutch driven disk is polluted by engine oil or

grease

Replace driven disk

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(III) Malfunction diagnosis flow chart

Clutch unreleased flow chart

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Incomplete release flow chart

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Incomplete junction flow chart

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Clutch slipping flow chart

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Clutch noise flow chart

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Clutch

III Clutch Pedal Free Travel Adjustment

(I) Special tool (No)

(II) Adjustment

1. Adjust clutch pedal free travel

1). Press clutch pedal to the dead point, and measure the clutch

pedal travel from starting position to the dead position.

2). Loosen the locking nuts and rotate bolts, and adjust clutch pedal

travel. After adjustment, fasten the locking nuts.

△

Caution: When adjusting clutch pedal height, do not push lever

to clutch master cylinder.

3). Use hands to press gently clutch pedal, and ensure clutch pedal

has free travel when there is resistance for pedal falling.

Standard parameter

6~20mm

4). Loosen the locking nuts and push the lever, and adjust clutch

pedal free travel. After adjustment, fasten the locking nuts.

Tightening torque

20~28N·m

5). Clutch pedal free travel should be within the standard value.

△

Caution: If clutch pedal free travel is not within the standard

value, then there is air in clutch hydraulic pipe or

clutch master cylinder has malfunctions. Please

conduct system exhaust, and disassemble and check

master cylinder or clutch.

IV Hydraulic Clutch Exhaust

(I) Special tool (No)

(II) Exhaust operation procedure

△

Caution: When disassemble clutch pipe, clutch master cylinder,

hydraulic release bearing and clutch pedal rubber,

please conduct system exhaust.

1. Exhaust air in the pipe

1). Loosen exhaust bolts on clutch

wheel cylinder.

2). Slowly press down clutch pedal, until air is completely exhausted.

3). Press the pedal completely and maintain, and tighten exhaust bolts.

4). Add hydraulic oil in clutch hydraulic system.

△

Caution: Always keep the fluid level between MIN and MAX.

5). Repeat the above procedures, until the exhausted clutch hydraulic

oil is clean and free of bubble.

2. Confirm clutch works normally.

1). Start the engine, press clutch pedal, and shift into reverse gear

after two seconds. If there is noise during shifting gear,

completely press down clutch pedal for 5 times to exhaust air

for the system.

2). After 30 seconds, check the working condition of clutch. If there is

still big noise, please repeat exhaust.

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V Clutch Master Cylinder

(I) Special Tool (No)

(II) Removal

1. Remove the battery and its mounting frame.

2. Remove instrument panel lower shield. Refer to Instrument Panel.

3. Remove clutch master cylinder.

1). Exhaust clutch hydraulic oil from clutch exhaust bolts.

2). Disconnect the connecting hose between clutch master cylinder

and brake master cylinder, and the connecting hard pipe

between clutch master cylinder and clutch wheel cylinder.

3). Disconnect the locking pin between clutch master cylinder push rod and clutch pedal.

4). Remove clutch master cylinder and the connecting bolts and mounting nuts on the vehicle body.

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5). Take out clutch master cylinder.

(III) Check

1. Check clutch pipeline

1). Check whether the clutch

pipeline is congested or not.

2). Check clutch hose and hard pipe for damage or rust.

(IV) Installation

1. Install clutch master cylinder

1). Install clutch master cylinder, and tighten mounting

nuts of clutch master cylinder.

Tightening torque 20~28N·m

2). Connect the locking pin between clutch master

cylinder push rod and clutch pedal.

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3). Connect the connecting hose between clutch master cylinder and

brake master cylinder, and the connecting hard pipe between

clutch master cylinder and clutch wheel cylinder.

2. Add clutch hydraulic oil, and exhaust. Refer to

Hydraulic clutch exhaust.

3. Install instrument panel lower shield.

4. Install battery frame and connect battery cable.

VI Clutch Wheel Cylinder

(I) Special tool (No)

(II) Removal

1. Remove battery and frame.

2. Remove Clutch wheel cylinder

1). Remove clutch wheel cylinder oil pipe

bolts, and disconnect pipeline.

2). Remove clutch wheel cylinder mounting bolts, and take down clutch wheel cylinder

△

Caution: The anti-dust cover and lever of wheel cylinder easily

fall off. When taking out wheel cylinder, please

avoid falling off.

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Clutch

(III) Installation

1. Install clutch wheel cylinder

1). Connect clutch cylinder onto the transmission housing and tighten

the bolts.

Tightening torque

20N·m

2). Smear grease on the connecting area between push

rod and release lever.

△

Caution: Do not stain anti-dust cover.

3). Connect clutch oil pipe onto clutch wheel cylinder and tighten the

bolts.

Tightening torque

10N·m

4). Add clutch hydraulic oil, and exhaust.

VII Clutch Master Cylinder Oilout Hard

Pipe

(I) Special tool (No)

(II) Removal

1. Remove air filter assembly. Refer to air filter assembly.

2. Remove clutch master cylinder oilout

hard pipe assembly.

1). Loosen exhaust screws, and exhaust

clutch fluid.

2). Disconnect oilout hard pipe with clutch wheel

cylinder.

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Clutch

3). Disconnect oilout hard pipe with clutch master cylinder.

4). Remove the connecting bracket between oilout hard pipe and transmission.。

5). Remove the connecting bracket between oilout hard pipe and frame.。

6). Take out clutch master cylinder oilout hard pipe assembly.。

(III) Installation

1. Install clutch master cylinder oilout hard pipe

assembly

1). Connect oilout hard pipe with clutch master

cylinder, and tighten.

2). Connect oilout hard pipe with clutch wheel cylinder, and tighten the mounting nuts.

Tightening torque

10N·m

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Clutch

3). Install transmission bracket.

4). Add clutch hydraulic fluid.

2. Hydraulic clutch exhaust.

3. Install air filter assembly.

VIII Clutch Pedal

(I) Special tool (No)

(II) Removal

1. Remove clutch pedal

1). Disconnect the locking pin between clutch

master cylinder push rod and clutch pedal.

2). Remove 2 bolts connecting clutch pedal upper part and vehicle

body, and 2 bolts connecting clutch lower part and clutch

master cylinder.

3). Take out clutch pedal.

(III) Check

1. Check clutch pedal

1). Check clutch pedal for twist, damage or cracked welded

junction.

If there is above situation, please replace clutch pedal assembly.

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Clutch

(IV) Installation

1. Install clutch pedal

1). Install clutch pedal, and tighten clutch pedal mounting nuts and bolts.

Tightening torque

20~30N·m

2). Connect the locking pin between clutch master cylinder push rod and clutch pedal.

2. Adjust clutch pedal free travel

IX Clutch Pressure Plate Assembly And Driven Disk

(I) Special tool

SN

Tool No.

Tool Name

Tool drawing

1

JAC-T1F011

Flywheel stopper

(II) Removal

1. Remove manual transmission assembly. Refer to transmission assembly.

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Clutch

2. Remove clutch pressure plate assembly

1). Use flywheel stopper to fix flywheel.

2). Equably loosen clutch pressure plate mounting bolts.

△

Caution: Each time please loosen each bolt for one or two

rounds, to avoid damaging flange of clutch housing.

3). Take out clutch pressure plate and clutch driven disk.

(III) Check

1. Check clutch driven disk

1). Check whether there are rivet looseness, single side contact, and fire

burns leading to cracking, and oil appendage on the surface. If any,

please replace clutch driven disk.

2). Measure the immersed length of rivet. If it exceeds the ultimate

value, please replace clutch driven disk.

Ultimate value：0.3mm

3). Check whether damper spring is loose or damaged. If any, please

replace clutch driven disk.

4).

Install clutch driven disk on input shaft, and check sliding mode and

looseness of rotation direction. If the sliding is poor, please clean.

After assembly, please replace if the sliding is still poor. If the

looseness is obvious, please replace clutch driven disk or input

shaft, or replace both of them.

2. Clutch pressure disk

1). Check whether diaphragm spring head is worn and there is height

difference. If there is obvious wear or the height difference exceed

ultimate value, please replace clutch driven disk.

Ultimate value：0.5mm

2). Check whether there are wear, crack, and color change on the

surface of pressure disk.

3). Check whether the rivet of pressure disk is loose. If it is loose,

please replace clutch pressure disk.

(IV) Installation

1. Clean and smear grease

1). Clean clutch driven disk and input shaft keyway, and eliminate

grease and worn metal chips.

2). Smear oil on input shaft key groove.

△

Caution: Recommended oil: SAE J310 or similar product.

Ensure the oil is smeared on the set position.

Otherwise, it will cause clutch produces noise, poor

separation or damage. Too much oil will lead to

sliding or vibration.

2. Install clutch pressure disk assembly

1). Use a special tool to conduct positioning installation of

clutch driven disk and clutch pressure disk.

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Clutch

2). Conduct in 1-2-3-4-5-6 sequence as shown in the picture, to evenly

tighten clutch mounting bolts successively.

Caution: Tighten each bolt for 1-2 rounds in proper sequence.

Tightening torque 15~22N·m

3. Install manual transmission

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Drive shaft

Drive Shaft

I Overview

(Ⅰ) Structure overview

The drive shaft is on the front sub-frame, and divides into left drive shaft assembly and right drive shaft assembly, and

transmits the torque and speed output from transmission to wheels.

Drive shaft inner side connects with transmission differential through spline, and depends on universal joint of inner side to roll

axially so as to offset the length change caused by wheel steering and jumping, and depends on universal joint of outside to

rotate in large angle, and connects with wheel hub inner ring through spline at the end of shaft, and locks through self-locking

nuts.

Drive shaft assembly structure

(II) Torque specification

SN

Item

Tightening torque (N·m)

1

Drive shaft self-locking nut

240~260

2

Connecting nut of Lower sway arm ball joint and steering

knuckle

100~120

3

Steering knuckle and steering tie-rod ball joint

50~55

4

Wheel nut

90~110

(III) Precautions for maintenance

1. Relevant issues needing attention during

maintaining drive shaft

1). None-overhaul parts such as steering

joint cannot be disassembled.

2). Try your best to operate on the platform

without dust.

3). Please clean the surface of parts first before dismantlement and assembly.

4). During operation, please be careful to avoid staining the parts and foreign materials entering. The disassembled parts should

be carefully re-assembled by following the correct sequence. If the operation is interrupted, please use clean cover to cover

the parts.

5). Please use paper cloth, and prevent cloth scraps sticking on the parts when using fiber cloth.

6). Please use kerosene to clean the dismantled parts (except rubber parts), and dry or use paper cloth to wipe dry.

2. Relevant issues needing attention during checking and repairing system or replacing parts

1) It is obliged to conduct the prescribed torque check on the mounted parts after assembly.

2) Please conduct necessary alignment after assembly.

3) Disposable parts cannot be repeatedly used.

4) Please check completely before repairing or replacing the parts.

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Drive shaft

(IV) Special tool

SN Tool Number

Tool Name

Outline drawing

Usage

1

JAC-T1D003 Steering driving rod

drawing die

Remove

steering ball

joint

2

Oil seal installation tool

Install oil

seal

II Malfunction diagnosis

(I) Malfunction diagnosis chart

SN

Malfunction

phenomenon

Malfunction reason analysis

Solution

Remark

Drive shaft steering knuckle wears

Replace

1

Vehicle running

deviation

Wheel bearing has wear, friction, or crack

sound

Replace

Front suspension and steering have defects.

Adjust and replace

Drive shaft wears, damages or bends

Replace

2

Vibration

Drive shaft and wheel hub have abnormal

noise

Replace

Wheel bearing has wear, friction, or crack

sound

Replace

3

Jump

Wheel unbalanced

Adjust and replace

Front axle steering knuckle has defects

Adjust and replace

Drive shaft wears, damages or bends

Replace

Drive axle wheel hub wears

Replace

4

Big noise

Drive shaft wheel hub wears

Replace

Wheel bearing wears, burns or has abnormal

noise

Replace

Wheel hub nuts become loose

Adjust and replace

Front suspension and steering have defects.

Adjust and replace

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Drive shaft

III Drive shaft

(I) Special tool

SN

Tool Number

Tool Name

Outline drawing

1

JAC-T1D003 Steering driving rod

drawing die

(II) Removal

1. Lift the vehicle.

2. Remove front wheel. Refer to wheel.

3. Remove front brake caliper assembly. Refer to front brake caliper (for the model with front disc and rear drum).

4. Remove wheel speed sensor. Refer to front wheel speed sensor.

5. Remove drive shaft.

1). Loose drive shaft self-locking nuts.

2). Remove the two connecting locking nuts between steering knuckle

and lower sway arm.

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Drive shaft

3). Disconnect the connection point between transverse stabilizer bar and stabilizer pull rod lower end.

4). Disconnect steering knuckle and steering transverse pull rod ball joint.

△

Caution: Please use a special tool, and avoid damaging ball joint anti-dust cover.

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

6). Pry drive shaft out from transmission, and pull out drive shaft assembly from wheel hub.

△

Caution: When removing drive shaft, the placed angle of drive

shaft universal joint should not be too large. Please

do not excessively pull the slip joint to avoid the

third ball pin falling from ball basket to damage it.

(III) Check

1. Rotate the universal joint to check whether it rotates smoothly and has serious looseness.

2. Check anti-dust cover for crack, damage and grease leakage.

3. If there is any abnormal situation, please disassemble drive shaft and replace the problematic part.

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Drive shaft

(IV) Installation

1. Install drive shaft

1). Replace a new transmission side oil seal.

2). Insert drive shaft into transmission and ensure snap rings are set at positions.

3). Install drive shaft on wheel hub and bearing assembly.

4). Tighten the connecting nuts of steering knuckle and steering transverse pull rod ball joint.

Tightening torque

50~55N·m

5). Tighten the connection point between transverse stabilizer bar and stabilizer pull rod lower end.

Tightening torque

55~65N·m

6). Tighten the two connecting nuts between steering knuckle and lower sway arm.

Tightening torque

100~120N·m

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Drive shaft

IV Differential oil seal

(I) Special tool

SN

Tool Number

Tool Name

Outline drawing

1

JAC-T1D003 Steering driving rod

drawing die

2

Oil seal installation

tool

(II) Removal

1. Remove the wheel. Refer to wheel.

2. Remove front constant velocity drive shaft. Refer to drive shaft.

3. Remove differential oil seal.

1). Use a pinch bar to pry the outer lip of seal, and remove differential oil seal.

△

Caution When using a pinch bar to pry seal, please be very

careful for not damaging transmission housing.

(III) Check

1. Check oil seal for crack, damage, and grease leakage.

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Drive shaft

2. Check anti-dust cover for crack, damage, and grease leakage.

3. If there is any abnormal situation, please replace the oil seal.

(IV) Installation

1. Install differential oil seal

1). Smear transmission oil on the lip of new

transmission oil seal.

2). Use a special tool to install the new transmission oil

seal.

2. Install drive shaft.

3. Install wheel.

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Front Suspension

I Overview

(I) Structure overview

Front suspension structure

Front shock absorber upright column assembly structure

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Front Suspension

Front sub-frame assembly structure

Front wheel hub assembly structure

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Front Suspension

(II) Technical parameter

Item

Parameter and Specification

Front suspension

type

McPherson independent suspension with coil spring

Type

Bidirectional hydraulic cylinder

Travel

168mm

Shock absorber

Stretch

549N±91N （0.3m/s）

Damping force

Compression

405N±85N （0.3m/s）

Coil spring

Free height: 329mm (Reference)

Color mark: a white yellow line

Wheel toe-in (front)

0°±10′

Wheel camber angle

0°±30′

Wheel alignment

(Non-loading)

Kingpin inclination angle 12.3°±30′

Kingpin caster angle

3.8°±30′

Kingpin offset

-1.2mm

(III) Torque

specification

SN

Item

Tightening torque (N·m)

1

Mounting bolts of front transverse stable rod mounting bracket and sub-frame

45~55

2

Connecting nuts between front transverse stable rod and transverse stable rod tie rod

55~65

3

Connecting nuts between front transverse stable rod tie rod and front upright column

assembly

55~65

4

Front shock absorber and vehicle body installing nuts

21~25

5

Upper self-locking nuts of front shock absorber

49~68.6

6

Connecting bolts between front shock absorber and steering knuckle

100~120

7

Connecting bolts between lower sway arm ball pin and steering knuckle

60~70

8

Connecting nuts between lower sway arm ball pin and lower sway arm

100~120

9

Connecting bolts between lower sway arm front bushing and sub-frame

170~190

10

Connecting bolts between lower sway arm rear bushing and sub-frame

100~120

11

Front mounting nuts of front sub-frame

170~190

12

Rear mounting nuts of front sub-frame

170~190

(IV) Precautions for maintenance

1. When installing suspension or rubber bushing, the final tightening must be conducted when tyres are on the ground and in non-

loading status.

2. After maintaining suspension parts, please check wheel alignment.

3. Engine oil will shorten service life of rubber bushing. Please clean the overflowed engine oil.

4. Non-loading condition means fuel, engine coolant, and lubricant are normally filled and spare tyre, jack, basic hand tool, and

foot pads are in specified position.

5. Locking nuts cannot be repeatedly used. It is obliged to use new nuts when installing. During replacement, do not wipe out the

rust-proof oil on the locking nuts before tightening them.

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Front Suspension

(V) Special tool

SN Tool number

Tool name

Outline drawing

Usage

1

JAC-T1D003 Steering driving rod die

Disassemble

steering ball

joint

2

JAC-T1D004 Damper spring disassembler

Disassemble and

install damper spring

3 Wheel hub installer

Install front and

rear wheel hub

II Malfunction Diagnosis

(I) Malfunction diagnosis chart

SN

Malfunction

phenomenon

Malfunction reason analysis

Solution

Remark

Front wheel alignment is improper

Adjust or replace

1

Heavy steering

Steering exceeds

lower sway arm ball joint

Replace

Tyre air pressure is too low

Inflate

No

power steering

Repair or replace

Front wheel alignment is improper

Adjust or replace

Shock absorber has failure

Repair or replace

2

Poor return

Transverse stabilizer bar wears or damages

Replace

Coil spring wears or damages

Replace

Lower sway arm bushing wears

Replace

Front wheel alignment is improper

Adjust or replace

3

Abnormal tyre

wear

Tyre air pressure is too low or too high

Adjust air pressure

Shock absorber has failure

Repair or replace

Front wheel alignment is improper

Adjust or replace

4

Vehicle running

deviation

Lower sway arm ball joint connecting

steering resistance is poor

Replace

Lower sway arm bushing is loose or wears

Replace

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Front Suspension

SN

Malfunction

phenomenon

Malfunction reason analysis

Solution

Remark

Front wheel alignment is improper

Adjust or replace

5

Vehicle

running

deviation

unilaterally

Lower sway arm ball joint connecting

steering resistance is poor

Replace

Lower sway arm bends

Replace

Coil spring wears or damages

Replace

Front wheel alignment is improper

Adjust or replace

6

Steering wheel

shimmies

Lower sway arm ball joint connecting

steering resistance is poor

Replace

Lower sway arm bushing is loose or wears

Replace

Shock absorber has failure

Repair or replace

III Lower Sway Arm Assembly

(I) Special tool (No)

(II) Disassembly

△

Caution: The methods of disassembling left and right lower sway arm assembly are similar.

