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JAC HFC4DA1-2C, Maintenance Manual

The JAC HFC4DA1-2C Maintenance Manual is a comprehensive guide to ensure proper care and maintenance of your vehicle. This manual covers all necessary procedures and maintenance schedules to keep your vehicle in top condition. Download your free copy from manualshive.com and keep your vehicle running smoothly.

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MT

MT

MT

MT Manual

Manual

Manual

Manual Transmission

Transmission

Transmission

Transmission

-32-

Instruction

Instruction

Instruction

Instruction and

and

and

and Operation

Operation

Operation

Operation

Exploded

Exploded

Exploded

Exploded View

View

View

View of

of

of

of Input

Input

Input

Input Shaft

Shaft

Shaft

Shaft Assembly

Assembly

Assembly

Assembly

S/N

Name

Qty.

S/N

Name

1

Circlip

1

5

3rd/4th gear synchronizer ring

2

Stop ring

1

3

Ball bearing (input shaft)

1

4

Input shaft assembly

1

Summary of Contents for HFC4DA1-2C

Page 1: ...of Engine 43 Section III Crankshaft and Flywheel System 68 Section IV Piston and Connecting Rod Group 69 Section V Valve Distribution Mechanism 70 Section VI Lubrication System 71 Section VII Cooling...

Page 2: ...of diesel 0 light diesel 10 light diesel 20 light diesel 35 light diesel Notice The cam of the high pressure fuel pump is being lubricated by the fuel Never cause engine flameout due to depletion of...

Page 3: ...vironment temperature 15 40 20 30 30 25 Extreme cold region Engine oil trademark 10W 40 50 or 15W 40 10W 30 40 50 5W 40 50 0W 40 50 Check engine oil level z Stop the engine and wait for several minute...

Page 4: ...ferent trademarks of coolants nor use such mixed coolant in order to prevent the chemical reaction from impairing the respective comprehensive anti corrosion performance e Never add the hard water suc...

Page 5: ...Fuel grade 10 Working sequence 1 3 4 2 Fuel supply advance angle Electronically controlled Flameout mode Fuel cut off Engine mass 270kg Emission limit test value China IV emission standard compliant N...

Page 6: ...0 1800 2000 2200 2400 2600 2800 3000 3200 3400 3600 rpm N m 0 10 20 30 40 50 60 70 80 90 k w 200 210 220 230 240 250 260 270 280 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 3200 3400 3600 r...

Page 7: ...ure C 4 Temperature of engine oil in main oil way C 5 Engine oil pressure kPa 700 82 95 130 400 600 2 Engine oil pressure at minimum stable speed kPa 98 3 Timing phase in rotation angle of crankshaft...

Page 8: ...ump filter screen assembly 20 11 Engine oil pump fixing bolt 20 12 Oil sump bolt 23 5 13 Flywheel baffle bolt 85 14 Flywheel bolt 25 for first step 70 for second step 120 for third step 15 Crankshaft...

Page 9: ...1 5 30 40 Socket nut of engine oil pump 30 41 Engine oil pump assembly bolt 25 42 Oil sump bolt 23 5 43 Cylinder head bolt 65 for first step 85 for second step 105 5 for third step 44 Rockshaft suppo...

Page 10: ...anifold and cylinder head 30 71 Bolt of exhaust pipe heat shield 25 72 Connecting bolt of turbocharger air bleeding pipe 25 73 Perforated bolt of lubricating oil pipe M12 41 M14 55 Comparison Table fo...

Page 11: ...Maintenance manual for sunray hfc4da1 2c china IV diesel engines 12 M22 1 5 256 422 370 555 433 649 M24 2 0 360 550 439 725 565 847...

Page 12: ...tappet 010 0 028 0 13 Clearance 0 01 0 046 0 10 Tappet bore 018 0 0 13 6 Radial run out of push rod 0 3 7 Deflection of rockshaft 0 3 8 Outside diameter of rockshaft 0 02 0 19 Clearance 0 01 0 05 0 2...

Page 13: ...34 Clearance 0 002 0 015 0 03 Piston pin bore 010 0 002 0 34 18 Thickness of connecting rod large end 0 07 0 33 Clearance 0 175 0 320 0 35 Opening of crankshaft connecting rod journal 250 0 175 0 33 1...

Page 14: ...inside diameter after pressed in Group A 93 021 93 032 Group B 93 032 93 043 Group C 93 043 93 054 Group D 93 054 93 065 24 Opening of piston ring 1st compression ring 0 2 0 4 1 5 2nd compression rin...

