S5
Workshop Manual
Sub-volume
of Circuit Overhaul Manual
Forward General
Catalogue
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This manual helps professional
repair technician authorized by JAC to provide effective and correct
maintenance and repair for JAC S5 series car. To ensure customer
satisfaction to JAC passenger car products, it is necessary for professional
repair technician of
JAC
passenger car to provide warm service and correct operation. Therefore, the
repair technician must fully understand this manual. This manual should be
placed to accessible place to facilitate reference at any time.
Contents of this manual including
photos and technical parameters are updated. But if the repair is affected
due to product improvement, the dealer of JAC multifunctional vehicle will
provide technical bulletin or ancillary volume. Therefore, for proper use of
this manual, please pay attention to obtain relevant update information. JAC
passenger car company reserves rights in design change, addition or
improvement of the product.
Without written approval of JAC
multifunctional vehicle dealer, it is strictly forbidden to copy or modify
the contents of this manual in any manner including but not limited to
electronic, paper, and audio and video versions.
During
maintenance and repair of JAC passenger car products, the use of accessories
or unqualified oil not provided by JAC will cause the damage of the vehicle.
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Table of contents
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ID
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Clutch
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CI
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Manual transmission
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MT
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Drive system
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DS
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Suspension
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FSU/RSU
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Brake
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BR/PB
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Electronic stability
system
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ESC
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Electric steering
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EPS
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CL Clutch
Precautions
■ The recommended clutch hydraulic oil is brake fluid “DOT 4“. Do not use gasoline or kerosene and other mineral oil; otherwise, the
rubber parts in hydraulic system may be corroded.
■ Do not reuse the drained clutch hydraulic oil.
■ Pay attention not to splash clutch hydraulic oil onto
the paint surface of the vehicle body.
■ Do not use gasoline to clean clutch pressure plate !
■ Release bearing is filled with grease. Do not use oil
or liquid to clean it.
Warning:
■ Please use a cleaner to clean clutch friction plate Do
not use compressor air to clean it!
Preparation Work
The special tools are shown as
follows:
l
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S/N
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Tools
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Overall Diagram
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Number
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Description
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1
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Flywheel brake
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JAC-T1F011
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Fixing flywheel
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System Description
System Diagram:
1- Clutch pedal 2-
Clutch master cylinder and oil inlet hose 3- Master cylinder oil outlet rigid pipe
assembly 4- Clutch bracket 5- Clutch hose 6- Clutch hose bracket 7-
Three-way valve oil inlet rigid pipe assembly 8- Three-way valve 9-
Three-way valve bracket 10- Sealing plug
11- Three-way valve oil outlet pipe assembly 12- Hydraulic release bearing
13- Clutch pressure plate 14- Clutch driven disc
Descriptions of principles:
Clutch mechanism controls the
engagement and release of clutch in the manner of remote distance hydraulic
operation, to achieve power transmission and cut between engine and
transmission. Detailed implementing process is shown as follows:
When releasing: The
driver steps clutch pedal 1. and push the pushing rod of on the master cylinder
2 of clutch and make the clutch special hydraulic oil in master cylinder 2 flow
into hydraulic release bearing 12 through clutch rigid pipe 3 and hose 5, so as
to push the release bearing to move forward in axial direction. So the release
finger of diaphragm spring of clutch pressure plate 13 is pushed to separate
and the clearance between disc 13 and flywheel increases. So the clearance
between driven disc 14 and dis 13 increases. Driven disc 14 gradually can't
transmit power to the first shaft of transmission due to the decrease of
friction, and the power is cut off.
When engaging: The driver slowly release clutch pedal 1 and release finger
of diaphragm spring of clutch pressure plate 13 gradually returns to its
position due to the reduction of pressure. Hydraulic chamber of hydraulic
release bearing becomes small. Hydraulic chamber of master cylinder becomes big
so as to push the clutch pedal slowly rise up. meanwhile, clearance between pressure
plate 9 and flywheel becomes small. and clearance between driven disc 14 and
flywheel and pressure plate 13 becomes small. drive disc can transmit power to
the first shaft of transmission due to the increase of friction force. Power is
tranmitted.
Inspection and Maintenance
1. Exhaust System
Once the clutch hydraulic pipe or
clutch master cylinder is dismantled, or hydraulic release bearing or clutch
pedal is soft when being pressed down, it is necessary to exhaust air from
hydraulic system.
(1) Release air
drain boltof three-way valve.
(2) Slowly unscrew air
drain boltof three-way valve.
(3) Fully step pedal
until air is exhausted out fully.
(4) Add hydraulic oil
for clutch hydraulic system.
Notes:
■ Aways keep the liquid level of oil reservoir between MIN and MAX.
(5) Repeat above steps
until the sytem drains clean clutch hydraulic oil without air bubbles.
(6) Make sure that
clutch works normally.
① Start the engine and step the clutch pedal. After 2s, engage reverse
gear carefully. If there is big noise during gear selection, fully step clutch
pedal for 5 times to exhaust air from the system.
② After waiting for 30s, re-inpsect the working condition of the clutch.
If there is still big
noise, please repeat exhaust step.
2. Overhaul of Master Cylinder of the Clutch
1. Dismantling
① Drain out all
hydraulic oil from the system through air exhaust bolt.
② Dismantle split pin connecting
pushing rod of master cylinder of the clutch and clutch pedal.
③ Dismantle clutch oil
outlet pipe and fixing nuts of master cylinder of the clutch.
④ Disconnect connecting
hose connecting master cylinder of the clutch and fluid reservoir.
⑤ Take out clutch pedal
and master cylinder of the clutch.
2. Inspection
① Inspect whether clutch
pipline is blocked.
② Inspect whether
clutch hose and rigid pipe have rusting or corrosion, and other damages.
③ Inspect whether
master cylinder of the clutch is sticking, has oil leakage, etc.
3. Installation
① Install master
cylinder of the clutch.
② Install clutch pipeline
and clamp.
③ Install pushing rod
of master cylinder of clutch onto clutch pedal.
④ Exhaust air from
clutch system.
3. Overhaul of Clutch Pedal
1. Dismantling
① Dismantle mounting
nuts of master cylinder of the clutch.
② Dismantle split pin connecting
pushing rod of master cylinder of the clutch and clutch pedal.
③ Dismantle mounting
bolts of clutch pedal, and take out clutch pedal.
2. Inspection
① Inspect whether
clutch pedal shaft and lining are worn.
② Inspect whether
clutch pedal is bent or deformed.
③ Inspect whether
boosting spring is damaged or deformed.
④ Inspect whether pedal
cushion is damaged or worn.
Notes:
■ If any damage or deformation is found during inspection, replace
clutch pedal.
⑤ Measure the stroke of
clutch pedal.
⑥ If the stroke of
clutch pedal isn't within the specified range, conduct the following
adjustment:
a.
Adjust clutch switch, and then tighten lock nut.
b.
Adjust pushing rod of master cylinder of the clutch to the specified
range, and then tighten lock nut.
Notes:
■ When adjusting the height of clutch pedal, do not push the pushing
rod towards master cylinder of the clutch.
⑦ After adjustment,
inspect whether the stroke and free stroke of clutch pedal are within the
specified range.
⑧ If the free stroke of clutch pedal isn't within the
specified range, there must have some air inside clutch hydraulic pipe or there
is fault in master cylinder the clutch. It is necessary to exhaust system, dismantle and inspect
master cylinder or clutch.
3. Installation
Install it in Reverse Order
of Dismantling.
Notes:
■ Do not let any oil grease contaminate the surface of
clutch friction plate, pressure plate and flywheel.
1. Dismantling
① Dismantle manual transmission assembly from the
vehicle. Please refer to “Manual Transmission Assembly”.
② Uniformly unscrew fixing bolts of clutch pressure plate.
And then dismantle clutch pressure plate and clutch friction plate
Notes:
■ Only unscrew one to two circles of each bolt at each
time, to avoid the damage of flange of clutch housing.
③ Dismantle fixing bolts of flywheel from the rear end of
cylinder block, and then remove flywheel.
④ Dismantle hydraulic release bearing from transmission
housing.
2. Inspection
① Clutch friction plate
■ Inspect whether the surface is deteriorated or stained
with grease due to the loosening of rivet, single surface contact, burning. If
yes, please replace clutch friction plate.
■ Measure the sinking depth of rivet. If it exceeds limiting
value, please replace clutch friction plate.
Limiting value: 0.3 mm
■ Inspect whether the return spring is loose or damaged.
If yes, please replace clutch friction plate.
■ Install clutch friction plate onto the input shaft, and inspect the
sliding condition and loosening of rotation direction. If the sliding condition is bad, clean it. If
it is still bad after assembly, replace it. If there is obvious loosening,
replace clutch friction plate or input shaft, or replace both at the same time.
② Clutch pressure plate
■ Inspect whether the end of diaphragm spring is worn
and whether there is height difference. If there is obvious abrasion or the height difference
exceeds limiting value, replace clutch friction plate
Limiting value: 0.5 mm
■ Inspect whether the surface of disc is worn, has crack
or color change.
■ Inspect whether the rivet of disc is loose. If yes,
replace clutch pressure plate.
③ Hydraulic release bearing
■ Inspect whether bearing is burned, damaged, or has
abnormal sound, unsmooth rotation, etc.
■ Inspect whether diaphragm spring of hydraulic bearing
is worn. If yes, please replace
it.
④ Flywheel
■ Use
ad dial indicator to measure the levelness of contact surface between flywheel
and clutch friction plate If it doesn't meet requirement, please replace the
flywheel.
■ If there is
ablation or color change between the contact surface of clutch pressure plate and
clutch friction plate, please use sand paper to grind and repair it.
Notes:
■ Please measure the levelness on the outer surface of
flywheel (do not measure it on the fixing pin).
3. Installation
① Clean the clutch friction
plate and input shaft key groove, and remove grease and worn metal chips.
② Apply grease onto the
key groove of input shaft.
Notes:
■ Recommended grease: SAEJ310 or equivalent.
■ Make sure that the grease is applied onto the proper
position; otherwise, it may cause the clutch produce noise, bad release
connection or damage. Too much grease may cause
the sliding or shaking.
③ Install flywheel and
tighten it to the specified torque; use special tool to install clutch friction
plate and clutch pressure plate .
④ Implement each step
according to the sequence shown in figure, to uniformly tighten fixing bolts of
clutch in order.
Notes:
■ Tighten each bolt to 1～2 circles and gradually tighten them.
Tightening toque: 18～25 N•m
⑤ Install hydraulic release
bearing.
⑥ Install manual
transmission onto the vehicle. For installation process, please refer to “Manual
Transmission”.
Fault Diagnostic
Diagnosis of performance of clutch
assembly and clutch control system should be carried out by skillful vehicle
repair technician.
After proper diagnosis,
adjust it according to according to relevant solutions and the contents of each
detailed procedure stated in repair manual, or replace parts according to the
requirements. all parts to be replaced must use genuine parts provided by JAC.
If the clutch pressure plate or clutch driven disc is damaged, do not repair
it, just replace the assembly.
Number is diagnostic
table doesn't mean the sequence of inspection. There is no sequence between
each possible cause.
Common Fault Diagnostic Table
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Inspection
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Possible
Cause
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Solutions
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Unable
to be released
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Unable
releasing means the clutch can't exert its function and cut off the power
transmitted from the engine.
Inspect
the following conditions:
1.
Clutch release rod is deformed.
2.
Diaphragm spring is deformed.
3.
Support ring of diaphragm spring is
broken.
4.
Clutch pedal
control system is adjusted improperly.
5.
Clutch friction plate and flywheel is bond
or bond with clutch pressure plate.
6.
Clutch pipeline has oil leakage.
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Replace the deformed, worn or broken
parts. Adjust clutch pedal control system.
Inspect the oil leakage position of clutch
pipeline, and tighten pipe joint or replace the leaked part.
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It
can't be released completely
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The
clutch can't be released completely, which may cause unabling to cut off the
power transmitted from the engine. The gear lever will become difficult to
operate due to the continuous rotation of clutch friction plate and input
shaft of transmission.
Inspect
the following conditions:
1.
Clutch friction plate is deformed and will
shake when it rotates.
2.
Clutch friction plate is damaged.
3.
Clutch friction plate spline isn't matched
with spline of input shaft of transmission, or the spline tooth is damaged.
4.
Clutch friction plate is stick with
flywheel or clipping clutch pressure plate.
5.
Thickness
of flywheel/ clutch pressure plate / clutch friction plate exceeds the
specified dimensions.
6.
Clutch
pedal control system has mechanical fault of is adjusted improperly.
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Replace
the deformed, worn, broken parts or parts with their sizes exceeding the
specified dimensions. If clutch friction plate can't work with spline of
input shaft of transmission well, replace clutch friction plate If necessary,
replace input shaft of transmission.
If the
dimension of clutch friction plate exceeds the specified dimensions or the
clutch friction plate is damaged, replace it.
Replace
improper clutch thrust bearing.
Adjust
clutch system to eliminate unnecessary clearance or mechanical faults.
Reinstall the parts which are not properly
assembled.
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It
can't be engaged completely.
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Uncompleted
engagement of the clutch may cause unabling to transmit power from the engine
to the input shaft of transmission, and it also can cause the sliding of
clutch friction plate
Inspect
the following conditions:
1.
Clutch friction plate is stained by oil or
grease.
2.
Clutch friction plate is damaged.
3.
Clutch pedal has no free stroke.
4.
Diaphragm
spring/ clutch pressure plate / clutch disengaging lever/ clutch friction
plate spline is deformed or damaged.
5.
Clutch pedal control system has mechanical
fault of is adjusted improperly.
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Replace the deformed, worn or broken
parts.
Replace clutch friction plate or fault
clutch assembly.
Properly
adjust free stroke of clutch pedal.
Adjust
clutch system to eliminate unnecessary clearance or mechanical faults.
Reinstall the parts which are not properly
assembled.
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Inspection
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Possible
Cause
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Solutions
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Sliding
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The
sliding of clutch friction plate may cause unabling to transmit power from
the engine. Inspect the following conditions:
1.
Clutch friction plate is worn.
2.
Clutch friction plate is stained by oil or
grease.
3. Clutch
can't be engaged completely.
4.
Thickness
of flywheel/ clutch pressure plate / clutch friction plate exceeds the
specified dimensions. And friction surface exceeds the specified
specification.
5.
The clutch housing has high temperature
due to improper driving.
6.
Improper clutch is
installed.
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Replace
the deformed, worn, broken parts and parts with their sizes exceeding the
specified dimensions.
The solutions are the same as “it can’t be released completely” and it
can't be engaged completely.
Stop
the engine and cool the temperature inside clutch housing (if the temperature
is too high), and then conduct next diagnosis.
Correctly
install the specified clutch.
Adjust
clutch pedal control system to eliminate unnecessary clearance or mechanical
faults.
Reinstall
the parts which are not properly assembled.
The driver is not allowed to put his feet
on the clutch pedal.
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Noise
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Inspect
the following conditions:
1. Improper
clutch friction plate
2. Bad
balance.
3.
Clutch thrust bearing has fault.
4.
Torque damping
spring of clutch friction plate is damaged.
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Replace
the deformed, worn and broken parts. install the specified clutch friction
plate
If
some parts have bad balance, replace clutch assembly.
Adjust clutch pedal control system.
Reinstall the parts which are not properly assembled.
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Shaking
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When
clutch friction plate can't softly engage with flywheel, this situation may
occur.
Inspect
the following conditions:
1.
Damping spring of clutch friction plate is
unqualified.
2.
Clutch friction plate is unqualified.
3.
Clutch friction
plate is stained by oil or grease.
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Replace clutch assembly
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Repair
Data and Specifications
Clutch specification table
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Clutch type
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Single sheet, dry type diaphragm spring
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Pressure plate assembly
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Assembly pressing load N
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5680 N
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Lever ratio of diaphragm spring
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3.25
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Lever height of diaphragm spring mm
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37.5
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Driven disc assembly
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Outer diameter X inner diameter mm
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Φ235×Φ155
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Area cm2
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245 cm2
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Spline dimensions
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Modulus 24/48; pressure angle 30°; Teeth
number: 23
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Clutch control mechanism
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Control type
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Hydraulic type
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Inner diameter/ outer diameter of hydraulic
release bearing mm
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Φ44/Φ3 2.2
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Release bearing
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Self-aligning type
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Technical Parameter Table
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Free stroke of clutch pedal
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5～15
mm
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Grease Table
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Master
pin of pedal
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Kunlun
No.2 low temperature grease
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Tightening
Torque Table
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S/N
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Name
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Quantity
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Tightening toque N•m
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1
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Fixing nut of master cylinder of clutch
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3
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20～28 N•m
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2
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Mounting bolts of clutch hose bracket assembly
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3
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20～28 N•m
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3
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Connecting pipe joint of clutch rigid pipe
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6
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18～22 N•m
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4
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Air drain bolton the three-way valve
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1
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8～12 N•m
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5
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Upper mounting bolt of clutch pedal
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1
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20～28 N•m
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MT Manual Transmission
Precautions:
■ Do not reuse the drained manual transmission gear oil.
■ When inspecting or replacing manual transmission gear
oil. Keep the vehicle level.
■ When dismantling and installing transmission, make
sure that there is no dust and sundries inside.
■ Before dismantling or disassembling, inspect and fix
proper installation position. If
it is necessary to make installation mark, make sure that it can't affect the
function of the marked part after making mark.
■ Follow the instructions and the diagonal sequence and
take several steps to first tighten the center and then the outer bolts and
nuts. If there is a requirement
to tightening sequence, follow this requirement.
■ Pay attention not to damage the
sliding surface and matching surface.
6-speed manual
transmission
Descriptions and Operation
1. There are marks on transmission clutch housing: “MF31B2☆xxxxxxx☆” as shown in figure.
Stamping position of
transmission mark
Preparation Work:
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S/N
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Tool Name
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Tool Photo
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Remarks
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1
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Installing tool of gear shifting
shaft oil seal
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2
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Installing tool of
drive shaft oil seal
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3
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Installing tool of input shaft oil
seal
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4
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Dismantling tool of
input shaft oil seal
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5
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Installing tool of
outer ring of main reducer bearing
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6
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Dismantling shim block
of main reducer bearing
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S/N
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Tool Name
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Tool Photo
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Remarks
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7
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Dismantling tool of
main reducer bearing
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8
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Dismantling tool of
reversing shaft bearing
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9
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Installing tool of reversing shaft bearing
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10
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Installing tool of
outer ring of output shaft front bearing
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11
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Installing tool of
outer ring of front bearing of intermediate shaft
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12
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Installing tool of shift shaft lining
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S/N
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Tool Name
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Tool Photo
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Remarks
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13
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Installing tool of
bearing of shift shaft line
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14
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Tool for pressing out
of input shaft
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15
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Installing tool of output
shaft rear bearing
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16
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Installing tool of
outer ring of rear bearing of intermediate shaft
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17
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Installing tool of rear
bearing of intermediate shaft
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18
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Dismantling tool of
outer ring of output shaft front bearing
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S/N
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Tool Name
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Tool Photo
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Remarks
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19
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Dismantling
tool of bearing of shift shaft line
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20
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Installing
tool of upper bearing of intermediate shaft
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21
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Installing
pressing tool of the 1st and 2nd gear synchronizer
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22
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Pressing
tool of intermediate shaft lining
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23
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Pressing
tool of intermediate shaft gear
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24
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Installing
tool of lower bearing of intermediate shaft
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S/N
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Tool Name
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Tool photo
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Remarks
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25
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Dismantling shim block
of lower bearing of intermediate shaft
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26
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Dismantling shim block
of upper bearing of intermediate shaft
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27
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Installing tool of
front lower bearing of output shaft
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28
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Dismantling shim block of
front lower bearing of output shaft
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29
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Dismantling tool of
outer ring of bearing
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Front
View of Overall Structure of Transmission
Front view
Plan view
Rear view
Transmission Assembly
Structure Type and Relevant Technical
Parameters
MF31B is full
sychronizer manual gear shifting mechnical transmission consisting 6 forward
gears and 1 reversing gear. The gear is slant type. 1st, 2nd and 3rd gears are
3D sychronizers. The rest is single dimension sychronizer. Gear shifting
mechanism is cable type remote control
1. Name and Meaning of Transmission
Two drives
Torque（310N/M)
Front mounted
Manual
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2. Relevant Technical Parameters
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Drive Type
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Two Front
Wheel Drive
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Gears of speed
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6
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Clutch control
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Hydraulic
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Weight kg
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55.8
(without oil)
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Specifications of lubricating oil
of gearbox
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SAE75W/90(GL-4)
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Filling method of lubricating oil
of gearbox
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Fill the specified oil volume from
the side oil filling hole.
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Filling
volume of lubricating oil of gearbox (6MT)
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(3+0.1)L
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3. Main Technical Parameters
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Control Type
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Remote Control
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Rated torque
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310 N•m
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Speed ratio
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1st gear
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3.917
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2nd gear
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2.042
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3rd gear
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1.257
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4th gear
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0.909
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5th gear
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0.902
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6th gear
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0.773
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Reversing gear
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4.792
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Main reduction ratio
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4.368/3.320
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4. Tightening
Torque and Installation Requirement
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S/N
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Name
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Installation Torque N•m
|
Specification of Torque Wrench N•m
|
Installation Requirements
|
|
1
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Mounting bolts of gear selector
flexible shaft bracket
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30〜42
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5〜50/0.5
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No
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2
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Mounting nuts of gear shift rocker
arm
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15〜22
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5〜50/0.5
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No
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3
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Mounting bolts of gear selector
seat
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30〜42
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5〜50/0.5
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No
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4
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Connecting bolts between housing
and clutch housing
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35〜45
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5〜50/0.5
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Apply suitable amount of
high-strength threaded glue
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5
|
Gear shifting locating pin
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55〜65
|
2〜100/2
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Apply suitable amount of
high-strength threaded glue
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6
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Reversing lamp switch
|
25〜35
|
5〜50/0.5
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Apply suitable amount of
high-strength threaded glue
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7
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Oil filling screw plug
|
30〜40
|
5〜50/0.5
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Apply suitable amount of silicone
sealant
|
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8
|
Oil drain bolt
|
40〜60
|
2〜100/2
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Apply suitable amount of silicone
sealant
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9
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Stud bolt
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35〜45
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5〜50/0.5
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Apply suitable amount of
high-strength threaded glue
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Dismantling and Disassembly of the Assembly
1. Section of Transmission
2. Movement Principles:
1st gear
Engine → clutch → input
shaft spline 1→ input into tooth 22 of the 1st gear → output tooth 7 of the
1st gear →1/2 gear sychronizer 6 → low gear output shaft 2 → main reduction
gear 3 of low gear output shaft 3 → differential 4
2nd gear
Engine → clutch → input
shaft spline 1 → input into tooth 23 of the 2nd gear → output tooth 5 of the
2nd gear →1/2 gear sychronizer 6 → low gear output shaft 2 → main reduction
gear 3 of low gear output shaft 3 → differential 4
3rd gear
Engine → clutch → input shaft spline 1 → input into tooth 12 of the 3rd gear → output tooth 10 of the 3rd gear →3/4 gear sychronizer 9 → low gear output shaft 2 → main reduction gear 3 of low gear
output shaft 3 →
differential 4
4th gear
Engine → clutch → input
shaft spline 1 → input into tooth 24 of the 4th gear → output tooth 8 of the
4th gear →3/4 gear sychronizer 9 → low gear output shaft 2 → main reduction
gear 3 of low gear output shaft 3 → differential 4
5th gear
Engine → clutch → input
shaft spline 1 → input into tooth 11 of the 5th gear → output tooth 13 of the
5th gear →5/6 gear sychronizer 14 → high gear output shaft 21 → main reduction
gear 19 of high gear output shaft 3 → differential 4
6th gear
Engine → clutch → input
shaft spline 1 → input into tooth 24 of the 6th gear → output tooth 15 of the
6th gear →5/6 gear sychronizer 14 → high gear output shaft 21 → main reduction
gear 19 of high gear output shaft 3→ differential 4
Reversing gear
Engine → clutch → input shaft spline 1 → input into tooth 22 of the reversing
gear → reversing gear idle gear
16 → reversing shaft 17 → output tooth 20 of reversing gear → main reduction gear 21 of high gear
output shaft →
main reduction gear 19 of high gear output shaft →differential 4
● Control
Through the control of control rod
inside driver's cab, the gear selector arm and shifting arm can be controlled
and gear shifting operation is conducted. The directions shown in ball head of
control rod handle are conresponding to different gear selecting and shifting
position. Each time of gearing off, the control rod will automatically return
to neutral position; gear can be selected only when the gear returns to neutral
position.
1. When shifting gear, it is necessary to completely step release pedal
to make the transmission loosen from engine torque and rapidly control
transmission rod. At the staring moment, it is necessary to use slow speed
gear.
2. When climbing or down slope and turning condition, it is necessary
to use slow speed gear. It is not allowed to release clutch and slide.
3. When it is difficult to operate transmission gear, it is necessary
to stop the vehicle and find out the cause. Do not use hard pushing force.
Proper Speed on Each Forward Gear of Transmission
is Shown as Follows:
|
Gear
|
1st gear
|
2nd gear
|
3rd gear
|
4th gear
|
5th gear
|
6th gear
|
|
Speed
(km/h)
|
0〜15
|
20〜30
|
35〜45
|
50〜60
|
65〜95
|
100〜120
|
Notes:
1. Gear shifting
operation of transmission should be carried out within this speed range.
2. When transmission
matches with different complete vehicle, the speed suitable for each ear is
different.
Gear Shifting Principles
Under complete vehicle
traveling forward condition, the gear shifting principle of transmission has
the following requirement: the speed increase gear shifting should be achieved
gradually from 1～6 gear; the speed decrease gear shifting should be achieved gradually from
6～1 gear. under vehicle traveling forward condition, it is
strictly forbidden to use reversing gear. Under complete vehicle gear shifting condition, to avoid
misoperation, the transmission is equipped with misoperation reversing gear
lock device. The reversing gear principle requires that the
complete vehicle is in parking condition, and then step the clutch and wait for
3s. It is not allowed to use reversing gear under vehicle traveling condition.
Meanwhile, it is not allowed to use forward gear when the vehicle is in
reversing condition.
Note: when the complete vehicle is
traveling and under emergency situation, it is allowed not to abide by gear
shifting principles of transmission.
Disassembly Schematic Diagram of Transmission
1. Disassembly Schematic Diagram
of Transmission Assembly
1. Clutch housing assembly 2. Hex flange bolt and plain
washer components (18 pieces) 3. Gear selecting locating pin 4.
Plug - 1(2 pieces) 5. Oil seal (2 pieces) 6. Retainer
ring (In the front of differential) 7. Differential assembly 8. Adjusting
shim (differential) 9. Hex flange bolt (5 pieces) 10. Gear selector
flexible shaft bracket assemblies 11. Housing assembly 12. Oil drain plug
13. Plug (input shaft) 14. Snap ring (deep groove ball bearing) 15. Plug 16.
Reversing lamp switch 17. Gear selecting lock components 18. Gear selecting locating
pin 19. Oil filling plug 20. Gear selecting shaft components 21. Wire
clamp 22. Fork assembly 23. Reversing shaft components 24. Shim (2 pieces
for reversing shaft) 25. Input shaft assembly 26. Oil guide plate 27. Low
gear output shaft assembly 28. Adjusting shim (2 pieces for output shaft) 29. Stud bolt（2 pieces)
30. High gear output shaft assembly 31. Gear selecting rocker arm
components 32. Split retaining ring
2. Disassembly Schematic Diagram of High Gear Output Shaft
Assembly
1. Tapered roller bearing (In the front of high gear output
shaft) 2. High gear output shaft 3. Reversing gear hub 4. Reversing gear
sleeve 5. Snap ring (reversing gear hub) 6. Needle bearing (output reversing
gear) 7. Output reversing gear components 8. Reversing spacer bush 9. Snap
ring (reversing spacer bush) 10. Needle bearing (output 6th gear) 11. Output
6th gear components 12. 5/6 gear synchronizer ring (2 pieces) 13. 5/6 gear synchronizer
spring (2 pieces) 14. 5/6 gear hub 15. Synchronizer sliding blocks 16. 5/6 spacer
bush 17. Snap ring (5/6 gear hub) 18. Needle bearing (output 5th gear) 19.
Output 5th gear components
20. Tapered roller bearing (output shaft rear) 21. Snap ring (the rear end of shaft)
3. Disassembly Schematic Diagram of Low Gear Output Shaft Assembly
1. Output 2nd gear components 2. Needle bearing (output
1/2/4 gear) 3. Low gear output shaft 4. Tapered roller bearing (In front of low
gear output shaft) 5. Plug (low gear output shaft) 6. 1/2 gear synchronizer
inner ring (2 pieces) 7. 1/2 gear synchronizer middle ring (2 pieces) 8. 1/2
gear synchronizer outer ring (2 pieces) 9. 1/2 gear synchronizer spring (2
pieces) 10. 1/2 gear hub 11. Synchronizer sliding blocks 12. 1/2 gear sleeve 13.
Snap ring (1/2 gear hub) 14. Output 1st gear components 15. Semicircular snap
ring (2 pieces) 16. Semicircular snap ring (2 pieces) 17. Output 4th gear components
18. 4th gear synchronizer ring 19. 3/4 gear synchronizer spring (2 pieces) 20.
3/4 gear hub 21. Synchronizer sliding blocks 22. 3/4 gear sleeve 23. Snap
ring (3/4 gear hub) 24. 3rd synchronizer outer ring 25. 3rd synchronizer middle
ring 26. 3rd synchronizer inner ring 27. Needle bearing (output 3rd gear) 28.
Output 3rd gear components 29. Tapered roller bearing (In behind of output
shaft) 30. Snap ring (rear end of shaft)
4. Disassembly Schematic Diagram of Input Shaft Assembly
1. Input shaft 2.
Input gear 3. Input 5th gear 4. Deep groove ball bearing 5. Snap ring (rear
end of shaft)
5. Disassembly Schematic Diagram of Transmission Assembly
1. Planetary gear thrusting washer (2
pieces) 2. Planetary gear (2 pieces) 3. Differential housing 4.
Axle shaft gear thrusting washer (2 pieces) 5. Axle shaft gear (2 pieces) 6. Rivet (12
pieces)
7. Main reduction gear 8. Tapered roller bearing (2 pieces)
9.
Elastic pin 10. Planetary gear shaft
6. Disassembly Schematic Diagram of Clutch Housing Assembly
1. Straight line bearing 2. Lining 3. Clutch
housing 4. Locating pin 5. Reversing shift shaft
6. End surface combination bearing 7. Snap ring (input
shaft front bearing) 8. Tapered roller bearing
9. Oil seal (input shaft)
7. Disassembly Schematic Diagram of Housing Assembly
1. Lining 2. End surface combination bearing 3.
Housing 4. Straight line bearing
Common Fault Diagnostic
(For abnormal condition and some faults which can't be solved
by yourself, please contact the authorized repair shop or professional
technician. For detailed disassembly schematic diagram and part number, please
refer to workshop manual)
|
Fault Condition
|
Possible Causes
|
Determination and Troubleshooting
|
|
It jumps to the neutral position
during vehicle traveling.
|
(1) Gear shifting head has excessive abrasion.
(2) Gear selecting locating pin
(3) Gear shifting working surface has excessive abrasion.
The contact surface between gear ring and gear sleeve
has excessive abrasion.
(4) Gear shaft is loose in axial direction.
|
(1) If the clearance is big when shifting, inspect whether
gear shifting head has excessive abrasion.
(2) If
the clearance is small when shifting, inspect whether gear shifting locating
pin is fail.
(3) Inspect whether operation system pushes gear shifting arm
of transmission into proper position, or inspect engagement condition by
removing transmission and using hands to push gear shifting shaft.
① If they are completely engaged,
inspect whether gear shifting fork is deformed or working surface has
excessive abrasion.
② If gear sleeve is engaged
completely, inspect whether the worn condition of taper positionbetween gear
sleeve and contacting tooth.
(4) Inspect whether the axial runout of gear shaft
is too big.
|
|
Under the condition that clutch has
no fault, it is difficult to shift gear and there is serious impact sound, or
some gear is difficult to gear on.
|
(1) Synchronizer ring has serious abrasion.
(2) Gear
taper has excessive abrasion
|
(1) Replace
synchronizer ring
(2) Replace
gear
|
|
Transmission has abnormal sound
① Regular knock sound.
② Uniform noise.
|
(1) Some teeth of gear
are broken.
(2) Gear
gap increases or gear is damaged.
(3) Bearing is worn.
(4) Lubricating oil volume is insufficient.
|
(1) Inspect
and find out the possible cause and eliminate it.
(2) Dismantle,
clean or replace the damaged gear or bearing.
(3) Replace
or add with new oil.
|
|
Oil leakage
|
(1) Oil level is too high
(2) Oil
seal has excessive abrasion or damage.
(3) Sealant isn't applied uniformly or sealing paper washer
is damaged.
(4) Ventilation plug
fails.
(5) Some bumping or collision on the contact surface is not
repaired timely.
|
(1) Dismantle
oil filling plug, and inspect oil level.
(2) Replace
oil seal.
(3) Dismantle
parts of each contact surface, and inspect bumping and collision condition,
and repair it to level condition.
(4) Uniformly
apply sealant.
(5) Replace
Ventilation plug.
|
|
Bearing is damaged abnormally.
|
(1) Lubricating
oil is too dirty.
(2) Lubricating
oil is insufficient or unqualified.
(3) Unqualified
bearing is used.
|
(1) Replace
lubricating oil.
(2) Inspect
oil surface of lubricating oil, fill or replace lubricating oil.
(3) Replace
bearing.
|
Disassembly of Transmission
1. Disassembly of Transmission Assembly
1. Drain Oil
Note: use a wrench to dismantle oil
drain plug and drain oil from drain hole. It is not allowed to drain oil from
other positions.
2. Dismantle Input Shaft Plug.
3. Dismantle Gear Shifting Flexible Shaft Bracket.
4. Dismantle Gear Selecting Rocker Arm Components.
5. Dismantle Gear Selecting and Shifting Shaft Component and
Gear Selecting and Shifting Seat.
