Dongfeng Sokon; C Series Repair & Maintenance Handbook Download Page 81

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2)Fix the wire harness.
3)Fix the bolts of the turning-gear box. And tighten the bolts according to the described torque

Torque

(b)

：

25 N·m

4)Fix the sway bar(L&R), refer to “Fixing of the sway bar” of the section 2)-6).
5)Check the alignment of the tyres.

Section 2 Rear Suspension

Ⅰ

.Components

The rear suspention is uint frame beam axle type which uses leaf springs as shown from illustration
below.

Summary of Contents for C Series

Page 1: ...Dongfeng Sokon Mini Automobile Repair Maintenance Handbook 维 C Series C35 ...

Page 2: ...k in running order C35 948 980 2 Performance Parameter Form 1 2 Form 1 2 Performance Parameters Items Parameters Optional Model of Engine DK15 06 SFD12C km h Max speed 135 105 Max Climbing Capacity 32 30 Time Needed from Start and then with continuous gear swift to accelerate 90km h 40 48 Economical Fuel Consumption Under Limited Condition like 50Km h etc 6 5 6 50km h Brake Distance 20 Outside Noi...

Page 3: ...2 Exhaust 1493 1248 Compression Ratio 9 5 1 8 8 1 Rating Power 60 5 38 5 Max Torque 102 74 Weight 98 97 Fuel Consumption 93 93 r min Idle Emission 750 50 900 50 r min Max Mini Swerving Speed 6000 750 50 5200 900 50 2 Transmission Technical Parameter Form 1 4 Form 1 4 Transmission Technical Parameter DK15 06 AF10 06 GearⅠ 4 425 3 652 GearⅡ 2 722 1 948 GearⅢ 1 792 1 423 GearⅣ 1 226 1 GearⅤ 1 000 0 7...

Page 4: ...rating parts and glass check the cleanliness of the interior including seats inner decoration parts check the state of windscreen cleaning device 8 Start the engine warm it up till it reaches the normal temperature then check it to see whether there is any leakage of oil gas water and electricity 9 After running with the gearshift lever in gear check the working condition of clutch transmission ha...

Page 5: ...When we drive the first 200km there is no appropriate friction If the braking works not well during this period we can properly add pressure on the pedal 2 2 Driving Proper driving not only shows the good technical performances of the car but also ensures safety driving Therefore as a driver we must do the daily maintenance work before driving and during driving we should drive the car properly ac...

Page 6: ...e switch start the starter no need to step the accelerograph Remark Loosen the switch key the moment the starter working in order to prevent the starter from passively working 4 After the engine starting to work you can drive at once and there is no need to warm up Remark Before the temperature of the engine reach the normal level do not let the engine work fast or step the accelerograph to the en...

Page 7: ...ich can reflect the working condition accurately If there has some hidden trouble they will warn us as soon as possible and require the driver to pay attention to it immediately to avoid accident with mechanical failure there are some important alarm units we should especial pay attention to 1 The pilot lamp alarms when the temperature of the cooling liquid is too high 2 The pilot lamp alarms when...

Page 8: ... the precondition of engine running without failure and long use Therefore when we add lube or change lube we must use the proper lube with high quality 1 When we check the lube level and engine working the consumption of lube is natural the consumption can reach to 0 138L 1000km So we must check the lube level terminally and had better check it when adding fuel every time When check the lube leve...

Page 9: ...vel may be higher than the highest mark Notice if the cooling liquid appears exceptional loss it may mean that the cooling system appears the breakage of leaking at this period of time merely depending on adding cooling liquid cannot solve the problem completely So do not waste any time come to the service station of the company right away to check the cooling system 2 Add the cooling liquid Close...

Page 10: ...heel right ahead stop the engine check the liquid level Open the cover of the oil ruler check the liquid level keep it between the maximum and minimum mark If under the minimum mark add power steering hydraulic oil according the regulations Remark 1 Do not mix braking liquid and power steering hydraulic oil Otherwise the braking system would not work 2 Power steering hydraulic oil is a kind of lub...

Page 11: ...locked and maintain proper contraction force The safe belt in the car is the kind of combined safe belt Notice the rightly use of safe belt is important to its function 2 Method of tying the safe belt across the waist Pull the head of the safe belt from one side to the other side across the waist and connect it to the other side until hearing the sound then pull the belt to see whether the belt is...