Page 15: ...ator specification 14V 90A Battery voltage 12V Intake system Turbocharger Radial flow variable section turbocharger The top speed of turbocharger is 220 000r m with turbocharger ratio at 2 2 EGR Type...

Page 16: ...inlet and outlet hoses of the engine z Disassemble the electronic control harness for engine ECU engine and complete vehicle z Disassemble the power supply wires for alternator starter and oil pressu...

Page 17: ...nd fixing bolts remove the fan clutch pulley and alternator belt and check the side face and toothed face of the belt for normal state c Remove the oil and vacuum pump oil return pipe connectors d Loo...

Page 18: ...haust pipe and turbocharger assembly e Remove the fixing bolts and nuts of exhaust pipe remove the exhaust manifold and turbocharger subassembly and remove the exhaust manifold gasket f Check A Whethe...

Page 19: ...pump and one is to loosen the nut of high pressure fuel pipe in order to prevent the fuel outlet of the fuel injection pump from follow up rotation Remove the high pressure fuel pipe and install the h...

Page 20: ...e out the fuel gas separator filter element Clean the fuel gas separator housing check the state of filter element and when necessary replace the filter element e Disassemble the fixing bolts of fuel...

Page 21: ...g pump and remove the power steering pump b Check the power steering pump for presence of oil leakage and check the belt pulley of power steering pump for presence of wear c Remove the EGR valve d Rem...

Page 22: ...pressure sensor assembly and the rail bracket and install the fuel pressure rail protective sleeve g Disassemble h Disassemble the fixing bolts of oil dipstick fixing sleeve and disassemble the oil di...

Page 23: ...sassemble the fixing bolts of thermostat housing and remove the thermostat housing l Remove the fixing bolts of cylinder head shield and remove the cylinder head shield m Remove the bolts and nuts of...

Page 24: ...surface of cylinder head r Remove the damping pulley Remove the fixing bolts of water pump remove the water pump and check the water pump blades for presence of cracking and corrosion and check the bl...

Page 25: ...onnector and lubricating oil pipe x Loosen the fixing nuts of fuel injection pump gear remove the hexagon socket fixing bolts of fuel injection pump and the fixing nuts of fuel injection pump gear kno...

Page 26: ...plate and remove the idler gear pressure plate idler gear and idler gear shaft z Remove the fixing bolts and fixing nuts of oil sump by one time as per the specified sequence and remove the oil sump a...

Page 27: ...ol to push out the piston Position the piston orderly Visually observe each piston for presence of cracking scratch and other excessive wear ee Disassemble the fixing bolts of timing gear chamber and...

Page 28: ...he piston cooling fuel injection pipe subassembly 5 Check the parts a Check the lower surface of the cylinder head Strict planeness tolerance is required for the fitting surface of the intake and exha...

Page 29: ...01 93 010mm e Use an inside micrometer to measure Standard value for inside diameter of cylinder bore fitted with cylinder sleeve A 93 021 93 030mm B 93 031 93 040mm C 93 041 93 050mm D 93 051 93 060m...

Page 30: ...er gauge to measure the axial run out clearance of the camshaft The axial run out clearance of camshaft is 0 05 0 114mm j Use a multimeter to measure the outside diameter of valve stem If the measurem...

Page 31: ...and the limit is 0 20mm m Use a feeler gauge to measure the clearance between piston ring groove and piston ring If the clearance between piston ring groove and piston ring is out of specified limit m...

Page 32: ...erlap position of oil control ring cushion spring and the opening of oil control ring steel strip shall be 180 away from each other and shall be 90 away from the 2nd compression ring r Measure the out...

Page 33: ...re measured above is the fitting clearance The wear limit shall not exceed 0 11mm Notice While measuring the inside diameter of crankshaft main bush bore install the bearing cap and bush onto the bear...

Page 34: ...or replace c Check the wear state of piston rings cylinder sleeves connecting rod small end bushes and connecting rod bushes and when necessary replace d Check the wear state of main bushes and thrus...

Page 35: ...haft thrust plates and main bearing caps a Install the upper and lower main bushes Align the stop opening of upper main bush with the slip groove of the main bearing block bore of engine block and pus...

Page 36: ...al portion and install the 1 4 main bearing caps of crankshaft as per the marked sequence The arrow markings on the bearing caps shall face to the front of the engine e Apply the liquid sealant onto t...

Page 37: ...ition the pointer of the dial gauge to the rear end face of crankshaft and use a straight screwdriver to pry lightly the crankshaft to check the axial clearance of crankshaft or push the crankshaft le...