6. Dismantle Snap Ring of Ball Bearing at the Rear End of Input
Shaft.
Remark: If the snap ring
is uneasy to dismantle, it is necessary to use copper bar to impact input shaft
from the direction of clutch housing, to make the gap at snap ring becomes big.
7. Dismantle Fastening Bolt (18 pieces in total)
8. Remove Housing
9. After Housing was Took Down as
Figure
Remark: after removing housing, remove each assembly and
shifting fork. The disassembly of transmission is finished.
2. Disassembly of High Gear Output Shaft
1. Appearance of High Gear Output Shaft is shown in Figure
2. Dismantle Snap Ring at the Rear End of Shaft.
3. Dismantle Output 5th
Gear and Rear Bearing of High Gear Output Shaft.
Remark: use special tool to hook the
bottom surface of output 5th gear to pull down the 5th gear and bearing.
r: Similar to the special tool shown
as figure below.
4. Remove Output 5th Needle Bearing and
5/6 Gear Synchronizer Ring
Remark: after removing
needle bearing, observe whether needle is damaged.
5. Dismantle 5/6 Gear Synchronizer Gear
Hub Snap Ring
6. Use Special Tool to Dismantle 5/6
Gear Synchronizer Assembly, 5/6 Gear Synchronizer Ring, Output 6th Gear.
Remark: When pulling by using special
tool, it is necessary to hook the bottom surface of 6th gear.
Note: it is not allowed to directly pull 5/6 gear synchronizer
gear sleeve to avoid damage of synchronizer.
7. Dismantle Output 6th Needle Bearing
and Reversing Spacer Snap Ring.
8. Dismantle Reversing Spacer.
Remark: use special tool
to pulldown reversing spacer.
9. Remove Output Reversing Gear and Output
Reversing Gear Needle Bearing.
Remark:
Gear and needle bearing can be removed directly.
10. Dismantle Reversing Synchronizer Hub Snap Ring.
11. Dismantle Reversing Synchronizer Assembly.
Remark: first remove
reversing gear sleeve, and then use special tool to pull down the reversing gear
hub.
3. Disassembly of Low Gear Output Shaft
Assembly
1. Low Gear Output Shaft Assembly is shown in Figure.
2. Dismantle Low Gear Output Rear End Snap Ring.
3. Dismantle Output 3rd Gear and Bearing
at the Rear End of Shaft.
Remark:
Use special tool to pull down gear and bearing.
4. Dismantle Output 3rd Gear Needle Bearing
and 3rd Gear Synchronizer Ring Components.
5. Dismantle 3rd Gear Synchronizer Gear
Hub Snap Ring.
6. Use Special Tool to Dismantle 3/4
Gear Synchronizer Assembly, 4th Gear Synchronizer Ring, Output 4th Gear.
Remark: use special tool to hook the
bottom surface of 4th gear.
Note: it is not allowed to directly pull 3/4 gear synchronizer
gear sleeve to avoid damage of synchronizer.
7. Dismantle Output 1/2/4 Gear Needle
Bearing, Semicircular Snap Ring Clamp,
8. Dismantle Output 1st Gear, 1/2 Gear Sychronizer Ring Components,
1/2/4 Gear Needle Bearing.
9. Dismantle 1/2 Gear Sychronizer Gear Hub Snap Ring
10. Dismantle 1/2 Gear Synchronizer Assembly,
1/2 Gear Synchronizer Ring Components, and Output 2nd Gear Together.
Remark: Use special tool to hook gear
and pull down the above parts.
11. Dismantle 1/2/4 Gear Needle Bearing.
4. Disassembly of Input Shaft Assembly.
1. Input Shaft Assembly is shown in Figure.
2 Dismantle Snap Ring at the Rear End
of Shaft.
3. Use Special Tool to Dismantle Cylinder
Roller Bearing and Input 5th Gear.
Remark: use special tool
to hook the end surface of 5th gear. Note: double-tooth and input shaft can't
be dismantled.
Inspection of Important Parts
1. Inspection of Input
Shaft.
(1) Inspect
whether input shaft gear has broken gear teeth, pits or serious abrasion on the
gear surface and gear binding. If any of the above condition occurs, replace
input shaft.
(2) Use hands to “feel“ whether bearing rotates freely, whether it is sitcking. If
the bearing doesn’t rotate freely or there is sticking situation, replace
bearing.
Notes:
■ Double-tooth on input shaft can't be disassembled. If
replacing double-tooth or input, these two parts must be replaced at the same.
2. High Gear Output Shaft,Low
Gear Output Shaft Inspection
(1) Inspect
whether high, low output shaft gear has broken gear teeth, pits or serious
abrasion on the gear surface and gear binding. If any of the above condition
occurs, replace output shaft.
(2) Inspect
whether high, low output shaft spline has serious abrasion and damage. If yes,
replace high, low gear input shaft.
(3) Use hands to”feel“ whether front bearing of high, low gear output shaft rotates freely,
whether it is sitcking. If the bearing doesn’t rotate freely or there is
sticking situation, replace bearing.
Notes:
Front bearing of high, low gear output shaft can’t be dismantled.
If replacing high, low output shaft or front bearing of high, low gear output
shaft, two parts must be replaced at the same.
3. Inspection of Differential Assembly
(1) Inspect whether
main reduction gear has broken gear teeth, pits or serious abrasion on the gear
surface and gear binding. If any of the above condition occurs, replace main
reduction gear components.
(2) Inspect whether
planetary gear and axle shaft gear and spline have serious abrasion and damage.
If yes, replace them.
(3) Inspect whether
outer ring and roller of tapered roller bearing have abrasion. If yes, replace
bearing.
Notes:
■ Inner ring of tapered roller bearing can't be dismantled.
■ Main reduction gear and differential housing can't be
dismantled.
■ If the inner ring of tapered roller bearing is
damaged, main reduction gear components and inner ring of tapered roller bearing
must be replaced at the same time. After replacement, adjusting shim of
differential must be selected again. magnitude of interference: 0.15-0.20 mm.
4. Inspection of Each Gear
Inspect whether each gear has broken
gear teeth, pits or serious abrasion on the gear surface and gear binding. If
any of the above condition occurs, replace relevant gear.
5. Inspection of Each Needle Bearing
Inspect whether each
needle bearing has serious abrasion, needle is falling, holder is in good
condition. If any of above damage occurs, replace needle bearing.
6. Inspection of Sychronizer
Ring
(1) Inspect
whether the surface of gear of sychronizer ring has damage.
(2) Inspect
whether the conical surface has damage or abrasion, and whether the thread is
crushed.
(3) The 4th, 5th and 6th gear sychronizer rings are single cone
ring. Press sychronizer ring into the gear to inspect the gap “A”. If “A“ is less than limiting value, replace sychronizer ring.
Synchronizer ring A=0.5 mm
(4) 1st,2nd
,3rd Sychronizer ring is as cone ring. Press
sychronizer ring into the gear to inspect the gap .“C”, if “B”.”C” is less than limiting
value, replace sychronizer ring assembly.
Limiting value “B”=0.5 mm Limiting value “C”=0.5 mm
7. Inspection of Sychronizer
(1) Assemble
sychronizer gear sleeve and gear hub, and inspect whether they can slide
smoothly without sticking.
(2) Inspect whether the
front and rear ends of inner surface of gear sleeve have damage.
Notes:
■ If
there is any sticking or damage and requires replacing, synchronizer must be
replaced in complete set.
Maintenance of Transmission
1. Repair and Maintenance
(1) Maintenance of
transmission, according to the requirements of use and maintenance of commercial
vehicle, can be divided into three technical maintenance grades.
(2) Regularly inspect
and replace (or add) transmission lubricating oil.
Regular Inspection and Maintenance List of Transmission
shows mileage and time (calculated in month). The inspection
should be subject to the first arrival date.
O Inspect level, tightening or adjustment; ★ Replace lubricating oil
|
Items
|
Interval (for mileage and month,
the first arrival date should prevail).
|
|
Month
|
—
|
3
|
6
|
12
|
18
|
24
|
30
|
36
|
42
|
48
|
54
|
|
Mileage
reading X1000 km
|
1
|
5
|
10
|
20
|
30
|
40
|
50
|
60
|
70
|
80
|
90
|
|
Inspection of inside of gearbox
|
|
Inspect gear oil level in gearbox.
|
|
|
○
|
|
○
|
|
○
|
|
○
|
|
○
|
|
Replace gear oil inside gearbox
|
General application condition
|
|
★
|
|
★
|
|
★
|
|
★
|
|
★
|
|
|
Extreme application condition
|
|
★
|
|
★
|
★
|
★
|
★
|
★
|
★
|
★
|
|
|
Other
inspection
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
■ Note: “extreme application
condition” includes the following conditions:
(1) Vehicle travels on
dusty areas or vehicle often exposes to salty air or salty water.
(2) Vehicle travels on
unflat, water deposited road or hill road.
(3) Vehicle travels in
cold areas.
(4) In cold season,
engine runs at idle speed for a long time or vehicle often travels in short
distance.
(5) It is necessary to
frequently use brake and emergency brake.
(6) Tow the vehicle.
(7) Vehicle is used as
renting car or you drives your renting car.
(8) Vehicle slowly
travels on crowd city road and traveling time exceeds 50% of total traveling
time at high temperature of above 32°C.
(9) Vehicle travels on
high way at the speed of above 120Km/h and traveling time exceeds 50% of total
traveling time at high temperature of above 30°C.
(10) Vehicle travels at
overload condition.
2. Lubrication and Sealing
|
Items
|
Grease and Sealant
|
Quantity
|
|
Transmission gear oil
|
Gear oil
75W/90GL-4
|
3.0(±0.1)L
|
|
Input shaft spline of transmission
|
Lubricating gease
|
Suitable amount
|
|
Contact surface between housing and
clutch housing
|
Kesai new ®1596F
|
Suitable amount
|
DS Drive Shaft
Precautions
1. Precautions when
repairing drive shaft
1) Some parts which
doesn't belong to overhaul parts such as steering knuckle can't be dismantled.
2) Conduct operation
on dust free working table as much as possible.
3) Before dismantling
and assembly, please clean the surface of parts.
4) When working, pay
attention to avoid stain the parts and prevent foreign matters from entering
into.
5) The disassembled
parts must be re-assembled in correct order. If work stops, it is necessary to
use clean shield to cover the parts.
6) It is necessary to
paper cloth to prevent cloth scrapings from attaching to the parts when using
fibre cloth.
7) The disassembled
parts (except for rubber parts) must be cleaned with kerosene and dried or
wiped by using paper cloth.
2. Precautions for
inspection, repair system or replacement of parts
1) After assembly, it
is neecssary to inspect the specified torque of fasteners.
2) After system is
assembled, conduct necessary positioning inspection.
3) Disposable parts
can't be reused.
4) Before repairing or
replacing parts, thoroughly inspect them.
Preparation Work
Use proper repair tool to dismantle
parts.
1. Common Tools
Common Repair Tool
Tables
|
S/N
|
Tools
|
Overall Diagram
|
Description
|
|
1
|
Power tool
|
|
Installation and dismantling of
bolts and nuts
|
2. Special Tools
Special
Tool Tables
|
S/N
|
Tools
|
Overall Diagram
|
Number
|
Description
|
|
1
|
Steering Drive Rod Die
|
|
JAC-T1D003
|
Dismantle connecting ball head
|
On-board Inspection:
1. Inspect whether drive shaft and universal joint are loose or have
any other damage.
2. Inspect whether dustproof sleeve has crack and other damage.
Notes:
■ If drive shaft has noise or vibration, please replace drive shaft
assembly.
Dismantling and Installation
Drive Shaft Assembly
Figure of left drive shaft assembly
Dismantling:
1. Rise up the vehicle and dismantle front wheel tire.
Notes:
■ Tightening toque：90 N•m〜110
N•m
2. Dismantle wheel speed sensor from universal joint. Please refer to “Wheel
Speed Sensor”
Notes:
■ Do not pull wire harness of wheel speed sensor.
■ Tightening toque：8 N•m〜10 N•m
3. Dismantle brake caliper assembly from steering knuckle, and hang and
fix it. Please refer to “front brake caliper”
Notes:
■ After dismantling of brake caliper, do not step brake pedal.
■ Tightening toque：65 N•m〜75 N•m
4. Unscrew locknut of drive shaft.
■ Tightening toque：240
N•m—260 N•m
5. Use hammer (or proper tool) and wooden block to slightly strike
drive shaft to separate wheel hub and steering knuckle assembly. And then
dismantle locknut of wheel hub.
Notes:
■ When lowering drive shaft, it is necessary to support
housing (universal joint components), shaft and other parts.
Notes:
■ If the wheel hub and drive shaft still can't be
separated after the above operation, a puller (or proper tool) can be used.
6. Dismantle
steering tie rod ball head from steering knuckle.
Notes:
■ To avoid damaging dustproof sleeve of ball head,
special tool should be used.
■ Tightening toque：15 N•m〜34 N•m
7. Loosen
fixing bolts and nuts of shock absorber and steering knuckle.
■ Tightening toque：75 N•m〜90 N•m
8.
Separate drive shaft from wheel hub and bearing assembly.
Notes:
■ The angle of placing universal joint of drive
shaft should not be too big, to avoid excessive tension and prevent
falling of ball cage.
Inspection
after Dismantling
① Rotate
universal joint and inspect whether it rotates freely and whether it has
serious loosening.
② Inspect
whether dustproof sleeve has crack, damage or grease leakage.
③ If
yes, please dismantle drive shaft and replace the fault parts.
Replace
assembly
Notes:
■
When installing drive shaft, it is necessary
to replace with a new transmission side oil seal.
Front
drive shaft
■ The installation is in reverse order of dismantling. About tightening torque, please
refer to “repair parameters“.
Notes:
■ Do not reuse disposable parts.
■ When inserting drive shaft into the side of
transmission, pay attention not to damage oil seal.
Notes:
■ Make sure that the snap ring on this side is completely
engaged.
■ Apply transmission gear oil on the drive shaft spline.
■
Before installing drive shaft, keep the
opening of snap ring downwards.
Replace
dustproof sleeve.
■ Follow the above dismantling
sequence to step 8 (separate drive shaft from wheel hub and bearing assembly)
1 Dismantle dustproof sleeve clamp.
2. Screw drive
shaft puller (or appropriate tooling) into the universal joint subassembly;
pull out universal joint subassembly from the shaft.
Notes:
■ If the universal joint assembly can't be pulled out,
first dismantle drive shaft from the vehicle, and then try to dismantle it.
3. Dismantle snap ring from drive shaft, and remove
dustproof sleeve.
4. Use paper towel to wipe the
grease from universal joint assembly.
5. Apply a suitable amount of
grease into the tooth hole of universal joint assembly, until the grease flows
out of round groove and tooth hole. After applying grease, use cloth to wipe the flowed old grease away.
6. Use adhesive tape to wrap
spline to avoid damaging dustproof sleeve.
Install
the new dustproof sleeve and dustproof sleeve clamp onto the drive shaft.
Notes:
■ Do not reuse dustproof sleeve and dustproof sleeve
clamp.
7. Remove
adhesive tape wrapped on the shaft.
8. Put snap ring onto the groove at the edge of the
shaft. Align the intermediate shaft on the edge of
the shaft with universal joint assembly. And then use snap ring to install
shaft onto the universal joint assembly.
Notes:
■ 
Do
not reused snap ring.
■ When installing snap ring, it is recommended to use
special tool.
9. Use
plastic hammer to install universal joint assembly onto the drive shaft.
Notes:
■ Make sure that the universal joint assembly is correctly
engaged when rotating drive shaft.
10. Uniformly apply a suitable amount of grease from
the big diameter of dustproof sleeve into the dustproof sleeve.
11. As shown in figure, install
dustproof sleeve into the groove.
Notes:
■
If
grease sticks to the fixing surface of dustproof sleeve (* mark), dustproof
sleeve may fall off. Clean and wipe all grease from the surface
of dustproof sleeve.
12. Insert
slotted screwdriver from the big diameter of dustproof sleeve, and
exhaust air and adjust the installation length of dustproof sleeve to avoid
deformation of dustproof sleeve.
Notes:
If the installation length of dustproof sleeve,
it may cause the damage of dustproof sleeve.
Attention should be paid when using slotted screwdriver
not to damage dustproof sleeve.
13. Use tool to fix the new dustproof sleeve clamp.
Notes:
Do not reuse dustproof sleeve clamp.
14. Fix universal joint subassembly and drive shaft,
and then make sure that the dustproof sleeve is in proper position when
rotating it.
Note:
if the installation position of dustproof sleeve is wrong, please reinstall
with a new dustproof sleeve clamp.
15. Make sure the snap ring on transmission drive shaft
side is completely engaged.
16. Insert drive shaft into wheel hub and bearing
assembly, and then tighten locknuts of wheel hub.
17. Install fixing bolts and nuts of shock absorber
and steering knuckle.
18. Install steering tie rod ball head and tighten
locknuts to the specified tightening torque.
Notes:
■ when installing, first fix bolts to prevent rotation,
and then tighten locknuts.
19. Install brake caliper components and fix brake
hose. Please refer to “Front Brake“ and “Brake Pipe“.
20. Install wheel speed sensor onto the steering
knuckle. Please refer to “Wheel Speed Sensor“.
21. Tighten locknuts of drive shaft to the standard
torque.
■ Tightening toque：240 N•m〜260 N•m
22. Install tire and tighten it to
the standard torque. Please refer to “Repair Parameters“.
Disassembly and assembly
1. Assembly
2. Disassembly
① On
transmission side
a. Fixing
drive shaft onto the caliper.
Notes:
■ When fixing drive shaft onto the caliper, please
use aluminium plate or copper plate to protect drive shaft.
b. Dismantle
dustproof boot clamp, and then pull the dustproof boot out of the drive shaft.
c. Make
assembly marks on the housing and drive shaft, and then pull drive shaft out of
the housing.
Notes:
■ Use oil paint or equivalent material to make
marks. Do not damage the surface.
d. Dismantle
snap ring, and then dismantle three-ball pin assembly from drive shaft.
e. Dismantle
dustproof boot from drive shaft.
f. Use
paper towel to wipe old grease from the housing.
② On
wheel side
a. Fixing drive shaft onto the
caliper.
Notes:
■ When
fixing drive shaft onto the caliper, please use aluminium plate or copper plate
to protect drive shaft.
a. Dismantle
dustproof boot clamp, and then pull the dustproof boot out of the drive shaft.
b. Screw
drive shaft puller (or proper tool) into the thread of universal joint
subassembly, and then remove drive shaft from universal joint assembly.
Notes:
■ If the universal joint subassembly isn’t'
dismantled successfully after several attempt, please replace drive shaft
assembly.
d. Dismantle
snap ring from drive shaft, and take out dustproof boot.
e. Dismantle
wheel speed sensor gear ring from drive shaft.
f. Rotate
ball cage and use paper towel to wipe old grease from universal joint assembly.
3. Inspection after disassembly
① Drive
shaft
Inspect
whether the drive shaft has jumping condition, crack or other damage. If yes,
please replace drive shaft assembly.
a. Universal
joint subassembly (wheel side)
Inspect
the following items:
■ Inspect whether universal joint subassembly has
excessive rotation, and whether drive shaft has excessive loosening condition.
■ When there is foreign matters entering inside of
the universal joint subassembly.
■ Whether universal joint subassembly is pressed,
has crack or inside damage.
If
yes, please replace universal joint subassembly.
b. Housing
and three-ball pin assembly (on transmission side)
If
the rolling contact surface of housing and three-ball pin has crack or
abrasion, please replace housing and three-ball pin assembly.
Notes:
Housing
and three-ball pin assembly are used in the same device.
② Dustproof
boot and wheel speed sensor
Notes:
■ Inspect
whether it has crack or other damage. If yes, replace it.
4. Assembly
① On
transmission side
a. Use
adhesive tape to wrap the spline of drive shaft, to avoid damaging dustproof
boot. Install new dustproof boot and dustproof boot clamp onto the shaft.
Notes:
■
Do not reuse dustproof boot and dustproof boot clamp.
b. Remove adhesive tape around the spline of drive shaft.
c. When installing three-ball pin
assembly, align it with the oil paint assembly matching mark. Put
the chamfer towards the shaft to install three-ball pin assembly.
d. Use
snap ring to fix the three-ball pin assembly onto the housing.
e. Apply
the recommended lubricating oil onto the three-ball pin assembly and sliding
surface.
f. Install
housing onto the three-ball pin assembly, and then use the recommended grease.
g. As
shown in figure, install clamp into the groove.
Notes:
■ If the grease sticks to the fixing surface of
dustproof boot, dustproof boot may fall down. Wipe
all grease from the surface.
h. Insert slotted screwdriver from
the big diameter of dustproof boot, and exhaust air and adjust the installation
length of dustproof boot to avoid deformation of dustproof boot.
Notes:
■ If the installation length of dustproof boot, it
may cause the damage of dustproof boot.
■ Attention
should be paid when using slotted screwdriver not to damage dustproof
boot.
i. Use special tool
to fixing new dustproof boot camp.
Notes:
■ Do not reuse dustproof boot clamp.
j. Fix housing and drive shaft, and
then make sure that the dustproof boot is in proper position when rotating it.
Notes:
if the installation position of dustproof boot is wrong, please reinstall with
a new dustproof boot clamp.
k. Install wheel speed sensor gear ring
and dustproof boot onto the housing.
② On wheel side
Assemble
it according to the step 14-23 stated in "Replacement of Drive Shaft
Dustproof boot".
Notes:
■ When
installing, make sure that the universal joint subassembly and drive shaft are
on the same line.
■ When
installing, make sure that the wheel speed sensor gear race and housing are
completely engaged.
Common
Fault Diagnostic
Diagnostic
Table of Common Faults
|
Fault Symptoms
|
Possible Causes
|
Solutions
|
|
Vehicle is off track
|
Steering knuckle of drive shaft is
worn.
|
Replace
|
|
Wheel bearing has abrasion,
friction or "clip" sound.
|
Replace
|
|
Front suspension and steering have
defects.
|
Adjust or replace
|
|
Vibration
|
Drive shaft has abrasion, damage or
bending.
|
Replace
|
|
Drive shaft and wheel hub spline
has abnormal sound.
|
Replace
|
|
Wheel bearing has abrasion,
friction or "clip" sound.
|
Replace
|
|
Jumping
|
Wheels are not in balance.
|
Adjust or replace
|
|
Steering knuckle of front axle has
defects.
|
Adjust or replace
|
|
Big noise
|
Drive shaft has abrasion, damage or
bending.
|
Replace
|
|
Drive shaft wheel hub spline has
abrasion.
|
Replace
|
|
Drive shaft wheel hub spline has
abrasion.
|
Replace
|
|
Wheel bearing has abrasion, burning
or abnormal sound.
|
Replace
|
|
Wheel hub nut is loose.
|
Adjust or replace
|
|
Front suspension and steering have
defects.
|
Adjust or replace
|
Repair
Parameters
1.
Tightening
Torque
Tightening Torque Table
|
Items
|
Tightening Torque
N•m
|
Items
|
Tightening Torque
N•m
|
|
Self-lock nuts of drive shaft
|
240-260
|
Connecting nut between rear suspension arm and rear
steering knuckle
|
130-150
|
|
Connecting nut between steering knuckle and shock
absorber assembly
|
75-90
|
Stabilizer rod nut
|
17-26
|
|
Connecting nut between lower swing arm ball head and
steering knuckle
|
60-72
|
Connecting nut between stabilizer rod and pulling
rod
|
35-45
|
|
Wheel nut
|
90-110
|
Connecting nut between rear suspension arm and vehicle
body
|
100-120
|
|
Lock nut of rear wheel hub bearing
|
180-220
|
Eccentric nut of rear suspension arm
|
80-100
|
|
Connect nut between rear shock absorber and rear
steering knuckle
|
75-90
|
Stopper limiting bolt of brake disc
|
10-15
|
FSU Front Suspension Assembly
Precautions
■ When installing suspension or rubber lining,
the final tightening operation must be conducted when the wheel tire is landing
and it is in no-load condition.
■ After repairing suspension parts, it is necessary
to inspect wheel alignment.
■ Oil may shorten the service life of rubber lining.
It is necessary to wipe away the flowed oil.
■ No-load condition refers to the condition that
fuel, engine coolant and lubricant are filled normally, and spare tires, jack,
attached tools and foot cushion are placed in proper position.
■ Locknut can't be reused. When
installing, always use new nuts. When replacing and tightening locknuts, do not
wipe anti-rust oil from lock nuts.
Preparation work
The special tools to be used are shown as
follows:
Special
Tool Tables
|
S/N
|
Tools
|
Overall Diagram
|
Number
|
Description
|
|
1
|
Steering drive rod die
|
|
JAC-T1D003
|
Dismantle connecting ball head
|
|
2
|
Detacher of damping spring
|
|
JAC-T1D004
|
Dismantle and install damping
spring
|
|
3
|
Dismantle front stabilizer rod ball
head
Withdrawal tool
|
|
JAC-27R0027
|
Dismantle front stabilizer rod ball
head
|
|
4
|
Steering knuckle ball head
Withdrawal tool
|
|
JAC-27R0026
|
Dismantle steering knuckle ball
head
|
Part
Assembly
Diagram of Steering Column Assembly
On-Board
Inspection:
Make
sure that the fixing condition (gap) and abrasion condition of each element are
normal.
1. Inspect
whether the lining has abrasion and deterioration.
2. Inspect
whether lower swing arm has bending and other damage.
3. Inspect
whether dustproof cover of ball joint has crack. If yes, replace ball joint.
4. Inspect
connecting bolts of lower swing arm.
5. Shake
stud bolt of ball joint for several times to check whether it is loose.
6. Inspect
the rotation start torque of lower arm ball joint.
Notes:
■ Please
do not damage dustproof boot of ball joint.
■ Do
not use hard force, to prevent damage of installation position.
7. Inspect
whether installation position of shock absorber has oil leakage, damage or
abrasion.
Inspection of Front
Wheel Alignment:
1. Descriptions:
The
inspection of wheel alignment must be conducted under no-load condition.
2. Pre-inspect
the following items:
① Whether
tire pressure is normal and tire is worn.
② Whether
wheel is jumping.
③ Whether there is end play of wheel
bearing.
④ Whether
there is end play of stabilizer rod.
⑤ Whether
each fixing point of axle and suspension is loose or deformed.
⑥ Whether
each suspension part, steering knuckle, shock absorber and steering tie rod
have crack, deformation and other damage.
⑦ Vehicle
body height.
Inspection of Toe-in of Front Wheel:
■ Standard
Value：
|
Parameters of Four Wheel Alignment of S5 Series
|
|
Parameters
|
Front Wheel
|
Rear Wheel
|
|
Wheel toe-in
|
General toe-in
|
0°± 0.2°
|
0.2°士0.2°
|
|
(0+2.4 mm)
|
(2.4 ± 2.4 mm)
|
|
Single side
|
0°± 0.1°
|
0.1°士0.1°
|
|
(0士1.2 mm)
|
(1.2士1.2 mm)
|
|
Wheel camber angle
|
-0.5° ± 0.5°
|
-1.0° ± 0.5°
|
|
Kingpin Caster angle
|
4.02°士0.5°
|
/
|
|
Kingpin inclination
|
12.91° ± 0.5°
|
/
|
Notes:
■ Wheel alignment must be conducted on flat ground
wire under no-load condition.
■ Front
toe-in value：0°± 0.1°
If
the toe-in value isn't within the standard range, adjust it according to the
following steps:
1) Inspect
the setting of toe-in value on four-wheel aligner.
2) 
Place the steering wheel to right front direction and
fix it.
3) Unscrew
locknut of steering tie rod end head.
4) Clockwisely
or counterclockwisely rotate left and right stabilizer rods, and adjust toe-in
value to the standard value.
Notes:
■ The
rotation amount of steering tie rod must be proper.
5) Lock the locknut of steering tie rod end head.
Fault
Diagnostic
Front
wheel camber angle: -0.5°± 0.5°
Kingpin
caster angle：4.02°±0.5
Kingpin
inclination angle：12.91° ± 0.5°
Notes:
■ The values of camber angle, kingpin caster angle
and kingpin inclination are already set before leaving factory; therefore, it
is unnecessary to adjust them.
■ If the values of camber angle, caster angle and
kingpin inclination are not within the standard range, please inspect whether
front suspension, steering knuckle, shock absorber and stabilizer rod are worn
or damaged. If yes, please replace drive shaft assembly.
■ After the adjustment of four wheel alignment, it
is necessary to reset the steering angle. For detailed operation, please refer
to setting procedures of EPS electronic power steering piece. If it is not set,
EPS function will be affected.
■ After the adjustment of four wheel alignment, it
is necessary to reset the horizontal acceleration sensor, longitudinal
acceleration sensor, pressure sensor. For detailed operation, please refer to
setting procedures of EPS electronic power steering piece. If it is not set,
EPS function will be affected.
Front
Shock Absorber Assembly
Component Assembly
Disassembly Diagram of Front Shock Absorber
Vertical Column Assembly
1- Upper dustproof cover 2- Nut 3-
Upper connecting plate assembly 4- Connecting plate bearing
5- Upper support cushion of spring 6-
Front damping block 7- Front dustproof cover
8- Spiral spring 9- Lower support cushion of spring 10-
Front shock absorber
Dismantling
and Assembly:
1. Dismantling
① Dismantle
front wheel tire.
② Disconnect
wheel speed sensor connector.
Notes:
■ Do
not pull wire harness of wheel speed sensor.
③ Dismantle
brake hose clamp and disconnect brake hose.
④ Dismantle
self-lock nut between shock absorber and vehicle body.
■ Tightening
torque: 45～60 N·m
⑤ Dismantle fixing bolts and nuts between shock
absorber and steering knuckle.
■ Tightening
torque: 140～160
N·m
⑥ Take out shock absorber assembly.
2) Installation
The
installation is in reverse order of dismantling.
Notes:
■ Do not use the damaged parts
■ Each
dismantled part of shock absorber should be finally tightened under the no-load
condition.
■ Inspect wheel alignment.
Disassembly and Assembly:
1. Disassembly
Notes
■ Do not damage the piston rod of shock absorber
when dismantling parts of shock absorber.
① Use
slotted screwdriver to dismantle trimming cover.
② Use
spring compressor to compress spiral spring until it is completely loosened.
Notes:
■ Make sure that the compressor is installed in
proper position, and then begin to compress spiral spring.
■ When tightening bolt of spring compressor, do
not use pneumatic tool.
③ Fix
the end of piston rod, and dismantle locknut of piston rod.
■ Tightening torque: 60～70 N·m
Notes:
■ Make
sure that the spiral spring to be compressed is loose.
④ Dismantle
support of spiral spring, upper damping cushion of spring, dustproof cover, and
buffer block.
⑤ Dismantle
spiral spring with compressor, and then slowly release compressor.
⑥ Dismantle lower vibration isolator of spring, and
remove shock absorber body.
Inspection
after Disassembly
① Shock
Absorber
Notes:
■ Inspect whether shock absorber has deformation,
crack and damage. If yes, please replace it.
■ Whether pushing rod has damage, abrasion and
deformation. If yes, replace it.
■ Whether piston has oil leakage. If
yes, please replace it.
② Vibration
isolator of spring, buffer block and dustproof cover.
Inspect
whether there is crack, and whether rubber part has abrasion. If yes, please
replace it.
③ Spiral
spring
Inspect
whether spiral spring has crack, abrasion and damage. If yes, please replace
it.
④ Upper
support of spring
Inspect
whether there is crack, abrasion, deformation and other damage. If yes, please
replace it.
2. Assembly
Assemble
it in reverse order of dismantling.
Notes:
■ When installing parts on the shock absorber, do
not damage piston rod.
■ Keep the big diameter end of spiral spring
downwards to align with lower support of spring.
■ Make sure the compressor is completely installed
onto the spiral spring, and then begin to compress spiral spring.
■ When releasing compressor, it is necessary to
inspect whether the installation position of spiral spring is correct.
■ Whether the assembly marks
is correct.
Lower Swing Arm
Schematic
Diagram of Installation Structure of Front Control Arm Assembly
|
1. Hex flange bolt
|
2. Full metal hex flange locknut
|
3. Hex flange bolt
|
|
4. Front control arm assembly
|
5. Swing arm ball head bolt
|
6. Full metal hex flange locknut
|
|
7. Split pin
|
8. Left front wheel hub assembly
|
|
Dismantling
and Assembly:
1 Dismantling
① Rise
up the vehicle, and dismantle wheel tire.
② Unplug
split pin, and dismantle fixing bolts between outside point of lower swing arm
and steering knuckle.
■ Tightening
torque: 100～120 N•m
③ Dismantle
rear fixing bolts between lower swing arm and auxiliary frame.
■
Tightening torque: 140～120
N•m
④ Dismantle
rear fixing bolts between lower swing arm and auxiliary frame.
■ Tightening
torque: 100～120 N•m
Notes:
■ When dismantling, it is necessary to fix lower
swing arm ball head, and then unscrew locknut to avoid rotation.
⑤ Remove lower swing arm
assembly.
2. Inspection
after Dismantling
① Visual
Inspection
■ Inspect whether lining has abrasion or
damage. If yes, please replace it.
■ Inspect whether lower swing arm has abrasion or
other damage. If yes, please replace it.
■ Inspect whether dustproof boot of lower arm ball
head has crack. If yes, please replace it.
■ Inspect all fixing bolts and nuts. If there is any damage, replace them.
3) Installation
The installation is in reverse order of
dismantling.
Notes:
■ Do not use the
damaged parts
■ Bolt of lower swing arm front rubber
sleeve and fixing bracket should be retightened to avoid rubber sleeve from
deformation.
■ When dismantling
shock absorber under the no-load condition, each dismantled part should be
re-tightened finally.
■ Inspect wheel
alignment.
Dismantling and Assembly:
1. Dismantling
① Dismantle fixing nut between connecting ball head of
left and right front stabilizer rod and front vertical column assembly.
