Content
Content
Overview ....................................................................................................................................................................... 1
I. Warnings and Precautions ................................................................................................................................. 1
(I) Warnings and Precautions ....................................................................................................................... 1
II. Vehicle inspection ............................................................................................................................................. 5
(I) Vehicle check items during operation ...................................................................................................... 5
(II) Items to be checked at least once a month ............................................................................................ 5
(III) Items to be checked at least twice a year .............................................................................................. 5
III Vehicle lifting .................................................................................................................................................... 5
(I) Vehicle lifting ............................................................................................................................................ 5
IV Maintenance ..................................................................................................................................................... 6
(I) Standard ................................................................................................................................................... 6
(II) Regular maintenance instructions .......................................................................................................... 7
V. Maintenance Information System .................................................................................................................... 9
(I) Description of arrow and symbol used in the manual ............................................................................. 9
VI Health and safety.............................................................................................................................................. 9
(I) Description .............................................................................................................................................. 9
(II) Acid and base .......................................................................................................................................... 9
(III) Brake fluid............................................................................................................................................ 10
(IV) Chemical materials ............................................................................................................................... 10
(V) Dust ....................................................................................................................................................... 10
(VI) Shock ................................................................................................................................................... 11
(VII) Exhaust ................................................................................................................................................ 11
(VIII) Fibrous isolation ................................................................................................................................. 11
(IX) Fire ........................................................................................................................................................ 11
(X) Emergency ............................................................................................................................................. 11
(XI) Foam – Polyurethane ........................................................................................................................... 11
(XII) Fuel ...................................................................................................................................................... 12
(XIII) Gas cylinders ...................................................................................................................................... 12
Content
Content
(XIV) Common workshop tools and equipment ......................................................................................... 12
(XV) Lubricant and Grease .......................................................................................................................... 13
VII Fastener specifications .................................................................................................................................. 13
(I) Fastener specifications ........................................................................................................................... 13
V
III Noise, vibration and abnormal sound .......................................................................................................... 15
(I) Diagnostic information and procedures................................................................................................. 15
(II) Maintenance guide................................................................................................................................ 17
IX. Vehicle identification ..................................................................................................................................... 18
(I) Vehicle identification number ................................................................................................................ 18
(III) Transmission identification number .................................................................................................... 20
(IV) Engine identification number .............................................................................................................. 20
Clutch .......................................................................................................................................................................... 21
I. Overview .......................................................................................................................................................... 21
(I) Structure Summary ................................................................................................................................ 21
(II) Maintenance parameters ...................................................................................................................... 23
(III) Torque parameters ............................................................................................................................... 23
(IV) Maintenance precaution ...................................................................................................................... 24
(V) Special tools .......................................................................................................................................... 24
II. Fault diagnosis ................................................................................................................................................ 24
(I) Common fault diagnosis ......................................................................................................................... 24
(II) Diagnosis table ...................................................................................................................................... 24
(III) Fault diagnosis flowchart ..................................................................................................................... 27
III Clutch pedal .................................................................................................................................................... 32
(I) Remove ................................................................................................................................................... 32
(II) Check ..................................................................................................................................................... 33
(III) Installation ........................................................................................................................................... 33
IV. Clutch pedal stroke ........................................................................................................................................ 34
VI. Clutch switch assembly ................................................................................................................................. 35
Content
Content
(I) Remove ................................................................................................................................................... 35
(II) Installation ............................................................................................................................................. 36
VII Clutch master cylinders and inlet pipe assembly .......................................................................................... 36
(I) Remove ................................................................................................................................................... 36
(II) Installation ............................................................................................................................................. 38
VIII Clutch cylinder and the inlet pipe assembly ................................................................................................. 39
(I) Remove ................................................................................................................................................... 39
(II) Installation ............................................................................................................................................. 41
IX Clutch hard pipe assembly .............................................................................................................................. 42
(I) Remove ................................................................................................................................................... 42
(II). Installation ............................................................................................................................................ 43
X Clutch cover and pressure plate assembly, clutch driven disc ........................................................................ 43
(I) Remove ................................................................................................................................................... 43
(II) Installation ............................................................................................................................................. 43
Drive shaft................................................................................................................................................................... 46
I. Overview .......................................................................................................................................................... 46
(I) Structure summary ................................................................................................................................. 46
(II) Torque parameters ................................................................................................................................ 47
(III) Maintenance precaution ...................................................................................................................... 47
(IV) Maintenance parameters..................................................................................................................... 47
(V) Special tools .......................................................................................................................................... 47
II. Fault diagnosis .............................................................................................................................................. 48
(I) Fault diagnosis table ............................................................................................................................... 48
III. Drive shaft ...................................................................................................................................................... 48
(I) Special tools ............................................................................................................................................ 48
(II) Remove .................................................................................................................................................. 49
(III) Check .................................................................................................................................................... 50
(IV) Installation ........................................................................................................................................... 50
Content
Content
IV. Drive shaft seal .............................................................................................................................................. 52
(I) Remove ................................................................................................................................................... 52
(II) Check ..................................................................................................................................................... 52
(III) Installation ........................................................................................................................................... 52
Front suspension ........................................................................................................................................................ 53
I. Overview .......................................................................................................................................................... 53
(I) Structure Summary ................................................................................................................................ 53
(II) Technical parameters ............................................................................................................................ 57
(III) Torque parameters ............................................................................................................................... 57
(IV) Maintenance precaution ...................................................................................................................... 57
(V) Special tools .......................................................................................................................................... 58
II. Fault diagnosis ................................................................................................................................................ 58
(I) Fault diagnosis table ............................................................................................................................... 58
III. Lower arm assembly ...................................................................................................................................... 59
(I) Remove ................................................................................................................................................... 59
(II) Installation ............................................................................................................................................. 60
IV. Front shock absorber and coil spring support assembly ............................................................................... 61
(I) Remove ................................................................................................................................................... 61
(II) Installation ............................................................................................................................................. 63
V. Stabilizer bar .................................................................................................................................................. 64
(I) Remove ................................................................................................................................................... 64
(II) Installation ............................................................................................................................................. 65
VI. Left ball pin rod assembly .............................................................................................................................. 65
(I) Remove ................................................................................................................................................... 65
(II) Installation ............................................................................................................................................. 66
VII. Front sub frame assembly ............................................................................................................................ 67
(I) Remove ................................................................................................................................................... 67
(II) Installation ............................................................................................................................................. 69
Content
Content
VIII. Front wheel hub assembly .......................................................................................................................... 72
(I) Special tools ............................................................................................................................................ 72
(II) Remove .................................................................................................................................................. 72
(III) Installation ............................................................................................................................................ 74
Rear Suspension ......................................................................................................................................................... 76
I. Overview .......................................................................................................................................................... 76
(I) Structure Summary ................................................................................................................................ 76
(III) Torque parameters ............................................................................................................................... 78
(IV) Maintenance precaution ...................................................................................................................... 78
(V) Special tools .................................................................................................................................................. 78
II. Fault diagnosis ................................................................................................................................................ 78
(I) Diagnostic table ...................................................................................................................................... 78
III. Rear shock absorber assembly ...................................................................................................................... 79
(I) Remove ................................................................................................................................................... 79
(II) Installation ............................................................................................................................................. 80
IV. Rear coil spring .............................................................................................................................................. 81
(I) Remove ................................................................................................................................................... 81
(II) Check ..................................................................................................................................................... 81
(III) Installation ............................................................................................................................................ 81
V. Rear torsion beam assembly ......................................................................................................................... 82
(I) Remove ................................................................................................................................................... 82
(II) Installation ............................................................................................................................................. 84
VI. Rear wheel hub assembly .............................................................................................................................. 86
(I) Special tools ............................................................................................................................................ 86
(II) Remove .................................................................................................................................................. 86
(III) Installation ............................................................................................................................................ 87
Wheel and Tire ........................................................................................................................................................... 89
I Overview ........................................................................................................................................................... 89
Content
Content
(I) Structure summary ................................................................................................................................. 89
(II) Maintenance parameters ...................................................................................................................... 94
(III) Torque parameters ............................................................................................................................... 94
(IV) Maintenance Precaution ...................................................................................................................... 95
II. Fault diagnosis ................................................................................................................................................ 95
(I) Fault diagnosis table ............................................................................................................................... 95
III Wheel alignment ............................................................................................................................................ 96
(I) Wheel alignment check and adjustment ............................................................................................... 96
IV Wheels ............................................................................................................................................................ 97
(I) Vehicle inspection .................................................................................................................................. 97
(II) Remove .................................................................................................................................................. 98
(III) Installation ............................................................................................................................................ 99
V Wheel balance ................................................................................................................................................. 99
(I) Remove ................................................................................................................................................... 99
(II) Adjustment ............................................................................................................................................ 99
VI. Wheel run out.............................................................................................................................................. 101
(I) Check wheel run out ............................................................................................................................ 101
VII Spare tire ..................................................................................................................................................... 101
(I) Remove ................................................................................................................................................. 101
(II) Installation ........................................................................................................................................... 101
Brake system ............................................................................................................................................................ 103
I. Overview ........................................................................................................................................................ 103
(I) Structure Summary .............................................................................................................................. 103
(II) Maintenance data and Specifications ................................................................................................. 106
(III) Torque parameters ............................................................................................................................. 106
(IV) Maintenance Precautions .................................................................................................................. 107
II. Fault diagnosis .............................................................................................................................................. 107
(I) Fault diagnosis table ............................................................................................................................. 107
Content
Content
III. Front brake pad friction plate ...................................................................................................................... 110
(I) Remove ................................................................................................................................................. 110
(II) Check ................................................................................................................................................... 110
(III) Installation .......................................................................................................................................... 111
IV. Front brake caliper assembly ...................................................................................................................... 111
(I) Remove ................................................................................................................................................. 111
(II) Installation ........................................................................................................................................... 112
V. Front brake discs .......................................................................................................................................... 113
(I) Remove ................................................................................................................................................. 113
(II) Check ................................................................................................................................................... 113
(III) Installation .......................................................................................................................................... 114
VI. Rear brake pad lining ................................................................................................................................... 114
(I) Remove ................................................................................................................................................. 114
(II) Inspection ............................................................................................................................................ 115
(III) Installation .......................................................................................................................................... 116
VII Rear brake caliper assembly ........................................................................................................................ 116
(I) Remove ................................................................................................................................................. 116
(II) Installation ........................................................................................................................................... 117
VIII Rear brake disc ........................................................................................................................................... 118
(I) Remove ................................................................................................................................................. 118
(II) Check ................................................................................................................................................... 118
(III) Installation .......................................................................................................................................... 119
IX Brake fluid ..................................................................................................................................................... 120
(I) Check .................................................................................................................................................... 120
(II) Brake fluid discharge ........................................................................................................................... 120
(III) Fill brake fluid ..................................................................................................................................... 120
X. Front brake hose ........................................................................................................................................... 121
(I) Remove ................................................................................................................................................. 121
Content
Content
(II) Installation ........................................................................................................................................... 121
XI. Rear brake hose assembly ........................................................................................................................... 122
(I) Remove ................................................................................................................................................. 122
(II) Installation ........................................................................................................................................... 123
XII. Brake pedal (MT) ........................................................................................................................................ 124
(I) Check and adjust .................................................................................................................................. 124
(II) Remove ................................................................................................................................................ 126
(III) Installation .......................................................................................................................................... 127
XIII. Brake light switch....................................................................................................................................... 128
(I) Disassembly .......................................................................................................................................... 128
(II) Check ................................................................................................................................................... 129
(III) Installation .......................................................................................................................................... 129
XIV. Unit assembly of vacuum booster with master cylinder (MT) .................................................................. 129
(I) Check on the car ................................................................................................................................... 129
(II) Disassembly ......................................................................................................................................... 129
(III) Installation .......................................................................................................................................... 131
XV. Unit assembly of vacuum booster with master cylinder (AT) .................................................................... 132
(I) Check on the car ................................................................................................................................... 132
(II) Disassembly ......................................................................................................................................... 132
(III) Installation .......................................................................................................................................... 133
XVI. Vacuum hose assembly ............................................................................................................................. 133
(I) Disassembly .......................................................................................................................................... 133
(II) Installation ................................................................................................................................................... 134
XVII Liquid sensor of brake fluid ....................................................................................................................... 134
(I) Disassembly .......................................................................................................................................... 134
(II) Installation ........................................................................................................................................... 135
XVIII Air-removal of brake system .................................................................................................................... 135
(I) System’s air-exhaust............................................................................................................................. 135
Content
Content
XIX Oil outlet tube of master cylinder .............................................................................................................. 137
(I) Disassembly .......................................................................................................................................... 137
(II) Installation ........................................................................................................................................... 137
XX Front brake pipe assembly .......................................................................................................................... 138
(I) Disassembly .......................................................................................................................................... 138
(II) Installation ........................................................................................................................................... 140
XXI Rear brake pipe assembly ........................................................................................................................... 141
(I) Disassembly .......................................................................................................................................... 141
(II) Installation ........................................................................................................................................... 143
XXII Rear brake hose assembly ......................................................................................................................... 145
(I) Disassembly .......................................................................................................................................... 145
(II) Installation ........................................................................................................................................... 145
XXIII Right-front brake oil pipe assembly.......................................................................................................... 146
(I) Disassembly .......................................................................................................................................... 146
(II) Installation ........................................................................................................................................... 146
Parking Brake System ............................................................................................................................................... 148
I General introduction ...................................................................................................................................... 148
(I) Brief introduction of structure ............................................................................................................. 148
(II) Maintenance parameter ..................................................................................................................... 148
(III) Torque parameter .............................................................................................................................. 149
II Failure diagnosis ............................................................................................................................................ 149
III Check and adjustment on the assembly of parking brake system ............................................................... 149
(I) In-car check .......................................................................................................................................... 150
IV Parking brake switch .................................................................................................................................... 150
(I) Disassembly .......................................................................................................................................... 150
(II) Installation ........................................................................................................................................... 151
V Parking brake system assembly ..................................................................................................................... 151
(I) Disassembly .......................................................................................................................................... 151
Content
Content
(II) Installation ........................................................................................................................................... 152
VI Parking brake fibre-drawing assembly ......................................................................................................... 152
(I) Disassembly .......................................................................................................................................... 152
(II) Installation ........................................................................................................................................... 153
Brake Control System ............................................................................................................................................... 155
I General introduction ...................................................................................................................................... 155
(I) Brief introduction on structure ............................................................................................................ 155
(II) System function ................................................................................................................................... 155
(III) Working principle ............................................................................................................................... 157
II ABS&ESP control module ............................................................................................................................... 160
(I) Components ......................................................................................................................................... 160
(II) Illustration of the stitch on ABS, ESP control module ......................................................................... 160
(III) Check on ABS&ESP control module ................................................................................................... 162
(IV) Torque parameter .............................................................................................................................. 163
(V) Maintenance precautions ................................................................................................................... 164
(VI) Special tools ....................................................................................................................................... 164
III Failure diagnosis ........................................................................................................................................... 164
(I) Brief introduction of failure diagnosis .................................................................................................. 164
(II) Fault diagnosis chart ........................................................................................................................... 165
(III) Diagnostic check on circuit ................................................................................................................. 172
IV Air-removal of ABS system ........................................................................................................................... 174
(I) Special tool ........................................................................................................................................... 174
(II) Conditions that needs air-removal ...................................................................................................... 174
(III) Air-removal of ABS ............................................................................................................................. 174
V Front wheels’ ABS wheel speed sensor assembly ......................................................................................... 180
(I) Disassembly .......................................................................................................................................... 180
(II) Installation ........................................................................................................................................... 180
VI Rear wheels’ ABS wheel speed sensor assembly ......................................................................................... 181
Content
Content
(I) Disassembly .......................................................................................................................................... 181
(II) Installation ........................................................................................................................................... 182
VII ESP controller assembly .............................................................................................................................. 183
(I) Disassembly .......................................................................................................................................... 183
(II) Installation ........................................................................................................................................... 183
EPS (Electronic Power Steering) .............................................................................................................................. 185
I Brief introduction ........................................................................................................................................... 185
(I) Structural introduction ......................................................................................................................... 185
(II) System’s working principle .................................................................................................................. 186
(III) Maintenance parameter .................................................................................................................... 186
(IV) Torque parameter .............................................................................................................................. 187
(V) Maintenance precautions ................................................................................................................... 187
II Failure diagnosis ............................................................................................................................................ 187
(I) Chart of diagnostic trouble codes for EPS ............................................................................................ 187
(II) Failure diagnosis .................................................................................................................................. 189
(III) Diagnostic flow chart .......................................................................................................................... 190
III Vehicle’s steering system check ................................................................................................................... 191
(I) Check .................................................................................................................................................... 191
IV Steering wheel assembly .............................................................................................................................. 192
(I) Disassembly .......................................................................................................................................... 192
(II) Installation ........................................................................................................................................... 193
V Steering column assembly ............................................................................................................................. 194
(I) Disassembly .......................................................................................................................................... 194
(II) Installation ........................................................................................................................................... 195
VI Steering shaft assembly with universal shaft ............................................................................................... 195
(I) Disassembly .......................................................................................................................................... 195
(II) Installation ........................................................................................................................................... 196
VII Steering gear assembly ................................................................................................................................ 196
Content
Content
(I) Disassembly .......................................................................................................................................... 196
(II) Installation ........................................................................................................................................... 197
Overview
Overview 1
Overview
I. Warnings and Precautions
(I) Warnings and Precautions
The definition of "Warning", "Important Notes" and "Caution"
The diagnostic and repair procedures in the service manual including the general and specific
nature of the two "Warning", "Important Notes" and "Caution", JAC provides maintenance information to
help service technicians to diagnose and repair, so that the vehicle can normally work, however, if the
technician is not operated by the recommended method, which may cause unpredictable hazards to the
technicians and the vehicle.
"Warning", "Important Notes" and "Caution" is prepared to prevent the above said danger, but not all
were able to foresee. Such information is located in a prominent position in the service manual and
prepared to prevent the types of information listed as follows:
• Cause serious injury to personnel
• Damage to the vehicle
• Unnecessary vehicle maintenance
• Unnecessary parts replacement
• Improper vehicle parts repair or replacement
The definition of "Warning"
When encounters "Warning", indicates to take the necessary measures or measures forbidden. If ignore
the "Warning" could lead to the following consequences:
• cause serious injury to personnel
• If the vehicle is not repaired properly, cause the driver and / or passenger serious injury.
The definition of "Important Notes"
"Important Notes" requires special attention to the necessary measures or measures forbidden. If ignore
the "Important Notes", will result in the following consequences:
• Damage to the vehicle
• Unnecessary vehicle maintenance
• Unnecessary parts replacement
• The maintained operation or performance of the components and system not normal
• Damage to related systems or components
• Damage to fasteners, basic tools or special tools
• Engine coolant, lubricating oil or other major oil leak
The definition of "Caution"
"Caution" the statement to stress the need for a diagnostic or repair procedure, the purpose of "Caution"
statement is as follows:
Overview
Overview 2
• Clear procedures
• provide additional information for the completion of a program
• clarify the reason of the recommended program operation
• provide a more effective way to complete the process of information
• provide past experience information to the technician in order to more easily complete the process
Warning about the lifting of a vehicle
△ Warning To avoid vehicle damage, serious personal injury or even fatality, when remove the main
part from the vehicle and use lift as support, jack should be used as support to stand the corresponding to
be demolished parts of the vehicle.
Warning on handling anti-lock braking system components
△ Warning certain parts alone in anti-lock braking system (ABS) cannot be repaired, disassemble or
attempt to disconnect some of the system components can result in personal injury and / or system
function abnormal. Only repair those components with permission to remove and install.
Warning about collision repair licensed device
△ WARNING avoid personnel injury caused by exposing to welding arc or plating (zinc oxide) metal
toxic fumes when grinding / cutting any type of metal or sheet molding. Repair work had to be done in a
well-ventilated area and wear approved respirator, goggles, earplugs, welder gloves and protective
clothing.
Warnings about driving assistant
△ WARNING when repair technician checking the fault position, the vehicle should be driven by the
assistant or it may result in personal injury.
Warning about battery disconnecting
△ WARNING Before maintaining any electrical components, the ignition key must be in the OFF or
LOCK position, and all electrical loads must be "OFF ", unless the procedure stated otherwise. If the tool
or device is easy to expose to charged electrical terminals, thus further disconnect the negative battery
cable is needed. Violation of these safety instructions could result in personal injury and / or damage to
the vehicle and vehicle parts.
△ WARNING if removing and installing airbags needed, disconnect the negative battery at least 90s,
then carry out dismantling work.
Warning about brake dust
When maintaining the wheel brake components, the following is not allowed:
• grinding the brake linings.
• sanding the brake linings.
• Use a dry brush or compressed air to clean the wheel brake components.
△ Warning some models or some installed brake parts after sales models may contain fibers, which may
mix with dust, inhalation of dust containing the fibers can cause serious injury to human body, which
makes it necessary to use a damp cloth to clean any dust on brake parts before maintenance.
Warning about brake fluid
Overview
Overview 3
△ WARNING Brake fluid can easily absorb wet and moisture, do not use brake fluid in open container,
which may be polluted by water, the use of improper or contaminated brake fluid may result in a system
failure, loss of vehicle control and personal injury.
Warning about the irritating of brake fluid
Brake fluid has irritation to skin and eye. Once touched, should take the following measures:
• Eye contact - rinse thoroughly with water
• Skin contact - wash with soap and water
Warning about the brake pipe replacement
△ WARNING Please be careful with fixation and installation when replacing the brake pipe and be sure
to use the correct fasteners, otherwise this may cause damage to the brake hose and brake systems and
causing bodily harm.
Warning about the clutch dust
△ WARNING When servicing clutch parts, do not grind or sand the clutch plate, and do not use a dry
brush or compressed air to clean parts, because which operation will generate dust. Use a damp cloth
moistened with water (but do not soak). Clutch plate may contain fiber, if generating dust during the
repair process, these fibers will mix with air. Inhalation of dust containing the fibers can seriously harm
human body.
Warning about the collision cut
△ WARNING recommends only to do parts of the cut, otherwise it will destroy the integrity of the
structure of the vehicle, and vehicle collision can cause human injury.
Warnings about eye protection
△ WARNING In implementing this program, wearing licensed goggles and gloves to reduce the risk of
injury.
Warning about the moving parts and hot surfaces
△ WARNING when working around a running engine, avoid contact with moving parts and hot surfaces
to avoid personal injury.
Warnings about the goggles and gloves
△ WARNING be sure to wear goggles and gloves when disassemble exhaust system parts, or the falling
rust and sharp edges from parts of the exhaust system can cause serious personal injury.
Warnings about removing reservoir cap
△ WARNING to avoid burns do not remove the reservoir cap before the engine is cool. Removing the
reservoir cap if when the engine and radiator are not cooled, the cooling system will release scalding
liquid and high-pressure steam.
Warning about the cooling system maintenance
△ Warning as long as there is pressure in the cooling system, even if there is no boiling solution in the
radiator, the temperature of the solution will be much higher than boiling water. If open reservoir cover
and perform maintenance on the cooling system when the engine is not cooled and under conditions of
high pressure, engine coolant could boil and immediately spray onto the operator body leading to serious
burns.
Overview
Overview 4
Warning about road test
△ Warning In the premise of ensuring safety and road test vehicle should comply with all traffic laws,
do not try anything that might jeopardize the operation of vehicle control, a breach of the safety
instructions can cause serious injury and damage to vehicles.
Warnings about the goggles and fuel
△ Warning when handling fuel, be sure to wear goggles to prevent fuel splashed into eyes.
Important note about brake system brake fluid filling
△ Important note: When you add brake fluid to the master cylinder reservoir tank, use brake fluid only in
clean, sealed brake fluid container and in line with DOT4. Not use the recommended brake fluid can lead
to pollution, causing damage to the hydraulic brake system components inside the rubber seal and / or a
rubber gasket.
Important note about brakes
△ Important Note: When removing the brake, use a wire to hang brakes to avoid damaging the brake pipe.
Special considerations about the affection of brake fluid on paint and electrical components
△ Important Note: Avoid brake fluid splashing on paint, electrical connectors, wire or cable, which will
damage the paint and cause corrosion of electrical components, if the brake fluid exposed to the paint,
wash the contact sites with water immediately, if the brake fluid contact with electrical connectors, wires
or cables wipe it with a clean rag.
Important note about fasteners
△ Important Note: Please use correct fasteners in the correct location, fastener replacement part number
must be correct, there is maintenance procedures in particular when requires to replace a fastener or use a
threaded fastener locking glue or sealant, do not use paint, lubricating oil or corrosion inhibitors on the
fastener or fasteners connecting surface, unless otherwise indicated. These varnishes affect fastener torque
and clamping force, and may damage the fastener. When install the fasteners, be sure to use the correct
tightening sequence and torque to avoid damage to the components and systems.
Important note about do not twist or bend hoses during installation
△ Important note: The inlet and outlet hose must not be twisted during installation, even to the
convenience of easily installation, as this may cause damage to the parts.
Important note about damage to machine surface
△ Important note: Do not nick, scratch or damage to the sealing surface, the sealing surface is machine
surface, damage which can cause leakage.
Important note about ring dismantle
△ Important Note: Do not pry the ring gear from the differential housing, pry the ring gear from the
differential housing may cause a ring gear and / or damage to the differential housing.
Important note about sealant
△ Important note: Do not let the room temperature curing sealant into the threaded blind hole, if so, it will
have hydraulic locking effect when tightening fasteners, a hydraulic locking fastener will cause fasteners
Overview
Overview 5
and / or other component damage, what’s more, the fastener cannot get the correct clamping force when
tightening, which will lead to improper seal and cause leakage. The firmware cannot properly tighten; it
will cause parts loosing or separating, and damage the engine severely.
Important note about steering wheel turning to the extreme position
△ Important Note: The duration of the steering wheel turning to the extreme position should not exceed 5s;
otherwise it may damage the steering motor.