1. Lift the vehicle.

2. Disassemble front wheel. Refer to wheel.

3. Disassemble lower sway arm assembly.

1). Pull out split pin, and disassemble lower sway arm ball pin and

the mounting groove nuts of lower sway arm.

2). Disassemble lower sway arm and sub-frame rear mounting bolts.

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Front Suspension

3). Disassemble lower sway arm and sub-frame front mounting bolts.

△

Caution: During removal, please fasten lower sway arm ball joint,

and then loosen locking nuts, to avoid rotation.

4). Take lower sway arm down.

(III) Check

Check lower sway arm assembly.

1. Check whether bushing wears or damages. If any, please replace.

2. Check whether lower sway arm deforms or has other damages. If

any, please replace.

3. Check whether lower sway arm ball joint anti-dust cover has crack. If

any, please replace.

4. Check whether all the mounting bolts and nuts have damage. If any,

please check.

(IV) Installation

1. Install lower sway arm assembly.

1). Install lower sway arm assembly on the correct position.

2). Tighten lower sway arm and sub-frame front mounting bolts.

Tightening torque

170~190N·m

3). Tighten lower sway arm and sub-frame rear mounting bolts.

Tightening torque

100~120N·m

4). Tighten lower sway arm ball pin and the mounting groove nuts of

lower sway arm, and install split pin.

Tightening torque

60~70N·m

2. Install front wheel.

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Front Suspension

IV Front Upright Column Assembly

(I) Special tool

(II) Disassembly

△

Caution: The methods of disassembling left and right front upright column assembly are similar.

1. Lift the vehicle.

△

Caution: In order to keep wheel balance, please mark relative position

of wheels before disassembling tyres.

2. Disassemble front wheel. Refer to wheel.

3. Disassemble front stabilizer connecting rod.

4. Disassemble front upright column assembly.

1). Disconnect the harness and oil pipe on front column, and

disconnect front brake oil pipe and wheel speed sensor from

shock absorber.

2). Disassemble the two connecting bolts between steering knuckle and front shock absorber.

3). Remove the three mounting nuts on front shock absorber.

4). Disassemble front upright column assemble from wheel cover side.

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Front Suspension

(III) Installation

1. Install front upright column assembly

1). Install front upright column from wheel cover side.

2). Tighten the three mounting nuts on front shock absorber.

Tightening torque

21~25N·m

3). Tighten the connecting bolts between steering knuckle and front

shock absorber.

Tightening torque

100~120N·m

4). Install front brake oil pipe and wheel speed sensor on shock

absorber, and connect the harness and oil pipe on front upright

column.

2. Install front stabilizer connecting rod.

3. Install front wheel.

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Front Suspension

V Front Shock Absorber Parts And Spring

(I) Special tool

SN

Tool number

Tool name

Outside drawing

1

JAC-T1D004 Damper spring remover

(II) Disassembly

△

Caution: The methods of disassembling and installing left and right front shock absorber parts and spring are similar.

1. Disassemble front upright column assembly. Refer to front upright column.

2. Disassemble front shock absorber parts and spring

1). Install two nuts and one bolt on the bracket of shock absorber,

and then mount front absorber assembly on bench vice.

2). Use a spring compressor to compress coil spring.

△

Caution: It is prohibited to use a pneumatic wrench to avoid damaging spring compressor.

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Front Suspension

3). Disassemble front shock absorber upper pedestal anti-dust cover,

and use a tool to mount spring seat and remove locking nuts.

4). Disassemble front shock absorber upper pedestal assembly, upper

pedestal, coil spring upper shock mount pad, coil spring, anti-

dust cover, buffer block, and front coil spring lower shock

mount pad.

(III) Installation

1. Install front shock absorber parts and

spring

1). Use a spring compressor to compress

coil spring.

2). On shock absorber bracket, install front coil spring lower shock

mount pad, buffer block, anti-dust cover, coil spring, coil spring

upper shock mount pad, upper pedestal, and front shock

absorber upper pedestal assembly.

△

Caution: Install the lower side of coil spring on the recess of

shock absorber spring seat.

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Front Suspension

3). Install locking nuts, and close front shock absorber upper pedestal anti-dust cap.

Tightening torque

49~68.6N·m

2. Install front upright column assembly

VI Front Transverse Stabilizer Bar

(I) Special tool (No)

(II) Disassembly

1. Lift the vehicle.

2. Remove front wheel. Refer to wheel.

3. Disassemble stabilizer bar tie rod lower mounting point.

4. Remove front transverse stabilizer bar.

1). Remove left and right stabilizer bar mounting bracket

mounting bolts, and take down mounting bracket and bushing.

2). Take down front transverse stabilizer bar assembly.

(III) Installation

1. Install front transverse stabilizer bar assembly.

1). Install front transverse stabilizer bar

assembly on the correct position.

2). Install mounting bracket and bushing, and

tighten left and right stabilizer bar mounting

bracket mounting bolts.

Tightening torque

45~55N·m

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Front Suspension

2. Tighten stabilizer bar tie rod lower mounting bolts.

Tightening torque

55~65N·m

3. Install front wheel.

VII Stabilizer Bar Tie Rod Assembly

(I) Special tool (No)

(II) Disassembly

△

Caution: The methods of disassembling and installing left and right

stabilizer bar tie rod are similar.

1. Lift the vehicle.

2. Remove front wheel. Refer to wheel.

3. Disassemble stabilizer bar tie rod.

1). Remove stabilizer bar tie rod connecting ball joint and

front upright column assembly mounting nuts.

2). Remove stabilizer bar tie rod connecting ball joint and front

stabilizer bar assembly mounting nuts.

(III) Installation

1. Install stabilizer bar tie rod assembly.

1). Place front stabilizer bar assembly at

the correct position.

2). Tighten stabilizer bar tie rod connecting ball joint and front

stabilizer bar assembly mounting nuts.

Tightening torque

55~65N·m

3). Tighten stabilizer bar tie rod connecting ball joint and front

upright column assembly mounting nuts.

Tightening torque

55~65N·m

2. Install front wheel.

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Front Suspension

VIII Lower Sway Arm Ball Joint Assembly

(I) Special tool

(II) Disassembly

△

The methods of disassembling and installing left and right lower sway arm ball joint assembly are similar.

1. Lift the vehicle.

2. Remove front wheel. Refer to wheel.

3. Disassembly lower sway arm ball joint assembly.

1). Remove the two connecting bolts between lower

sway arm ball joint and steering knuckle.

2). Pull out split pin, and disassemble the mounting groove nuts between lower sway arm ball joint and lower sway arm.

3). Disconnect the connection between lower sway arm ball joint and lower sway arm.

4). Use a special tool to remove lower sway arm ball joint.

△

Caution: Please only use a special tool to disconnect lower

sway arm ball joint and steering knuckle. It is

prohibited to use hammer or pinch bar to remove

lower ball joint from steering knuckle. If do not use

the recommended tool, it will result in the damage of

lower ball joint and sealing.

(III) Installation

1. Install lower sway arm ball joint assembly

1). Install lower ball joint and lower sway arm assembly, and tighten groove nuts.

Tightening torque

60~70N·m

2). Install split pin.

3). Tighten the two connecting bolts between lower sway arm ball joint and steering knuckle.

Tightening torque

60~70N·m

2. Install front wheel.

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Front Suspension

IX Front Sub-Frame Assembly

(I) Special tool (No)

(II) Disassembly

1. Lift the vehicle.

2. Remove front wheel. Refer to wheel.

3. Disassemble lower sway arm assembly. Refer to lower sway arm

assembly.

4. Remove the connecting bolts between stabilizer bar tie rod lower

side and transverse stabilizer bar.

5. Remove front sub-frame

assembly

1). Use jack to support

sub-frame.

2). Remove the four

mounting bolts between

steering gear and sub-frame.

3). Remove the two

mounting bolts between

engine rear suspension and

front sub-frame.

4). Remove the two mounting bolts

between sub-frame and the front section of vehicle body.

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5). Remove the two mounting bolts between sub-frame and the rear section of vehicle body.

6). Take down front sub-frame assembly.

(III) Installation

1. Install front sub-frame

assembly

1). Install front sub-

frame assembly.

2). Tighten the two mounting bolts between sub-frame

and the rear section of vehicle body.

Tightening torque 170~190N·m

3). Tighten the two mounting bolts between sub-frame

and the rear section of vehicle body.

Tightening torque

170~190N·m

4). Tighten the two mounting bolts between engine rear

suspension and front sub-frame.

Tightening torque

115~145N·m

5). Tighten the four mounting bolts between steering

gear and sub-frame.

Tightening torque

100~121N·m

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Front Suspension

2. Tighten the connecting bolt between stabilizer bar tie rod lower side and transverse stabilizer bar.

3. Install lower sway arm assembly.

4. Install front wheel.

X Front Wheel Hub Assembly

(I) Special tool

SN

Tool number

Tool name

Outside drawing

1

Wheel hub

installation tool

(II) Removal

1. Lift the vehicle.

2. Remove front wheel. Refer to wheel.

3. Remove brake caliper. Refer to front brake caliper (For Vehicle Model with front disc and rear drum).

4. Remove front brake disc. Refer to front brake disc (For Vehicle Model with front disc and rear drum).

5. Remove lower sway arm. Refer to lower sway arm assembly.

6. Remove front wheel speed sensor. Refer to front wheel speed sensor.

7. Remove steering transverse tie rod ball joint. Refer to steering gear and tie rod assembly.

8. Remove front wheel hub

assembly.

1). Disconnect steering

knuckle and shock absorber.

2). Remove axle nuts, and disconnect wheel hub and drive shaft.

3). Take down steering knuckle.

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Front Suspension

4). Remove front wheel hub mounting circlip.

5). Use a special tool to remove front wheel hub from

steering knuckle.

(III) Installation

1. Install front wheel hub assembly.

1). Place a wood block under wheel hub, and install front

wheel hub into front steering knuckle.

2). Install front wheel hub mounting circlip.

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Front Suspension

3). Install axle nuts.

4). Install steering

knuckle and shock

absorber.

2. Install steering transverse tie

rod ball joint.

3. Install front wheel speed

sensor.

4. Install lower sway arm

assembly.

5. Install front brake disc.

6. Install front brake caliper.

7. Install front wheel.

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Rear Suspension

I Overview

(I) Structure overview

Rear suspension structure

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Rear Suspension

Shock absorber upright column assembly structure

Rear torsion beam assembly structure

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Rear Suspension

Rear wheel hub assembly structure

Rear wheel hub assembly installation diagram

(II)

Technical

parameter

Item

Parameter and Specification

Rear suspension type

Torsion beam

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Rear Suspension

Item

Parameter and Specification

Type

Bidirectional hydraulic cylinder

Travel

223mm

Shock absorber

Stretch

451N79N 0.3m/s

Damping

force

Compression

202N52N 0.3m/s

Type

Coil straight spring

Coil spring

Free height

365mm

(Reference)

Color mark

Same color on both sides

Wheel total toe-in

2420

Wheel alignment

Single wheel toe-in

1210

Wheel camber angle

-130

(III) Torque

specification

SN

Item

Tightening torque (Nm) Nm

1

Rear shock absorber and vehicle body installing bolt

45~55

2

Rear shock absorber upper self-locking nut

24.5~34.3

3

Rear shock absorber and rear torsion beam connecting

bolt

100~120

4

Rear wheel hub and torsion beam connecting bolt

55~75

5

Rear torsion beam and vehicle body installing bolt

130~150

(IV) Precautions for maintenance

1. When installing suspension or rubber bushing, the final tightening must be conducted when tyres are on the ground and in non-

loading status.

2. After maintaining suspension parts, please check wheel alignment.

3. Engine oil will shorten service life of rubber bushing. Please clean the overflowed engine oil.

4. Non-loading condition means fuel, engine coolant, and lubricant are normally filled and spare tyre, jack, basic hand tool, and

foot pads are in specified position.

5. Locking nuts cannot be repeatedly used. It is obliged to use new nuts when installing. During replacement, do not wipe out the

rust-proof oil on the locking nuts before tightening them.

(V) Special tool

SN Tool number

Tool name

Outside drawing

Usage

1

Damper spring remover

Remove and install

damper spring

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Rear Suspension

II Malfunction Diagnosis

(I) Malfunction diagnosis chart

SN

Malfunction

phenomenon

Malfunction reason analysis

Solution

Remark

Loose installation

Tighten

1

Abnormal noise

Wheel bearing fatigue or damaged

Replace

Shock absorber assembly damaged

Replace damaged part

Tyre air pressure is too high

Adjust air pressure

Shock absorber assembly damaged

Replace damaged part

2

Vibration

Wheel nuts become loose

Tighten

Coil spring becomes short or breaks

Replace

Tyre quality is poor

Replace

3

Vehicle body

sway

Coil spring becomes short or breaks

Replace

III Rear Shock Absorber

(I) Special tool (No)

(II) Removal

Caution: The methods of removing left and right rear shock absorber are similar.

1. Lift the vehicle.

2. Remove wheel. Refer to wheel.

3. Remove rear shock absorber.

1). Remove the connecting bolts

between shock absorber and vehicle

body.

2). Remove the connecting bolts between shock absorber and rear torsion beam.

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(III) Check

1. Check shock absorber

1). Check shock absorber for oil leakage. If

any, please replace.

2). Check whether piston push rod damages, wears and deforms. If any, please replace.

2. Check buffer block and anti-dust cover

1). Check buffer block and anti-dust cover for wear or

damage. If any, please replace.

3. Check rear shock absorber upper installation plate

1). Check rear shock absorber upper installation plate for wear or damage. If any, please replace.

4. Check pedestal for limiting position and upper installation vibration

isolation pad.

1). Check pedestal for limiting position and upper installation vibration

isolation pad for wear or damage. If any, please replace.

(IV) Installation

1. Install rear shock absorber

1). Use a spring compressor to compress coil spring.

2). Install shock absorber and rear torsion beam, and tighten connecting bolts.

Tightening torque

100~120Nm

3). Tighten the connecting bolts between shock absorber and vehicle body.

Tightening torque

45~55Nm

Caution: It is prohibited to use damaged parts. Under non-loading

condition, please conduct final tightening on each

part removed during disassembling shock absorber.

2. Install wheel.

3. Check wheel alignment.

IV Rear Coil Spring

(I) Special tool

SN

Tool number

Tool name

Outside drawing

1

Damper spring

remover

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Rear Suspension

(II) Removal

Caution: The methods of disassembling and installing left and right rear coil

spring are similar.

1. Lift the vehicle.

Caution: In order to keep wheel balance, please mark the relative position of

wheel before removing tyres.

2. Remove tyre. Refer to tyre.

3. Disassemble rear coil spring.

1). Remove the connecting bolts between

rear shock absorber and rear torsion

beam.

2). Take down rear coil spring upper rubber pad, rear coil spring, rear coil

spring lower rubber pad.

(III) Check

1. Check rear coil spring upper rubber pad and rear coil spring lower rubber

pad

1). Check rear coil spring upper rubber pad and rear coil spring lower

rubber pad for wear or damage. If any, please replace.

2. Check coil spring

1). Check coil spring for wear or damage. If any, please

replace.

(IV) Installation

1. Install rear coil spring.

1). It is prohibited to use damaged

parts.

2). Install rear coil spring upper rubber pad, rear coil spring, and rear coil

spring lower rubber pad.

3). Use a spring compressor to compress coil spring

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4). Tighten the connecting bolts between rear shock absorber and rear torsion beam.

Tightening torque

130~150Nm

5). When installing spring lower cushion, please align lower cushion rubber

column with the respective spring cushion holes on rear torsion beam, and

install to the position. Place big diameter side of coil spring downward, and

align with spring lower cushion.

6). Check whether installation mark is correct. Conduct the final tightening

on each part under non-loading codition.

2. Install wheel.

3. Check wheel alignment.

V Rear Torsion Beam Assembly

(I) Special tool (No)

(II) Removal

1. Remove wheel. Refer to wheel.

2. Remove shock absorber. Refer to rear shock absorber.

3. Remove rear brake drum assembly.

4. Remove rear brake device assembly. Refer to rear drum brake device (for Vehicle Model with front disc and rear drum).

5. Remove rear torsion beam

assembly.

1). Take down coil spring

and accessories.

2). Use a jack to support rear torsion beam assembly.

Caution: During removal, it is prohibited to let jack slipping.

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Rear Suspension

(III) Installation

1. Install rear torsion beam

1). Tighten the two mounting bolts between rear torsion beam and

the left and right side of vehicle body.

Tightening torque

130~150Nm

2). Use a jack to support rear torsion beam assembly.

3). Use a spring compressor to compress coil spring.

4). Tighten the connecting bolts between rear torsion beam and shock

absorber.

Tightening torque

100~120Nm

2. Install rear brake device assembly.

3. Install rear brake drum assembly.

4. Install shock absorber.

5. Install wheel.

VI Rear Wheel Hub Assembly

(I) Special tool (No)

(II) Removal

Caution: The methods of disassembling and installing left and right rear

wheel hub assembly are similar.

1. Lift the vehicle.

Caution: In order to keep wheel balance, please mark the relative position of

wheel before removing tyres.

2. Remove rear wheel. Refer to wheel.

3. Remove rear wheel hub

assembly.

1). Disconnect rear wheel

speed sensor.

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Rear Suspension

2). Remove rear brake drum mounting screws, and take down rear brake drum.

3). Remove the four rear wheel hub assembly mounting bolts from the inner side of torsion beam.

4). Take down rear wheel hub assembly, and keep brake device on the torsion beam bracket.

(III) Installation

1. Install rear wheel hub assembly.

1). Connect left rear parking brake assembly and rear wheel hub

unit with torsion beam successively.

Caution: The installation direction of wheel hub unit is the installation convex end forwardness of sensor.

2). Install rear wheel hub assembly from the inner side of torsion beam, and tighten the four connecting bolts.

Tightening torque

60~80Nm

3). Tighten rear wheel speed sensor.

Tightening torque

16~18Nm

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Wheel and Tyre

I Overview

(I) Structure overview

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Wheel and Tyre

Spare tyre structure

Tyre pressure

The air pressure of tyres has a decisive effect on the wear of tyres, fuel consumption, failures, etc. Thus, for a safe driving, it is

necessary to keep a standard air pressure and check air pressure periodically.

The loading capacity of tyres is corresponding to the inflation pressure. Please confirm the reasonable pressure according to the

vehicle’s loading situation. The change of climate and season should be the reason to adjust the air pressure of tyres.

Incorrect tyre pressure may cause:

1). Insufficient air pressure will result in easy wear of tyres, twisting

of tyres, and the increase of rolling resistance.

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Wheel and Tyre

2). Excessive air pressure will make the middle part of tyre tread

wear easily, and reduce cushioning capacity of tyres.

Change of position of tyres

The wear situation of a vehicle’s front and rear tyres is different

due to their loading capacity is different during operation. Thus, in order

to avoid tyre wearing in a single direction, periodically change the

positions of tyres will make tyres wear evenly so as to extend the life of

tyres. It is necessary to change the positions when replacing new tyres.

Note: Recommended change of position of tyre shown in the picture.

Replace tyres

1. Please replace tyres after normally running 50,000km.

2. If one of the following situations happens,

please also replace:

1). There are at least three wear signs on tyre

tread.