■ Tightening
torque: 100～120N•m
Horizontal Stabilizer Rod
Diagram
of Structure of Front Stabilizer Rod Assembly
|
1. Full metal hex flange locknut
|
2. Front stabilizer rod pulling rod
|
3. Front stabilizer rod clamp
|
|
4. Full metal hex flange locknut
|
5. Front stabilizer rod Lining
|
6. Hex flange bolt
|
|
7. Hex flange nut
|
8. Front stabilizer rod
|
9. Front sliding column assembly
|
② Dismantle
fixing nut between connecting ball head of left and right front stabilizer rod pulling
rod and front stabilizer rod assembly.
■
Tightening
toque: 100～120 N•m
③ Dismantle
fixing bolt of fixing bracket of left and right stabilizer rod, and remove fixing
bracket and lining.
■ Tightening
toque: 45～55
N•m
④ Dismantle
stabilizer rod assembly.
2. Inspection
after Dismantling
■ Inspect whether stabilizer rod, stabilizer
connecting pulling rod, fixing bracket of stabilizer rod and stabilizer
rod lining have deformation and abrasion. If
yes, please replace them.
■ Use hands to move ball head bolt to confirm
whether it moves freely.
■ Inspect whether dustproof cover of pulling
rod of stabilizer rod has crack and grease leakage. If
yes, please replace them.
3.
Installation
■ The installation is in reverse order of
dismantling.
■ When tightening locknut, first fix the bolt of pulling
rod of horizontal stabilizer rod to avoid rotation.
Notes:
■ Do not reuse the disposable parts.
■ When
installing lining and fixing bracket of stabilizer rod, pay attention to
their installation direction.
■ Each dismantled part of front
stabilizer rod should be finally tightened under the no-load condition.
Remove front Auxiliary Frame Assembly.
Part
Assembly:
Front
Auxiliary Frame Element Figure
Dismantling
and Assembly:
1. Dismantling
① Use
a jack to support engine oil pan.
Notes:
■ Add a soft cushion between engine oil pan and
jack.
② Dismantle
fixing bolt of engine rear suspension and front auxiliary frame.
③ Front
point fixing nut of auxiliary frame and vehicle body.
■ Tightening torque: 180～200 N•m
④ Rear
point fixing bolt of auxiliary frame and vehicle body.
■ Tightening torque: 180～200 N•m
⑤ Remove
front auxiliary frame assembly.
2. Inspection after Dismantling
■ Inspect
whether the auxiliary frame has crack.
3) Installation
■ The
installation is in reverse order of dismantling.
Fault Diagnostic
Diagnostic
Table of Common Faults
|
Fault Symptoms
|
Possible Causes
|
Solutions
|
|
Heavy steering
|
Front wheel alignment is improper.
|
Adjust
|
|
Rotation exceeds lower swing arm
ball head
|
Replace
|
|
Tire pressure is too low.
|
Inflate air
|
|
No power steering
|
Repair or replace
|
|
Bad return action
|
Front wheel alignment is improper.
|
Adjust
|
|
Shock absorber has fault
|
Repair or replace
|
|
Horizontal stabilizer rod has
abrasion or damage.
|
Replace
|
|
Spiral spring has abrasion or
damage.
|
Replace
|
|
Lower swing arm lining has
abrasion.
|
Replace
|
|
Tire has abnormal abrasion
|
Front wheel alignment is improper.
|
Adjust
|
|
Tire pressure is too low or too
high.
|
Adjust air pressure
|
|
Shock absorber has fault.
|
Repair or replace
|
|
Vehicle is off track
|
Front wheel alignment is improper.
|
Adjust
|
|
Connecting steering resistance of
lower swing arm is insufficient.
|
Replace
|
|
Lower swing arm lining is
loose or worn.
|
Replace
|
|
Vehicle is off track on one side
|
Front wheel alignment is improper.
|
Adjust
|
|
Connecting steering resistance of
lower swing arm is insufficient.
|
Replace
|
|
Lower swing arm is bending.
|
Replace
|
|
Spiral spring has abrasion or
damage.
|
Replace
|
|
Steeringwheel is swinging and
vibrating
|
Front wheel alignment is improper.
|
Adjust
|
|
Connecting steering resistance of
lower swing arm is insufficient.
|
Replace
|
|
Lower swing arm lining is
loose or worn.
|
Replace
|
|
Shock absorber has fault
|
Repair or replace
|
|
Horizontal stabilizer rod has
abrasion or damage.
|
Replace
|
|
Spiral spring has abrasion or
damage.
|
Replace
|
|
Vehicle is sinking
|
Spiral spring has abrasion or
damage.
|
Replace
|
|
Shock absorber has fault
|
Repair or replace
|
Repair
Data and Specifications
Table
of Technical Specifications
|
Items
|
Parameters and Specifications
|
|
Front suspension type
|
Mcpherson independent suspension
with spiral spring
|
|
Shock absorber
|
Type
|
Double-direction hydraulic socket
type
|
|
Stroke
|
160.5 mm
|
|
Damping force
|
Tension
|
680 N +108 N(0.3 m/s)
|
|
Compression
|
287 N + 66 N(0.3 m/s)
|
|
Spiral spring
|
Free
height: 312 ±5 mm Color mark: 1 white strip and 1 yellow strip
|
|
Wheel alignment
|
Wheel toe-in (front)
|
0° ± 0.1°
|
|
Wheel camber angle
|
-0.5° ± 0.5°
|
|
Kingpin inclination
|
4.02°士0.5°
|
|
Kingpin castor angle
|
12.91° ± 0.5°
|
|
Kingpin offset distance
|
5.8 mm
|
Tightening
Torque Table
|
Items
|
Torque N•m
|
|
Fixing bolt of mounting frame of
front horizontal stabilizer rod and auxiliary frame
|
45〜55
|
|
Fixing nut of mounting frame of
front horizontal stabilizer rod and auxiliary frame
|
45〜55
|
|
Connecting nut between front
horizontal stabilizer rod and horizontal stabilizer rod pulling rod
|
100〜120
|
|
Connecting nut between front
horizontal stabilizer rod and front vertical column assembly
|
100〜120
|
|
Assembly nut of front shock
absorber and vehicle body
|
45〜60
|
|
Upper locknut of front shock
absorber
|
45〜65
|
|
Connecting bolt between front shock
absorber and steering knuckle
|
140〜160
|
|
Connecting bolt between front lower
swing arm ball head and steering knuckle
|
100〜120
|
|
Connecting bolt of front lower
swing arm front lining and auxiliary frame
|
120〜140
|
|
Connecting bolt of front lower
swing arm front lining and auxiliary frame
|
170〜190
|
|
Front fixing nut of front auxiliary
frame
|
180-200
|
|
Rear fixing bolt of front auxiliary
frame
|
180-200
|
RSU Rear Suspension Assembly
Precautions
■ When installing suspension, the final tightening
operation must be conducted when the tire is landing and under no-load
condition.
■ After repairing suspension parts, it is
necessary to inspect wheel alignment.
■ When installing rubber lining, the final
tightening operation must be conducted when the tire is landing and under
no-load condition.
■ Oil may shorten the service life of rubber lining.
It is necessary to wipe away the flowed oil.
■ No-load condition refers to the condition that
fuel, engine coolant and lubricant are filled normally, and spare tires, jack,
attached tools and foot cushion are placed in proper position.
■ Locknut can't be reused. When
installing, always use new nuts. When replacing and before tightening locknut,
do not wipe anti-rust oil of locknut.
Preparation
work
The
common and special repair tools to be used are shown in following table:
Table of Common Tools
|
S/N
|
Tools
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Overall Diagram
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Description
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1
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Power tool
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Installation and dismantling of
bolts and nuts
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Special
Tool Tables
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S/N
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Tools
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Overall Diagram
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Number
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Description
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1
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Steering drive rod die
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JAC-T1D003
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Dismantle connecting ball head
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2
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Detacher of damping spring
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JAC-T1D004
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Dismantle and install damping spring
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Rear Suspension Assembly
Part Assembly
Rear Suspension Assembly Subassembly Figure
■ Rear
suspension of this vehicle uses E type multi-rod independent suspension.
On-Board
Inspection:
1. Confirm the fixing condition (gap and loosening)
of each element and element condition (abrasion, damage).
2. Inspect whether the installation position of
shock absorber has oil leakage or damage.
Inspection
of Rear Wheel Alignment:
Notes:
■ If relevant parts of rear suspension have abrasion
or modification, it is necessary to inspect whether the parameters of rear
wheel alignment meet requirement. If no, adjust them according to the following
steps:
■ If they can't be adjusted to the standard value,
please replace relevant deformed and worn parts.
■ Standard
value：
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Parameters of four
wheel alignment of S5 series
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Parameters
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Front Wheel
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Rear Wheel
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Toe-in of front wheel
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General toe-in
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0°+ 0.2°
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0.2° ± 0.2°
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(0+2.4 mm)
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(2.4 ± 2.4 mm)
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Single side
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0°±0.1°
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0.1° ± 0.1°
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(0 + 1.2 mm)
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(1.2 ± 1.2 mm)
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Wheel camber angle
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-0.5° ± 0.5°
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-1.0° ± 0.5°
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Kingpin caster angle
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4.02°+ 0.5°
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/
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Kingpin inclination
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12.91°± 0.5°
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/
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Rear swing arm
eccentric bolt (Main adjusting camber angle）
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Eccentric bolt
of rear tie rod (mainly adjust toe-in)
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1. Descriptions:
Measure
wheel alignment under no-load condition.
2. First Inspect the Following Items:
① Whether
tire pressure is normal and tire is worn.
② Whether
wheel is jumping.
③ Whether
there is end play of wheel bearing.
④ Inspect
the gap of each element of suspension and whether each fixing point is loose.
⑤ Shock
absorber operation performance.
⑥ Whether each suspension arm has crack, deformation
and other damage.
⑦ Vehicle body height.
3. Adjustment
① Adjustment
of camber angle
Place
the vehicle on four-wheel aligner. If rear wheel camber angle exceeds standard
value, loosen nut of rear lower swing arm assembly and rear auxiliary frame (do
not tighten out). Rotate eccentric bolt and adjust rear wheel camber angle to
the standard value, and then tighten bolt.
■ Tightening
torque: 140～160 N•m
② Adjustment
of Toe-In
Place
the vehicle on four-wheel aligner. If rear wheel toe-in exceeds standard value,
loosen nut of rear upper pulling rod and rear auxiliary frame (do not
tighten out). Rotate eccentric bolt and adjust rear wheel toe-in to the
standard value, and then tightening nut.
■ Tightening
torque: 100～120 N•m
Notes:
■ During adjustment of rear wheel toe-in, camber
angle may have slight change. Accordingly, during adjustment of rear wheel
camber angle, toe-in may also have slight change. Therefore, the adjustment of
rear wheel toe-in and camber angle should be coordinated.
■ After the adjustment of four wheel alignment, it
is necessary to reset the steering angle. For detailed operation, please refer
to setting procedures of EPS electronic power steering piece. If it is not set,
EPS function will be affected.
■ After the adjustment of four
wheel alignment, it is necessary to reset the horizontal acceleration sensor,
longitudinal acceleration sensor, pressure sensor. For detailed operation,
please refer to setting procedures of EPS electronic power steering piece. If
it is not set, EPS function will be affected.
Rear Shock
Absorber
Part Assembly
Rear Shock Absorber Assembly Subassembly Figure
1- Hex flange bolt 2- Rear wheel hub assembly 3- full metal hex flange locknut 4- Rear shock absorber assembly
Dismantling
and Assembly:
1. Dismantling
① Rise
up the vehicle, and dismantle wheel tire.
② Dismantle
connecting bolt between shock absorber and vehicle body.
■ Tightening torque: 50～65 N•m
③ Dismantle
connecting bolt between shock absorber and steering knuckle.
■ Tightening torque: 140～160 N•m
2. Inspection
after Dismantling
① Shock
Absorber
■ Inspect whether shock absorber has oil leakage. If yes, please replace it.
■ Inspect whether piston rod is damaged, worn and
deformed. If yes, please replace it.
② Buffer
Block and Dustproof Cover
■ Inspect whether buffer block and dustproof cover
have abrasion or damage. If yes, please replace them.
3) Installation
The
installation is in reverse order of dismantling.
Notes:
■ Do not use the damaged parts.
■ Each
dismantled part of shock absorber should be finally tightened under the no-load
condition.
■ Inspect wheel alignment.
Notes:
■ Do not use the damaged parts
■ Each
dismantled part of shock absorber should be finally tightened under the no-load
condition.
■ Inspect wheel alignment.
Rear Spiral Spring
1. Dismantling
① Dismantle
connecting bolt between rear lower swing arm and steering knuckle.
Tightening toque:
140～160 N·m
② Remove upper support
cushion of rear spring, rear spiral spring and lower support cushion of rear
spring in sequence.
Notes:
During
dismantling, attention should be paid to sudden falling of spring, and avoid
personnel injury!
2. Inspection after Dismantling
① Inspect
whether upper support cushion and lower support cushion of rear spring have
abrasion or damage. If yes, replace them. If yes, please replace it.
② Spiral
spring
■ Inspect whether spiral spring has
abrasion or damage. If yes, please replace it.
3. Installation
The installation is in
reverse order of dismantling.
Notes:
■ Do not use the damaged parts.
■ When installing lower support cushion of spring, it is necessary to
align spring support hole on lower support cushion rubber cylinder with rear
lower swing arm and install them to proper position.
■ Keep the big diameter end of spiral spring downwards to align with
lower support of spring.
■ Make sure that the compressor is installed onto the spiral spring,
and then begin to compress spiral spring.
■ When releasing compressor, it is necessary to inspect whether the
installation position of spiral spring is correct.
■ Whether the assembly mark is correct.
■ Final tightening operation of each part should be conducted under
no-load condition.
■ Inspect wheel alignment.
Left/Right Rear Longitudinal Arm Assembly
1- Left/right rear longitudinal arm assembly 2- Rear wheel hub assembly 3- Hexagon bolt, spring washer, flat
washer assembly
Dismantling and Assembly:
1. Dismantling
① Dismantle fixing bolt between
left/right rear longitudinal arm assembly and vehicle body.
■ Tightening torque: 100～120 N·m
② Dismantle connecting bolt between left/right rear
longitudinal arm and steering knuckle.
■ Tightening toque: 45～55 N·m
③ Take
out left/right rear longitudinal arm assembly.
2. Inspection after Dismantling
■ Inspect whether left/right rear longitudinal arm
assembly has deformation, lining has abrasion or other damage. If yes, please replace it.
3. Installation
The
installation is operated in reverse order of dismantling.
Notes:
■ Final tightening operation of the dismantled
left/right rear longitudinal arm assembly should be conducted under no-load
condition.
■ It is necessary to conduct rear wheel alignment
inspection for the vehicle.
Rear Upper Swing Arm Assembly and Rear Support Rod Assembly
Dismantling
and Assembly:
1. Dismantling
① Dismantle
fixing bolt between rear upper swing arm assembly and rear support rod assembly
and auxiliary frame.
■ Tightening torque: 140～160 N·m
② Dismantle
connecting bolt of rear upper swing arm assembly and rear steering knuckle.
■ Tightening torque: 140～160 N·m
2. Inspection after Dismantling
■ Inspect whether rear upper swing arm assembly
and rear support rod have deformation, and lining has abrasion and other
damage. If yes, please replace it.
3. Installation
■ The installation is in reverse
order of dismantling.
Notes:
■ When installing rear upper swing arm, pay attention to the
installation direction (the arrow can be seen and upwards when standing on the
swing arm at the rear of the vehicle).
■ Tighten connecting bolts.
■ Final tightening operation of
the dismantled rear upper swing arm assembly and rear support rod assembly
should be conducted under no-load condition.
Rear Lower Swing Arm Assembly
Dismantling and Assembly:
1. Dismantling
① Dismantle fixing bolt between rear
lower swing arm assembly and auxiliary frame.
■ Tightening torque: 140～160 N·m
② Dismantle connecting bolt between
rear lower swing arm assembly and rear steering knuckle.
■ Tightening torque: 140～160 N·m
2. Inspection after Dismantling
■ Inspect whether rear lower swing arm assembly has deformation, and lining
has abrasion or other damage. If yes, please replace
it.
3) Installation
The installation is in reverse order
of dismantling.
Notes:
■ Tighten connecting bolts.
■ Final tightening operation of
the dismantled rear lower swing arm assembly should be conducted under no-load
condition.
Rear Stabilizer Rod Pulling Rod
Dismantling
and Assembly:
1. Dismantling
① Dismantle
locknut between rear stabilizer rod pulling rod and rear lower swing
arm.
■ Tightening torque: 100～120 N·m
② Dismantle
self-lock nut between rear stabilizer rod pulling rod and rear
stabilizer rod.
■ Tightening torque: 100～120 N·m
2. Inspection after Dismantling
■ Inspect whether rear stabilizer rod pull has
deformation. If yes, replace it.
■ Inspect whether dustproof cover of pulling
rod of stabilizer rod has crack and grease leakage. If
yes, please replace them.
3. Installation
The installation is in reverse order
of dismantling.
Notes:
■
Do not use the damaged parts
Rear Stabilizer Rod Assembly
Dismantling and Installation
1. Dismantling
① Dismantle locknut between rear stabilizer rod pulling
rod and rear stabilizer rod.
Tightening toque: 100～120 N·m
② Dismantle
connecting bolt between mounting bracket of rear stabilizer rod and auxiliary
frame, remove mounting bracket and lining, and make them in symmetrical
form on left and right sides.
■ Tightening toque: 45～55 N·m
③ Dismantle rear
horizontal stabilizer rod.
2. Inspection
after Dismantling
■ Inspect whether rear stabilizer rod assembly and
mounting bracket of rear stabilizer rod assembly have deformation, crack and
abrasion. If yes, replace them.
■ Inspect whether lining of rear stabilizer
rod has crack and abrasion. If yes, replace them.
3) Installation
The
installation is in reverse order of dismantling.
Notes:
Rear Auxiliary Frame Assembly:
Component：
Rear
Auxiliary Frame Assembly Figure
Dismantling
and Assembly:
1. Dismantling
① Dismantle
connecting bolt between rear auxiliary frame and vehicle body.
■ Tightening
torque: 160～180 N·m
② Use
a jack to support rear auxiliary frame assembly.
Notes:
■ During
dismantling, it is not allowed to make the jack sliding down.
③ Dismantle
left and right fixing nuts of rear auxiliary frame.
■ Tightening
torque: 160～180
N·m
2) Installation
The
installation is in reverse order of dismantling.
Notes:
■ Do
not use the damaged parts
■ When installing auxiliary frame, please pay attention to
installation direction.
Fault Diagnostic
Common Fault Diagnostic Table
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Fault Symptoms
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Possible Causes
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Solutions
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Assembly is loose.
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Tighten
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Abnormal sound
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wheel bearing is fatigue or
damaged.
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Replace
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Shock absorber assembly is damaged.
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Replace the damaged part
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Tire is unqualified.
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Replace
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Vibration
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Tire pressure is excessive.
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Adjust air pressure
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Shock absorber assembly is damaged.
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Replace the damaged part
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Wheel nut is loose.
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Tighten
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Spiral spring becomes short or
broken.
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Replace
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Tire is unqualified.
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Replace
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Vehicle body tilting
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Spiral spring becomes short or
broken.
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Replace
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Repair
Data and Specifications
Table of Technical Specifications
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Items
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Parameters and Specifications
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Rear suspension type
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Multi-rod type
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Shock absorber
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Type
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Double-direction hydraulic socket
type
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Stroke
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170 mm
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Damping force
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Tension
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550 N + 92 N (0.3m/s)
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Compression
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394 N士83 N (0.3m/s)
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Spiral spring
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Type
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Spiral straight spring
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Free height
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348士5 mm
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Color mark
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One white strip or one yellow strip
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Wheel alignment
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Rear wheel toe-in (rear)
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0.1°士0.1°
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Rear wheel camber angle
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-1°士0.5°
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Tightening Torque Table
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Items
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Tightening Toque N•m
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Assembly nut of rear shock absorber
and vehicle body
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50〜65
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Upper locknut of rear shock
absorber
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34〜47
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Connecting bolt between rear shock
absorber and steering knuckle
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140〜160
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Connecting bolt between left/right
rear longitudinal arm and vehicle body
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100〜120
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Connecting bolt between lef/right
rear longitudinal arm and steering knuckle
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45〜55
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Connecting bolt between rear upper
swing arm and rear support rod and auxiliary frame
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140〜160
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Connecting bolt between rear upper
swing arm and steering knuckle
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140〜160
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Connecting bolt between rear lower
swing arm and auxiliary frame
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140〜160
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Connecting bolt between rear lower
swing arm and steering knuckle
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140〜160
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Connecting bolt between rear tie
rod and auxiliary frame
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110〜120
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Fastening nut between rear tie rod and
steering knuckle
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45〜55
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Connecting nut between rear
stabilizer rod and rear lower swing arm
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100〜120
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Connecting nut between rear
stabilizer rod and stabilizer rod pulling rod
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100〜120
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Fixing bolt between mounting frame
of rear stabilizer rod and rear auxiliary frame
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45^55
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Assembly bolt between rear
auxiliary frame and vehicle body
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160〜180
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Fastening nut between rear
auxiliary frame and vehicle body
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160〜180
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BR Brake System
Brake Pedal
Inspection and Adjustment:
Adjustment of bolt clearance between
brake pedal and brake limit switch:
1. Dismantle lower protective plate assembly on driver's side.
2. Disconnect brake lamp switch connector, loosen brake limit switch
nut, release brake pedal, and rotate switch bolt to make the clearance between
switch bolt and brake pedal within 0.5 mm～1 mm.
■ Tightening toque：8〜10 N·m
Free Stroke of Brake Pedal:
1. Under the engine stopping condition, step brake pedal for 2～3 times.
2. Make sure that the vacuum inside brake vacuum booster is eliminated,
and then press pedal with hands.
3. Inspect whether free stroke of pedal is within standard range before
resistance appears.
■ Standard value：3 mm〜8 mm
4. If the free stroke exceeds standard range, adjust it.
Notes:
■ If free stroke doesn't exceed standard range, please replace the
damaged parts.
Dismantling and Assembly:
1. Dismantling
① Dismantle lower protective
plate assembly on driver's side.
② Disconnect brake lamp switch
connector.
③ Dismantle lock pin connecting
brake vacuum booster, and disconnect the connection of brake vacuum booster.
④ Dismantle fixing bolt between
brake pedal and vehicle body, and fixing nut between it and brake vacuum
booster.
■ Tightening torque: 17～26 N·m
⑤ Take out brake pedal.
2. Inspection after Dismantling
① Brake
pedal
■ Inspect whether moving pin of brake
pedal has abrasion or deformation.
■ Inspect whether brake pedal has
crack, twisting or other damage.
② Lock
pin and lining
■ Inspect whether lock pin and lining
have damage or deformation. If yes, please replace them.
③ Brake
lamp switch
a. Use a multimeter to test 2
terminals of brake switch and test whether it is conductive when pressing and
releasing brake lamp switch.
b. As shown in figure, when pressing
switch ＞4mm, terminals are
not conductive; while releasing it, terminals are conductive. It indicates that
the brake lamp switch works normally.
3. Installation
The
installation is operated in reverse order of dismantling.
Notes:
■ Inspect whether brake pedal
operation is smooth.
■ Inspect free stroke of brake pedal.
■ Inspect the clearance between
brake pedal and brake lamp switch.
Brake
Master Cylinder
On-Board
Inspection:
Inspect
whether the mounting surface, oil reservoir mounting surface of master cylinder
and brake pipe joint have leakage.
Dismantling
and Assembly:
1. Dismantling
① Drain brake fluid.
② Dismantle air filters assembly.
③ Dismantle the plug of brake fluid level
switch.
④ Use oil pipe wrench to disconnect brake rigid pipe
of master cylinder.
■ Tightening
torque: 13～17 N·m
⑤ Dismantle connecting pipe between
brake master cylinder and clutch master cylinder and fixing nut of master
cylinder, and then dismantle master cylinder components.
Notes:
■ Do not bend or damage brake pipe.
2. Installation
Notes:
■ It is necessary
to apply grease onto the pin shaft of master cylinder before installation:
SAEJ310 or equivalent.
① Install master cylinder components
onto the brake vacuum booster, and then tightening nuts.
Notes:
■ Please do not
dmage the sliding surface of piston pulling rod and do not let foreign
matters fall down on its surface.
② Install brake rigid pipe onto
the master cylinder components and tighten it.
③ Use oil pipe wrench or similar
tool to tighten brake oil pipe nuts.
④ Install brake fluid level switches
connector.
⑤ Install brake fluid level switches
connector.
Brake Fluid
Parameters of Brake Fluid
Inspect the Height of Brake Fluid Level:
1. Inspect and
verify whether brake fluid level in oil reservoir is within the specified range
(between MAX and MIN). If the fluid level is too low, please inspect whether
there is leakage around oil reservoir or inside brake system.
2. Start the vehicle and release parking
control handle. Observe whether brake warning light goes out. If no, please inspect whether parking
brake switch, brake fluid level switch have faults.
Brake Pipe
Hydraulic Pipeline
Control Diagram:
Diagram of Hydraulic Pipeline
1-
Master cylinder 2- ABS actuator
Notes:
■ All brake oil
pipes are not allowed to be bent twisted or stretched.
■ Make sure that
all brake oil pipes will not clash with other parts when vehicle is stationary
or steering.
■ Brake oil pipe is
a very important safe part. If any leakage of brake fluid is found, always
tighten its fixing position. If any damaged part is
found, please replace it with a new proper part.
■ When
disconnecting brake pipe, please seal the joint end to avoid dust entering.
Front Brake Pipe and Hose:
1. Dismantling
① Dismantle wheel tire.
② Dismantle
brake hose bolts.
Notes:
■ Pay attention not to let bolts and washers fall down.
■ Tightening toque：25〜30 N·m
■ Tightening torque: 16～18 N·m
③ First disconnect the joint between brake master cylinder oil pipe and
ESC hydraulic adjuster assembly, and then disconnect each joint in sequence.
■ Tightening
torque: 16～18 N·m
Notes:
■ Do not drain all brake
fluid from ESC hydraulic adjuster assembly or dismantle ESC hydraulic adjuster.
2. Installation
Notes:
■ First install ABS
hydraulic adjuster brake and then tighten it with bolts. And then make the
hydraulic adjuster assembly clip onto the ABS bracket. Installation sequence of
hydraulic adjuster assembly is shown in right figure:
■ Do not deform the
brake pipe due to the difficulty of installation. When installing each pipe
assembly, make sure that each fixing pipe clip and protective sleeve are installed
properly.
① Connect left front brake hose
assembly to left front brake caliper, and then let the overall pipe smoothly go
through the bracket of shock absorber, and then go through bracket of vehicle
body and install it with left front brake rigid pipe and clip them.
Finally, use bolt to fix them at steering knuckle. Installation of right side
is the same as that of left side.
② Use bolts to fix rear brake
exhaust pipe assembly under the vehicle body.
③ Install air filter assembly, battery assembly and engine ECU assembly.
④ Refill brake fluid and exhaust
air.
3. Inspection after Installation:
Notes:
■ If the joint
between brake pipe and brake hose has leakage, please retighten it. If any
damaged part is found, please replace it.
① Inspect whether brake hose, brake
pipe and joint have liquid leakage, damage, twisting, deformation or other part
clashing and loosening.
② When
the engine is running, exert some brake force and keep for several seconds, and
then inspect whether each part has liquid leakage.
③ Use oil pipe wrench to dismantle
the joint between brake hose and brake pipe, and then remove the clip.
■ Tightening toque：13〜17
N•m
④ Remove brake hose and brake pipe.
2. Installation
The installation is in reverse order of dismantling.
Notes:
■ Please do not
reuse shim and oil pipe clip.
■ Pay attention to
the installation direction of brake hose joint.
■ Refill brake
fluid and exhaust air.
Rear Brake Pipe and Brake Hose:
1. Dismantling
① Dismantle fixing bolt of rear
brake cylinder hose.
■ Tightening
toque：25〜30 N•m
② Dismantle the joint between rear
brake hose and brake rigid pipe, and remove the clip.
■ Tightening toque：13〜17 N•m
③ Remove brake hose and brake rigid
pipe.
2) Installation
The installation is in reverse order of dismantling.
Brake Master Cylinder and ABS Hydraulic
Adjuster Brake Rigid Pipe:
1) Dismantling
① Dismantle
air filters assembly.
② Dismantle
battery assembly.
③ Dismantle engine ECU assembly.
④ Dismantle brake master cylinder
oil pipe joint.
Brake Vacuum Booster
Structure Assembly
Brake
Vacuum Booster has Fault.
1-Vacuum booster assembly 2- Brake master
cylinder 3- Brake oil reservoir 4- Brake pedal assembly
On-Board Inspection:
1. Operation
Inspection
Stop
the engine, and then step brake pedal for several times to make the vacuum
inside brake vacuum booster flush with air. Completely step brake pedal and
start the engine. When vacuum reaches standard range, confirm whether the gap
between brake pedal and floor is shortened.
Notes:
■ The
interval for stepping brake pedal is 5s.
2. Inspection
of Air Tight
■ Start and run the engine at idle speed for 1min,
and then stop the engine when there is vacuum inside brake vacuum booster. Step brake pedal normally to eliminate vacuum. Confirm whether
the gap between brake pedal and floor increases.
■ Step brake pedal when engine is
running, and then step the pedal to stop the engine. Step brake pedal for 30s,
and then confirm whether pedal stroke has change.
Dismantling and Assembly:
Notes:
■ When
dismantling brake vacuum booster, please do not bend brake pipe.
■ Please replace the damaged lock pin.
■ Do not damage the thread of fixing bolt of brake
vacuum booster.
1 Dismantling
① Dismantle
air filters assembly.
② Remove
vacuum hose clamp, and dismantle vacuum hose from brake vacuum booster.
③ Dismantle
lock pin and washer from brake pedal.
④ Dismantle
connecting nut between brake pedal and brake vacuum booster.
■
Tightening
toque: 17～26
N•m
⑤ Dismantle
brake vacuum booster on the engine compartment.
2. Inspection after Dismantling
① Inspection
of length of pushing rod
a. Use a manual vacuum pump to exert vacuum
pressure of -66. 7 KPa to brake vacuum booster.
b. Inspect the length of pushing rod.
■ Length
of pushing rod: 122.5～123.5
mm
② Vacuum
hose
Inspect
whether it is damaged or has crack. If yes, please replace it.
3. Installation
① Install
brake master cylinder and vacuum booster assembly onto relevant
positions of the vehicle body, and make brake pedal assembly go through the
pushing rod of vacuum booster and install it onto the vacuum booster bolts, and
then tighten mounting nuts.
② Install brake pedal and pin shaft of pushing rod
of vacuum booster. Meanwhile, apply grease SAE J310, NLGI No.0 onto the surface
of pin shaft. When pin shaft isn't installed normally,
adjust the length of pedal adjusting bolt, to ensure that the pin shaft can be
installed normally. But do not adjust the length of pushing rod of vacuum
booster, or let the pushing rod of vacuum booster in compression condition.
③ Use hex
combination bolt to fix the upper bracket of brake pedal.
■ Tightening torque: 17～26
N•m
④ Fix
vacuum hose assembly onto the proper position of vacuum booster.
Notes:
■ When installing, insert vacuum hose into proper
position.
■ Please use lubricating oil when installing it.
⑤ Adjust
free stroke of brake pedal.
⑥ Tighten
locknut of pushing rod to the specified tightening torque.
⑦ Install
air filters assembly.
⑧ Refill
brake fluid and exhaust air.
Front Disc Brake Caliper:
On-Board Inspection
1.
Inspection of
abrasion condition of brake shoe.
Notes:
■ Standard thickness: 11 mm
■ limiting worn thickness: 2 mm
2. Dismantling
① Dismantle
wheel tire.
■ Tightening torque: 100～120 N•m
② Dismantle
sliding pin shaft of brake caliper assembly.
■ Tightening torque: 22～32
N•m
③ Use
a rope to lift brake caliper assembly, and then dismantle brake shoe, etc.
3. Installation
① Install
brake shoe shim and washer retainer ring onto each brake shoe.
Notes:
■ Install
it according to fixing direction of muffler.
② When installing
brake shoe, press piston, and then install brake cylinder onto the fixing
bracket of brake cylinder.
③ Install brake
shoe onto the fixing bracket of brake cylinder.
Notes:
■ Pay attention to the brake fluid level in brake
fluid reservoir.
④ Install
sliding screw of brake cylinder and tighten it.
⑤ Fix
brake disc, and step brake pedal until brake has response.
⑥ Inspect
rotation resistance of brake.
⑦ Install wheel
tire.
Dismantling
and Installation of Brake Caliper Components:
1. Dismantling
① Dismantle
wheel tire.
② Dismantle
brake hose bolts and then disconnects brake hose.
■ Tightening torque: 25～30
N•m
Notes:
■ Pay attention not to let bolts and washers fall
down.
③ Dismantle
bolts of fixing bracket of brake caliper assembly, and then dismantle brake
caliper components.
■ Tightening torque: 70～90
N•m
2) Installation
The
installation is in reverse order of dismantling.
Disassembly
and Assembly:
1. Disassembly
① Dismantle
sliding screw of brake cylinder, and dismantle brake cylinder from the fixing
bracket of brake cylinder. If necessary, dismantle brake shoe, muffler of brake
shoe from the fixing bracket of brake cylinder.
Notes:
■ Pay
attention not to let bolts and washers fall down.
② Dismantle
sliding pin of brake slave cylinder and dustproof boot of sliding pin from the
fixing bracket of brake slave cylinder.
③ As
shown in figure. Place a suitable wooden block, and then blow air into the
fixing bolt hole of brake hose, and then dismantle piston and dustproof boot of
piston.
Notes:
■ Pay
attention not to let your fingers is clamped by piston.
④ Use
a slotted screwdriver to dismantle piston sealing ring from brake slave cylinder.
Notes:
■ Pay attention not to damage inner wall of brake slave
cylinder block.
2. Inspection after Disassembly
① Brake slave cylinder block.
Notes:
■ Use new brake fluid to clean cylinder block. Do not use gasoline or kerosene, etc.
■ Inspect whether inner wall of cylinder block has
abrasion or damage. If yes, please replace brake slave cylinder.