Page 12: ... mile 6 12 18 24 30 36 42 48 The interval of repairing and maintenance The interval should be fixed according to the odometer orthe using months month 6 12 18 24 30 36 42 48 1 engine l 1 driving belt R 1 2 Top camshaft timing belt Change it per 100 000kms l 3 valve clearance l 4 SE SF SG SH SJ engine oil and engine oil filter R R R R R R R R 1 5 Cooling system tube and junction 1 6 Cooling liquid ...

Page 13: ...clutch 7 2 tyre 7 3 tyre turntable 7 4 impending shelf setting 7 5 transmission shaft 7 6 manual transmission oil R R 7 7 differential gear oil R R 7 8 redirector system 7 9 gemel and lock 7 10 shift control staff and axis Remark R Replacing Inspecting replacing when needed 1 7 R is used only for installing rubber stuff on exhausting system Advice when the car drove under bad condition Obey the ma...

Page 14: ...ntial gear oil R every 20 000km or 12 months B Bolts nuts on Chassis T every 10 000kms or 6 months ABC Brake set and front pad Brake drum and brake show rear every 10 000kms or 6 months R Replacing Inspecting when needed T Screw down 1 More frequently checking or replacing is needed when traveling on dusty roads 二 Maintenance 1 engine Transmission strap Warning cut off the cathode of the battery b...

Page 15: ...a 8 11mm sink Replacing air conditioner s compressing transmission strap 1 Cut the cathode of the battery 2 Release the strain of the old belt and change the new one instead 3 Change the pump belt by the new belt 4 Adjust the strain of the belt according to the demand of technology 5 Connect the cathode of the accumulator Notice When we change the new belt the strain should be adjusted to press th...

Page 16: ... out plug Then install it and screw tight as per the following requirements Tightening toque a 35N m 3 Loosen the oil filter with appropriative spanner Appropriative tools A 09915 47340 4 Put engine oil on the o ring of new oil filter 5 Screw the new oil filter on the holder of it by hand screw it until the surface contacted the o ring Attention In order to screw the oil filter properly please fin...

Page 17: ...t the cover of the radiator down at once the hot water and steam will spurt out by pressure change Notice never put down the cover of thermostat 1 Don t remove the radiator cover until the engine cool down 2 Screw out radiator drain out plug to drain out the coolant 3 Remove the liquid storing kettle and drain out coolant 4 Screw on the drain out plug install the liquid storing kettle 5 Add a cert...

Page 18: ... Check and ensure the hose joints remain fastened Crankcase ventilation valve 1 Continued to cast cylinder head of the crankcase ventilation valve and then plug the hole and stuffed it into his cast cylinder head 2 Idle running engine 3 Put hand on the end of the crankcase ventilation valve control switch to check whether there are any vacuum If there is no vacuum it should check valve plug If nec...

Page 19: ...ink with new damping line and clip it tightly Don t pull the damping line joint but only pull the cover Ignition time Check Use fault decoder to check and be sure whether the ignition time is appropriate while it is rotating If it can not meet the requirement please check the valve timing or electronic control system 5 Fuel Engine idle speed and exhaust gas mixture Check Check engine idle speed an...

Page 20: ...hange fuel filter interval Refer to chapter three for detail knock down and installment Fuel pipe and fuel case Check Check if there s any leakage crack or damage of the fuel tank fuel pipes and connectors make sure that all clips are tightly fixed Replace the connectors when it s leaking Also change when there re cracks or damages 6 Arrester 1 Fuel pump 5 Drain out valve 2 Fuel pump filter 6 Two ...

Page 21: ...Brake tube and oil tube Check Do the checking under the enough bright light Use checking mirror necessarily Check the brake tube and oil tube whether appropriate or not Change it when it is leaking cracking blocking wearing eroding bending torturing and some other damage Please change it when necessary Caution After changing the brake tube and oil tube please exhaust the air Brake liquid Inspectio...

Page 22: ...body Clutch Inspection Check the free stroke of the clutch pedal The processes of checking and adjusting refer to unit 2 of chapter 6 a free stroke of pedal 10 15mm Tire Inspection 1 Check whether the tire is worn or damaged too much If it is change it 2 Check the inflating pressure and adjust the pressure according to the technical requirement when it is needed Caution The tire inflating pressure...