2). There is cord fabric or cord fabric line on

tyre rubber.

3). There is crack on the tread or shoulder of tyre, and there is cord

fabric layer.

4). Tyres bump, bulge, or layer.

5). Tyres are punctured, lacerated, or have other damages which

cannot be repaired.

Four-wheel alignment

The correct four-wheel alignment plays an important role in ensuring

a vehicle’s stability and nice control, eliminating abnormal wear of tyres,

and reducing tiredness of drivers.

Parameters of four-wheel alignment include:

·Toe-in

Toe-in is the difference value between the distance of front

sections of two wheels and the distance of rear sections of the same

two wheels. If two wheels are parallel, the toe-in is zero. If wheel

front section inclines to a vehicle’s center line, the toe-in angle is

positive. Otherwise, it is negative.

The function of toe-in is to compensate the trend of inward or

outward rolling due to camber angle and surface resistance, to

ensure a vehicle’s straightness.

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Wheel and Tyre

·Camber angle

Camber angle is an angle of inclination that a tyre is relative to a vertical reference line. When the top of a wheel inclines

outward, the angle is positive. Otherwise, it is negative. The setting of camber angle can influence the control of direction of a

vehicle and the wear of tyres.

Improper setting of camber angle can cause quick or uneven wear

of tyres. Excessive big positive camber angle can cause the outer wear

of tyre tread. When outer tread loading is higher than inner tread

loading, this uneven wear will happen.

Excessive big negative camber angle can cause the inner wear of

tyre tread. When inner tread loading is higher than outer one, this

uneven wear will happen.

·Caster angle

Caster angle is an included angle between caster axis of a wheel

and vertical plane of the ground. Caster angle can ensure the

stability of straight-line travel: if a vehicle has a positive caster

angle, when a wheel moves left, the left wheel will move left

around caster. Due to caster line inclines backward, the ground

point of wheel has the trend of moving downward in vertical

direction, and in fact the vehicle body of this side is lifted upward.

After steering and release steering wheel, the lifted vehicle body

weight will force the steering knuckle moves downward. In this

way, axle journal returns back to the original position of sharp

forward direction.

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Wheel and Tyre

（I）Maintenance parameter

Item

Parameter

Tyre pressure (Cold state) 1

220±10KPa

Tyre pressure (Cold state) 2

240±10KPa

Tyre size 1

205/55 R16 94V

Tyre size 2

185/65R15 88H

Wheel run-out value

Radial direction

Aluminum wheel

0.3mm

Axial direction

Aluminum wheel

0.3mm

Balance weight

5g/10g/15g/20g/25g/30g/35g/40g

Front wheel

camber

angle

0°±30′

Caster angle

3.8°±30′

Front wheel

Kingpin inclination

angle

12.3°±30′

Four-wheel alignment parameter

Front wheel single toe-in

angle

0°±5′

Front wheel toe-in angle

0°±10′

Rear wheel toe-in

12′±10′

Rear wheel

Total toe-in

24′±20′

Rear wheel

camber

angle

-1°±30′

（I）Torque parameter

SN

Item

Tightening torque (N.m)

1

Wheel nut

90~110

（I）Precautions for maintenance

1. Please use the original factory wheels.

2. During the running-in period of new tyres, please avoid sudden starting, sudden turning, and sudden braking. Avoid operate

under severe working conditions to prevent quick wear of new tyres.

3. Before using new tyres, please conduct wheel balance.

II Malfunction Diagnosis

Diagnosis chart

SN

Malfunction

phenomenon

Malfunction reason analysis

Solution

Remark

Excessive wobbling of tyre and wheel hub

Replace

Wheel nuts loose

Lock tightly

Tyre unbalance

Adjust

1

Steering wheel

circular vibration

Uneven wear of tyre

Adjust or replace

Insufficient tyre pressure

Adjust

Front wheel bearing damages or wears

Adjust or replace

Steering system malfunction

Adjust or replace

Suspension system malfunction

Adjust or replace

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Wheel and Tyre

Tire pressure is not correct

Adjust

2

Tyre wear in

advance

Wheel positioning error

Adjust toe-in or replace

Rear wheel need change torsion beam

3

Tyre noise

Incorrect tyre pressure

Adjust

Tire metamorphic

Replace

Insufficient tyre pressure

Adjust

4

Road noise or

body shake

Tire uneven

Adjust

Rims or tire deformation

Repair or replace

Uneven tyre wear

Adjust or replace

Tyres and rims excessive deflection Replace

Wheel nut loose Lock tightly

5

Steering wheel up

and down shaking

Tire uneven Adjust

Engine

bracket

break or wear of rubber

Replace

Transmission

bracket

break or wear of

rubber Replace

Incorrect tyre pressure Adjust

6

Steering wheel

inclines to one

side

Excessive wear or tyre wear is not average Adjust or replace

Steering system malfunction Adjust or replace

Suspension system malfunction

Adjust or replace

Uneven tyre pressure on two sides

Adjust

Wheel hub or tyre deforms

Repair or replace

7

Driving instability

Wheel nuts loose

Lock tightly

Steering system malfunction

Adjust or replace

Suspension system malfunction

Adjust or replace

8

Braking inclines

to one side

Uneven tyre pressure on two sides

Adjust

Brake system malfunction

Adjust or replace

Insufficient tyre pressure

Adjust

9

Steering wheel

becomes heavy

Steering system malfunction

Adjust or replace

Suspension system malfunction

Adjust or replace

Insufficient tyre pressure

Adjust

10

Steering wheel

return ability is

poor

Steering system malfunction

Adjust or replace

Suspension system malfunction

Adjust or replace

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Wheel and Tyre

III Four-wheel alignment

(I) Special tool (No)

(II) Four-wheel alignment check and adjustment

1. Check four-wheel alignment parameter

1). Whether meet the requirement. If not, please timely adjust front

wheel toe-in. Check the reasons if other parameters do not meet the

requirement, and replace the parts.

Front wheel single toe-in 0°±5′

Front wheel toe-in 0°±10′

Caution: This model’s camber angle, caster angle, kingpin

inclination angle of front wheel, and rear wheel toe-

in and camber angle are determined during design,

which cannot be adjusted.

2. Adjust toe-in

1). When wheel is at the position of straight-line travel, if toe-in

exceeds standard value, loosen the locking nuts of left and right

steering tie rods, use a wrench to respectively rotate left and right tie

rod to adjust toe-in to standard value, and then lock the locking nuts.

When adjusting the length of left and right tie rod, please pay

attention to keep the lengths of left and right tie rod are the same

(reverse direction).

Tightening torque

45~55N·m

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Wheel and Tyre

IV Wheel

(I) Special tool(No)

(II) On-vehicle check

1. Check tyre appearance

1). Confirm wheels free of wear, improper inflation, crack, or

other damages.

2. Check wheel tyre

1). Use a high quality tyre pressure gauge to check wheel tyre

pressure. If not within standard value, please inflate or deflate.

Standard value ：

220±10KPa

Standard value ：

240±10KPa

3. Check tyre tread

1). Check the depth of tyre tread.

Note: Tyre size 205/55 R16 94V

Tyre size 185/65R15 88H

△

Caution: When the depth of tyre tread approaches limit value

or even smaller, wear sign will exist on tyre tread.

When there is wear sign, please replace tyres.

2). Check whether there is foreign material in tyre tread. If any, please clean.

(III)

Removal

1. Remove wheel.

1). Loosen the five nuts on the wheel.

2). Lift the vehicle.

3). Remove wheel nuts.

4). Remove the wheel.

(IV)

Installation

1. Install wheel

1). Follow the pictured sequence 1-2-3-4-5 to install wheel nuts, and

slightly tighten.

2). Put down the

vehicle.

3). Follow the pictures sequence to tighten wheel nuts.

Tightening torque

90~110N·m

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Wheel and Tyre

V Wheel Balance

(I) Removal

1. Remove the wheel needed adjustment. Refer to wheel.

2. Remove the old balance weight at the two sides of wheel, and clean the foreign material on the tyre tread.

△

Caution:

1. During removal, be careful not scratching the wheel.

2. If new tyres, please remove the adhesive tape on the

tyres.

(II) Adjustment

1. Wheel dynamic balance

1). Take center hole as guide, install wheel on the balance machine,

and start wheel balance machine.

2). When the unbalance values of inner and outer sides are shown on

the monitor of wheel balance machine, select a balance weight

near to the shown value and install on the position of inner and

outer side of wheel as shown on the balance machine.

△

Caution: After installing outer balance weight, please then install

inner balance weight. Before installing balance weight,

please clean the fitting surface on the wheel.

3). Install balance weight on the pictured position.

4). When installing balance weight on the wheel, as the right picture

shows, please place in the trench area of wheel, and make the

center of balance weight align with the position (or angle)

indicated by wheel balance machine.

5). If the calculated balance weight exceeds 50g, install the two

balance weights on the same straight line.

△

Caution: Balance weight cannot be repeatedly used. Replace a

new one every time. Only install maximum three

pieces of balance weights. Always use original

balance weights. It is prohibited to place one balance

weight on the other one.

6). Re-start wheel balance machine.

7). According to the position (or angle) indicated by wheel balance

machine, tap balance weight into the inner side of wheel.

8). Start balance machine, and confirm the unbalance value of inner

and outer side is only 5g or less. If any side exceeds, please re-

calibrate and add balance weight.

△

Caution: Use balance weight on demand. The usage size refers to maintenance technical parameter sheet.

VI Spare Tyre

(I) Special tool (No)

(II) Removal

1. Remove spare tyre

1). Open the trunk.

2). Open trunk cover.

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I Overview

(I)Structure overview

Front disc brake structure

2

3

4

1

5

9

8

7

10

6

1. Mounting bolts for

brake caliper bracket

6. Brake pad

2.

Steering knuckle

7. Guiding piece for bake pad

3.

Dust cover for disc

brake

8. Brake caliper bracket

4.

Hub assembly

9. Floating pin seal

5.

Brake disc

10.Brake caliper

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Rear drum brake structure

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Installation location chart for rear disc brake

1

2

4

3

1. Rear brake caliper assembly

3. Rear wheel hub assenbly

2. Rear brake hose assembly

4. Rear brake disc

Vacuum brake booster assembly

5

4

3

2

1

1. Vacuum booster

4. oil input hose

2. Brake master cylinder

5.

small oiler

3. Brake master oiler

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(II) Principle of operation

Hydraulic brake system

1

2

1. Brake master pump

2. ABS module assembly ABS

1.3 Technical parameter

Item

Specification

Brake master pump

Type

Cascade

Cylinder bore

22.22mm

Type

Vacuum

Brake booster

Specification(size)

10 inch

Power ratio

7.3:1

Type

Clamp- floating / ventilated discs

Brake disc diameter

256mm

Rear brake

Brake disc thickness

22mm

Friction block thickness

10.8mm

Cylinder bore

54mm

Type

Drum brake

Rear parking brake

Sub-pump diameter

17.46mm

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Brake drum diameter

204mm

Friction block thickness

4mm

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(IV) Torque parameters

Serial NO.

Item

Tightening torque(Nm)

1

Connecting bolt between the front brake caliper and steering knuckle

65~75

2

Connecting bolt between the rear brake and rear wheel hub

65~85

3

Exhaust bolt of the front and rear brake caliper

7~13

4

Fixing bolt for the bracket on the brake pedal

20~25

5

Brake pedal fixing pedal

20~25

6

Connecting bolt between the brake hose and brake caliper

25~30

7

Brake pipe joint

16~18

(V) Maintenance precautions

1. All brake oil lines are forbidden to be excessively bent, twisted or stretched.

2. Make sure all brake oil lines do not contact with other parts at rest or steering.

3. Brake oil lines are important safety parts, so make sure all its fixtures are always tightened. If any damaged parts are found, replace

them with new application parts.

4. When disconnect the brake oil lines, make sure the connector ends are tightly sealed to avoid any dust entrance.

5. It is recommended to use DOT4 braking liquid.

6. Do not reuse the drained braking liquid.

7. Take care to avoid spraying the braking liquid on painted surface because it will damage the paint. If the painted surface is sprayed

with brake liquid, rinse it clean with water.

8. Use clean brake liquid to wash all parts in the brake cylinder.

9. Do not use gasoline, kerosene or other mineral oil to avoid any damage to the rubber parts in the brake hydraulic system.

10. Use a special wrench to remove and install the oil pipe. Make sure to check the tightening torque when install the oil pipe.

11. After repair or replace the brake disc and brake shoe, or spongy brake appears after a short travel, make use to run in the brake

combination surface.

12. Make sure there is no braking liquid on the brake disc. Do not spay braking liquid on the brake disc or it will result in brake failure.

(VI) Special tool

SN Tool NO. Tool name Outline drawing

Usage

1

Oil pipe wrench

Remove and

install the oil

pipe

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II Malfunction diagnosis

(I) Malfunction diagnosis chart

Malfunction diagnosis chart for braking system

Serial

NO.

Malfunction

phenomenon Malfunction reason analysis Solution

Remark

The left and right tire pressure are different. Adjust

The front wheels parameters are adjusted incorrectly. Adjust

The brake pads or shoes are poorly contacted. Adjust

1

There is grease or oil on the braking pads or shoes surface. Replace

The vehicle

deviates to one

side when brakes.

The brake drum is eccentric or worn unevenly. Replace

The brake sub-pump is installed incorrectly. Adjust

The self-adjusting mechanism is faulty. Adjust

The braking liquid is not enough or polluted

Supply or

replace

There is air in the braking system

System

exhaust

The braking booster is faulty Adjust

2

Insufficient

braking force

The braking pads or shoes are contacted poorly. Adjust

There is grease or oil on the braking pads or shoes surface. Replace

The self-adjusting mechanism is faulty. Adjust

Adjust

The braking rotation parts are overheated caused by braking

pads or shoes dragging.

There is air in brake system.

System

exhaust

Brake fluid leaks. Adjust

3

The self-adjusting mechanism is faulty. Adjust

Increased pedal

travel(The distance

between the pedal

and floor is

reduced)

The gap between the pushing rod and brake master cylinder

is too large. Adjust

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The return spring of the braking pedal is worn. Replace

4

Brake lag

The oil returning port of the braking master cylinder is

blocked. Adjust

The return spring of the rear drum brake is damaged. Replace

The return spring of the brake master cylinder plunger is

defective. Replace

Malfunction diagnosis chart for the rear brake

Serial

NO.

Malfunction

phenomenon Malfunction reason analysis

Remark

Solution

There is leakage in the pipe joints or rear brake cylinder

cups.

Tighten or

replace after

cleaning

The residual air in the pipeline is not exhausted completely. Exhaust

1

The braking force

is insufficient. The gap between the brake shoe and drum is too large. Re-adjust

The brake shoe is stuck with oil spots or hardening. Rub or replace

The drum is overheating and the pipeline is with gas

resistance.

Replace, cool,

exhaust

The rear brake shoes are severely worn. Replace

2

The brake drum is not circular.

Boring cut and

balancing

performance

verification

Braking is hard to

be released.

The rear brake shoe surface is too smooth and with low

friction. When the braking pressure is large, the smooth

surface will produce friction noise during sliding or there is

foreign body that will squeeze the friction surface.

Remove

foreign body

and use coarse

sandpaper to

rub the rear

brake shoe.

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III Front braking bushing (vehicle model with front disc and rear drum)

(I) Special tool(no)

(II) Disassembly

Caution The disassembly method for front left and front right braking pads are similar.

1. Lifting the vehicle

Caution: In order to maintain wheel balance, remark the relative position of the wheels before removing the tire.

2. Remove the front wheels. Refer to vehicle wheels

3. Disassemble the front braking bushing

1). Loosen the two connecting bolts between the brake caliper and

the upper and lower ends of the installation bracket. 2

2). Remove the one connecting bolt between the brake caliper and the

lower end of the installation bracket. 1

SN

Malfunction phenomenon

Malfunction reason

analysis

Solution

Remark

3

Brake drum overheating

caused by braking drag

Brake clearance and brake

pedal free

travel are extremely small.

When loosening brake

pedal, brake force is not

completely eliminated,

which makes long-time

fraction state; difficult

start-up, weak driving, and

you can feel hot when

touching wheel drum

surface.

When facing this situation,

just follow instructions to r

e-adjust brake clearance.

The energy generated by

braking make return spring

hot and deformed, elastic

force falls or disappears,

and braking assembly

cannot be timely returned.

Braking malfunction cannot

be timely eliminated, which

causes brake drum hot.

Rear brake disk should be

examined or replace return

spring, then the malfunction is

eliminated.

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3).Take down the braking pads and spring piece.

(III) Installation

1. Check the braking bushing

Standard thickness11mm11mm

Wear limited thickness2mm2mm

Replace the front braking pad if the braking pad thickness

is smaller thanthe minimum value.

(IV) Installation

1. Install the braking pad

1). Install the pad spring piece to the

respective braking pad.

Caution: Install according to the fixed direction of the muffler

piece.

2). When install the braking pad, press the plunger and then install

the sub-cylinder to the installation bracket.

3). Install the braking pad on the installation bracket of the braking

sub-cylinder.

Caution: Take note the braking liquid level of the braking oiler.

4). Close the braking caliper and tighten the two connecting bolts

between the braking caliper and the upper and lower ends of the

installation bracket. 2

Tightening torque 25~30Nm

2. Install the front wheels

Tightening torque 90~110Nm

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IV Front brake caliper (vehicle model with front disc and rear drum)

(I) Special tool

Serial

NO.

Tool NO. Tool name

Outline Drawing

1

Oil pipe

wrench

(II) Disassembly

Caution: The disassembly method for the front left and front right brake caliper are similar.

Warning: Refer to warning about lifting the vehicle and special precautions about braking liquids effect to paint and

electrical parts in warning and precautions.

1. Lifting the vehicle

Caution: In order to maintain wheel balance, remark the relative position of the wheels

before removing the tire.

2. Disassemble the front wheels. Refer to vehicle wheels

3. Disassemble front brake caliper

1). Remove the braking pipe bolt in the braking sub-cylinder and

then disconnect the brake hose. Plug the brake caliper inlet and

brake hose to avoid braking liquid from lossing or polluting.

Caution: Take care to avoid the drop of the copper washer at the

two ends of the bolts.

2). Remove the two connecting bolts between the installation bracket

of the brake caliper assembly and steering knuckle and then

take down the brake caliper parts. 2

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(III) Installation

1. Install the front brake caliper

1). Install the front brake caliper parts and tighten the two

connecting bolts between the installing bracket of the brake

caliper assembly and steering knuckle.

Tightening torque 65~75Nm

2).2)Connect the braking hose and tighten the braking hose bolt.

Tightening torque 25~30Nm

2. Braking pipe exhaust. Refer to hydraulic

braking system exhaust

3. Install the front wheels

Tightening torque 90~110Nm

V Front brake disc (vehicle model with front disc and rear drum)

(I) Special tool

SN Tool NO Tool name

Outline drawing

1

Oil pipe

wrench

(II) Disassembly

Caution: The disassembly method for the front left and front right brake disc is similar.

1. Remove the front wheels. Refer to vehicle wheels

2. Disassemble the brake caliper assembly. Refer to front brake caliper (vehicle model with front disc and rear drum).

3. Remove the front brake disc.

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1). Remove the cruciform screw from the brake disc.