Page 38: ...cting rod and bolts shall not come into contact with the cylinder bore and the large end bore of connecting rod shall be orthometric with the crankshaft journal c After installing the large end cap of...

Page 39: ...4da1 2c china IV diesel engines 40 4 Install the timing gear and related accessories a Insert the lubricated tappets in turn into the tappet holes b Install the water manifold The water manifold is pa...

Page 40: ...hfc4da1 2c china IV diesel engines 41 c Spray oil to the crankshaft gear and then install d Install the gasket of timing gear chamber e Install the timing gear chamber and idler gear lining plate and...

Page 41: ...il to the head of tappet and spray lubricating oil onto the camshaft subassembly g Install the camshaft with the bottom facing upward and the left facing forward h Tighten the fixing bolt subassembly...

Page 42: ...r gear C bush and lightly rotate into the idler gear shaft C Then apply oil onto the surface of idler gear A bush and use nylon bar to lightly knock into the idler gear shaft A Take caution to apply t...

Page 43: ...tly rotate the crankshaft to help installation n Use the hexagon flange bolts to install the idler gear pressure plates A B and C onto the idler gear shaft and tighten the fixing bolts of pressure pla...

Page 44: ...ng gear chamber and the lower rear end of engine block d Install the oil sump gasket e Apply the sealant for the second time to both sides of oil sump gasket f Install the oil sump assembly with oil d...

Page 45: ...ump j Place the fuel injection pump into installation position install and pre tighten the hexagon socket fixing bolts of fuel injection pump and install the fuel injection pump gear and fixing nuts o...

Page 46: ...and attach and tighten the fixing bolts of gear chamber cover to 20 5 N m p Torque for hexagon socket fixing bolt 60 10 N m q Install the damping pulley and attach and tighten the fixing bolts of damp...

Page 47: ...d portion of cylinder head bolts into oil and then install into the cylinder head and pre tighten d Tighten the cylinder head bolts by steps from the center to two sides as per the specified sequence...

Page 48: ...bracket onto the cylinder block and tighten to 37 5 9 5N m b Use hexagon flange bolts to install the fuel rail assembly with rail pressure sensor onto the fuel rail bracket and tighten to 25 5N m c In...

Page 49: ...Install the intake manifold harness bracket and intake pressure and temperature sensor 8 Install the push rod rocker arm subassembly and adjust the valve clearance a Dip the tip of push rod with oil a...

Page 50: ...d center of compression stroke 1236 If the 1st cylinder intake valve is pressed tightly by exhaust valve push rod the 4th cylinder piston is at top dead center of compression stroke 4578 e Valve clear...

Page 51: ...ly fuel injection pump high pressure fuel pipe 3rd cylinder high pressure fuel pipe assembly and 4th cylinder high pressure fuel pipe assembly and tighten the corresponding nuts Notice 1 Notice the in...

Page 52: ...shock absorber subassembly and install and pre tighten the fixing bolts g Install the water inlet pipe gasket and water pump inlet pipe weldment subassembly pre tighten the bolt spring and plain wash...

Page 53: ...tall the cylinder head shield and install and tighten the cylinder head shield bolts to 13 5N m k Install the exhaust manifold gasket and install the exhaust manifold and turbocharger subassembly l In...

Page 54: ...the fixing bolts o Apply sealant onto the thread of vacuum pump oil inlet pipe connecting bolts install the connecting bolts onto the cylinder block oil outlet and tighten to 18 2 N m p Install the al...

Page 55: ...and clutch fixing nuts s Tighten the alternator fixing nuts t Install the vacuum pump oil inlet pipe fixing bolts I M8 20 and tighten the fixing bolts to 18 2N m and 25 5N m respectively u Install the...

Page 56: ...inlet pipe assembly onto the turbocharger oil inlet and use perforated bolts I and copper washers I to install another end onto the cylinder block oil hole and tighten the perforated bolts I and II 1...

Page 57: ...Apply oil to the outer ring and lip of the crankshaft rear oil seal and use installation jig I to push the rear oil seal into the oil seal groove Then install the installation jig II and knock with s...

Page 58: ...m by steps in order to prevent the occurrence of false tightening torque This tightening torque is really high and will easily lead to thread failure of the bolts f Install the lubricated guide ball...

Page 59: ...lance weights to improve the rigidity and bending strength of the crankshaft z The crankshaft is made of high strength steel alloy forging with fillet rolled journals z Its front end adopts rubber emb...