Page 23: ...ntain or change it Propeller shaft Inspection 1 Check the propeller shaft and universal joint and the spline to see whether they have Kata noise If there is change the damaged parts 2 Check the propeller shaft flange nut and bolt is tight or not If needed tighten again Tightening torque a 50N m Replacement 1 Balance the car Take away the oil drain out plug drain out the oil 2 Smear the oil drainer...

Page 24: ...ng pole is loosen or damaged for damaged parts repair or replacement is needed 4 Examine whether the steering pole shield and gear box cover are damaged leakage tear etc If defects are found new cover replacement is required 5 Check the universal joints for the sound card if there is kata sound and damages replacement is required 6 Check whether the steering wheel can turn around easily If turning...

Page 25: ...fe and fixing device to see whether it is broken or tore Check the safe belt to see whether it can be locked tightly Check the level of electrolyte in battery Check whether all units electrolyte level in battery is between the highest and lowest mark If the battery have inside indicators we can check the state of the battery through indicators Operation of the accelerating pedal Check whether the ...

Page 26: ... stops on the steep road should ensure that there is nothing in front of the car in case of injury or property damage Even if the car starts moving the car still can realize braking immediately When the car stops at a safe steep road and if the brake pole is pulled completely we should ensure that the braking is effective Steering Check the stability of the steering wheel and make sure that there ...

Page 27: ...ronic Control 1 The metering is precise spot injection uniformly keep the air fuel ratio in a good state 2 Three NO bring three GOOD No throat resistance and intake preheating influence but charging efficiency is good No flow loss and influence of reverse and air change but burning condition is good No influence of poor atomization and misdistribution but the thermal efficiency is good 3 Get a goo...

Page 28: ...n technology multiple point injection technology and digital injection technology and the intelligentization and the electric control of the autos have become the inevitable trend for the development of the autos There will be ae significant technological breakthrough and leap in this aspect Section II Fuel Injection Electronic System of Engine Makeup The electric injection system of engine for Do...

Page 29: ... absolute pressure inside the reference space is close to zero This forms a micro electricity machine system Activity surface of silicon chip endure a pressure close to zero its back endure a intake manifold absolute pressure not test yet which pulled into by a hose Thickness of silicon chip only few microns the change of absolute pressure of intake manifold will make silicon chip get mechanical d...

Page 30: ...eter pen connects with No 3 4 separately The referring voltage on the 3 stitch should be 5v and the voltage on the 4 stitch should be 1 3v while at idle speed the exact value is related to the vehicle model open the throttle slowly while with zero load the voltage on the pliers stitch will not change a lot then open the throttle quickly and the voltage on the 4 stitch will immediately reach to 4v ...

Page 31: ...sensor or more than one knock sensor can be installed on the cylinder block The sensitive element of the sensor is a piezoelectricity element The vibration will pass to the piezoelectric crystal through the quality block inside the sensor Because of the pressure caused by the vibration of the quality block the piezoelectric crystal will produce voltage on the two polar faces and convert the vibrat...

Page 32: ...nt break And avoid high pressure electricity being got through between stitch 1 and stitch 2 which may cause the electric component broken Brief Measure Method Remove the tie in make the digital multimeter in ohm gear the two should be connected to stitch 1 2 and stitch 3 4 the resistance value under normal temperature should be more than 1MΩ and make the digital multimeter to millivolt gear and s...

Page 33: ...ric potential difference is high quantity oxygen ion concentration move out from inside output voltage is high close to 800mV 1000mV if the mixed air concentration is low just little oxygen ion concentration move out output voltage is low close to 100mV Signal voltage occur mutation at the theory air fuel ration λ 1 3 Technical Specification Scope Value Unit Room Temperature 30 MΩ Exhaust Temperat...

Page 34: ...peed sensor is composed of a permanent magnet and its outside loop The oscillator is a kind of fluted disc it should have 58 teeth but two of which is vacant The oscillator is fitted on the crankshaft and moving around along with the crankshaft When tooth cusp pass the ends of induction type rotate speed sensor closely pulse wheel made of ferromagnetic material is cutting magnetic line of force of...

Page 35: ...ft 1 Brief Drawing Stitch Stitch mark 1 as connect earth mark 2 as signal output mark 3 as connect power positive 2 Working Principle The sensor takes advantage of the Hall Principle and the Hall Voltage is influenced by the changed magnetic induction intensity Hall Sensor Principle When the electricity current Is pass through a semiconductor flake on the way of voltaic dextral will produce Hall v...