II. Vehicle inspection
(I) Vehicle check items during operation
Tire, vehicle and position operation
Be alert when steering wheel or seat vibration occurs at normal highway speeds, which could
indicate a need to balance the wheels, in addition, if running deviation on the flat road may indicate the
need to adjust the tire pressure or wheel alignment.
Steering operation
Be alert when change steering operation, when the steering wheel turning is difficult or its free travel
is too large and abnormal sound during turning or parking, it need to be checked.
(II) Items to be checked at least once a month
Tires, wheels and pneumatic inspection
Check the tires for abnormal wear or damage and whether the wheel is damaged, check the tire
pressure before running, spare tire included, to maintain the recommended tire pressure label.
Oil leak check
If the vehicle parked a certain time, regularly check to see whether there is water r, engine oil, fuel or
other liquids on the ground under the vehicle. Dripping from air conditioning system after use is normal,
if fuel leak or smoke, find the cause and fault diagnosis should be carried out right away.
(III) Items to be checked at least twice a year
Brake master cylinder reservoir level
Check the fluid and keep a proper level, low level may indicate a brake pad or worn of brake lining,
in which case repair is needed, check the tank vent cover to ensure airway patency and with no dirt.
Clutch pedal free travel
Check the clutch pedal free travel and adjust if necessary. Refer to clutch pedal free travel adjustment.
Doors and windows sealant lubrication
Seal coated with silicon grease film with clean rags.
III Vehicle lifting
(I) Vehicle lifting
Refers to "Warnings and Important Notes" in the "warning about vehicle lifting." To avoid personal injury,
Overview
Overview 6
when use jack to support the vehicle or any work under the vehicle, be sure to use the jack stand.
Vehicle lifting point
△ Note Rear lifting machine block can't meet the threshold plate to the side frame rails or floor.
Put rear lifting machine block in the following locations: under the connection between the rear frame
rails and side frame rails.
△ Note Front lifting machine block can't meet the threshold plate to the side frame rails or floor. Put
front lifting machine block in the following locations: under the connection between the front frame rails
and side frame rails.
IV Maintenance
(I) Standard
Main liquid parameters
Name
Brand
Capacity
unleaded gasoline
unleaded gasoline at least 93
#
42L
1.3L engine coolant
50% ethylene glycol
5.5L
1.5L engine coolant
50% ethylene glycol
6L
Transmission lubricating oil
SAE.75W-90
2.0L
Engine Oil
SAE10W-30 SJ or above
4L
Air conditioning refrigerant
PAG56
0.12L
Brake fluid
DOT4
650ml±50ml
Air condition coolant
R134a
520g±20g
Washing liquid
NC310-c
4L
Power indicators
Project
Unit
1.5
5MT
1.5
CVT
Continuous shift start acceleration time (0-100km / h)
S
≤ 15
≤ 14
Direct gear acceleration (80-120Km / h)
S
≤ 26
≤ 11
Maximum speed
Km/h
≥ 180
≥ 170
Maximum grade ability
%
≥ 30
≥ 30
Fuel economy indicators
Item
1.5
CVT
Integrated/km）
≤ 6.8
90km/h constant speed （L/km）
≤ 5.5
Transmission gear ratio
Operational method
Remote operation
Overview
Overview 7
Rated input torque
200 N·m
Model
MF70B22
Ratio
3.769
2.053
1.393
1.031
0.778
3.25
4.056
Front and rear wheel maintenance parameters and location parameters
Item
Parameters
Tire pressure (cold)
220±10KPa
Tire size (1.5 5MT models)
205/55 R16 94V
Tire size (1.5 5CVT models)
205/55 R16 94V
Wheel run out
Radial
steel wheels
轮
1.0mm
aluminum wheels
轮
0.3mm
Axial
steel wheels
轮
1.0mm
aluminum wheels
轮
0.3mm
Item
Parameters
location parameters
Front tire
front wheel toe Angle
3.75′±6.75′
front-wheel camber
24′±30′
kingpin inclination angle
10.5°±1°
kingpin caster angle
3.65°±0.75°'
Rear tire
The rear toe Angle
24′±24′
The rear wheel unilateral toe
Angle
12′±12′
The rear wheel camber
Angle
-56′±30 ＇
(II) Regular maintenance instructions
Vehicle normal maintenance schedule
Maintenance item is given for the vehicle assumed for the following purposes:
To transport restrictions passengers and cargo indicated by the tire label located in the edge of the driver's
door. Travel within the statutory limit and on the appropriate operating road.
Planned maintenance item instructions
Detailed maintenance items listed in the maintenance schedule as below: in the implementation of the
following maintenance item, be sure to replace all the parts and complete all necessary repairs before
driving, and be sure to use the proper fluid and lubricants.
Tire and wheel inspection and transposition
Check the tires for abnormal wear or damage, if to make the tire wear evenly and extend tire life, the tire
transposition is needed. If abnormal or premature wear, check the wheel alignment situation, and then
Overview
Overview 8
check the wheels for damage.
Overview
Overview 9
V. Maintenance Information System
(I) Description of arrow and symbol used in the manual
1. Indicator arrow
2. Move direction of the arrow
3. Turn direction of the arrow
4. Part number label
5. Part enlarged
VI Health and safety
(I) Description
Vehicle maintenance, repair and many related operations will affect personal safety or health problems,
this section some of the risks associated with material and equipment operation listed, and also safety
guidelines to avoid such hazards.
This section does not include all matters related to health and safety, so all operations and procedures to
deal with the material should be implemented in the precondition of safety and health. Before using any
product, product manual provided by the manufacturer or supplier shall be consulted.
(II) Acid and base
Such as corrosive sodium carbonate and sulfuric acid.
Use of batteries and other cleaning materials are irritating or aggressive to eyes, skin, nose and
throat, which will also cause burns to human body and damage to ordinary protective clothing.
Avoid splashing in the eyes, skin and clothing as well as wear suitable protective clothing, gloves
and goggles to avoid inhalation spray. Be sure to prepare nearby wash devices such as: eye wash
bottle, lotus and soap for convenience and timely help when splash events occur. Eye danger signs
Overview
Overview 10
should be marked prominently.
(III) Brake fluid
There will be a slight irritation if splashed on the skin and eyes, try to avoid direct contact with the skin
and eyes, because of its very low pressure, inhalation of brake fluid vapor at room temperature is not high
risk.
(IV) Chemical materials
The using, storing and handling of chemical materials such as solvents, sealants, adhesives, coatings, resin
foam, battery acid, engine coolant, brake fluid, fuel, lubricating oil and grease should be noted. They may
be toxic, harmful, corrosive, irritant or highly flammable, and there odors and dust is a high risk.
The impact of long-term excessive exposure to chemical environment could be immediate or chronic,
transitory or eternal, cumulative, surface, life-threatening, or may affect life expectancy.
Chemical materials - operation should be performed
• Carefully read and follow the warnings and cautions on raw container, and any accompanying leaflets,
posters or other instructions for use, health and safety information table of the raw material, all of which
can obtain from the manufacturer.
• If stained with chemicals, should be removed from the skin and clothing immediately, if immersed
serious, clothing should be replaced immediately and thorough cleaned.
• Strictly compliance with work step instructions, and wear protective clothing to avoid direct contact with
skin and eyes.
• When in the course of processing chemicals, wash first before break, eating, smoking, or using toilet
facilities.
• Keep the work area clean, tidy and with non-chemical material spill.
Chemical materials - actions should be avoided
• Do not freely mix chemicals unless with the manufacturer's instructions; some chemicals can form other
toxic or harmful ones, when mixing, it can release other toxic and harmful gases and may lead to other
explosions and other accidents.
• Do not spray chemicals in a closed environment.
•Do not heat chemicals unless with the manufacturer's instructions; because some chemicals are highly
flammable, and some may emit poisonous gases.
• Do not let chemicals container remain open, its emitted gases may accumulate to toxic, harmful or
explosion degree. Some gas is heavier than air and may accumulate in a confined space.
• Do not put chemical materials into an unmarked container.
• Do not use chemical materials for hands and clothing cleaning. Chemicals, solvents and fuels in
particular, will make the skin becomes dry, and may cause allergies leads to skin inflammation or through
the skin directly absorbing toxic and hazardous substances to affect health.
• Do not store other chemical materials freely with an empty container unless the container has been
cleaned with supervision
• Do not arbitrarily olfactory or smell chemicals. Exposed to high concentrations of gas shortly may still
poison or get injured.
(V) Dust
Powder, dust and dirt may be irritating, noxious or poisonous, inhaling powdered chemical
materials as well as due to dry friction operation raised dust should be avoided, if ventilation is poor,
a respiratory mask protective gear should be wearied to prevent inhalation of dust.
Overview
Overview 11
Dust combustible material may cause a risk of explosion, explosion item and fire should be
avoided.
(VI) Shock
Use of electrical equipment incompliance to description, or misuse of equipment in good condition,
may cause electric shock. Be sure to regular maintenance and test the electrical equipment within the
specified time. Faulty equipment shall be marked, it is best to move outside of the work area. Worn,
kinks, cut, cracked or otherwise damages to wires, cables, plugs and sockets are prohibited and do not
allow electrical equipment and wiring in contact with water. Ensure to protect electrical equipment with
proper protection fuse. Do not misuse electrical equipment or use any equipment with hidden faults, if so
its result may affect personal safety. Be sure moveable electrical equipment cables will not be nipped and
damaged.
Implement basic first aid training must be carried on a dedicated appliance operator.
In the event of a shock:
• Before contact with the victim, first turn off the power
• If cannot turn off the power, then use a dry insulator material to remove the power off the victim.
• If received specialized first aid training, preform first aid immediately.
• Request medical assistance.
(VII) Exhaust
Exhaust gas contains toxic and hazardous chemicals, such as carbon oxides, nitrogen oxides,
acetaldehyde, lead and aromatic hydrocarbon substances. Only in the case of appropriate exhaust
ventilation equipment or common ventilation equipment with open space, engine can operate.
(VIII) Fibrous isolation
Fibers are used to isolate noise and sound. Its surface nature with sharp edges can cause skin irritation.
During operation, the procedures should comply with instructions and wear gloves to avoid skin contact
with excessive fiber.
(IX) Fire
Many materials related to vehicle maintenance are extremely flammable. After burning, some
materials will produce toxic and harmful gases. In the storage and handling of flammable materials or
solvents, do follow fire safety, especially near electrical equipment or ongoing welding operation areas.
Before using electrical and welding equipment, first make sure there is no fire hazard. When using
welding or heating equipment, prepare a proper fire extinguisher around the work area.
(X) Emergency
Not only to comply with the law, in the workplace it is best to have personnel who has received
professional training in first aid. If spill to the eyes, rinse with water at least 10min. If the skin is
contaminated, use soap and water to clean the contaminated area. If it is cold injury, it should be
immersed in ice water or cold water.
Personnel who inhale toxic gases should be immediately transferred to fresh air if adverse
phenomenon persists, should seek medical attention immediately or taken to hospital. If accidentally
swallowed the liquid should inform physicians label information marked on the container. Unless there is
instruction on the label, otherwise do not blindly lead to vomit.
(XI) Foam – Polyurethane
Foam is used for curing the seat cushion and decoration. Comply with manufacturer's instructions.
Overview
Overview 12
Component does not produce chemical yet may have irritant effects and may be harmful to the skin and
eyes, when operate, wear gloves and goggles. Personnel, who has chronic respiratory diseases, asthma,
bronchial problems, or suffering from a topic, should not handle or near the uncured materials, its spare
parts, vapor or spray may cause direct irritation and allergic reactions and may be toxic and harmful. Do
not breathe vapor or spray, these materials must be used in a well-ventilated, and respiratory protection
situation. The mask cannot be removed immediately after spraying, wait until the vapor and spray
dissipated completely.
Burn uncured foam components with the aged ones will produce toxic and harmful gases. During
the foam operation, prohibit smoking, use of fire and electrical equipment unless vapor, spray has been
completely cleared. All foam or special foam thermal cutting, should be operated in a well-ventilated
environment.
(XII) Fuel
Minimize direct skin contact with fuel, if exposed, wash the exposed skin immediately with soap and
clean water.
Gasoline Easily combustible material - comply with the smoking ban. If swallowed can cause
mouth and throat irritation, stomach absorption can lead to general weakness and confusion, a small
amount of gasoline will affect the lives of children, therefore, the effect to lungs is a very dangerous thing.
Gasoline can cause dry skin; prolonged or frequent exposure will cause skin allergies inflammation,
if entering eyes will cause pain. Motor gasoline may contain large amounts of benzene, can cause
poisoning after inhaling, so the concentration of gasoline vapors must be kept low. High concentrations of
gasoline vapor may cause physical discomfort to eye, nose and throat irritation, nausea, headache,
depression and drunken, and lead to rapid loss of consciousness.
When gasoline is processed, maintain good ventilation, when operating in confined spaces spy
especial attention to avoid the risk of inhalation of gasoline vapors due to spills.
When clean and maintain store gasoline equipment, pay special attention. Gasoline cannot be used as a
cleaning agent, do not use mouth to suck it.
(XIII) Gas cylinders
Gases like oxygen, acetylene, argon and propane, usually stores in the 13.8Mp (2001psi) pressure
gas cylinder, be particularly careful in the process of dealing with these cylinders, avoid mechanical
property damage to cylinder or valve. Gas filled in the cylinders should be given a clear and appropriate
label.
Cylinders should be stored in a well-ventilated place, and avoid exposure to ice or sunlight
environment. Fuel gases, such as acetylene and propane should not be stored together with the oxygen
cylinders.
Pay special attention to prevent gas cylinders and pipeline leaks, and avoid sources of ignition.
Only trained personnel can be conducted with a gas cylinder-related work.
(XIV) Common workshop tools and equipment
It is very important to always keep all of the tools and equipment in good working order and proper
operation. Remember not to leave any tools or equipment used contrary to the purpose as its design
features. Do not make equipment like cranes, jacks, axles and chassis brace or sling load in excess of its
maximum load limit. Damage caused by overload may not necessarily immediately apparent, but may
cause severe accident when use the next time. Do not use damaged or poor working conditions tools or
equipment, especially some high-speed devices such as: wheel. Damaged wheel will be broken and crack
without warning and cause serious injury.
Overview
Overview 13
When using the wheel, chisel or blasting equipment, wear appropriate eye protection equipment. When
using the sandblasting equipment to handle asbestos-containing materials or using a spray device to do
business, wear appropriate breathing mask. Ventilation equipment to control the dust, spray and dust
content in the environment is needed.
(XV) Lubricant and Grease
Avoid prolonged repeated contact with mineral oil, all lubricants and grease, all of which are irritated
to the eyes and skin.
Health Protection Security Code
• Avoid long and repeated contact with engine oil, in particular with the used ones.
• Wear protective clothing, including impervious gloves.
• Do not put engine oil stained cloth into pocket.
• Avoid engine oil to contaminate clothing, especially underwear.
• Do not dress in clothing and shoes contaminated by engine oil. Overalls must be cleaned regularly and
kept clean.
• Open wounds should be able to receive timely emergency treatment.
• At work, apply cream to the skin to avoid direct skin contact with engine oil.
• Use soap and water to clean, remove all of the engine oil. Apply protective agent containing lanolin
will help replace the natural oils removed on the skin.
• If the skin lesions occur, seek medical attention and medical treatment immediately.
Remove the residual grease before working on the assembly if possible.
• If there may be direct contact with eyes, wear goggles, like chemical goggles or face shield; what’s
more, eye wash equipment should be equipped.
Environmental precautions
Used waste engine oil and oil filter should be recycled through an authorized or licensed waste
disposal business, or waste engine oil recyclers. If in doubt, contact the local authorities of workplace-
related departments to deal.
Discard the used engine oil directly into the ground, sewer or drainage, or pour into water pipe is
illegal.
(XVI) Noise
During certain operations, high-decibel noise will be produced which may cause hearing damage. In
this case, wear proper hearing protection devices.
VII Fastener specifications
(I) Fastener specifications
JAC engineering standards have been adopted part of ISO defined standard metric fasteners size,
which aimed at reducing the number of fastener size, while maintaining optimal quality of each screw
thread size. (II) Main fastener tightening torque table
No
Item
Torque（N·m）
Remark
1
clutch pedal fixing bolt
20~28
2
clutch pedal fixing nut
20~28
Overview
Overview 14
3
pipe mounting bracket
20~28
4
exhaust bolts
8~12
5
shaft self-locking nuts
240~260
6
lower arm ball joint connection nut and knuckle
100~120
7
damper assembly connected to knuckle nut
100~120
8
speed sensors
10~15
9
front horizon bar mounting bracket and the sub-frame
mounting bolts
60~72
10
front shock absorber and body mounting nuts
60~72
11
front shock absorber self-locking nut
50~70
12
bolt connected with front shock absorber and knuckle
100~120
13
lower arm ball pin and knuckle connecting bolt
60~72
14
lower arm pin and lower arm connecting nut
60~70
15
lower arm front liner and sub frame connecting bolts
130~150
16
lower arm rear liner and sub frame connecting bolts
130~150
17
engine rear suspension and front sub frame connecting bolts
130~150
18
front sub frame front fixing nut
110~130
19
front sub frame rear fixing nut
60~72
20
drive shaft and front hub assembly self-locking nut
240~260
21
rear shock absorber and body mounting bolts
30~45
22
Rear shock absorber and rear torsion beam connecting bolts
60~72
23
Bolt connect to torsion beam and rear hub
60~72
24
rear twist beam and body mounting bolts
130~150
25
wheel nut
90~110
26
steering tie rod nut
45~55
27
spare tire fixing stud
25~35
28
front brake caliper and knuckle connecting bolt
75~85
29
brake and rear hub connecting bolt
65~75
30
rear twist beam rear brake caliper bolts
65~85
31
brake caliper positioning pins
35~45
32
brake disc and hub fixing screw
10~15
33
front and rear brake caliper bleed screw
7~13
34
brake pedal bracket bolt
20~25
35
brake pedal fixing nut
20~25
36
brake hose and brake caliper bolts
25~30
37
brake hardware fittings
16~18
38
parking brake control lever fixing bolt
20~25
Overview
Overview 15
39
fixing screw 39 parking brake switch
6~8
40
parking brake drawing mounting bracket nuts and bolts
7~11
41
speed sensor fixing bolt
8~10
42
brake hardware fittings nut
16~18
43
ABS controller and body assembly bolts
20~25
44
steering wheel retaining nut
42~52
45
steering column mounting nuts
20~25
46
steering column mounting bolts
20~30
47
controller mounting bracket bolts
8~10
48
steering column assembly and steering shaft assembly connecting
bolts
30~35
49
Steering shaft assembly and mechanical steering bolts
30~35
50
mechanical main steering gear mounting bolts
95~105
51
mechanical auxiliary steering gear mounting bolts
95~105
52
front tie rod bundle adjustment nut
45~55
53
Steering outer ball head slotted nut
40~50
V
III Noise, vibration and abnormal sound
(I) Diagnostic information and procedures
Wind noise / air sound
△ WARNING Refers to "Warnings and Precautions" in the "warning about the assistant driver."
△ Note when the technician is repairing the fault location, the vehicle should drive by assistant,
otherwise, may cause injury.
In order to accurately confirm the location of wind noise, test drive should be in the car. In general,
the presence of wind noise has major leaks and minor leaks, if not repair all leaks in the repair process, it
can only reduce wind noise but not completely eliminate wind noise. Test drive service personnel should
take the following tools to help diagnose the specific location of wind noise:
• Stethoscope
• Masking tape
• Caulking article
• Marker
• Screwdriver road test in accordance with the following procedures:
• Select a line, which has straight direction of east, south, west, north four different streets.
• Select fewer or smaller traffic noise streets to avoid affection.
• In the speed that the customer thinks is most obvious noise or emit noise to test, exceeding legal limits
of speed is strictly prohibited.
The following wind noise is the external wind noise:
• After lowering the window glass of the vehicle while driving, wind noise can be heard immediately.
• When post tape on various decorative seal and gap, wind noise immediately disappear.
The internal wind noise is caused by air escape from the car, repairing should take the following
methods:
• When determining the leak position, put tape on the door pillar relief valve to form the pressure and
Overview
Overview 16
enhance wind noise.
• Use a stethoscope to confirm leak location.
• Use masking tape to temporary repair leak site.
• Continue road test to confirm whether totally eliminated wind noise or there is other leak site.
• Make sure that all the leak test found by road test, return to the repair shop, repair permanently with a
professional sound positioning methods and sealing materials.
Vibration
Most high-speed vibrations are caused by the dynamic balance of the wheel lost, if there are vibrations
after the dynamic equilibrium, refers to the following reasons:
• tire round failure
• rim round loss
• Tire has hardness deviation
Measure free run out of tire and wheel, if cannot detect all causes of vibration, the above-mentioned
three reasons called load run out, replace the original tire and wheel assembly with known good tire and
wheel assembly to repair the fault vehicle.
Vibration occurs in speed lower than 64km / h usually caused by beating. Vibration occurs in speed
higher than 64km / h usually caused by beating and imbalance.
Correct uneven tire
There are two ways to correct tires balanced but still have vibration. One method is to use automatic
machine, mount the tire to the machine and rub a small amount of rubber from the tire tread around the
high point on both sides. This method to correct the tire is usually permanent. If comply with
specifications when operate, will not have a significant impact on the appearance and tread life of the tire.
Use with edge-type tire repair tools for correction is not recommended, since this would shorten the life of
the tire, and cannot solve the problem fundamentally.
Another method is to disassemble the tire, turn the rim upside down by 180 ° which only used when
vibration of the tire and wheel assembly is confirmation of the diagnosis because this method may cause a
good wheel assembly has vibration intact.
Abnormal sound
If at high engine speeds the car creaks, check whether the underbody heats shield.
• Lift the vehicle and perform a visual inspection
• Bent the insulation panels slightly to make a gap with the bottom of the body.
Vehicle front end squeak when the weather is cold
Check front balancing pole isolation pouches
- Road test the vehicle when it’s cold and passing from the road potholes to reach the maximum stroke of
the front suspension.
- Removing the tape from the isolated pouches on the front balancing pole, and reinstall the isolation
pouches on tape.
Vehicle issued abnormal sound when bumping
Check the baggage compartment if the spare tire is properly fixed
- Open the luggage compartment; check the spare tire and vehicle tools.
- Reseat spare tire and vehicle tools.
- Road test the vehicle to inspect wither abnormal noise is eliminated.
Overview
Overview 17
Rear part of the vehicle issued glass percussion sound when bumping.
Check whether the rear door latch improperly adjusted
- Road test vehicle to check the situation.
- Loosen the lock nut and adjust the latch.
Door creak
Check whether the door interior panel harness connector creak.
- Tap the interior panels and carefully observe whether heard creaking
- Remove the door interior panels and wrap wiring harness connector with foam pad according
to actual situation of the vehicle
Door squeak when using
Check whether the door hinge lack of lubrication.
- Operating the door back and forth and listen carefully to see whether the door squeaks.
- Use loose rust door hinge and apply grease lubrication.
Squeak when shifting manual gearbox (cold and appear at the cold state)
Check the manual shift manual gearbox assembly under the dashboard fender starter jacket
- Switch gear shift lever in the room and see if there is squeak.
- Remove the floor console and replace the jacket under the shift lever or coat it with talcum.
(II) Maintenance guide
Wind noise / air sound external
Wind noise Wind noise leak repair methods are very close to water leakage. The actual repair
procedure depends on the type of repair seal.
Vibration
Wheels and tires under balancing
Use an electric balancing machine to dynamically balance car wheel. Balancing machines are
easy to use both for static equilibrium and dynamic equilibrium. Different from the car balancing
machines the under car balancing machine cannot correct the imbalance of the brake disc.
However, the accuracy of the under balancing overcome this drawback, fix the wheel to the
balancing machine, make a cone through the center hole of the back, without passing through the
wheel nut holes.
Wheels and tires car balancing
Car balancing can correct the brake disc vibration caused by imbalance.
△ Warning Control the lower supporting arm in the normal horizontal position to avoid drive axle
damage. When the wheels sink reaches full stroke, do not operate the vehicle in gear.
• During the car balancing operation, removing the balancing pad installed during the dynamic balancing
is prohibited.
• If doing balancing there is the need to increase the weights over 25g, divide the balancing pad into two
blocks, and mount to the inner and outer rim.
• Using the engine to turn the driven wheel and wheel assembly.
Overview
Overview 18
Wheel and tire position fitting
Wheels and tires are fitted at the factory, and match thicker parts of the tire radial direction (also
referred to as the high point) to the minimum radius of the wheel (also called low point). When the tire
just finished, tire initial high point marked with a red paint mark or outer wall is attached to label.
Wheel low position is the valve core. Before removing the tire from the wheel, mark first in the tire
valve core, to ensure that it can be installed into its original position.
Abnormal sound
Abnormal sound maintenance
Abnormal noise mainly comes from the vehicle relative motion which should not exist between the
parts. Repair abnormal sound in three ways:
• Secure fastening parts, to make sure there is no relative movement of the vehicle in the process of
moving.
• Separate components, so that they are not in contact at work.
• Isolate parts, so that there is no abnormal noise components generated when moving. Uniform low
friction surface can be used to eliminate viscosity between the sliding parts
IX. Vehicle identification
(I) Vehicle identification number
1. Vehicle identification number
1) The vehicle identification number (VIN) plate is a
statutory marker.
2. Vehicle identification number (VIN) print position
Vehicle identification number (VIN) plate has two
printing positions
1). One position of the vehicle identification number (VIN)
is engraved on the front seat and right side of front
crossbar. Adjust the passenger seat to the back end; open
the carpet under the seat cover to see printed VIN code
2). The other location is in upper left corner of the
instrument panel which can be seen through the front
window outside the vehicle
Overview
Overview 19
(II) Signs
1. Plate.
1). Plate is located in the front passenger side of the
lower portion of the outer B-pillar.
2) Plate - vehicle compliance certification.
2. Tire information plate
1) There is some basic information about the tire on the
tire information signs.