② Fixing
bracket of brake slave cylinder.
■ Inspect whether fixing bracket has abrasion,
crack or damage. If yes, please replace them.
3. Piston
■ Inspect whether the surface of piston has
corrosion, abrasion or damage. If yes, please replace them.
■ Do not use sand paper to grind the surface of
piston.
④ Sliding screw, screw
bolt and screw dustproof boot
■ Inspect whether sliding screw, screw bolt and
screw dustproof boot have abrasion and crack. If
yes, please replace them.
3 Assembly
Note:
■ When assembling, use the
specified rubber grease.
■ Do not reuse piston sealing ring and piston dustproof boot.
① Apply rubber grease onto the
piston sealing ring, and install it into the cylinder block.
② Apply brake fluid onto the piston,
and apply rubber grease onto the piston dustproof boot. Cover the piston end with piston dustproof boot cap, and then slowly fix
the cylinder block side of piston dustproof boot onto the groove of cylinder
block.
③ Plunge your hands into the cylinder
block and insert the side edge of dustproof boot of piston into the piston
groove.
Notes:
■ Uniformly press
piston, to avoid rubber ring in the inner wall of cylinder block.
④ Install sliding pin and dustproof
boot of sliding pin onto the fixing bracket of brake slave cylinder.
⑤ Install muffler of brake shoe
onto the brake shoe.
Notes:
■ Install it
according to fixing direction of muffler.
⑥ Install brake shoe components
onto the fixing bracket of brake slave cylinder.
⑦ When installing brake shoe, press
piston, and then install brake slave cylinder onto the fixing bracket of brake slave
cylinder.
⑧ Tighten
pin screw bolt。
Inspection of Brake Disc:
1. Visual Inspection
■ Inspect whether the surface of brake disc has
nonuniform abrasion, crack and serious damage. If
yes, please replace them.
2. Inspection of Runout
① Fix
brake disc onto the wheel hub.
Notes:
Before
measuring, make sure that the axial clearance between wheel bearings isn't
excessive.
② Use
dial indicator to inspect runout. (The
measurement can be conducted at 10 mm inside the edge of brake disc)
■ Limiting value of runout: 0.05 mm
③ If
runout value exceeds the specified value, please replace or conduct necessary
process.
3. Inspection of Thickness
■ Use dial indicator to inspect the thickness of
brake disc. If the thicknesses lower than limiting
worn value, please replace brake disc.
Standard
thickness: 26 mm
Limiting
worn value：24.4 mm
Steps
for Brake Running-In:
After
repairing or replacing brake disc and replacing brake shoe, or during short
distance traveling, if soft brake symptom appears, please run in the contact
surface of brake disc and brake shoe.
■ Before running-in, if brake effect is bad,
please control the vehicle speed.
■ This step can only be carried out on safe road
and traffic condition, and pay attention to safety problem.
1. Make the vehicle travel on flat and straight
road.
2. Control the stepping force
of brake pedal, make the vehicle brake within 3～5s.
3. After driving vehicle for a distance, stop the
vehicle for 3mins to cool brake system.
4. Repeat
steps 1～3 until brake shoe
and brake disc are completely engaged.
Rear
Disc Brake Caliper
Inspection
of Abrasion Condition of Brake Shoe.
Notes:
■ Please use a scale to inspect.
■ Standard thickness: 8 mm
■ Limiting worn thickness: 2 mm
Dismantling
and Assembly:
1. Dismantling
① Dismantle
wheel tire.
② Dismantle
bolts of brake slave cylinder.
Notes:
■ Tightening torque: 22～32 N•m
④ Use
rope to lift cylinder, and then dismantle brake shoe, shoe washer retainer
ring.
2) Installation
① Install
brake shoe shim and brake retainer ring onto each brake shoe.
Notes:
■ Install it according to the fixing direction of
brake shoe shim and brake shoe retainer ring.
② When
installing brake shoe, press piston, and then install brake slave cylinder onto
the fixing bracket of brake slave cylinder.
③ Install
brake shoe onto the fixing bracket of brake slave cylinder.
Notes:
■ Brake fluid in brake fluid reservoir.
④ Install
sliding screw of cylinder, and tighten it.
⑤ Use
tire nut to fix brake disc, and step brake pedal until there is brake effect.
⑥ Inspect
rotation resistance of brake.
⑦ Install wheel
tire.
Installation of Rear Brake:
Schematic Diagram of Rear Brake Assembly
1-Rear brake caliper assembly 2- Rear brake hose assembly 3-Rear wheel
hub assembly
4- Rear brake disc 5-
Rear parking brake assembly
① At last, install rear
brake hose assembly and brake oil pipe hole bolt, shim.
Notes
■
Precautions to be paid
during installing are the same as these of front brake.
② After installing brake
system, step brake pedal for several times to ensure that the brake shoe is
installed properly.
Inspection of Brake Disc:
For detailed steps, please refer to
front disc brake caliper.
1. Inspection of Thickness
Notes:
■
Use a dial indicator to
inspect the thickness of brake disc. If the thicknessis lower than limiting
worn value, please replace brake disc.
Standard
thickness: 10 mm
Limiting worn
value:
8.4 mm
2. Inspection of Runout
① Fix brake disc onto
the wheel hub。
② Use dial indicator to
inspect runout. (The measurement can be conducted at 10mm inside the edge
of brake disc)
Notes:
Limiting
value of runout: 0.05 mm
Fault Diagnostic
Diagnostic Table of Common Faults
|
Fault Symptoms
|
Possible Causes
|
Solutions
|
|
When braking, vehicle is off track
towards one side.
|
Left and right tire pressure is
insufficient.
|
Adjust
|
|
Front wheel alignment is improper.
|
Adjust
|
|
Brake shoe has bad connection.
|
Adjust
|
|
The surface of brak shoe has grease
or oil.
|
Replace
|
|
Brake cylinder is installed
improperly.
|
Adjust
|
|
Self-adjusting mechanism has fault.
|
Adjust
|
|
Brake force is insufficient.
|
Brake fluid is insufficient or
contaminated.
|
Fill or replace
|
|
There is air inside brake system
|
Exhaust air
|
|
Brake vacuum booster has fault.
|
Adjust
|
|
Brake shoe has bad connection.
|
Adjust
|
|
The surface of brak shoe has grease
or oil.
|
Replace
|
|
Self-adjusting mechanism has fault.
|
Adjust
|
|
Brake shoe lagging causes overheat
of brake rotation part.
|
Adjust
|
|
Brake pipe has limit.
|
Adjust
|
|
Brake stroke increases (distance
between pedal and floor is shortened)
|
There is air inside brake system
|
Exhaust air
|
|
Brake fluid has leakage.
|
Adjust
|
|
Self-adjusting mechanism has fault.
|
Adjust
|
|
Clearance between pushing rod and
brake master cylinder is too big.
|
Adjust
|
|
Brake is lagging.
|
Parking brake is not completely
released.
|
Release
|
|
Parking brake is adjusted
improperly.
|
Adjust
|
|
Return spring of brake pedal has
abrasion.
|
Replace
|
|
Return oil port of brake master
cylinder has limit.
|
Adjust
|
|
Sliding part has insufficient
lubrication.
|
Lubricate
|
|
One-way valve of brake master
cylinder or piston return spring has fault.
|
Replace
|
|
Clearance between pushing rod and
brake master cylinder is too small.
|
Adjust
|
|
Parking brake function is bad.
|
Rear brake shoe is damaged.
|
Adjust
|
|
The surface of rear brak shoe has
grease or oil.
|
Replace
|
|
Parking brake cable is sticking.
|
Adjust
|
|
Self-adjusting mechanism has fault.
|
Adjust
|
|
Stroke of parking brake handle is
too big.
|
Adjust
|
Repair Data and Specifications
Table of Technical Specifications
|
Items
|
Specification
|
|
Brake master cylinder
|
Type
|
Series arrangement
|
|
Bore
|
22.22
mm
|
|
Vacuum booster
|
Type
|
Vacuum
|
|
Effective diameter
|
203〜228
mm
|
|
Boosting ratio
|
9
: 1
|
|
Front brake
|
Type
|
Floating caliper/ vent disc
|
|
Diameter of brake disc
|
280
mm
|
|
Thickness of brake disc
|
26
mm
|
|
Thickness of friction block
|
11
mm
|
|
Cylinder bore
|
57
mm
|
|
Rear brake
|
Type
|
Floating caliper/ solid disc
|
|
Diameter of brake disc
|
262mra
|
|
Thickness of brake disc
|
10mm
|
|
Thickness of friction block
|
8mm
|
|
Cylinder bore
|
34mm
|
Tightening
Torque Table
|
Items
|
Torque N•m
|
|
Connecting bolt between front brake caliper and
steering knuckle
|
69〜85
|
|
Connecting bolt between rear brake caliper and
steering knuckle
|
69〜85
|
|
Air drain bolt of front and rear
brake calipers
|
6〜9
|
|
Fixing bolt of upper bracket of brake pedal
|
30〜35
|
|
Fixing nut of brake pedal
|
30〜35
|
|
Connecting bolt between brake hose and brake caliper
|
25〜30
|
|
Brake rigid pipe joint
|
13〜17
|
PB Parking Brake
Precautions
■ Inspect and adjust parking brake under common brake condition.
■ When inspecting parking brake system, place the vehicle on flat ground
and fix the wheel by using triangle wooden block.
Parking Brake Control:
On-Board Inspection
1. Stroke of Parking Handle
■ Use 200 N force to pull up parking brake handle, and make sure the
pawl is in the specified groove (there is "clip" sound when it passes
through one tooth. The inspection can be achieved by listening and counting the
sound produced by pawl).
■ Standard value: 8～9 teeth
2. Assembly Inspection
① Confirm whether the
fixing condition of each element is normal.
② Whether parking brake
handle assembly has bending, damage or crack. If yes, replace it.
③ Whether parking brake
cable is worn or damaged. If yes, please replace them.
④ Whether parking brake warning
light switch is normal. If it can't work normally, please inspect and
replace it.
⑤ Dismantle parking
brake switch connector, and inspect the conductivity between positive terminal
and vehicle body.
■ If parking handle is upwards, they are conducted.
■ If parking handle is downwards, they aren't conducted.
3. Adjustment
① Under
the condition that parking control handle is in release condition,
insert left and right parking brake cable connectors into the mounting hole of
balance plate of parking control handle. As shown in figure. After
installing cable, tighten adjusting nuts to ensure the distance L between
adjusting nut and the end of the cable is 8 ± 2 mm.
Parking Brake Schematic Diagram
1-Parking handle assembly 2- Adjusting
nut 3- Threaded pulling rod 4- Parking cable assembly joint
② After commissioning, if pulling parking
handle with about 200 N•m force in vertical direction with handle, it is
possible to pull up 8～9
teeth. Otherwise, adjust the distance L through adjusting adjusting nut.
Detailed adjusting method: if the pulling up teeth number is less than 8, the L
value should be decreased; if the pulling up teeth number is more than 8, the L
value should be increased.
4. Component Assembly
Diagram of Parking Brake Cable
System
1- Parking handle assembly 2- Left
and right cable fixing combination clip 3- Right parking brake cable assembly
4- Left parking brake cable assembly 5- Buckle
5. Dismantling and Installation
Dismantling
a. Dismantle auxiliary instrument panel rear section assembly.
b. Unscrew adjusting nut, and dismantle left and right parking brake
cable assembly from cable buckle.
c. Disconnect parking brake switch wire harness, dismantle fixing bolt
of parking brake handle, and take out parking brake handle assembly.
■ Tightening torque: 25～30 N•m
b. Unscrew adjusting nut, and dismantle left and right parking brake
cable assembly from cable buckle.
e. Take out parking
brake cable from the mounting hole at the bottom of vehicle body.
ESC Electronic Stability Control System
Precautions
■ When vehicle travels on bumpy, gritty or snowy and other wet road,
the brake distance will be longer than the vehicle without ABS.
■ When ESC, ESC, OFF, HDC,
ABS or other warning light indication have fault, before repairing them,
it is necessary to collect necessary information (what has happened on what
condition) from the client and find out the simple cause. Besides the
inspection of electrical system, it is also necessary to inspect the
operation of vacuum booster, whether brake fluid level and liquid have leakage.
■ If you don't use proper dimension and type of tires according to
correct requirement, or brake shoe is not JAC original part, brake distance or
steering stability may deteriorate.
■ If you installed parts bought from the market (on-board stereo sound
equipment, CD player, etc.), inspect whether electric wire harness is clamped,
has open-circuit or improper wiring.
■ Before conducting welding operation, first disconnect connector from
ESC control module.
■ Because electric stability control system part is very sensitive to
EMC (Electromagnetic Interference), be careful to the arrangement, position,
installation and orientation of all anti-lock brake system parts, and whether
the wiring, connector, clip and support have clash.
■ Do not use quick charger to start the engine or charge the battery
which is still connecting, because this may cause battery failure or damage of
parts of anti-lock brake system.
■ When repairing, it is necessary to turn off ignition switch, and
then disconnect negative pole of battery, and then disconnect connector of ESC
control module assembly; otherwise, it may cause the damage of control module.
■ Do not try to repair any anti-lock brake system parts. Faults of all
ESC parts should be eliminated only by replacing them.
■ Do not suspension parts hang on wire harness of wheel speed sensor,
to avoid damage of sensor wire harness.
■ Do not put ESC
control module in environment with high temperature of more than 105 °C.
■ Do not use liquid containing petroleum base in brake master cylinder,
because petroleum may cause expansion and deformation of rubber parts in
hydraulic brake system.
■ After turning ignition switch to “ON” position, start the vehicle and the brake pedal may vibrate or sound from
motor of ESC hydraulic assembly during working condition can be heard. This is
the normal condition of operation inspection.
Preparation Work
Common repair tools and special tools
used during repairing.
Special Tool Tables
|
S/N
|
Tools
|
Overall Diagram
|
Number
|
Description
|
|
1
|
X431 Fault diagnostic instrument
|
|
|
Fault diagnosis of ESC system
|
System Description
System Diagram:
ESC System Diagram
1-Left front brake assembly 2- Brake master
cylinder assembly 3- Vacuum booster
4- Right front brake
assembly 5- ESC control module with hydraulic assembly
6- Brake master
cylinder 7- Left rear brake assembly 8- Right rear brake assembly
ESC
Functions:
Anti-lock braking
system (ABS) is a kind of hyraulic brake device used for controlling four
wheels during emergency brake or vehicle travels on hazard road, to prevent
wheel lock. Main features of ABS are shown as follows:
(1) When some barriers are
encountered during emergency brake, it can reliably steer direction.
(2) When conducting emergency
braking on curve road, it can keep stable parking of vehicle.
Notes:
■ If electrical system is cut, fail protection mode will be
actuated. ABS enters non-operational condition. ABS warning light will
light up.
■ Special diagnostic instrument provided by JAC can be used for
diagnosis of ABS electrical system.
■ During braking, brake pedal will have slight vibration, and some
mechanical sound will be heard. This is normal ABS working condition
EBD Functions:
Electronic brake
distribution(EBD) is a kind of scale system used for protecting vehicle
stability during braking. Under normal braking
condition, effective balance brake requires equal wheel speed. Under
the condition that it is difficult to brake, because vehicle weight is
transmitted to the front wheels and rear wheels requires smaller brake force,
EBD will make use of ABS to increase or reduce pressure to maintain brake
pressure required for rear wheels, to provide effective brake and vehicle
stability.
HBA Functions:
During traveling and
when encountering emergency situation which requires brake, when driver quickly
steps brake pedal but can't provide sufficient brake force, hydraulic brake
auxiliary system (HBA) can positively reduce pressure to shorten brake
distance.
Notes:
■ In HBA effecting process, brake pedal will automatically sink.
■ When brake pedal is sinking, do not release brake.
TCS Functions:
Electronic traction
control system (TCS) monitors each wheel signal and keep the sliding of drive
wheel, stability and acceleration of vehicle in optimal condition through the
control of brake pressure and (or) engine torque.
ESC Functions:
Electronic stability
control (ESC) can drag the vehicle to its original traveling track when the
vehicle is in steering transition. When vehicle steering is insufficient, it
can drag the vehicle to its original traveling track.
HSA Functions:
Hill start auxiliary
system (HSA) is used to release brake pedal when vehicle stops or parks on hill
slope, or prevent vehicle overturning when parking brake operation isn't
conducted.
Notes:
■
HSA function can work only at neutral, 1st gear and
reversing gear.
HDC Functions:
Hill descent control
system (HDC) is used for automatically controlling vehicle at low speed through
driver's selection during the vehicle travels on steep slope.
■
HDC can work only at 1st gear and reversing gear.
■ When pressing HDC switch, if the gear is on 1st or reversing gear
and HDC warning light is green, HDC is able to work (it has no work
ability when warning lights of other gears don't light up). When HDC
works, warning light flashes.
■
When
HDC works, vehicle speed is controlled at 10 Km/h.
Fault Protection Functions:
ABS system has electric
fault, and ABS warning light will light up. If EBD electric fault
occurs, brake warning light and ABS warning light will light up
at the same time.
Meanwhile, ABS system
will change into one of the following situations of fault protection function.
1) For ABS fault, only actuate EBD, and vehicle status is the same as that of
vehicle without ABS system.
2) For EBD fault, both EBD and ABS are not allowed to be used. And vehicle
status is the same as that of vehicle without ABS, EBD system.
ESC system has electric
fault, and ESC warning light will light up. If EBD electric fault
occurs, brake warning light, ABS warning light and ESC warning
light will light up at the same time. If ABS electric fault occurs, ABS warning
light and ESC warning light will light up at the same time.
HDC system has electric
fault, and HDC warning light will light up (red).
Anti-lock Brake Mode:
If the wheel has
sliding movement during braking, ABS will enter into anti-lock brake mode.
During anti-lock braking operation, pressure of each wheel hydraulic circuit
will be controlled to avoid wheel sliding movement. Each wheel is equipped with a separte hydraulic circuit
and valve. ABS can reduce, maintain or increase brake hydraulic
pressure of each wheel. But ABS can't increase hydraulic pressure to the value
exceeding pressure value transmitted by master cylinder during braking
operation. During anti-lock braking
operation. Brake pedal will feel a series of quick vibration. Pedal vibration
will occur during anti-lock braking operation and disappear during normal brake
of vehicle or vehicle completely stops. Due to the quick recycling of
electromagnetic valve, some noise can be heard. When starting anti-lock braking
operation on dry road, tire will produce intermittent sharp sound when it is
near sliding. This sound and pedal vibration is normal during anti-lock braking
operation. Durning normal braking operation, brake pedal has no
difference with ABS system. keeping the force
stepping pedal balance can not only keep the stability of the vehicle but also
ensure shortest parking distance.
1. Pressure Maintaining
When ABS control module
detects the sliding movment of the wheel, it will close oil inlet valve and
close the oil outlet valve in hydraulic assembly, to separate system. This
operation can keep the stability of pressure on the brake and prevent the
hydraulic pressure from increasing or reducing.
2. Pressure UP
If ABS control module
still can detect the sliding movement of the wheel in pressure maintaining
condition, it will reduce the pressure of the wheel which is affected. Oil inlet valve closes, while oil
outlet valve is open.. Residual liquid/ pressure is temporarily
stored in accumulator of hydraulic assembly until pump motor can transmit brake
fluid into the oil reservoir of master cylinder .
3. Pressure DOWN
If ABS control module
detects the reduction of sliding movement of the wheel in pressure maintaining
or pressure DOWN mode , it will make use of master cylinder presure to
increase the pressure of the wheel which is affected. Oil inlet valve closes, while oil outlet valve is open..
Part or all pressure from brake master cylinder is exerted onto the wheel.
4. ABS Working Processing
During vehicle traveling
condition, each wheel speed sensor will produce a voltage signal of rotation
speed which is in direct proportional to the wheel. ABS control
module receives wheel speed data and determines whether there is 1 or more
wheel speed is fast (by comparison with vehicle speed). This is called sliding
movement. ABS control module will actuate module according to the need. Module
will control brake pressure of each wheel to optimize it.
Hydraulic Schematic Diagram of ESC System
Schematic Diagram of ABS Hydraulic System
1-
1- Master cylinder 2- Oil
inlet valve/LF 3-Oil
outlet valve/LF 4- Oil inlet valve/RR 5-
Oil outlet valve/RR 6- Damper 7- Oil return pump 8- Accumulator
9-Oil
inlet valve/ RF 10- Oil outlet valve/RF
11-Oil
inlet valve/ RF 12. Oil outlet valve/LR 13- Simulation valve
Wheel Speed Sensor
It consists of the sensor itself and
gear ring. Each wheel is equipped with one group of sensor. This vehicle uses positive wheel speed sensor which can work only when
adding a power supply (12V). A constant amplitude
signal is provided no matter what's the size of wheel speed.
Elements:
It consists of the sensor itself and
gear ring. Each wheel is equipped with one group of sensor.
Dismantling:
1. Front wheel
① Rise up the vehicle.
② Dismantle fender and
disconnect sensor connector.
③ Unscrew fixing bolt of
sensor, and slowly take out sensor.
■ Tightening torque: 8~10 N•m
Notes:
■ Please do not drag wire harnesss of wheel speed sensor with hard
force.
■ When installing, pay attention to the gap between wheel speed sensor
and signal gear ring.
Standard value: 0.8±0.4 mm
2. Rear Wheel
① Rise up the vehicle
and dismantle rear wheel tire.
② Dismantle lower trimming plate of C column.
③ Disconnect sensor
connector.
④ Unscrew fixing bolt of
wheel speed sensor, and slowly take out wheel speed sensor.
Notes:
■ Please do not drag wire harnesss of wheel speed sensor with hard
force.
■ When installing, pay attention to the gap between wheel speed sensor
and signal gear ring.
Standard value:
0.8±0.4 mm
Inspection after Dismantling:
1. Inspect whether there is foreign matter inside the mounting hole of
sensor, and whether the surface of brake disc has metal scraps and other
foreign matters.
2. Before installing, clean the mounting hole of sensor and the surface
of brake disc.
Installation:
The installation is in
reverse order of dismantling, and then tighten bolts to the specified torque.
Notes:
■ After installation, wire harness should not have
twisting.
Electronic Hydraulic Control Unit
Note: this brake system
is X-type arrangement, and vacuum booster will provide brake boosting force
Hydraulic electronic
control unit (HECU) consists of hydraulic control unit (HCU) and electronic
control unit (ECU).
Notes:
■
HECU must be replaced as a whole. It is not allowed to only
replace HCU or ECU.
Preparation Work:
Before repairing, use
diagnostic instrument to find out the cause of failure. Error code will be read
in ECU and marked.
Necessary tools and parts to be
replaced:
1. Socket
wrench, length of 10-11 mm
2. Fork wrench, 10 mm, 11 mm
3. Torque wrench, working
range 4-15 N•m
4. Tester
5. Accessory includes: 1 wet type
HECU
Description of Dismantling
■ Replacement of part should be conducted by professional technician
under instructions of workshop manual provided by complete vehicle plant.
■ Keep the vehicle in stationary status.
■ If there is failure code in ECU, before replacing HECU, it requires confirmation
of online diagnostic system.
■ Take out spare parts to be installed only before installation.
■ Use original spare parts.
■ Do not touch, stain and damage the surface of connector.
■ If HECU assembly
is impacted (falling down or bumping), it can not be used.
■ Incorrect installation will affect the performance of brake system.
■ During replacing, make sure the brake system is clean.
■ Use clean material without producing burr.
■ Before installation, uses agent rather than mineral oil to clean the
surface.
■ Make sure that the brake fluid can't enter into the connector of
electric appliance.
■ After dismantling HECU, immediately use suitable protective cover to
seal oil port.
■ Dismantle all parts which may affect the replacement of HECU.
Dismantling of HECU Assembly
1. Turn off ignition switch, and
unplug battery ground wire.
2. Turn on ECU connector, and dismantle wire harness of electric
appliance from ECU.
3. Step the brake
pedal to close the centre valve of brake master cylinder, and prevent
brake fluid from flowing out of open-loop system.
4. Connect exhaust
reservoir to the front shaft and rear shaft wheel cylinder, and open air
drain bolt to drop pressure.
5. Confirm and mark
brake pipeline, dismantle brake pipeline (pipe A and B in figure 2)
connecting main cylinder, and use protective cover to promptly seal relevant
oil port.
6. Confirm and mark
brake pipeline, dismantle brake pipeline (pipeline 1-4 in figure 2) connecting
wheel cylinder , and use protective cover to promptly seal oil port.
Note: there is no rubber damping cushion between HECU assembly and
bracket.
1. Dismantle HECU
assembly from the support
2. Before packing HECU assembly, make sure there is no pollutant and
brake fluid entering into.
Note: there is no rubber damping cushion between HECU assembly and
bracket.
1. Dismantle HECU
assembly and rubber damping cushion from bracket.
2. Dismantle rubber damping cushion from HECU assembly.
3. Before packing HECU assembly, make sure there is no pollutant and
brake fluid entering into.
Installation of HECU Assembly
Important tip: HECU oil
port protective cover is allowed to be dismantled only when brake pipe is
prepared (to prevent pollution).
Tighten HECU assembly onto the bracket by using suitable bolts and
tightening torque.
Note: there is rubber damping cushion between HECU assembly and bracket.
1. Install rubber cushion onto the HECU assembly.
2. Install HECU and rubber cushion onto the bracket, and all bolts must
be tightened with equal torque.
Note: Make sure that
there is a good coordination between rubber and HECU. If necessary, replace
rubber cushion.
1. Dismantle oil port protective cover, and screw brake pipeline of
whee cylinder onto the oil port of HECU.
2. Dismantle oil port protective cover, and screw brake pipeline of
master cylinder onto the oil port of HECU, to ensure the verticality of oil
port bolt and oil port and prevent damaging thread teeth.
■ Tightening torque: tightening torque
of bolt M10X1 and M12X1 is 13-20 N•m.
3. Connect and lock connector.
4. Connect the ground wire terminal of battery.
5. Add new DOT4 brake fluid to brake fluid reservoir to “MAX” position. And exhaust air according to exhaust
instruction provided by complete plant.
6. Put ECU code into new ECU.
7. Mark the angle sensor of steering wheel, lateral and longitudinal
angle speed sensor (if available) according to diagnostic instrument.
8. Turn on ignition switch, and ABS and ESP warning light will
disappear after successful self-inspection).
9. Clean online diagnosed error code
and re-read this information to facilitate inspection.
10. When conducting test driving, make sure that ABS control at least
completes 1 working cycle (brake pedal can feel vibration when ABS comes into
force.
Installation Instructions
1. Only use brake fluid having the same grade with DOT4, and it is not
allowed to use mineral oil type brake fluid.
2. For the subsequent work, inspect basic brake system and ESP system
functions according to the instructions of manufacturer. Inspect the sealing of all oil ports and connectors.
ESC Hydraulic Assembly
Dismantling and Installation:
1. Dismantling
① Turn off ignition
switch and disconnect negative terminal post of battery.
② Dismantle ESC control module connector.
③ Step pedal > 60 mm and fix it with pedal bracket.
■ Close centre valve
of hydraulic assembly, so as to prevent brake fluid from flowing out of oil
port when opening system.
④ First dismantle brake rigid
pipe on hydraulic assembly connecting to master cylinder and make marks,
and then immediately plug the port.
⑤ Dismantle brake rigid
pipe connecting to each wheel and make marks, and then immediately plug the
port.
⑥ Dismantle bolts from fixing bracket
of ESC hydraulic assembly.
2) Installation
Notes:
■ Tighten brake pipe joints connecting to ESC hydraulic assembly to
the specified torque.
Tightening torque: 16 ~18 N•m
■
The plug for hydraulic opening on ESC hydraulic assembly
can be dismantled only when brake rigid pipe is to be installed, to
prevent foreign matters from entering into the brake system.
■ If ESC hydraulic assembly has fault, replace the assembly.
① Install ESC hydraulic assembly onto the bracket and
tighten it to the specified torque.
② Dismantle plug from
hydraulic opening, install brake rigid pipe and make sure that the rigid
pipe is connected correctly.
③ Connect hydraulic
assembly to brake rigid pipe of master cylinder.
④ Assemble brake rigid pipe and tighten it to the
specified torque.
⑤ Fill new brake fluid into oil reservoir until the level
reaches MAX, and then exhaust air according to the specified methods.
⑥ When turning ignition switch to “ON” position, the warning lights of ABS, ESC, ESC
off, brake, HEC must light up and then go out.
⑦ Clear memory fault
code and re-read whether there is still fault code.
⑧ At last, conduct trial driving to confirm whether ESC
function is normal.
Replace ESC Control Module.
Components：
This model uses continental MK60E PYA ESC electronic stability
control system.
ESC control module is integrated with hydraulic assembly.
Pin Diagram of ESC Control
Module
Pin Descriptions of
ESC Control Module:
Table of Pin Description
of ESC Control Module
|
Pin No.
|
Description
|
Pin No.
|
Description
|
|
1
|
Power supply terminal (positive) of motor
|
25
|
Null pin
|
|
2
|
Null pin
|
26
|
Null pin
|
|
3
|
Vehicle speed signal output
|
27
|
Null pin
|
|
4
|
Null pin
|
28
|
Null pin
|
|
5
|
Null pin
|
29
|
Null pin
|
|
6
|
HDC switch signal input
|
30
|
Null pin
|
|
7
|
Right rear wheel speed signal output
|
31
|
Null pin
|
|
8
|
Ignition signal input
|
32
|
Power supply terminal (positive) of ESC
|
|
9
|
Left rear wheel speed signal output
|
33
|
Signal terminal (right front) of wheel speed sensor
|
|
10
|
Diagnostic K wire
|
34
|
Power supply terminal (right front) of wheel speed sensor
|
|
11
|
Right front wheel speed signal output
|
35
|
|
|
12
|
CAN - high
|
36
|
|
|
13
|
CAN - low
|
37
|
Power supply terminal (left rear) of wheel speed sensor
|
|
14
|
Left front wheel speed signal output
|
38
|
Signal terminal (left rear) of wheel speed sensor
|
|
15
|
Null pin
|
39
|
Brake lamp switch input
|
|
16
|
Null pin
|
40
|
ESC switch input
|
|
17
|
Null pin
|
41
|
Null pin
|
|
18
|
Null pin
|
42
|
Null pin
|
|
19
|
Null pin
|
43
|
Signal terminal (right rear) of wheel speed sensor
|
|
20
|
Null pin
|
44
|
Power supply terminal (right rear) of wheel speed sensor
|
|
21
|
Null pin
|
45
|
|
|
22
|
Null pin
|
46
|
Power supply terminal (left front) of wheel speed sensor
|
|
23
|
Null pin
|
47
|
Signal terminal (left front) of wheel speed sensor
|
|
24
|
Null pin
|
|
Ground wire
|
Inspection of ESC Control
Module:
Notes:
■ If there is no special requirements, do not dismantle ESC hydraulic
assembly (including control module).
1. Basic inspection of brake system
① Inspect brake fluid
level. If the level is low, add brake fluid.
② Inspect whether brake pipe and areas near ESC hydraulic
assembly have leakage. If any leakage is found,
conduct the following inspection:
a. If the connecting position of ESC hydraulic assembly is loose,
tighten oil pipe nuts of pipe to the specified torque (16~18 N•m) Re-inspect leakage condition to
ensure that there is no brake fluid leakage.
b. If oil pipe nuts on
connection position and the thread of actuator are damaged, please replace the
damaged parts. Re-isnpect leakage condition to ensure that there is no brake
fluid leakage.
c. If the leakage locates at the place other than connecting position
of actuator, use clean cloth to wipe, and then re-inspect it. If there is still leakage, replace the damaged parts.
d. If the leakage is found on the hydraulic assembly, use clean cloth
to wipe, and then re-inspect it. If
there is still leakage, replace hydraulic assembly.
③ Inspect whether brake
shoe is worn.
④ Inspect whether
circuit terminal of power supply is loose or negative pole of battery is loose,
and whether the voltage is normal.
2. Inspection of warning lights of ESC, ESCOFF, HDC,
ABS and brake warning light
① Make sure that when turning ingition switch to
"ON" position, warning lights of ESC, ESCOFF, HDC, ABS light
up for 1.8s, and brake warning light also lights up. If they didn't
light up, please refer to "Fault Diagnosis".
② Inspect whether warning lights of ESC, ESCOFF,
HDC, ABS go out when turning ignition switch to “ON” position for 1.8s, and
whether brake warning light goes out after the starting of the engine.
If they didn't go out, please refer to “Fault Diagnosis”.
③ If warning lights
of ESC, ESC OFF, HDC and ABS didn't go out after 10s of the starting of engine,
please refer to "Fault Diagnosis".
Notes:
■ Brake warning light will light up during parking brake
operation (when the switch is placed to "ON" position) and brake
fluid level sensor works (brake fluid is insufficient).
3. Use diagnostic instrument to inspect ECS control module
Use diagnostic instrument
to inspect control module data and record fault code. If there is any abnormal
condition, repair it according to fault tips.
Air Exhaust of ESC System
Air Exhaust Conditions of
ESC System:
ESC exhaust procedures
must be carried out when any of the following conditions occurs
1. Brake pipe can't achieve required pedal height and feeling with
traditional exhaust method.
2. Replace ESC hydraulic assembly.
3. Liquid is consumed too much.
4. Air is suspected to be absorbed.
■ This procedure uses fault diagnostic instrument to drive system
valve and run pump motor to clean air from secondary loop. These secondary
loops are often closed and will be opened only during initialization and ESC
operation when vehicle is started. Automatic
exhaust procedure opens these secondary loops to let air flow out and collected
into hyraulic assembly where it can be eliminated out of the system.
Exhaust Procedures of
ESC System:
1. Required material to be prepared
① Diagnostic instrument
with correct software.
② Brake fluid.
③ Lifting jack.
④ Exhaust bottle equipped with recycling vehicle brake
fluid hose.
⑤ Suitable safe
equipment, including safe glass.
⑥ Two repair technicians
are required: one is responsible for stepping brake pedal and controlling
diagnostic instrument; the other is responsible for maintaining hydraulic oil
level in main chamber of brake master cylinder and closing and opening air
drain bolt according to the tips of diagnostic instrument.