2). Take down the brake disc.

Caution: Make marks on the brake disc and wheel hub.

(III) Inspection

1. Visually check whether there is uneven wear, cracks and damage on the

brake disc surface. If it is, replace the brake disc.

2. Swash check

1). Fix the brake disc on the wheel hub.

Caution: Before measurement, make sure the gap

Between the wheel bearing and axial direction is not too large.

2). Use a dial gauge to measure the swash value.( Make

measurement about 10mm inside the brake disc edge) 10mm

Swash limited value0.05mm

3). If the swash is over than the requested value, replace it or make

necessary processing.

4. Thickness check

Use a dial gauge to measure the brake disc thickness. If the thickness is

lower than the wear limited value, please replace the brake disc.

Standard thickness22mm

Wear limited thickness20.4mm

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(IV) Installation

1. Install the front brake disc

1) Make marks with alignment of the brake disc and wheel hub and

install the brake disc.

2) Tighten the cruciform screw on the brake disc.

Tightening torque 10~15Nm

2. Install the brake caliper assembly

3. Install front wheels

VI Rear drum brake (vehicle model with front disc and rear drum)

(I) Special tool

SN Tool NO Tool name

Outline drawing

1

Oil pipe

wrench

(II) Inspection on the vehicle

1. Lifting the vehicle

2. Check the brake shoe wear.

1). Check the thickness of the brake shoe from the

checking hose of the braking bottom plate.

(III) Disassembly

Caution The disassembly method for the rear left and rear right brake is similar.

1. Remove the rear wheels. Refer to vehicle wheels

2. Remove rear brake drum. Refer to rear wheel hub assembly

3. Disassemble the rear wheel speed sensor. Refer to rear wheel speed sensor

4. Discharge braking liquid

5. Disassemble rear drum brake

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1). Remove the four connecting bolts between the rear wheel hub

and torsion beam.

2). Loosen the parking brake and remove the circlip and head of the

parking brake wiring.

3). Remove the rear brake pipe joint.

4). Take down the rear drum brake assembly.

(IV) Inspection

1. Check the brake drum

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Check whether the brake drum diameter and round jumpiness are

within the standard value. If they are not, make processing or

replacement.

Standard value204mm

Round jumpiness<0.05mm

2. Check the brake shoe

1).Measure the brake shoe thickness and its contact with the brake

drum. If they are not within standard vale, make replacement.

Standard thickness of brake shoe (A):4mm

Allowed ultimate thickness(A):1mm

3.

Check the brake bottom plate

Check whether the brake bottom plate is worn or damaged.

4.

Check the sub-cylinder

A

Check whether there is oil leakage in the sub-cylinder.

(V) Installation

1. Install the rear drum brake

1). Put the rear drum brake assembly in the

correct position.

2). Install the rear drum brake pipe joint.

Tightening torque 16~18Nm

3). Install the circlip and head of the parking brake wiring and pull

tightly the handbrake.

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4). Install the four connecting bolts between the rear wheel hub and rear

torsion beam.

Tightening torque 68~88Nm

2. Install the rear wheel speed sensor.

3. Install the rear brake drum

Tightening torque 10~15Nm

4. Add braking liquid

Caution: Add clean braking liquid to the master pump

Reservoir to correct level.

5. Air exhaust of the braking system. Refer to hydraulic braking system exhaust

6. Install the rear wheels

VII Braking pads (vehicle model with front disc and rear disc)

(I) Special tool (no)

(II) Disassembly

Caution: The disassembly method for the front, rear, left and right braking pads are

similar.

1. Lifting the vehicle

Caution: In order to maintain wheel balance, mark the wheel relative position before

removing the tire.

2. Remove the wheels. Refer to vehicle wheels

3. Remove the front braking pads.

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1). Loosen the two connecting bolts between the brake caliper

and upper and lower ends of the installing bracket.

2). Remove the one connecting bolt between the brake

caliper and lower end of the installing bracket.

3).Take down the braking pads and spring piece.

(III) Inspection

1. Check the braking pad

Standard thickness: 9.5mm

Wear ultimate thickness: 2mm

If the braking pad thickness is smaller than the minimum value, replace.

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(IV) Installation

1. Install the braking pad

1). Install the spring piece to respective braking pad.

Caution: Install according to the muffler piece fixed direction.

2). Press the plunger when installing the braking pad and then install

the sub-cylinder to the installing bracket.

3). Install the braking pad to brake sub -cylinder bracket.

Caution: Take note of the braking liquid level in the braking liquid oiler.

4). Close the brake caliper and tighten the two connecting bolts

between the brake caliper and upper and lower ends of the

installation bracket.

Tightening torque 25~30Nm

2. Install the front wheels

Tightening torque 90~110Nm

VIII Font brake caliper (vehicle model with front disc and rear disc)

(I) Special tool

SN Tool NO Tool name

Outline drawing

1

oil pipe wrench

(II) Disassembly

Caution: The disassembly method for the front left and front right brake caliper are similar.

Warning: Refer to warning about lifting the vehicle and precautions

about braking liquids effect to paint and electrical parts

in warning and precautions.

1. Lifting the vehicle

Caution: In order to maintain wheel balance, mark the wheel relative position before

removing the tire.

2. Disassemble the front wheels. Refer to vehicle wheel.

3. Remove the front brake caliper.

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1). Remove the braking pipe bolt in the braking sub-cylinder and

then disconnect the brake hose. Plug the brake caliper inlet and

brake hose to avoid braking liquid from lossing or polluting.

Caution: Take care to avoid the drop of the copper washer at the

two ends of the bolts.

2). Remove the two connecting bolts between the installation

bracket of the brake caliper assembly and steering knuckle and

then take down the brake caliper parts.

(III) Installation

1. Install the front brake caliper

1). Install the front brake caliper parts and tighten the two

connecting bolts between the installing bracket of the brake

caliper assembly and steering knuckle.

Tightening torque 65~75Nm

2). Connect the braking hose and tighten the braking hose bolt.

Tightening torque 25~30Nm

2. Braking pipe exhaust. Refer to hydraulic braking system exhaust

3. Install the front wheels

Tightening torque 90~110Nm

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IX Rear disc brake caliper (vehicle model with front disc and rear disc)

(I) Special tool

SN Tool NO. Tool name

Outline drawing

1

Oil pipe

wrench

(II) Removal

Caution: The disassembly method for the rear left and rear right brake disc are similar.

1. Disassemble the rear wheels. Refer to vehicle wheels.

2. Loosen the parking brake.

Disconnect the parking brake wiring. Refer to parking brake assembly and wiring assembly (vehicle

model with front disc and rear disc)

3. Disassemble the rear disc brake caliper

1).Remove the braking pipe bolt in the braking sub-cylinder and

then disconnect the brake hose. Plug the brake caliper inlet and

brake hose to avoid braking liquid from losing or polluting.

2). Remove the two connecting bolts between the brake caliper

assembly and installation bracket and then take down the brake

caliper parts.

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(III) Installation

1. Install the rear disc brake caliper assembly

1). Install the brake caliper parts to correct position and tighten the

two connecting bolts between the brake caliper assembly and

installation bracket.

Tightening torque 65~75Nm

2). Connect the braking hose and tighten the braking hose bolt.

Tightening torque 25~30Nm

2. Install the parking brake cable.

3. Braking pipe exhaust. Refer to hydraulic

braking system exhaust.

4. Install the rear wheels.

X Braking disc. ( vehicle model with front disc and rear disc)

(I) Special tool

SN Tool NO. Tool name

Outline drawing

1

Oil pipe

wrench

(II) Disassembly

Caution: The disassembly method for the front, rear, left and right brake disc are similar.

1. Disassemble the front wheels. Refer to vehicle wheels.

2. Release the parking brake.(This operation is performed during removing the rear brake disc)

3. Remove the parking brake wiring. (This operation is performed during removing the rear brake disc)

Refer to parking brake assembly and wiring assembly(vehicle model with front disc and rear disc)

4. Disassemble the brake caliper assembly. Refer to front brake caliper.(vehicle model with front disc and rear drum)

5. Remove the front brake disc.

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1). Remove the cruciform screw on the brake disc.

2). Take down the brake disc.

Caution: Mark on the brake disc an axle hub.

(III) Inspection

1. Visually check whether there is uneven wear, cracks and severe

damage on the brake disc surface. If it is, replace the brake disc.

2. Swash check

1). Fix the brake disc on the axle hub.

Caution: Before measurement, make sure the wheel axial gap is not

too large.

2). Use a dial gauge to check the swash. (Measure about 10mm

inside the brake disc edge).

Swash ultimate value0.05mm

3). If the swash is over than the requested value, replace it or make

necessary processing.

4. Thickness check

Use a microcalliper to measure the brake disc thickness. If it is lower

than the wear limit, replace the break disc.

Standard thickness: 25mm

Wear ultimate thickness: 23mm

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(IV) Installation

1. Install the front brake disc.

1). Install the brake disc and mark with alignment to the brake disc

and wheel axle hub.

2). Tighten the cruciform screw on the brake disc.

Tightening torque 10~15Nm

2. Install the front brake caliper assembly

3. Install the parking brake cable (Install the rear brake disc)

4. Install the front wheels

XI Braking pedal

(I) Special tool (no)

(II) Check and adjust

1.Adjust the gap between the braking pedal and brake limiting switch bolt.

1). Disassemble the protection plate assembly on the driving side.

2). Disconnect the braking lamp switch connectors and loosen the

braking limiting switch nut. Release the braking pedal and rotate the

switch bolt to make the gap between the switch bolt and braking

pedal is 0.5mm~1mm.

Standard value: 0.5mm~1mm

Tightening torque: 8~10Nm

2. Free travel of the braking pedal

1). Step down the braking pedal two or three times

when the engine is off.

2). Make sure the vacuum in the brake vacuum booster is eliminated and press down

the braking pedal with hand.

Standard value: 3mm~8mm

3). Check whether the free travel of the braking pedal is within the

standard value before any resistance occurs.

Caution: If the free travel is not within the standard value, replace

the damaged parts.

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(III)Disassembly

1. Open the engine compartment cover

2. Disconnect the negative cable of the battery

3. Disassemble the upper and lower cover of the dashboard. Refer to dashboard upper cover and dashboard lower cover.

4. Remove the braking pedal

1). Service Brake System

2). Disassemble the lockpin connected with the brake vacuum booster and disconnect the brake vacuum booster.

3). Disassemble the connection bolt between the braking pedal and

vehicle body and fixing nut connected with the brake vacuum

booster.

4). Take down the braking pedal.

(IV) Check and adjust

1.

Braking pedal

1). Check whether the movable pin of the braking pedal is worn or deformed.

2). Check whether there is cracks, twist or other damage on the braking pedal.

2.

Lockpin and bushing

1). Check whether the lockpin and bushing are damaged or deformed. If it is, replace them.

3.

Braking light switch

1). Use a multimeter to check whether the two terminals

Of the braking light switch are conducted when pressing and releasing the braking light switch.

2). If the terminals are not conducted when the switch is

pressed more than 4mm and are conducted when the switch

Is released, the braking light switch works normally.

5nn

(V) Installation

1. Install the braking pedal

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1). Install the braking pedal to corresponded position and tighten the two

fixing bolts between the braking pedal and vehicle body and four

fixing nuts connected to the brake vacuum booster.

Tightening torque 20~25Nm

2). Install the lockpin connected with the brake vacuum booster to connect the brake vacuum booster.

3). Install the braking light switch connectors.

4). Check whether the braking pedal is operated smoothly. Check

the free travel of the braking pedal and the gap between the

braking pedal and braking light switch.

2. Install the upper and lower cover of the dashboard.

XII Brake master cylinder

(I) Brake master cylinder

(II) Removal

1. Open the engine compartment cover

2. Disconnect the negative cable of the battery

3. Disassemble the air filter assembly. Refer to air filter assembly.

4. Disassemble the braking liquid level sensor. Refer to braking liquid level sensor.

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5. Service Brake System

1). Use an oil wrench to disconnect the two brake

pipes of the master cylinder.

Caution: Do not twist or damage the brake pipe.

2). Discharge the braking liquid.

3). Disconnect the connecting pipe between the brake master cylinder

and clutch master cylinder.

4). Disassemble the two fixing nuts between the brake master cylinder

and vacuum booster.

5). Remove the master cylinder parts.

Caution

(III) Installation

1. Install the brake master cylinder

1). Before installing the master cylinder, daub grease such as SAEJ310;

NLGINo2 or similar products on the master cylinder pin roll.

2). Install the master cylinder parts.

3). Install the connecting pipe between the brake master cylinder and

clutch master cylinder.

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4). Tighten the two fixing nuts between the brake master cylinder and vacuum booster.

Tightening torque 20~25Nm

5). Tighten the brake pipe of master cylinder.

Tightening torque 16~18Nm

2. Install the braking liquid level sensor and switch connectors.

3. Add braking liquid

4. Braking system air exhaust. Refer to hydraulic

braking system exhaust

5. Install the air filter assembly

6. Connect the negative cable of the battery

7. Close the engine compartment cover

XIII Front braking pipe and braking hose

(I) Special tool

SN Tool NO. Tool name

Outline drawing

1

Oil pipe

wrench

(II) Disassembly

1. Lift the vehicle

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2. Disassemble the front wheels. Refer to vehicle wheels

3. Disassemble the front braking pipe and braking hose

1). Disassemble the braking hose bolt.

2). Discharge part of braking liquid.

3). Use an oil wrench to remove the braking hose and braking pipe

connector and take down the piece.

4). Disassemble the fixing bolt in the middle part of the braking

hose from the front absorber and vehicle body.

5). Take down the braking hose and braking pipe.

(III)Installation

1. Install the front braking pipe and braking hose.

1). Install the front braking hose and braking pipe

2). Tighten the fixing bolt in the middle of the braking hose on

the front absorber and vehicle body.

Tightening torque 16~18Nm

3). Install new piece and tighten the braking hose and braking

pipe connector.

Tightening torque 16~18Nm

Caution: Take note of the installing direction of the braking

hose connector.

4). Replace new copper washer and tighten the braking hose

bolt.

Tightening torque 25~30Nm

2. Install vehicle wheels

3. Add braking liquid

4. Braking system air exhaust. Refer to hydraulic braking system

exhaust

5. Check leakage.

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XIIII Rear braking pipe and braking hose (vehicle model with front disc and rear drum)

(I) Special tool

SN Tool NO Tool name

Outline drawing

1

Oil pipe

wrench

(II) Disassembly

1. Lift the vehicle

2. Disassemble the rear wheels. Refer to vehicle wheel

3. Disassemble the rear braking pipe and braking hose

1). Disassemble the braking pipe connector on the rear brake end.

2). Discharge part of braking liquid.

3). Use an oil pipe wrench to remove the braking hose and braking

pipe connector and take down the piece.

4). Disassemble the fixing bolt in the middle of the braking hose

from the rear torsion beam and vehicle body.

5). Take down the braking hose and braking pipe.

(III) Installation

1. Install the rear braking pipe and braking hose

1). Install the rear braking hose and braking pipe.

Caution: Take note of the installing direction of the braking hose connector.

2). Tighten the fixing bolt in the middle of the braking hose on the rear torsion beam and vehicle body.

Tightening torque 16~18Nm

3). Install new card and tighten the braking hose and braking pipe

connector.

Tightening torque 16~18Nm

4). Replace new copper washer and tighten the braking hose bolt.

Tightening torque

25~30Nm

Caution: Please do not reuse the gasket and oil pipe card.

2. Install the wheels.

3. Add braking fluid.

4. Braking system air exhaust. Refer to hydraulic braking system exhaust.

5. Inspection for any leakage.

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XV Rear braking pipe and braking hose (vehicle model with front disc and rear disc

(I) Special tool

SN Tool NO Tool name

Outline drawing

1

Oil pipe

wrench

(II) Disassembly

1. Lift the vehicle

2. Disassemble the rear wheels. Refer to vehicle wheels.

3. Disassemble the rear braking pipe and braking hose

1). Disassemble the rear braking pipe connector on the rear brake end.

2). Discharge part of braking liquid.

3).Use an oil wrench to remove the braking hose and braking pipe

connector and take down the card.

4). Remove the fixing bolt in the middle of the braking pipe from

the rear torsion beam and vehicle body.

5). Take down the braking hose and braking hard pipe.

(III) Installation

1. Install the rear braking pipe and braking hose

1). Install the rear braking hose and braking pipe

Caution: Take note of the installing direction of the braking hose connector.

2). Tighten the fixing bolt in the middle of the braking hose on the rear torsion beam and vehicle

body.

Tightening torque 16~18Nm

3). Install new card and tighten the braking hose and braking hard pipe connector.

Tightening torque 16~18Nm

4). Replace new copper washer and tighten the braking hose bolt.

Tightening torque 25~30Nm

Caution: Do not reuse the gasket and oil pipe card.

2. Install the wheels

3. Add braking fluid

4. Braking system air exhaust . Refer to hydraulic braking system exhaust

5. Check if there is any leakage.

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XVI Brake master cylinder and braking hard pipe of the ABS module assembly (vehicle

model with front disc and rear drum + ABS)

(I) Special tool

SN Tool NO Tool name

Outline drawing

1

Oil pipe

wrench

(II) Disassembly

1. Open the engine compartment cover

2. Disconnect the negative cable of the battery

3. Disassemble the air filter assembly. Refer to air filter assembly

4. Disassemble the brake master cylinder and ABS module assembly ABS

1). Disassemble the two oil pipe connectors of the brake master cylinder.

2). Disassemble the two oil pipe connectors of the ABS module assembly.

3). Discharge part of braking liquid.

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4). Disassemble the two fixing nuts in the middle of the braking hard pipe and then remove the brake cylinder parts.

5). And then disconnect the four oil pipe connectors of the ABS module assembly in turn.

Caution: Do not drain the braking liquid in the ABS module

assembly completely or disassemble the ABS module

assembly.

(III) Installation

Caution: Do not make the brake pipe deformed because of

installation difficulty. When install each pipe assembly,

make sure every fixed pipe clamp and jacket to be installed

correctly.

1. Install the brake master cylinder and ABS module assembly ABS

1). Install the four oil pipe connectors of the ASB module assembly.

Tightening torque 16~18Nm

2). Install the brake master cylinder parts and tighten the two fixed nuts in the middle of the brake hard pipe.

Tightening torque 10~15Nm

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3). Install the two oil pipe connectors of the ABS module assembly.

Tightening torque 16~18Nm

4). Tighten the two oil pipe connectors of the brake master cylinder.

Tightening torque 16~18Nm

2.

Add braking liquid

3.

Braking system exhaust. Refer to hydraulic braking system exhaust

4.

ABS system exhaust. Refer to ABS system exhaust ABS

Caution: If there is leakage in the connector of the braking pipe and

braking hose, re-tighten it or if some parts are damaged, replace them.

5.

Install the air filter assembly

6.

Connect the negative cable of the battery

7.

Close the engine compartment cover

XVII Brake master cylinder and braking hard pipe of the ABS module assembly (vehicle

model with front disc and rear disc + ESP model) ABS ( +ESP )

(I) Special tool

SN Tool NO Tool name

Outline drawing

1

Oil pipe

wrench

(II) Disassembly

1. Open the engine compartment cover.

2. Disconnect the negative cable of the battery.

3. Disassemble the air filter assembly. Refer to air filter assembly.

4. Disassemble the brake master cylinder and ESP module assembly.

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1).Disassemble the two oil pipe connectors of the brake master

cylinder.