3. Tire pressure label
1). Tire pressure label affixed to the driver's door side of
the vehicle, the label display the cold tire inflation
pressure and specifications. The recommended cold tire
inflation pressure on the label indicated is the minimum
pressure required to support maximum vehicle load.
轮胎气压标签 轮胎充气压力
轮胎规格
前轮
FRONT
220 220205/55R16 94W
REAR
后轮
TIRE SIZE
S2-w3005b
Overview
Overview 20
(III) Transmission identification number
1. Engraving position of the identification number.
(IV) Engine identification number
1. Engraving position of the identification number.
1). Engraving position of the engine identification
number
Clutch
Clutch 21
Clutch
I. Overview
(I) Structure Summary
Architectural Overview
Clutch assembly is located between the engine and gearbox, the clutch pressure plate is fixed to the
rear plane of the flywheel by a bolt assembly. Clutch disc and gearbox are connected by a spline input
shaft which can slide axially, and transmit torque to the surrounding. During driving, according to the
depressing or releasing the clutch pedal to temporary separate and gradually engage the engine and
gearbox to cut off or pass the input power from the engine to the transmission.
Clutch system includes the following components:
• Active parts: clutch pressure plate assembly clutch pressure plate assembly is bolted to the flywheel.
• Follower: Clutch disc Clutch disc and gearbox are connected by a spline input shaft. Active parts and
the follower are kept in contact by spring pressure. This pressure is exerted by a diaphragm spring
pressure inside plate assembly.
• Operating parts: clutch control system includes a clutch pedal, master cylinder, tubing, cylinder,
separation fork and bearing, when depress the clutch pedal, through hydraulic pressure, master cylinder
pushes cylinder, separation fork, through bearing pushes diaphragm spring separation claw, release the
pressure plate, to disengage the clutch
Clutch
Clutch 22
Clutch control system
1. Clutch pedal assembly
2. Clutch hard pipe assembly -I
3. Clutch bracket -I
4. Clutch master cylinder and the inlet pipe assembly
5. Clutch cylinder assembly
Clutch
Clutch 23
Structure chart of clutch pressure plate and driven disc
1. Clutch cover and pressure plate assembly
2. Clutch driven disc
3. Hexagon head bolt and spring washer assemblies
(II) Maintenance parameters
Maintenance parameters
No
Item
Parameters
1
clutch pedal free travel
6~20mm
grease
No
Item
Grease model
1
cylinder
kingpin
Kunlun II low temperature grease
(III) Torque parameters
No
Item
Torque（N·m）
Remark
1
clutch pedal fixing bolt
20~28
2
clutch pedal fixing nut
20~28
3
oil pipe mounting bracket
8~12
4
exhaust bolt
20~28
5
clutch pressure plate mounting bolts
20~28
Clutch
Clutch 24
(IV) Maintenance precaution
Precautions
• The recommended clutch hydraulic oil is brake fluid "DOT 4".
• Do not reuse drained clutch hydraulic oil.
• Be careful not to spill clutch hydraulic oil on the body paint.
• Do not use gasoline or kerosene and other mineral oils; otherwise it will corrode the rubber parts of the
hydraulic system.
• Do not disassemble master cylinder and hydraulic release bearing.
△ WARNING Use vacuum cleaner to clean clutch plate, but not with compressed air.
Inspection Points
△ CAUTION Do not use a vacuum pump or any other type of evacuation power plant to operate the
system. Check the fluid level of the clutch hydraulic oil; make sure that the level is normal. Do not let
the clutch hydraulic oil fall on the body paint or other components. If the clutch hydraulic oil spilled on
the body paint or other parts, immediately wipe clean with a dry cloth.
(V) Special tools
No
Tool
Tool Dimensions
Description
1
Flywheel stopper
Fixed flywheel
II. Fault diagnosis
(I) Common fault diagnosis
Clutch assembly and clutch control system performance diagnosis should be performed by an
experienced driver or a skilled vehicle maintenance technician.
The following (failure) diagnosis involves common problems and possible causes. After appropriate
diagnosis, make adjustments according to the respective solutions in service manual diagnostic table and
corresponding to the appropriate section in each of the specific program, replace the parts as required.
During vehicle maintenance, clutch pressure plate and clutch disc cannot be repaired, if any one of
them is broken, replace the entire assembly.
If the clutch driven plate rivets polished or clutch disc polluted by oil or grease dirt, then it cannot be
used. If you need to replace a part, use well qualified new parts to replace it. The table below will help
diagnose the causes under the following conditions leads to emergence of a clutch system: not separation,
separation incomplete; the engagement incomplete, slip, noise and jitter
The number in the diagnosis table does not mean order of examination, there is no precedence
relations among the various possible causes.
(II) Diagnosis table
No
Failure
performance
Failure cause analysis
Solution
Remark
clutch lever deformation
replace the deformation part
Refers to
Clutch
Clutch 25
1
Unable to
separate
diaphragm spring deformation
replace the deformation part
clutch
unable to
separate
flowchart
diaphragm spring support ring
broken
replace the broken part
clutch pedal spring break and fatigue
replace the worn and broken part
clutch driven disc and flywheel or
clutch pressure plate or bonding
adjusting clutch system
2
Unable to
incomplete
separate
clutch driven disc deformation
when it turns it will swing
replace deformation, wear,
cracks and exceeding standard
size parts
Refers to the
unable to
incomplete
separate
flowchart
clutch driven disc broken
Replace clutch driven disc
clutch driven disc input does not
match with the gearbox shaft input,
or the input surface is worn
spline clutch disc not work well
with the gearbox input shaft
spline, to replace the clutch disc,
if any necessary, replace the
gearbox input shaft
clutch partly adhesive flywheel or
clutch pressure plate or bite
replace the non-qualified parts
flywheel / clutch pressure plate /
clutch disc exceeds standard size
replace the non-qualified parts
clutch pedal and the clutch control
system drawing mechanical failure
or improper adjustment
adjust clutch system, remove
unnecessary gap, eliminate
mechanical failure and reinstall
improper assembly parts
3
Unable to
incomplete
connect
clutch driven disc stained by oil or
grease dirt
Clean up the oil or grease dirt
Refers to the
unable to
incomplete
connect
flowchart
clutch driven disc broken
replace the deformation worn and
broken part
no clutch pedal free travel
properly adjust clutch pedal free
travel 程
diaphragm spring / clutch pressure
plate / clutch lever/ Clutch disc
splines deformed or damaged
replace clutch disc or clutch
assembly problem
Clutch pedal and the clutch control
system drawing mechanical failure
or improper adjustment
adjust clutch system, remove
unnecessary gap, eliminate
mechanical failure and reinstall
improper assembly parts
clutch plate wear
replace driven disc
Refers to
Clutch
Clutch 26
4
Slipping
Clutch contaminated by oil or grease
clean the grease or replace driven
disc
clutch
slippage
flowchart
Clutch engagement is not complete
The same with "incomplete
separation" and "engaging
incomplete" solutions
Flywheel / clutch pressure plate /
clutch plate thickness exceeds a
predetermined size
Replace non-qualified parts
improper driving leads to clutch
housing over heating
Turn off the engine, cool the
temperature in the clutch(if
overheated) and operate further
diagnosis
Improper installation
reinstall
5
noise
Improper clutch driven disc
Install requested clutch driven
disc
Refers to
clutch noise
flowchart
Improper balancing
If any part has improper
balancing, replace the whole
cutch
Clutch thrust bearing failure
adjusting clutch brush
and reinstall improper
assembly of parts
Clutch disc torsion damping spring
damaged
replace deformation, wear and
tear parts
6
Jitter
Clutch damper spring does not meet
the specifications
Replace the driven disc
Clutch driven disc does not meet
specifications
Replace the driven disc
Clutch pollution by oil or grease
Replace the driven disc
Clutch
Clutch 27
(III) Fault diagnosis flowchart
Clutch unable to separate flowchart
Clutch
Clutch 28
Unable to incomplete separate flowchart
Clutch
Clutch 29
Unable to complete connect flow chart
Clutch
Clutch 30
Clutch slippage flowchart
Clutch
Clutch 31
Clutch noise flowchart
Clutch
Clutch 32
III Clutch pedal
(I) Remove
1. Open the engine hatch,
2. Disconnect the negative battery cable,
3. Drain the clutch hydraulic oil refers to clutch hydraulic oil,
4. Remove the lower driver's side fender body refers to the lower driver's side fender body
5. Remove the driver's airbag assembly refers to driver's airbag assembly
6. Remove the steering assembly refers to steering assembly See
7. Remove the steering column on the shell package; under the steering column cladding refers to the
steering column cladding
8. Remove the clock spring refers to clock spring
9. Remove the combination switch refers to combination Switch
10. Removing burglar alarm induction coil refers to induction coil
11. Remove ignition lock assembly refers to the ignition lock assembly
12. Remove the steering column assembly refers to the steering column assembly
13. Removing the clutch pedal
1). Disconnect clutch wire harness connector.
2). Remove the clamp connected clutch pedal and
the clutch master cylinder, disassembly latch,
disengage the connection of clutch pedal and
clutch master cylinder.
3). Remove the two bolts connecting upper part
of clutch pedal and body.
Clutch
Clutch 33
4). Remove the two fixing nuts connecting clutch
pedal and the lower part of the body.
5). Remove the clutch pedal.
(II) Check
1. Check the clutch pedal after demolition
1) Check if the clutch pedal is distorted, damaged,
cracked or appears weld.
2). If occurs, please replace the clutch pedal assembly
(III) Installation
1. Install the clutch pedal
1). Place the clutch pedal to the mounting position.
2). Install two nuts connecting he clutch pedal and
the lower part of the body.
Tightening torque 20~28N·m
3). Install two bolts connecting the clutch pedal and
the upper portion of the body. Tightening torque 20 ~
28N • m
4). Install lock pin, install the clamp connecting
clutch pedal and the clutch master cylinder.
△ Note Before installation, coat low grease Kunlun II
to the outer surface of the front pin。
Clutch
Clutch 34
5) Connect clutch harness connector.
2. Adjust the clutch pedal free travel
3. Install the steering column assembly
4. Install the ignition lock assembly
5. Install anti-theft induction coil
6. Install the combination switch
7. Install the clock spring
8. Install the lower steering column cladding, under
the steering column cladding
9. Install the steering wheel assembly
10. Install the driver's airbag assembly
11. Install the lower driver side fender body
12. Fill the clutch hydraulic oil
13. Connect the negative battery cable
14. Close the engine hatch
IV. Clutch pedal stroke
1. Measure clutch pedal free travel
1). gently press the clutch pedal by hand to determine
when the pedal drop resistance, measure clutch pedal
free travel by scale.
Free travel: 6 ~ 20mm
△ Attention if the clutch pedal free travel is not in
specified region, then it must be the clutch hydraulic
circuit with air or clutch master cylinder is faulty.
Exhaust the systems, check the master cylinder or
dismantle the clutch.
2. Adjust the clutch pedal travel
1) Loosen the lock nut and turn the bolt, adjust the
clutch pedal travel. After adjusting, tighten the
lock nut.
Tightening torque 20 ~ 28N • m
△ Attention when adjust the height of the clutch
pedal, do not push the lever to the clutch master
cylinder.
V. Clutch hydraulic oil
1. Drain the clutch hydraulic oil
1) Open the brake fluid filler cap.
2) Place drip pan.
3). Empty brake fluid
4) Install the brake fluid filler cap.
Clutch
Clutch 35
△ Note cover the painted surface with a rag or cloth to
prevent adhesive of brake fluid.
2. Fill clutch hydraulic oil
1). Depress the brake pedal several times until the
complete elimination of the vacuum booster pressure.
2) Open the brake fluid filler cap.
3) Fill brake fluid.
△ NOTE Open the front tank cover, clean, only allowed to
store brake fluid in a sealed container.
3. Clutch system exhaust
△ Note after installing the clutch line, clutch master
cylinders, clutch assembly and clutch cylinder, if found
pedal weak, exhaust the system
1) Loosen the clutch working cylinder exhaust bolts。
2) Slowly depress the clutch pedal until the air is
completely discharged.
3).) fully depress the pedal and hold, tighten the exhaust
bolts.
4) Supply clutch hydraulic system with hydraulic oil.
△ Note always keep the liquid level in the tank between
MIN and MAX
5) Repeat steps 1-4 until clutch hydraulic oil discharged
from the system is clean and with no air bubbles.
4. Check whether the clutch is working properly
1) Start the engine; depress the clutch pedal, carefully
hang in reverse gear after 2s. If there is big noise during
gear selection, fully depress the clutch pedal five times to
exhaust the system.
2) After waiting for about 30s and then check the work
situation of the clutch. If there is still big noise, repeat the
above step
VI. Clutch switch assembly
(I) Remove
1. Open the engine hatch
2. Disconnect the negative battery cable
Clutch
Clutch 36
3. Remove the lower driver's side fender body refers to the lower driver's side fender body
4. Remove the clutch switch assembly
1). Disconnect the clutch switch harness connector.
2). Remove the buckle connecting the clutch pedal with
clutch switch harness, disconnect the clutch switch and
pedal.
3) Removing the clutch switch fixed nut.
4) Remove the clutch switch.
(II) Installation
1. Install the clutch switch assembly
1). Place clutch switch assembly to the mounting
position.
2) Tighten the clutch switch fixing nut.
3) Install the knuckle connecting clutch switch and
clutch pedal
4) Connect the clutch switch harness connector.
2. Install the lower driver side fender body
3. Connect the negative battery cable
4. Close the engine hatch
VII Clutch master cylinders and inlet pipe assembly
(I) Remove
1. Open the engine hatch
Clutch
Clutch 37
2. Drain clutch hydraulic oil, refers to clutch hydraulic oil
3. Remove the inlet pipe assembly
1). Remove the clip, disengage inlet pipe assembly
and brake master cylinder.
2). Remove the clip, disengage inlet pipe assembly and
clutch master cylinder.
3) Remove the inlet pipe assembly.
4. Remove the clutch master cylinder
1). Removing the clip, disengage inlet pipe assembly
and clutch master cylinder.
2) Remove the flare nut and disengage the clutch
hard pipe assembly - I and clutch master cylinder.
Clutch
Clutch 38
3). Remove the clamp connecting the clutch pedal and
clutch master cylinders, remove the latch, disengage the
clutch pedal and the clutch master cylinder.
4) Remove the two fixing nuts connecting clutch master
cylinder and clutch pedal body.
5) Remove the clutch master cylinder.
(II) Installation
1. Install the clutch master cylinder
1). Place the clutch master cylinder to the installation
location.
2) Install the two fixing nuts connecting clutch master
cylinder and clutch pedal body.
Tighten torque 20 ~ 28N • m
3) Install the lock pin, install clamp connecting clutch
pedal and the clutch master cylinder.
△ Note Coat low temperature grease Kunlun II on the
outer surface of the front pin.
4). Install nut connecting the clutch hard pipe assembly
- Ⅰ and clutch master cylinder.
Tightening torque 16 ~ 18N • m
Clutch
Clutch 39
5). Install clamps to connecting clutch master
cylinder inlet pipe assembly and the clutch master
cylinder.
2. Install the inlet pipe assembly
1). Install clamp to connect inlet pipe assembly and
brake master cylinder.
2) Install clamp to connect inlet pipe assembly clutch
master cylinder.
3. Fill the clutch hydraulic oil refers to clutch
hydraulic oil
4. Drain clutch system refers to the clutch hydraulic oil
5. Close the engine hatch
VIII Clutch cylinder and the inlet pipe assembly
(I) Remove
1. Open the engine hatch
2. Drain clutch hydraulic oil refers to clutch hydraulic oil
3. Remove the clutch inlet pipe assembly
Clutch
Clutch 40
1) Remove connection nut between the clutch inlet
pipe and the clutch hard tube assembly
2). Remove the fixing nut connecting clutch inlet pipe
and clutch working cylinder.
3). Disengage clutch inlet pipe assembly
4. Remove clutch cylinder
1). Remove bolts connecting the clutch inlet pipe and
the clutch cylinder.
2). Remove the latch and rivets connecting the clutch
cylinder and separation fork.
Clutch
Clutch 41
3) Remove the two fixing bolts connecting the clutch
cylinder and the gearbox.
4) Remove the clutch cylinder.
(II) Installation
1. Install clutch cylinder
1). Connect the latch and rivets to the clutch cylinder
and separation fork
2). Install fixing bolts connecting the clutch inlet pipe
and the clutch cylinder
3). Install two fixing bolts to connect the clutch
cylinder and the gearbox.
Tightening torque 14.7 ~ 21.6N • m
Clutch
Clutch 42
2. Install the clutch inlet pipe assembly
1) Install the fixing bolts to connect the clutch inlet
pipe and the clutch cylinder.
2) Install the connection nut between the clutch inlet
pipe and the clutch hard tube assembly - Ⅰ.
Tightening torque 16 ~ 18N • m
3. Fill the clutch hydraulic oil refers to clutch hydraulic
oil
4. Drain clutch system refers to the clutch hydraulic oil
5. Close the engine hatch
IX Clutch hard pipe assembly
(I) Remove
1. Open the engine hatch
2. Drain clutch hydraulic oil refers to the clutch
hydraulic oil
3. Remove clutch hard tube assembly
1) Remove the connection nut between the clutch inlet
pipe and the clutch hard tube assembly
2) Remove the pipe nut and the connection between the
clutch hard pipe assembly and clutch master cylinder.
3) Remove the clutch hard tube assembly
Clutch
Clutch 43
(II). Installation
1. Install the clutch hard tube assembly
1) Install oil pipe nuts and remove the connection
between clutch hard pipe assembly - Ⅰ and clutch master
cylinder.
Tightening torque 16 ~ 18N • m
2) Install the connection nut between the clutch inlet
pipe and the clutch hard tube assembly - Ⅰ
Tightening torque 20 ~ 28N • m
2. Fill the clutch hydraulic oil refers to clutch hydraulic
oil
3. Drain clutch system refers to clutch hydraulic oil
4. Close the engine hatch
X Clutch cover and pressure plate assembly, clutch driven disc
(I) Remove
1. Remove the transmission assembly refers to gearbox assembly
2. Remove the clutch cover and pressure plate assembly,
clutch driven disc
1). Remove the clutch cover and pressure plate assembly,
6 fixed bolts connecting clutch driven disc and the engine
.
(II) Installation
1. Install the clutch cover and pressure plate assembly,
clutch driven disc
1) Clean the clutch friction plate and the input shaft
keyway to remove grease and wear metals crumbs.
2) Apply grease to the input shaft keyway.
Grease: SAE J310
△ Note ensure that the grease is applied in the
predetermined position, if not may lead to clutch noise,
separation bad or damage. Too much oil can lead to slip
or jitter.
3) Install the clutch cover.
4) Use the special tool to install clutch plates and the
Clutch
Clutch 44
clutch pressure plate.
5) As shown in Figure through 1-2-3-4-5-6 sequence
tighten the clutch fixing bolts successively and evenly.
Tightening torque 20 ~ 28N • m
△ Note tighten each bolt 1 to 2 laps in turn progressively.
2. Install the transmission assembly
Drive shaft
Drive shaft 46
Drive shaft
I. Overview
(I) Structure summary
Drive shaft is located above the front sub frame and combined with left drive shaft assembly and right
drive shaft assembly, who transmit the transmission output torque and speed to the wheels. The inside of
the drive shaft is connected to gearbox differential by spline, by the inside universal joints can slide
axially inside the steering wheel in order to compensate for the change in length caused by turning and
jitter; through the outer universal joint it can have a large rotation angle and through a spline at the end of
the shaft, connect hub inner ring and lock with self-locking nuts.
Drive shaft assembly structure
1. Left front drive shaft assembly 2. Right front drive shaft assembly
Drive shaft
Drive shaft 47
(II) Torque parameters
No
Item
Torque （N·m）
Remark
1
Drive shaft self-locking nuts
240~260
2
Lower arm ball head and knuckle
connection nut
100~120
3
knuckle and shock absorber
assembly connection nut
100~120
4
speed sensors
10~15
(III) Maintenance precaution
1. Maintenance precaution related to the drive shaft
1). Knuckle and other non-repair parts are not removable.
2) Operate in a clean work surface.
3) Clean the outer parts surface before assembling and
disintegration.
4) When working, take care not to contaminate the parts
and prevent outer matter from entering. The disintegrated
components must be carefully reassembled in the correct
order. If the work is interrupted, cover the parts with clean
cover.
5) Use paper cloth to prevent the use of fiber debris
attached to the components.
6) Clean the disintegrated components (except rubber
parts) with kerosene and dry with a paper or cloth.
2. Things to be noted when check, repair system or replace parts.
1) Check whether the fastener torque is specified after
assembly.
2) Carry out necessary position checks after assembly.
3) Do not reuse the disposable parts.
4) Check thoroughly before repair or replace parts.
(IV) Maintenance parameters
Drive shaft
Item
outside
inside
Drive shaft
universal joint type
GI
AC
maximum allowable angle
23°
45°
Lubrication grease
Item
Lubrication grease
quantity
Drive shaft
GI
GRBN-1000
120±10g
AC
CVJM-2008J
120±10g
(V) Special tools
Drive shaft
Drive shaft 48
No
Tool
Outer look
Description
1
Japanese-style
ball puller
Remove ball head
z2
Differential oil
seal installation
tool
JAC-T6B025 S2-0610-9025-HL
II. Fault diagnosis
(I) Fault diagnosis table
No
Failure
Cause
Failure Cause analysis
Solution
Remark
1
Vehicle
deviation
shaft knuckle worn
replace
wheel bearing wear, friction or pop sound
replace
front suspension and steering defect
Adjust and replace
2
Vibration
shaft wear, damaged or bent
replace
shaft and hub splines loose or broke
replace
wheel bearing wear, friction or pop sound
replace
3
Beating
wheel unbalance
Adjust and replace
front axle steering defect
Adjust and replace
4
Loud noise
shaft wear, damaged or bent
replace
hub splines friction
replace
Drive shaft hub end spline wear
replace
wheel bearing wear, friction or abnormal
sound
replace
Wheel hub nut loose
Adjust and replace
front suspension and steering defect
Adjust and replace
III. Drive shaft
(I) Special tools
No
Tool
Outer look
Description
1
Japanese-style
ball puller
Remove ball head
Drive shaft
Drive shaft 49
2
Differential oil
seal installation
tool
JAC-T6B025 S2-0610-9025-HL
(II) Remove
1. Open the engine hatch
2. Remove the wheels refers to the wheels
3. Remove the drive shaft
1). Remove cotter pin and hex slotted nuts connecting to
the knuckle and tie rod.
2) Separate connection between the knuckle and steering
tie rod.
3) Remove the cotter pin and slotted nut connecting the
lower arm and knuckle.
4) Detach the lower arm and knuckle connection with a
special tool.
△ Note avoid violent demolition.
5) Remove the front brake hose and connect to the front
strut assembly bracket bolts. Disengage the connection of
the front brake hose and the front pillar.
Drive shaft
Drive shaft 50
6) Remove the drive shaft self-locking nuts
7) Tap the shaft with a hammer (or a suitable tool) and
wood, make the drive shaft and front wheel hub
assembly do relative activity.
△ Note if the hub and the drive shaft cannot be separated,
use puller (or a suitable tool).
8). Disengage the drive shaft and the front hub assembly.
△ Note avoid pulling the brake hose.
9) Insert a lever between the transmission housing and
the joint housing; separate the drive shaft from the
transmission.
△ Note support housing (joint assembly), shafts and other
components of the drive shaft before putting down.
△ Note Do not place a too big angle with the drive shaft
universal joint. Avoid excessive stretching, prevent cage
shedding.
(III) Check
1. Check all parts of the drive shaft
1) Check whether there is damage on left and right drive
shaft splines.
2) Check whether there is damage around the drive shaft
dust cover or securely installed.
3) Check whether there is clamp damage or missing on
the moving ends of the left and right shaft.
4) Universal joint should be able to ride in any direction
around the drive shaft.
(IV) Installation
1. Install the drive shaft
1). Apply gear oil on the drive shaft splines.
Drive shaft
Drive shaft 51
2) Slightly rotate the drive shaft
3) Match mobile end outer spline with the differential inner spline movement, then further push,
install the drive shaft mobile end to the transmission differential.
△ Note the clamp of the mobile end must be assembled in position.
△ Note the clamp open side should be downward.
4) Install the shaft fixed end of on the front hub
assembly.
△ Note self-locking nuts of the fixed end must be
assembled in position.
5) Install the shaft self-locking nuts. Tightening Torque
240 ~ 260N • m
6) Install the front brake hose to the front shock absorber
welded bracket bolts. Tightening torque 20 ~ 25N •
7) Install the cotter pin and slotted nut connecting the
lower arm and knuckle.
Tightening torque 60 ~ 72N • m
Drive shaft
Drive shaft 52
8) Install the cotter pin and hex slotted nuts connecting
the steering and knuckle tie rod.
Tightening torque 50 ~ 55N • m
2. Install the wheel
3. Check the wheel alignment refers to the wheel
alignment
4. Close the engine hatch
IV. Drive shaft seal
(I) Remove
1. Open the engine hatch
2. Remove the wheels refers to the wheels
3. Remove the drive shaft refers to the shaft
4. Remove the drive shaft seal
1). By using a pry bar to pry the outer seal lip,
disassemble the differential oil seal.
△ Note when use a pry bar to pry the seal, it should be
particularly careful not to damage the transmission
casing and seals.
(II) Check
1. Check the seal for cracks, damage and grease leakage.
2. Check the dust cover for cracks, damage and grease
leakage.
3. If there is non-compliance situation, replace the seals.
(III) Installation
1. Install the shaft seals
1). Apply the transmission oil on the new differential
lip seal assembly.
△ Note replace a new seal
2). By using special tools to install the new
differential seal components.