Page 36: ...rol 5V 100mA supply power for sensor 5v 100mA closed loop control with self adapting Control the control valve of canister A C switch Engine fault indicator lamp fuel fixed amount correction Output of the engine rotating speed signal Input of the speed signal Fault self Diagnosis Receive the engine load signal 3 Stitch Connecting Point Type Stitch Connecting Point Type 1 J1 D5 Oxygen Sensor Heatin...

Page 37: ... input 59 J1 D10 signal of vehicle speed input 19 shock sensor A input 60 20 shock sensor B input 61 J1 D7 power earth 1 earth 21 62 22 63 not continuing power input 23 64 J2 A1 phase of step motor D output 24 65 J2 A3 phase of step motor A output 25 66 J2 A4 phase of step motor B output 26 67 J2 A2 phase of step C output 27 J1 C4 oil injection nozzle 1 the first cylinder out put 68 28 69 J2 A12 f...

Page 38: ...rge the battery power supply one minute later discharge the ECU 3 Store the ECU discharged 4 Don t install any circuit on the connection line of ECU Brief Measure Method 1 Plug the tie in Read the fault record of the engine by engine data K 35 Sensor earth 3 earth 76 J2 A8 blower switch input 36 sensor earth 2 earth 77 headlight switch input 37 Intake air pressure Sensor input 78 38 79 phase senso...

Page 39: ...The electric fuel pump that dipped into the fuel tank supplies fuel to the main fuel tube and fuel flows to the distributor and pressure adjustor which guarantee the stable fuel pressure after passing through the fuel filter to make sure the fuel injection mass will not be affected by the pressure and the fuel pump will supply fuel to the injector consecutively and the surplus fuel will return to ...

Page 40: ...te The electric fuel pumps of same structure adjust the rotate speed of engine by changing the turns of the coil so as to rectify the flow So don t use one model of electric fuel pump to another model of vehicle 3 Fault Symptom Judgment Method Fault Symptom running with big noise poor acceleration incapable of start hard start etc General Reasons usage of poor quality fuel which causing 1 the coll...

Page 41: ...the fuel pump works if not check the stitch to see if there is voltage or check the if the fuel pump relay is good if the fuel pump runs check the fuel pressure to see if it is around 260kPa at idle speed pull out the vacuum pipe of fuel pressure adjustor and check if the fuel pressure is around 300kPa Injector 1 Brief Figure and Stitch Stitch every injector has two stitches and the one beside the...

Page 42: ...owed 4 When unloading and reinstall oil atomizer must change O shaped circule don t damage the oil atomizer sealing face at the same time 5 Don t put out O circule supporting bead from the oil atomizer Don t damage oil atomizer parts like oil inlet o circule supporting bead jet board plug If any damage stop using 6 Doing fuel distribution assembled leakage test after oil atomizer installed no leak...

Page 43: ...rence between down chamber fuel pressure and upper chamber suction manifold pressure Assumption the valve is closed at the beginning because of the reduction load of engine suction manifold pressure decrease or fuel pressure goes up making the above pressure difference increase ultimately the film is jack uped by fuel pressure valve open Fuel through pressure regulator centre oil returen hole come...

Page 44: ...S S fuel injector and fuel pressure regulator DR Used for storage and distribute fuel 2 malfunction malfunction and judgement Fuel distribution pipe s sealing is test can be check by descrease testingTest the O circle at the 4 5bar test s largew5 1 5cm min Section Ⅳ enter and exhaust system The quantity of air which come into cylinder after through air cleaner is controlled by monomer valve the ai...

Page 45: ...air temperature to improve the fuel steam generation It is not influenced by drive condiction and outside temperature keep the eternal state distribute every cylinder symmetrical mixed air and keep the air fuel mixing ratio steady Inside the air cleaner case there is a 热蜡 sensor used for transducing entering air termperature The connecting with hot wax sensor is a toggle and baffle When the enteri...

Page 46: ...ng the hot wax sensor and baffle the whole air cleaner assemble should be changed ee re install the air cleaner upper cover Throttle body Throttle is one valve for air supplying control Operator control it by accelerator pedal Air throttle and air throttle body s structure as the following pics There is a assistant path which parallels air throttle on the Air throttle body It is controlled by the ...

Page 47: ...the rotation direction of rotor will be reversed The nut connecting with the rotator centre drives one screw mandrel Because screw rod is designed for not running so its only can move on the axes direction also be called straight shaft The head of screw rod is choke plug so the choke plug can retract and hang out so that increase or decrease the induction trunk section surface which besides the id...