2). Disassemble the two oil pipe connectors of the ABS module

assembly.

3). Discharge part of braking liquid.

4). Disassemble the two fixed nuts in the middle of the brake hard

pipe and remove the master cylinder parts.

5). And then disconnect the four oil pipe connectors of the ESP

module assembly in turn.

Caution: Do not drain the braking liquid in the ESP module

assembly completely or disassemble the ESP module

assembly.

(III) Installation

Caution: Do not make the brake pipe deformed because of installation

difficulty. When install each pipe assembly, make sure every fixed pipe

clamp and jacket to be installed correctly.

1. Install the brake master cylinder and ESP module assembly ESP

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1). Install the four oil pipe connectors of the ESP module

assembly.

Tightening torque 16~18Nm

2). When install the master cylinder parts, tighten the two

alignment nuts in the middle of the brake hard pipe.

Tightening torque 10~15Nm

3). Tighten the two oil pipe connectors of the ESP module

assembly.

Tightening torque 16~18Nm

4). Tighten the two oil pipe connectors of the brake master

cylinder.

Tightening torque 16~18Nm

2. Add braking liquid

3. Braking system exhaust. Refer to hydraulic braking system

exhaust.

4. ESP system exhaust. Refer to ESP system exhaust ESP

Caution: If there is leakage in the connector of the braking pipe

and braking hose, re-tighten it or if some parts are

damaged, replace them.

5. Install the air filter assembly.

6. Connect the negative cable of the battery.

7. Close the engine compartment cover.

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XVIII Vacuum booster assembly

(I) Special tool (no)

(II) Inspection

1. Operation inspection

1). Turn off the engine and step down the braking pedal for several

times to make the vacuity in the vacuum booster is even to the air.

Step down the braking pedal to the end and start the engine. When

the vacuity reaches standard value, check whether the gap between

the braking pedal and floor is shortened.

Caution: The interval time to step down the braking pedal is five

seconds.

2. Airtight check

1). Start the engine and keep at idle running for one minute and turn

off the engine when the vacuum brake vacuum booster reaches

vacuity. Step down the braking pedal normally to eliminate the

vacuity. Check whether the gap between the braking pedal and floor

is increasingly widening.

2). Step down the braking pedal when the engine is running and then

turn off the engine while stepping the braking pedal. After step down

the braking pedal for more than thirty seconds, check if the braking

pedal travel changed.

(III) Disassembly

Caution: 1. Do not make the brake pipe bent when removing the

brake vacuum booster.

2. Replace the damaged lockpin.

3. Do not damage the thread of the fixed bolt on the

vacuum booster.

1. Open the engine compartment cover

2. Disconnect the negative cable of the battery

3. Disassemble the upper and lower cover of the dashboard. Refer to

upper and lower cover of the dashboard.

4. Disassemble the upper and lower cover of the dashboard. Refer to

upper and lower cover of the dashboard.

5. Disassemble the upper and lower cover of the dashboard. Refer to

upper and lower cover of the dashboard.

6. Disassemble the upper and lower cover of the dashboard. Refer to

upper and lower cover of the dashboard.

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7. Disassemble the braking pedal. Refer to braking pedal.

8. Disassemble the brake master cylinder. Refer to brake master cylinder.

9. Disassemble the upper and lower cover of the dashboard. Refer to upper and lower cover of the dashboard.

1). Take down the vacuum hose clamp and remove the vacuum hose

from the brake vacuum booster.

2). Remove the vacuum booster from the engine compartment.

Caution: The vacuum hose assembly on the MT model has no vacuum booster valve.

Caution: The vacuum hose assembly on the CVT model has vacuum booster valve.

(IV) Inspection

1. Inspect the pushing rod length.

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1). Use a hand-operating vacuum pump to apply a vacuum pressure

of -66.7KPa to the brake vacuum booster.

2). Check the pushing rod length

Pushing rod length116.7~117.3mm

2. Vacuum hose

1). Check whether the vacuum hose is

damaged or cracked. If it is, replace it.

(V) Installation

1. Install the vacuum booster assembly

1). Install the brake vacuum booster from

the engine compartment

Caution: The vacuum hose assembly on the MT model has no vacuum

booster valve.

Caution: The vacuum hose assembly on the CVT model has vacuum

booster valve.

2). Connect the vacuum hose on the brake vacuum booster and install the

clamp of the vacuum hose.

2. Install the braking pedal and pushing rod pin roll of the vacuum booster.

3. Install the brake master cylinder. Adjust the free travel of the braking

pedal. Refer to braking pedal.

4. Install the brake master cylinder.

5. Install air filter assembly

6. Install dashboard

7. Add braking liquid and make braking system to exhaust. Refer to hydraulic

braking system exhaust

8. Connect negative cable of the battery

9. Close the engine compartment

XVIIII Hydraulic braking system exhaust

(I) Special tool (no)

(II) System exhaust

1. Preparation:

Caution: The air in the hydraulic brake regulator cannot be exhausted

by manual operation. If the ABS hydraulic regulator is

mixed with air or if the ABS hydraulic brake regulator is

not fulfilled with oil, a malfunction diagnostic instrument

should be used to exhaust the air in the braking system.

The ABS hydraulic brake regulator is full with oil and

exhausted when leaving the factory. During normal

maintenance procedure regarding to the regulator, the air

will enter the ABS hydraulic brake regulator. In this

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case, the exhaust can be operated manually.

1). While the engine is off, step down the braking pedal

several times until the pressure in the booster is

eliminated.

2). Add braking liquid to brake master cylinder reservoir. During

exhausting, the level of the brake master cylinder reservoir

must be kept more than a half.

2. Brake master cylinder exhaust

Caution: If the brake master cylinder is re-installed or the reservoir

is empty, the brake master cylinder must exhaust.

1). Step down the braking pedal slowly to the end and keep that state.

2). Loosen one brake oil pipe on the brake master cylinder and

tighten the brake oil pipe connector when braking liquid flows

from the terminals.

Tightening torque 16~18Nm

3). Loosen another brake oil pipe on the brake master cylinder and

tighten the brake oil pipe connector when braking liquid flows

from the terminals.

Tightening torque 16~18Nm

Caution: Put a cleaning cloth or rag on the painted surface to avoid

the braking liquid from being stuck with the paint.

4). Make repetitive operation from step one to step three for three to

four times.

3. Braking pipe exhaust.

1). Open the exhaust screw cover.

2). Connect a transparent tube to the exhaust screw of the left

and rear brake and immerse the tube in the braking liquid in the

transparent reservoir.

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3). Step down the braking pedal slowly several times to the end

and keep this state.

Caution: Do not step down the braking pedal sharply and furiously.

4). Loosen the exhaust screw while stepping on the braking pedal

and exhaust.

5).Tighten the exhaust screw when the braking liquid does not spill

and release the braking pedal slowly.

6).Take repetitive operation from step three to step five until the air

in the braking liquid is exhausted completely.

7).When loosen the exhaust screw, there is no bubbles in the

reservoir. That means the air is exhausted completely.

Caution: During exhausting, the level of the brake master cylinder

reservoir must be kept more than a half.

8).Tighten the exhaust screw

Tightening torque 16~18Nm

9). Operate according to step one to eight to exhaust air in rest

reservoir.

10).After exhaust of air in all brake, check whether the braking pedal

is limp. If it is, repeat whole exhaust procedure until it is

normal.

XX Braking liquid level sensor

(I) Special tool (no)

(II) Disassembly

1. Open the engine compartment cover

2. Disconnect the negative cable of the battery

3. Disassemble the air filter. Refer to air filter assembly.

4. Disassemble the braking liquid level sensor.

1). Disconnect the harness connector of the

braking liquid level sensor.

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2). Remove the braking liquid level sensor from the bottom of the braking liquid reservoir.

Caution: No need to discharge the braking liquid.

(III) Installation

1. Install the braking liquid level sensor

1).Install the braking liquid level sensor to correct bottom

position of the reservoir.

2).Connect the harness connector of the braking liquid level sensor.

2. Install the air filter assembly.

3. Connect the negative cable of the battery.

4. Close the engine compartment cover.

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Parking Brake System

1. Overview

1.1 Structure overview

Parking brake control handle with bracket assembly structure

1

2

3

4

1. Parking brake handle assembly

3. Adjusting nuts

2. Left parking brake switch

4. Adjusting thread rod

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Parking brake system structure (Vehicle

model with front disc and rear drum)

3

1

4

2

1. Parking brake handle assembly

3.Right parking brake wire drawing assembly

2. Left parking brake wire drawing assembly

4. Circlip

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Parking brake system structure (Vehicle model

with front disc and rear disc)

3

1

4

2

1.

Parking brake handle assembly

3. Right parking brake wire

drawing assembly

2.

Left parking brake wire drawing assembly

4. Circlip

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1.2 Maintenance

parameter

Item

Parameter

Tpye

Drum brake

Rear parking brake (Vehicle Model

with front disc and rear drum)

Pump

diameter

17.46mm

Brake drum

diameter

204mm

Brake pad

thickness

4mm

Type

Floating caliper /

Ventilated disc

Brake disc

diameter

275mm

Rear parking brake (Vehicle Model

with front disc and rear disc)

Brake disc

thickness

9mm

Brake pad

thickness

8mm

Cylinder

diameter

34mm

1.3 Torque specification

SN

Item

Tightening torque (N·m)

1

Parking brake wire drawing

upper bracket mounting bolt

20~25

2

Parking brake control mechanism

mounting bolt

20~25

2. Malfunction

Diagnosis

2.1 Malfunction diagnosis

chart

SN

Malfunction

phenomenon

Malfunction

reason analysis

Solution

Rema

rk

Check whether indication lamp has

performance damage

Replace indication lamp

1

Indication lamp is

always ON or OFF

Adjust

Check whether the screw

connection between indication

lamp and toothed plate seat is

loose

2

Brake lag

Parking brake is not completely

released

Release

Improper parking brake

adjustment

Adjust

Rear brake shoe damages

Adjust

Rear brake show surface has

grease or oil

Replace

3

Parking brake zipper jammed

Adjust

Parking brake

insufficiency

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Self-adjusting mechanism has

malfunction

Adjust

Parking brake handle travel is

too big

Adjust

4

Parking brake

does not work

Common wire drawing or jacket

corroded, stiff spring breaks,

falls off, or loses elasticity,

which lead to parking brake

control wire drawing or brake

wire drawing cannot be

smoothly pulled in jacket. As a

result, parking brake handle

cannot be released and fails to

work.

Please check brake control wire

drawing and brake system parts

surface for damage, whether control

handle operates smoothly, or has

jammed situation; wire drawing

connecting point and mounting

section is loose or damaged. If

necessary, please repair or replace.

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3. Parking Brake Control Mechanism Assembly

Switch

3.1 Special tool (No)

3.2 Disassembly

1. Disconnect the negative wire of the battery.

2. Disassemble the rear section of auxiliary fascia console. Refer to

auxiliary fascia console.

3. Disassemble parking brake control

mechanism assembly switch.

1) Release parking brake control

mechanism assembly.

2) Disconnect parking brake control mechanism assembly switch

harness connector.

3) Remove parking brake control mechanism assembly switch

mounting screws, and take down the switch.

3.3 Installation

1. Install parking brake control mechanism assembly switch

1) Install parking brake control mechanism assembly switch on the

parking brake control handle.

Tightening torque 6~8N·m

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2) Pull up parking brake control mechanism assembly.

3) Connect parking brake control mechanism assembly switch harness connector.

2.

Install auxiliary fascia console.

3.

Connect the negative wire of the battery.

4. Parking Brake Control Mechanism Assembly

4.1 Special tool (No)

4.2 Disassembly

1. Disconnect the negative wire of the battery.

2. Disassemble auxiliary fascia console. Refer to auxiliary fascia console.

3. Disassemble parking brake control mechanism assembly switch. Refer to parking brake control mechanism assembly switch.

4. Disassemble parking brake control mechanism assembly.

1) Remove the four connecting bolts between parking brake

control mechanism assembly and vehicle body.

2) Release parking brake zipper assembly.

3) Take out parking brake control mechanism assembly.

4.3 Installation

1. Install parking brake control mechanism assembly.

1)

Install parking brake control mechanism assembly onto vehicle

body, and tighten the four mounting bolts.

Tightening torque

20~25N·m

2) Install parking brake zipper assembly.

3) Pull up parking brake control mechanism assembly.

2. Adjust parking brake control mechanism assembly.

3. Install parking brake control mechanism assembly switch.

4. Install auxiliary fascia console.

5. Connect the negative wire of the battery.

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5. Parking Brake Assembly Zipper Assembly

(Vehicle Model With Front Disc And Rear Drum)

5.1 Special tool

5.2 Disassembly

1. Disconnect the negative wire of the battery.

2. Disassemble auxiliary fascia console. Refer to auxiliary fascia

console.

3. Disassemble parking brake control mechanism assembly. Refer to

parking brake control mechanism assembly.

4. Remove rear wheel. Refer to wheel.

5. Remove brake drum. Refer to rear wheel hub assembly.

6. Remove parking brake zipper

assembly.

1) Release parking brake control

mechanism assembly.

2) Remove parking brake zipper assembly adjusting nuts.

3) From zipper balance clip, disconnect left and right parking brake

zipper.

4) Lift the vehicle.

5) Disconnect left and right rear parking brake shoe circlip, and

remove parking brake wire drawing assembly head from brake

shoe with parking handle assembly.

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6) Remove the four mounting bolts which mount the bracket on parking zipperper.

7) Take out parking brake zipperper from vehicle bottom pipe installation hole.

5.3 Installation

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1. Install parking brake zipperper assembly.

1) Install the four mounting bolts on parking brake control

mechanism.

Tightening torque

20~25N·m

2) Install parking brake zipperper assembly head, and tensioning

left and right rear parking brake shoe circlip.

3) Tighten the four mounting bolts which mount the bracket on

parking brake zipper.

Tightening torque

20~25N·m

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4) Install left and right rear parking brake zippers on the zipper balance clip.

5) Tighten parking brake zipper assembly adjusting nuts.

6) If necessary, adjust parking brake control mechanism assembly.

7) Pull up parking brake control mechanism assembly.

2. Install brake drum.

3. Install rear wheel.

4. Install parking brake control mechanism assembly.

5. Install auxiliary fascia console.

6. Connect the negative wire of the battery.

6. Parking Brake Assembly Zipper Assembly (Vehicle Model With Front Disc And Rear

Disc)

6.1 Special tool (No)

6.2 Disassembly

1. Disconnect the negative wire of the battery.

2. Disassemble auxiliary fascia console. Refer to auxiliary fascia console.

3. Disassemble parking brake control mechanism assembly. Refer to parking brake control mechanism assembly.

4. Remove rear wheel. Refer to wheel.

5. Remove brake drum. Refer to rear wheel hub assembly.

6. Remove parking brake zipper

assembly.

1) Release parking brake control

mechanism assembly.

2) Remove parking brake zipper assembly adjusting nuts.

3) From zipper balance clip, disconnect left and right parking brake

zipper.

4) Lift the vehicle.

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5) Loosen adjusting nuts, and remove parking brake wire drawing

assembly head from brake caliper clip.

6) Remove the four mounting bolts which mount the bracket on

parking zipper.

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7) Take out parking brake zipper from vehicle bottom pipe installation hole.

6.3 Installation

1. Install parking brake zipper assembly.

1) Install the four mounting bolts on parking brake control mechanism.

Tightening torque

20~25N·m

2) Install parking brake zipper assembly head into brake shoe wire

drawing clip, and tighten adjusting nuts.

3) Tighten the four mounting bolts which mount the bracket on parking brake zipper.

Tightening torque

20~25N·m

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4) Install left and right rear parking brake zippers on the zipper

balance clip.

5) Tighten parking brake zipper assembly adjusting nuts.

6) If necessary, adjust parking brake control mechanism assembly.

7) Pull up parking brake control mechanism assembly.

2. Install brake drum.

3. Install rear wheel.

4. Install parking brake control mechanism assembly.

5. Install auxiliary fascia console.

6. Connect the negative wire of the battery.

7. Parking Brake Control Mechanism Assembly

Adjustment

7.1 Special tool

7.2 Adjustment

1. Release parking brake control mechanism assembly.

2. Lift the vehicle.

3. Check whether parking brake control mechanism assembly wire

drawing can move freely.

4. Put down the vehicle.

5. Disassemble auxiliary fascia console. Refer to auxiliary fascia

console.

6. Disassembly rear bracket assembly of

auxiliary fascia console. Refer to

parking brake control mechanism assembly switch.

7. Parking brake control mechanism assembly

adjustment

1) Lift the vehicle slightly, and make wheels

move freely.

2) Tight parking brake control mechanism assembly wire drawing

adjusting nuts, until wheels cannot move.

3) Loosen the nuts, until rear wheel can just move freely, and gear is the

position of seventh to ninth gear.

4) Put down the vehicle.

5) Pull up parking brake.

8. Install rear bracket assembly of auxiliary fascia console.

9. Install auxiliary fascia console.

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ABS Anti-lock Braking System / ESP Electronic Stability Program

I、Summary

（I）Structure abstract

Braking system structure

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Instructions: The arrow direction of number two refers to the force direction born by the braking

pedal. The arrow direction of number three refers to the booster implement direction. All other

arrows refer to the liquid movement direction.

ESP alarming lamp instruction:

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Functions of ESP (Electronic Stability Program)

ESP is an active-safety system. It is a non-independent system which is built based on other traction

controlling systems. ESP contains not only all functions of ABS, but is added with function of TCS (Traction

Controlling system) and ESP (Electronic Stability Program). Moreover, many optional functions can be achieved

by increasing some sensor or signal input.

The controlling unit of the ESP system monitors the vehicle operating status through signals such as turning

sensor, wheel sensor, side skidding sensor, lateral accelerator sensor etc and issue controlling instructions

accordingly. It analyzes the vehicle operating information from sensors and then issue corrective instruction to the

ABS and ASR in order to keep the vehicle dynamically balanced and best stabilized in various situation. This

effect is more obvious in the case of over steering and under steering.

Functions of the ABS

The anti-lock braking system is to control the hydraulic braking pressure of all four wheels in the case of

emergency braking and braking on dangerous roads so as to prevent the wheels from blocking. Using ABS has

following advantages:

(1) The vehicle can steer well when meets with an obstacle during emergency braking.

(2) The vehicle can be parked stably and operationally during emergency braking in the corners.

Caution:

1. If the electrical system is interrupted, the failure-protection mode will be activated. The ABS enters

non-operational status and the alarming lamp will be lit up.

2. The ABS electrical system can be diagnosed by special diagnostic apparatus provided by JAC.

3. During the braking process, the braking pedal will vibrate lightly and some mechanical noise can be heard.

Those are normal working phenomenon of the ABS.

Functions of EBD

The Electronic Brake Distribution (EBD) can accurately control the braking force of each wheel and ensure

stability of the vehicle during braking process. In normal braking conditions, it can efficiently balance the wheel

speed equally required for braking. ESD mains the braking pressure of each wheel by making use of the inlet

valve and outlet valve in the ABS hydraulic adjustment module so as to achieve efficient braking and vehicle

stability.