2. Install the drive shaft
3. Install the wheel
4. Close the engine hatch
Front suspension
Front suspension 53
Front suspension
I. Overview
(I) Structure Summary
1. The left lower arm assembly
2. The right lower arm assembly
3. The left front shock absorber and coil spring support assembly
4. The right front shock absorber and coil spring support assembly
5. The sub-frame assembly
6. The left front wheel hub assembly
7. The right front wheel hub assembly
8. Stabilizer bar
9. Left ball pin rod assembly
10. Right-ball rod assembly
Front suspension
Front suspension 54
Front shock absorbers and coil springs support assembly structure
1. Front shock absorber assembly
2. The front coil spring
3. The decorative cover
4. The buffer block
5. Dust cover
6. Upper spring cushion
7. Upper installation buffer block
8. Damper bearing
9. Upper spring seat
10. Self-locking nuts
11. (Fixed bearing) Nuts
Front suspension
Front suspension 55
Sub-frame assembly structure
1. Sub-frame assembly
2. Hex flange locking bolt pad assembly
3. Hex flange locking bolt pad assembly
4. Hex flange locking bolt pad assembly
Front suspension
Front suspension 56
Front hub assembly structure
1. Knuckle
2. Fender
3. Clamp
4. Flange plate
5. Bearing
6. (Fixed fender) bolt
Front suspension
Front suspension 57
(II) Technical parameters
Item
parameters and specifications
Front suspension mode
McPherson independent front suspension form with coil
spring suspension
Shock
absorber
model
Bidirectional hydraulic cylinder
stroke
140mm
Damping force
pill
806N±125N （0.3m/s）
press
443N±91N （0.3m/s）
Coil spring
free height：326mm
(reference）
Color rematk: yellow
and white stripe
Wheel
alignm
ent (no
load)
Wheel toe
3.75′±6.75′
Wheel camber
24′±30′
Kingpin inclination
10.5°±1°
Kingpin caster
3.65°±0.75°
Kingpin offset
-3.8mm
(III) Torque parameters
No
Item
Torque（N·m）
R
e
m
a
r
k
1
front stabilizer bar mounting bracket and the sub-frame fixing bolts
60~72
2
front shock absorber and body assembly nut
60~72
3
front shock absorber self-locking nut
50~70
4
front shock absorber and steering knuckle connecting bolt
100~1
20
5
stabilizer link assembly and stabilizer bar / damper assembly
connecting nut
60~72
6
lower arm ball pin and lower arm connecting nut
60~70
7
lower arm front liner and sub frame connecting bolt
130~1
50
8
lower arm rear liner and sub frame connecting bolt
130~1
50
9
Engine rear suspension and front sub frame connecting bolt
130~1
50
10
front sub frame front mounting nut
110~1
30
11
front sub frame rear mounting nut
60~72
12
drive shaft and front wheel hub assembly self-locking nut
240~2
60
(IV) Maintenance precaution
1. When install suspension or rubber liner, final tightening must be carried out under the condition that
the tire is on ground and with no-load.
2. After finish suspension components maintenance, be sure to check wheel alignment.
3. The oil will shorten the life of the rubber liner. Be sure to clean the spilled oil.
4. The no-load condition is the condition that fuel, engine coolant and lubricant are normally raised,
and spare tire, jack, hand tools and mats are in designated positions.
Front suspension
Front suspension 58
5. The locking nut should not be reused. Always use a new nut during installation. When replacing,
before tighten the locking nut, do not wipe anti-rust oil on the locking nut.
(V) Special tools
No.
Tool
Outlook
Description
1
Japanese-style ball
puller
Remove ball head
2
Damping spring
puller
Remove, install damper spring
3
Hub Installation
Tool
Install front and rear wheel hub
II. Fault diagnosis
(I) Fault diagnosis table
No.
Failure
Cause
Failure Analysis
Solution
Remark
1
Heavy steering
wheel alignment improper
Adjust
rotation beyond lower arm ball head
replacement
replace
tire pressure too low
charge air
With no power to steer
Maintain or replace
2
Improper
return
Front wheel alignment improper
Adjust
Shock absorber fault
Maintain or replace
anti-roll bar worn or damaged
replace
coil spring worn or damaged
replace
Lower arm liner worn
replace
3
Tire worn
abnormal
Front wheel alignment improper
Adjust
Tire pressure too low or too high
Adjust pressure
Shock absorber fault
Maintain or replace
4
Vehicle
deviation
front wheel alignment improper
adjust or replace
Lower arm ball head connector turn
without enough resistance
replace
Lower arm liner worn or loosen
replace
No.
Failure
Cause
Failure Analysis
Solution
Remark
5
vehicle
unilateral
deviation
improper front wheel alignment
adjust or replace
Lower arm ball head connector turn
without enough resistance
Replace
Lower arm bent
Replace
coil spring worn or damaged
Replace
Front suspension
Front suspension 59
6
Steering
wheel shimmy
improper front wheel alignment
adjust or replace
Lower arm ball head connector turn
without enough resistance
Replace
Lower arm liner loose or worn
Replace
shock absorber fault
maintain or replace
Anti-roll bar worn or damaged
Replace
coil spring worn or damaged
replace
7
vehicle
sagging
coil spring worn or damaged
replace
shock absorber fault
maintain or replace
III. Lower arm assembly
(I) Remove
△ Note to maintain wheel balance, before removing the
tire, mark the relative positions of the wheel.
1. Remove the wheels refers to the wheels
2. Remove the lower arm assembly
1) Remove the cotter pin and slotted nut connecting the
lower arm and knuckle.
2). Remove the front connection bolt between the lower
arm assembly and front sub frame.
3). Disengage the lower ball pin and the joint connection
with a special tool.
△ Note to avoid violent demolition.
Front suspension
Front suspension 60
4) Remove front connection bolt between the lower arm
assembly and front sub frame.
(II) Installation
1. Install the lower arm assembly
1) Place the lower arm assembly to the mounting position.
2) Install front connection bolt between the lower arm
assembly and front sub frame.
Tightening Torque 130 ~ 150N • m
3) Install rear connection bolt between the lower arm
assembly and front sub frame.
Tightening Torque 130 ~ 150N • m
Front suspension
Front suspension 61
4). Install the cotter pin and slotted nut connecting the
lower arm and knuckle
Tightening torque 60 ~ 72N • m
2. Install the wheel
IV. Front shock absorber and coil spring support assembly
(I) Remove
△ Note To maintain wheel balance, before removing the
tire, mark the relative positions of the wheel.
1. Open the engine hatch
2. Remove the wheels refers to the wheels
3. Remove the front shock absorber and coil spring support assembly
1). Remove the fixing bolt connecting the front shock
absorber in the central of the front brake hose, disengage
the connection between the front brake hose and the front
shock absorber.
2). Disengage a fixing point connecting the front wheel
speed sensor harness and front shock absorber.
Front suspension
Front suspension 62
3). Remove a fixing nut connecting the front shock
absorber assembly and the left damper ball lever;
disengage the front shock absorber assembly and the left
damper ball lever.
4) Remove a self-locking nut connecting front shock
absorber and coil springs support assembly nut and the
body.
5) Remove two bolts and nuts connecting the front shock
absorber assembly and the front knuckle.
Front suspension
Front suspension 63
6) Remove the front shock absorber and coil spring
support assembly from the wheel cover side.
(II) Installation
1. Install the front shock absorber and coil springs support assembly
1) Place the front shock absorber and the coil spring
support assembly to the mounting position.
2) Install two bolts and nuts connecting the front shock
absorber assembly and the front knuckle.
Tightening Torque 100 ~ 120N • m
3) Inset all a self-locking nut connecting front shock
absorber and coil springs support assembly nut and the
body.
Tightening torque 60 ~ 72N • m
Front suspension
Front suspension 64
4) Install a fixing nut connecting the front shock absorber assembly and the left ball pin lever.
Tightening torque 55 ~ 65N • m
5) Connect a fixing-point connection between the front
wheel speed sensor harness and front shock absorber.
6) Install the fixing bolt connecting the central of the front
brake hose and the front shock absorber.
Tightening torque 55 ~ 65N • m
2. Install the wheel
3. Close the engine hatch
V. Stabilizer bar
(I) Remove
△ Note To maintain wheel balance, before removing the
tire, mark the relative positions of the wheel.
1. Remove the left front wheel refers to the wheel
2. Remove the right front wheel refers to the wheel
3. Remove the stabilizer bar on the front sub frame and steering gear assembly refers to the front sub
frame assembly
4. Remove the stabilizer bar
1). Disassemble the four hex flanges bolt pad connecting
stabilizer bar and front sub frame.
2) Remove the stabilizer bar fixing bracket.
3) Remove the stabilizer bar liner.
4) Remove the stabilizer bar.
Front suspension
Front suspension 65
(II) Installation
1. Install the stabilizer bar
1) Place the stabilizer bar to the front sub frame mounting
position.
2) Place the stabilizer bar liner, stabilizer bar mounting
bracket; tighten the four hex flanges bolt pad connecting
stabilizer bar and front sub frame.
Tightening torque 60 ~ 72N • m
2. Install the stabilizer bar of the front sub frame and steering gear assembly
3. Install the left front wheel
4. Install the right front wheel
VI. Left ball pin rod assembly
(I) Remove
1. Lift vehicle
2. Remove the left ball pin rod assembly
1). Remove a self-locking nut connecting the left ball pin
rod assembly and stabilizer bar; disengage the left ball pin
rod assembly and stabilizer bar connection.
Front suspension
Front suspension 66
2). Remove a self-locking nut connecting the left ball pin
rod assembly and the front shock absorber assembly;
disengage the left ball pin rod assembly and the front
shock absorber connection.
3) Remove the left ball pin rod assembly
(II) Installation
1. Install the left ball pin rod assembly
1) Install a self-locking nut connecting the left ball pin rod
assembly and front shock absorber assembly.
Tightening torque 55 ~ 65N • m
△ Note self-locking nut cannot be reused, it must be
replaced with new ones.
2) Install a self-locking nut connecting the left ball pin rod
Front suspension
Front suspension 67
assembly and stabilizer bar.
Tightening torque 55 ~ 65N • m
△ Note self-locking nuts cannot be reused, it must be
replaced with new ones.
2. Lower the vehicle
VII. Front sub frame assembly
(I) Remove
1. Remove the left front wheel refers to the wheel
2. Remove the right front wheel refers to the wheel
3. Remove the left lower arm assembly refers to the lower arm assembly
4. Remove the right lower arm assembly refers to the lower arm assembly
5. Remove the rear suspension assembly refers to the rear suspension assembly
6. Remove the stabilizer bar of the front sub frame and diverter assembly
1). Remove a mounting bolt connecting the steering shaft
with a universal joint assembly and diverter.
2) Remove a self-locking nut connecting the left ball pin
rod assembly and stabilizer bar.
Front suspension
Front suspension 68
3) Remove a cotter pin and slotted nut connecting the
knuckle and tie rod.
4). Remove the two fixing bolts connecting the front sub
frame and the body front point.
5) Remove the two fixing bolts connecting the front sub
frame and the body middle point.
6) Remove the two fixing bolts connecting the front sub
frame and the body rear point.
7) Remove the front sub frame with stabilizer bar and
diverter assembly.
7. Remove the front sub frame
1). Remove the two hex flange bolts connecting diverter
assembly and the front sub frame and two locking nuts on
the diverter.
2) Remove the diverter assembly.
Front suspension
Front suspension 69
3). Disassemble four hex flange bolts pad connecting
stabilizer bar and front sub frame.
4) Remove the stabilizer bar fixing bracket.
5) Remove the stabilizer bar liner.
6) Remove the stabilizer bar.
(II) Installation
1. Install the front sub frame
1) Place the stabilizer bar to the mounting position of the
front sub frame.
2) Place the stabilizer bar liners, stabilizer bar mounting
bracket; tighten the four hex flange bolts pad connecting
the stabilizer bar and front sub frame.
Tightening torque 60 ~ 72N • m
3) Place the diverter assembly to the front sub frame
mounting position.
4) Install the two hex flange bolts connecting diverter
assembly and the front sub frame and two locking nuts of
diverter.
Tightening torque 95 ~ 105N • m
Front suspension
Front suspension 70
2. Install the front sub frame with stabilizer bar and diverter assembly
1) Place the front sub frame with stabilizer bar and
diverter assembly to the mounting position.
2) Install two fixing bolts connecting the front sub frame
and the body rear point.
Tightening torque 60 ~ 80N • m
3) Install two fixing bolts connecting the front sub frame
and the body middle point.
Tightening Torque 130 ~ 150N • m
4) Install two fixing bolts connecting the front sub frame
and the body front point.
Tightening Torque 110 ~ 130N • m
5) Install a self-locking nut connecting the left tie ball pin
rod assembly and stabilizer bar.
Tightening torque 55 ~ 65N • m
Note that self-locking nuts cannot be reused and must be
replaced for the new ones.
Front suspension
Front suspension 71
6) Remove a cotter and slotted nut connecting the knuckle
and tie rod.
7) Install a mounting bolt connecting the steering shaft
with a universal joint assembly and the diverter.
Tightening torque 30 ~ 35N • m
3. Install the rear suspension assembly
4. Install the left lower arm assembly
5. Install the right lower arm assembly
6. Install the right front wheel
7. Install the left front wheel
Front suspension
Front suspension 72
VIII. Front wheel hub assembly
(I) Special tools
Hub Installation Tools
No.
Tool No.
Tool name
outlook
1
Hub Installation Tools
(II) Remove
1. Open the engine hatch
2. Disconnect the negative battery cable
3. Remove the wheels refers to the wheels
4. Remove the front brake caliper assembly refers to the front caliper assembly
5. Remove the front brake disc refers to the front brake discs
6. Remove the front wheel hub assembly
1). Remove a mounting bolt connecting the front wheel
ABS wheel speed sensor and front steering section.
2) Remove the cotter pin and slotted nut connecting the
lower arm assembly and knuckle.
3) Disconnect the lower arm assembly and knuckle with a
special tool.
Front suspension
Front suspension 73
4) Remove the cotter pin and slotted nut connecting the
diverter assembly and knuckle, disengage the diverter
assembly and knuckle connection.
5) Remove the two bolts and nuts connecting the knuckle
and front shock absorber assembly.
6) Remove self-locking nuts connecting the drive shaft
and wheel hub assembly.
7) Disconnect the drive shaft and front hub assembly.
8) Remove the front wheel hub assembly.
Front suspension
Front suspension 74
(III) Installation
1. Install the front wheel hub assembly
1) Install the self-locking nuts connecting the drive shaft
and the front wheel hub assembly.
Tightening Torque 240 ~ 260N • m
2) Install the two bolts and nuts connecting the knuckle
and front shock absorber assembly.
Tightening Torque 100 ~ 120N • m
3). Install the cotter pin and slotted nut connecting the
diverter assembly and the knuckle.
Tightening torque 50 ~ 55N • m
Front suspension
Front suspension 75
4) Install the cotter pin and slotted nut connecting the
lower arm assembly and knuckle.
Tightening torque 60 ~ 72N • m
5) Install a mounting bolt connecting the front wheel ABS
wheel speed sensor and the front diverter.
Tightening torque 10 ~ 15N • m
2. Install the front brake discs
3. Install the front brake caliper assembly
4. Install the wheel
5. Connect the negative battery cable
6. Close the engine hatch
Rear suspension
Rear suspension 76
Rear Suspension
I. Overview
(I) Structure Summary
Rear suspension structure
1. Rear torsion beam assembly
2. Rear spool assembly
3. Rear coil spring
4. Rear wheel hub assembly
Rear suspension
Rear suspension 77
Rear shock absorber assembly structure
1. Rear shock absorber
2. Isolation pad B
3. Rear buffer block
4. Dust cover
5. Buffer block bearing
6. Isolation pressure pad
7. Isolation pad A
8. Nuts
Rear suspension
Rear suspension 78
(II) Technical parameters
Item
parameters and specifications
Rear suspension mode
Torsion beam form
Shock
absorber
model
Bidirectional hydraulic cylinder
type
stroke
160mm
Damping
force
Stretch
726N±134N （0.3m/s）
compression
434N±96N （0.3m/s）
coil spring
model
Straight spiral spring
Free height
352.5mm( reference)
Color mark
Same color by both sides
Wheel
Alignment
wheel total toe (rear)
24′±24′
single round beam
12′±12′
Wheel camber
-56′±30′
(III) Torque parameters
No
Item
Torque （N·m）
remark
1
Rear shock absorber and body assembly connecting bolts
30~45
2
Rear shock absorber and rear torsion beam connecting bolts
60~72
3
Rear hub and torsion beam connecting bolts
60~72
4
rear torsion beam and body connecting bolts
130~1
50
(IV) Maintenance precaution
1. When install suspension or rubber liner, final tightening must be carried out under the condition that
the tire is on ground and with no-load.
2. After finish suspension components maintenance, be sure to check wheel alignment.
3. The oil will shorten the life of the rubber liner. Be sure to clean the spilled oil.
4. The no-load condition is the condition that fuel, engine coolant and lubricant are normally raised,
and spare tire, jack, hand tools and mats are in designated positions.
5. The locking nut should not be reused. Always use a new nut during installation. When replacing,
before tighten the locking nut, do not wipe anti-rust oil on the locking nut.
(V) Special tools
NO
Tool
Outlook
Description
1
Shock absorber
spring puller
Remove, install damper spring
II. Fault diagnosis
(I) Diagnostic table
Rear suspension
Rear suspension 79
No.
Failure
Cause
Failure Analysis
Solution
Remark
1
Abnormal
sound
assembly loose
fasten
wheel bearing fatigue or damaged
replace
Damper assembly damaged
Replace broken parts
2
Vibration
Tire over pressure
Adjust pressure
Damper assembly damaged
Replace broken parts
wheel nuts loose
fasten
coil spring became shorter or broken
replace
tire defective
replace
3
Body tilt
coil spring became shorter or broken
replace
III. Rear shock absorber assembly
(I) Remove
1. Remove the rear wheels refers to wheels
2. Remove the rear seat cushion assembly refers to rear seat cushion assembly
3. Remove the rear seatback assembly refers to rear seatback assembly
4. Remove the rear door entry guard assembly refers to rear door entry guard assembly
5. Remove the C-pillar lower trim panel assembly refers to C-pillar lower trim panel assembly
6. Remove the C pillar upper trim panel assembly refers to C pillar upper trim panel assembly
7. Remove the tailgate entry guard assembly refers to tailgate entry guard assembly
8. Remove the tailgate trim panel assembly refers to tailgate trims panel assembly
9. Remove shock absorber assembly
1) Disassemble two nuts connecting the rear damper
assembly and body.
2) Disassemble fixing bolt connecting damper assembly
and rear torsion beam.
Rear suspension
Rear suspension 80
3) Remove the rear shock absorber assembly.
(II) Installation
1. Install the rear shock absorber assembly
1) Install two nuts connecting the rear damper assembly
and body.
Tightening torque 30 ~ 45N • m
2) Install fixing bolt connecting damper assembly and rear
torsion beam.
Tightening torque 60 ~ 72N • m
2. Install the rear door trim panel assembly
3. Install the tailgate entry guard assembly
4. Install the C pillar upper trim panel assembly
5. Install the C-pillar lower trim panel assembly
6. Install the rear door entry guard assembly
7. Install the rear seatback assembly
8. Install the rear seat cushion assembly
9. Install the rear wheels
Rear suspension
Rear suspension 81
IV. Rear coil spring
(I) Remove
1. Remove the rear wheels refers to wheels
2. Remove the rear coil springs
△ Note Mark before removing.
1). Remove a fixing bolt connecting the left side damper
assembly and torsion beam assembly.
△ Note during demolition process, pay attention to
spring sudden off to avoid personal injury!
2) Remove a mounting bolt connecting the right side
damper assembly and the torsion beam assembly.
3) Disassemble rear sprung rubber cushion, rear coil
springs, rear unsprang rubber cushion.
(II) Check
1. Check rear spring upper rubber cushion, and lower rubber cushion
1). Check whether there is wear or damage to the rear
spring upper rubber cushion, and lower rubber cushion. If
so, replace it.
2. Check the coil spring
1) Check whether there is wear or damage to the coil
spring. If so, replace it
(III) Installation
1. Install the rear coil spring
1) In accordance with the installation marks to install rear
upper rubber cushion, rear coil springs, rear lower rubber
Rear suspension
Rear suspension 82
cushion.
△ Note When install rear spring upper rubber cushion,
make the springs and rear spring upper rubber cushion fit.
△ Note put the lower end of the coil spring open toward
back then install.
2) Install a fixing bolt connecting the left side of damper
assembly and the torsion beam assembly.
3) Install a fixing bolt connecting the right side of damper
assembly and the torsion beam assembly.
Tightening torque 60 ~ 72N • m
2. Install the rear wheels.
V. Rear torsion beam assembly
(I) Remove
1. Open the engine hatch
2. Disconnect the negative battery cable
3. Drain the brake fluid refers to brake fluid
4. Remove the left rear wheel refers to the wheel
5. Remove the right rear wheels refers to the wheel
6. Remove the left rear brake caliper assembly refers to the rear caliper assembly
7. Remove the right rear brake caliper assembly refers to the rear caliper assembly
8. Remove the left rear brake pipe assembly, the right rear brake pipe assembly refers to brake hose
assemblies
9. Remove the torsion beam assembly
1). Lower the parking brake.
Rear suspension
Rear suspension 83
2) Disassemble the card and nuts connecting the torsion
beam assembly and rear brake discharge pipe assembly.
3) Remove the connecting of parking brake beam
assembly drawing and the rear wheel ABS wheel speed
sensor assembly and torsion beam assembly.
4) Remove the four fixing bolts connecting the torsion
beam assembly and the left rear wheel hub assembly.
5) Remove the four fixing bolts connecting the torsion
beam assembly and the right rear wheel hub assembly.
6). Remove a fixing bolt connecting torsion beam
assembly and the left side of body.
7) Remove a fixing bolt connecting torsion beam
assembly and the right side of body.
Rear suspension
Rear suspension 84
8). Remove a fixing bolt connecting torsion beam
assembly and the left rear shock absorber.
9). Remove a fixing bolt connecting torsion beam
assembly and the right rear shock absorber.
10) Remove the torsion beam assembly
(II) Installation
1. Install torsion beam assembly
1) Place the torsion beam assembly to the mounting
position.
2) Install a fixing bolt connecting torsion beam assembly
and the left side of body.
Tightening Torque 130 ~ 150N • m
3) Install a fixing bolt connecting torsion beam assembly
and the right side of body.
Tightening Torque 130 ~ 150N •
Rear suspension
Rear suspension 85
4) Install a fixing bolt connecting torsion beam assembly
and the left rear shock absorber.
Tightening torque 60 ~ 72N • m
5) Install a fixing bolt connecting torsion beam assembly
and the right rear shock absorber.
Tightening torque 60 ~ 72N • m
6) Connect the four fixing bolts connecting the torsion
beam assembly and the left rear wheel hub assembly.
Tightening torque 60 ~ 72N • m
7) Connect the four fixing bolts connecting the torsion
beam assembly and the right rear wheel hub assembly.
Tightening torque 60 ~ 72N • m
8) Install the two fixing bolt and two brackets connecting
the parking brake beam assembly drawing and the rear
wheel ABS wheel speed sensor and torsion beam
assembly.
Tightening torque 7 ~ 11N • m
Rear suspension
Rear suspension 86
9). Install the fixing point connecting the rear brake
discharge pipe assembly and the torsion beam assembly.
2. Install the left rear brake pipe assembly, the right rear brake pipe assembly.
3. Install the left rear caliper assembly
4. Install the right rear brake caliper assembly
5. Install the right rear wheel
6. Install the left rear wheel
7. Fill the brake fluid refers to brake fluid
8. Drain brake System refers to brake system
9. Connect the negative battery cable
10. Close the engine hatch
VI. Rear wheel hub assembly
(I) Special tools
No
Tool No
Tool name
Outlook
1
Hub Installation
Tools
(II) Remove
1. Remove the wheels refers to the wheels
2. Drain the brake fluid refers to the brake fluid.
3. Remove the rear brake caliper assembly refers to the rear brake caliper assembly
Rear suspension
Rear suspension 87
4. Remove the brake disc assembly refers to the rear brake discs
5. Remove the rear wheel hub assembly
1). Remove a fixing bolt connecting the rear ABS wheel
speed sensor and rear hub assembly.
2). Disengage the connection between the rear ABS wheel
speed sensor and the rear wheel hub assembly.
3) Remove four fixing bolts connecting the rear torsion
beam assembly and hub assembly.
4) Remove the rear wheel hub assembly.
(III) Installation
1. Install the rear wheel hub assembly
1).Successively connects the rear brake disc, rear brake
fender, and the rear wheel hub assembly to the torsion
beam.
2) Install four mounting bolts from inside the torsion beam
assembly connecting the rear hub assembly and the
torsion beam.
Tightening torque 60 ~ 72N • m
Rear suspension
Rear suspension 88
3) Install a fixing bolt connecting the rear ABS wheel
speed sensor and rear hub assembly.
Tightening torque 8 ~ 10N • m
2. Install the rear brake disc assembly
3. Install the rear brake caliper assembly
4. Fill the brake fluid refers to brake fluid
5. Drain the brake system refers to brake system
6. Install the rear wheel
Wheel and Tire
Wheel and Tire 89
Wheel and Tire
I Overview
(I) Structure summary
Tire structure （steel）
1. Tire (205/55 R16)
2. TR414 valve
3. Balancing Pad
4. Steel rim (6.5Jx16)
5. Tire nut
6. The wheel cap
Wheel and Tire
Wheel and Tire 90
Tire structure (aluminum wheels）
1. Aluminum rims (6.5Jx16)
2. The tire (205 / 55R16)
3. The tire pressure sensors
4. The decorative cover assembly
5. Wheel Nut
6. The tire pressure label
Wheel and Tire
Wheel and Tire 91
Spare tire structure
1. Tires
2. The balance weight
3. Rim
4. The spare tire fixing stud assembly
5. Valve
Wheel and Tire
Wheel and Tire 92
Tire pressure
Tire pressure has a decisive influence on the aspects of tire wear, fuel consumption, fault damage,
therefore, in order to drive safely, maintain standard pressure and check the tire pressure regularly.