2. Preliminary inspection
① Inspect the charging
condition of battery, and repair battery and charging system if necessary.
② Connect diagnostic
instrument, and select current and history diagnostic fault code. Before carrying out ESC exhaust procedures, clear all fault diagnostic code.
If diagnostic code can't be cleared,
please first eliminate fault.
③ Inspect whether the
appearance has damage or leakage. Repair it if necessary.
3. Actions to be taken before exhausting
① Start the engine.
② Connect diagnostic instrument, and establish
communication with ESC control module.
③ Rise up and properly
support vehicle.
4. Carry out air exhaust procedures on-board.
5. After air exhaust, make mark for ESC.
Notes:
■ Pressing EXIT key on diagnostic tester can stop automatic exhaust
procedures at any time.
① Select “adding fluid exhaust
function” on diagnostic instrument and follow the instructions.
② During step 1 and step
2, it is necessary to step brake pedal and keep the brake fluid level in brake
master cylinder.
③ When exhausting air for
the first wheel, make sure that the hose connects with air drain bolt and
air is exhausted into the container with brake fluid. This container must be 30 mm higher than bolt of hose filled with brake
fluid. This is to prevent air
re-entering into the brake pipe.
④ This first step is to
exhaust air basically. This step must be conducted before
automatic exhaust for the purpose of obtaining proper pedal height and pedal
feeling and ensuring optimal ABS performance.
⑤ During next step, the
diagnostic instrument will request repair technician to open one of exhaust
bolts. And then disgnosis tester will inspect pressure supply
valve and pump motor for 30s in cycle form. In the whole processing, brake pedal requires constant
pressure increase and decrease.
⑥ For the rest exhaust
bolt, diagnostic instrument will repeat step ⑤ to exhaust air.
⑦ When automatic exhaust
procedures are completed, diagnostic instrument will display relevant
information.
⑧ Step brake pedal to
measure pedal height and feeling. Repeat step ① to ⑦ until pedal recovers its normal
height.
Warning:
■ If it is necessary to repeat some
phase or the whole exhaust processing, you must wait for 5m to let the electromagnetic
valve cool; otherwise, electromagnetic valve may be damaged due to
overheat.
6. Automatic air exhaust procedures
Exhaust Steps Carried out
by Diagnosis Tester：
① Enter into JAC
specially used fault diagnostic system.
② Select JAC specially used V22.00
full system.
③ Select S5 Diagnostic
procedures and click “OK”.
④ Select ESC electronic stability system
⑤ Directly click “adding fluid
exhaust function”
Warning
■ All warnings contained in instrument!
⑥ Interface in right
figure appears when clicking “adding fluid exhaust”, and then follow the
instructions.
■ Make sure that exhaust bolts of all wheel are closed;
■ Open the air drain boltof front right wheel (FR), and insert
the hose of brake fluid recycle bottle into the outlet;
■ Step brake pedal for 7 times. After this operation, click “OK”
to enter into next step.
Notes:
■ Brake pedal can be released only when air drain bolt of front
right wheel is closed.
■ After recycling, it is not
allowed to reuse brake fluid.
⑦ Follow the
instructions in right figure:
■ Close air
drain bolt of front right wheel (FR);
Open air drain bolt of
rear right (RR) wheel. and insert the hose of brake fluid recycle bottle into
the outlet.
■ Step brake pedal for 7 times. After this operation, click “OK”
to enter into next step.
Notes:
■ Brake pedal can be released only
when air drain bolt of rear right wheel is closed.
⑧ Close air drain bolt of rear
right wheel (RR), step brake pedal for 3 times. After this operation, click “OK”
to enter into next step.
⑨ Note: Inspect the
fluid level in fluid reservoir. If necessary, re-fill fluid.
■ Open the air drain bolt of rear left wheel ( FR ), and insert
the hose of brake fluid recycle bottle into the outlet.
■ Step brake pedal for 7 times. After this operation, click “OK” to enter into next step.
Notes:
■ Brake pedal can be released only when air drain bolt of left
wheel is closed.
⑩ Follow the instructions in right
figure to operate:
■ Close air
drain bolt of rear left wheel (RL);
■ Open air drain bolt of front left wheel (FL), and insert the
hose of brake fluid recycle bottle into the outlet;
■ Step brake pedal for 7 times. After this operation, click “OK”
to enter into next step.
Notes:
■ Brake pedal can be released only
when air drain bolt of front left wheel is closed.
⑪Close front left (FL) exhaust bolt. After this operation, click “OK”
to enter into next loop.
Notes:
■ At this moment, valve will be
started automatically, and there is about 10s of vibration sound. This is
normal.
⑫ Close front right (FR) exhaust bolt. After this
operation, click “OK” to enter into next step.
⑬ Constantly step brake pedal and continue to
exhaust air until the flowed brake fluid has no air bubble. After this
operation, click “OK” to enter into next step.
⑭Close front right (FR) exhaust bolt, open rear right (RR) exhaust bolt, constantly step brake pedal and continue to exhaust air until the flowed
brake fluid has no air bubble. After this operation, click “OK” to enter
into next loop.
⑮ Close rear right (RR) exhaust bolt, open rear
left (RL) exhaust bolt, constantly step brake pedal and continue to exhaust
air until the flowed brake fluid has no air bubble. After this operation, click
“OK” to enter into next step.
⑯ Close rear left (RL) exhaust bolt, open
front left (FL) exhaust bolt, constantly step brake pedal and continue to
exhaust air until the flowed brake fluid has no air bubble. After this
operation, click “OK” to enter into next step.
⑰ Close front left
(FL) exhaust bolt. Fluid adding exhaust operation is completed.
Sensor Calibration
Calibration of Lateral Acceleration Sensor,
Longitudinal Acceleration Sensor, Pressure Sensor, and Steering Angle.
Notes:
■ It is necessary to calibrate lateral acceleration sensor,
longitudinal acceleration sensor, pressure sensor, and steering angle when
replacing ESC assembly.
■ It is necessary to calibrate lateral acceleration sensor,
longitudinal acceleration sensor, pressure sensor, and steering angle after the
completion of four wheel alignment.
■ It is necessary to calibrate lateral acceleration sensor,
longitudinal acceleration sensor, pressure sensor, and steering angle when
replacing front suspension and relevant parts.
■ If above sensor calibrations are not conducted, it may affect ESC
functions and cause vehicle faults.
Steps for Sensor Calibration:
① Enter into JAC
specially used fault diagnostic system.
② Select JAC specially used V22.00 full system.
③ Select
ESC electronic stability Diagnostic procedures and click “OK”.
④ Select sensor calibration, and
click it to enter.
⑤ Select lateral acceleration sensor calibration, click
the procedure to start marking.
⑥ After the
success of calibration of sensor, the following interface will appear. Click “OK”
to enter into next step.
⑦ Select longitudinal acceleration sensor calibration,
click the procedure to start marking.
⑧ After the
success of calibration of sensor, the following interface will appear. Click “OK”
to enter into next step.
⑨ Select pressure sensor calibration, click the
procedure to start marking.
⑩ After the success of calibration of sensor, the
following interface will appear. Click “OK” to finish marking.
⑪ Select
steering angle calibration, click the procedure to start marking.
⑫ After the success of calibration of
steering angle, the following interface will appear. Click “OK” to
finish marking.
Notes:
■ If the
diagnostic interface doesn't indicate that the calibration of steering angle is
successful, please inspect relevant parts or re-mark it.
List of ESC Fault Code
|
DTC
code
|
DTC
|
Information Of Fault Code
|
|
U0167
|
C167
|
Reserved and unused
|
|
U0131
|
C131
|
Power steering control
unit fault
|
|
U0100
|
C100
|
Engine control unit
fault
|
|
U0101
|
C101
|
Transmission control
unit fault
|
|
U0155
|
C155
|
Instrument cluster
control unit fault
|
|
U0151
|
C151
|
Airbag control unit
|
|
U0114
|
C114
|
Intelligent four-wheel
drive control unit fault
|
|
C130A
|
530A
|
Steering wheel turning angle
signal fault
|
|
C120E
|
520E
|
Brake lamp switch fault
|
|
C1003
|
5003
|
ESC control unit
fault
|
|
C1090
|
5096
|
Vacuum booster fault
|
|
C0031
|
4031
|
Left front wheel speed
sensor fault
|
|
C0034
|
4034
|
Right front wheel speed
sensor fault
|
|
C003A
|
403A
|
Right rear wheel speed
sensor fault
|
|
C0037
|
4037
|
Left rear wheel speed
sensor fault
|
|
C129C
|
529C
|
KL.30 power supply
fault
|
|
C1412
|
5412
|
ECU doesn't code
|
|
C1414
|
5414
|
ECU code isn't
correct
|
|
C146A
|
546A
|
ABS valve fault
|
|
C14FC
|
54
FC
|
Hydraulic valve fault
|
|
C1513
|
5513
|
Data bus diagnostic
interface fault
|
|
U1000
|
D000
|
Data bus BUS-OFF fault
|
|
C15CE
|
55
CE
|
EOL test fault
|
|
C1825
|
5825
|
Incorrect
installation of ESC control module
|
|
C1FD8
|
5FD8
|
ECU fault, RAM
(random access memory) fault
|
|
C1FD9
|
5FD9
|
ECU fault, exterior
RAM fault
|
|
C1FDB
|
5FDB
|
ECU fault, EEPROM
error
|
|
C1FDC
|
5FDC
|
ECU fault, wrong
correction
|
|
C1FDE
|
5FDE
|
ECU fault, incorrect
self-testing
|
|
C1FDF
|
5FDF
|
ECU fault, incorrect
procedure
|
|
C1FE0
|
5FE0
|
ECU fault, electronic
fault
|
|
C1FE1
|
5FE1
|
ECU fault, fault
|
|
C1FE3
|
5FE3
|
ECU fault, watchdog
timer
|
|
C1FF4
|
5FF4
|
ECU fault, interior
sensor fault
|
|
C1664
|
5664
|
Engine control unit
coding is wrong,
|
|
C1722
|
5722
|
Steering wheel angle
signal has initialization fault.
|
|
C0062
|
4062
|
Lateral acceleration
sensor fault
|
|
C0063
|
4063
|
Cross swing angle
sensor fault
|
|
C0046
|
4046
|
Pressure sensor fault
|
|
C0061
|
4061
|
Longitudinal acceleration
sensor fault
|
Fault Diagnosis
Table of Fault Diagnosis
1) Conduct fault diagnosis, and completely understand
each vehicle system.
2) Inspect and understand customer complaint. Fully
understand fault symptol, and carefully ask the customers about their
complaint.
3) It is necessary to conduct symptom inspection from
the preliminary stage to faciliate complete repair of fault. For intermittent
fault, it is very important to recall the symptom according to the discussion
with the customer and previous cases. Do not conduct inspection according to
some special conditions. Most of intermittent faults are caused by bad
connection. In this case, the effective method is to shake wire suspicious wire
harness and connectors.
4) After completing diagnosis, make sure to carry out
“clear fault code”.
Diagnostic Diagram:
Diagnostic Process as Follow:
Diagnosis Information and Flow Chart:
1. Self-diagnosis
ESC control module can
conduct self-diagnosis to the system and detect systsem fault. Once any fault
is found, it will set diagnostic trouble code (DTC), and make the ABS warning
light light up; meanwhile, it will also disable all functions.
2. Display of diagnostic trouble code
Use a special diagnostic instrument
(diagnostic instrument) to display DTC.
3. Clear DTC
DTC in ESC control
module memory can be cleared by diagnostic instrument.
Notes:
■ It is necessary to check whether system operation is normal and
confirm DTC will not appear again after the completion of clearing steps.
■ DTC can't be cleared by dismanting ESC control mudule connector,
disconnecting battery wire or flameout, etc.
4. Most of intermittent fault or bad connection are caused by the
following conditions:
① Electric wiring is
wrong.
② Electric connection is
wrong.
③ Relay or electromagnetic
valve is sticking.
5. Initialization sequence
ESC control module will
conduct initialization test at the beginning of each ignition cycle.
Initialization sequence is: electromagnetic
valve and pump motor, to inspect whether part operation is normal. If any fault is detected, ESC control module will set relevant DTC. If some actions can be heard or felt
during initialization sequence, this is part of normal system operation. If
ESC control module finds that the brake switch has no signal input (foot leaves
off brake pedal), initialization will be carried out immediately. If brake
switch has signal input (pedal on brake pedal), initialization will not be
carried out until brake switch has no signal input (foot leaves off brake pedal),
or vehicle speed reaches to 16 km/h.
Inspection of Diagnosis Circuit:
1. System Description:
Diagnostic circuit can
detect some faults caused by ESC system fault. Diagnostic circuit will guide the repair technician to
carry out next step of fault diagnosis.
2. Diagnostic Procedures
Steps for repairing of
ESC system are shown as follows:
① Inspect whether vehicle has
mechanical fault related to brake system.
■ Brake fluid level is correct.
■ Inspect whether
brake fluid in master cylinder is contaminated.
■ Inspect whether
brake master cylinder/ ESC hydraulic assembly have leakage.
■ Inspect brake
parts of all wheels.
■ Verify whether there is brake
dragging.
■ Verify whether brake is stable
(no pull backward or forward).
■ Inspect whether brake shoe has
abrasion/ damage.
■ Inspect whether wheel bearing has
damage.
■ Inspect wheel speed sensor and
wire harness.
■ Inspect whether wheel speed
sensor connector/ gear ring has damage/ inspect tire pattern depth/ abrasion
condition.
■ For road test vehicle, correct it
after verifing its condition.
② The inspection of Diagnostic
circuit must be carried out according to proper fault Diagnostic procedures. After
all system faults are eliminated, clear ESC DTC.
Table of Fault Diagnosis
|
Steps
|
Diagnosis
|
Yes
|
No
|
|
1
|
1. If possible, connect
or install all disconnected or dismantled parts.
2. Turn ignition switch
to ON position, and stop the engine.
3. Install proper
diagnostic instrument onto OBD to make it communicate with ESC control
module.
|
To step 2.
|
To step 4.
|
|
2
|
Whether there is current or history DTC?
|
To step 3.
|
To step 7.
|
|
3
|
1. Record current DTC.
2. Record DTC history.
3. Record history data,
such as the times set for each DTC, initial set times of each DTC; last set
times of each DTC; speed when DTC is set, and other data which can help for
diagnosis.
4. Before diagnostic
instrument record information, do not clear DTC.
|
|
|
|
4
|
Whether diagnostic instrument can communicate with
other modules on the same data circuit?
|
To step 5.
|
To step 6.
|
|
5
|
To “no communication with ABS control module” in fault procedure
of ESC control module.
|
|
|
|
6
|
To other electric control module unit for diagnosis.
|
|
|
|
7
|
1. Stop the engine.
2. Wait for 10s
3. Start the engine.
4. Observe ABS warning
light after starting the engine.
|
To step 8.
|
To step 9.
|
|
8
|
Does the light light up constantly?
|
To step 9.
|
To step 10.
|
|
9
|
To relevant lamp “ON” fault procedure.
|
|
|
|
10
|
To relevant lamp “disable” fault procedure.
|
|
|
ESC Common Symptols and
Analysis Procedures:
1. There is no
communication with ESC control module.
Typical causes for
unabling to communicate with ESC control module:
■ Diagnosis port has bad connection.
■ ESC control
module isn't grounded.
■ No battery or
ignition switch to supply voltage for ESC control module.
■ Data circuit has open-circuit/ short-circuit/ resistance is too
high.
2. ESC warning
light doesn't light up/ no DTC.
Typical causes for ESC warning
light failure and no DTC setting:
■ ESC warning
light bulb has fault/ socket is loose.
■ Instrument panel fuse is disconnected.
■ Instrument warning light drive module has fault.
■ ESC control
module has fault.
■ There is
open-circuit or short-circuit between ESC control module and instrument.
3. ABS warning
light lights up/ No DTC
Typical causes for ABS warning
light lighting up during the setting of DTC:
■ Circuit between instrument and ABS has open-circuit.
■ ABS control
module isn't grounded.
■ Circuit between instrument and ABS has short-circuit.
■ Instrument warning light drive module has fault.
■ ABS control
module has fault.
4. Brake warning
light lights up.
Typical causes for lighting up of
brake warning light under the condition that there is no DTC setting:
■ Parking brake switch has fault.
■ Brake fluid level is too low or brake fluid switch has
fault.
■ Circuit between instrument and ABS control module has
open-circuit.
■ Warning light circuit has fault.
■ Instrument has fault.
■ ABS control module has fault.
5. Brake warning
light doesn't light up/ no DTC setting
Typical causes for brake warning
light isn't light up and no DTC setting.
■ Bulb has fault/ socket is loose.
■ Instrument panel fuse is disconnected.
■ Instrument has fault.
■ ABS control module has fault.
■ Circuit between ABS control
module and instrument has ground wire connection.
ABS DTC Analysis
C129(01) -Voltage of
ESC control module: too high
Circuit Descriptions：
This circuit is used for
monitoring the level of voltage provided to ABS control module. If the voltage rises up to a certain
level, it may cause damage of system.
Conditions for Setting DTC:
If the voltage of terminal 32 of ABS
control module is more than 17 V/s, DTC 129 (01) can be set only when wheel
speed is more than 8 mile /h (5 mile/h).
Actions to be Taken When Setting DTC:
1. Store DTC C129(01).
2. Disable all relevant functions.
3. Light up warning light related to some
functions.
Conditions for Clearing DTC:
If the condition
for setting C129C (01) disappears, DTC can be cleared by using proper
diagnostic instrument.
DTC which
doesn't appear during 40 drive cycles will be cleared from history data.
Diagnostic Help:
Typical
causes for setting DTC C129 (01):
1. Charging
system has fault.
2. Bad
connection.
3. ESC
control module has fault.
|
C129(01)
-Voltage of ESC Control Module: Too High
|
|
Steps
|
Diagnostic
Actions
|
Expected
Value
|
Yes
|
No
|
|
1
|
Whether
inspection of circuit diagnosis is finished?
|
|
To step 2.
|
To step 3.
|
|
2
|
1. Connect a
voltmeter between positive pole and negative pole of battery.
2. Turn off all electric appliances.
3. Start the engine.
4. Monitor voltage
shown in voltmeter when engine runs at 2000 r/min for several seconds.
1.
Whether voltage is within the specified
range?
|
Less than 17V.
|
To step 3.
|
To step 5.
|
|
3
|
1. Connect
diagnostic instrument and select ESC data list.
2. Monitor battery
voltage shown in ESC data list when engine runs at 2000 r/s for several
seconds.
Whether
voltage is within the specified range?
|
Less than 17V.
|
To step 6.
|
To step 7.
|
|
4
|
Conduct
test for Diagnostic circuit
|
|
|
|
|
5
|
Refer
to the diagnosis of start system and charging system.
|
|
|
|
|
6
|
The
condition is intermittent.
|
|
|
|
|
7
|
Replace ESC control module. Whether the repair is finished?
|
|
To step 8.
|
|
|
8
|
Use
a diagnostic instrument to clear DTC. When there is a condition to set DTC,
whether DTC is reset?
When
there is condition to set DTC, whether DTC is reset?
|
|
System
is OK
|
To step 1.
|
C129C(02) -
Voltage of ESC control module: too low
Circuit Description:
This circuit is used
for monitoring the level of voltage provided to ESC control module. If the voltage drops to a certain
level, it is unable to ensure all performances of the system are normal. During
ESC operation, there are some conditions which may cause battery voltage to
drop. Therefore, it is necessary to monitor voltage before ESC operation to
show good charging condition. And so do as the condition when the voltage may
drop dramatically. Conditions for setting DTC when there is no ESC or initialization
is that DTC C1102 can be set only when wheel speed is more than 8 km/h if the
voltage of terminal 32 of ESC control module is less than 10.5V. Under the
condition that there is ESC, DTC C1102 can be set only when ignition voltage is
less than 10.5V and battery voltage is less than 9.0V.
Actions to be Taken When Setting DTC:
1. Store DTC C129C (02).
2. Disable all
relevant functions.
3. Light up warning
light related to some functions.
Conditions for Clearing DTC:
1. If the condition for setting DTC C129C
(02) disappears, DTC can be cleared by using proper diagnostic instrument.
C1102 - Voltage of ESC control
module: too low
Circuit Descriptions:
This circuit is used
for monitoring the level of voltage provided to ESC control module. If the voltage drops to a certain
level, it is unable to ensure all performances of the system are normal. During
ESC operation, there are some conditions which may cause battery voltage to drop.
Therefore, it is necessary to monitor voltage before ESC operation to show good
charging condition. And so do as the condition when the voltage may drop
dramatically. Conditions for setting DTC when there is no ESC or initialization
is that DETCC1102 can be set only when wheel speed is more than 8 km/h if the
voltage of terminal 32 of ABS control module is less than 10.5V. Under the
condition that there is ESC, C129C(02) can be set only when ignition voltage is
less than 10.5V and battery voltage is less than 9.0V.
Actions to be Taken When Setting DTC:
1. Store DTCC129C
(02).
2. Disable all
relevant functions.
3. Light up warning
light related to some functions.
Conditions for Clearing DTC:
1. If the
condition for setting DTC C129C (02) disappears, DTC can be cleared by using
proper diagnostic instrument.
2. DTC which doesn't appear during 40
drive cycles will be cleared from history data.
Diagnostic Help:
Typical
causes for setting DTC C129C (02):
■ Battery voltage is weak or used up.
■ Battery terminal has bad connection.
■ Originally assembled or after-sales optional equipment (adding load)
leads too much voltage from battery.
■ Battery has bad ground wire connection on the engine cylinder
block or chassis.
■ Terminal of ESC
control module has bad connection.
■ ESC control
module has bad ground wire connection.
For charging system fault
(engine), it is necessary to completely inspect wires and connectors. Careless
and incomplete inspection of wiring and connectors may cause the replacement of
parts, but the fault can't be eliminated.
|
C129C(102)
- Voltage of ESC Control Module: Too Low
|
|
Steps
|
Diagnostic Actions
|
Expected
Value
|
Yes
|
No
|
|
1
|
Whether the inspection of Diagnostic circuit is
finished?
|
|
To step 2.
|
To step 6.
|
|
2
|
1. Inspect battery
load.
2. Inspect charging
system.
3. Carry out
additional load test.
Whether the tests for battery, charging system and
additional load test pass?
|
Battery must keep more than 9.6V for 10s and not more than 20
milliampere.
|
To step 3.
|
To step 7.
|
|
3
|
1. Stop the engine.
2. Disconnect
positive and negative poles of battery.
3. Disconnect wire harness from ESC
control module.
4. Inspect whether
the following items have bad connection:
Battery terminal cable
Negative cable to engine or chassis positive cable to engine
coil or terminal box Terminal 32 and terminal 38 of ESC control module.
Ground wire of ESC control module to chassis ground
wire. Whether above
connections are good?
|
|
To step 4.
|
To step 8.
|
|
4
|
1. ESC control module
is still disconnected.
2. Battery cable is
still disconnected.
3. Connect an
ohmmeter between terminal 38 of ESC control module wire harness and negative
cable of battery.
Whether the resistance is within the specified range?
|
Less than 2Ω.
|
To step 5.
|
To step 9.
|
|
5
|
1. Connect battery
cable.
2. ESC control module is still disconnected.
3. Turn on ignition
switch.
4. Use a voltmeter
to measure the voltage between terminal 32 and terminal 38 of ESC control
module wire harness. Whether voltage value between two terminals exceeds
the specified range.
|
Battery voltage
|
To step 11.
|
To step 10.
|
|
Steps
|
Diagnostic
Actions
|
Expected
Value
|
Yes
|
No
|
|
6
|
Conduct
test for Diagnostic circuit
|
|
|
|
|
7
|
Repair charging system and/ or recharge / replace battery and/
or find out the cause and repair additional leakage of voltage
Whether
the repair is finished?
|
|
To step 12.
|
|
|
8
|
If necessary, repair terminal and/ or connector. Whether the repair is finished?
|
|
To step 12.
|
|
|
9
|
Find out the causes and repair the fault of high resistance between
negative cable of battery and wire harness connector of ABS control module.
Whether
the repair is finished?
|
|
To step 12.
|
|
|
10
|
Find out the causes and repair the fault of terminal voltage of
ESC control module. Whether
the repair is finished?
|
|
To step 12.
|
|
|
11
|
Replace ESC control module. Whether the repair is finished?
|
|
To step 12.
|
|
|
12
|
Use
a diagnostic instrument to clear DTC. When there is a condition to set DTC,
whether DTC is reset?
When
there is condition to set DTC, whether DTC is reset?
|
|
System
is OK
|
To step 1.
|
C0031(0C) - front left wheel speed sensor: open-circuit/ short-circuit
Circuit Descriptions:
When wheel is rotating, with the
increase of wheel speed, speed sensor can produce a squre wave signal. ESC control module uses the frequency of this square wave signal to
calculate wheel speed. Speed sensor is connected to ESC control module by
“twisted pair wire”.
Conditions for Setting DTC:
DTC C0031(0C) can be
set at any time when ESC control module detects that the front left wheel speed
circuit has open-circuit, short-circuit to the ground wire connection or
short-circuit to battery.
Actions to be Taken When Setting DTC:
1. Store DTC C00C1 (0C).
2. Disable all relevant functions.
3. Light up warning light related to some
functions.
Conditions for Clearing DTC:
1. If the condition for setting DTC C0031 (0C)
disappears, DTC can be cleared by using proper diagnostic instrument.
2. DTC which doesn't appear during 40 ignition cycles
will be cleared from history data.
Diagnostic Help:
When intermittent DTC is detected,
please completely inspect wiring and connectors. This includes:
1. Dismantle protective guide pipe, and inspect
whether circuit is damaged, has short-circuit or contaminated.
2. Inpsect whether
terminal is deformed and damaged.
3. Use
standby positive/ negative terminal to inspect the contact maintaining ability
of terminal.
4. Dismantle
terminals from connector, and inspect whether the wire terminal of voltage wire
is falsely connected.
|
C0031(0C)
- Front Left Wheel Speed Sensor: Open-Circuit/ Short-Circuit
|
|
Steps
|
Diagnostic Actions
|
Expected
Value
|
Yes
|
No
|
|
1
|
Whether inspection of circuit diagnosis is finished?
|
|
To step 2.
|
To step 14.
|
|
2
|
1. Stop the engine.
2. Inspect
whether front left wheel speed sensor, sensor wire harness and gear ring have
physical damage?
Whether any physical damage is found?
|
|
To step 15.
|
To step 3.
|
|
3
|
Test vehicle on various wheel speed and road surface. Whether C0031 (0C) is
reset?
Whether above connections are good?
|
|
To step 4.
|
To step 16.
|
|
4
|
1. Stop
the engine and vehicle.
2. Rise
up and properly support the vehicle.
3. Disconnect
front left wheel speed sensor wire harness.
4. Connect
an ohmmeter to terminal 1 and terminal 2 of front left wheel speed sensor.
Whether
voltage value is within the specified range?
|
75Ω士1%
|
To step 5.
|
To step 17.
|
|
5
|
1. Disconnect front
left wheel jumping connection wire harness from front left wheel speed
sensor.
2. Connect an
ohmmeter terminal 1 between vehicle body ground wire and front left
wheel speed sensor.
Whether the resistance is within the specified range?
|
01 (open-circuit)
|
To step 6.
|
To step 17.
|
|
6
|
1. Disconnect wire
harness from ESC control module.
2. Disconnect front
left wheel speed sensor wire harness.
3. Connect an
ohmmeter to terminal 22 of ESC control module wire harness, and then connect
to terminal 2 of front left wheel speed sensor.
Whether the resistance is within the specified range?
|
Less than 2Ω.
|
To step 7.
|
To step 18.
|
|
7
|
1. Disconnect wire harness from ESC control module.
2. Disconnect front
left wheel speed sensor wire harness.
3. Connect an
ohmmeter to terminal 34 of ESC control module wire harness, and then connect
to front left wheel speed sensor connector 1.
Whether the resistance is within the specified range?
|
Less than 2Ω.
|
To step 8.
|
To step 19.
|
|
8
|
1. Disconnect wire
harness from ESC control module.
2. Disconnect front
left wheel speed sensor wire harness.
3. Connect a
voltmeter to terminal 22 of ESC control module wire harness, and then connect
to vehicle body ground wire.
Whether voltage value is within the specified range?
|
Less than 1V
|
To step 9.
|
To step 20.
|
|
Steps
|
Diagnostic Actions
|
Expected Value
|
Yes
|
No
|
|
9
|
1. Disconnect wire
harness from ESC control module.
2. Disconnect front
left wheel speed sensor wire harness.
3. Connect a
voltmeter to terminal 34 of ESC control module wire harness, and then connect
to vehicle body ground wire.
Whether voltage value
is within the specified range?
|
Less than 1V
|
To step 10.
|
To step 21.
|
|
10
|
1. Disconnect wire
harness from ESC control module.
2. Disconnect front
left wheel speed sensor wire harness.
3. Connect an
ohmmeter to terminal 22 of ESC control module wire harness, and then connect
to vehicle body ground wire.
Whether the resistance
is within the specified range?
|
OL(open-circuit)
|
To step 11.
|
To step 22.
|
|
11
|
1. Disconnect wire
harness from ESC control module.
2. Disconnect front
left wheel speed sensor wire harness.
3. Connect an
ohmmeter to terminal 34 of ABS control module wire harness, and then connect
it to vehicle body ground wire.
Whether the resistance
is within the specified range?
|
OL(open-circuit)
|
To step 12.
|
To step 23.
|
|
12
|
1. Disconnect wire
harness from ABS control module.
2. Disconnect front
left wheel speed sensor wire harness.
3. Connect an
ohmmeter to terminal 22 and terminal 34 of ABS control module wire harness.
4. Whether the
resistance is within the specified range?
|
OL(open-circuit)
|
To step 13.
|
To step 24.
|
|
13
|
1. Replace front left
wheel speed sensor wire harness.
2. Test vehicle on
various wheel speed and road surface.
Whether C0031 (0C) is
reset?
|
|
System is OK
|
To step 25.
|
|
14
|
Conduct Diagnostic
circuit inspection.
|
|
|
|
|
15
|
Repair the damaged
front left wheel speed sensor, wire harness and/ or gear ring.
Whether the repair is
finished?
|
|
To step 26.
|
|
|
16
|
DTC C0031 (0C) is
intermittent.
|
|
|
|
|
17
|
Replace front left
wheel speed sensor.
Whether the repair is
finished?
|
|
To step 26.
|
|
|
18
|
Repair open-circuit
or high resistance between terminal 34 and terminal 1.
Whether the repair is
finished?
|
|
To step 26.
|
|
|
19
|
Repair open-circuit
or high resistance between terminal 22 and terminal 2.
Whether the repair is
finished?
|
|
To step 26.
|
|
|
20
|
Repair voltage
short-circuits between terminal 34 and terminal 1.
Whether the repair is
finished?
|
|
To step 26.
|
|
|
21
|
Repair voltage
short-circuits between terminal 22 and terminal 2.
Whether the repair is
finished?
|
|
To step 26.
|
|
|
22
|
Repair ground wire
short-circuits between terminal 34 and terminal 1.
Whether the repair is
finished?
|
|
To step 26.
|
|
|
Steps
|
Diagnostic
actions
|
Expected
value
|
Yes
|
No
|
|
23
|
Repair ground wire
short-circuits between terminal 22 and terminal 2.
Whether the repair is
finished?
|
|
To step 26.
|
|
|
24
|
Repair the short-circuit between two circuits. Whether the repair is finished?
|
|
To step 26.
|
|
|
25
|
Replace ESC control module. Whether the repair is finished?
|
|
To step 26.
|
|
|
26
|
Use
a diagnostic instrument to clear DTC. When there is a condition to set DTC,
whether DTC is reset?
When
there is condition to set DTC, whether DTC is reset?
|
|
System
is OK
|
|
C0031 (08) - front left wheel speed sensor: exceeding limit, wrong
performance, intermittent signal.
Circuit Descriptions:
When wheel is rotating, with the
increase of wheel speed, speed sensor can produce a squre wave signal. ABS control module uses the frequency of this square wave signal to
calculate wheel speed. Speed sensor is connected to ABS control module by
“twisted pair wire”.
Conditions for Setting DTC:
DTC
C0031 (08) can be set only when all the following conditions occur:
1. DTC C0031 (0C) or C0034 (0C) or C0037
(0C) or C003A (0C) is not current.
2. Disconnect brake
switch.
3. Speed acceleration
or decleration of front left wheel exceeds proper range.
Actions to be Taken When Setting DTC:
1. Store DTC C0031(08).
2. Disable all relevant functions.
3. Light up warning light related to some
functions.
Conditions for Clearing DTC:
1. If the condition
for setting DTC C0031(08) disappears, DTC can be cleared by using proper
diagnostic instrument.
2. DTC which doesn't
appear during 40 ignition cycles will be cleared from history data.
Diagnostic Help:
When intermittent DTC is detected,
please completely inspect wiring and connectors. This includes:
1. Dismantle protective guide pipe, and inspect whether
circuit is damaged, has short-circuit or contaminated.
2. Inspect whether
terminal is deformed and damaged.
3. Use standby positive/ negative terminal to inspect
the contact maintaining ability of terminal.
4. Dismantle terminals
from connector, and inspect whether the wire terminal of voltage wire is
falsely connected.
|
C0031
(08) - Front Left Wheel Speed Sensor: Exceeding Limit,
Wrong Performance, And Intermittent Signal.
|
|
Steps
|
Diagnostic Actions
|
Expected Value
|
Yes
|
No
|
|
1
|
Whether inspection of
circuit diagnosis is finished?
|
|
To step 2.
|
To step 12.
|
|
2
|
Whether the C0031 (08)
is set to be current DTC or history DTC?
|
|
To step 13.
|
To step 3.
|
|
3
|
1. Stop the engine and vehicle.
2. Inspect whether front left wheel speed sensor
and sensor wire harness are damaged?
3. Completely
inspect front left gear ring to learn whether it has damage (crack, shortage
of teeth, loosening).
Whether physical damage
is found?
|
|
To step 14.
|
To step 5.
|
|
4
|
1. Parking
2. Connect diagnostic instrument and select data
list.