Page 48: ...hatever the maintenance all should be taken after cooling When take Maintenance or other service check the exhaust system in a way as follow Check the rubber pad whether still fine without damage aging displacement Check the exhaust system whether leakage joint loose impress and damage If the bolt and nut already loose screw them down according to the torsion moment Check the whether around exhaus...

Page 49: ... open computer will control decreasing the air input of the main air intake Fuel vapor gathering system also is a supplement to the fuel feeding system when the emission valve open computer will control decreasing the oil spout of the oil spout machine Corresponding to the one operating condition of the engine mixed consistence and air input is changeless parts constitution and working principle T...

Page 50: ...on jar after running 50 000 miles every time 2 Fuel tank pressure control valve check a Take down the fuel pump assembly which installed on the fuel tank Refer to chapter 6C b Blow in air by through the vaporize soft tube air should waltz through the valve c At the same time when the vacuum pump connect with vaporize soft tube and loading gradually air should through the soft tube A Special purpos...

Page 51: ...nefficacy ignition This high tension power distribution though lost a little power because of inefficacy ignition however this let the ignition system cancelled the distributor block improved the ignition reliability decreased fault Spark plug AF10 06 electroject engine spark plug type F6RTC 4C7T screw thread M14 1 25 Useful time run 30 000km change BG13 20 electroject engine spark plug type K7RTC...

Page 52: ...nd second termipoint has the failure of turnoff If still no light then connect the third termipoint until its light and the failure is in the circuit between the last termipoint and first one mostly its turn off failure 2 Test lamp with power resource Test lamp with power resource is similar with 12V test lamp it just plus two 1 5V dry battery in handle like rightside picture showed Its used for t...

Page 53: ...uction manifold produce vacuum vacuum source of vacuum control system mostly use the induction manifold vacuum can use vacuum meter test vacuum source 4 Pressure gauge Pressure gauge can test pipeline vessel and liquid inside equipment or air pressure Because of using convenience price cheap be used broadly in vehicle workshop 1 气缸压力表 Cylinder pressure gauge Cylinder pressure gauge is for testing ...

Page 54: ...t menu item when testing simple and convenient for using showing in simplicity diagnosis data transmission cable which connecting with diagnosis socket with multi interface used for plug diagnosis socket of multi type vehicles At the end of monitor with PROM socket use relevant PROM magnetic card when testing different veheicle Basic principles and attention items of failure diagnosis 1 Operation ...

Page 55: ... voltage even over 7000V let the microcomputer and sensor damaged heavily List parts of some equipments can t be cut any cable of storage cell gas mixture control electromagnetic valve idle speed control equipment step motor Electromagnetic fuel atomizer secondary air injection electromagnetic valve the wire of ignition prom of microcomputer any wire of microcomputer conductor jointer of blower mo...

Page 56: ...d fuel enter into exhaust pipe damage the three unique catalyst 17 Idle speed system with self adjust function so the adjust of idle speed is auto finished by electric eject system no need manual adjust The set screw of air damper already be adjusted well when it was produced user change its initial position freely is not allowed 18 Don t connect anode and cathode wrongly when connecting storage c...

Page 57: ...ator Fuel pressure regulator easy get the failure blockage of regulator and membrane damage This will easy make engine supply fuel unsteady start difficult accelerate powerless and so on Failure alarm System with the function of failure alarm Alarm function of system expressed by detect lamp lighten picture right side which on the panel Normally after turn on the ignition switch detect lamp will b...

Page 58: ...source fast First should get know the situation condition how and whether be examined something about failure when failure happened So must give audience to client s description about failure though the description may not integrity or be misconstrued or maybe self contradiction but it often get the key of the problem The best way is after listen client s first opinion think for a moment do a firs...

Page 59: ...ltage of sensor of throttle position signal voltage of sensor of cooling fluid signal voltage of sensor of intake temperature sensor signal voltage of intake pressure 1 stitch signal voltage of shock sensor 2 stitch signal voltage of shock sensor 2 Electric injection state display Guard against theft system state if there is cooling system state stable operating condition dynamic operating conditi...

Page 60: ...m s fuse of the automobile for 30 seconds also works Press one key of the special tester to clear out the failure code Attention clearing out the failure code in the way of dismantling the battery s negative electrode will remove the EMS memory of the equipments such as quartz pin and the sound Therefore the battery s negative electrode can t be discharged casually It s better to clear the failure...