Page 60: ...e consumption of engine oil and the grain emission while meeting the Euro IV emission standard 40 50 of the frictional power consumption of the engine is attributed to the pistons and piston rings The...

Page 61: ...chanism z It s a device that opens and closes at fixed times the intake and exhaust valves of all cylinder to enable the ingress of fresh air into cylinders and the exhaust of exhaust gas from the cyl...

Page 62: ...ong with the engine oil will speed up the wear of engine parts and may block the oil pipe or oil passage z The engine oil pump is of externally engaged gear pump and is driven by the crankshaft z The...

Page 63: ...is always under working state and is not subject to the restraints of large or small recirculation Dual thermostat control When the water temperature is less than 82 C the thermostat is under natural...

Page 64: ...air to approximate 60 C The inter cooler is located in front of the radiator or at windward position easily arranged in order to reduce the temperature of air entering into the cylinder further impro...

Page 65: ...hina IV diesel engines 66 section passage is greatly higher than that passing through the constant section passage Idling of engine Small passage section Large passage section High speed running of en...

Page 66: ...combustion temperature of engine and reduce the formation of NOx z The NOx is increased following the increasing of engine load and the EGR ratio shall increase accordingly z The EGR is not be perform...

Page 67: ...d Under the control of the EGR valve the exhaust gas is mixed with fresh air and enters into the combustion chamber to realize exhaust gas recirculation and reduce the emission 4DA1 2C diesel engine r...

Page 68: ...ing technology and advanced fuel injection mechanism The main characteristic of this technology is as below The main parameters including speed torque power oil temperature oil pressure water temperat...

Page 69: ...essure fuel return pipeline z It adopts direct injection combustion chamber system and common rail fuel supply system to realize high performance clean emission low noise and low vibration z Single ca...

Page 70: ...sure fuel pump in order to help the normal functioning of the high pressure pump The contaminant impurity and particle in the fuel will lead to the damage of pump units fuel supply valve and fuel inje...

Page 71: ...direction While rotating two gears engages to vacuumize the fuel into the chamber formed between gears and pump walls and then conveys to the outlet pressure end The closing line of the rotating gear...

Page 72: ...he ingress of sealant into the manual pump 3 Fuel leakage of manual pump Replace the manual pump The knocking or improper use will lead to fuel leakage of manual pump 4 Slow acceleration and difficult...

Page 73: ...pressure of common rail and the speed of the fuel pump fuel delivery amount Working mode Through one water separator the fuel delivery pump pumps out the fuel from the fuel tank and the fuel enters in...

Page 74: ...ccordance with the directive of the ECU the fuel injectors spray high pressure well atomized fuel into the combustion chamber at specified moment and specified pressure for a specified duration The fu...

Page 75: ...ctric signals of the directives Actuator It s functioned to convert the electric signals of the directives issued by the ECU into mechanical parameters I Sensor part 1 Crankshaft position sensor 1 Ove...

Page 76: ...nal of top dead center which will lead to the frequency variation of output signal When the number of teeth is reduced the voltage output amplitude will vary greatly This pulse signal is transmitted t...

Page 77: ...e signal and output as square wave signal z The camshaft position sensor is installed on the cylinder head shield z Wiring terminals 1 5V power supply 2 Signal output 3 Grounding z The clearance betwe...

Page 78: ...e difference sensor 1 Overview z The pressure difference sensor is functioned to real time monitor the pressure drop of the POC and determine whether the after treatment system is working normally The...

Page 79: ...of evaluation circuit is transmitted to ECU and then the turbocharger pressure is obtained by means of the programming characteristic curve z The temperature sensor incorporates one negative temperat...

Page 80: ...ut the malfunction data in the ECU 5 Troubleshooting Use Sunray special diagnosis instrument to check the trouble code and determine whether there is short circuit or open circuit between circuit of m...

Page 81: ...intake airflow flows through the diaphragm the temperature of the temperature sensing unit on the front of diaphragm is slightly lower than that of temperature sensing unit on the rear Based on this c...

Page 82: ...d Printed circuit board PCB with electric evaluation circuit sensor housing with electric connector The fuel flows into the rail pressure sensor via one hole on the common rail and the end of this ho...

Page 83: ...s of one voltage division circuit the ECU converts the resistance change of thermistor to one varying voltage and provides to the ECU and thus monitors the change of water temperature internal structu...

Page 84: ...instrument to check the trouble code and determine the malfunction position Mainly check the circuit of sensor and determine whether there is short circuit or open circuit between circuit and the gro...

Page 85: ...down the signal voltage of the accelerator pedal position sensor 1 is increased namely from approximate 0 7V at the free position to above 4V at the fully stepped down position When the accelerator p...