3. Monitor wheel speed sensor.
4. Start the engine and monitor wheel speed sensor
when vehicle doesn't move.
5. Slightly step accelerator pedal to increase
engine idle speed.
Whether C0031 (08) is
reset or reading of front left wheel speed exceeds 0km/h when vehicle stops?
|
|
To step 15.
|
To step 5.
|
|
5
|
1. Still connect diagnostic instrument.
2. Monitor wheel speed sensor.
3. Carry out trial run of vehicle at maximum speed,
and then slowly reduce the speed to Zero.
Do this operation for
several times.
Whether C0031 (08) is
reset or change of front left wheel speed exceeds 5 km/h when comparing with
other wheels during vehicle is traveling.
|
|
To step 6.
|
To step 16.
|
|
6
|
1. Stop the engine and vehicle.
2. Rise up and properly support the vehicle.
3. Disconnect front left wheel speed sensor wire
harness.
4. Connect an ohmmeter to two terminals of front
left wheel speed sensor.
Is the resistance
within the specified range?
|
75Ω±1%
|
To step 7.
|
To step 17.
|
|
7
|
1. Wheel speed sensor is still disconnected with
jumping wire harness.
2. Connect a voltmeter to two terminals of front
left wheel speed sensor.
3. Select millivolt scale.
4. Rotate front left wheel; meanwhile observe
voltage on measuring scale.
|
At least 100 millivolt
|
To step 8.
|
To step 17.
|
|
8
|
1. Disconnect wire harness from ESC control module.
2. Disconnect front left wheel speed sensor wire
harness.
3. Connect an ohmmeter to terminal 22 of ABS
control module wire harness, and then connect it to connector 2 of front left
wheel speed sensor.
Whether the resistance
is within the specified range?
|
Less than 2Ω.
|
To step 9.
|
To step 18.
|
|
9
|
1. Disconnect
wire harness from ESC control module.
2. Disconnect front left wheel speed sensor wire
harness.
3. Connect an ohmmeter to terminal 34 of ABS control module
wire harness, and then connect it to connector 1 of front left wheel speed
sensor.
Whether the resistance
is within the specified range?
|
Less than 2Ω.
|
To step 10.
|
To step 19.
|
|
Steps
|
Diagnostic Actions
|
Expected value
|
Yes
|
No
|
|
10
|
1. Disconnect wire harness from ABS control module.
2. Disconnect front left wheel speed sensor wire
harness.
3. Connect an ohmmeter to terminal 22 and 34 of ABS
control module wire harness.
4. Whether the resistance is within the specified
range?
|
OL
(open-circuit)
|
To step 11.
|
To step 20.
|
|
11
|
1. Replace front left wheel speed sensor wire
harness.
2. Test vehicle on various wheel speed and road
surface. Whether C0031 (08) is reset?
|
|
system is OK
|
To step 21.
|
|
12
|
Carry out inspection of diagnosis circuit before making DTC C0031
(08) fault chart.
|
|
|
|
|
13
|
Make C1200 diagnostic chart before making DTC C0031 (08) fault
chart.
|
|
|
|
|
14
|
Repair the damaged front left wheel speed sensor, wire harness
and/ or gear ring.
Whether the repair is finished?
|
|
To step 22.
|
|
|
15
|
C0031 (08) is caused by the condition that ignition noise is
induced to front left speed sensor circuit.
Inspect whether front left ABS module wire harness and/ or
sensor wire harness has potential ignition noise source, such as spark plug
wire. According to the need, re-arrange wiring.
Whether the repair is finished?
|
|
To step 22.
|
|
|
16
|
DTC C0031 (08) is intermittent.
|
|
|
|
|
17
|
Replace front left wheel speed sensor.
Whether the repair is finished?
|
|
To step 22.
|
|
|
18
|
Repair open-circuit or high resistance between terminal 22 and
terminal 2.
Whether the repair is finished?
|
|
To step 22.
|
|
|
19
|
Repair open-circuit or high resistance between terminal 34 and
terminal 1.
Whether the repair is finished?
|
|
To step 22.
|
|
|
20
|
Repair short-circuits between two wires.
Whether the repair is finished?
|
|
To step 22.
|
|
|
21
|
Replace ESC control module.
Whether the repair is finished?
|
|
To step 22.
|
|
|
22
|
Use diagnostic instrument to clear DTC.
When there is condition to set DTC, whether DTC is
reset?
|
|
System is OK
|
To step 1.
|
C0031(03) - Rear Left Wheel
Speed Sensor: Fail Signal/ No Signal
Circuit Description:
When wheel is rotating, with the
increase of wheel speed, speed sensor can produce a squre wave signal. ECU uses the frequency of this square wave signal to calculate wheel
speed. Speed sensor is connected to ECU control module by “twisted pair wire”.
Conditions for Setting DTC:
DTC C0031(03) can be
set only when all the following conditions occur:
1. DTCC0031 (0C)
or C0034 (03) or C0037 (0C) or C003A (0C) is not current.
2. Disable all
relevant functions.
3. Disconnect
brake switch. Front left wheel speed equals to 0, and all other wheel speed
sensors are: at least more than 8 km/h within 2.5s.
Conditions for Clearing DTC:
1. If the
condition for setting DTCC0031 (03) disappears, DTC can be cleared by using
proper diagnostic instrument.
2. DTC which
doesn't appear during 40 ignition cycles will be cleared from history data.
Diagnostic Assistance:
When intermittent DTC is detected,
please completely inspect wiring and connectors.
This will includes:
1. Dismantle
protective guide pipe, and inspect whether circuit is damaged, has
short-circuit or contaminated.
2. Inspect
whether terminal is deformed and damaged.
3. Use standby
positive/ negative terminal to inspect the contact maintaining ability of
terminal.
|
C0031(03)
- Front Left Wheel Speed Sensor: Fail Signal/ No Signal
|
|
Steps
|
Diagnostic Actions
|
Expected Value
|
Yes
|
No
|
|
1
|
Whether inspection of circuit diagnosis is finished?
|
|
To step 2.
|
To step 12.
|
|
2
|
1. Stop the engine.
2. Inspect whether
front left wheel speed sensor, sensor wire harness and gear ring have physical
damage?
Whether physical damage is found?
|
|
To step 13.
|
To step 3.
|
|
3
|
Whether the C0031 (03) is set to be current DTC or history DTC?
|
|
Step 14
|
To step 4.
|
|
4
|
1. Connect
diagnostic instrument and select data list.
2. Monitor wheel
speed sensor.
3. Carry out trial
run of vehicle at 24 km/h speed, and then slowly reduce the speed to Zero. Do
this operation for several times.
Whether C0031 (03) is reset or front left wheel speed reduces to
Zero before vehicle stops completely?
|
|
To step 5.
|
To step 15.
|
|
5
|
1. Stop the engine.
2. Rise up and
properly support the vehicle.
3. Disconnect wire
harness from ESC control module.
4. Connect a
voltmeter to terminal 22 and terminal 34 of ABS control module wire harness.
5. Select AC
millivolt scale.
6. Rotate front left
wheel and observe voltage. (When wheel speed increases, voltage also
increases).Whether square wave value is within the specified range?
|
At least 100 millivolt
|
To step 16.
|
To step 6.
|
|
6
|
1. Disconnect front
left wheel speed sensor wire harness.
2. Connect an
ohmmeter to two terminals of front left wheel speed sensor.
Whether voltage value is within the specified range?
|
75Ω士1%
|
To step 7.
|
To step 17.
|
|
7
|
1. Disconnect front
left wheel speed sensor wire harness.
2. Connect a
voltmeter to two terminals of front left wheel speed sensor.
3. Select AC
millivolt scale.
4. Rotate front left
wheel and observe voltage. (When wheel speed increases, voltage also
increases).Whether square wave value is within the specified range?
|
At least 100 millivolt
|
To step 8.
|
To step 17.
|
|
8
|
1. Disconnect wire
harness from ESC control module.
2. Disconnect front
left wheel speed sensor wire harness.
3. Connect an
ohmmeter to terminal 22 and 34 of ABS control module wire harness.
Whether voltage value is within the specified range?
|
OL(open-circuit)
|
To step 9.
|
To step 18.
|
|
Steps
|
Diagnostic Actions
|
Expected value
|
Yes
|
No
|
|
9
|
1. Disconnect wire
harness from ABS control module.
2. Disconnect front
left wheel speed sensor wire harness.
3. Connect an
ohmmeter to terminal 34 of ABS control module wire harness, and then connect
it to terminal 1 of sensor connector.
Whether voltage value
is within the specified range?
|
Less than 2Ω.
|
To step 10.
|
To step 19.
|
|
10
|
1. Disconnect wire harness from ESC control module.
2. Disconnect front left wheel speed sensor wire
harness.
3. Connect an ohmmeter to terminal 22 of ABS
control module wire harness, and then connect it to terminal 2 of sensor
connector.
Whether voltage value is within the specified range?
|
Less than 2Ω.
|
To step 11.
|
To step 20.
|
|
11
|
1. Replace front left wheel speed sensor connector.
2. Test vehicle on various wheel speed and road
surface.
Whether it is reset?
|
|
System is OK
|
To step 16.
|
|
12
|
Before treating this fault, inspect diagnostic
circuit.
|
|
|
|
|
13
|
Repair the damaged front left wheel speed sensor, wire harness
and/ or gear ring.
Whether the repair is finished?
|
|
To step 21.
|
|
|
14
|
Diagnose DTC C0031 (0C) before carrying out this testing step.
|
|
|
|
|
15
|
DTC C0031 (03) is intermittent.
|
|
|
|
|
16
|
Replace ESC control module.
Whether the repair is finished?
|
|
To step 21.
|
|
|
17
|
Replace front left wheel speed sensor.
Whether the repair is finished?
|
|
To step 21.
|
|
|
18
|
Find out and repair the short-circuit fault between 2 circuits.
Whether the repair is finished?
|
|
To step 21.
|
|
|
19
|
Repair open-circuit or high resistance between terminal 34 and
terminal 1.
Whether the repair is finished?
|
|
To step 21.
|
|
|
20
|
Repair open-circuit or high resistance between terminal 22 and
terminal 2.
Whether the repair is finished?
|
|
To step 21.
|
|
|
21
|
Use diagnostic instrument to clear DTC.
When there is condition to set DTC, whether DTC is
reset?
|
|
System is OK
|
To step 1.
|
C0034(0C) - front right
wheel speed sensor: open-circuit/ short-circuit
Circuit Descriptions
When wheel is rotating, with the
increase of wheel speed, speed sensor can produce a squre wave signal. ABS control module uses the frequency of this square wave signal to
calculate wheel speed. Speed sensor is connected to ABS control module by
“twisted pair wire”.
Conditions for Setting DTC:
DTCC 0034(0C) can be
set at any time when ABS control module detects that the front right wheel
speed circuit has open-circuit, short-circuit to the ground wire connection
or short-circuit to battery.
Actions to Be Taken When Setting DTC:
1. Store DTC C0034 (0C) „
2. Disable all
relevant functions.
3. Light up warning
light related to some functions.
Conditions for Clearing DTC:
1. If the condition for setting DTC C0034
(0C) disappears, DTC can be cleared by using proper diagnostic instrument.
2. DTC which doesn't appear during 40
ignition cycles will be cleared from history data.
Diagnostic Help:
When intermittent DTC is detected,
please completely inspect wiring and connectors. This will includes:
1. Dismantle protective guide pipe,
and inspect whether circuit is damaged, has short-circuit or contaminated.
2. Inpsect whether
terminal is deformed and damaged.
3. Use standby positive/ negative
terminal to inspect the contact maintaining ability of terminal.
4. Dismantle terminals from connector, and inspect
whether the wire terminal of voltage wire is falsely connected.
|
C0034(0C)
- Front Right Wheel Speed Sensor: Open-Circuit/ Short-Circuit
|
|
Steps
|
Diagnostic Actions
|
Expected Value
|
Yes
|
No
|
|
1
|
Whether inspection of
circuit diagnosis is finished?
|
|
To step 2.
|
To step 14.
|
|
2
|
1. Stop the engine.
2. Inspect whether
front right wheel speed sensor, sensor wire harness and gear ring have
physical damage?
Whether physical damage
is found?
|
|
To step 15.
|
To step 3.
|
|
3
|
Test vehicle on various
wheel speed and road surface. Whether C0034 (0C) is reset?
Whether above
connections are good?
|
|
To step 4.
|
To step 16.
|
|
4
|
1. Stop the engine
and vehicle.
2. Rise up and
properly support the vehicle.
3. Disconnect front
right wheel speed sensor wire harness.
4. Connect an
ohmmeter to terminal 1 and terminal 2 of front right wheel speed sensor.
Whether voltage value
is within the specified range?
|
75Ω士1%
|
To step 5.
|
To step 17.
|
|
5
|
1. Disconnect front right
wheel jumping wire harness from front right wheel speed sensor.
2. Connect an
ohmmeter to terminal 1 between vehicle body ground wire and front
right wheel speed sensor.
Whether the resistance
is within the specified range?
|
01 (open-circuit)
|
To step 6.
|
To step 17.
|
|
6
|
1. Disconnect wire
harness from ABS control module.
2. Disconnect front
right wheel speed sensor connector.
3. Connect an
ohmmeter to terminal 6 of ABS control module wire harness, and then connect
it to terminal 2 of front right wheel speed sensor.
Whether voltage value
is within the specified range?
|
Less than 2Ω.
|
To step 7.
|
To step 18.
|
|
7
|
1. Disconnect wire
harness from ESC control module.
2. Disconnect front
right wheel speed sensor connector.
3. Connect an
ohmmeter to terminal 18 of ESC control module wire harness, and then connect
it to connector 1 of front right wheel speed sensor.
Whether voltage value
is within the specified range?
|
Less than 2Ω.
|
To step 8.
|
To step 19.
|
|
8
|
1. Disconnect wire
harness from ESC control module.
2. Disconnect front
right wheel speed sensor connector.
3. Connect a
voltmeter to terminal 6 of ABS control module wire harness, and then connect
it to vehicle body ground wire.
Whether voltage value
is within the specified range?
|
Less than 1V
|
To step 9.
|
To step 20.
|
|
9
|
1. Disconnect wire
harness from ESC control module.
2. Disconnect front
right wheel speed sensor connector.
3. Connect a
voltmeter to terminal 18 of ABS control module wire harness, and then connect
it to vehicle body ground wire.
Whether voltage value
is within the specified range?
|
Less than 1V
|
To step 10.
|
To step 21.
|
|
Steps
|
Diagnostic Actions
|
Expected Value
|
Yes
|
No
|
|
10
|
1. Disconnect wire harness from ESC control module.
2. Disconnect front right wheel speed sensor
connector.
3. Connect an ohmmeter to terminal 6 of ABS control
module wire harness, and then connect it to vehicle body ground wire.
Whether the resistance
is within the specified range?
|
OL(open-circuit)
|
To step 11.
|
To step 22.
|
|
11
|
1. Disconnect wire harness from ESC control module.
2. Disconnect front right wheel speed sensor
connector.
3. Connect an ohmmeter to terminal 18 of ABS
control module wire harness, and then connect it to vehicle body ground
wire.
Whether voltage value
is within the specified range?
|
OL(open-circuit)
|
To step 12.
|
To step 23.
|
|
12
|
1. Disconnect wire harness from ESC control module.
2. Disconnect front right wheel speed sensor
connector.
3. Connect an ohmmeter to terminal 6 and 18 of ABS
control module wire harness.
4. Whether the resistance is within the specified
range?
|
OL(open-circuit)
|
To step 13.
|
To step 24.
|
|
13
|
1. Replace front right wheel speed sensor wire
harness.
2. Test vehicle on various wheel speed and road
surface.
Whether C0034 (0C) is
reset?
|
|
System is OK
|
To step 25.
|
|
14
|
Conduct diagnostic
circuit inspection.
|
|
|
|
|
15
|
Repair the damaged
front right wheel speed sensor, wire harness and/ or gear ring.
Whether the repair is
finished?
|
|
To step 26.
|
|
|
16
|
C0034 (0C) is
intermittent.
|
|
To step 26.
|
|
|
17
|
Replace front right
wheel speed sensor wire harness.
Whether the repair is
finished?
|
|
To step 26.
|
|
|
18
|
Repair open-circuit
or high resistance between terminal 18 and terminal 1.
Whether the repair is
finished?
|
|
To step 26.
|
|
|
19
|
Repair open-circuit
or high resistance between terminal 6 and terminal 2.
Whether the repair is
finished?
|
|
To step 26.
|
|
|
20
|
Repair voltage
short-circuits between terminal 18 and terminal 1.
Whether the repair is
finished?
|
|
To step 26.
|
|
|
21
|
Repair voltage
short-circuits between terminal 6 and terminal 2.
Whether the repair is
finished?
|
|
To step 26.
|
|
|
22
|
Repair ground wire
short-circuits between terminal 18 and terminal 1.
Whether the repair is
finished?
|
|
To step 26.
|
|
|
23
|
Repair ground wire
short-circuits between terminal 6 and terminal 2.
Whether the repair is
finished?
|
|
To step 26.
|
|
|
24
|
Repair the
short-circuit between two circuits.
Whether the repair is
finished?
|
|
To step 26.
|
|
|
25
|
Replace ESC control
module.
Whether the repair is
finished?
|
|
To step 26.
|
|
|
26
|
Use a diagnostic
instrument to clear DTC. When there is a condition to set DTC, whether DTC is
reset?
|
|
System is OK
|
To step 1.
|
C1205- Front Right Wheel
Speed Sensor: Fail Signal/ No Signal
Circuit Description:
When wheel is rotating, with the
increase of wheel speed, speed sensor can produce a squre wave signal. ECU uses the frequency of this square wave signal to calculate wheel
speed. Speed sensor is connected to ECU control module by “twisted pair wire”.
Conditions for Setting DTC:
DTCC1205 can be set
only when all the following conditions occur:
1. DTCC1200 or
C1203 or C1206 or C1209 is not current.
2. ABS is failed.
3. Disconnect brake switch. Front right
wheel speed equals to 0, and all other wheel speed sensors are: at least more
than 8 km/h within 2.5s.
Conditions for Clearing DTC:
1. If the
condition for setting DTCC1205 disappears, DTC can be cleared by using proper
diagnostic instrument.
2. DTC which doesn't appear during 100
ignition cycles will be cleared from history data.
Diagnostic Help:
When intermittent DTC is detected,
please completely inspect wiring and connectors.
This includes:
1. Dismantle
protective guide pipe, and inspect whether circuit is damaged, has
short-circuit or contaminated.
2. Inspect whether
terminal is deformed and damaged.
3. Use standby
positive/ negative terminal to inspect the contact maintaining ability of
terminal.
C1205- Front Right
Wheel Speed Sensor: Fail Signal/ No Signal
|
Steps
|
Diagnostic
Actions
|
Expected
Value
|
Yes
|
No
|
|
1
|
Whether
the inspection of Diagnostic circuit is finished?
|
|
To step 2.
|
To step 12.
|
|
2
|
1. Stop the engine.
2. Inspect
whether front right wheel speed sensor, sensor wire harness and gear ring
have physical damage?
Whether
physical damage is found?
|
|
To step 13.
|
To step 3.
|
|
3
|
Whether the C1203 is set to be current DTC or history DTC?
|
|
To step 14.
|
To step 4.
|
|
4
|
1. Connect
diagnostic instrument and select data list.
2. Monitor
wheel speed sensor.
3. Carry out trial run of vehicle at 24 km/h speed, and then
slowly reduce the speed to Zero. Do this operation for several times.
Whether C1205 is reset or front right wheel speed reduces to
Zero before vehicle stops completely?
|
|
To step 5.
|
To step 15.
|
|
Steps
|
Diagnostic Actions
|
Expected Value
|
Yes
|
No
|
|
5
|
1. Stop
the engine.
2. Rise
up and properly support the vehicle.
3. Disconnect
wire harness from ESC control module.
4. Connect
a voltmeter to terminal 6 and terminal 18 of ABS control module wire harness.
5. Select
AC millivolt scale.
6. Rotate
front right wheel, and observe voltmeter. (When
wheel speed increases, voltage also increases).
Whether square wave
value is within the specified range?
|
At least 100 millivolt
|
To step 16.
|
To step 6.
|
|
6
|
1. Disconnect
front right wheel speed sensor wire harness.
2. Connect
an ohmmeter to two terminals of front right wheel speed sensor.
Whether voltage value
is within the specified range?
|
75Ω士1%
|
To step 7.
|
To step 17.
|
|
7
|
1. Disconnect
front right wheel speed sensor connector.
2. Connect
a voltmeter to two terminals of front right wheel speed sensor.
3. Select
millivolt scale.
4. Rotate
front right wheel, and observe voltmeter. (When wheel speed increases,
voltage also increases).
Whether square wave
value is within the specified range?
|
At least 100 millivolt
|
To step 8.
|
To step 17.
|
|
8
|
1. Disconnect
wire harness from ESC control module.
2. Disconnect
front right wheel speed sensor connector.
3. Connect
an ohmmeter to terminal 6 and terminal18 of ABS control module wire harness.
Whether the resistance
is within the specified range?
|
OL(open-circuit)
|
To step 9.
|
To step 18.
|
|
9
|
1. Disconnect
wire harness from ESC control module.
2. Disconnect
front right wheel speed sensor connector.
3. Connect
an ohmmeter to terminal 18 of ABS control module wire harness, and then
connect it to terminal 1 of sensor connector.
Whether voltage value
is within the specified range?
|
Less than 2Ω.
|
To step 10.
|
To step 19.
|
|
10
|
1. Disconnect
wire harness from ESC control module.
2. Disconnect
front right wheel speed sensor connector.
3. Connect
an ohmmeter to terminal 6 of ABS control module wire harness
|
Less than 2Ω.
|
To step 11.
|
To step 20.
|
|
And then connect it
to connector terminal 2. Whether voltage value is within the specified range?
|
|
|
|
|
11
|
1. Replace
rear right wheel speed sensor connector.
2. Test
vehicle on various wheel speed and road surface.
Whether it is reset?
|
|
System is OK
|
To step 16.
|
|
12
|
Before treating this
fault, inspect Diagnostic circuit.
|
|
|
|
|
13
|
Repair the damaged
front right wheel speed sensor, wire harness and/ or gear ring.
Whether the repair is
finished?
|
|
To step 21.
|
|
|
Steps
|
Diagnostic
Actions
|
Expected
Value
|
Yes
|
No
|
|
14
|
Diagnose C1203 before carrying out this testing step.
|
|
|
|
|
15
|
DTC C1205 is intermittent.
|
|
|
|
|
16
|
Replace ESC control module.
Whether
the repair is finished?
|
|
To step 21.
|
|
|
17
|
Replace
front right wheel speed sensor wire harness.
Whether
the repair is finished?
|
|
To step 21.
|
|
|
18
|
Find out and repair the short-circuit fault between 2 circuits.
Whether
the repair is finished?
|
|
To step 21.
|
|
|
19
|
Repair open-circuit or high resistance between terminal 18 and
terminal 1.
Whether
the repair is finished?
|
|
To step 21.
|
|
|
20
|
Repair open-circuit or high resistance between terminal 6 and
terminal 2.
Whether
the repair is finished?
|
|
To step 21.
|
|
|
21
|
Use
diagnostic instrument to clear DTC.
When
there is condition to set DTC, whether DTC is reset?
|
|
System
is OK
|
To step 1.
|
C0037(0C) -
Rear Left Wheel Speed Sensor: Open-Circuit/ Short-Circuit
Circuit Descriptions:
When wheel is rotating, with the
increase of wheel speed, speed sensor can produce a squre wave signal. ABS control module uses the frequency of this square wave signal to
calculate wheel speed. Speed sensor is connected to ESC control module by
“twisted pair wire”.
Conditions for Setting DTC:
DTC C0037(0C) can be
set at any time when ESC control module detects that the rear left wheel speed
circuit has open-circuit, short-circuit to the ground wire connection or
short-circuit to battery.
Actions to be Taken When Setting DTC:
1. Storing DTC C0037(0C).
2. Disable
all relevant functions.
3. Light up warning lights related to some functions.
Conditions for Clearing DTC:
1. If
the condition for setting DTC C0037 (0C) disappears, DTC can be cleared by
using proper diagnostic instrument.
2. DTC
which doesn't appear during 40 ignition cycles will be cleared from history
data.
Diagnostic Help:
When intermittent DTC is detected,
please completely inspect wiring and connectors. This includes:
1. Dismantle protective guide pipe, and inspect whether circuit
is damaged, has short-circuit or contaminated.
2. Inspect whether terminal is deformed and damaged.
3. Use standby positive/ negative terminal to
inspect the contact maintaining ability of terminal.
4. Dismantle terminals
from connector, and inspect whether the wire terminal of voltage wire is
falsely connected.
C0037 (0C) - Rear Left
Wheel Speed Sensor: Open-Circuit/ Short-Circuit
|
Steps
|
Diagnostic Actions
|
Expected Value
|
Yes
|
No
|
|
1
|
Whether inspection of
circuit diagnosis is finished?
|
|
To step 2.
|
To step 14.
|
|
2
|
1. Stop the engine.
2. Inspect whether rear left wheel speed sensor,
sensor wire harness and gear ring have physical damage?
Whether physical damage
is found?
|
|
To step 15.
|
To step 3.
|
|
3
|
Test vehicle on various
wheel speed and road surface. Whether C0037 (0C) is reset?
Whether above
connections are good?
|
|
To step 4.
|
To step 16.
|
|
4
|
1. Stop the engine and vehicle.
2. Rise up and properly support the vehicle.
3. Disconnect rear left wheel speed sensor wire
harness.
4. Connect an ohmmeter to terminal 1 and terminal 2
of rear left wheel speed sensor.
Whether the resistance
is within the specified range?
|
75Ω士1%
|
To step 5.
|
To step 17.
|
|
5
|
1. Disconnect rear left wheel jumping wire harness
from rear left wheel speed sensor.
2. Connect an ohmmeter to terminal 1 of vehicle
body ground wire and rear left wheel speed sensor.
Whether the resistance
is within the specified range?
|
OL(open-circuit)
|
To step 6.
|
To step 17.
|
|
6
|
1. Disconnect wire harness from ESC control module.
2. Disconnect rear left wheel speed sensor
connector.
3. Connect an ohmmeter to terminal 33 of ABS
control module wire harness, and then connect it to terminal 2 of rear left
wheel speed sensor.
Whether the resistance
is within the specified range?
|
Less than 2Ω.
|
To step 7.
|
To step 18.
|
|
7
|
1. Disconnect wire harness from ESC control module.
2. Disconnect rear left wheel speed sensor
connector.
3. Connect an ohmmeter to terminal 20 of ABS
control module wire harness, and then connect it to connector 1 of rear left
wheel speed sensor.
Whether the resistance
is within the specified range?
|
Less than 2Ω.
|
To step 8.
|
To step 19.
|
|
8
|
1. Disconnect wire harness from ESC control module.
2. Disconnect rear left wheel speed sensor wire
harness.
3. Connect a voltmeter to terminal 33 of ABS
control module wire harness, and then connect it to vehicle body ground
wire.
Whether voltage value
is within the specified range?
|
Less than 1V
|
To step 9.
|
To step 20.
|
|
9
|
1. Disconnect wire harness from ESC control module.
2. Disconnect rear left wheel speed sensor wire
harness.
3. Connect a voltmeter to terminal 20 of ABS
control module wire harness, and then connect it to vehicle body ground
wire.
Whether voltage value
is within the specified range?
|
Less than 1V
|
To step 10.
|
To step 21.
|
|
Steps
|
Diagnostic Actions
|
Expected Value
|
Yes
|
No
|
|
10
|
1. Disconnect wire harness from ESC control module.
2. Disconnect rear left wheel speed sensor wire
harness.
3. Connect an ohmmeter to terminal 33 of ABS
control module wire harness, and then connect it to vehicle body ground
wire.
Whether the resistance
is within the specified range?
|
OL
(open-circuit)
|
To step 11.
|
To step 22.
|
|
11
|
1. Disconnect wire harness from ESC control module.
2. Disconnect rear left wheel speed sensor wire
harness.
3. Connect an ohmmeter to terminal 20 of ABS
control module wire harness, and then connect it to vehicle body ground
wire.
Whether the resistance
is within the specified range?
|
OL
(open-circuit)
|
To step 12.
|
To step 23.
|
|
12
|
1. Disconnect wire harness from ESC control module.
2. Disconnect rear left wheel speed sensor wire
harness.
3. Connect an ohmmeter to terminal 33 and terminal 20
of ABS control module wire harness.
4. Whether the resistance is within the specified
range?
|
OL(open-circuit)
|
To step 13.
|
To step 24.
|
|
13
|
1. Replace rear left wheel speed sensor wire
harness.
2. Test vehicle on various wheel speed and road
surface.
Whether C0037 (0C) is
reset?
|
|
System is OK
|
To step 25.
|
|
14
|
Conduct Diagnostic
circuit inspection.
|
|
|
|
|
15
|
Repair the damaged
rear left wheel speed sensor, wire harness and/ or gear ring.
Whether the repair is
finished?
|
|
To step 26.
|
|
|
16
|
DTC C0037 (0C) is
intermittent.
|
|
To step 26.
|
|
|
17
|
Replace rear left wheel
speed sensor.
Whether the repair is
finished?
|
|
To step 26.
|
|
|
18
|
Repair between terminal
20 and terminal 1
Whether the repair is
finished?
|
|
To step 26.
|
|
|
19
|
Repair open-circuit
or high resistance between terminal 33 and terminal 2.
Whether the repair is
finished?
|
|
To step 26.
|
|
|
20
|
Repair voltage
short-circuit between terminal 20 and terminal 1.
Whether the repair is
finished?
|
|
To step 26.
|
|
|
21
|
Repair voltage
short-circuit between terminal 33 and terminal 2.
Whether the repair is
finished?
|
|
To step 26.
|
|
|
22
|
Repair ground wire
short-circuit between terminal 20 and terminal 1.
Whether the repair is
finished?
|
|
To step 26.
|
|
|
23
|
Repair ground wire
short-circuit between terminal 33 and terminal 2.
Whether the repair is
finished?
|
|
To step 26.
|
|
|
24
|
Repair the
short-circuit between two circuits.
Whether the repair is
finished?
|
|
To step 26.
|
|
|
25
|
Replace ABS control
module. Whether the repair is finished?
|
|
To step 26.
|
|
|
26
|
Use diagnostic
instrument to clear DTC.
When there is condition
to set DTC, whether DTC is reset?
|
|
System is OK
|
To step 1.
|
C0037(08) - Rear Left Wheel
Speed Sensor: Exceeding Limit, Wrong Performance, Intermittent signal.
Circuit Description:
When wheel is rotating, with the
increase of wheel speed, speed sensor can produce a squre wave signal. ABS control module uses the frequency of this square wave signal to
calculate wheel speed. Speed sensor is connected to ABS control module by
“twisted pair wire”.
Conditions for Setting DTC:
DTC C0031(08) can be
set only when all the following conditions occur:
1. DTCC0037
(0C) or C0034 (0C) or C0037 (0C) or C003A (0C) is not current.
2. Disconnect
brake switch.
3. Speed
acceleration or deceleration of rear left wheel exceeds proper range.
Actions to be Taken When Setting DTC:
1. Store DTC C0037
(08).
2. Disable all
relevant functions.
3. Light up warning
light related to some functions.
Conditions for Clearing DTC:
1. If the
condition for setting DTC C0031 (08) disappears, DTC can be cleared by using
proper diagnostic instrument.
2. DTC which
doesn't appear during 40 ignition cycles will be cleared from history data.
Diagnostic Help:
When intermittent DTC is detected,
please completely inspect wiring and connectors. This includes:
1. Dismantle
protective guide pipe, and inspect whether circuit is damaged, has
short-circuit or contaminated.
2. Inspect
whether terminal is deformed and damaged.
3. Use standby
positive/ negative terminal to inspect the contact maintaining ability of
terminal.
4. Dismantle
terminals from connector, and inspect whether the wire terminal of voltage wire
is falsely connected.
C0037 (08) - Rear Left
Wheel Speed Sensor: Exceeding Limit, Wrong Performance, and Intermittent Signal.
|
Steps
|
Diagnostic
Actions
|
Expected
Value
|
Yes
|
No
|
|
1
|
Whether
the inspection of Diagnostic circuit is finished?
|
|
To step 2.
|
To step 12.
|
|
2
|
Whether the DTC C0037 (0C) is set to be current DTC or DTC history?
|
|
To step 13.
|
To step 3.
|
|
3
|
1. Stop the engine and vehicle.
2. Inspect whether rear left wheel
speed sensor and sensor wire harness are damaged?
3. Completely inspect rear left gear
ring to learn whether it has damage (crack, shortage of teeth, loosening).
Whether
physical damage is found?
|
|
To step 14.
|
To step 5.
|
|
Steps
|
Diagnostic Actions
|
Expected value
|
Yes
|
No
|
|
4
|
1. Parking
2. Connect
diagnostic instrument and select data list.
3. Monitor wheel
speed sensor.
4. Start the vehicle
and run the engine, and monitor wheel speed sensor when the vehicle doesn't
move.
5. Slightly step
accelerator pedal to increase engine idle speed.
Whether C0037 (08) is
reset or reading of front left wheel speed exceeds 0 km/h when vehicle stops?
|
|
To step 15.
|
To step 5.
|
|
5
|
1. Still connect
diagnostic instrument.
2. Monitor wheel
speed sensor.
3. Carry out trial
run of vehicle at maximum speed, and then slowly reduce the speed to Zero. Do
this operation for several times.
Whether C0037 (08) is
reset or change of rear left wheel speed exceeds 5 km/h when comparing with
other wheels during vehicle is traveling.
|
|
To step 6.
|
To step 16.
|
|
6
|
1. Stop the engine
and vehicle.
2. Rise up and
properly support the vehicle.
3. Disconnect rear
left wheel speed sensor wire harness.
4. Connect an ohmmeter
to two terminals of rear left wheel speed sensor.
Is the resistance
within the specified range?
|
75Ω+1%
|
To step 7.
|
To step 17.
|
|
7
|
1. Wheel speed
sensor is still disconnected with jumping wire harness.