Page 61: ...cted 24 P0136 LSH_NP_CDC O2 Sensor Circ Bank1 Sensor2 Malfunction 25 P0138 LSH_MX_CDC O2 Sensor Circ Bank1 Sensor2 High Voltage 26 P0140 LSH_SI_CDC O2 Sensor Circ Bank1 Sensor2 No Activity Detected 27 P0170 FRST_NP_CDC Fuel Trim Bank1 Malfunction 28 P0171 FRST_MX_CDC Fuel Trim Bank1 System too Lean 29 P0172 FRST_MN_CDC Fuel Trim Bank1 System too Rich 30 P0201 EV1_SI_CDC Cylinder 1 Injector Circuit...

Page 62: ...MD01_MN_CDC Cyl 3 Misfire Detected 52 P0303 MD01_MX_CDC Cyl 3 Misfire Detected 53 P0303 MD01_NP_CDC Cyl 3 Misfire Detected 54 P0304 MD02_MN_CDC Cyl 4 Misfire Detected 55 P0304 MD02_MX_CDC Cyl 4 Misfire Detected 56 P0304 MD02_NP_CDC Cyl 4 Misfire Detected 57 P0318 SWE_MN_CDC Rough Road Sensor A Signal Circuit 58 P0318 SWE_MX_CDC Rough Road Sensor A Signal Circuit 59 P0318 SWE_NP_CDC Rough Road Sens...

Page 63: ...it High 78 P0480 LUEA_SI_CDC Cooling Fan 1 Control Circuit Index PCOD E DFP_Bosch Description of PCODE 79 P0501 VFZ_SI_CDC Vehicle Speed Sensor Range Performance 80 P0506 LLR_MN_CDC Idle Control System RPM Lower than Expected 81 P0507 LLR_MX_CDC Idle Control System RPM Higher than Expected 82 P0508 STPE_MN_CDC Idle Air Control System Circuit Low 83 P0509 STPE_MX_CDC Idle Air Control System Circuit...

Page 64: ... Cooling Fan 1 Control Circuit Low 102 P0692 LUEA_MX_CDC Cooling Fan 1 Control Circuit High 103 P1651 SVSE_CDC Data Bus Powertrain missing messages 104 P2177 FRAU_MX_CDC System Too Lean Off Idle 105 P2178 FRAU_MN_CDC System Too Rich Off Idle 106 P2187 RKAZ_MX_CDC System Too Lean at Idle 107 P2188 RKAZ_MN_CDC System Too Rich at Idle 108 P2195 LATV_MX_CDC O2 Sensor Signal Stuck Lean Bank 1 Sensor 1 ...

Page 65: ...e influence of car maintenance cylinder pressure air cleaner and so on to the system during the checking process 4 Replacing ECU and test If the failure code can be cleaned the failure position is at ECU if the failure code still can t be cleaned then replace the previous ECU repeat process do the examine work again Diagnosis flow of examine and repair of electric injection system based on failure...

Page 66: ...eed transducer 4 Ignition loop 5 Machine part of engine No Operation Step Test Result Follow up step Yes Next step 1 Using multimeter check the voltage between the two pillars of battery cell whether get 8 12V when the engine start No Replace battery cell Yes Next step 2 Keeping the ignition switch in the start position check if the voltage of anode in the pillar is more than 8v with multimeter No...

Page 67: ... idling mode disconnect vacuum hose of the fuel pressure regulator check whether the fuel pressure is about 300kpa No Check and repair oil supply system Yes Next step 2 Pull out the wire of one cylinder connecting with the spark plug make the distance between the spark plug electrode and the engine body 5mm and then check whether there is high voltage or not No Check and repair ignition system Yes...

Page 68: ...be used in the material of sealant manufacturer or equivalent with the sealant in the jointed surface of the aluminum gearbox Tightening bolts with torque wrench to the required torque Thoroughly cleaning all the parts and then assembling after they are dry Trouble Diagnosis Trouble Trouble Analysis The Way To Deal With Gear Shift Fork Wear Gear Shift Fork or synchronizer Wear The Flexibility of S...

Page 69: ...t oil inadequate or the kind of the oil improper bearing wear or damaged gear damaged or wear synchronous gear ring damaged or wear Inverse gear in the gear cover or gear damaged or wear makeup or replace replace replace replace replace ...