Functions of TCS

The Traction Control System (TCS)s function is to monitor the slipping rate of the driving wheel. When the

slipping rate is too large, the TCS will issue a directive to the engine to decrease fuel injection or reduce throttle

opening so as to reduce torque output. It also can guarantee the driving wheel to get larger adhesion when the

slipping rate is optimal. When the road adhesion difference between left and right wheels is too large( for

example, one side is asphalt, the other side is ice), the TCS will actively exert a braking force on the driving

wheel with low adhesion to prevent wheel-slipping and inject the driving wheel with high adhesion to get a

driving force as large as possible .

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Fault protection functions

When the ABS and ESP electrical system fails, the ABS and ESP alarming lamp will be lit up. If the EBD

electricity fails, the braking alarming lamp and ABS alarming lamp will be lit up. At the same time, the ABS will

be changed to one of the following fault protection functions:

1

.

If the ABS fails, only the EBD can be activated, and the vehicle status will be same as the vehicle without

ABS system.

2

.

If the EBD fails, neither the EBD nor the ABS can be workable, and the vehicle status will be same as the

vehicle without ABS and EBD.

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（

II

）Principle of Operation

ABS hydraulic system working principle diagram

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E

PS hydraulic system working principle diagram

1.

Brake master pump 6. Reflux pump

2.

Hydraulic unit 7. Input valve

3.

High-pressure valve 8. Output valve

4.

Loop control valve

9. Pressure

accumulator

5.

Reflux pump motor

10.

Pressure

sensor

Anti-lock braking mode

The ABS enters anti-lock braking mode when the wheels slip during braking process. In the anti-lock braking

mode, the pressure of the hydraulic reflux of each wheel is under control so as to prevent the wheels from

slipping. Each wheel is equipped with separate hydraulic pipeline and valve. The ABS can reduce, maintain or

enhance the hydraulic braking pressure of each wheel. But the ABS cannot increase the hydraulic pressure to

exceed the value transferred by the master cylinder during braking process. In the anti-lock braking, a series of

rapid vibrations can be felt on the braking pedal which is caused by rapid change of each valve position according

to the required wheel speed. The vibration on the braking pedal occurs in anti-lock braking and stops in normal

braking or when the vehicle is parked completely. Action noise can be heard due to rapid cycling of the solenoid

valve. When anti-lock braking is activated on dry pavement, the tires will issue intermittent sharp sound when

approaching slipping. These sounds and vibrations on braking pedal are normal phenomenon when the anti-lock

braking operates. The braking pedal operation during normal braking is same for the vehicle with or without the

ABS system. Keeping a balanced force on the braking pedal can achieve vehicle stability and the shortest

stopping distance.

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1.

Pressure maintenance

When the ABS controlling module monitors wheel slipping, it will close the oil input valve and output

valve in the hydraulic assembly so as to isolate the system. This can help to keep the braking pressure stabilized

and the hydraulic pressure cannot be increased or reduced.

2.

Pressure reduction

If the ABS controlling module monitors wheel slipping in pressure maintenance mode, it will reduce the

pressure of the wheel impacted. The input valve will be closed and the output valve will be opened. The

excessive liquid and pressure will be temporarily stored in the hydraulic accumulator assembly until the pump

motor transports the braking liquid back to the reservoir of the master cylinder.

3.

Pressure increase

If the ABS controlling module monitors reduction of the wheel slipping in pressure maintenance or pressure

reduction mode, it will increase the pressure on the impacted wheel by making use of the master cylinder pressure.

The input valve will be opened and output valve will be closed. A part of or all pressure from the braking master

pump will be put on the wheels.

4.

ABS working process

ABS

During the vehicle moving process, each wheel speed sensor will produce a voltage signal in proportion to

the rotating speed of the wheels. The ABS controller receives the wheel speed data and determines whether is

one or more wheels decelerating too fast (compared with the reference vehicle speed) which is called slipping.

The ABS controller activates necessary module to control the braking pressure of each wheel and make it

optimized.

The ABS controlling module inspection

Caution: please check the braking system basically.

1.

Basic inspection for braking system

1).

Check the braking liquid level. Add more braking liquid if the liquid level is too low.

2).

Check whether there is any leakage in the braking lines or the area near the ABS hydraulic assembly. If

any leakage found, check by following steps

(1)

.

If the connector of the ABS hydraulic assembly loosens, tighten the pipe tubing nut to specified

torque (16 18Nm). Re-check and ensure no braking liquid leakage.

(2)

.

If the tubing nut of the connector and the thread part of the actuator damaged, replace the damaged

parts. Re-check and ensure no braking liquid leakage.

(3)

.

If leakage is found outside of the actuator connector, wipe it with a clean cloth and then check again.

If leakage still exists, replace the damaged parts.

(4).

If leakage is found on the hydraulic assembly, wipe it with a clean cloth and then check again. If

leakage still exists, replace the hydraulic assembly.

Caution: Do not dismantle the ABS hydraulic assembly (include controlling module) without any special

need.

3).

Check the braking pad or shoe part if any wear exists.

4).

Check the battery and the power circuit if loosens.

Caution: Check the positive and negative terminal of the battery if loosens and confirm the battery voltage is

normal.

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2.

Inspection for the ABS alarming lamp and braking alarming lamp

1).

Confirm when the ignition switch turned to ON, the ABS alarming lamp will lighten for about three

seconds and the braking alarming lamp will lighten. If they are not lit, please refer to ABS common

symptoms and analysis procedure.

2).

Check the ABS alarming lamp will extinguish or not after the ignition switch turned to ON for about three

seconds, and the braking alarming lamp will extinguish or not after the engine started. If they are

extinguished, please refer to ABS common symptoms and analysis procedure.

3).

If the ABS alarming lamp does not extinguish ten seconds after the engine started, please refer to ABS

common symptoms and analysis procedure.

Caution: The braking alarming lamp lights up in parking braking operation (when the ignition switch is at

ON) and the braking liquid level sensor works (braking liquid shortage).

3.

Use diagnostic instrument to check ABS controlling module and detect fault code of the controlled

data and memory. If there is something abnormal, repair it according to fault prompt, please refer

to failure diagnosis.

（

III

）Technical parameters

Description table for ABS controlling module pin

Pin number

Description

Pin number

Description

1

Supplying terminal of motor power

(positive pole)

20

N.C.

2

Wheel speed sensor output(front right

wheel)

21

N.C.

3

Active EBD alarming lamp

22

N.C.

4

Wheel speed sensor signal ends( front

right)

23

N.C.

5

N.C.

24

N.C.

6

K-line diagnosis

25

Power terminal of valve relay

7

N.C.

26

CAN-high

8

Grounding terminal of the power

27

Active ABS alarming lamp

ABS

9

N.C.

28

Power terminal of ECU( ignition cable)

10

N.C.

29

Wheel speed sensor signal ends( rear

right)

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11

N.C.

30

Braking lamp switch input

12

N.C.

31

Supplying terminal of wheel speed

sensor(rear left)

13

Grounding terminal of the power

32

N.C.

14

CAN-low

33

Vehicle speed signal input

15

N.C.

34

N.C.

16

Supplying terminal of wheel speed

sensor(front right)

35

N.C.

17

Supplying terminal of wheel speed

sensor (rear right)

36

N.C.

18

Signal ends of wheel speed sensor( rear

left)

37

N.C.

19

Supplying terminal of wheel speed

sensor( front left)

38

ECU grounding lines

ABS controlling module pin position diagram

（IV）

Torque parameters

SN

Item

Tightening torque (Nm)

1

Mounting bolt of wheel speed sensor

8~10

2

Brake hard pipe joint nut

20~25

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（V）

Maintenance cautions

Follow below general cautions when repairing ABS and ESP, or it may damage them.

1.

Disconnect all connectors from the ABS and ESP controlling module before performing welding work.

2.

The anti-lock braking system components are particularly sensitive to EMI(electromagnetic interference).

Check carefully the traces of all anti-lock braking system components, location, installation and positioning,

wiring, connectors, clamps and brackets if any interference occurs.

3.

Do not use a quick charger to start the engine or charge the battery which still connected, otherwise, it may

result in battery failure or damage to components of the anti-lock braking system.

4. Make sure to turn off the ignition switch first and then disconnect the negative pole of the battery. After that,

disconnect the connectors from the ABS and ESP controlling module assembly.

5. Do not attempt to repair any components of the anti-lock braking system. All ABS and ESP components can

only be repaired by replacement.

6. In order to avoid any damage to the wheel speed sensor harness, it is forbidden to hang the suspension parts

on it.

7. The ABS and ESP controlling module should not be placed in an environment with temperature higher than

one hundred and five degree.

8. The braking circuits should not contain minerals like chlorine and sulfur, mineral oil or ester plasticizer and

softer (include components which can dissolute these substances).

9. It is normal phenomenon that the braking pedal vibrates lightly and mechanical noise can be heard when the

ABS and ESP operates.

10. After turning the ignition switch to ON and starting the vehicle, the braking pedal may vibrate or working

noise may be heard from the ABS and ESP hydraulic assembly motor. This is normal state of operational

inspection.

11. When the vehicle is traveling on rough, gravel or snow( deep snow) roads, the braking distance may be longer

than the vehicle without ABS and ESP.

12. When the braking system fails, distinguish the reason between the ABS and ESP and general braking system

such as vacuum booster, braking hydraulic system, braker or other parts.

13. If the tire size and type are used in incorrect combination or the braking shoes are not authentic components

provided by JAC, the braking distance or turning stability may get worsen.

（VI）

Special tools

SN Tool No. Tool Name

Outside drawing

Usage

1

ABS failure

diagnostic apparatus

Diagnose ABS failure

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II、

Failure diagnosis

（I）

General introduction of failure diagnosis

1)

Diagnose the failure and get a thorough understanding of each system of the vehicle(control and

organization)

2) Get to know customers complaints before inspection. Consult the customer carefully about dissatisfaction

after getting full knowledge of symptoms.

3)Symptom check must be started from the beginning stage so as to repair the fault completely. For

intermittent fault, it is very important to reproduce the symptoms according to talks with customer and

passed cases. Do not check according to some special cases. Most intermittent faults are caused by poor

contact which can be effectively solved by shaking the suspected harness or connector.

4)Do execute clear fault codes after diagnosis finished.

（II ）Failure diagnosis table

ABS fault code table

SN

Fault code

1

C190004

ECU Voltage supply: high voltage

2

C190104

ECU Voltage supply: low voltage

3

C100004

ECU error (hardware, Micro-controller error)

4

C101008

ECU error (general software problem)

5

C006B06

ABS/ESP implausible

control (control time too

long, etc.)

6

C003108

Wheel-speed sensor,

front left: (signal failure)

out of range, lost, noise, Intermittent

7

C003200

Wheel-speed sensor, front left: open

8

C00A000

Wheel-speed sensor, front left: short to GND

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SN

Fault

code

Fault code

9

C00A100

Wheel-speed sensor, front left: short to UBATT

10

C00A900

Wheel-speed sensor, front left: general error

11

C003408

Wheel-speed sensor, front right: (signal failure)

out of range, lost, noise, Intermittent

12

C003500

Wheel-speed sensor, front right: open

13

C00A200

Wheel-speed sensor, front right: short to GND

14

C00A300

Wheel-speed sensor, front right: short to UBATT

15

C00AA00

Wheel-speed sensor, front right: general error

16

C003708

Wheel-speed sensor, rear left: (signal failure)out

of range, lost, noise, Intermittent

17

C003800

Wheel-speed sensor, rear left: open

18

C00A400

Wheel-speed sensor, rear left: short to GND

19

C00A500

Wheel-speed sensor, rear left: short to UBATT

20

C00AB00

Wheel-speed sensor, rear left: general error

21

C003A08

Wheel-speed sensor, rear right: (signal failure)

out of range, lost, noise, Intermittent

22

C003B00

Wheel-speed sensor, rear right: open

23

C00A600

Wheel-speed sensor, rear right: short to GND

24

C00A700

Wheel-speed sensor, rear right: short to UBATT

25

C00AC00

Wheel-speed sensor, rear right: general error

26

C109904

Wheel-speed sensor generic error (sensor swap,

multiple sensors error )

27

C001004

valve fault, inlet valve FL

28

C001104

valve fault, outlet valve FL

29

C001404

valve fault, inlet valve FR

30

C001504

valve fault, outlet valve FR

31

C001804

valve fault, inlet valve RL

32

C001904

valve fault, outlet valve RL

33

C001C04

valve fault, inlet valve RR

34

C001D04

valve fault, outlet valve RR

35

C109504

Valve relay error

36

C002004

Return pump fault

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37

C007208

General Valve fault (overheat protection, signal invalid,

hardware fault )

38

C004460

Pressure sensor fault

(signal)

39

C004510

Pressure sensor fault (wiring lines)

40

C004008

Braking lamp switch fault

41

C006108

Lateral accelerator sensor signal fault

42

C006208

Vertical accelerator sensor signal fault

43

C006308

Yaw angle speed sensor fault

44

C019604

Yaw angle speed sensor fault

45

C00A800

Yaw angle speed sensor uncalibrated or

calibration failed

46

U000500

CAN bus voltage: too high

47

U000700

CAN bus voltage: too low

48

C100104

CAN bus fault: hardware

49

U000104

CAN bus fault: closure

50

U100104

External CAN bus fault

51

U010004

EMS CAN message timeout

52

U010008

EMS date break or signal ineffective

53

C106600

SAS steering wheel angle sensor calibration fault

54

C046008

SAS steering wheel angle sensor fault(signal)

55

U012604

SAS steering wheel angle sensor fault(message

timeout)

56

U012608

SAS steering wheel angle sensor fault(date break

or signal ineffective)

57

U010104

TCU CAN message timeout

58

U010108

TCU data break or signal ineffective

59

C104C04

ESP closing switch fault

60

C121208

Configuration coding error

61

C108C08

Reversing gear switch signal ( too high or too

low)

62

U015504

ICM CAN communication timeout

63

U042308

ICM data break

64

C003129

Front left wheel speed sensor fault: direction

65

C003429

Front right wheel speed sensor fault: direction

66

C003729

Rear left wheel speed sensor fault: direction

67

C003A29

Rear right wheel speed sensor fault:direction

68

C101038

Two wheels speed sensor fault: direction

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ABS fault diagnosis chart

SN

Fault

phenomenon

Fault reason analysis

Solution

Reamrk

Poor contact of diagnostic terminals

Inspect and connect

ABS controlling module ungrounded

Inspect and connect

Refer to ABS

data flow

diagnosis

diagram

The ABS

controlling

module data

unreadable

ABS controlling module without

voltage provided by battery

Inspect and connect

1

ABS controlling module without

voltage provided by ignition switch

Inspect and connect

Data circuit : disconnected or short

circuit

Inspect, connect or replace

Data circuit: resistance is too high

Inspect and replace

ABS alarming lamp bulb fault/socket

loosen

Inspect, connect or replace

Refer to ABS

alarming lamp

not light and no

diagnostic code

diagnosis flow

chart

ABS alarming

lamp not light

up

Instrument panel fuse disconnect

Inspect and replace

2

Instrument warning lamp driving

module fault

Inspect and replace

ABS controlling module fault

Inspect and replace

Disconnected or short circuit between

instrument panel and ABS controlling

module

Inspect, connect or replace

Open circuit between instrument panel

and ABS controlling module

Inspect or connect

Short circuit between instrument panel

and ABS controlling module

Inspect and replace

Refer to ABS

alarming lamp

not light and no

diagnostic code

diagnosis flow

chart

3

ABS alarming

lamp not light

up

ABS alarming lamp not light up

Inspect and replace

ABS controlling module ungrounded

Inspect or repair

ABS controlling module fault

Inspect and replace

Bulb fault or socket loosen

Inspect, connect or replace

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Instrument panel fuse disconnect

Inspect and replace

Refer to

braking

alarming lamp

not light and no

diagnostic code

diagnosis flow

chart

Braking

alarming lamp

not light up

4

Instrument panel fault

Inspect and replace

Circuit between ABS controlling

module and instrument panel ground

Inspect and replace

ABS controlling module fault

Inspect and replace

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（III）

Fault diagnosis flow chart

ABS alarming lamp not light and no diagnostic code diagnosis flow chart

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ABS alarming lamp not light and no diagnostic code diagnosis flow chart (Continued)

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ABS data flow unreadable diagnosis flow chart

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ABS data flow unreadable diagnosis flow chart (Continued)

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ABS warning lamp is on but no diagnosis fault

code diagnosis flow chart

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Braking alarming lamp is off and no diagnostic code diagnosis flow chart

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Braking alarming lamp is off and no diagnostic code diagnosis flow chart (Continued)

（IV）

Diagnosis information and process

1.

Self-diagnosis

ABS controlling module can make self-diagnosis to detect the system fault. If any fault is found, the ABS

controlling module will set diagnostic trouble code (DTC) as well as lighten ASB alarming lamp and close the

ABS.

2.

Displaying of diagnosed fault code

Special tools (diagnostic instrument) can be used to display

the diagnostic trouble code.

3.

Delete diagnostic trouble code

The diagnostic trouble code in the memory of the ABS controlling module can be cleaned up by scanning

tools (diagnostic instrument).

Caution: After cleaning, verify the system to see whether is can operate normally and the diagnostic trouble

code will not occur again. The diagnostic fault code should not be deleted by dismantling

connectors of the ABS controlling module, disconnecting battery terminals or switching off the

engine.

4.

Intermittent failure or intermittent failure of poor

contact are mostly caused by following reasons

1).

Electrical wiring error.

2).

Electrical connection error.

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3).

Binding of relay or solenoid valve.

5.

Initialization sequence

The ABS controlling module will make initialization test in the beginning of every ignition cycle.

The initialization sequence is: electromagnetic valve and pump motor, to check whether the operation of the

components is normal. If any fault is detected, the ABS controlling mode will set corresponding diagnostic fault

code. It is normal operation of the system when you can hear some action sound when the initialization sequence

is proceeding. If the ABS controlling module detects no signal input for the braking switch (You foot dost not

step on the braking pedal), initialization will take place immediately. If there is signal input for the braking switch

(Your foot is stepping on the braking pedal), initialization will not proceed unless no signal input is detected for

the braking pedal (Your foot does not step on the braking pedal) or the vehicle speed reaches 25KM/H

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（V）

Inspection for diagnostic circuit

1.

Systematic introduction

Diagnosis for circuit can detect the problems caused by ABS/EBD systematic failure. Inspection for

diagnostic circuit will guide the maintenance technician to next step for diagnosing the fault.

2.

Diagnosis procedure

Steps for maintaining the ABS/EBD system

1)

.

Check the vehicle if any mechanical failure relating to the braking system exists

(1).

The level of the braking liquid tank is correct.

(2).

The level of the braking liquid tank is correct.

(3)

.

Check the braking master pump and ABS hydraulic assembly to be without leakage

(4).

Check braking parts of all wheels.

(5).

Check if any braking dragging exits.

(6).

Check if the braking is stabilized (without rear-pulling or front punching)

(7).

Check the braking shoes to be without wear or damage.

(8).

Check the wheel bearing to be without damage.