Page 86: ...clutch pedal is stepped down the lower central position of the clutch switch springs out In such case two pins of the clutch switch are connected When the clutch pedal is released two pins of the clut...

Page 87: ...are used to control the fuel amount during the braking This means that the operation of accelerator pedal will not lead to malfunction when the brake pedal is stepped down but the operation of accele...

Page 88: ...actuated by means of the output signal and supplies proper power to the actuators to control the common rail pressure and the high pressure pump units In addition the actuators can control the engine...

Page 89: ...tion Interface A A01 High fuel injector of 3rd cylinder A31 Low fuel injector of 2nd cylinder A02 High fuel injector of 2nd cylinder A32 A03 A33 Low fuel injector of 4th cylinder A04 Power supply of E...

Page 90: ...gnal A23 A53 Temperature signal of absolute pressure sensor A24 A54 Pressure signal of absolute pressure sensor A25 A55 A26 A56 Shielding wire of crankshaft position sensor A27 A57 Signal of camshaft...

Page 91: ...Exhaust brake relay control K76 K30 Anti theft cable K77 Water level signal K31 Position signal of EGR K78 Auxiliary brake switch K32 K79 K33 K80 Earthing of pressure difference sensor K34 K81 Accele...

Page 92: ...In such case the fuel injection amount depends on the open moment and the pressure in the common rail When the solenoid valve is no longer working and is closed the fuel supply process is completed Th...

Page 93: ...hen the fuel drainage hole is closed the valve spring will press the ball vale of armature onto the fuel return orifice The high pressure of common rail is formed in the valve control chamber Afterwar...

Page 94: ...ed in event of any of the following conditions z Replacement of fuel injector z Replacement of ECU z Confusion of installation serial number before and after the maintenance While performing the match...

Page 95: ...minant such as dust into the valve The open extent of the VNT solenoid valve is regulated by the PWM wave issued by ECU and the solenoid valve is installed on the crossbeam of the body water tank 2 Me...

Page 96: ...der cold state 2 Working Principle The preheating control unit is functioned to ensure effective cold start and shorten the warm up time which is closely related to the exhaust emission The preheating...

Page 97: ...rminal of the electric heating plug control instrument is connected to the electronic control unit ECU via multi pole plug To prevent the voltage drop the series connection circuit connected to the el...

Page 98: ...e occurrence of malfunction The vehicle shall be serviced as soon as possible z The malfunction indicator lamp lights up during the test of the malfunction indicator lamp z If the diagnosis procedure...

Page 99: ...ing Principle This is one data transmission interface for communication with ECU and is one standard OBD interface 3 Measurement analysis 4 Malfunction Mode Short circuit or open circuit between engin...

Page 100: ...round wire of the battery from the system or removing ECU harness connector will result in the loss of diagnosis and self learning information stored in ECU If the vehicle model is different the time...

Page 101: ...stem DTCs should be cleared by using the special diagnostic instrument for JAC commercial vehicles z It is not allowed to touch the engine gear train and rotating parts when the engine is at high spee...

Page 102: ...be a lot of system failures Operation Procedures 1 It is necessary to keep maintenance site clean it should be free of dust especially 2 It is necessary to keep maintenance tools clean they should be...

Page 103: ...nt carry out fuel injector matching with special diagnostic apparatus 9 Keep pressing manual oil delivery pump on oil water separator to provide low pressure line with fuel oil until the pump can not...

Page 104: ...rt short to power supply positive pole or short to ground Unreliable signal 4 Fault Frequency Counter For every identified fault there is an individual frequency counter value HZ Frequency counter val...

Page 105: ...paratus 8 Fault Detection After obtaining fault information records with means above only suspicious positions for fault occurrence are known However this does not mean faults have been detected There...

Page 106: ...level of intercooler downstream temperature is too high 17 P00BE The original value of fuel rail pressure is incoherent 18 P0100 The supply voltage of air flow sensor exceeds the limit 19 P0101 Timeou...

Page 107: ...47 P0201 The 1st cylinder fuel injector circuit is open 48 P0202 The 2nd cylinder fuel injector circuit is open 49 P0203 The 3rd cylinder fuel injector circuit is open 50 P0204 The 4th cylinder fuel...

Page 108: ...or is below the limit 75 P024F The signal level measured by EGR cooler bypass valve position sensor is above the limit 76 P0251 The fuel metering unit circuit is open 77 P0252 The temperature of fuel...