The load capacity of the tire is corresponding to inflation pressure; determine a reasonable tire
pressure according to the condition of the vehicle load capacity. Climate and season changes should not
be a reason to adjust the tire pressure.
Incorrect tire pressure can cause:
1) Tires with no enough pressure will cause tire shoulder
quicker wear, tire deflection, rolling resistance increasing
2). Excessive tire pressure causes rapid wear of the
middle part of the tire tread, and reduce tire buffer
capacity.
Tire transposition
When running the wear situation of the front and rear wheels of the vehicle will be very different
according to the different load capacity, so in order to avoid tire wear by a single direction, regular and
timely transposition to make tires wear evenly, thereby extending the life of the tire.
NOTE: tire should be transposed when reach 8000km.
Tires should be transposed if new tires are replaced.
1) The recommended tire transposition
Wheel replacement
1. The wheel should be replaced when reaches 50000km in normal driving.
2. If one of the following occurs, it needs to be replaced:
1).The tire tread has worn at least three markers.
2) Tire rubber cords or cords appear.
Wheel and Tire
Wheel and Tire 93
3) The tire tread or tire shoulder crack and cords occur.
4) Tire bump, bulge or delamination.
5) Tire punctured, scratched or otherwise damaged, its
extent is difficult to repair.
Wheel alignment
Correct wheel alignment plays an important role for stable good control of the vehicle, eliminating the
abnormal tire wear, reducing driver fatigue.
Wheel alignment parameters include:
1. Toe
Toe is the difference between the distance of the two front wheels and the distance of the same
wheels two rear ends. If the wheels are perfectly parallel and the toe is zero. If the front wheel inwardly
inclined to car center line, the toe angle is positive. Otherwise the toe is negative.
The function of the toe is compensating the inward or outward rolling tendency caused by camber
angle of the tire and the road surface resistance.
2. Camber
Camber is tire relative angle to the vertical reference line, when the top of a wheel tilts outward,
portion is defined as positive, otherwise defined as negative. Camber settings can affect the control of
the vehicle direction and tire wear.
Improper camber settings can cause excessive tire wear or uneven wear, too much positive
camber will cause the outer tire tread wear, when the load of the outside tread is higher than the inner
side, it will cause uneven wear.
Excessive negative camber will cause the inside of the tire tread wear, the load of the inside tread
is higher than the outside, it will cause uneven wear.
3. Caster
Caster angle is the vertical angle between the kingpin axis and the ground. Kingpin caster angle
Wheel and Tire
Wheel and Tire 94
can produce a stability straight line running: The vehicle has a positive kingpin caster angle, while
rotating the wheel to the left, the left wheel will turn left around the kingpin, as the kingpin axis tilt
backward, the wheel ground movement trend downward in the vertical direction, so that it actual lift
up the left vehicle body. When turning is completed, after the release of the steering wheel, and force
the tire rise upwards and return to the relative original height of the body, so that the journal back to
the original position of driving towards the front.
(II) Maintenance parameters
Item
Parameters
Tire pressure (cold)
220±10KPa
Tire size(1.5VVT + 5MT 1.5VVT + CVT)
205/55 R16 94V
Tire size (1.5VVT + 5MT)
205/55 R16 94V
Wheel run out
Radial
steel wheels
1.0mm
Aluminum wheels
0.3mm
Axial
steel wheels
1.0mm
aluminum wheels
0.3mm
Item
Parameters
Wheel alignment parameters
Front
wheel
Front wheel toe
3.75′±6.75′
Front wheel camber
24′±30′
Kingpin Inclination
10.5°±1°
Kingpin caster angle
3.65°±0.75°'
Kingpin offset
mm
Rear
wheel
The total rear wheel toe angle
24′±24′
Unilateral rear wheel toe
angle
12′±12′
Rear wheel camber angle
-56′±30 ＇
(III) Torque parameters
No
Item
Torque (N • m)
Remarks
1
wheel nut
90~110
2
rod length adjustment lock nut
45~55
3
spare wheel fixing stud
25~35
Wheel and Tire
Wheel and Tire 95
(IV) Maintenance Precaution
1. Please use the original wheels.
2. During the new tire run-in period emergency start, sharp turns, sudden braking and using in bad
condition should be avoided to prevent new tires premature failure.
3. The new tire should be carried out wheel balance before using.
II. Fault diagnosis
(I) Fault diagnosis table
No.
Failure
Cause
Failure Analysis
Solution
Remark
1
steering wheel
circumference
vibration
the tire and rim excessive deflection
replace
Wheel nut loose
fasten
Wheel unbalance
replace
Tire unevenly tear
Adjust or replace
Tire insufficient pressure
replace
Front wheel bearing damaged or
worn
Adjust or replace
steering system failure
Adjust or replace 换
suspension system
failure
Adjust or replace 换
2
tire premature
wear
tire pressure incorrect
Adjust
Wheel alignment bad
Adjust toe and replace
Replace the rear tire torsion
beam
3
Tire noise
tire pressure incorrect
Adjust
tire deteriorate
replace
No.
Failure
Cause
Failure Analysis
Solution
Remark
4
Road noise or
body
vibration
insufficient tire pressure
Adjust
Unbalanced wheel
Adjust
Deformed rim or tire
Maintain or replace
Tire unevenly wear
Adjust or replace
5
Steering
wheel motive
up and down
Tire and rim excessive wear
replace
Wheel nut loose
Fasten
Unbalanced wheel
Adjust
engine mounting rubber
cracked or worn
replace
gearbox mounting rubber
cracked or worn
replace
6
steering wheel
tilt unilateral
Tire pressure on each side
is uneven
Adjust
Wheel and Tire
Wheel and Tire 96
Braking system failure
Adjust or replace
Tire pressure incorrect
Adjust
Excessive tire wear or
wear unevenly
Adjust or replace
steering system failure
Adjust or replace
Braking system failure
Adjust or replace
suspension system failure
Adjust or replace
7
Unstable
running
Tire pressure on each side
is uneven
Adjust
Rim or tire deformation
maintain or replace
wheel nuts loose
Fasten
steering system failure
Adjust or replace
suspension system failure
Adjust or replace
8
Steering wheel
heavy
insufficient tire pressure
Adjust
steering system failure
Adjust or replace
suspension system failure
Adjust or replace
9
steering wheel
return bad
insufficient tire pressure
Adjust
steering system failure
Adjust or replace
suspension system failure
Adjust or replace
III Wheel alignment
(I) Wheel alignment check and adjustment
1. Check the wheel alignment parameters
1) Check wheel alignment parameters to see whether it
meets the requirements, if not the front toe should be
adjusted in time, if other parameters not match, find the
cause and replace the parts.
Front toe angle parameters are as follows:
Front toe angle 3.75 '± 6.75'
△ Note the position inspection must carried out on flat
ground under no-load conditions
△ Note the front wheel camber, caster, kingpin inclination
angle and the rear wheel toe-in, rear wheel camber of this
model are pre-programmed at the factory, do not adjust.
△ Note If camber, caster and kingpin inclination is not
within the standard range, check the front suspension,
steering knuckle, shock absorber and tie rod for wear or
damage. If there is the above mentioned condition, replace
suspect parts.
Front wheel camber, kingpin caster angle, kingpin
inclination angle and the rear wheel toe-in, rear wheel
Wheel and Tire
Wheel and Tire 97
camber parameters are as follows:
Front wheel camber: 24 '± 30' Kingpin caster angle: 3.65 °
± 0.75 ° Kingpin Inclination: 10.5 ° ± 1 ° total rear wheel
toe angle: 24 '± 24' rear wheel unilateral toe: 12 '± 12' rear
wheel camber angle: -56 '± 30
2. Adjust the front wheel toe
△ Note the position inspection must carried out on flat
ground under no-load conditions
Front toe angle 3.75 '± 6.75'
If the toe is not within the standard range, adjust as
follows:
1) Check the set toe value on the wheel alignment meter.
2). Straighten steering wheel and lock dead.
3) Loosen the tie rod end locking nuts.
4) Turn clockwise or counter clockwise around the tie rod
beam, adjust the toe value to the standard value.
△ Note the turning amount of the tie rod should be
considerable
5) Locking the tie rod end locking nuts.
Tightening torque 45 ~ 55N •m
IV Wheels
(I) Vehicle inspection
Wheel and Tire
Wheel and Tire 98
1. Check tire appearance
1). Make sure whether there is wheel wear, inflatable
improper, cracks or other damage.
2. Check the tire pressure.
1) Use a well performed tire gauge to check tire pressure,
if not within the standard value, inflate or deflate the tire.
Standard value: 220 ± 10KPa
3. Check the tire treads
1) Check the depth of the tire treads
Tire size: 205/55 R16 (1.5VVT + 5MT) tire size: 205/55
R16 94V (1.5VVT + 5MT /1.5VVT + CVT)
△ Note when the depth of the tire tread reaches the limit or
less, tire tread has wear indicator. When there is an
indicator, replace the tires.
2) Check the tire treads to see whether there are foreign
objects. If yes, please remove.
(II) Remove
1. Remove the wheel
1) Loosen 5 wheel nuts on the wheel.
2). Lifting.
3) Remove 5 wheel nuts on the wheel.
4) Remove the wheel
Wheel and Tire
Wheel and Tire 99
(III) Installation
1. Install the wheel
1). According to the sequent ①-②-③-④-⑤ showed in
the pig to install the wheel nuts, tighten slightly.
2). Lower the vehicle.
3) According to the sequent ①-②-③-④-⑤ showed in the
pig to tighten wheel nuts.
Tightening torque 90 ~ 110N • m
△ Note 1. If manual installation, preload, then evenly
tightening according to the sequence as ① - ② - ③ - ④-
⑤.
2. If the automatic tightening, tightening torque should be
adjusted, tightened once.
3. Strictly tighten all wheel nuts according to fig showed
sequence
V Wheel balance
(I) Remove
1. Remove the wheels needed to be adjusted refers to the tire wheel
2. Remove the old balance weight on both side of the wheels, and remove foreign objects on the tire
treads
△ Note 1. When removing, be careful not to scratch the
wheels.
2. If the tire is new, remove the tape.
(II) Adjustment
1. Adjust the wheel balance
1). Use the center hole as the guide; mount the wheel on
the balancing machine and start the wheel balancing
machine.
2). When the value of internal and external imbalances on
both sides of the wheel have emerged on the balancing
machine monitor, select a balancing pad which weight
Wheel and Tire
Wheel and Tire 100
close to the equilibrium value and assembly specified in
the balancer wheel on the outside of the corresponding
position.
△ Note Install the outer balance weight before install the
inside ones. Before installing the balance weight, be sure
to clean the wheel surface.
△ Note 1. The balance weight cannot be reused, get a new
one every time.
2. Installed the balance weight pads cannot be more than
three.
3. Always use original pads.
4. Do not place weight pad on another piece.
S2-w3077b
3) Start the wheel balancer again.
4) In accordance with the position (or angle) of the wheel
balancer indication, knock balance pads into the inside of
the wheel.
5) Start balancing machine, confirm the remaining inside
and outside imbalance value is less than 5g, if either side
residual unbalance value is bigger than 5g, please continue
to the above work,
△ Note balance pad should be used according to the
Wheel and Tire
Wheel and Tire 101
demand, the using standard refers to service technical
parameters form.
VI. Wheel run out
(I) Check wheel run out
1. Remove tire wheel which needed to be checked refers to the wheels.
2. Install the wheel on the wheel balance machine.
3. Set the indicator as shown; inspect vehicle lateral run out and radial run out
Radial run out: 1mm
Lateral run out: 0.3mm
VII Spare tire
(I) Remove
1. Remove the spare tire
1). Open the trunk lid.
2). Uncover spare tire cover.
3) Get the vehicle tool box.
4) Loosen stud fixing the spare tire stud assembly.
5) Remove the spare tire.
(II) Installation
1. Install the spare tire
1) Place the spare tire well.
2). The fixing stud of spare tire stud assembly is screwed
into the rear body floor, the plastic part of the spare tire
stud assembly should fit with the rim center of the hole
edge.
Tightening torque 25 ~ 35N • m
Wheel and Tire
Wheel and Tire 102
3) Load the vehicle tool box.
4) Close the spare tire cover.
5) Close the trunk lid.
Wheel and Tire
Wheel and Tire 103
Brake system
I. Overview
(I) Structure Summary
Brake system diagram (front & rear plate models)
1. Left front brake caliper assembly
2. Right front brake caliper assembly
3. Front brake discs
4. Rear brake disc
5. Left rear brake caliper assembly
6. Right rear brake caliper assembly
7. Master cylinder flow lines assembly
8. Front brake exhaust pipe assembly
9. Right front brake pipe assembly
10. Rear brake exhaust pipe assembly
11. Left front brake hose assembly
12. Right front brake hose assembly
13. Left rear brake hose assembly Ⅱ
14. Right rear brake hose assembly Ⅱ
15. Vacuum booster with brake master pump assembly
16. Brake pedal assembly
Wheel and Tire
Wheel and Tire 104
Rear disc brake caliper structure (Front & Rear plate models)
1. The guide seat
2. Strut nut
3. The torsion spring
4. Strut
5. Guide seat bolt
6. Plug
7. Hex head bolt
8. Cylinder
9. The Under-pin
10. The bushing
11. Piston composition
12. Dust cover
13. The yoke spring
14. The inner brake assembly
15. Bracket
16. Bleeder screw and nut
17. The outer brake assemblyVacuum booster assembly diagram
Wheel and Tire
Wheel and Tire 105
1. The vacuum booster
2. The master cylinder
3. Brake fluid reservoirHydraulic line chart
1. Brake master cylinder 2. ABS / ESP module assembly
Wheel and Tire
Wheel and Tire 106
(II) Maintenance data and Specifications
Item
Specifications
master cylinder
type
Cascade
cylinder bore
22.22mm
brake booster
type
vacuum
Size (size)
10 inches
assist ratio
7.3:1
Front brake (front
disc rear drum
type)
type
Floating type/ventilated disc
Brake disc diameter
256mm
Brake disc thickness
22mm
Friction block thickness
10.8mm
cylinder bore
54mm
Rear brake (front
disc rear drum type)
type
Drum brake
Sub brake disc diameter
17.46mm
Brake disc thickness
204mm
Friction block thickness
4mm
Front brake (front
disc rear disc type)
type
Floating type/ventilated disc
Brake disc diameter
294mm
Brake disc thickness
25mm
Friction block thickness
9.5mm
cylinder bore
54mm
Rear brake (front
disc rear disc type)
type
Floating type/ventilated disc
Brake disc diameter
275mm
Brake disc thickness
9mm
Friction block thickness
8mm
cylinder bore
34mm
(III) Torque parameters
No.
Item
Torque (N • m)
Remarks
1
front brake caliper and knuckle connecting bolt
75~85
2
rear brake caliper and torsion beam bolt
65~75
3
rear brake and rear hub connecting bolt
65~85
4
front and rear brake caliper bleeder screw
7~13
5
brake pedal upper bracket bolt
20~25
6
brake pedal fixing nut
20~25
7
brake hose and brake caliper bolt
25~30
8
brake hardware fittings
16~18
Wheel and Tire
Wheel and Tire 107
(IV) Maintenance Precautions
1. All brake lines should not be excessive bending, twisting and stretching.
2. Verify that all vehicle brake lines do not interfere with other parts at ease or during steering.
3. The brake lines is an important safety part, always tighten its fixture. If found damaged parts, replace
the applicable component.
4. When disconnecting the brake pipe, please seal the connector end to avoid dust entering.
5. "DOT 4" brake fluid is recommended.
6. Do not reuse drained brake fluid.
7. Be careful not to splash brake fluid on painting, to avoid damaging the paint. If splashed on painted
areas, wash clean immediately with water.
8. Please wash with clean brake fluid all parts in the brake cylinder.
9. Do not use gasoline or kerosene and other mineral oil, to avoid damaging the rubber parts of the
hydraulic system.
10. Please use a dedicated pipe wrench when removing and installing tube, during brake tube
installation, be sure to check tightening torque.
11. After repairing or replacing brake discs, brake shoes, or appear lack of brake with a very short
distance, be sure to run-brake joint surface.
12. Make sure there is no brake fluid on the brake disc, do not spill brake fluid on the brake disc,
otherwise it will lead to brake failure.
II. Fault diagnosis
(I) Fault diagnosis table
Common braking system fault finding chart
No.
Failure Cause
Failure Analysis
Solution
Remark
1
when braking
the vehicle
deviate to one
side
insufficient left & right tire pressure
adjust
Front wheel adjusted incorrectly
adjust
Brake shoe has poor contact
adjust
Brake shoe surface has grease or oil
replace
brake drum eccentric or unevenly
worn
replace
Brake cylinder assembly adjusted
incorrectly
adjust
Self-adjusting mechanism is faulty
adjust
2
insufficient
braking force
lack of brake fluid or contaminated
Refill to replace
Brake system has air
Drain the system
The brake booster is faulty
Adjust
Brake shoe has poor contact
Adjust
Brake shoe surface has grease or oil
Replace
Self-adjusting mechanism is faulty
Adjust
Dragging brake shoe and brake
rotating parts cause overheating
Adjust
brake lines limits
Adjust
3
Increase the
pedal stroke
Brake system has air
Drain the system
Brake fluid leak
Adjust
Wheel and Tire
Wheel and Tire 108
(pedal to the
floor to reduce
the distance)
Self-adjusting mechanism is faulty
Adjust
Pushrod to the brake master cylinder
gap is too big
Adjust
No.
Failure
Cause
Failure Analysis
Solution
Remark
4
Brake
hysteresis
parking brake is not fully liberalized
liberalize
parking brake improperly adjusted
adjust
Brake pedal return spring worn
replace
Brake master cylinder reservoir port
restrictions
adjust
Rear drum brake return spring damaged
replace
lading parts insufficient lubrication
lubricate
One-way valve or the master cylinder
piston return spring defective
replace
master cylinder pushrod and gap is too
small
lubricate
5
parking
brake
function is
insufficient
rear brake shoe damage
adjust
The surface of rear brake shoe has grease
or oil
replace
Parking brake fastener jammed
adjust
Self-adjusting mechanism is faulty
adjust
The parking brake lever stroke is too big
adjust
6
Braking
force is
insufficient
pipe joints or brake cylinder cups leak
wipe clean and tighten or
replace
Pipeline residual exhaust air is not
drained
drain
Shoe drum gap is too large
retune
Hoof surface sticky oil or hardened
friction or replace
The drum overheating, pipe vapor
resistance
Replace, cooling, drain
7
brake is
hard to
release
brake cylinder cups back to the hole
blocked or remove
expansion or replace
drum shoe gap is too small
retune
Shoe return spring elastic weakened or
broken
replace
Hoof or floor deformation, return
blocked
Adjust or replace
8
noise
rear brake shoe severely worn
replace
Brake drum out of round
Cut and need balance
performance verification
Wheel and Tire
Wheel and Tire 109
Rear brake shoe surface is too smooth,
when friction coefficient is small and the
brake pressure is high, the noise will be
generated when friction and slipping the
smooth surface or when there is foreign
object between the extrusion friction
surface
After clearing the foreign
object, use sandpaper to polish
brake shoe
9
Brake
dragging
caused
brake drum
heating
brake gap and pedal free travel is too
small, when release the brake pedal, the
braking force is not fully liberated, so
that the friction lasts a long time; cause
start difficulties, driving weakness, when
touches the surface of the drum, it is hot
遇此情况 readjust the brake timing and
gap according to the request
brake handle is not fully liberalized,
caused by negligent operation or
improper adjustment, resulting in a long
time friction and heat
If necessary adjustments
according to specifications
The heat generated by braking causes
return spring thermal deformation, the
elastic force decline or disappear, which
makes that it after braking it cannot
guarantee that brake shoe assembly
return in time, the heat of the brake and
brake drum cannot be completely
removed
应检修或更 repair or replace the return
spring to eliminate failure
10
Parking
failure
Common brush or jacket rust, traction
spring break, fall off or elasticity
disappear, causing parking brake control
drawing or brake drawing is not flexible
in its coat, which makes the parking
brake does not release and cause failure.
Check whether there is injury
of the brake systems and brake
parts drawing surface, handle
maneuvers whether flexible
and without jam, the
connection of drawing is loose
and the fixed portion is
damaged, repair or replace
parts if necessary.
Wheel and Tire
Wheel and Tire 110
III. Front brake pad friction plate
(I) Remove
△ Note To maintain wheel balance, before removing the
tire, mark the relative positions of the wheel.
1. Remove wheels refers to the wheels
2. Remove the front brake caliper friction plate group
1). Remove mounting bolts of the brake caliper assembly
positioning pin.
2). Flip caliper clamp body assembly.
△ Note avoid pulling the brake hose
S2-w3085b
3). Remove the inner and outer brake pads.
(II) Check
1. Check the thickness of brake shoe (disc brakes)
1). Check brake shoe thickness with the scale.
Front brake caliper Standard lining thickness (front disc rear drum models): 11mm
Front brake caliper pad wear limit thickness (front disc rear drum models): 2mm
Front brake caliper standard lining thickness (front disc rear disc models): 9.5mm
Front brake caliper pad wear limit thickness (front disc rear disc models): 2mm
Rear caliper standard lining thickness (front disc rear disc models): 8mm
Front brake caliper pad wear limit thickness (front disc rear disc models): 2mm
△ Note that if the brake shoe thickness less than the
thickness of the wear limit, replace the brake shoe
Wheel and Tire
Wheel and Tire 111
S2-w3087b
(III) Installation
1. Install the caliper lining
1). Mount the caliper brake friction plate on the caliper
bracket.
2) Install front brake caliper assembly positioning pin
fixing bolts and tighten.
Tightening torque 35 ~ 45N • m
3). Fix brake disc, tread the brake pedal until the brake
respond.
4) Check the rotation resistance of brake caliper.
5) Install the wheel
IV. Front brake caliper assembly
(I) Remove
1. Remove the wheels refers to the wheels
2. Discharge brake fluid refers to brake fluid
3. Remove the front brake caliper assembly
Wheel and Tire
Wheel and Tire 112
1). Remove the brake hose bolts and copper washer
connecting brake hose and front brake caliper.
△ Note attention not to drop copper washer on both ends
of the bolt
2). Remove the two mounting bolts connecting the front
brake caliper assembly and steering knuckle.
3) Remove the front brake caliper assembly.
(II) Installation
1. Install the front brake caliper assembly
1). Place the caliper assembly to the mounting position,
pre-tightening two mounting bolts connecting clamp
caliper assembly and steering knuckle.
2) Tighten two mounting bolts connecting clamp caliper
assembly and steering knuckle.
Tightening torque 75 ~ 85N • m
3) Install the caliper bolts and copper washers connecting
the front brake hose and front brake hose.
Wheel and Tire
Wheel and Tire 113
Tightening torque 25 ~ 30N • m
2. Fill brake fluid refers to brake fluid
3. Drain brake system exhaust refers to the brake system exhaust
4. Install the wheel
V. Front brake discs
(I) Remove
1. Remove the wheels refers to the wheels.
2. Remove the front brake caliper assembly refers to front brake caliper assembly.
3. Remove the front brake disc.
1). Remove the brake discs on the front cross screws.
2) Remove the front brake discs.
(II) Check
1. Visually check
Check whether there is front brake disc surface uneven
wear, cracks and badly damaged. If yes, please replace it.
2. Check run out
1) Fix front brake disc to the hub.
△ Note before measurement, make sure the wheel bearing
axial clearance should not be too large.
2) Use a dial indicator to check run out. It can be
measured at 10mm inside edge of the brake disc
Run out limit: 0.05mm
3) If the run out exceeds the limit, replace the brake disc
or make the necessary processing.
Wheel and Tire
Wheel and Tire 114
3. Check the thickness
1) Use a micrometer to check the brake disc thickness. If
the thickness is less than wear limit, replace the brake disc.
Standard thickness (front disc rear drum models): 22mm wear limit (front disc rear drum models):
20.4mm standard thickness (front disc rear disc models): 25mm wear limit (front disc rear disc models):
23mm
(III) Installation
1. Install the front brake discs
1) Install the front brake discs.
2) Tighten the cross-shaped screws.
Tightening torque 10 ~ 15N • m
2. Install the front brake caliper assembly
3. Install the wheel
VI. Rear brake pad lining
(I) Remove
△ Note To maintain wheel balance, before removing the
Wheel and Tire
Wheel and Tire 115
tire, mark the relative positions of the wheel.
1. Remove the rear wheel refers to wheels.
2. Remove the rear brake caliper lining
1). Lower the parking brake.
2) Demolition two mounting bolts of rear caliper
positioning pin.
3) Flip rear caliper clamp body assembly.
△ Note avoid pulling the brake hose
4). Remove the inner and outer brake pad lining.
(II) Inspection
1. Check thickness of the brake pads friction plates
1). Check the thickness with the caliper scale lining. Brake
caliper lining standard thickness (front disc rear disc
models): 8mm rear brake caliper pad wear limit thickness
(front disc rear disc models): 2mm
△ Note that if the brake shoe thickness less than the
thickness of the wear limit, replace the brake caliper lining
Wheel and Tire
Wheel and Tire 116
(III) Installation
1. Install the caliper lining
1). Mount the brake caliper friction disc to the brake
caliper mounting bracket.
△ Note install in accordance with the friction plate pad and
friction plate retaining ring direction
2) Install rear brake caliper assembly positioning pin
fixing bolts and tighten
Tightening torque 22 ~ 32N • m
3). Fix brake disc, tread the brake pedal until the brake
respond.
4) Check the rotation resistance of brakes.
2. Install the rear wheels
VII Rear brake caliper assembly
(I) Remove
1. Remove the wheels refers to wheels
2. Discharge brake fluid refer to brake fluid
3. Remove the rear brake caliper assembly
1). Lower the parking brake.