Page 70: ... turning off the engine and uprising the automobile levelly 2 After uprising the automobile examine the amount of the oil and make sure whether the oil leaks If it does leak then make maintenance 3 After discharging the waste oil apply the airproof lubrication to the whorl part of the tuck ...

Page 71: ...fretted The elasticity of the stable spring has been weaken or damaged The bearing on the input bearing or the main bearing fretted The reverse gear on the gear cover and the gear fretted Open spring ring dispatched or fall off replace replace replace replace replace the gear cover and the gear ring install Can t change the gear or can t quit from the current gear The elasticity of the synchromesh...

Page 72: ...would bear cut stress because the power in the driven gear is transmitted to the differential shell through bolts Therefore those specialized bolts should be made in chrome steel not be replaced by normal bolts A 99000 32020 a 80 90 N m Gear bearing Two roller bearings should be installed in the gear bearing outer seat circle installed in the final differential shell and the inside seat circle ins...

Page 73: ...earing Suppress the bearings to the inner of the differential Shell correctly with special implements not allowing to knock the bearing into the inner of the shell Special implements A 09940 53111 Special Implements ...

Page 74: ...before transmitting to the knuckle At last they are transmitted to the wheels to make the wheels turn During the whole courses with the movement of the knuckle the struts are turned through strut bearings and ballpins Ⅱ Check And Adjustment 1 Stabilizer Bar And Bushing Stabilizer Bar If it is spoiled or distorted you should replace it Bushing Check wheather it is spoiled or worn you should change ...

Page 75: ...re are cracks distortion or spoilages 5 Chenck the bushings of the sway bar Check wheather they are spoiled or worn 6 Check ballpin of the sway bar 1 Wheather they are turning smoothly 2 Wheather the kingpin ball joint if they are g 3 Check wheather the dust proof covers are spoiled 3 4 Check the windage of the ball joint if it is abnormal you should change it Attention The sway bar and the kingpi...

Page 76: ...ing to prescribed torque Attention Pay high attention when tightening the stabilizer bar to make sure the underlay and the washer are well fixed Torque a 25 N m b 50 N m c 23N m 2 Reinforcer And Bushing Disassembly 1 Jack up the vehiecle 2 Loose the stabilization bar Refer to loose down stabilization bar bushing 3 Loose the front and the back screws 4 Loose the stabilizer bar 5 Loose the bracket 1...

Page 77: ... of disassembly 1 9 Fix a screw in the position shown from the illustration 2 Tighten all the bolts and screws according to the described torque Torque a 73 N m b 95 N m c 35 N m 4 Hub And Spiaral Pole Disassembly 1 Lift the vehiecle and remove the wheels 2 Remove the axis cover as shown from the illustration Knock the cover properly for three times Don t spoil or distort the seat of the cover 3 L...

Page 78: ...ly to make sure the tiny teeth accord with the former ones 1 Fix the axis cover and tighten the bolts as describeb below Torque a 175 N m 2 Fix the brake pads 3 Fix the caliper and it s bracket 4 Tighten the bolts to the described torque below Torque b 95N m 5 Tighten the nuts of the wheel axis as shown in the illustration Warning Tighten the nuts properly to avoid cracks Any cracked nuts must be ...

Page 79: ...on 2 Fix the strut to the sway bar Refer to the illustration to make sure the direction of the nuts and bolts is right Attention The nuts should be loose 3 Fix the ball joint to the knuckle Set the slots of the ball joint and the bolts of knuckle well as show from the illustration And tighten the bolts according to the described torque below Torque a 55 N m 4 Tighten the front bolt of reinforcer a...

Page 80: ...t Tighten the bolts and the nuts according to the described torque below Torque a 95N m b 55N m 2 Fix the speed sensor If there is 3 Cnnect the tie rod with the knuckle and tighten the nuts of the tie rod to the described torque below 3 Torque c 45 N m Attention When tighening the nuts of tie rod Boost up the end of tie rod with jack to stop the rotation of the knuckle 4 Follow the fixing order ab...

Page 81: ...g to the described torque Torque b 25 N m 4 Fix the sway bar L R refer to Fixing of the sway bar of the section 2 6 5 Check the alignment of the tyres Section 2 Rear Suspension Ⅰ Components The rear suspention is uint frame beam axle type which uses leaf springs as shown from illustration below ...