Page 109: ...cooler downstream temperature sensor is relatively low 107 P040D The signal level of EGR cooler downstream temperature sensor is relatively high 108 P0426 Upstream temperature fault of oxidation catal...

Page 110: ...igh voltage 141 P060D The accelerator pedal voltage signal is unreliable 142 P0611 The injection frequency is limited by system 143 P061B Error reported in torque comparison 144 P061C The deviation di...

Page 111: ...ly monitoring fault 3 175 P0704 Clutch signal error 176 P0737 Then engine speed output signal circuit is open 177 P0738 Then engine speed output signal circuit is short to ground 178 P0739 Then engine...

Page 112: ...osing or opening 207 P1038 The physical value of EGR valve position sensor is too high 208 P1039 The physical value of EGR valve position sensor is too low 209 P103A The signal level of intercooler do...

Page 113: ...he air flow meter is above the upper limit 244 P1103 The duty cycle of air temperature sensor on the air flow meter is below the lower limit 245 P1106 The time interval measured by the air temperature...

Page 114: ...der fuel injector 269 P1207 1st cylinder special error 270 P1208 2nd cylinder special error 271 P1209 3rd cylinder special error 272 P120A 4th cylinder special error 273 P120B 5th cylinder special err...

Page 115: ...mes into effect 301 P1253 An error is triggered when the ET time of the 4th cylinder reaches the maximum limit when the ZEL comes into effect 302 P1254 An error is triggered when the ET time of the 1s...

Page 116: ...nder is too strong 330 P1427 The minimum exhaust temperature signal of the 2nd cylinder is too strong 331 P1428 The minimum exhaust temperature signal of the 3rd cylinder is too strong 332 P1429 The m...

Page 117: ...ss 364 P145D Maximum value of particulate filter smoke mass 365 P145E The signal level of particulate filter flow impedance is relatively high 366 P145F The signal level of particulate filter flow imp...

Page 118: ...86 The oxygen sensor voltage in shunting exceeds the threshold 399 P148A The signal level of turbocharger upstream temperature sensor is relatively high 400 P148B The signal level of turbocharger upst...

Page 119: ...t is short to power supply 428 P1609 EGR valve circuit is short to ground 429 P160A EGR valve circuit is open 430 P160B Overtemperature of EGR valve bridge H chip 431 P160C Overcurrent of turbocharger...

Page 120: ...low the lower limit 461 P163B ECU temperature sensor SPI fault LM71 462 P1640 Compressor overtemperature in electrifying phase 463 P1643 Signal safety checkout error 464 P1645 The injection frequency...

Page 121: ...t fault 494 P1674 Monitoring fault mode 3 495 P1675 The negative deviation of throttle controller is below the lower limit for a long time 496 P1676 Open circuit of EGR valve bridge H 497 P1677 Overlo...

Page 122: ...pening 528 P2077 The signal level of swirl valve position sensor is relatively low 529 P2078 The signal level measured by the variable swirl valve position sensor is above the limit 530 P207A Overtemp...

Page 123: ...60 P2455 The signal level of particulate filter differential pressure sensor is relatively high 561 P2458 Particulate filter regeneration permanent fault 562 P245A EGR cooler bypass valve fault 563 P2...

Page 124: ...e valve control line is short to ground P0478 The exhaust brake valve control line is short to high level Fault Description The engine control unit ECU shall actuate the exhaust braking after processi...

Page 125: ...ult Tree ECU Y N N Y ECU Y N N Check the connection of brake valve Connector fault Repair or replace it Check the appearance of brake valve Fault of brake valve Replace the brake valve Check the ECU c...

Page 126: ...is also for determining the barometric pressure BARO When the ignition switch is turned on without starting the engine the following condition shall occur As long as the accelerator pedal position se...

Page 127: ...wer than the change of accelerator pedal position For poor contact inspection between ECU and IAT sensor please check the ECU harness connector for the following conditions Loose terminal Poor matchin...

Page 128: ...nt connector Connector fault Repair or replace it Repair or replace it Detect the sensor Sensor fault Replace the sensor Fault of ECU connector Get the Technical Support Repair the harness Check conti...

Page 129: ...r example during idling period the low level signal voltage shall be detected by the ECU When it is relatively high for example with the accelerator pedal fully open WOT the high level signal voltage...

Page 130: ...or sunray hfc4da1 2c china IV diesel engines 131 Terminal ECU A06 Power supply terminal of common rail pressure sensor A52 Signal terminal of common rail pressure sensor A40 Ground terminal of common...