2. Connect a
voltmeter to two terminals of rear left wheel speed sensor.
3. Select AC
millivolt scale.
4. Rotate rear left
wheel; meanwhile observe the voltage on measuring scale.
|
At least 100 millivolt
|
To step 8.
|
To step 17.
|
|
8
|
1. Disconnect wire
harness from ESC control module.
2. Disconnect rear
left wheel speed sensor wire harness.
3. Connect an
ohmmeter to terminal 33 of ABS control module wire harness, and then connect
it to connector 2 of rear left wheel speed sensor.
Whether voltage value
is within the specified range?
|
Less than 2Ω.
|
To step 9.
|
To step 18.
|
|
9
|
1. Disconnect wire harness from ESC
control module.
2. Disconnect rear
left wheel speed sensor wire harness.
3. Connect an
ohmmeter to terminal 20 of ABS control module wire harness, and then connect
it to connector 1 of rear left wheel speed sensor.
Whether voltage value
is within the specified range?
|
Less than 2Ω.
|
To step 10.
|
To step 19.
|
|
10
|
1. Disconnect wire
harness from ESC control module.
2. Disconnect rear
left wheel speed sensor wire harness.
3. Connect an ohmmeter
to terminal 33 and terminal 20 of ESC control module wire harness.
4. Whether the
resistance is within the specified range?
|
OL
(open-circuit)
|
To step 11.
|
To step 20.
|
|
Steps
|
Diagnosis Actions
|
Expected Value
|
Yes
|
No
|
|
11
|
1. Replace rear left
wheel speed sensor wire harness.
2. Test vehicle on
various wheel speed and road surface.
Whether C0037 (08) is reset?
|
|
System is OK
|
To step 21.
|
|
12
|
Carry out inspection of diagnosis circuit before making DTCC1207
fault chart.
|
|
|
|
|
13
|
Make C0037 (08) diagnosis chart before making DTC1207 fault
chart.
|
|
|
|
|
14
|
Repair the damaged rear left wheel speed sensor, wire harness
and/ or gear ring.
Whether the repair is finished?
|
|
To step 22.
|
|
|
15
|
C0037 (08) is caused by the condition that ignition noise is
induced to rear left speed sensor circuit.
Inspect whether rear left ESC module wire harness and/ or sensor
wire harness has potential ignition noise source, such as spark plug wire. According to the need,
re-arrange wiring.
Whether the repair is finished?
|
|
To step 22.
|
|
|
16
|
DTCC1207 (0C) is intermittent.
|
|
|
|
|
17
|
Replace rear left wheel speed sensor.
Whether the repair is finished?
|
|
To step 22.
|
|
|
18
|
Repair open-circuit or high resistance between terminal 33 and
terminal 2.
Whether the repair is finished?
|
|
To step 22.
|
|
|
19
|
Repair open-circuit or high resistance between terminal 20 and
terminal 1.
Whether the repair is finished?
|
|
To step 22.
|
|
|
20
|
Repair short-circuits between two wires.
Whether the repair is finished?
|
|
To step 22.
|
|
|
21
|
Replace ESC control module.
Whether the repair is finished?
|
|
To step 22.
|
|
|
22
|
Use diagnosis tester to clear DTC.
When there is condition to set DTC, whether DTC is
reset?
|
|
system is OK
|
To step 1.
|
C0037(03) -
Rear Left Wheel Speed Sensor: Fail Signal/ No Signal
Circuit Descriptions:
When wheel is rotating, with the
increase of wheel speed, speed sensor can produce a squre wave signal. ECU control module uses the frequency of this square wave signal to
calculate wheel speed. Speed sensor is connected to ECU control module by
""twisted pair wire"".
Conditions for Setting DTC:
DTCC0037(03) can be set
only when all the following conditions occur:
1. DTCC0037 (0C) or C0034 (0C) or C0037
(0C) or C003A (0C) is not current.
2. ABS is fail.
3. Disconnect brake switch. Rear
left wheel speed equals to 0, and all other wheel speed sensors are: at least
more than 8km/h within 2.5s.
Conditions for Clearing DTC:
1. If the condition for setting DTCC0037 (03)
disappears, DTC can be cleared by using proper diagnosis tester.
2. DTC which doesn't appear during 40 ignition cycles
will be cleared from history data.
Diagnosis Assistance:
When intermittent DTC is detected,
please completely inspect wiring and connectors.
This will includes:
1. Dismantle protective guide pipe, and inspect
whether circuit is damaged, has short-circuit or contaminated.
2. Inspect whether terminal is deformed and
damaged.
3. Use standby positive/ negative terminal to
inspect the contact maintaining ability of terminal.
C0037 (03) - Rear Left
Wheel Speed Sensor: Fail Signal/ No Signal
|
Steps
|
Diagnosis Actions
|
Expected Value
|
Yes
|
No
|
|
1
|
Whether the inspection
of diagnosis circuit is finished?
|
|
To step 2.
|
To step 12.
|
|
2
|
1. Stop the engine。
2. Inspect whether
rear left wheel speed sensor, sensor wire harness and gear ring have physical
damage?
Whether physical damage
is found?
|
|
To step 13.
|
To step 3.
|
|
3
|
Whether the C003A (03)
is set to be current DTC or history DTC?
|
|
To step 14.
|
To step 4.
|
|
4
|
1. Connect diagnosis
tester and select data list.
2. Monitor wheel
speed sensor.
3. Carry out trial
run of vehicle at 24km/h speed, and then slowly reduce the speed to Zero. Do
this operation for several times.
Whether C0037 (03) is
reset or rear left wheel speed reduces to Zero before vehicle stops
completely?
|
|
To step 5.
|
To step 15.
|
|
5
|
1. Stop the engine。
2. Rise up and
properly support the vehicle.
3. Disconnect wire
harness from ESC control module.
4. Connect a
voltmeter to terminal 33 and terminal 20 of ESC control module wire harness.
5. Select AC mill
volt scale.
6. Rotate rear
left wheel and observe voltage. (Voltage raised with wheel speed increased)
Whether
square wave value is within the specified range?
|
At least 100 millivolt
|
To step 16.
|
To step 6.
|
|
6
|
1. Disconnect rear
left wheel speed sensor wire harness.
2. Connect an
ohmmeter to two terminals of rear left wheel speed sensor.
Whether resistance is within the specified range?
|
75Ω±1%
|
To step 7.
|
To step 17.
|
|
Steps
|
Diagnosis Actions
|
Expected Value
|
Yes
|
No
|
|
7
|
1. Disconnect rear
left wheel speed sensor wire harness.
2. Connect a
voltmeter to two terminals of rear left wheel speed sensor.
3. Select AC
millivolt scale.
4. Rotate rear left
wheel and observe voltage. (When wheel speed increases, voltage also
increases).
Whether square wave
value is within the specified range?
|
At least 100 millivolt
|
To step 8.
|
To step 17.
|
|
8
|
1. Disconnect wire
harness from ESC control module.
2. Disconnect rear
left wheel speed sensor connector.
3. Connect an
ohmmeter to terminal 33 and 20 of ABS control module wire harness.
Whether the resistance
is within the specified range?
|
OL(open-circuit)
|
To step 9.
|
To step 18.
|
|
9
|
1. Disconnect wire
harness from ESC control module.
2. Disconnect rear
left wheel speed sensor wire harness.
3. Connect an
ohmmeter to terminal 20 of ESC control module wire harness, and then connect
it to terminal 1 of sensor connector.
Whether the resistance
is within the specified range?
|
Less than 2Ω.
|
To step 10.
|
To step 19.
|
|
10
|
1. Disconnect wire
harness from ESC control module.
2. Disconnect rear
left wheel speed sensor wire harness.
3. Connect an
ohmmeter to terminal 33 of ESC control module wire harness, and then connect
it to terminal 2 of sensor connector.
Whether the resistance
is within the specified range?
|
Less than 2Ω.
|
To step 11.
|
To step 20.
|
|
11
|
1. Replace rear left
wheel speed sensor connector.
2. Test vehicle on various wheel speed and
road surface.
Whether it is reset?
|
|
system is OK
|
To step 16.
|
|
12
|
Carry out inspection of
diagnosis circuit before treating this fault.
|
|
|
|
|
13
|
Repair the damaged rear
left wheel speed sensor, wire harness and/ or gear ring.
Whether the repair is
finished?
|
|
To step 21.
|
|
|
14
|
Diagnose DTCC0037 (0C)
before carrying out this testing step.
|
|
|
|
|
15
|
DTCC0031 (0) is
intermittent.
|
|
|
|
|
16
|
Replace ESC control
module.
Whether the repair is
finished?
|
|
To step 21.
|
|
|
17
|
Replace rear left wheel
speed sensor.
Whether the repair is
finished?
|
|
To step 21.
|
|
|
Steps
|
Diagnosis
Actions
|
Expected
Value
|
Yes
|
No
|
|
18
|
Find out and repair the short-circuit fault between 2 circuits.
Whether the repair is finished?
|
|
To step 21.
|
|
|
19
|
Repair open-circuit or high resistance between terminal 20 and
terminal 1.
Whether the repair is finished?
|
|
To step 21.
|
|
|
20
|
Repair open-circuit or high resistance between terminal 33 and
terminal 2. Whether the repair
is finished?
|
|
To step 21.
|
|
|
21
|
Use
diagnosis tester to clear DTC.
When
there is a condition to set DTC, whether DTC is reset?
Whether
it is reset?
|
|
system
is OK
|
To step 1.
|
C003A(0C) -
Rear Right Wheel Speed Sensor: Open-circuit/ Short-circuit
Circuit Descriptions:
When wheel is rotating, with the
increase of wheel speed, speed sensor can produce a squre wave signal. ESC control module uses the frequency of this square wave signal to
calculate wheel speed. Speed sensor is connected to ESC control module by
""twisted pair wire"".
Conditions for setting DTC:
DTCC003A(0C) can be set
at any time when ABS control module detects that the rear right wheel speed
circuit has open-circuit, short-circuit to the ground wire connection or
short-circuit to battery.
Actions to Be Taken When Setting DTC:
1. Storing DTC C003A(0C)。
2. Disable all relevant functions.
3. A lights up warning light of relevant functions.
Conditions for Clearing DTC:
1. If the condition for setting DTCC003A (0C)
disappears, DTC can be cleared by using proper diagnosis tester.
2. DTC which doesn't appear during 40 ignition cycles
will be cleared from history data.
Diagnosis Assistance:
When intermittent DTC is detected,
please completely inspect wiring and connectors. This will includes:
1. Dismantle protective guide pipe, and inspect whether
circuit is damaged, has short-circuit or contaminated.
2. Inspect whether terminal is deformed and damaged.
3. Use standby positive/ negative terminal to inspect
the contact maintaining ability of terminal.
4. Dismantle terminals from connector, and inspect
whether the wire terminal of voltage wire is falsely connected.
C003A (0C) - Rear Right
Wheel Speed Sensor: Open-circuit/ Short-circuit
|
Steps
|
Diagnosis Actions
|
Expected Value
|
Yes
|
No
|
|
1
|
Whether the inspection of diagnosis circuit is
finished?
|
|
To step 2.
|
To step 14.
|
|
2
|
1. Stop the engine。
2. Inspect whether
rear right wheel speed sensor, sensor wire harness and gear ring have
physical damage?
Whether physical damage is found?
|
|
To step 15.
|
To step 3.
|
|
3
|
Test vehicle on various wheel speed and road surface.
Whether C003A (0C) is reset?
Whether above connections are good?
|
|
To step 4.
|
To step 16.
|
|
4
|
1. Stop the engine
and vehicle.
2. Rise up and
properly support the vehicle.
3. Disconnect rear
right wheel speed sensor wire harness.
4. Connect an
ohmmeter to terminal 1 and terminal 2 of rear right wheel speed sensor.
Whether the resistance is within the specified range?
|
75Ω土1%
|
To step 5.
|
To step 17.
|
|
5
|
1. Disconnect rear
right wheel speed sensor wire harness from rear right wheel speed sensor.
2. Connect an
ohmmeter to terminal 1 of vehicle body ground wire and rear right
wheel speed sensor.
Whether the resistance is within the specified range?
|
OL(open-circuit)
|
To step 6.
|
To step 17.
|
|
6
|
1. Disconnect wire
harness from ABS control module.
2. Disconnect rear
right wheel speed sensor connector.
3. Connect an
ohmmeter to terminal 19 of ABS control module wire harness, and then connect
it to terminal 2 of rear right wheel speed sensor.
Whether the resistance is within the specified range?
|
Less than 2Ω.
|
To step 7.
|
To step 18.
|
|
7
|
1. Disconnect wire
harness from ABS control module.
2. Disconnect rear
right wheel speed sensor connector.
3. Connect an
ohmmeter to terminal 31 of ABS control module wire harness, and then connect
it to connector 1 of rear right wheel speed sensor.
Whether the resistance is within the specified range?
|
Less than 2Ω.
|
To step 8.
|
To step 19.
|
|
8
|
1. Disconnect wire
harness from ABS control module.
2. Disconnect rear
right wheel speed sensor connector.
3. Connect a
voltmeter to terminal 19 of ABS control module wire harness, and then connect
it to vehicle body ground wire.
Whether voltage value is within the specified range?
|
Less than 1V
|
To step 9.
|
To step 20.
|
|
9
|
1. Disconnect wire
harness from ABS control module.
2. Disconnect rear
right wheel speed sensor connector.
3. Connect a
voltmeter to terminal 31 of ABS control module wire harness, and then connect
it to vehicle body ground wire.
4. Whether voltage value is within the specified
range?
|
Less than 1V
|
To step 10.
|
To step 21.
|
|
Steps
|
Diagnosis Actions
|
Expected Value
|
Yes
|
No
|
|
10
|
1. Disconnect wire
harness from ABS control module.
2. Disconnect rear
right wheel speed sensor connector.
3. Connect an
ohmmeter to terminal 19 of ABS control module wire harness, and then connect it
to vehicle body ground wire.
Whether the resistance
is within the specified range?
|
OL(open-circuit)
|
To step 11.
|
To step 22.
|
|
11
|
1. Disconnect wire
harness from ABS control module.
2. Disconnect rear
right wheel speed sensor connector.
3. Connect an ohmmeter
to terminal 31 of ABS control module wire harness, and then connect it to
vehicle body ground wire.
Whether the resistance
is within the specified range?
|
OL(open-circuit)
|
To step 12.
|
To step 23.
|
|
12
|
1. Disconnect wire
harness from ABS control module.
2. Disconnect rear
right wheel speed sensor connector.
3. Connect an
ohmmeter to terminal 19 and 31 of ABS control module wire harness.
4. Whether the
resistance is within the specified range?
|
OL(open-circuit)
|
To step 13.
|
To step 24.
|
|
13
|
1. Replace rear right
wheel speed sensor wire harness.
2. Test vehicle on
various wheel speed and road surface.
Whether C003A (0C) is
reset?
|
|
system is OK
|
To step 25.
|
|
14
|
Conduct diagnosis
circuit inspection.
|
|
|
|
|
15
|
Repair the damaged
rear right wheel speed sensor, wire harness and/ or gear ring.
Whether the repair is
finished?
|
|
To step 26.
|
|
|
16
|
DTCC003A (0C) is
intermittent.
|
|
To step 26.
|
|
|
17
|
Replace rear right
wheel speed sensor.
Whether the repair is
finished?
|
|
To step 26.
|
|
|
18
|
Repair open-circuit
or high resistance between terminal 31 and terminal 1.
Whether the repair is
finished?
|
|
To step 26.
|
|
|
19
|
Repair open-circuit
or high resistance between terminal 19 and terminal 2.
Whether the repair is
finished?
|
|
To step 26.
|
|
|
20
|
Repair voltage
short-circuits between terminal 31 and terminal 1.
Whether the repair is
finished?
|
|
To step 26.
|
|
|
21
|
Repair voltage
short-circuits between terminal 19 and terminal 2.
Whether the repair is
finished?
|
|
To step 26.
|
|
|
22
|
Repair ground wire
short-circuits between terminal 31 and terminal 1.
Whether the repair is
finished?
|
|
To step 26.
|
|
|
23
|
Repair ground wire
short-circuits between terminal 19 and terminal 2.
Whether the repair is
finished?
|
|
To step 26.
|
|
|
24
|
Repair the
short-circuit between two circuits.
Whether the repair is
finished?
|
|
To step 26.
|
|
|
25
|
Replace ABS control
module.
Whether the repair is
finished?
|
|
To step 26.
|
|
|
26
|
Use diagnosis tester to
clear DTC.
When there is a
condition to set DTC, whether DTC is reset?
|
|
system is OK
|
To step 1.
|
C003A(08) - Rear Right Wheel
Speed Sensor: Exceeding Limit, Wrong Performance, Intermittent Signal.
Circuit Descriptions:
When wheel is rotating, with the
increase of wheel speed, speed sensor can produce a squre wave signal. ABS control module uses the frequency of this square wave signal to
calculate wheel speed.
Conditions for Setting DTC:
DTCC003A(08) can be set
only when all the following conditions occur:
1. DTCC0031 (0C) or C0034 (0C) or C007
(0C) or C003A (0C) is not current
2. Disconnect brake
switch.
3. Speed acceleration
or decleration of rear right wheel exceeds proper range.
Actions to Be Taken When Setting DTC:
1. Store DTC C003A(08).
2. Disable all relevant functions.
3. Light up warning light related
to some functions.
Conditions for Clearing DTC:
1. If the condition for setting
DTC C003A(08) disappears, DTC can be cleared by using proper diagnosis tester.
2. DTC which doesn't appear during
40 ignition cycles will be cleared from history data.
Diagnosis Assistance:
When intermittent DTC is detected,
please completely inspect wiring and connectors. This will includes:
1. Dismantle protective guide
pipe, and inspect whether circuit is damaged, has short-circuit or
contaminated.
2. Inpsect whether terminal is
deformed and damaged.
3. Use standby positive/ negative
terminal to inspect the contact maintaining ability of terminal.
4. Dismantle terminals from
connector, and inspect whether the wire terminal of voltage wire is falsely
connected.
C003A(08) - Rear Right Wheel
Speed Sensor: Exceeding Limit, Wrong Performance, Intermittent Signal.
|
Steps
|
Diagnosis
Actions
|
Expected
Value
|
Yes
|
No
|
|
1
|
Whether
inspection of circuit diagnosis is finished?
|
|
To step 2.
|
To step 12.
|
|
2
|
Whether the DTCC003A (0C) is set to be current DTC or history
DTC?
|
|
To step 13.
|
To step 3.
|
|
3
|
1. Stop the engine and vehicle.
2. Inspect whether rear right
wheel speed sensor and sensor wire harness are damged?
3. Completely inspect rear right
gear ring to learn whether it has damage (crack, shortage of teeth,
loosening).
Whether
physical damage is found?
|
|
To step 14.
|
To step 5.
|
C1210 - Rear Right
Wheel Speed Sensor: Exceeding Limit, Wrong Performance, Intermittent Signal.
|
Steps
|
Diagnosis Actions
|
Expected Value
|
Yes
|
No
|
|
4
|
1. Parking
2. Connect diagnosis tester and
select data list.
3. Monitor wheel speed sensor.
4. Start the engine and monitor
wheel speed sensor when vehicle doesn't move.
5. Slightly step accelerator
pedal to increase engine idle speed.
Whether C1210 is
reset or reading of rear right wheel speed exceeds 0 km/h when engine runs
and vehicle stops?
|
|
To step 15.
|
To step 5.
|
|
5
|
1. Still connect diagnosis
tester.
2. Monitor wheel speed sensor.
3. Carry out trial run of
vehicle at maximum speed, and then slowly reduce the speed to Zero. Do this operation for several times.
|
|
To step 6.
|
To step 16.
|
|
5
|
Whether C003A (08) is
reset or change of rear right wheel speed exceeds 5km/h when comparing with
other wheels during vehicle is traveling.
|
|
To step 6.
|
To step 16.
|
|
6
|
1. Stop the engine and vehicle.
2. Rise up and properly support
the vehicle.
3. Disconnect rear right wheel
speed sensor wire harness.
4. Connect an ohmmeter to two
terminals of rear right wheel speed sensor.
Does the resistance is
within the specified range?
|
75Ω±1%
|
To step 7.
|
To step 17.
|
|
7
|
1. Wheel speed sensor is still
disconnected with jumping wire harness.
2. Connect a voltmeter to two
terminals of rear right wheel speed sensor.
3. Select AC millivolt scale.
4. Rotate rear right wheel and
observe voltage on measuring scale.
|
At least 100 millivolt
|
To step 8.
|
To step 17.
|
|
8
|
1. Disconnect wire harness from
ESC control module.
2. Disconnect rear right wheel
speed sensor connector.
3. Connect an ohmmeter to
terminal 19 of ABS control module wire harness, and then connect it to
connector 2 of rear right wheel speed sensor.
Whether the resistance
is within the specified range?
|
Less than 2Ω.
|
To step 9.
|
To step 18.
|
|
9
|
1. Disconnect wire harness from
ESC control module.
2. Disconnect rear right wheel
speed sensor connector.
3. Connect an ohmmeter to
terminal 31 of ABS control module wire harness, and then connect it to
connector 1 of rear right wheel speed sensor.
Whether the resistance
is within the specified range?
|
Less than 2Ω.
|
To step 10.
|
To step 19.
|
|
10
|
1. Disconnect wire
harness from ESC control module.
2. Disconnect rear
right wheel speed sensor connector.
3. Connect an ohmmeter
to terminal 19 and 31 of ABS control module wire harness.
4. Whether the
resistance is within the specified range?
|
OL(open-circuit)
|
To step 11.
|
To step 20.
|
|
Steps
|
Diagnosis Actions
|
Expected Value
|
Yes
|
No
|
|
11
|
1. Replace rear
right wheel speed sensor wire harness.
2. Test vehicle on
various wheel speed and road surface. Whether C003A (08) is reset.
|
|
system is OK
|
To step 21.
|
|
12
|
Conduct inspection of
diagnosis circuit before making DTCC003A (08) fault chart.
|
|
|
|
|
13
|
Make C003A (0C)
diagnosis chart before making DTC C003A (08) fault chart.
|
|
|
|
|
14
|
Repair the damaged
rear right wheel speed sensor, wire harness and/ or gear ring. Whether the repair is
finished?
|
|
To step 22.
|
|
|
15
|
C003A (08) is caused
by the condition that ignition noise is induced to rear right speed sensor
circuit. Inspect whether rear right ABS module wire harness and/ or sensor
wire harness has potential ignition noise source, such as spark plug wire. According to the need,
re-arrange wiring.
Whether the repair is
finished?
|
|
To step 22.
|
|
|
16
|
DTCC003A (08) is
intermittent.
|
|
|
|
|
17
|
Replace rear right
wheel speed sensor.
Whether the repair is
finished?
|
|
To step 22.
|
|
|
18
|
Repair open-circuit
or high resistance between terminal 19 and terminal 2.
Whether the repair is
finished?
|
|
To step 22.
|
|
|
19
|
Repair open-circuit
or high resistance between terminal 31 and terminal 1.
Whether the repair is
finished?
|
|
To step 22.
|
|
|
20
|
Repair short-circuits
between two wires 2.
Whether the repair is
finished?
|
|
To step 22.
|
|
|
21
|
Replace ABS control
module.
Whether the repair is
finished?
|
|
To step 22.
|
|
|
22
|
Use diagnosis tester to
clear DTC.
When there is condition
to set DTC, whether DTC is reset?
|
|
system is OK
|
To step 1.
|
C003A(03) -
Rear Right Wheel Speed Sensor: Fail Signal/ No Signal
Circuit Descriptions:
When wheel is rotating, with the
increase of wheel speed, speed sensor can produce a squre wave signal. ECU uses the frequency of this square wave signal to calculate wheel
speed. Speed sensor is connected to ECU control module by ""twisted
pair wire"".
Conditions for Setting DTC:
DTCC003A(03) can be set
only when all the following conditions occur:
1. DTCC0031(0C) or C0034(0C) or C0037(0C) or C003A(0C)
is not current.
2. Disable relevant
functions.
3. Disconnect brake
switch. Rear left wheel speed equals to 0, and all other wheel
speed sensors are: at least more than 8km/h within 2.5 s.
Conditions for Clearing DTC:
1. If the condition for setting DTCC003A(03) disappears, DTC can be
cleared by using proper diagnosis tester.
2. DTC which doesn't appear during 40 ignition cycles will be cleared
from history data.
Diagnosis Assistance:
When intermittent DTC is detected,
please completely inspect wiring and connectors.
This will includes:
1. Dismantle
protective guide pipe, and inspect whether circuit is damaged, has short-circuit
or contaminated.
2. Inspect whether
terminal is deformed and damaged.
3. Use standby positive/ negative terminal to inspect the contact
maintaining ability of terminal.
C003A (03) - Rear Right
Wheel Speed Sensor: Fail Signal/ No Signal
|
Steps
|
Diagnosis Actions
|
Expected Value
|
Yes
|
No
|
|
1
|
Whether the inspection of diagnosis circuit is
finished?
|
|
To step 2.
|
To step 12.
|
|
2
|
1. Stop the engine.
2. Inspect whether
rear right wheel speed sensor, sensor wire harness and gear ring have
physical damage?
Whether physical damage is found?
|
|
To step 13.
|
To step 3.
|
|
3
|
Whether the C003A (03) is set to be current DTC or history DTC?
|
|
To step 14.
|
To step 4.
|
|
4
|
1. Connect diagnosis
tester and select data list.
2. Monitor wheel
speed sensor.
3. Carry out trial
run of vehicle at 24 km/h speed, and then slowly reduce the speed to Zero. Do
this operation for several times.
Whether C003A (03) is reset or rear right wheel speed reduces to
Zero before vehicle stops completely?
|
|
To step 5.
|
To step 15.
|
|
5
|
1. Stop the engine。
2. Rise up and
properly support the vehicle.
3. Disconnect wire
harness from ESC control module.
4. Connect a
voltmeter to terminal 19 and terminal 31 of ESC control module wire harness.
5. Select millivolt
scale.
6. Rotate rear right
wheel and observe voltage. (When wheel speed increases, voltage also
increases).
Whether voltage value is within the specified range?
|
At least 100 millivolt
|
To step 16.
|
To step 6.
|
|
6
|
1. Disconnect rear
right wheel speed sensor wire harness.
2. Connect an
ohmmeter to two terminals of rear right wheel speed sensor.
Whether voltage value is within the specified range?
|
75Ω土1%
|
To step 7.
|
To step 17.
|
|
Steps
|
Diagnosis Actions
|
Expected Value
|
Yes
|
No
|
|
7
|
1. Disconnect rear
right wheel speed sensor connector.
2. Connect a
voltmeter to two terminals of rear right wheel speed sensor.
3. Select millivolt
scale.
4. Rotate rear right
wheel and observe voltage. (When wheel speed increases, voltage also
increases).
Whether voltage value
is within the specified range?
|
At least 100 millivolt
|
To step 8.
|
To step 17.
|
|
8
|
1. Disconnect wire
harness from ESC control module.
2. Disconnect rear
right wheel speed sensor connector.
3. Connect an
ohmmeter to terminal 19 and 31 of ABS control module wire harness.
Whether the resistance
is within the specified range?
|
OL(open-circuit)
|
To step 9.
|
To step 18.
|
|
9
|
1. Disconnect wire
harness from ESC control module.
2. Disconnect rear
right wheel speed sensor connector.
3. Connect an
ohmmeter to terminal 31 of ABS control module wire harness, and then connect
it to terminal 1 of sensor connector.
Whether the resistance
is within the specified range?
|
Less than 2Ω.
|
To step 10.
|
To step 19.
|
|
10
|
1. Disconnect wire
harness from ESC control module.
2. Disconnect rear
right wheel speed sensor connector.
3. Connect an
ohmmeter to terminal 19 of ABS control module wire harness, and then connect
it to terminal 2 of sensor connector.
Whether the resistance
is within the specified range?
|
Less than 2Ω.
|
To step 11.
|
To step 20.
|
|
11
|
1. Replace rear
right wheel speed sensor connector.
2. Test vehicle on various wheel speed and
road surface. Whether it is reset?
|
|
system is OK
|
To step 16.
|
|
12
|
Carry out inspection
of diagnosis circuit before treating this fault.
|
|
|
|
|
13
|
Repair the damaged
rear right wheel speed sensor, wire harness and/ or gear ring.
Whether the repair is
finished?
|
|
To step 21.
|
|
|
14
|
Diagnose DTCC003A (0C)
before carrying out this testing step.
|
|
|
|
|
15
|
DTCC003A (03) is
intermittent.
|
|
|
|
|
16
|
Replace ESC control
module.
Whether the repair is
finished?
|
|
To step 21.
|
|
|
17
|
Replace rear right
wheel speed sensor.
Whether the repair is
finished?
|
|
To step 21.
|
|
|
18
|
Find out and repair
the short-circuit fault between 2 circuits.
Whether the repair is
finished?
|
|
To step 21.
|
|
|
19
|
Repair open-circuit
or high resistance between terminal 31 and terminal 1.
Whether the repair is
finished?
|
|
To step 21.
|
|
|
20
|
Repair open-circuit
or high resistance between terminal 19 and terminal 2.
Whether the repair is
finished?
|
|
To step 21.
|
|
|
21
|
Use diagnosis tester to
clear DTC.
When there is condition
to set DTC, whether DTC is reset?
|
|
system is OK
|
To step 1.
|
CIFXX(OF) - Wheel Speed
Frequency Error (Common Wheel Speed Sensor Fault, Shortage of Teeth or Wrong Teeth
Number)
For overhauling
procedures of this fault, please refer to fault overhauling of C0031 (03/08),
00034(03/08), 00037(03/08), C003A (03/08)
C1604—ABS Control Module Hardware
Fault
Circuit Descriptions:
This DTC confirms that
it has possible fault inside ESC control module.
Conditions for Setting DTC:
Set DTCCFXX(OE) when
there is possible fault of internal parts/ microprocessor.
Actions to Be Taken When Setting DTC:
1. Disconnect electromagnetic
relay and disconnect power supply of oil return pump and solenoid.
2. Relevant function
is fail.
3. Storing DTC CIFXX(OE)。
4. Switch on relevant warning
light s.
Conditions for Clearing DTC:
1. If the condition for setting DTC CIFXX(0E) disappears,
DTC can be cleared by using proper diagnosis tester.
2. DTC which doesn't appear during 40 drive cycles will
be cleared from history data.
Diagnosis Assistance:
1. When displaying DTC CIFXX(0E) on diagnosis tester, it
should have two subsequent number (XX) which can display other DTC and record
it at any time.
2. Before conducting DTC CIFXX(0E) fault tree analysis,
first repair low voltage, driving performance or other electric faults.
3. Make sure that the connection between ABS control
module and ABS hydraulic assembly is reliable, firm and without corrosion,
leakage and/ or damage.
CIFXX (OE) - ABS Control
Module Hardware Fault
|
Steps
|
Diagnosis Actions
|
Expected Value
|
Yes
|
No
|
|
1
|
Whether the inspection of diagnosis circuit is
finished?
|
|
To step 2.
|
To step 5.
|
|
2
|
1. Install
diagnosis tester
2. Turn on ignition switch when engine
stops.
3. Use diagnosis
tester to observe DTC information.
Whether DTC is set in current or history data except for CIFXX (0E).
|
|
To step 6.
|
To step 3.
|
|
3
|
1. Stop
the engine。
2. Disconnect ABS control module wire
harness from ESC control module.
3. Inspect whether
connector has damage, corrosion and whether there is any problem when
terminal contacts with each other?
|
|
To step 7.
|
To step 4.
|
|
4
|
Replace ESC control module.
Whether the repair is finished?
|
|
To step 8.
|
|
|
Steps
|
Diagnosis Actions
|
Expected Value
|
Yes
|
No
|
|
5
|
Conduct test for diagnosis circuit
|
|
|
|
|
6
|
Conduct diagnosis for other DTC.
|
|
|
|
|
7
|
Repair it if necessary. Whether the repair is
finished?
|
|
To step 8.
|
|
|
8
|
Use a diagnosis tester to clear DTC. When there is a
condition to set DTC, whether DTC is reset?
When there is condition to set DTC, whether DTC is
reset?
|
|
System is OK
|
To step 1.
|
CIFEO(0E) - Valve Relay Fault
Circuit Descriptions:
This DTC confirms that
it has possible fault inside ESC control module. Actuate ESC control module
relay (switch on); and supply power to coil and return valve of electromagnetic
valve.
Conditions for Setting DTC:
If internal fault is
possible to exist, set DTCCIFEO(0E).
Actions to be taken when setting DTC:
1. ABS warning
light isn’t turned on.
2. Storing DTCCIFEO(0E)。
3. ABS still
has function.
Conditions for Clearing DTC:
1. If the
condition for setting DTCCIFEO (0E) disappears, DTC can be cleared by using
proper diagnosis tester.
2. DTC which
doesn't appear during 40 drive cycles will be cleared from history data.
Diagnosis Assistance:
1. Before
conducting DTCCIFXX (0E) fault tree analysis, first repair low voltage, driving
performance or other electric faults.
2. Make sure
that the connection between ESC control module and ESC hydraulic assembly is
reliable, firm and without corrosion, leakage and/ or damage.
3. Possible
cause for setting DTC CIFEO (0E) is internal relay of ABS control module has
fault.
CIFEO (0E) - Valve Relay
Fault
|
Steps
|
Diagnosis Actions
|
Expected Value
|
Yes
|
No
|
|
1
|
Whether the inspection of diagnosis circuit is
finished?
|
|
To step 2.
|
To step 5.
|
|
2
|
1. Install
diagnosis tester
2. Turn on ignition switch when engine
stops.
3. Use diagnosis
tester to observe DTC information.
Whether diagnosis tester sets any DTC in current or history data
except for CIFEO (0E)?
|
|
To step 6.
|
To step 3.
|
|
3
|
1. Stop
the engine
2. Disconnect ABS control module wire
harness from ABS control module.
3. Inspect whether
connector has damage, corrosion and whether there is any problem when
terminal contacts with each other?
|
|
To step 7.
|
To step 4.
|
|
4
|
Replace ABS control module.