2) Remove the brake hose bolts and copper washers
connecting to the rear brake hose and the rear brake
caliper.
△ Note attention not to drop copper washer at both ends of
Wheel and Tire
Wheel and Tire 117
the bolt
3) Demolition two mounting bolts connecting rear caliper
assembly and rear torsion beam assembly.
4) Remove fixing nuts and cards connecting rear brake
caliper assembly and rear parking brake drawing;
disengage the rear brake caliper assembly and rear parking
brake drawing.
5) Remove the rear brake caliper assembly.
(II) Installation
1. Install the rear brake caliper assembly
1). Place the rear caliper assembly to the mounting
position, pre tighten brake caliper mounting bracket bolts.
2). Tighten two mounting bolts connecting the rear caliper
assembly and torsion beam assembly.
Tightening torque 65 ~ 75N • m
Wheel and Tire
Wheel and Tire 118
3) Install brake hose bolts and copper washers connecting
the rear brake hose and brake pad.
Tightening torque 25 ~ 30N • m
4) Install rear brake caliper assembly and rear parking
brake drawing connections.
2. Fill brake fluid refers to brake fluid.
3. Drain brake system exhaust refers to brake system exhaust.
4. Install the wheel
VIII Rear brake disc
(I) Remove
1. Remove the wheels refers to wheels
2. Remove the rear brake caliper assembly refers to the rear brake caliper assembly
3. Remove the rear brake disc
1). Remove the brake disc rear cross screws.
2). Remove the brake disc
(II) Check
Wheel and Tire
Wheel and Tire 119
1. Visually check
Check that whether there is the rear brake disc surface uneven wear, cracks and badly damaged. If there is,
replace it.
2. Check run out
1) Fix the rear brake disc to the hub.
△ Note before measurement, make sure the wheel bearing
axial clearance should not be too large.
2) Use a dial indicator to check run out. It can be
measured at the10mm inside edge of the brake disc
Run out limit: 0.05mm
3) If the run out exceeds the limit, replace the brake disc
or make the necessary processing
3. Check the thickness
1) Use a micrometer to check the brake disc thickness. If
the thickness is less than wear limit, replace the brake disc.
Standard rear brake disc thickness (front disc rear disc
models): 9mm
Rear brake disc wear limit (front disc rear disc models):
8mm
(III) Installation
1. Install the brake disc
1) Install the rear brake disc.
2) Tighten the cross screws.
Tightening torque 10 ~ 15N • m
Wheel and Tire
Wheel and Tire 120
2. Install the rear brake caliper assembly
3. Install the wheel
IX Brake fluid
(I) Check
1. Check the brake fluid level
1) Verify whether the brake fluid level oiler height is
within a predetermined range
Standard size between mark MAX and MIN
2) If the level is too low, Check whether brake system and
surrounding oiler leaks.
(II) Brake fluid discharge
1. Drain brake fluid
1) Open the brake fluid filler cap.
2) Place drip pan.
3). Empty brake fluid
4) Install the brake fluid filler cap.
△ Note cover with a cloth or piece of cloth on the painted
surface to prevent brake fluid adhesion.
(III) Fill brake fluid
1. Fill brake fluid
1). Depress the brake pedal several times until the
complete elimination of the vacuum booster pressure.
2) Open the brake fluid filler cap.
3). Fill the brake fluid.
Wheel and Tire
Wheel and Tire 121
△ Note clean before open the front tank cover, only use
brake fluid stored in a sealed container.
X. Front brake hose
(I) Remove
1. Drain brake fluid refers to brake fluid
2. Remove the wheels refers to wheels
3. Remove the front brake hose
1). Remove brake hose bolt and copper washers
connecting the front brake hose and front brake caliper.
△ Note attention not to drop copper washers
2). Remove the connector between the brake hose and
brake hardware with a pipe wrench, disengage the card.
3). Remove fixing bolts connecting the central of brake
hose and the front shock absorber.
4) Remove the front brake hose.
(II) Installation
1. Install the front brake hose assembly
1) Install the card, install the brake hose and brake
hardware connector with a pipe wrench.
Tightening torque 16 ~ 18N • m
2) Install fixing bolts connecting the central of the brake
hose and the front shock absorber.
Tightening torque 20 ~ 25N • m
Wheel and Tire
Wheel and Tire 122
3) Install brake hose bolts and copper washers connecting
the front brake hose and front brake pads.
Tightening torque 25 ~ 30N • m
△ Note Do not reuse gaskets and tubing cards.
△ Note pay attention to the brake hose installation
direction.
2. Install the wheel
3. Fill brake fluid refers to brake fluid
4. Drain brake system exhaust refers to brake system exhaust
XI. Rear brake hose assembly
(I) Remove
1. Drain brake fluid refers to brake fluid
2. Remove wheel refers to wheels
3. Remove the rear brake hose
1) Remove bolts and copper washers connecting the rear
brake hose and rear brake caliper Ⅱ.
△ Note attention not to drop copper washers
Wheel and Tire
Wheel and Tire 123
2). Remove the connector between rear brake hose
assemblies Ⅱ and the brake hardware with a wrench.
Disengage the card.
3) Remove the rear brake hose assembly Ⅱ.
(II) Installation
1. Install the rear brake hose assemblies Ⅱ
1) Install the card, the connector between rear brake hose
assemblies Ⅱ and the brake hardware with a wrench.
Tightening torque 16 ~ 18N • m
2) Install bolts and copper washers connecting the rear
brake hose and rear brake caliper Ⅱ..
Tightening torque 25 ~ 30N • m
△ Note Do not reuse gaskets and tubing cards.
Wheel and Tire
Wheel and Tire 124
△ Note pay attention to the brake hose installation
direction.
2. Install the wheel
3. Fill brake fluid refers to brake fluid
4. Drain brake system exhaust refers to brake system exhaust
XII. Brake pedal (MT)
(I) Check and adjust
1. Adjust the clearance between the brake pedal and the brake limit switch bolt
1). Remove guard assembly under the driving side.
2) Disconnect the brake lamp switch harness connector.
3) Loosen the lock nut of brake limit switches, release the
brake pedal.
4). Rotate switch bolt, keep the gap of switch bolt and the
brake pedal between 0.5 ~ 1mm
Tightening torque 8 ~ 10N • m
Wheel and Tire
Wheel and Tire 125
2. Check brake pedal free travel
1) When the engine stalls state, depress the brake pedal 2
or 3 times.
2) confirm the vacuum brake booster vacuum-elimination,
pressed pedal with hand.
3) Before verify resistance occurs, check the brake pedal
free travel is within the standard range.
Standard value: 3mm ~ 8mm
△ Note that if the free travel is not within the standard,
replace the damaged parts.
3. Adjust the brake pedal free travel
1) Release the brake limit switch nut, relax the brake pedal,
rotate switch bolt, and keep the gap of switch bolt and the
brake pedal in 0.5mm ~ 1mm.
Free travel standard value: 3mm ~ 8mm
Wheel and Tire
Wheel and Tire 126
(II) Remove
1. Open the engine hatch
2. Disconnect the negative battery cable
3. Remove the lower part of the dashboard fender refers to the lower part of the dashboard fender
4. Remove the brake pedal
1) Disconnect the stop lamp switch harness connector.
2). Remove lock pin connecting the brake pedal and the
brake booster vacuum, disconnect the brake pedal and the
brake booster vacuum
3) Remove the two fixing nuts connecting the brake pedal
and the body.
4). Remove four fixing nuts connected the brake pedal and
the vacuum booster to the vehicle body
5) Remove the brake pedal.
Wheel and Tire
Wheel and Tire 127
(III) Installation
1. Install the brake pedal
1) Install four fixing nuts connected the brake pedal and
the vacuum booster to the vehicle body and pre-tighten.
Tightening torque 20 ~ 25N • m
2). Install the two fixing nuts connecting the brake pedal
and the body and tighten.
Tightening torque 20 ~ 25N • m
3) Install the brake pedal and the brake booster vacuum
plastic ring, cotter pins, the main pump latch locking.
△ Note the main pump kingpin should be normally
moving in the mounting hole with no jam phenomenon.
△ Note when the main pump kingpin cannot be installed
according to requirements, adjust the pedal length of the
bolt to ensure kingpin correctly fit, but do not adjust the
length of vacuum booster pushrod, or keep the vacuum
Wheel and Tire
Wheel and Tire 128
booster pushrod in a compressed state.
4) Connect the brake lamp switch harness connector.
2. Install the lower part of the dashboard fender
3. Connect the negative battery cable
4. Turn off the engine hatch
XIII. Brake light switch
(I) Disassembly
1. Open the engine hood
2. Disconnect the battery’s negative cable
3. Remove the dashboard’s bottom cover. Please refer to
“dashboard’s bottom cover”
4. Disassemble the brake light switch
1). Disconnect the harness connector of brake light switch
2). Remove the fixed bolt of light switch
3). Remove the brake light switch
Wheel and Tire
Wheel and Tire 129
(II) Check
1. Check the brake light switch
1). Use multimeter to check the two terminals of light
switch, and confirm whether it’s brakeover when you turn
on or off the light switch
2). If the terminals do not brake over when the switch is
pushed more than 4mm in depth, and restore brake-over
when you turn off the switch, then the brake light switch
is functional
(III) Installation
1. Install brake light switch
1). Install the fixed bolt of brake light switch (tightening
torque: 20~25N.m)
2). Link the harness connector of brake light switch
2. Install the dashboard’s bottom cover
3. Connect the battery’s negative cable
4. Close the engine hood
XIV. Unit assembly of vacuum booster with master
cylinder (MT)
(I) Check on the car
1. Check fluid leakage
1). Check whether leakage exists on the fitting surface of
master cylinder, oilcan or brake hose’s joint
(II) Disassembly
1. Open the engine hood.
2. Disconnect the battery’s negative cable
Wheel and Tire
Wheel and Tire 130
3. Drain the brake fluid (please refer to “brake fluid”)
4. Remove the liquid level sensor of brake fluid (please refer to “liquid level sensor of brake fluid”)
5. Remove the vacuum booster with master cylinder
1). Remove the lockpin that connects vacuum booster and
brake pedal
2). Remove the girdle clamp and disconnect vacuum
booster and hose
3). Disconnect the master cylinder and its outlet tube
assembly
4). Remove the girdle clamp and disconnect brake master
cylinder and the hose of clutch master cylinder
5). Remove the four screws that connect vacuum booster
and brake pedal
Wheel and Tire
Wheel and Tire 131
(III) Installation
1. Install the unit assembly of vacuum booster with
master cylinder
1). Install the four screws that connect vacuum booster
and brake pedal.
(tightening torque: 20~25N.m)
2). Install the connection of master cylinder and its outlet
tube
(tightening torque: 16~18N.m)
3). Install the girdle clamp to connect vacuum booster
and its hose
4). Install the girdle clamp to connect the hose that links
brake master cylinder and clutch cylinder
5). Install the lockpin and cotter that connect vacuum
booster and brake pedal
Wheel and Tire
Wheel and Tire 132
2. Install the liquid level sensor of brake fluid
3. Add the brake fluid (please refer to “brake fluid”)
4. Exhaust air inside the brake system (please refer to air-removal of brake system)
5. Connect the battery’s negative cable
6. Close the engine hood
XV. Unit assembly of vacuum booster with master cylinder (AT)
(I) Check on the car
1. Check fluid leakage
1). Check whether leakage exists on the fitting surface of
master cylinder, oil can or brake hose’s joint
(II) Disassembly
1. Open the engine hood
2. Disconnect the battery’s negative cable
3. Drain the brake fluid (please refer to “brake fluid”)
4. Remove the liquid level sensor of brake fluid (please refer to “liquid level sensor of brake fluid”)
5. Remove the vacuum booster with master cylinder
1). Remove the lockpin that connects vacuum booster
and brake pedal
2). Remove the girdle clamp and disconnect vacuum
booster and hose
3). Disconnect the master cylinder and its outlet tube
assembly
4). Remove the four screws that connect vacuum
booster and brake pedal
Wheel and Tire
Wheel and Tire 133
(III) Installation
1. Install the unit assembly of vacuum booster with master
cylinder
1). Install the four screws that connect vacuum booster
and brake pedal
(tightening torque: 20~25N.m)
2). Install the joint between master cylinder and its outlet
tube assembly
(tightening torque: 16~18N.m)
3). Install the girdle clamp to connect the vacuum booster
and its hose
4). Install the lockpin and cotter that connect vacuum
booster and brake pedal
2. Install the liquid level sensor of brake fluid
3. Add the brake fluid (please refer to “brake fluid”)
4. Exhaust air inside the brake system (please refer to air-removal of brake system)
5. Connect the battery’s negative cable
6. Close the engine hood
XVI. Vacuum hose assembly
(I) Disassembly
1. Open the engine hood
2. Disassemble the vacuum hose assembly
1). Remove the girdle clamp to disconnect vacuum hose
and booster
Wheel and Tire
Wheel and Tire 134
2). Remove the girdle clamp to disconnect vacuum hose
and vacuum power steel pipe
(II) Installation
1. Install the vacuum hose assembly
1). Install the girdle clamp to connect vacuum hose and
booster
2). Install the girdle clampto connect vacuum hose and
power steel pipe
2. Close the engine hood
XVII Liquid sensor of brake fluid
(I) Disassembly
1. Open the engine hood
2. Disconnect the battery’s negative cable
3. Remove the liquid sensor
1). Remove the clamp to disconnect sensor’s harness
connector
Wheel and Tire
Wheel and Tire 135
2). Take out the sensor from the side face of storage tank
△Notice No need to discharge the brake fluid
(II) Installation
1. Install the liquid sensor of brake fluid
1). Install the sensor into the correct position of the liquid
tank
2). Connect the harness connector of sensor
2. Connect the battery’s negative cable
3. Close the engine hood
XVIII Air-removal of brake system
(I) System’s air-exhaust
△Notice Air cannot be exhausted from hydraulic brake on
MT type. If the air is mixed in ABS hydraulic brake, or
unfilled ABS hydraulic brake is installed, it is necessary to
use fault diagnosis tester to exhaust air from the brake
system. The situation of ABS brake when the car goes off-
line is filled without air, and air will not enter the ABS
brake during normal service process. Under this situation,
please use manual air-removal process.
1. Preparation
Wheel and Tire
Wheel and Tire 136
1). Keep the engine shut down, and stamp the brake pedal
for several times till no assist power exists.
2). Add brake fluid into fluid storage of master cylinder,
and ensure the liquid level more than half during air-
removal process
2. Exhaust air from master cylinder
△Notice If the master cylinder is re-installed, or the
liquid storage is empty, please exhaust the air from the
master cylinder
1). Stamp and hold the brake pedal till the end side
2). Loosen one brake oil pipe from the master cylinder,
and fasten the joint after the brake fluid runs off
3). Loosen the other brake oil pipe from the master
cylinder, and fasten the joint after the brake fluid runs off
△Notice Cover the painting side with rag to prevent fluid
adhesion
4). Repeat step 1) to 3) for 3~4 times
3. Exhaust air from brake pipe
1). Remove the dust cover of bleeder screw on the brake
2). Connect a transparent tube with the bleeder screw on
the left-rear brake, and soak
△Notice Exhaust air from brake pipe consecutively from
far to near ABS brake
3). Stamp the brake pedal slowly for several times till the
pedal is on the end side
△Notice Do not stamp the pedal quickly
4). Loosen the bleeder screw and exhaust air from brake
while holding the brake pedal
5). Tighten the bleeder screw and slowly loosen the brake
pedal when the brake fluid stops overflowing
6). Repeat step 3) to 5) till the air in the brake fluid is
completely exhausted
7). If no air bubble appears in the tank when loosen the
bleeder screw, it means the air is completely exhausted
△Notice ensure the liquid level is more than half during
air-removal process
8). Tighten the bleeder screw
Tightening torque 7~13N.m
9). Exhaust air in other brakes by following step 1) to 8)
10). Check whether the brake pedal is stamped softly or
not after exhausting air from all brakes. If yes, please
Wheel and Tire
Wheel and Tire 137
repeat the whole process till it works normally.
XIX Oil outlet tube of master cylinder
(I) Disassembly
1. Open the engine hood
2. Drain the brake fluid (please refer to “brake fluid”)
3. Remove the assembly of master cylinder’s fuel outlet pipe
1). Loosen the screw on fuel pipe to disconnect pipe
assembly and brake master cylinder
2). Remove the oil pipe screw to disconnect fuel outlet
pipe assembly and ABS/ESP controller
3). Loosen the two pipe clamps and 2 front pipe clamps
that fix the oil outlet pipe assembly
(II) Installation
1. Install the oil outlet pipe assembly
1). Install the assembly on the 2 pipe clamps and 2 front
pipe clamps
Wheel and Tire
Wheel and Tire 138
2). Install the oil pipe screw to connect the assembly and
ABS/ESP controller
Tightening torque: 16~18N.m
3). Install oil pipe screw to connect assemblyand master
cylinder
Tightening torque: 16~18N·m
2. Add brake fluid (please refer to “brake fluid”)
3. Exhaust air from brake system (please refer to “air-
removal of brake system”)
4. Close the engine hood
XX Front brake pipe assembly
(I) Disassembly
1. Open the engine hood
2. Drain the break fluid (please refer to “brake fluid”)
3. Remove the left-front brake oil pipe assembly
1). Remove the screw that connects left-front brake pipe
assembly and brake hose
Wheel and Tire
Wheel and Tire 139
2). Loosen the screw to disconnect left-front brake oil
pipe assembly and ABS/ESP controller
3). Unfix the two pipe clamps and two white three-hole
clamps that tighten the left-front brake oil pipe
4). Detach the left-front brake oil pipe assembly
4. Remove the left-rear and right-rear brake pipe assembly
1). Remove the oil pipe screw that connects left-rear brake
pipe assembly and pipe itself
2). Remove the oil pipe screw that connects right-rear
brake pipe assembly and pipe itself
3). Remove the oil pipe screw that connects left-rear brake
pipe assembly and pipe itself
4). Remove the oil pipe screw that connects right-rear
brake pipe assembly and pipe itself
Wheel and Tire
Wheel and Tire 140
5). Unfix the two pipe clamps and teo white three-hole cla
mps that tighten the left-rear and right-rear brake pipe
assembly
6). Detach the left-rear and right-rear brake pipe assembly
(II) Installation
1. Install the left-front brake oil pipe assembly
1). Install the screw that connects left-front brake oil pipe
and brake hose
Tightening torque: 16~18N·m
2). Install the screw that connects left-front brake oil pipe
and ABS/ESP controller
Tightening torque: 16~18N·m
3). Install the left-front brake oil pipe to the two pipe
clamps and two front clamps that fix the left-front brake
oil pipe assembly
Wheel and Tire
Wheel and Tire 141
2. Install the left-rear and right-rear brake pipe assembly
1). Tighten the screw that fixes the left-rear brake pipe
assembly and ABS/ESP controller
Tightening torque: 16~18N·m
2). Tighten the screw that fixes the right-rear brake pipe
assembly and ABS/ESP controller
Tightening torque: 16~18N·m
3). Install the screw that connects the left-rear brake pipe
assembly and the final part of left-rear brake pipe
Tightening torque 16~18N.m
4). Install the screw that connects the right-rear brake
pipe assembly and the final part of right-rear brake pipe
Tightening torque 16~18N.m
5). Install the left-rear and right-rear brake pipe assembly
on the two pipe clamps and two white triple clamps
3. Add brake fluid, please refer to “brake fluid”
4. Exhaust air from brake system, please refer to “Air-
removal of brake system”
5. Close the engine hood
XXI Rear brake pipe assembly
(I) Disassembly
1. Open the engine hood
2. Drain the brake fluid, please refer to “brake fluid”
3. Remove the rear wheel, please refer to “wheel”
4. Disassemble the final parts of left-rear and right-rear
brake pipe assembly
1). Remove the cover-sheet assembly of rear brake pipe
assembly
Wheel and Tire
Wheel and Tire 142
2). Loosen the screw that connects left-rear brake pipe and
the final part of left-rear brake pipe
3). Loosen the screw that connects right-rear brake pipe
and the final part of right-rear brake pipe
4). Loosen the screw that connects final part of left-rear
brake pipe assembly and left-rear brake hose
5). Loosen the screw that connects final part of right-rear
brake pipe assembly and right-rear brake hose
6). Dismantle the five pipe clamps and the single pipe
clamp that connects final-part of left-rear assembly and
car body
7). Dismantle the five pipe clamps and three single pipe
clamp that connects final-part of right-rear assembly and
car body
8). Take off the final part of left-rear and right-rear brake
pipe assembly
5. Dismantle the assembly of left-rear and right-rear brake pipe
1). Loosen the screw that connects left-rear brake pipe
assembly and left-rear brake hose II
2). Loosen the screw that connects right-rear brake pipe
assembly and right-rear brake hose II
Wheel and Tire
Wheel and Tire 143
3). Loosen the screw that connects left-rear brake pipe
assembly and left-rear brake hose
4). Loosen the screw that connects right-rear brake pipe
assembly and right-rear brake hose
5). Take off the left-rear and right-rear brake pipe
assembly
6. Remove the rear brake oil pipe support
1). Loosen the fixed bolt that connects rear brake oil
pipe and car body
2). Take off the rear brake oil pipe support
(II) Installation
1. Install the final part of left-rear and right-rear brake pipe assembly
1). Tighten the screw that connects left-rear brake pipe
assembly and the final part of left-rear brake pipe
Tightening torque 16~18N.m
2). Tighten the screw that connects right-rear brake pipe
assembly and the final part of right-rear brake pipe
Tightening torque 16~18N.m
3). Install the screw that connects the final part of left-
rear brake pipe assembly and left-rear brake hose
Tightening torque 16~18N.m
4). Install the screw that connects the final part of right-
rear brake pipe assembly and right-rear brake hose
Tightening torque 16~18N.m
Wheel and Tire
Wheel and Tire 144
5). Install the five pipe clamps and the single pipe clamp
that connect the final part of left-rear brake pipe
assembly and car body
6). Install the five pipe clamps and three single pipe
clamps that connect the final part of left-rear pipe
assembly and car body
7). Install the cover sheet of the final part of rear brake
pipe
2. Install the assembly of left-rear and right-rear brake
pipe
1). Install the screw that connects left-rear brake pipe
assembly and left-rear brake hose II
Tightening torque 16~18N.m
2). Install the screw that connects right-rear brake pipe
assembly and right-rear brake hose II
Tightening torque 16~18N.m
3). Install the screw that connects left-rear brake pipe
assembly and left-rear brake hose
Tightening torque 16~18N.m
4). Install the screw that connects right-rear brake pipe
assembly and right-rear brake hose
Tightening torque 16~18N.m
3. Install the rear brake oil pipe support
1). Install the two fixed bolts that connect rear brake oil
tube support and car body
Tightening torque 20~25N.m
4. Add brake fluid, please refer to “brake fluid”
5. Exhaust air from brake system, please refer to
“Air-removal of brake system”
6. Install the rear wheels
7. Close the engine hood
Wheel and Tire
Wheel and Tire 145
XXII Rear brake hose assembly
(I) Disassembly
1. Lift the car
2. Drain the brake fluid, please refer to “brake fluid”
3. Dismantle the rear brake hose assembly
1). Remove the screw that connects rear brake hose
assembly and the final part of rear brake pipe
2). Remove the screw that connects left-rear brake hose
assembly and the left-rear brake pipe assembly
3). Take off the rear brake hose assembly
(II) Installation
1. Install the rear brake hose assembly
1). Install the screw that connects left-rear brake hose
assembly and the final part of left-rear brake pipe
Tightening torque 16~18N.m
2). Install the screw that connects left-rear brake hose
assembly and the left-rear brake pipe assembly
Tightening torque 16~18N.m
Wheel and Tire
Wheel and Tire 146
2. Add brake fluid, please refer to “brake fluid”
3. Exhaust air from brake system, please refer to “Air-
removal of brake system”
4. Lift down the car
XXIII Right-front brake oil pipe assembly
(I) Disassembly
1. Open the engine hood
2. Drain the brake fluid, please refer to “brake fluid”
3. Dismantle the right-front oil pipe assembly
1). Loosen the screw that connects right-front brake oil
pipe assembly and right-front brake hose
2). Loosen the screw that connects right-front brake oil
pipe assembly and ABS/ESP controller
3). Take off the right-front brake oil pipe assembly
(II) Installation
1. Install right-front brake oil pipe assembly
1). Tighten the screw that connects right-front brake oil
pipe and right-front brake hose
Tightening torque 16~18N.m
Wheel and Tire
Wheel and Tire 147
2). Tighten the screw that connects right-front brake oil
pipe and ABS/ESP controller
Tightening torque 16~18N.m
2. Add brake fluid, please refer to “brake fluid”
3. Exhaust air from brake system, please refer to “Air-removal of brake system”
4. Close the engine hood
Parking Brake System
Parking brake system 148
Parking Brake System
I General introduction
(I) Brief introduction of structure
Structure diagram of parking brake system
1. Parking brake handle assembly 3. Fibre-drawing assembly of right-parking brake
2. Fibre-drawing assembly of left-parking brake
(II) Maintenance parameter
Project
Specification
Rear parking
brake
Type
Drum
Diameter of wheel cylinder
17.46mm
Diameter of brake drum
204mm
Thickness of frictional pad
4mm
Type
Floating caliper/Ventilated disc
Disc diameter
275mm
Disc thickness
9mm
Thickness of frictional pad
8mm
Cylinder diameter
34mm
Parking Brake System
Parking brake system 149
(III) Torque parameter
No.
Project
Torque (N.m)
Remark
1
Fixed bolt of parking brake handle
20~25
2
Fixing screw of parking brake
switch
6~8
3
Nut and bolt of fixing support for
parking brake
7~11
II Failure diagnosis
(I) Chart of failure and diagnosis
No.