Page 131: ...ingly Check the common rail pressure sensor Fault of common rail pressure sensor Repair accordingly Repair accordingly Fault of the low pressure oil circuit Fault of the high pressure oil circuit Repa...

Page 132: ...dingly Fault of low pressure pipeline Ensure there is no air bubble in the low pressure oil circuit Is there air in the oil circuit Find out where the air comes from and repair the system and then cle...

Page 133: ...low reference voltage circuit If the signal voltage of engine coolant temperature sensor detected by ECU is too low indicating the temperature is too high or too high indicating the temperature is to...

Page 134: ...at part If the DTC won t appear again the fault record data can be used for determining the self diagnostic code and the running mileage after the previous setting can be used for determining the occu...

Page 135: ...r accordingly Repair accordingly Replace the sensor Detect the sensor resistance Is it consistent with the vehicle condition Fault of sensor resistance Fault of ECU connector Check continuity and insu...

Page 136: ...osition to above 2V at the fully depressed position APP sensor 1 and 2 are installed in the accelerator pedal assembly Each one consists of the following circuits z A 5V reference voltage circuit z A...

Page 137: ...l engines 138 Terminal ECU K28 Power supply terminal of APP sensor 1 K81 Signal terminal of APP sensor 1 K67 Ground terminal of APP sensor 1 K22 Power supply terminal of APP sensor 2 K60 Signal termin...

Page 138: ...air the harness Repair accordingly Replace the component Check the component connector Connector fault Visually check the component Component fault ECU connector fault Check continuity and insulating...

Page 139: ...ector via adopting a device named Driver to supply PWM current to each fuel injector control circuit The driver owns a feedback circuit which is monitored by ECU to verify if the control circuit is op...

Page 140: ...Inspection of Fuel Injector Wiring listed below Clear the DTC turn off the ignition switch reconnect the fuel injector and turn on the ignition switch Does the problem reoccur Replace relevant fuel i...

Page 141: ...r switching on each fuel injector via adopting a device named Driver to supply PWM current to each fuel injector control circuit The driver owns a feedback circuit which is monitored by ECU to verify...

Page 142: ...Inspection of Fuel Injector Wiring listed below Clear the DTC turn off the ignition switch reconnect the fuel injector and turn on the ignition switch Does the problem reoccur Replace relevant fuel i...

Page 143: ...e time for switching on each fuel injector via adopting a device named Driver to supply PWM current to each fuel injector control circuit The driver owns a feedback circuit which is monitored by ECU t...

Page 144: ...Inspection of Fuel Injector Wiring listed below Clear the DTC turn off the ignition switch reconnect the fuel injector and turn on the ignition switch Does the problem reoccur Replace relevant fuel i...

Page 145: ...e time for switching on each fuel injector via adopting a device named Driver to supply PWM current to each fuel injector control circuit The driver owns a feedback circuit which is monitored by ECU t...

Page 146: ...Inspection of Fuel Injector Wiring listed below Clear the DTC turn off the ignition switch reconnect the fuel injector and turn on the ignition switch Does the problem reoccur Replace relevant fuel i...

Page 147: ...etering component is mounted at the fuel inlet of high pressure pump The engine s fuel supply shall be affected directly by the opening sectional area of the fuel metering unit control valve Provided...

Page 148: ...it Repair accordingly Repair accordingly Repair the harness Repair the fuel metering unit Get the Technical Support Connector fault Check the ECU connector Connector fault Check continuity and insulat...

Page 149: ...ot The circuits between CKP sensor and ECU include Signal circuit of CKP sensor Low reference voltage circuit of CKP sensor Shielded and grounded circuit If the number of crankshaft position pulses se...

Page 150: ...ection of ECU and engine is reliable and clean If the DTC is determined to be intermittent failure please refer to the fault records to find out when the previous DTC is set Terminal ECU A13 Signal te...

Page 151: ...epair accordingly Check the ECU connector Connector fault Repair accordingly Repair the harness Electrical fault Check continuity and insulating property The new sensor is connected Does the problem s...

Page 152: ...on signal circuit When no occurrence of minimum camshaft position synchronization is detected by ECU or there is failure in CMP sensor signal circuit DTCs shall be generated Diagnosis Hint Prior to ma...

Page 153: ...air accordingly Repair accordingly Repair the harness Signal fault Check the signals of camshaft and crankshaft sensor with oscilloscope if possible Check continuity and insulating property Electrical...

Page 154: ...low plug and indicate it to the driver A multilevel socket is equipped on the control input terminal of glow plug controller for connecting with ECU To avoid voltage drop screw pins or plugs should be...