Whether the repair is finished?
|
|
To step 8.
|
|
|
5
|
Inspect diagnosis circuit.
|
|
|
|
|
6
|
Conduct diagnosis for other DTC.
|
|
|
|
|
7
|
Repair it if necessary.
Whether the repair is finished?
|
|
To step 8.
|
|
|
8
|
Use a diagnosis tester to clear DTC. When there is a
condition to set DTC, whether DTC is reset?
When there is condition to set DTC, whether DTC is
reset?
|
|
system is OK
|
To step 1.
|
C146A(08) -
Fluid Inlet Valve or Outlet Valve Fault
Circuit Descriptions:
Fluid inlet valve coil
or outlet valve coild is an integrated part of ABS control module. When ignition switch is switched on,
use battery to supply power to the coil, and solenoid relay closes. If
necessary, ESC control module will make coil circuit to ground wire
connection to control electromagnetic valve.
Conditions for setting DTC:
When ESC control module
sensor has ground wire open-circuit, short-circuit or power supply
short-circuit to any inlet valve or outlet valve coil, relevant DTC will be
set.
Actions to Be Taken When Setting DTC:
1. Turn on electromagnetic relay and disconnect power
supply of electromagnetic valve.
2. Storing DTC。
3. Disable relevant functions, and light up warning
light s of relevant functions
Conditions for Clearing DTC:
1. If the condition for setting DTC C146A (08)
disappears, DTC can be cleared by using proper diagnosis tester.
2. DTC which doesn't appear during 40 drive cycles will
be cleared from history data.
Diagnosis Assistance:
Make sure that the connection between ABS control module and
ABS hydraulic assembly is reliable, firm and without corrosion. Because electromagnetic
valve coil is a part of ABS control module, and DTC set commonly indicates
the internal fault of ABS control module.
C146A (08) - Fluid Inlet
Valve or Outlet Valve Fault
|
Steps
|
Diagnosis Actions
|
Expected Value
|
Yes
|
No
|
|
1
|
Whether the inspection of diagnosis circuit is
finished
|
|
To step 2.
|
To step 5.
|
|
2
|
1. Stop the engine。
2. Inspect whether ESC control module and
ESC hydraulic assembly have physical damage.
Whether any physical damage is found?
|
|
To step 6.
|
To step 3.
|
|
3
|
1. Disconnect ABS control module wire
harness from ESC control module.
2. Dismantle ABS c control module from ESC
hydraulic assembly.
3. Inspect whether the inner chamber of
ABS control module and ABS hydraulic assembly has liquid leakage, corrosion
and/ or damage
Whether the inner chamber has any liquid leakage,
damage or corrosion?
|
|
To step 7.
|
To step 4.
|
|
4
|
1. Install diagnosis tester
2. Turn on ignition switch when the engine
stops.
3. Use a diagnosis tester to clear DTC.
When there is a condition to set DTC, whether DTC is reset?
4. Drive the vehicle when running DTC.
5. Whether DTC is reset to be current DTC?
|
|
To step 8.
|
For intermittent fault, go to step 5.
|
|
5
|
Inspect diagnosis circuit. Whether any fault is found?
|
|
To relevant procedures.
|
system is OK
|
|
6
|
Replace the damaged parts. Whether the repair is
finished?
|
|
To step 9.
|
|
|
7
|
Replace ESC control module and ESC hydraulic assembly. Whether the repair is
finished?
|
|
To step 9.
|
|
|
8
|
Replace ESC control module. Whether the repair is
finished?
|
|
To step 9.
|
|
|
9
|
Use a diagnosis tester to clear DTC. When there is a
condition to set DTC, whether DTC is reset?
When there is condition to set DTC, whether DTC is
reset?
|
|
system is OK
|
To step 1.
|
EPS Electronic Power Steering System
Precautions
■ When inspecting steering system, place vehicle on the flat and dry
groud.
■ Bolts of components of steering system must be tightened according
to the specified torque.
■ After the overhaul of steering column assembly, steering gear and
other steering mechanism, inspect wheel alignment.
■ Maximum voltage of the system should not exceed 18V and minimum
voltage should not exceed 9V.
■ Frequently inspect and keep the tire pressure meet the specified
requirement.
■ Once there is abnormal gap, sticking, swinging, analyze which
position the problem occurs, such as steering drive device, power steering
system or steering tie rod system, and eliminate the problem.
■ Frequently and carefully inspect whether steering system parts
experience abnormal impact.timely replace the
damaged or fault parts.
■ Do not weld the parts of steering gear and system rods in any
manner.
■ Regularly inspect whether EPS wire harness has clashing or abrasion,
connector is loose. If yes, timely replace them.
Preparation:
Special Tool Tables
|
S/N
|
Tools
|
Overall Diagram
|
Number and Appearance
|
Description
|
|
1
|
Steering wheel puller
|
|
JAC-T1D002
|
Dismantling of steering wheel
|
|
2
|
Mechanical centering tool
|
|
JAC-27R0028
|
Centering of steering angle
|
Overall of Electric Power Steering System
Electric power steering system is
equipped on the vehicle to reduce the working strength of the driver. With the
speed increase of car and increase of load on steering wheel, power steering
system becomes absolutely necessary and now it is widely used. Power steering
system has the following features:
■ Reduced the steering force exerted on steering wheel, especially
obvious power steering at original place steering and low speed big steering
angle.
■ Improved steering sensitivity.
■ Reduced the effect of ground wire bounce-back on steering
wheel.
■ Under tire bursting condition, it can betterly prevent wheel from
sudden steering, so as to improve driving safety.
■ It allows more load on steering wheel, which can add freedom of
general arrangement.
■ More energy-saving and environmental friendly.
EPS has the following
functions:
① Power steering
function;
② Automatic centering
function;
③ Main damper control
function;
④ Friction compensation;
⑤ Stopper limit
function;
⑥ Straight line
traveling performance;
⑦ Overheat protection;
⑧ Overvoltage protection
⑨ System network
management, diagnosis function;
Electric Power Steering System:
Electric power steering system can
work only when the engine runs.
For electric power steering system,
steering power is not provided by hydraulics but by mechanical type with a
electric motor. This steering sytem has advantages that it has no hose, oil
reservoir, filter or hydraulic oil and other hydraulic parts. In addition, it
has remarkable energy-saving advantage. Different from hydraulic power steering
system which requires constant hydraulic power steering, electric power
steering sytem requires energy only when it is in actual steering operation.
This working type of requiring electricity only on actual need can reduce oil
consumption.
When using electric power steering
system, steering power can be automatically adjusted according to the vehicle
speed, steering torque and steering angle of the wheel.
Indicator lamp ? (its
shape is similar with steering wheel)condition. When turning on ignition
switch, indicator lamp (red) will light up for several seconds.
If indicator lamp ?
doesn't go out after lighting up or it lights up during vehicle traveling
condition (red), it indicates that the electric power steering system has
fault.
Consitution of Electric Power Steering
System:
Vehicle's electric power steering
system consists of steering wheel assembly, steering column with intermediate
shaft assembly, mechanical steering gear assembly, etc. Of which mechanical
steering gear is an acutating component of electric power of steering system.
Steering column motor is connected with power supply system of the complete
vehicle to provide power source.
Structure of power
steering system is shown in figure below:
Structure diagram of
power steering system
1-Steering wheel assembly 2- Steering
column with intermediate shaft assembly 3- Mechanical steering gear assembly
Working Principles:
Battery supplies energy
and motor supplies power. EPS controller collects engine speed
signal, vehicle speed signal, steering torque signal, etc to judge the size of
power steering and control the power output of motor, so as to achieve power
control.
1. Steering Process:
When rotating steering
wheel, torque sensor will detect the torque change exerted on steering wheel
and instruct power motor to rotate through ECU control unit, so as to drive
steering tie rod assembly to achieve power steering.
2. Return Process:
After the completion of
steering, the force exerted on steering wheel disappears, and torque sensor
will detect torque change exerted on steering wheel and instruct power motor to
stop rotating. Under the effect of vehicle front wheel automatic centering
torque, vehicle will move towards straight line position until it returns to
straight line position.
3. Road Sensing Effect:
Road sensing effect refers to an
ability to produce steering feeling. When the driver exerts force to steering
wheel, this force is also exerted to the torque rod of steering gear to make it
produce torque deformation. This deformation degree depends on wheel steering
resistance. When steering resistance increases, this deforamtion degree also
increases. Therefore, driver can judge the change of steering
resistance according to the force he exerted on the steering wheel, so as to
obtain ""road sensing"" effect.
Steering Wheel
On-board Inspection:
1. Inspect Installation Condition
① Inspect installation
conditions of steering device assembly, front suspension, axle and steering
column.
② Inspect whether there
is moving gap when steering wheel moves up and down, left and right and axial
direction.
③ Inspect
whether fixing nuts and bolts of steering device assembly are loose.
2. Inspect Free Stroke of Steering Wheel
① Rotate steering wheel
to let the front wheel locate at straight ahead position. Start the engine, and
slightly rotate steering wheel to left and right directions until the front
wheel begins to move. Measure the movement of steering wheel on outer circle.
■ Free stroke of steering wheel: 30 mm
② When measuring value
exceeds standard value, inspect the installation condition of each joint of
steering column and steering mechanism. Correct or replace relevant parts if
necessary.
③ If the no-load running stroke still exceeds 30m, turn
off the engine to let the front wheel locate at straight line traveling
condition. Exert 5N force along the circumference of steering wheel and inspect
this no-load running stroke. This stroke should not exceed 10mm. If it exceeds
10mm, inspect whether steering gear assembly is qualified.
④ If this stroke is Limiting value, let the steering wheel
locate middle position when engine stops, and exert 4±0.6N force along the
circumference of steering, and then inspect its free stroke.
■ Standard Value ：＜15mm
⑤ If this value exceeds
standard value, dismantle steering gear and inspect total torque of pinion.
3. Inspect Middle Position
① Make sure that the
installation of steering device assembly, steering column and steering wheel is
correct.
② After wheel alignment,
carry out inspection to middle position. Please refer to
""Inspection of Front Wheel Alignment"".
③ Park the vehicle and
make it towards straight ahead, and make sure that steering wheel locates at
middle position.
④ Loosen locknut of tie
rod and rotate adjusting rod to left and right directions for slight
adjustment, and then verify whether steering wheel locates at middle position.
4. Inspect Static Steering Force of Steering Wheel
① Park the vehicle on
the flat and dry ground, and pull up parking brake handle.
② Start the engine.
Notes:
■ Tire pressure should be within the specified value.
③ Rotate steering wheel from middle position to 360°, and
inspect steering force of steering wheel and whether it has obvious
fluctuation.
■ Steering force of steering wheel
:< 34N Allowed fluctuation: <5.9N
④ If the steering force
of steering wheel exceeds the specified value, please inspect or adjust the
following items:
a.
Whether lower swing arm
and steering tie rod ball head are damaged.
b.
Gear preload of steering
gear and rotation torque of steering tie rod ball head.
c.
Rotation torque of lower swing arm ball head.
5. Inspect automatic return of
steering wheel
Notes:
■ Conduct slow and sharp turning, to feel and confirm whether its
effect force and returning condition has no difference between right direction
and left direction.
■ This step must be carried out on safe road and traffic condition,
and pay attention to your safety.
Rotate steering wheel to 90° and drive the vehicle at 35km/h
speed for several seconds, and then release steering wheel, the return must be
at least 70%.
6. Inspect Front Wheel
Wteering Angle.
① After the inspection
of front wheel toe-in, inspect front wheel steering angle. Place front wheel
onto the steering wheel measuring gauge (front wheel alignment steering wheel),
and then inspect maximum inner and outer wheel steering angle of left and right
wheels.
■ Inner wheel: 38°±1.5°
Outside wheel ：30.5°±1.5°
② When the engine is at
idle speed, completely rotate steering wheel to left and right directions to
measure steering angle.
■ If the measured value isn't within the standard range, adjust tie
rod.
Adjustment method of steering angle
is shown as follows:
When steering angle
exceeds standard value, loosen locknuts of left and right steering tie rods.
Use wrench to respectively rotate left and right tie rods to adjust steering
angle to standard value, and then tighten locknuts with tightening toque of 45〜55N•m. When adjusting the
exposed thread length of left and right tie rods (as length shown in figure
below). Make sure that the length of left and right tie rods are the same.
Diagram of tie rod EPS-6
Notes:
■ When inner wheel steering angle exceeds standard and adjusting
outward rotation of tie rod on this side, inner wheel steering wheel will
increase; when outer wheel steering angle exceeds standard and adjusting outer
rotation of tie rod on this side, outer wheel steering angle will decrease.
Notes:
■ Parameters of toe-in and the rest four-wheel alignment, steering
angle are interrelated.
7. Inspect Dustproof Cover of Ball Head
① Use finger to press and inspect whether dustproof sleeve
has crack or damage.
② If yes, it is
necessary to replace tie rod ball head.
Notes:
■ When dustproof sleeve has crack or damage, it may cause ball head
damage.
8. Inspect Rotation Torque of Steering Tie Rod Ball Head
① Quickly swing tie rod for 10 times.
② Use spring balance to measure the swing resistance of
tie rod.
■ Standard value: 0.5～3 N•m
■ If the measured value isn't within the standard range, replace it.
Steering
Wheel Assembly
Dismantling
and Assembly:
1. Dismantling
① Disconnect negative terminal post of battery, and wait
for 3mins.
② Dismantle drive's
safety airbag module from the steering wheel.
③ Dismantle fixing nuts
of steering wheel after locking steering.
■ Tightening torque：35〜45N•m
④ Take out steering
wheel from steering shaft.
Note: if it can't be taken out
easily, please use steering wheel puller.
2) Installation
The Installation Is Operated in Reverse
Order of Dismantling.
Detailed Steps for Dismantling
of Horn Cover Assembly Are Shown as Follows:
1. Steering Wheel and DAB Clip Area
(Red Circle)
3. DAB Dismantling Diagram (Total Three Steps). Diameter of Dismantling
Tool is 5mm. It Is Not Allowed to Use Sharp Tip Tools:
① Lay the product in horizontal position, one hand holds
steering wheel, and another hand push tool into 3H dismantling hole to make DAB
housing and steering wheel frame separate.
② Lay the product in horizontal position, one hand holds
steering wheel, and another hand push tool into 9H dismantling hole to make DAB
housing and steering wheel frame separate.
③ laid
the product in horizontal position, one hand holds steering wheel, and another
hand push tool into 3H dismantling hole to make DAB housing and steering wheel
frame separate.
④ Assembly of horn cover assembly
Correspondingly press
steering wheel and DAB clip area; meanwhile inspect whether its matching
clearance is uniform.
Notes:
■ The installation must be carried out when wheel locates at straight
line traveling condition and steerin wheel locates at middle position. or make marks on steering wheel and
fixing bolts in advance before dismantling. When installing, make sure marks
are matched.
■ Under installation condition, steering column must rotate smoothly
without any clip sound or sticking condition.
■ After installing other parts onto the steering wheel, adjust the
gradient of steering wheel and steering column for 5～6 times; force for operating lock position of steering
column should not exceed 60～100N. When the lock position of steering column locates at free position,
maximum operating force of gradient of steering wheel and steering column
should not exceed 100N.
■ Installation position of timer spring (hair spring).
■ Do not twist timer spring after tightening it.
Steering Column Assembly
Diagram of Steering Column
Assembly:
Diagram of
steering c olumn assembly:
1-Steering column assembly 2-Intermediate shaft assembly
Notes:
■ 
do not exert too much axial force to
steering column assembly when dismantling and installing it.
■ do not move steering gear when
dismantling steering column.
Dismantling
and Assembly:
1. Dismantling
① Park the vehicle on straight ahead.
② Disconnect terminal post of battery
and wait for 3 mines.
③ Dismantle driver's
safety airbag module.
④ Dismantle steering wheel.
⑤ Dismantle upper
and lower protective cover of steering column and the lower section of
instrument panel on driver's side.
⑥ Dismantle combined
switch assembly and timer spring.
⑦ Disconnect each wire harness connector installed on
steering column, and then move wire harness from steering column assembly.
⑧ Dismantle connecting bolts between
steering column and lower shaft, and separate steering column and steering
gear.
■ Tightening torque: 46〜50N•m
⑨ Dismantle fixing nuts of steering column assembly,
lower steering column and remove steering column assembly.
■ Tightening torque ：15〜25N•m
2. Inspection after Dismantling
① Inspect whether steering column has crack,
deformation or other damage. If yes, replace it.
② Inspect whether steering column shaft spline has
abrasion and broken teeth, if yes, please replace it.
3. Disassembly
① Disassembly
a.
Loosen connecting bolts between steering
column and connecting shaft universal joint, and then disconnect universal
joint.
b.
If necessary, dismantle steering lock.
Notes:
■ When reinstalling steering lock, it
is necessary to replace special bolts.
c. If necessary, dismantle
adjustable steering column and bracket.
② Key points of
disassembly Dismantling of special bolts:
a.
Use electric drill to
drill hole on special bolt to accommodate screw.
b.
Use reacting thread screw
to tap, and dismantle special bolt.
4. Inspection after Disassembly
① Inspect whether
adjusting bracket and spring have crack and damage.
② Inspect whether
steering lock mechanism operates normally.
5. Assembly
Assemble steering lock assembly,
steering lock bracket and special bolt.
Notes:
■ When installing steering lock assembly and steering lock bracket
onto the steering column assembly,align steering column lock cut and
temporarily lock steering lock.
■ After making sure that the action of steering lock is correct,
tighten special bolts until bolt lock is cut.
6) Installation
The installation is operated in
reverse order of dismantling.
Notes:
■ Do not reused disposable parts.
■ Make sure that the steering column assembly is installed on the
middle position of steering wheel.
■ When installing connecting shaft onto the steering column, please
pay attention to installation position.
7. Inspection after installation
When placing vehicle on straight line
direction, completely rotate steering wheel for several times to confirm
whether steering wheel operates freely.
Mechanical Power Steering Gear Assembly
Element ：
Notes:
■ If rotating steering wheel when
separating steering column and steering gear assembly, it may damage timer
spring. Therefore, make sure to fix the steering wheel to prevent it from
rotating.
Dismantling and Assembly:
1. Dismantling
① Place the vehilce on
straight ahead line.
② Dismantle connecting
bolts between intermediate shaft assembly and mechanical steering gear from
driver's cab, and separate steering column and steering gear.
■ Tightening torque ：46〜50N•m
③ Dismantle locknut of
tie rod ball head.
■ Tightening torque: 32〜38N•m
④ As shown in figure,
use special tool to dismantle steering tie rod ball head from steering knuckle.
⑤ Dismantle front
auxiliary frame assembly and engine suspension.
Notes:
■ Please use jack to support.
⑥ Dismantle fixing bolts
of mechanical steering gear from auxiliary frame.
■ Tightening torque: 90〜110N•m
⑦ Remove
power steering gear assembly from the frame.
Notes:
■ Be careful to slow take it out, and do not damage tie rod dustproof
sleeve.
2. Inspection after dismantling
① Mechanical steering
gear
■ Inspect whether gear and rack works smoothly and whether gear and
rack have abrasion.
■ Inspect gear preload.
a.
Rotate gear with the speed of 4～6s for each circle, and measure gear preload within therack
full traveling range.
■ standard value ：0.6〜1.3N•m
b.
If the measured value
exceeds standard, first adjust plug, and then re-inspect gear preload.
c. If it still can't obtain the specified gear preload after adjusting
plug, inspect or replace plug components.
② Steering tie rod
■ Inspect rotation torque of steering tie rod.
a.
Quickly swing tie rod for 10 times.
b.
Use spring balance to
measure the swing resistance of tie rod.
■ Standard value: 0.5～3 N•m
If t he measure value isn't in
standard range, please replace it.
Notes:
■ If tie rod swings slowly without excessive gap, it can be used even
the measured value is lower than standard value. If the measured value is lower
than 4.3N•m, tie rod must be replaced.
③ Dustproof sleeve of
tie rod
■ Inspect whether dustproof sleeve has damage. If yes, please replace
it.
■ Inspect whether the intallation position of dustproof sleeve is
correct.
3) Installation
The installation is operated in
reverse order of dismantling.
Note: do not use disposable parts.
Notes:
■ When connecting mechanical steering gear and steering column, pay
attention to installation position.
■ After installation, exhaust air from steering hydraulic system.
■ When dismantling mechanical steering gear assembly, keep the tire on
horizontal ground on no-load condition, and conduct final tightening to nuts
and bolts.
■ Inspect wheel alignment.
4) Inspection after installation
■ Completely rotate steering wheel to left and right directions to
confirm whether steering wheel operates freely.
Calibration
Processing For Changing of EPS System
Important Tips:
■ After replacing, dismantling and repairing of the following prats,
it is necessary to re-calibrate them by using X431 diagnosis tester.
1. After replacing parts of EPS, it is necessary to conduct
commissioning according to the following steps.
2. After replacing parts of ESC, it is necessary to conduct
commissioning according to the following steps. Because it requires EPS
steering signal, it is necessary to correct it after changing parts.
3. When replacing some chassis parts and it is necessary to reconduct
four-wheel alignment, commissioning should be conducted according to the
following steps. Therefore, the output value of EPS steering signal should be
matched with four-wheel alignment parameters (toe-in).
Operation processing:
|
Steps
|
Content
|
Equipment
|
Remarks
|
|
First
step
|
Center
the mechanical position of steering system to make the left and right
steering angles of steering wheel the same, which means steering gear rack is
the same in left and right sides; (mechanical centering method is shown in
figure below)
|
For equipment of mechanical position centering of steering
system, refer to special tool 2.
|
This
step should be conducted on four-wheel aligner, to avoid movement of vehicle
after centering.
|
|
Second
steps
|
After
mechanical centering and correction of steering system, keep this position
for installation of steering wheel, and then fix steering wheel. Proceed with
four-wheel alignment operation.
|
Level gauge or other equipment can be used to fix
steering wheel.
|
This
step should be conducted on four-wheel aligner, to avoid movement of vehicle
after centering.
|
|
Third step
|
For four-wheel alignment, adjust four-wheel alignment
parameters.
|
Four-wheel aligner
|
After finishing
commissioning, make sure that the steering system is on mechanical centering
position;
|
|
Fourth
step
|
EPS system
calibration and initialization of steering angle signal can make the system
electronic centering position match with mechanical centering position. After
initialization of steering signal, effective and actual steering angle value
of steering wheel can be output and corresponds with complete vehicle
traveling condition, such as straight line traveling, steering angle signal
will output zero <relative value>. For details please refer to
calibration processing.
|
Diagnosis
tester
|
During
calibration processing, it requires: "steering wheel rotates ±25 degree
around center in circulation type with speed of less than 200°/s". Swing
to 25° to left side, return to the center position, swing to 25° to right
side and then return to the center position.
|
|
Fifth step
|
Inspect whether the calibration is successful: check the EPS malfunction
lamp on instrument. If the yellow indicator lamp goes out, it indicates that
the calibration is successful; otherwise, re-calibrate it.
|
|
Yellow malfunction lamp indicates that the system
isn't calibrated and initialized; red indicates that there is system fault.
It is necessary to use diagnosis tester to inspect.
|
Mechanical Centering Methods
1. Mechanical Centering
Tool
Back structure diagram of mechanical centering tool
|
|
Front structure diagram of mechanical centering
tool
|
|
Matching diagram of mechanical centering tool and
steering gear column
|
|
2. Mechanical
Centering Methods
Step 1: rise up the
vehicle by using double-column lifter to make the four wheels of the vehicle
leave off the ground and ensure that steering column has no load;
Step 2: Insert the back
side groove of centering tool into the spline of steering column, and ensure
that they are engaged tightly;
Step 2: Hold tool
handle and drive steering column rotate in counterclosewise, until steering
gear is completely in bottom position;
Step 3: rotate level
gauge to right upper direction by hand, and correct level gauge to ensure its
horizontal position;
Step 4: Use mark pen to
draw line on the cut on the middle of level gauge;
Step 5: Hold tool
handle to drive steering column rotate 1.63 circle counterclosewisely (visually
inspect and make sure the mark line is vertical);
Step 6: Remove centering tool, install steering wheel in
vertical with mark line. Mechanical centering is completed.
3. Simple Mechanical Centering Methods
① When replacing relevant parts of EPS module, it is necessary to use
centering tool to operate, so as to ensure calibration of steering angle.
② When repairing or replacing parts other than EPS module,
it is necessary to conduct mechanical centering, but simple methods can be used
(because the relative position of the whole steering system doesn't change);
③ Simple methods:
dismantle lower protective cover of steering column, manually rotate steering
wheel to center the tire, and observe bolt position of universal joint of
steering column, to make the bolt head (hex) is vertical to horizontal
direction.(hexagon face) perpendicular with horizontal direction
4. Descriptions of Steering Angle
Steering angle of complete vehicle
steering wheel:
Steering gear angle
stroke：153.6mm
Steering gear wire angle
drive ratio ：47mm/r
Full stroke steering
angle of S5 complete vehicle steering wheel：1176.5106
Steps for Calibration of Steering Angle:
① Enter into JAC specially used fault diagnostic system.
② Select JAC specially used V22.00
version, and enter into S5 diagnosis system.
③ Select EPS electric power steering
system, and click to enter into.
④ Select
steering angle calibration, and click to enter into.
⑤ after entering, follow the
instructions shown in interface. Turn the key to ON position and wait for 2s.
After operation, please click ""OK"".
Notes:
■ please follow the instructions shown in tester;
otherwise, the calibration will not be successful!
⑥ Follow the
instructions shown in tester, and satisfy preconditions of steering
calibration.
1. 9V
battery with voltage of 16V;
2. Speed 7kPh;
3. Engine runs
After the following conditions are
satisfied, click ""yes"".
⑦ Note: follow the instruction below
to conduct operation.
Please make sure that the mechanical
shaft is in correct position;
Steering wheel rotates
25 degree around center in circulation type with speed of less than 200°/s.
Adjust front wheel to make it loacate at straight line position, and then adjust
steering wheel to make it locate at center position.
After the following
conditions are satisfied, click ""yes"".
⑧ When
all steps are finished, instrument interface will instruct: calibration of
steering angle is successful.
Detection of Steering System Fault
If EPS has fault, its
mulfunction lamp on the instrument will light up (red). Diagnosis tester can be
used to conduct relevant inspection, so as to assist determination of fault
cause and troubleshooting and repair. Diagnosis tester can detect the following
fault codes. it is necessary to inspect or replace relevant parts according to
the displayed fault information.
Relation Between Steering System and Other
System
1. EPS and ESC system
If wheel speed signal
from ESC is incorrect, it may cause EPS no power or power weakness;
2. EPS and EMS system
If engine speed signal
from EMS is incorrect, it may cause EPS no power or power weakness;
3. EPS and instrument system
If signal from
instrument system is incorrect, it may cause EPS mulfunction lamp sends wrong
information;
Correct display methods are shown as
follows:
1. Under normal condition, when system is switched on, instrument
self-inspection lamp will light up for 3s (red) and then goes out;
2. If system has fault, warning light will light up (red) on
working condition or not go out after system is switched on;
3. If instrument lights up (yellow), it indicates that the EPS system
isn't calibrated or successfully calibratd; EPS system doesn't finish
initialization of steering angle signal.
4. If instrument lights up (yellow), instrument first lights up in red
color and then in yellow color. At this moment, steering angle signal requires
to be re-initialized; after rotating steering wheel (±200 degree) in original
position or vehicle travels a short time, if yellow lamp will go out, steering
angle signal requires the completion of re-initialization.
Common Fault Troubleshooting
Abnormal Sound:
1. Installation bolt of intermediate shaft assembly is loose, which
makes its spline engagement has gap;
2. The installation of mechanical steering gear is loose, and
mechanical steering gear has internal abrasion or gear, rack are adjusted
improperly.
3. If parts between systems is mismatched before leaving factory,
system will produce abnormal sound and failure, and other faults.
4. There is collision, scratch, abnormal sound during the whole
steering stroke.
Troubleshooting of Abnormal Sound:
1. Inspect and tighten fasteners on mounting points of each part of
steering system.
2. Replace relevant parts;
3. If necessary, return the fault parts for diagnosis analysis.
Heavy Steering:
1. Tire pressure is insufficient,
and steering column has clash with other parts, connection is loose, steering
gear assembly and other parts has loose connection.
2. Wire harness connected with EPS control module is disconnected or
connector is loose;
3. CAN signal required by EPS is missing.
Troubleshooting of Heavy Steering:
1. Inspect insufficient tire pressure, eliminate clashing between
steering column and other parts, loose connection of steering gear assembly and
other parts.
2. Use diagnosis tester to inspect EPS control module itself and CAN
network, and eliminate relevant faults or replace relevant parts.
Vehicle's off Track (Trial Run Vehicle
on Flat Road in Two Directions):
Fault Causes:
1. Steering wheel ball head joint is loose or front wheel alignment is
improper.
2. Steering rod system has twisting, deformation or excessive abrasion.
3. Pretension of rack inside power steering gear is adjusted
improperly.
4. Steering wheel has bad centering function, shaking or kickback.
Troubleshooting:
1. Adjust front wheel alignment and steering wheel ball head.
2. Adjust or repair pretension of power steering gear rack.
3. Inspect and adjust each
connection position in steering system according to the specification.
Calibration Processing of
Diagnosis Tester
Diagnostic
test send and start calibration
|
|
Safety verification send secret key
|
|
Diagnostic unit
input, stop calibration
|
|
Diagnostic unit
display condition dissatisfy
|
|
Calibration
and initialization was completed
|
|
Turn key into the OFF
gear , wait for 3 seconds
|
|
Check steering wheel
torque
|
|
Adjust front wheel in
the straight line
|
|
Steering wheel was
swing around the center of ±25°
|
|
Pre-conditions of inspection as follow
① 9V ＜Battery voltage ＜16V ② Speed＜17kPh; ③ Engine running
|
|
Please turn key into the ON gear, wait
for 2seconds
|
|
Repair Data and Specifications
Specification Table
|
Items
|
Specification
|
|
Steering wheel diameter
|
375mm
|
|
Steering column and lower shaft
|
Three-stage shrinking
|
|
Operation torque of steering wheel
|
3.0±0.5N•m
|
|
Power steering gear rack stroke
|
153.6±2mm
|
|
Line-angle drive ratio
|
47
|
|
Circle number of steering wheel
|
3.26±0.1
|
|
Type of mechanical steering gear
|
Gear rack
|
Tightening Torque Table
|
Items
|
Quantity
|
Tightening Toque (NMS)
|
|
Fixing nuts of steering wheel
|
1
|
42〜52
|
|
Mounting nuts of steering column
|
2
|
15〜25
|
|
Mounting bolts of steering column
|
2
|
15〜25
|
|
Connecting bolt between steering column assembly and
intermediate shaft assembly
|
1
|
38〜42
|
|
Connecting bolt between intermediate shaft assembly
and mechanical steering gear
|
1
|
38〜42
|
|
Main fixing bolts of mechanical steering gear
|
4
|
90〜110
|
|
Auxiliary fixing bolts of mechanical steering gear
|
4
|
40〜60
|
|
Adjusting nut of toe-in of steering tie rod
|
2
|
45〜55
|
|
Slotted nut of steering gear exterior ball head
|
2
|
30〜38
|
|
Mounting bolt of heat isolator
|
2
|
11〜13
|
|
Mounting nut of heat isolator
|
1
|
11〜13
|
DTC Table
of EPS System
|
DTC
code
|
DTC(Hex)
|
Descriptions
|
|
U0073
|
C073
|
Control module
communication bus is closed
|
|
U0100
|
C100
|
Miss communication
with ECM/ PCM ""A""
|
|
U0129
|
C129
|
Miss communication with
brake system control module
|
|
U0155
|
C155
|
Miss communication
with instrument panel cluster (IP C) control module
|
|
U0401
|
C401
|
Data from
ECM/PCM""A"" is fail.
|
|
U0418
|
C418
|
Data from brake system
control module is fail.
|
|
U0423
|
C423
|
Data from instrument cluster
control module
|
|
C1000
|
5000
|
Truth of power supply
voltage is difficult to distinguish
|
|
C1001
|
5001
|
Power supply voltage is
too high.
|
|
C1002
|
5002
|
Power supply voltage is
too low.
|
|
C1003
|
5003
|
Power supply voltage
exceeds critical value.
|
|
C1004
|
5004
|
Power supply voltage is
lower than critical value.
|
|
C1005
|
5005
|
ECU hardware error
|
|
C1006
|
5006
|
On torque sensor, when
reading software, a fault is detected.
|
|
C1007
|
5007
|
On toque sensor drive
procedures, when reading software, a fault is detected.
|
|
C1008
|
5008
|
Wrong address coding
|
|
C1009
|
5009
|
Measure phase current
range.
|
|
C100A
|
500A
|
Steering angle signal
is error (inspect the rationality of steering angle signal)
|
|
C100B
|
500B
|
Electric control unit
(ECU) is turned off improperly.
|
|
C100C
|
500C
|
Exceeding temperature
range
|
|
C100D
|
500D
|
Angle of rotor position
has error.
|
|
C100E
|
500E
|
Internal steering angle
is lack of credibility
|
|
C100F
|
500F
|
During ASIC
self-testing, errors related to internal steering angle are found.
|
|
C1010
|
5010
|
Steering system detects
excessive friction
|
|
C1011
|
5011
|
Index value of steering
signal position is wrong
|
|
C1012
|
5012
|
Switching of motor
rotor position sensor magnetoelectric signal is wrong
|
|
C1013
|
5013
|
Under system
overheating condition, reduce assisting torque.
|
|
C1014
|
5014
|
Under too low system
power supply voltage condition, reduce assisting torque.
|
|
C1015
|
5015
|
Because power density
is too high, reduce assisting torque.
|
|
C1016
|
5016
|
Complete vehicle
calibration data is wrong (the system updated calibration data)
|
|
C1017
|
5017
|
An error is found in
output grade.
|
|
C1018
|
5018
|
Electric rotor position
sensor detects a key deviation.
|
|
C1019
|
5019
|
The main signal
calculation value and auxiliary signal calculation value of electric rotor
position sensor have deviation.
|