Failure
Diagnosis
Solution
Remark
1
Indicator lamp
keeps lighting or
doesn’t work
Check whether the indicator lamp on
dashboard is broken
Change the indicator lamp
on dashboard
Check whether the bolt between the
switch and tooth plate is fixed
Adjustment
2
Brake delay
The parking is not released totally
Release the parking brake
Improper adjustment on parking brake
Adjustment
3
Insufficient
parking brake
force
Rear brake shoes are broke
Adjustment
Lubriacating grease or oil exists on the
surface of rear brake shoes
Change the brake shoes
The fibre-drawing of parking brake is
stuck
Adjustment
Malfunction appears in self-adjustment
mechanism
Adjustment
Excessive distance for parking brake
handle
Adjustment
4
Parking brake
fails
Fibre-drawing or sleeve corrodes
Stiff spring is broken, brake off or loses
elasticity
Check whether the fibre-
drawing or spare parts for
braking system are broken;
Check whether the handle
works smoothly without
delay; Check the connector
and fixed part of fibre-
drawing is loosen or
broken, and repair&change
these parts if necessary
III Check and adjustment on the assembly of parking brake system
Parking Brake System
Parking brake system 150
(I) In-car check
△Notice Check and adjust parking brake system only
when the brake works normally
△Notice While checking parking brake system, the car
must be parked on even ground, with wheels being fixed
by wedges
Check spare parts
1. Check whether all spare parts are fixed normally
2. Check whether the brake handle is crooked, broken or has cracks, and change the handle if necessary
3.Check whether the fibre-drawings are worn or broken, and change them if necessary
4. Check whether the indicator lamp switch works normally, and repair&change the lamp if it doesn’t
work
5. Dismantle the switch connector of parking brake, and check the continuity between positive terminal
and car body. The circuit should be on when the handle is pulled up, and off when the handle is pulled
down
Check the working distance of parking brake
1. Pull up the parking brake, and confirm that when the handle is pulled up, the number of teeth that the
handle passed stays in standard
Standard teeth number: 7~9
△Notice there will be a tick every time when the handle
passes a tooth, by counting the tick, you can judge
whether the brake handle works in standard when pulled
up
Adjust the working distance of parking brake
1. Open the engine hood
2. Dismantle the vice dashboard, please refer to “vice dashboard”
3. Adjust the working distance of parking brake handle
1). Adjust the adjusting nut on the parking brake system,
and ensure the distance (L) between the adjusting nut and
the final part of fibre-drawing stays in standard
Standard: L=20~25mm
Standard teeth number: 7~9
△Notice Decrease L if the number of passed teeth is less
than 7, and increase L if the number of passed teeth is
more than 9
4. Pull down the parking brake
5. Check whether the rear wheels are delayed when parking
IV Parking brake switch
(I) Disassembly
1. Open the engine hood
2. Disconnect the negative cable of battery
3. Dismantle the vice dashboard, please refer to “vice
dashboard”
Parking Brake System
Parking brake system 151
4. Remove the parking brake switch
1). Pull down the parking brake handle
2). Disconnector the harness connector of parking brake
lamp
3). Loosen the fixed bolt of parking brake switch and take
off the switch
(II) Installation
1. Install the parking brake switch
1). Install the fixed bolt of parking brake switch
Tightening torque 6~8N.m
2). Connect the harness connector of parking brake
switch
2. Install the vice dashboard
3. Connect the negative cable of battery
4. Close the engine hood
V Parking brake system assembly
(I) Disassembly
1. Open the engine hood
2. Disconnect the negative cable of battery
3. Dismantle the vice dashboard, please refer to “vice dashboard”
4. Disassemble the parking brake switch, please refer to “parking brake switch”
5. Disassemble the parking brake system assembly
1). Loosen the nut on the adjusting sprial
2). Loosen the two fixed bolts that connect parking brake
system assembly and car body
3). Disconnect fibre-drawing from balance bar
4). Take off the parking brake system
Parking Brake System
Parking brake system 152
(II) Installation
1. Install the parking brake system assembly
1). Tighten the two fixing bolts that connect parking brake
system assembly and car body
Tightening torque 20~25N.m
2). Adjust the nut into a proper position on the final part
of threaded rod, and install the fibre-drawing on the
balance bar
2. Check and adjust the parking brake system assembly,
please refer to “Check and adjustment on the assembly of
parking brake system”
3. Install the parking brake switch
4. Install the vice dashboard
5. Connect the negative cable of battery
6. Close the engine hood
VI Parking brake fibre-drawing assembly
(I) Disassembly
1. Open the engine hood
2. Disconnect the negative cable of battery
3. Dismantle the vice dashboard, please refer to “Vice dashboard”
4. Disassemble the parking brake system assembly, please refer to “Parking brake system assembly”
5. Remove the rear wheels, please refer to “Wheel”
6. Disassemble the rear brake caliper, please refer to
“Front brake caliper assembly”
7. Remove thermal baffle I and II, please refer to
“Thermal baffle”
8. Disassemble the parking brake fibre-drawing assembly
1). Adjust the nut on the final part of thredded rod
2). Disconnect the left-rear and right-rear parking brake
fibre-drawing from balance plate
Parking Brake System
Parking brake system 153
3). Remove the bolts and nuts on the fixing support
4). Take out the fibre-drawing from the mounting sleeves
that locate in the bottom of the car
5). Disconnect the parking brake fibre-drawing and
parking brake disc
6). Take off the parking brake fibre-drawing assembly
(II) Installation
1. Install the parking brake fibre-drawing
1). Connect the parking brake fibre-drawing and parking
brake disc
Parking Brake System
Parking brake system 154
2). Tighten the bolts and nuts on the fixing support of
parking brake fibre-drawing
Tightening torque 7~11N.m
△Notice the route of fibre-drawings should be smooth
3). Install the fibre-drawings into the mounting sleeves
that locate on the bottom of the car.
4). Install the left-rear and right-rear parking brake
fibre-drawings on the balance plate
2. Check and adjust the parking brake system assembly, please refer to “Check and adjustment on the
assembly of parking brake system”
3. Install the vice dashboard
4. Install the rear brake caliper assembly
5. Install the rear wheels
6. Install the thermal baffle I and II
7. Connect the negative cable of battery
8. Close the engine hood
Brake Control System
Brake Control System 155
Brake Control System
I General introduction
(I) Brief introduction on structure
Structural diagram of brake system (front & rear braking disc model)
1. Front wheel’s ABS speed sensor assembly 3. ESP controller assembly
2. Rear wheel’s ABS speed sensor assembly 4. ESP controller’s fixing support
(II) System function
1. ABS
ABS (anti-skid brake system) can control the hydraulic brake force on wheels during emergency braking
or braking when the road situation is dangerous, and prevent wheels from skidding. ABS has the
following advantages:
(1) Steering will be reliable when facing obstacles during
emergency braking
(2) The vehicle can stop steadily on curve roads during
emergency braking
2. ESP
ESP (electronic stability program) is an active safety system. It is a dependent system based on other
Brake Control System
Brake Control System 156
driving control system. ESP includes all functions of ABS, and increases TCS (traction control system).
Meanwhile, additional functions can be applied on it by adding sensors and input signals.
Basic functions:
ABS (anti-skid brake system)
EBD (electric brake force distribution)
AYC (active yawing control)
TCS (traction control system)
Braking assistance:
HBA (hydraulic braking assistance)
Static control system:
HAS (hill-start assist system)
ESP can judge the working conditions of vehicles by analyzing signals provided by steering sensor, wheel
sensor, yawing sensor, transverse acceleration sensor and etc. After analysis, it sends rectifying signals to
ABS and ASR, so as to help the vehicle to maintain mobile balance and achieve utmost stability under
various situations. Its performance will be more apparent when the steering process is excessive or
insufficient.
3. EBD
Each wheel’s adhesion coefficient provided by ground will be different as the situation of road to which
the wheel sticks will be different. What’s more, the vehicle’s barycenter will change during emergency
brake, which may lead to vehicle’s skid, bias or roll-over. During the moment of emergency brake, EBD
can instantly figure out the friction’s numerical difference due to wheels’ different adhesion coefficients.
Then it adjusts the electromagnetic valves in hydraulic units, so they can adjust themselves instantly
during dynamic situation. It can achieve the match of break force and friction, and ensure the vehicle’s
stability and safety. During emergency brake, EBD will balance each wheel’s valid traction before ABS,
and prevents the vehicle from whipping or side-swing. Generally speaking, EBD is an additional function
of ABS. it can distribute brake force automatically according to the changes of road situation and carrying
capacity, and improve ABS’s performance.
EBD can control each wheel’s break force precisely and ensure the vehicle’s stability. On normal
breaking situation, it can effectively equal each wheel’s speed. By controlling the input & output oil
valves of hydraulic adjustment module in ABS, EBD can control each wheel’s breaking pressure in order
to provide effective breaking and stability for vehicles.
4. TCS
TCS can monitor the slippage rate of driving wheels. If the rate is too big, TCS will send signals to engine,
decreasing the amount of fuel injected by nozzle, or the opening of throttle valve, thus decreasing the
torque output, and optimizing the drive wheel’s slippage rate, which promises drive wheels with bigger
adhesion force. If the difference between the drive wheels’ adhesion coefficients is too large, TCS will
actively impose break force to the drive wheel which has low coefficient, prevent the wheel from skidding,
and ensure the drive wheel which has larger coefficient to gain bigger drive force.
5. Failure protection
If electric failure happens in ABS or ESP, the warning light of ABS or ESP will automatically turn on. If
electric failure happens in EBD, the brake warning light and ABS warning light will turn on. Meanwhile,
ABS will change into one of the following failure protection:
1) For ABS’s failure, only EBD will be activated, and the
Brake Control System
Brake Control System 157
vehicle’s condition will be the same as the one without
ABS.
2) For EBD’s failure, neither EBD nor ABS will be
available, and the vehicle’s condition will be the same as
the one without ABS or EBD.
(III) Working principle
Diagram of ABS’s hydraulic working principle
Brake Control System
Brake Control System 158
Diagram of ABS
Brake Control System
Brake Control System 159
Diagram of ESP’s hydraulic working principle
Anti-skid brake mode
During vehicle’s brake, should the wheels skid, ABS will be activated into anti-skid brake mode. During
this period, all wheels’ hydraulic pressure will be under control in case of slippage. Each wheel has its
own hydraulic pipeline and valve. ABS can change, or maintain each wheel’s hydraulic pressure during
vehicle’s brake. However, ABS cannot increase the hydraulic pressure to the amount which the master
cylinder transfers during brake. Thus, during anti-skid brake, the brake pedal will vibrate quickly. The
vibration is triggered by the quick changes of each valve’s position. This kind of vibration will appear
during anti-skid brake mode, and stop during normal brake or when the vehicle completely stops. As the
electromagnetic valve circulates quickly, there will be some noise. If the anti-skid mode is activated when
the vehicle is on dry roads, harsh noise will appear intermittently when the wheels are close to slippage.
All these noise and vibration are normal circumstances during anti-skid brake. When you stamp the pedal
during narmal brake, the operation should be the same when you drive the one without ABS. keeping the
power balance during stamping pedal can promise shortest braking distance while maintaining the
vehicle’s stability.
Brake Control System
Brake Control System 160
During anti-skid brake period, the brake system’s pressure adjustment can be divided into three phases.
1. Pressure maintenance
When the slippage was detected by ABS control module, it will close oil inlet valve, and close the oil
outlet valve in hydraulic assembly to isolate the system. This will maintain the pressure stability of
arrester and keep the hydraulic pressure still.
2. Pressure reduction
Should slippage still was detected by ABS control mode under pressure maintenance mode, ABS will
reduce the pressure of the wheel which was affected. It will close oil inlet valve, and open oil outlet valve.
Redundant fluid or pressure will be stored temporally in the power accumulator of hydraulic assembly
until when the pump motor sends the brake fluid back to the reservoir of master cylinder
3. Pressure increase
If ABS control module detects that the wheel slippage has reduced under pressure maintenance or
reduction mode, the module will use the pressure of cylinder to increase the affected wheel’s pressure.
The oil inlet valve will open, and the oil outlet valve will be closed. Part or all pressure from brake
system’s master cylinder will be added to wheels.
The working process of ABS
When the vehicle is moving, rach wheel speed sensor will produce an voltage signal which is proportional
to the wheel’s rotational speed. ABS controller will receive the speed data and determine whether one or
more wheels’ speed reduction is too fast, and activate control module if needs. The module will control
and optimize each wheel’s brake pressure.
II ABS&ESP control module
(I) Components
The front-disc-rear-drum model applies BOSCH ABS 9, with ABS control module and hydraulic
assembly being integrated together; the front-disc-rear-disc model applies BOSCH ESP 9, with ESP
control module and hydraulic assembly being integrated together.
(II) Illustration of the stitch on ABS, ESP control module
Illustration of stitch in ABS control module
Stitch
No.
Illustration
Stitch
No.
Illustration
1
Motor’s battery terminal (positive)
2
Speed sensor output (right-front wheel)
3
Active EBD warning light
4
Speed sensor’s signal terminal (right-
front)
5
N.C.
6
K line
7
N.C.
8
Speed sensor’s signal terminal (left-
front)
9
N.C.
10
N.C.
11
N.C.
12
N.C.
13
Motor’searth terminal
14
CAN-low
15
N.C.
16
Speed sensor’s power terminal (right-
front)
17
Speed sensor’s power terminal (right-
rear)
18
Speed sensor’s signal terminal (left-
rear)
19
Speed sensor’s power terminal (left-
front)
20
N.C.
21
N.C.
22
N.C.
Brake Control System
Brake Control System 161
23
N.C.
24
N.C.
25
Valve relay’s power terminal
26
CAN-high
27
Active ABS warning light
28
ECU’s power terminal (ignition cable)
29
Speed sensor’s signal terminal (right-
rear)
30
Brake light switch input
31
Speed sensor’s signal terminal (left-
rear)
32
N.C.
33
Speed signal output
34
N.C.
35
N.C.
36
N.C.
37
N.C.
38
ECU’s earth wire
Diagram of the stitch’s position in ABS control module
Illustration of stitch in ESP control module
Stitch
No.
Illustration
Stitch
No.
Illustration
1
Motor’s battery terminal (positive)
2
Speed sensor output (right-front wheel)
3
N.C.
4
Speed sensor’s signal terminal (right-
front)
5
N.C.
6
N.C.
7
N.C.
8
Speed sensor’s signal terminal (left-
front)
9
N.C.
10
N.C.
11
N.C.
12
ESP switch
13
Motor’s earth terminal
14
CAN- low
15
N.C.
16
Speed sensor’s power terminal (right-
front)
17
Speed sensor’s power terminal (right-
rear)
18
Speed sensor’s signal terminal (left-
rear)
Brake Control System
Brake Control System 162
19
Speed sensor’s power terminal (left-
front)
20
N.C.
21
N.C.
22
N.C.
23
N.C.
24
N.C.
25
Valve relay’s power terminal
26
CAN- high
27
N.C.
28
ECU’s power terminal (ignition cable)
29
Speed sensor’s signal terminal (right-
rear)
30
Brake light switch input
31
Speed sensor’s power terminal (left-
rear)
32
N.C.
33
N.C.
34
N.C.
35
N.C.
36
N.C.
37
N.C.
38
ECU’s earth wire
Diagram of the stitch’s position in ESP control module
(III) Check on ABS&ESP control module
△Notice please go on basic check on brake system first
Basic check on brake system
1. Check the liquid level of brake fluid, and add brake fluid if necessary
2. Check whether any leakage exists in brake pipeline or ABS hydraulic assembly. Should the leakage
exists, please make the following checks:
a: If the connector part of ABS hydraulic assembly is
loosen, please tighten the tubing nut to the designated
torque (16~18N.m), check the leakage situation again, and
make sure no brake fluid leaks.
Brake Control System
Brake Control System 163
b: If the connector part’s tubing nut or the actuator’s
whorl part is broken, please replace the broken parts and
check the leage again. Make sure no break fluid leaks.
c: If no leakage exists except in actuator’s connector part,
use clean rags to wipe the stain and check again. Should
the leakage still exists, please replace the broken part.
d: If the leakage exists on hydraulic assembly, use clean
rags to wipe the stain and check again. Should the leakage
still exists, please replace the hydraulic assembly.
△Notice do not disassemblr ABS or ESP hydraulic
assembly unless with special needs.
3. Check whether the filler block or the shoe plate is broken.
4. Check whether the circuit terminal or the battery is loosen.
△Notice check whether the battery’s positive/negative
terminal is loosen, and confirm whether the battery’s
voltage is normal
Check the warning light of ABS and brake system
1). Check whether when the ignition switch turns to “ON”,
the ABS warning light will light for 3 seconds, and the
brake warning light keep lighting. If they don’t light,
please refer to “common failures and analysis process of
ABS”
2). Check whether after 3 seconds when the ignition
switch turns to “ON”, the ABS warning light will go out,
and the brake warning light will go out after the engine
starts. If not, please refer to “common failures and
analysis process of ABS”
3). If the ABS warning light doesn’t go out in 10 seconds
after the engine starts, please refer to “common failures
and analysis process of ABS”
△Notice the brake warning light will turn on during
parking brake process (when the switch is at “ON”
position) and when the brake fluid’s liquid sensor is
working
Use fault diagnosis instrument to check ABS control module
Use fault diagnosis instrument to check the data and failure code of control module, and repair the vehicle
according to the failure codes. Please refer to “failure diagnosis”
(IV) Torque parameter
No.
Project
Torque （N·m）
Remark
1
Fixing bolt of speed sensor
8~10
2
Collar nut of brake pipe
16~18
Brake Control System
Brake Control System 164
3
The bolt that connects ABS
controller and car body
20~25
(V) Maintenance precautions
During the maintenance of ABS and ESP, please pay attention to the following precautions, or they may
suffer unnecessary damages due to improper maintenance
1. Before undertake the electric welding, disconnect the connector assembly from ABS control module
2. The spare parts in ABS is very sensitive to EMI, please confirm that no interference exists in all
parts’ traces, position, installation, connectors and supports.
3. Do not use quick charger to start the engine or charge the battery which is connected to the engine,
because this will make battery invalid or cause damage to the spare parts in ABS.
4. Make sure the ignition switch be closed first, then disconnect the negative terminal of battery, and
disconnect the connector of ABS control module
5. Do not try to repair any spare parts in ABS, since all parts of ABS can only be replaced
6. Do not hang the suspension’s parts on the harness of speed sensor, in case of damage on sensor’s
harness.
7. The ABS control module cannot be placed under situation whose temperature is higher than 105 ℃.
8. Chlorine, sulphur and relevant inorganic substances cannot exist in brake circuit, nor the mineral oil
or ester/lubricant plasticizer, including parts that may ooze these kinds of substances.
9. During ABS operation, the brake pedal will vibrate mildly with mechanic noise. These are normal
circumstances.
10. When the ignition switch is turned to “ON” position and the car is started, the brake pedal may
vibrate, and the motor in ABS hydraulic assembly may make some noises. These are normal
circumstances during operation check.
11. When the vehicle is running on bumpy, sand or deep fresh-snow road, the brake distance may be
longer than vehicles without ABS.
(VI) Special tools
No.
Tools
Mechanical dimensions
Illustration
1
Fault diagnosis
instrument
ABS&ESP fault diagnosis
III Failure diagnosis
(I) Brief introduction of failure diagnosis
1). Failure diagnosis can thoroughly understand every
system of the vehicle
2). Understand the customer’s complaint before the check,
and inquire their dissatisfaction in detail after fighting out
the failure.
3). Make sure check the vehicle’s failure from the
Brake Control System
Brake Control System 165
beginning in order to comprehensively repair the fault. For
intermittent failure, it is very important try to reappear the
failure according to the talk with customer and past cases.
Do not check under some special situations, as most
intermittent failures are caused by poor contacts. Under
this situation, swaying suspectable harness or connectors
with hands is an effective way.
4). After the diagnosis, be sure to “clear trouble codes”
(II) Fault diagnosis chart
Failure code chart for ABS
Trouble code
Failure illustration
C190104
Inadequate ECU’s voltage
C100004
Failure of ECU’s hardware
Failure diagnosis chart for ABS
No.
Symptom
Analysis on symptom
Solutions
Remark
1
Cannot read the data stream
of ABS control module
Poor contact of diagnosis port
Check and connect
Please refer to
“diagnostic flow
chart of
unabling to read
ABS data
stream”
ABS control module unearthed
Check and replace
The battery hasn’t provided
voltage to ABS control module
Check and replace
The ignition switch hasn’t
provided voltage to ABS control
module
Check and replace
The data circuit is broken or in
short-cut
Check, connect or
replace
Excessive data circuit’s electric
resistance
Check and replace
2
ABS warning light cannot be
lighted
ABS warning light fails/socket
loosening
Check, connect or
replace
Please refer to
“diagnostic flow
chart of
unlighted ABS
warning light,
no trouble
codes”
Dashboard’s fuse broken
Check and replace
Drive module of dashboard’s
warning light fails
Check and replace
ABS control module fails
Check and replace
The circuit between dashboard
and ABS control module is broken
or in short-cut
Check, connect or
replace
3
ABS warning light keeps
lighting
Open circuit between dashboard
and ABS control module
Check and connect
Please refer to
“diagnostic flow
chart of ABS
warning light
keeps lighting,
no trouble
Short circuit between dashboard
and ABS control module
Check and replace
Drive module of dashboard’s
warning light fails
Check and replace
Brake Control System
Brake Control System 166
ABS control module unearthed
Check and restore
codes”
ABS control module fails
Check and replace
Brake Control System
Brake Control System 167
Diagnostic flow chart of unlighted ABS warning light, no trouble codes
Brake Control System
Brake Control System 168
Diagnostic flow chart of unlighted ABS warning light, no trouble codes (continue)
Brake Control System
Brake Control System 169
Diagnostic flow chart of “unable to read ABS data stream”
Brake Control System
Brake Control System 170
Diagnostic flow chart of “unable to read ABS data stream” (continue)
Brake Control System
Brake Control System 171
Diagnostic flow chart of ABS warning light keeps lighting, no trouble codes
Brake Control System
Brake Control System 172
Diagnostic flow chart of ABS warning light keeps lighting, no trouble codes (continue)
Diagnostic information and procedures
1. Self-diagnostics
ABS control module can implement self-diagnostics on system and check the faults within. Once it finds
any fault, it will set diagnostic trouble code (DTC), lighten the ABS warning light, and shut down the
ABS system.
2. Reveal DTC
Specific scan tool (diagnostic instrument) can reveal the DTC
3. Clear DTC
DTC which is in the memorizer of ABS control module can be cleared by scan tool (diagnostic instrument)
△Notice please verify whether the system works
normally after the clearance procedure, and whether the
DTC doesn’t appear again. The DTC cannot be cleared by
dismantling the connector of ABS control module,
disconnecting the battery or stopping the engine.
4. The following situations may cause intermittent failure or poor contacts:
1). Error in electrical wiring
2). Error in electrical connection
3). Stagnation in electric valve or electromagnetic valve
5. Initialization’s order
ABS control module will set out initialization test during every beginning of ignition period. The
initialization order is electromagnetic valve and pump motor. Once the failure is detected, ABS control
module will set corresponding diagnostics.
During initialization period, there will be some noises and vibrations, which are a part of normal system
operation. If the ABS control module finds no signal input in brake switch (when your feet are away from
the pedal), the initialization will be set out immediately. If there is signal input in brake switch (your feet
are on brake pedal), the initialization will not be set out till no signal input is detected, or the speed
reaches 25 Km/h.
(III) Diagnostic check on circuit
Brake Control System
Brake Control System 173
1. System introduction
Circuit diagnostics can detect problems caused by failures of ABS or EBD. The diagnostic check on
circuit can lead the technicians to diagnose the failures.
2. Diagnostic procedures
The procedures of ABS/EBD’s maintenance come follow:
1). Check whether any mechanical failure exists in brake
system
(1). Is the liquid level of fluid reservoir correct?
(2). Is there any pollution in the brake fluid?
(3). Is there any leakage in brake’s master cylinder or ABS hydraulic assembly?
(4). Do all spare parts in brake system work normally?
(5). Is there any stagnation during braking?
(6). Is the braking steady?
(7). Are the brake shoes broken?
(8).Are the bearings broken?
(9). Do all sensors and harness work normally?
(10). Check whether the sensors’ connectors and tooth rings are broken, and check the wheel’s abrasion
degree
(11). Test the vehicle on road, check and correct the situation.
2). Set out diagnostic check on circuit
Please follow the corresponding diagnostic procedures during the circuit check. When all systematic
failures are eliminated, please clear the trouble code of ABS. Please refer to the following chart for
specific procedures and solutions.
Chart of diagnostic check on circuit
Procedures
Concrete measures
Next measure
Y
N
1
If possible, connect and install all spare parts which have been
disconnected or dismantled
Turn to
procedure 2
Turn to
procedure 4
Turn the ignition switch to "ON", and the engine is dead
When install the appropriate diagnostic instrument on DLC,
does it communicate with ABS control module?
2
Are there any current or past DTC stored?
Turn to
procedure 3
Turn to
procedure7
3
Record the current or the past DTC, and the historical data, like
the times when each DTC appears, the time when each DTC
first appears, the latest time when each DTC appears, the DTC's
setting speed, and other relevant data that can help the
diagnostics. Do not clear DTC before the diagnostic instrument
record the information
Turn to
procedure 5
Turn to
procedure 6
Brake Control System
Brake Control System 174
4
Can the instrument communicate with other modules that in the
same data circuit?
5
Refer to "no communication with ABS control module" in
failure procedure of ABS control module
6
Refer to "data chain connector unit of electrical terminal"
7
Shut down the engine
Turn to
procedure 8
Turn to
procedure 9
Wait for 10 seconds
Start the engine
Observe the ABS warning light after the engine has started
8
Does there any light keep lighting?
Turn to
procedure 9
Turn to
procedure
10
9
Refer to failure procedure of the corresponding light “keeps
working”
10
Refer to failure procedure of the corresponding light “out of
operation”
IV Air-removal of ABS system
(I) Special tool
No.