(9).

Check the wheel (speed) sensor and harness.

(10)

.

Check the speed sensor connectors/gear rim with damage or not/ check the tires thread depth/ wear

degree.

(11)

.

Make a road test and make necessary correction according to actual situation.

2)

.

Inspection for diagnostic circuit should be performed in accordance with applicable diagnostic fault

procedure. The ABS diagnostic fault code should be removed with following steps after all system failure

is ruled out:

Inspection chart for diagnostic circuit

Next step

Step

Measures

Yes

No

If possible, connect or install all components which are disconnected or

dismantled originally.

1

The engine is turned off when the ignition switch is at ON.

Turn to

step two

Turn to step

four

Install applicable diagnostic instrument to DLC to see whether it can be

communicated to the ABS controlling module.

2

Is there any fault code saved currently or in the past?

Turn to

step three

Turn to step

seven

Record the current fault code.

Record the past fault code.

3

Record past data, such as the setting times of each diagnostic fault code,

setting times after the diagnostic fault code is set for the first time;

setting times after the diagnostic fault code is set last time; the speed

when the diagnostic fault code is set; other data which is helpful for the

diagnosis; Do not rule out the diagnostic fault code before recording

information from the diagnostic instrument.

Turn to

step five

Turn to step

six

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4

Does the diagnostic instrument can communicate with other module of

the same data line?

5

Refer to No communication of the ABS controlling module in the ABS

controlling module fault procedure

6

Refer to the data connector unit of the electrical terminals.

Flameout

7

Wait for ten seconds

Turn to

step eight

Turn to step

nine

Start the engine

Observe the ABS alarming lamp after started.

8

Is there any lamp that always lights?

Turn to

step nine

Turn to step

ten

9

Refer to the Open failure procedure of corresponded lamp.

10

Refer to the Malfunction failure procedure of corresponded lamp.

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（VI）

Diagnosis for code fault and general diagnostic methods

1.

C190004; C190104 ECU Power failure

The failure may be caused by following reasons:

(1).

The battery voltage is too high or too low

;

(2).

The vehicle

body is ungrouned.

Maintenance and

diagnosis method

(1).

Measure the battery voltage and charge the battery if necessary ( voltage standard value 9.3V~16.8V).

(2).

Check the two grounding points of the ESP, including the electrical controlling unit grounding of the

ESP and reflux pump motor grounding.

(3)

.

Turn on all electrical appliances with high-power and measure the supplying voltage of the ESP.

High-power load may result in electricity shortage.

(4)

.

Measure the voltage fluctuation produced when the vehicle is started and high-power electrical

appliances are switched on and off. Potential electrical appliance failure may lead to voltage

fluctuation by a large margin of the supplying circuit.

2. C100004; C101008 ECU failure

Possible reason for failure:

The ECU is damaged.

Maintenance and diagnosis method: replace the ESP assembly and make the braking pipe to exhaust.

3. C006B06 Abnormal operation of the braking system( The ABS/ESP works for too long time)

Possible reason for the failure:

(1)

.

Drive intensely and continuously or brakes continuously for a long time;

;

(2)

.

The speed sensor signal is incorrect.

;

(3).

The turning sensor of the steering wheel and speed sensor of the yawing angle are abnormal.

Maintenance and diagnosis method

(1)

.

Use a diagnostic instrument to read the data stream of the speed sensor and observe whether there is a

speed sensor that sustains too high or too low.

(2)

.

Make a test driving in the shape of number eight. During the test, the steering wheel needs to be

turned to left and right side to its limit and read the failure code again.

(3)

.

If there is no failure code relating to the turning sensor of the steering wheel and speed sensor of the

yawing angle, check the installation position of the ESP to be horizontal and tightened.

4. C003200; C00A000; C00A100; C003500; C00A200; C00A300; C003800; C00A400; C00A500; C003B00;

C00A600; C00A700 wiring failure of the speed sensor

Possible reasons for the failure are as follows:

(1).

The wheel speed sensor wiring is disconnected or the plug is loosen or broken.

(2).

The signal wiring of the speed sensor is connected in the opposite direction with the power line.

(3)

.

The signal

wiringis short circuit

to the ground.

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Maintenance and diagnosis method

(1).

Check if there is open circuit or short-circuit of the speed sensor harness.

(2).

Check if there is any loose or disconnection for the connectors of the speed sensor wiring.

(3).

Check if there is opposite connection for the speed sensor power line and signal wiring.

(4).

Make the ESP system to self-check after speeding up the vehicle to more than 40km/h.

(5).

Replace the speed sensor if the failure cannot be ruled out after dynamic self-checking.

5. C003108; C00A900; C003408; C00AA00; C003708; C00AB00; C003A08; C00AC00; C109904 Signal

failure of the speed sensor

Possible reasons for the failure:

(1).

The speed sensor harness is twisted and the connector is loosen or broken.

(2).

The signal wiring of the speed sensor is short-circuit.

(3).

The power line of the speed sensor is short-circuit to the ground.

(4).

The gear ring is not installed or there is missing tooth, or the gear ring is dirty, demagnetized or

eccentric.

(5).

The gap between the sensor and gear ring is too large.

(6).

The speed sensor is interfered by external magnetic field( The wheels or axles are not demagnetized)

;

(7).

The speed sensor body fails.

(8).

The gear tooth error.

(9).

The tire size is not standard.

Maintenance and diagnosis method

(1).

Check if the speed sensor harness is twisted.

(2).

Check if there is any loose or disconnection for the connectors of the speed sensor wiring.

(3).

Check if the speed sensor harness is short-circuit to the ground.

(4).

Check if the speed sensor is fixed correctly.

(5).

Use a diagnostic instrument to read the data stream of the speed sensor and record whether each

wheel speed is same to the accelerator displayed and the speed displayed is correct or not.

(6).

If the wheel speed is displayed inconsistently, check the corresponded gear ring of the speed sensor if

there is any missing, dirt, foreign matter, demagnetization or eccentric phenomenon.

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(7).

After any maintenance to the speed sensor, make the ESP to self-check dynamically after speeding up

the vehicle to more than 40km/h.

(8).

Replace the speed sensor if the failure cannot be ruled out after dynamic self-checking.

8.

C004460; C004510 Pressure sensor failure

Possible reasons for the failure:

(1).

Braking lamp switch failure or circuit failure;

;

(2).

Pressure sensor

failure.

Maintenance and

diagnosis method

(1).

Check if the braking lamp switch and circuit are normal.

(2).

Replace the ESP assembly if ESP damage is confirmed through cross-validation, make the braking

pipe to exhaust.

9.

C004008 braking light switch(BLS) fault

C004008 (BLS)

Possible reasons for the failure:

(1).

The braking light switch wiring is open or disconnected.

(2).

The braking light switch is installed incorrectly.

(3).

The braking light

switch is damaged

Maintenance and

diagnosis method

(1).

Check the braking light switch and its harness.

(2).

Replace the braking light switch.

10.

C006108; C006208; C006308; C019604; C00A800

The yawing rate sensor failure, the yawing rate sensor includes three signals: lateral accelerator, vertical

accelerator and yawing angle speed. The yawing rate sensor is integrated within the ESP9i controller.

Possible reasons for the failure:

(1).

The ESP is installed incorrectly.( The ESP must be installed horizontally and without inclination in

vertical direction).

(2).

The yawing rate sensor is not calibrated incorrectly.

(3).

The yawing rate

sensor is damaged.

Maintenance and diagnosis method

(1).

Check if the ESP installation bolt or bracket is loosen or deformed.

(2).

Re-calibrate the yawing rate sensor.

(3).

Replace the ESP assembly if ESP damage is confirmed through cross-validation, make the braking

pipe to exhaust.

11. U000500; U000700; C100104; U000104; U100104 CAN bus line failure

Possible reasons for the failure:

(1).

The battery voltage is too high or too low.( voltage value9.3v~16.8v).

(2).

The CAN bus network is failed.

(3).

The ECU is

damaged.

Maintenance

and diagnosis

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method

(1).

Measure the battery voltage and charge the battery if necessary.

(2).

Investigate the CAN bus and all bus nodes.

(3).

Replace the ESP assembly if ESP damage is confirmed through cross-validation and make the braking

pipe to exhaust.

12.

C106600; C046008; U012604 Steering wheel angle sensor failure

Possible reasons for the failure:

(1).

The steering angle sensor is not calibrated correctly.

(2).

The steering angle sensor wiring is failed.

(3).

Check and re-insert the steering wheel sensor plug.

(4).

The steering angle sensor is damaged.

Maintenance and diagnosis method

(1).

Cancel the steering angle sensor calibration and re-calibrate.(The steering wheel must be in the middle

position).

(2).

Check the steering wheel sensor harness.

(3).

Check and re-insert the steering wheel sensor plug.

(4).

When the steering wheel sensor failure is confirmed after cross-validation, replace the sensor and

calibrate the new sensor.

13. U010004; U010008; U010104; U010108; U015504; U042308 CAN Bus nodes failure

Possible reasons for the failure:

(1).

The CAB bus communication is interrupted.

(2).

The CAN bus nodes are badly powered.

(3).

The CAN bus nodes are failed(The bus nodes are off from the CAN bus or the ECU is failed).

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Maintenance and diagnosis method

(1).

Check if the CAN bus communication is normal.

(2).

Turn off the ignition switch and measure the resistance of the CAN-H and CAN-L wiring from the

CAN bus nodes to the ESP.( Standard value: under5).

(3).

Measure the resistance between CAN-H wiring and CAN-L through the connectors of the CAN bus

nodes.(Keep the plug connected);(standard value:60)

(4).

Check if the CAN bus nodes are well powered.

(5).

Read the fault code of the CAN bus nodes and inspect it accordingly.

12. C001004; C001104; C001404; C001504; C001804; C001904; C001C04; C001D04; C000104; C000204;

C000304; C000404; C007208 Electromagnetic valve

Possible reasons for the failure:

(1).

Re-read the fault code after cooling for 10minutes.The system is overheated.

;

(2).

The electronic control unit of the ESP is damaged.

Maintenance and diagnosis method

(1).

Re-read the fault code after cooling for 10minutes.

(2).

Replace the ESP assembly if ESP damage is confirmed through cross-validation and make the braking

pipe to exhaust.

13.

C109504 Electromagnetic valve relay failure

Possible reasons for the failure:

(1).

The electromagnetic valve is badly powered. (Low voltage, damaged fuse or poor contact).

(2).

The electronic control unit of the ESP is badly contacted to the ground.

ESP

(3).

The electronic control unit of the ESP is damaged.

Maintenance and diagnosis method

(1).

Check the power supplying line, fuse and voltage of the electromagnetic valve replay.

(2). 21W ESP ; 0.2V

(3). 21W ESP ESP ECU ; 0.2V

(4).

Make the ESP to self-check dynamically after speeding up to more than 40km/h.

40km/h ESP ;

(5).

Replace the ESP assembly if ESP damage is confirmed through cross-validation and make the

braking pipe to exhaust.

14.

C002004 Reflux pump power

15.

Possible reasons for the failure:

(1).

The system is overheated.

(2).

The pump motor is badly powered. (Low voltage, damaged fuse or poor contact)

(3).

The pump motor is badly powered. (Low voltage, damaged fuse or poor contact)

(4).

The pump motor is damaged.

Maintenance and diagnosis method

(1).

Re-read the fault code after cooling for 10minutes.

(2).

Check the power supplying line, fuse and voltage of the pump motor.

(3).

Check the power supplying line, fuse and voltage of the pump motor.

21W ESP ; 0.2V

(4). 21W ESP ; 0.2V

(5).

Make the ESP to self-check dynamically after speeding up to more than 40km/h.

(6).

Replace the ESP assembly if ESP damage is confirmed through cross-validation and make the braking

pipe to exhaust.

15. C104

C04 ESP Close the

switch failure

Possible reasons for the

failure:

(1).

ESP closed switch things down ;

(2).

ESP close switch or damage of the circuit ;

Maintenance and diagnosis method

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(1).

Through the ESP close switch manually close and reopen the ESP function;

(2). Check the ESP close switch.

16.

C

121208ESP

configuration failure

Possible reasons for the

failure:

(1).

The configuration information is not input.

(2).

The configuration information is not matching.

Maintenance and diagnosis method

(1).

Input correct configuration information with diagnostic instrument.

17. C108C08 B

rake light switch /

Normally on reverse signals

Possible reasons for the failure.

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(1)

.

The braking lamp switch signal is

abnormal.

(2)

.

The braking lamp switch harness

is open or short circuit.

(3).

The reversing

signal is abnormal.

Maintenance and diagnosis method

(1).

Check the braking lamp switch.

;

(2).

Check the braking lamp switch

harness.

;

(3).

Check the reversing signal.

;

(4).

Check the TCU and diagnose according to the TC

U fault code.

TCU TCU

III、

Front wheel speed sensor

（I）

Special tool (No)

（II）

Disassembly

1.

Disconnect the negative cable of the

battery.

2.

Dismantle the front wheel. Refer to Wheel

3.

Dismantle the front fender liner, refer to

Fender liner.

4. Disconnect the front wheel speed sensor.

1) Disconnect the connector of the front

wheel speed sensor.

2) Unlock the buckle of the

sensor harness.

3).

Dismantle the fixing bolt of the front

wheel speed sensor.

4).

Dismantle the front wheel speed sensor.

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（III）

Installation

1.

Install front wheel speed sensor

1).

Install the front wheel speed sensor.

2).

Tighten the fixing bolt of the front wheel sensor.

Tightening torque 8~10N.m

Caution:

1. Do not pull the harness of the wheel speed sensor hardly.

2. Pay attention to the gap between the wheel speed

sensor and signal gear ring during installation.

Standard value: 0.2~1.1mm

3).

Install the sensor harness buckle.

4)

.

Install the connector for the front wheel speed sensor.

2.

Install front fender liner.

3.

Install front wheel.

4.

Connect the negative cable of the battery.

IV、

Rear wheel speed sensor

（I）

Special tool (No)

（II）

Disassembly

1.

Disconnect the negative cable of the battery.

2.

Dismantle the rear wheel. Refer to wheel.

3.

Dismantle the rear fender liner. Refer to fender liner.

4.

Dismantle the trunk side trim. Refer to decorating plate under the column.

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5.

Disassemble rear wheel speed sensor

1)

.

Disconnect the connector

of the rear wheel speed

sensor.

2)

.

Unlock the sensor harness buckle.

3)

.

Disassemble the fixing bolt of the rear wheel speed

sensor.

4)

.

Dismantle the rear wheel speed sensor.

（III）

Installation

1.

Installation of the rear wheel speed sensor.

1).

Install the rear wheel speed sensor.

2).

Tighten the fixing bolt of the rear wheel speed sensor.

Tightening torque 8~10Nm

Caution:

1. Do not pull the harness of the wheel speed sensor

hardly.

2. Pay attention to the gap between the wheel speed

sensor and signal gear ring during installation.

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Standard value 0.2~1.1mm

3).

Install the sensor harness buckle.

4)

.

Connect the connectors for the rear speed sensor.

2.

Install the trunk side trim.

3.

Install the rear fender liner.

4.

Install the rear wheel.

5.

Connect the negative cable of the battery.

V、

ABS hydraulic assembly

（I）

Special tool

SN

Tool number

Tool name

Outside drawing

1 Diagnostic instrument

for ABS fault

（II）

Dismantlement

1.

Disconnect the negative cable of the battery.

2.

Dismantle the air filter. Refer to Air filter assembly.

3.

Dismantle the air intake hole of the engine. Refer to Air filter assembly.

4.

Discharge the braking fluid.

5.

Step down the braking pedal.

6.

Dismantle the ABS hydraulic assembly.

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1)

.

Press the card pin of the plug and pull the lock buckle

up and disconnect the harness connector of the

hydraulic assembly.

2).

Dismantle the connector nut of six braking oil pipe from the

ABS hydraulic assembly and wipe the over spilled braking fluid.

3).

Using a tag or making records to mark the location for re-

connection.

3

4

5

6

2

1

4).

Dismantle two fixing nuts of the ABS hydraulic assembly

bracket and take the ASB hydraulic assembly down.

（III）

Installation

1.

Installation of the ABS hydraulic assembly

ABS

1) Install the hydraulic control unit and tighten the fixing nut.

Tightening torque

20~25Nm

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2) Install and tighten six connector nuts of the braking pipe

Tightening torque

20~25Nm

3) Press down the lock buckle and connect the harness connector of the hydraulic electronic control unit.

2.

Release the braking pedal.

3.

Fill brake fluid.

4. Bleed air of the hydraulic braking system.

Refer to Emission of the hydraulic braking system.

5. Bleed the air of the ABS.

Refer to Emission of the ABS.

6. Check if there is any leakage in the braking system.

7.

Connect the negative cable of the battery.

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VI、

Exhaust of the ABS

ABS

（I）

Special tool

SN

Tool number

Tool name

Outside drawing

1

Diagnostic

instrument for

ABS faul

（II）

Exhaust condition for the ABS

The ABS exhaust program should be performed if any one of the following cases occur:

ABS exhaust program:

1）

Exhaust for the braking pipe according to traditional method cannot achieve the needed pedal height or

feel.

2）

The ABS hydraulic assembly is replaced.

3）

High fluid loss occurs.

4）

Air inhalation is doubted.

This program uses the diagnostic instrument to drive the system valve and run the pump motor and remove

air from the secondary circuit. These secondary circuits are usually closed and only opened when the vehicle is

started and the ABS is operating. The automatic exhaust program makes these secondary circuits open and collect

all air to the hydraulic assembly and exhaust it out from the system.

（III）

Exhaust of the ABS.

1.

Required items

1).

Diagnostic instrument

with correct software

2).

Braking fluid.

3).

Lifting machine.

4).

Exhaust bottle equipped with pipe to recycle the liquid from the vehicle.

5).

Safety equipment including protective glasses.

6).

Two repair personnel: one steps on the braking pedal and control the diagnostic instrument, another one

keeps the hydraulic oil level of the braking master pump cavity and turn on and off the exhaust screw

according to the diagnostic instrument process.

2.

Preliminary inspection

1).

Check the charging state of the battery and repair the

battery and charging system if needed.

2).

Connect the diagnostic instrument and choose current and past diagnostic fault code. Rule out all fault code

before ABS exhaust. Please troubleshoot first if rule-out is failed.

ABS

3).

Check if there is any damage or leakage of the appearance. Repair it if needed.

Caution: Pressing down the EXIT key of the diagnostic instrument can terminate the automatic exhaust

program any time.

3. Exhaust of the ASB

1).

Choose Automatic exhaust program on the diagnostic instrument and proceed

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according to the instructions.

2)

.

During the process of general exhaust and automatic exhaust, step the braking

pedal and keep the braking liquid level of the braking master pump.

3).

When exhaust a wheel, ensure the hose is connected with the exhaust screw and empty it into the cavity

with braking fluid. In order to prevent the air inhalation into the braking hose, the cavity must be 30mm

higher than the bolt of the hose with braking fluid.

4)

.

The first step is general exhaust. This must be finished before automatic exhaust in order to get better

braking pedal height as well as feel and to ensure the best performance of the ABS.

5).