Page 82: ...Shock absorber5 Shock Absorber 6 Washer7 Lock Washer8 Bolt Bottom Mounting 9 Bolt Top Mounting10 Bolt Bottom Mounting 2 1 Shock absorber Diassembly 1 Jack up the vehiecle 2 Remove the bolts of bottom bracket 3 Remove the shock absorber Fixing 1 Refer to the illustration below and fix the shock absorber 2 Tigten the bolts 3 Lay down the jack ...

Page 83: ...fting eye pin Press the bushing into the mate member Wipe some suds on the bushing to make it easier Attention Don t wipe any oil on the bushing 1 Leaf spring 2 Bushing Leaf Spring 1 Fix the pin of the lifting eye from the center of the vehiecle outward 2 Fix the front bolt of the leaf spring inward 3 Fix the central bolt and nut of the leaf spring Then tighten the bolt according to the torque 4 T...

Page 84: ...5 Draw out the brake drum with 8mm bolt 6 Rotate the lock pin of brake disk and remove the lock spring as shown from the illustration 7 Release the hand brake and remove brae shoe 8 Remove the hand brake cable from the chasis ...

Page 85: ...cable 2 Clip 9 Draw out the brake oil Then detach brake pipe from brale cylinder Cover the head of the pipe to avoid the leakage of the brake oil 10 Detach the nuts of base plate of brake from the rear axle housing ...

Page 86: ... Pay attention to the fixing of wheel bearing Bolts of the Hub When fixing make sure the head is tigtly fixed within step of the wheel axle 2 use oil press to press down the new bearing and closing ring Attention Protect the surface of closing ring from spoilage Otherwise oil may leak from differential carrier housing to the brake pad When pressing down the closing circle use 3 5 tons of power 3 W...

Page 87: ...ce between brake shoe and brake drum use screw driver to remove the ratchet wheel as shown from the illustration 11 Fix the brake drum 12 Top on enough oil for the rear axle housing and tighten the filler screw and drain screw according to the described torque 13 Dischage the air from the brake pipe And refill brake fluid 14 Fix wheels and tighten the screws according to the described torque Torqu...

Page 88: ...heather it is concave distorted or cracked Change the seriously spoiled disc 2 Check the nuts and tighten them is necessary 3 Check the wear degree of the bearing When checking the axial clearance remove the central cover of the disc and set a indicating gauge on the hub Torque of wheel nuts 50 80 N m Max axial clearance rear wheel 0 8mm Change the bearing if the measured value exceeds the max val...

Page 89: ...formance of some key parts It can cause high upkeep If it is time to change them you should replace them by the same and equivalent parts instead of inferior ones Also it is important to tighten them according to the torque described in the manul Don t weld these elements to avoid spoilage or reduce the intensity of the metal 1 Tyre 1 Tyre type of the vehiecle 165 70R14 It is tubeless tyre When in...

Page 90: ...m right for reference 4 Chage The Tyre If the tyre is bent hollow the lateral misalignment or the radial motion is too much there is leakage from weld line the screw is elonged or eyescrew cap is loose or badly rusted the tyre must be changed If the jerking motion value of the lateral misalignment or the radial motion is higher than the one below the tyre may cause harmful boboing The new tyre sho...

Page 91: ...o avoid injury of the operator and obtain a better balanceof the vehiecle Check wheather there is damnification with the tyre And do the balance examination according to the rules of equipment manufacturer Adjust the balance from balancer Most of the electronic balancer are more accurate than rotary balancer With easier operation it offers dynamic two planes balance Althoufh it doesn t amend the b...

Page 92: ...e pressure according to the tag in the vehiecl door 8kpa when the tyre is hot After parking don t deflate the tyre or reduce the tyre Higher pressure than advised may cause 1 Hard driving and reduced comfort 2 Tyre crack spoilage of tyre case or even burst of the tyre 3 Accelerate the wear of the central tread of the tyre Different tyre pressure in the same axle can cause 1 Odds in brake 2 Steerin...

Page 93: ...he equipments instructions when disassembling or fixing the tyre Don t use manul tools only because they may spoil flange or the rim Attention Don t stand on the tyres when inflating the tyres Otherwise the tyres may be spoiled and cause injuries Otherwise the flange may be broken and cause serious injury Inflate the tyre according to the described pressure in the manul If the flange isn t set wel...

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Dongfeng Sokon; C Series, Repair & Maintenance Handbook

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Summary of Contents for C Series

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