Tool
Mechanical dimension
Introduction
1
Fault diagnostic
instrument
Systematic trouble diagnostics for
ABS/ESP
(II) Conditions that needs air-removal
Should any of the following condition happen, it is necessary to remove air from ABS:
1. The traditional air-removal method for brake pipeline cannot achieve the pedal’s height that needs.
2. The ABS controller assembly is replaced.
3. Extreme fluid loss
4. Suspicion that some air exists in ABS controller.
This program, by using diagnostic instrument, can drive the system’s valve, run the pump motor, and
remove air from secondary circuits. These circuits are closed during normal condition, and open during
only the initialization or ABS’s working periods. The automatic air-removal program can open these
secondary circuits, exhaust all air and collect it inside the ABS controller assembly, where it can be
exhausted out of the system.
(III) Air-removal of ABS
1. Necessary tools
1). Diagnostic instrument installed with correct software
2). Brake fluid
Brake Control System
Brake Control System 175
3). Lifting jack
4). Gas-exhaustion bottle with hose that can recycle fluid in the vehicle
5). Appropriate safety equipment, like safety glasses
6). Two maintenance personnel: one needs to stamp the brake pedal and control the instrument, and
the other one needs to maintain the liquid level of hydraulic oil in master cylinder, and adjust the air-
removal screw according to the instrument’s judgement.
2. Preliminary check
1). Check the battery’s charging condition, and repair the battery and charging system if necessary
2). Connect the diagnostic instrument and choose the current or past DTC. Clear all DTC before the
procedure of ABS’s air-removal. If DTC cannot be cleared, please eliminate the failures first.
3). Check whether any damage or leakage exists on vehicle’s appearance, and repair them if
necessary.
△Notice by pressing the “EXIT” button on diagnostic instrument, you can terminate auto air-
removal program at any time
3. Air-removal in the car
1). Choose “auto air-removal program” and follow the instructions. (Please refer to practical program
in diagnostic instrument)
2). During basic and auto air-removal, please stamp the brake pedal to maintain the liquid level of
brake fluid in master cylinder
3). When exhaust air for a wheel, keep the hose jointing with air-removal screw, and exhaust air into
chamber with brake fluid. The chamber must be 30mm higher than the bolt of hose filled with brake
fluid, in order to prevent air from entering brake pipeline.
4). The first step is basic air-removal. This step must be carried out before auto air-removal, in order
to get better pedal’s height and driver’s feeling, and maintain the ABS’s best performance.
5). The first step of auto air-removal is to loosen the pump and pressure-reduction valve for 30
seconds. Air-removal screw doesn’t need to be opened during this step. The brake pedal keeps
increasing and reducing pressure during the whole process.
6). During the next step, the instrument will ask the personnel to open one of the air-removal screws,
and the instrument will circularly check the pressure valve and pump motor for 30 seconds. The
brake pedal keeps increasing and reducing pressure during the whole process.
7). For the remaining air-removal screws, the instrument will repeat step 6 to remove air.
8). When the auto air-removal program completes, the instrument will display relevant information.
9). Stamp the brake pedal to test the pedal’s height and driver’s feeling. Repeat step 1 to 8 till the
pedal’s feeling is acceptable.
△Notice when repeat the operation, the auto air-removal program may stop temporaily into
“cooldown” mode
△Notice only continue the next step when the time for the current step is up, and all steps cannot be
skipped.
Brake Control System
Brake Control System 176
4. Auto air-removal
1). Launch the failure diagnostic system for JAC Motors
2). Choose the V10.01 system for JAC Motors only
3). Launch the auto air-removal program
4). Carry out the first step
Brake Control System
Brake Control System 177
5). Air-removal is in process
6). Step 1 is complete
7). Carry out step 2
8). Air-removal is in process
9). Step 2 is complete
Brake Control System
Brake Control System 178
10). Air-removal is in process
11). Step 3 is complete
12). Carry out step 4
13). Air-removal is in process
Brake Control System
Brake Control System 179
14). Step 4 is complete
15). Carry out step 5
16). Air-removal is in process
17). Air-removal process is complete
Brake Control System
Brake Control System 180
V Front wheels’ ABS wheel speed sensor assembly
(I) Disassembly
1. Open the engine hood
2. Disconnect the negative cable of battery
3. Dismantle the front wheels, please refer to “wheels”
4. Dismantle front wheels’ cover, please refer to “front wheel’s cover”
5. Disassemble the front wheel’s ABS wheel speed
sensor assembly
1). Disconnect the harness connector of front wheels’
speed sensor
2). Uncouple the buckle that connects sensor’s harness
and vehicle body, two fixing points, and the fixing
point which connects with front shock absorber
3). Remove the fixing bolt that fixes the front wheel’s
speed sensor, and take out the sensor slowly.
(II) Installation
1. Install the front wheels’ ABS wheel speed sensor
assembly
1). Install the fixing bolt that fixes speed sensor
Tightening torque 8~10N.m
△Notice
1. Do not drag the sensor’s harness brutely
2. Mind the gap between speed sensor and signal’s
gear ring
Standard: 0.2~1.1mm
2). Install the buckle that connects sensor’s harness
and vehicle body, two fixing points, and the fixing
point which connects with front shock absorber
3). Connect the harness connector of front wheel’s
Brake Control System
Brake Control System 181
speed sensor
2. Install the front wheels’ cover
3. Install the front wheels
4. Connect the negative cable of battery
5. Close the engine hood
VI Rear wheels’ ABS wheel speed sensor assembly
(I) Disassembly
1. Open the engine hood
2. Disconnect the negative cable of battery
3. Dismantle the rear wheels, please refer to “wheels”
4. Dismantle the rear seat’s cushion, please refer to “rear seats”
5. Dismantle the rear seat’s backrest, please refer to “rear seats”
6. Dismantle the rear seat’s rotating bracket
7. Dismantle C column’s trim and decorated board
8. Dismantle the rail-gate threshold’s cover
9. Dismantle the rear-gate threshold’s cover
10. Dismantle the tailgate’s side panel threshold’s cover
11. Disassemble the rear wheels’ ABS wheel speed
sensor assembly
1). Disconnect the rear wheels’ speed sensor’s harness
connector
2). Uncouple the buckle that connects sensor’s harness
and vehicle body, and the three fixing point which
connect with rear torsion beam
3). Remove the fixing bolt that connects the rear
wheel’s speed sensor and rear hub assembly, and take
out the sensor slowly.
Brake Control System
Brake Control System 182
(II) Installation
1. Install the rear wheels’ ABS speed sensor assembly
1). Install the fixing bolt that fixes rear wheels’ speed
sensor
Tightening torque 8~10N.m
△Notice
1. Do not drag the sensor’s harness brutely
2. Mind the gap between speed sensor and signal’s gear
ring
Standard: 0.2~1.1mm
2). Install the fixing point that connects sensor’s
harness and vehicle body, and the three fixing points
that connect with rear torsion beam
3). Connect the harness connector of front wheels’
speed sensor
2. Install the front wheels’ hub
3. Install the railgate’s side panel
4. Install the reargate’s threshold cover
5. Install the tailgate’s threshold cover
6. Install the rear seat’s rotating bracket
7. Install the C column’s trim and decorated
8. Install the rear seat’s backrest
9. Install the rear seat’s cushion
10. Install the rear wheels
11. Connect the negative cable of battery
12. Close the engine hood
Brake Control System
Brake Control System 183
VII ESP controller assembly
(I) Disassembly
1. Open the engine hood
2. Disconnect the negative cable of battery
3. Drain the brake fluid, please refer to “brake fluid”
4. Dismantle ESP controller assembly
1). Disconnect the harness connector of ESP controller
assembly
2). Disassemble the oil outlet tube assembly in master
cylinder, front brake pipeline assembly and right-front
brake oil pipe assembly, which are connected to ESP
controller assembly
3). Dismantle the ESP controller’s support and the three
fixing nuts that fix the support
4). Take out the ESP controller
(II) Installation
1. Install the ESP controller
1). Install the three fixing nuts that connect ESP
controller and the support
Brake Control System
Brake Control System 184
2). Install the oil outlet tube assembly in master cylinder,
front brake pipeline assembly and right-front brake oil
pipe assembly, which are connected to ESP controller
assembly
Tightening torque 16~18N.m
3). Connect the harness connector of ESP controller
assembly
2. Add brake fluid, please refer to “brake fluid”
3. Exhaust air from brake system, please refer to “air-removal of brake system”
4. Connect the negative cable of battery
5. Close the engine hood
EPS (Electronic Power Steering)
EPS (Electronic Power Steering) 185
EPS (Electronic Power Steering)
I Brief introduction
(I) Structural introduction
EPS’s structural diagram
1. Steering wheel assembly 3. Steering shaft with universal shaft
2. Steering column assembly 4. Steering gear assembly
EPS (Electronic Power Steering)
EPS (Electronic Power Steering) 186
(II) System’s working principle
Diagram of system’s working principle
(III) Maintenance parameter
Project
Standard
Type of manual steering gear
Gear rack
Parameter of steering wheel
φ375mm
Steering column and lower shaft
Crumple level 3
Operating torque of steering wheel
≤ 5N·m
Power steering gear rack’s travel distance
134±1mm
Cord’s transmission ratio
46.82
Steering wheel’s number of turns
2.86±0.04
EPS (Electronic Power Steering)
EPS (Electronic Power Steering) 187
(IV) Torque parameter
No.
Project
Torque
（N·m）
Remark
1
Steering wheel’s fixing nut
42~52
2
Steering column’s installing nut
20~25
3
Steering column’s installing bolt
20~30
4
Controller support’s fixing bolt
8~10
5
Connecting bolt of steering column assembly and steering shaft
assembly
30~35
6
Connecting bolt of steering shaft assembly and manual steering gear
30~35
7
Primary fixing bolt of manual steering gear
95~105
8
Secondary fixing bolt of manual steering gear
95~105
9
Toe-in adjusting nut of steering tie rod
45~55
10
Slotted nut of steering gear’s external ball
40~50
(V) Maintenance precautions
1. When checking steering system, park the car on dry and level ground
2. All bolts of spare parts in steering system must be tightened with standard torque
3. Check the wheel alignment after finishing the maintenance of steering column assembly, steering
gear and other steering part.
4. The system’s voltage standard is 9~18V.
5. Check the tire’s pressure often and make sure it meets the standard.
6. Once abnormal gap or front-sway appears, confirm which system or assembly the problem exists in,
and solve the problem.
7. Check whether the spare parts of steering system suffer abnormal crash, and replace the broken or
problematic parts immediately
8. It is unacceptable to weld any part of steering gear or system rod piece.
9. Check regularly whether any interference or abrasion is on EPS harness, or whether the connector is
loosen, and replace harness if necessary.
II Failure diagnosis
(I) Chart of diagnostic trouble codes for EPS
No.
DTC
Description
1
C1611
Failure happens in torque sensor’s main signal
2
C1613
The difference between primary and secondary circuit of
torque sensor is excessive
3
C1614
Torque sensor’s power failure
4
C1615
Failure of signal in torque sensor’s secondary circuit
5
C1621
Vehicle speed’s signal loss
6
C1622
Wheel speed’s signal loss
7
C1624
Vehicle speed’s reduction exceeds normal level
8
C1641
Motor’s circuit is open or I short-out; drive circuit is
abnormal
9
C1642
Motor’s practical current is far higher than estimated
current
EPS (Electronic Power Steering)
EPS (Electronic Power Steering) 188
10
C1643
Motor’s current is too excessive
11
C1645
Motor’s practical current is far lower than estimated current
12
C1651
Angle transducer’s signal is abnormal
13
C1652
Controller’s relay fails
14
C1653
Power voltage is too low
15
C1654
Power voltage is too high
16
C1655
Drive failure (over-temperature, undervoltage)
17
U0073
EPS communication is down
18
U0100
Loss of communication with EMS/ECU
19
U0129
Loss of communication with ABS/BSM
20
C1611
Torque sensor-primary signal’s cross-border
21
C1612
Torque sensor-secondary signal’s cross-border
22
C1613
Torque sensor-sum of primary and secondary signal brakes
limit
23
C1614
Torque sensor-torque sampling overtime
24
C1661
Relay’s circuit is open
25
C1621
Battery’s voltage is too high
26
C1622
Battery’s voltage is too low
27
C1662
Current sensor-mid-current’s calibration error
28
C1663
Current sensor-excessive current
29
C1664
+5VA voltage error
30
C1632
EEPROM data consistency failure
31
C1643
Ignition signal loss
32
C1651
Motor-circuit’s short-out
33
C1667
Temperature sensor-MOSFET overheat
34
C1615
Angle sensor-PWM’s duty-ratio exceeds the limit
35
C1617
Angle sensor-angle’s calculation error
36
C1615
Angle sensor-PWM frequency is abnormal
37
C1616
Angle sensor-P or S signal sampling overtime
38
C1641
CAN- invalid vehicle speed
39
C1641
CAN- vehicle speed sampling is overtime
40
C1642
CAN- invalid wheel speed
41
C1642
CAN- wheel speed sampling is overtime
42
U1000
CAN-BUSOFF
EPS (Electronic Power Steering)
EPS (Electronic Power Steering) 189
43
U1000
CAN-message transmission overtime
44
C1665
EPS controller-inside failure
(II) Failure diagnosis
No.
Symptom
Failure’s reason
Solution
Remark
1
Vehicle’s deviation
Steering wheel’s ball joint
is loosen or the front
wheel’s alignment is
inappropriate
Adjust the alignment
and ball joint in steering
wheel
Please refer
to ”vehicle’s
steering system
check”
Steering lever system is
broken or suffer excessive
abrasion
Check and adjust each
joint part in steering
system according to the
instructions
Rack’s pre-tightening
degree is in maladjustment.
Adjust or repair the
rack’s pre-tightening
degree in the steering
gear
2
Power-steering is
sporadic or back to
normal after
restarting the engine.
Harness connector is loosen
or in poor contact
Check and reconnect the
connectors, make sure
they are connected
firmly
Please refer
to ”vehicle’s
steering system
check”
Motor’s fuse is loosen or in
poor contact
Re-install the fuse, make
sure it is installed
properly
Motor’s failure
Replace the motor
EPS controller’s failure
Replace the EPS
controller
EPS (Electronic Power Steering)
EPS (Electronic Power Steering) 190
(III) Diagnostic flow chart
Flow chart of combination instrument’s EPS warning light keeps lighting, no steering function
EPS (Electronic Power Steering)
EPS (Electronic Power Steering) 191
III Vehicle’s steering system check
(I) Check
1. Check the installation
1). Check the installing situation of steering gear assembly, front suspension, axle and steering
column
2). Check whether there is any gap during axial movement
3). Check whether the fixing nuts and bolts of steering gear assembly are loosen
2. Check the free-running distance of steering wheel
1). Turn the steering wheel and keep the front wheels straight ahead. Start the engine, and slightly
turn the wheel left or right, tillthe front wheel starts to move, and measure the steering wheel’s
distance on the excircle
Steering wheel’s free-running distance: 30mm
2). If the measured value exceeds the standard, check the installing situation of all joints of steering
column and the steering assembly, and adjust or replace relevant spare parts if necessary.
3). If the free-running distance still exceeds 30mm, then shut down the engine and keep the front
wheels straight ahead. Apply a force of 5N along the steering wheel’s periphery and check the free-
running distance. If the distance exceeds 10mm, then it is necessary to check whether the steering
assembly is qualified.
4). If the distance still stays at limit, then keep the wheel straight when the engine is dead, apply a
force of 4±0.6N along the wheel’s periphery, and check the free-running distance.
Standard: <15mm
5). If the distance above exceeds the standard, then disassemble the steering gear and check pinion’s
total torque.
3. Check the middle position
1). Confirm whether steering gear assembly, column and
wheel are installed correctly.
2). Carry out middle position check after the front
wheels’ alignment. Please refer to “front wheels’
alignment”
3). Park the vehicle directly, and confirm the steering
wheel is in the middle position.
4). Loosen the locknut of tie rod and turn the adjustment
lever slightly, and confirm whether the steering wheel
still stays at middle position.
4. Check the steering wheel’s static steering force
1). Park the vehicle on dry and level ground, and pull up the brake handle.
2). Start the engine.
△Notice the tire’s pressure should stays in limit
3). Turn the steering wheel a circle from middle position, check the wheel’s steering force, and
whether any apparent fluctuation exists.
steering wheel’s steering force: <34N
acceptable fluctuation: <5.9N
EPS (Electronic Power Steering)
EPS (Electronic Power Steering) 192
4). If the steering force exceeds the limit, please check or adjust the following parts:
(1). Check whether the lower suspension arm or steering tie rod’s ball joint is broken
(2). Check the steering gear’s preload and the driving torque of steering tie rod
(3). Check the driving torque of lower suspension arm’s ball joint
5. Check the steering wheel’s self-return
1). Turn the steering wheel for 90°, and drive the vehicle in 35km/h. Keep the speed for several
seconds, and loosen the steering wheel. The auto-return should be at least 70%.
△Notice During slow or sharp turn, check whether the
auto-return in left and right direction is same, by using
personal feeling. This check must be carried out on safe
roads, and keep personal safety as priority
6. Check the front wheels’ steering angle
1). After the toe-in check of front wheel, carry out
steering angle check. When the vehicle is still, and
engine is in idle speed, place the front wheel on steering
angle measurer, and check the maximum steering angle
of inner and external wheels.
Inner wheel: 35.1°±1.5°
External wheel: 30.6°±1.5°
△Notice if the measured value is not in the limit, adjust
the tie rod
7. Steering angle’s adjusting method
1). When the steering angle exceeds the limit, loosen the locknut of left and right steering tie rod, and
use wrench to adjust the tie rod till the angle meets the standard. Then tighten the locknut, and the
tightening torque is 45~55N.m. When re-adjust left and right tie rod, keep the left rod and right rod
equal
△Notice if the inner wheel’s steering angle exceeds limit, adjusting the tie rod to the outside will
increase inner wheel’s angle; when external wheel’s steering angle exceeds limit, adjusting the tie rod
to the outside will reduce external wheel’s angle. The vehicle’s toe-in is relevant to the adjustment of
other four wheels’ alignment and steering angle.
8. Check the dust cover of ball joint
1). Press the cover by fingers to check whether the dust cover is chap or broken
2). If any chap or damage exists on dust cover, replace the tie rod’s ball joint immediately.
△Notice dust cover’s chap or damage on surface may also cause ball joint to suffer damage.
9. Check the tie rod’s ball joint
1). Quickly sway the tie rod for 10 times
2). Use spring scale to measure the swinging resistance of tie rod
Standard: 0.5~3N.m. If the measured value exceeds the limit range, replace tie rod immediately.
IV Steering wheel assembly
(I) Disassembly
1. Open the engine hood
EPS (Electronic Power Steering)
EPS (Electronic Power Steering) 193
2. Disconnect the negative cable of battery
△Notice
wait for at least 3 minutes after disconnecting the cable, in case of air bag’s explosion during
disassembly
3. Dismantle driver’s air bag assembly, please refer to
“driver’s air bag assembly”
4. Disassemble the steering wheel assembly
1). Turn the steering wheel, and make sure the front
wheels are on straight line
2). Lock the steering wheel
△Notice make marks before pulling out steering wheel,
and make sure the steering wheel’s position after
installation is the same as the one before.
3). Loosen the fixing nut of steering wheel
4). Pull out the steering wheel from steering shaft
△Notice pre-tighrten the fixing nut to steering wheel,
in case of injuring maintenance personnel when pulling
out the steering wheel
△Notice if the steering wheel cannot be pulled out
manually, it is OK to use professional tools
(II) Installation
1. Install the steering wheel assembly
1). Turn the clock spring clockwise till the stop position,
and turn it 3 circles counter-clockwise
2). Engage the steering wheel to the spline of steering
column
△Notice the locking slot, which is in the bottom of
steering wheel, must match the locating pin of spiral
cable
3). Install the fixing nut and washers
Tightening torque: 42~52N.m
4). Adjust the steering wheel’s steering angle to 0
△Notice after the dismounting of steering column, the wheel’s steering angle may be affected,
while the pilot lamp on dashboard hasn’t lighted. It is necessary to carry out steering wheel’s signal
calibration. After calibration, when the ignition switch is in “ON” position, EPS controller will
inspect each module of the system, and light the EPS pilot lamp. If self-inspection is normal, the pilot
lamp will die in 2 seconds.
2. Install driver’s air bag assembly
3. Connect the negative cable of battery
4. Close the engine hood
EPS (Electronic Power Steering)
EPS (Electronic Power Steering) 194
V Steering column assembly
(I) Disassembly
1. Open the engine hood
2. Disconnect the negative cable of battery
△Notice wait for at least 3 minutes after disconnecting
the cable, in case of air bag’s explosion during
disassembly
3. Dismantle driver’s air bag assembly, please refer to “driver’s air bag assembly”
4. Disassemble the steering wheel assembly, please refer to “steering wheel assembly”
5. Disassemble the cladding of steering column, please refer to “cladding of steering column”
6. Disassemble the clock spring, please refer to “clock spring”
7. Dismantle the combination switch, please refer to “combination switch”
8. Dismantle the driver side’s back-plate, please refer to “driver side’s back-plate”
9. Disassemble the guard induction coil, please refer to “guard induction coil”
10. Dismantle the ignition lock assembly, please refer to
“ignition lock assembly”
11. Disassemble the steering column assembly
1). Disconnect the harness connector on steering column
2). Unfix the harness on steering column
3). Loosen the fixing bolt that connects the lower end of
steering column assembly and dashboard skeleton
4). Loosen the two fixing bolts that connect the upper
end of steering column and dashboard skeleton
5). Loosen the fixing bolt that connects steering column
assembly and steering shaft assembly with universl shaft
6). Take off the steering column assembly
EPS (Electronic Power Steering)
EPS (Electronic Power Steering) 195
(II) Installation
1. Install the steering column assembly
1). Install the fixing bolt that connects the lower end of
steering column assembly and dashboard skeleton
Tightening torque 20~30N.m
2). Install the two fixing bolts that connect the upper end
of steering column assembly and dashboard skeleton
Tightening torque 20~25N.m
VI Steering shaft assembly with universal shaft
(I) Disassembly
1. Open the engine hood
2. Disconnect the negative cable of battery
△Notice wait for at least 3 minutes after disconnecting
the cable, in case of air bag’s explosion during
disassembly
3. Dismantle driver’s air bag assembly, please refer to “driver’s air bag assembly”
4. Disassemble the steering wheel assembly, please refer to “steering wheel assembly”
5. Disassemble the cladding of steering column, please refer to “cladding of steering column”
6. Disassemble the clock spring, please refer to “clock spring”
7. Dismantle the combination switch, please refer to “combination switch”
8. Dismantle the driver side’s back-plate, please refer to “driver side’s back-plate”
9. Disassemble the guard induction coil, please refer to “guard induction coil”
10. Dismantle the ignition lock assembly, please refer to “ignition lock assembly”
11. Disassemble the steering shaft assembly with universal shaft
1). Loosen the fixing bolt that connects steering column
and steering shaft
2). Loosen the fixing bolt that connects steering shaft
and steering gear
3). Take off the steering shaft assembly with universal
joint
EPS (Electronic Power Steering)
EPS (Electronic Power Steering) 196
(II) Installation
1. Install the steering shaft assembly with universal joint
1). Tighten the fixing bolt that connects steering shaft
and steering gear
Tightening torque 30~35N.m
2). Tighten the fixing bolt that connects steering column
assembly and steering shaft assembly
Tightening torque: 30~35N.m
3). Adjust the steering wheel’s steering angle to 0
△Notice after the dismounting of steering column, the
wheel’s steering angle may be affected, while the pilot
lamp on dashboard hasn’t lighted. It is necessary to carry
out steering wheel’s signal calibration. After calibration,
when the ignition switch is in “ON” position, EPS
controller will inspect each module of the system, and
light the EPS pilot lamp. If self-inspection is normal, the
pilot lamp will die in 2 seconds.
2. Install the guard induction coil
3. Install the driver-side back-plate
4. Install the combination switch
5. Install the clock spring
6. Install the steering wheel assembly
7. Install the cladding of steering column
8. Install the driver’s air bag assembly
9. Connect the negative cable of battery
10. Close the engine hood
VII Steering gear assembly
(I) Disassembly
1. Disassemble the left-front wheel, please refer to “wheels”
2. Disassemble the right-front wheel, please refer to
“wheels”
3. Dismantle left-lower suspension arm assembly, please
refer to “lower suspension arm”
4. Dismantle right-lower suspension arm assembly, please
refer to “lower suspension arm”
5. Dismantle the front sub-frame assembly with stabilizer
bar and steering gear, please refer to “front sub-frame
EPS (Electronic Power Steering)
EPS (Electronic Power Steering) 197
assembly”
6. Disassemble the steering gear assembly
1). Disassemble the two hex flange-face nuts and two
gear locknuts that connect gear assembly and front
subframe
2). Take off the steering gear assembly
(II) Installation
1. Install the steering gear assembly
1). Put the gear assembly on the installing position of front
sub-frame
2). Install the two hex flange-face nuts and two gear
locknuts that connect gear assembly and front sub-frame
Tightening torque 95~105N.m
3). Adjust the tie rod’s left and right length according to
the value before maintenance, and tighten the locknut
after the adjustment.
Tightening torque 45~55N.m
4). Adjust the steering wheel’s steering angle to 0
△Notice after the dismounting of steering column, the
wheel’s steering angle may be affected, while the pilot
lamp on dashboard hasn’t lighted. It is necessary to carry
out steering wheel’s signal calibration. After calibration,
when the ignition switch is in “ON” position, EPS
controller will inspect each module of the system, and
light the EPS pilot lamp. If self-inspection is normal, the
pilot lamp will die in 2 seconds.
2. Install the front sub-frame assembly with stabilizer bar and steering gear
3. Install the right lower suspension arm assembly
4. Install the left lower suspension arm assembly
5. Install the right-front wheel
6. Install the left-front wheel