The first step of the automatic exhaust program is to rotate the pump and pressure absorber for about thirty

seconds. There is no need to open or close the exhaust bolt during this step. The braking pedal is consistently

compressed or depressed in the whole process.

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6)

.

In the next step, the diagnostic instrument requires the repair personnel to open one of the exhaust bolts and

then make circulatory inspection for the pressure valve and pump motor for about thirty seconds.

7).

Regarding the rest exhaust bolts, the diagnostic instrument will exhaust according to the sixth step.

8)

.

The diagnostic instrument will display corresponded information after the automatic exhaust program is

finished

9)

.

Calculate the height and feel of the braking pedal by stepping down the pedal. Make adjustment according

to step one to step eight until the pedal location is accepted.

Caution: During repeated operations, the automatic

exhaust program may stop temporarily and

enter Cool down waiting mode.

Caution: It will continue proceeding when the timer is over and this process cannot be got over.

10).

Enter JAC PV Exclusive Malfunction Diagnosis System.

11).

Choose JAC PV Exclusive V10.01 System.

12).

Enter into automatic exhaust program and proceed

according to the instructions.

,

13).

First step of system exhaust.

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14).

The exhaust is going on.

15).

The first step is finished.

16).

The second step of exhaust.

17).

The exhaust is going.

18).

The third step.

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19).

The exhaust is going on.

20).

The third step is finished.

21).

The fourth step.

22).

The exhaust is going on.

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23).

The fourth step is finished.

29;61

24).

The fifth step.

25).

The exhaust is going on.

26).

The exhaust is finished.

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Electronic Power Steering

Ⅰ.

Overview

（I）

Structure overview

Decomposition chart of Electronic Power Steering System

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Electronic Power Steering

（II）

Working principle of the system

Principle diagram

（III）

Maintenance parameter

Maintenance data and specification

Item

Specification

Mechanical steering type

Pinion and rack

Steering wheel diameter

φ375mm

Steering column and lower axle

Third stage collapse

Steering wheel operating torque

≤ 5N·m

Rack travel of the power steering gear

130±1mm

Line angle ratio

45.3

Steering wheel ring number

2.87±0.1

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Electronic Power Steering

（IV）

Torque parameter

SN

Item Tightening torque (N·m)

1

Fixing nut of the steering wheel

42~52

2

Installation nut of the steering column

20~25

3

Installation bolt of the steering column

20~30

4

Connecting bolt between the steering column assembly

and the intermediate axle assembly

30~35

5

Connecting bolt between the intermediate axle assembly

and the mechanical steering gear

30~35

6

Master fixing bolt of the mechanical steering gear

100~110

7

Subsidiary fixing bolt of the mechanical steering gear

110~120

8

Adjusting nut for the front beam of the steering horizontal

rod

50~55

9

Slotting nut for the outer ball head of the steering gear

50~55

（V）

Maintenance precautions

1. Make the vehicle to be on level and dry ground when checking the steering system.

2. All the bolts of the steering system components should be tightened according to the required torque.

3. Check the wheel positioning after the repair for the steering column assembly, steering gear or other steering

parts is finished.

4. The maximum voltage for the system should not exceed 18V and the minimum voltage should not be less than

9V.

5. Check the tire regularly and maintain the tire pressure as required.

6. Once some abnormal phenomenon such as gap, hairpin or swinging head occurs, please analyze whether the

problem is in the steering rotation equipment or power steering system or a part of the steering rod system and

then solve it accordingly.

7. Check the steering system components regularly and carefully that whether they are suffered from abnormal

impact. The damaged or faulty parts should be replaced promptly.

8. The components of the steering gear and system rod should not be welded in any way.

9. Check regularly that whether there is interference wear for the EPS harness or the connectors are loose. Replace

it timely if any abnormal phenomenon occurs.

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Electronic Power Steering

（VI）

Special tool

SN

Tool number

Tool name

Outline drawing

Usage

1

JAC-T1D002

Steering wheel puller

Dismantle the

steering wheel

2

JAC-T1D003

Steering rotating

mould

Dismantle steering

ball head

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Electronic Power Steering

Ⅱ.

Fault diagnosis

（I）

EPS ECU fault code chart

SN

Fault code Description

1

C1111 Fault in the main signal of the sensor

2

C1115 Fault in the subsidiary of the sensor

3

C1114 Fault in the power supply of the sensor

4

C1113 Sensor main and auxiliary fault

5

C1141 Open current of the motor

6

C1142 Abnormal current of the motor 1

7

C1145 Abnormal current of the motor 2

8

C1153 Low power voltage

9

C1112 High power voltage

10

C1154 Abnormal electric relay

11

C1121 Fault in the speed signal 1

12

C1123 Fault in the speed signal 3

13

C1124 Fault in the speed signal 4

14

C1122 Fault in the engine speed sensor

15

C1155 Abnormal temperature or ROM error

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Electronic Power Steering

（II）

Fault diagnosis

SN

Phenomenon Fault cause Solution Remark

The steering wheel ball

head is loose or the front

wheel is improperly

aligned.

Adjust the front wheel alignment

and steering wheel ball head.

1

Vehicle

deviation

The steering rod is

deformed because of

twist or excessively

worn.

Check and adjust

every connector

of the steering system

accordingly to instructions.

Refer to vehicle

deviation diagram

The preload of the

steering rack is

imbalanced.

Adjust or repair the preload of

the steering rack.

The harness connector is

loose or poorly contacted.

Check and re-connect the poorly

contacted harness stably.

The steering

power is

effective Power

steering goes and

comes, or when

vehicles restarts,

it resumes

normal

2

The motor fuse is loose or

poorly contacted. Re-install the fuse well.

Refer to steering

power goes and

comes flow chart.

The motor is faulty. Replace the motor.

The electronic steering

controller is faulty.

Replace the electronic steering

controller.

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Electronic Power Steering

（III）

Diagnosis flow chart

Flow chart for vehicle deviation

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Flow chart of steering power goes and comes

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Ⅲ.

Inspection for the vehicle steering system

(I) Special tool (No)

(II)

Check

1.

Inspection for the installation

1).

Check the installation of the steering device

assembly, front suspension, axle and steering column.

2).

Check whether there is a moving gap when the steering wheel is moved up and down, left and right and

axially.

3).

Check whether the fixing nut and bolt of the steering device assembly is loose.

2.

Check the free travel of the steering wheel

1).

Turning the steering wheel to make the front wheels to be in straight ahead position. Start the engine and

turn the steering wheel to left and right slightly until the front wheels begin to move. Measure the movement

of the steering wheel in the outer circle.

Free travel of the steering wheel is 30mm.

2).

When the measurement exceeds the standard value, check every connector of the steering column and

installation of the steering device. Correct or replace related parts according to the situation.

3).

If the idle stoke is still more than 30mm, turn off the engine and make the front wheels to be in running

state of a straight line. Apply a force of five N along the circumference of the steering wheel and check the

idle stroke which should not be more than 10mm. If it is more than 10mm, check whether the steering gear

assembly is qualified.

4).

If the stoke is still at its limited value, turn the steering wheel to the neutral position when the engine is

off. Apply a force of 4±0.6N to the circumference of the steering wheel and check its free travel.

The standard value is less than 15mm.

5).

If it exceeds the standard vale, remove the steering gear and check the general toque of the small pinion.

3.

Check the intermediate position

1).

Check the installation of the steering device

assembly, steering column and steering wheel.

2).

After the wheels are aligned, check the intermediate position. Refer to “Alignment and inspection for front

wheels”.

3).

Park the vehicle in straight ahead direction, make sure that the steering wheel is in the middle position.

4).

Loosen the locked nut of the lateral rod and fine-tune the lever to left and right so as to confirm whether

the steering wheel is in the middle position.

4.

Check the stationary steering force of the steering

wheel

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Electronic Power Steering

1).

Park the vehicle on level and dry ground and pull

up the handbrake.

2).

Start the engine.

△

Precautions: the tire pressure should be within the standard values.

3).

Turn the steering wheel by three hundred and sixty degree from the central position. Check the steering

force and whether there is significant fluctuation.

Steering force of the steering wheel should be less than 3.4N and the allowed fluctuation is less than 5.9N.

4).

If the steering force of the steering wheel exceeds the standard value, check or adjust below items:

(1).

Check whether the lower swinging arm and ball head of the steering lateral rod are damaged.

(2).

Check preload of the steering pinion and rotating torque of the ball head for the steering bilateral rod.

(3).

Check the rotating torque of the ball head for the lower swinging arm.

5.

Inspection for the automatic return of the steering wheel

△

Caution: Turn slowly and sharply to feel the force and check whether there is any difference in return

between left and right. This step must be performed in a safe road and traffic condition and be careful.

1). Turn the steering wheel by 90° and drive at 35km/h. Keep this state for several seconds and then release the

steering wheel which should return for at least more than 70%.

6.

Inspection for the steering angle of front wheels

1).

Check the steering angle of front wheels after inspection for

front wheel beam is finished. Put the front wheels

on the steering angle device (Front wheels align the

steering wheel) and check the largest inner and outer

steering angle of the left and right wheels.

Inner wheel:

36°±1.5°

Outer wheel:

30°±1.5°

2).

When the engine is idling, turn the steering wheel to left and

right to the end and measure the steering angle.

△

Caution: Adjust the lateral rod if the measurement is

not within the standard value.

Adjust the steering angle by following steps:

When the steering angle exceeds the standard value,

loosen the lock nut of the lateral rod in left and right sides.

Use a wrench to rotate the lateral rod in left and right sides

to adjust the steering angle to standard value, and then lock the

nut and tighten the torque by 50~55N·m. Adjust the exposed

length of the thread for the left and right lateral rod. Make sure

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Electronic Power Steering

the lateral rod length of the left and right should be consistent.

△

Caution: When the inner wheel steering angle exceeds the standard value, adjust the lateral rod of this

side outwards to increase the inner wheel steering angle. When the outer wheel steering angle

exceeds the standard, adjust the lateral rod of this side outwards to reduce the outer wheel

steering angle. The toe-in is interrelated with the rest wheel alignment parameters and

adjustment of the steering angle.

7.

Inspection for the dust cover of the ball

head

1).

Press the dust cover with a finger to

check whether it’s cracked or damaged.

2).

Replace the ball head of the lateral rod when the dust cover is cracked or damaged.

△

Caution: When the dust cover is cracked or damaged, it may cause associated damage to the ball head.

8.

Inspection for the ball

head of the steering

lateral rod

1).

Sway the lateral rod fast

for ten times.

2).

Use a spring balance to measure the swing resistance of the lateral rod.

Standard value: 0.5~3N Replace the lateral rod if the measurement is not within the standard value.

Ⅳ.

Steering wheel assembly

(I)

Special tool

SN

Tool Number

Tool Name

Outline Drawing

1

JAC-T1D002

Steering

wheel

puller

(II) Removal

1.

Disconnect the negative cable of the battery.

△

Caution: Disconnect the negative cable of the

battery and wait for more than three

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Electronic Power Steering

seconds in order to prevent the airbag

from deploying in the disassembling

process.

2.

Dismantlement for the drivers's airbag module, refer to “ Airbag for the Driver”.

3.

Dismantlement for the steering

1）

Lock the steering wheel and disassemble the fixing nut

of the steering wheel.

2）

Pull out the steering wheel from the steering column

axle.

△

Caution: If the steering wheel cannot be pulled out easily,

please use the steering wheel puller.

（III）

Installation

1. Installation for the steering wheel

1). Install the steering wheel to the steering column.

2). Install the fixing nut.

Tightening torque: 42~52N·m

2. Install the driver’s airbag module.

3. Connect the battery cable.

V.

Controller assembly

（I）

Special tool (No)

（II）

Dismantlement

1. Disassemble the steering cover. Refer to “Steering Cover”.

2.

Dismantle the controller assembly.

1). Disconnect the connectors of the controller harness.

2). Remove the two fixing bolts of the controller bracket.

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3). Remove the three fixing bolts of the controller bracket and take the controller assembly from it.

（III）

Installation

1. Install the controller assembly.

1). Install the controller bracket to the controller and tighten the three fixing bolts.

2). Install the controller and bracket assembly to the steering column and tighten the two fixing bolts.

3). Connect the harness connector of the controller.

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VI.

Motor assembly for the EPS

（I）

Special tool (No)

（II）

Dismantlement

1. Remove the steering cover. Refer to “Steering Cover”.

2. Disassemble the steering column assembly. Refer to “Steering column assembly”.

3. Dismantle the motor assembly of the EPS.

1). Disconnect the harness connector of the EPS motor wiring.

2). Remove the two fixing bolts between the motorand fixing bracket.

（III）

Installation

1. Install EPS motor assembly.

1). Install the two fixing bolt between the motor and bracket.

2). Connect the harness connector of the EPS motor wiring.

2. Install the steering column assembly.

3. Install the steering cover.

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Electronic Power Steering

VII.

Steering column assembly

（I）

Special tool (No)

（II）

Dismantlement

1. Disconnect the negative cable of the battery.

△

Caution: Disconnect the negative cable of the battery and wait for more than three seconds in order

to prevent the airbag from deploying.

2. Disassemble the driver’s airbag module. Refer to “Driver’s airbag module”.

3. Remove the steering wheel. Refer to “Steering wheel”.

4. Dismantle the upper and lower cover of the steering column. Refer to “Upper and lower cover of the

steering column”.

5. Remove the clock spring. Refer to “Clock spring”.

6. Dismantle the combined switch assembly. Refer to “Combined switch assembly”.

7. Remove the ignition lock. Refer to “Ignition lock”.

8. Dismantle the steering column assembly.

1). Disconnect the harness connector of the EPS.

2). Remove the connecting bolt between the steering column and lower axle to separate the steering

column and steering gear.

3). Remove the two fixing nut between the upper side of the steering column assembly and bracket.

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4). Remove the bolt between the lower side of the steering column and bracket.

5). Lower the steering column and remove the steering column assembly.

（III）

Inspection

1. Inspection for the steering column.

1). Check whether the steering column is cracked, deformed or damaged. Replace it if above phenomenon

occur.

2). Check whether the spline of the steering column axle is worn or broken. Replace if if above

phenomenon occur.

（IV）

Disassembly

1. Disassemble the intermediate axle assembly.

1). Loosen the connecting bolt between eh steering column and universal joint of the connecting axle.

2. Dismantle the steering lock

1). Use a drill to drill a hole on the screw bolt which isenough to

put a bolt in.

2). Use a thread screw to remove the two special bolt.

3). Remove the steering lock from the steering column.

△

Caution: This fixed screw is disposable and must be replaced

after removal.

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3. Removal for the adjustable bracket.

1). Remove the fixed bolt and nut.

（V）

Inspection

1. Check the adjustable bracket and steering lock mechanism.

1). Check whether the adjustable bracket and spring are cracked or damaged.

2). Check whether the operation of the steering lock mechanism is normal.

（Ⅵ）Install

ation

1. Install the steering lock

1). Install the steering lock assembly and steering lock bracket

on the steering column assembly.

2). After the steering lock is confirmed to be correctly installed,

tighten the special bolt until the bolt head is broken.

1. 2. Install the adjustable bracket

1). When installing the steering lock assembly and steering lock

bracket on the steering column assembly, turn

it

towards the steering column gap and temporarily

lock

the steering lock.

3. Install the intermediate axle assembly

1). Install the intermediate axle assembly on the steering column.

2). Fix the internal nut and tighten the fixing bolt.

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（Ⅶ）Install

ation

1. Install the steering column assembly

1). Install the steering column assembly on the vehicle.

2). Install the connecting bolt between the lower part of the steering

column and the bracket and make it tightened.

Tightening torque 20~30N·m

3). Install the two fixing nut between the upper part of the steering column and the bracket and make it

tightened.

Tightening torque 20~30N·m

4). Connect steering column and steering gear and tighten the fixing bolt.

Tightening torque 30~35N·m

5). Connect the harness connector of the EPS.

2. Install the ignition lock.

3. Install the combined switch assembly.

4. Install the clock spring.

5. Install the upper and lower over of the steering column.

6. Install the steering wheel.

7. Install the driver’s airbag module.

8. Connect the negative cable of the battery.

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Electronic Power Steering

（Ⅷ）

Steering gear and rod assembly

1. Special tool

SN

Tool number

Tool name

Outline Drawing

1

JAC-T1D003

Steering rod

drawing tie

2.

Dismantlement

1.

Lifting the vehicle.

2.

Remove the front wheels. Refer to “Wheels”.

3.

Remove the ball head assembly of the lower swing arm. Refer to “Ball head assembly of the lower swing

arm”.

4. Remove the stability rod lever. Refer to “Stability rod lever assembly”.

5. Remove the front sub-frame and steering assembly.

1). Remove the connecting bolt between the intermediate axle

assembly and mechanical steering gear from the driving room

to separate the steering column assembly and steering gear.

2). Remove the lock nut of the lateral rod ball head.

3). Use a special tool to remove the ball head of the steering

lateral rod form the steering joint.

KBD.U2E114

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4). Remove the fixed bolt between the rear suspension of the

engine and the front sub-frame.

5). Dismantle the four fixed bolt connecting the sub-frame

and the vehicle body and put down the sub-frame and steering

assembly slowly.

6. Remove the steering gear and rod assembly

1). Remove the four fixed bolt of the steering gear from

the sub-frame.

2). Remove the steering assembly from the sub-frame.

△

Caution: Remove the steering assembly carefully and

slowly and try to avoid any damage to the dust cover of the

lateral rod.

（III）

Inspection

1. Inspection for the mechanical steering gear.

1). Check whether the gear and rack works smoothly and whether they are worn.

2. Inspection for the preloading of the gear.

1). Rotate the gear at 4-6 seconds per lap and measure the gear preloading in the full rack stroke range.

2). If the measurement exceeds the standard value, adjust the block first and then re-check the gear preloading.

3). If it still fails to get the required gear preloading after adjusting the block, check or replace the blocking parts.

3.Inspection for the rotating torque for the lateral rod.

1). Sway the lateral rod for ten times quickly.

2). Use a spring balance to measure the swinging resistance of the lateral rod.

Standard value：0.5~3N

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3).Replace the lateral rod if the measurement is not within the standard value.

△

Caution: If there is no excessive gap when the lateral rod swings slowly, it can be used even though the

measurement is lower than the standard value. The lateral rod should be replaced if the measurement is larger

than 4.3N·m.

4. Inspection for the dust cover of the lateral rod.

1) Check whether the dust cover is damaged and replace it if it is.

2) Check whether the dust cover is installed in correct location.

(Ⅳ) Installation

1. Installation for the steering gear and rod assembly

1). Install the steering gear assembly on the sub-frame.

2). Install the fixing bolt between the steering gear assembly

and sub-frame and tighten it.

Tightening torque: 110~120N·m

2. Installation for the sub-frame and steering gear assembly

1). Use a lift to support the sub-frame and steering assembly.

2). Install the four fixing bolt of the sub-frame and tighten them.

Tightening torque 170~190N·m

3). Install the fixing bolt between the rear suspension of the engine and the front sub-frame.

Tightening torque: 115~145N·m

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Electronic Power Steering

4). Install the ball head of the lateral rod on the steering joint and tighten the fixing nut.

Tightening torque: 50~55N·m

5). Install the steering gear to the universal joint of the intermediate axle and tighten the fixing bolt.

Tightening torque 30~35N·m

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