Page 155: ...N Y N Y Check the connector of glow plug Connector fault Repair accordingly Repair accordingly Check the ECU connector Connector fault Check continuity and insulating property Electrical fault Repair...

Page 156: ...all convert the signal voltage into vehicle speed and make use of the vehicle speed signal to determine the working status of vehicle If this signal is lost or abnormal relevant DTCs shall be generate...

Page 157: ...lt Tree Check the sensor connection Connector fault Repair accordingly Check the ECU connector Connector fault Repair accordingly Repair the harness Electrical fault Check continuity and insulating pr...

Page 158: ...s The switch signals are relevant to the accelerator pedal for controlling the fuel amount during braking There should be no failure when you operate the accelerator pedal at the point of depressing t...

Page 159: ...nnector Connector fault Repair accordingly Visually check the component Component fault Replace the component ECU connector fault Repair accordingly Check continuity and insulating property Electrical...

Page 160: ...on voltage circuit When the voltage exceeds the set range the parts may be damaged and the input reading may be incorrect When the system voltage detected by ECU is too low below 11V or too high above...

Page 161: ...ry Check the battery connection Fault of battery connectors Repair accordingly Repair accordingly Check the ECU connector Connector fault Check the resistance between chassis and ECU ground Adjust the...

Page 162: ...osis If the self diagnosis process is not finished the control module shall record the corresponding operating condition and store this information into Fault Records to set DTC Diagnosis Hint If the...

Page 163: ...ur due to virtual connection or poor connection of control circuit etc Sensor supply voltage 1 The power supply for accelerator pedal 1 and CMP sensor Sensor supply voltage 2 The power supply for acce...

Page 164: ...r Match the connector correctly Provided that the signal lost is caused by a certain sensor disconnect each sensor one by one until the fault disappears and the failed sensor is located If all sensors...

Page 165: ...ernal control module via ECU Pin K01 K03 and K05 If the ECU signal for relay control is distorted DTC shall be generated Diagnosis Hint The intermittent failure may be caused by poor contact abrasion...

Page 166: ...the relay connector Connector fault Repair accordingly Check the ECU connector Connector fault Repair accordingly Repair the harness Check continuity and insulating property Electrical fault Replace...

Page 167: ...gives command to drive electric oil pump high pressure fluid generated in the pump goes through solenoid valve and gets into clutch cylinder ECU controls magnitude of current of solenoid valve for the...

Page 168: ...echnical Support Repair accordingly Repair the harness Replace the clutch switch Check clutch switch Clutch switch fault Check clutch switch harness Harness fault Check clutch switch power supply volt...

Page 169: ...cuit DTC occurs In the case of 20 samplings for output status of MIL drive open circuit or overhigh temperature faults are detected in 15 samplings at least There are 100msec for each sampling ECU det...

Page 170: ...lt Tree ECU Y N Y N Y Get the Technical Support Repair the harness Repair accordingly Check connection between instrument panel and ECU Connector fault Electrical fault Check continuity and insulating...

Page 171: ...ass air flow MAF sensor possesses circuits as follows One ignition 1 voltage circuit One ground circuit One signal circuit ECU applies a voltage to sensor via signal circuit The sensor uses the voltag...

Page 172: ...in mass air flow sensor it will lead to sensor deviation and DTC occurrence Wide open throttle during vehicle acceleration for starting may lead to rapid parameter increase of mass air flow sensor on...

Page 173: ...N Y N Y Get the Technical Support Repair the harness Repair accordingly Repair accordingly Check air flow meter connectors Connector fault Check ECU connectors Does the problem still exist Connector f...

Page 174: ...is high When air temperature increases sensor resistance value decreases In the case of high sensor resistance voltage of air temperature sensor signal circuit detected by ECU is high With decrease of...

Page 175: ...diagnostic tool If display of IAT changes it is indicated that there is fault in the part Fault Tree Y N N Y ECU Y N Y N Get the Technical Support Repair the harness Repair accordingly Repair accordi...

Page 176: ...operation condition in frozen fault condition and updates fault record Diagnosis Hint Influence factors for misfire diagnosis In the case of misfire diagnosis it is required that all vehicle parts are...

Page 177: ...or clearance Are faults in crankshaft position sensor clearance Check damping belt pulley and sensor Check belt pulley and sensor for interference Check crankshaft position sensor Faults are in cranks...

Page 178: ...aust gas recirculation valve and simultaneously monitors signals of intake manifold air pressure MAP sensor and exhaust gas recirculation position sensor In the case of inconformity of intake manifold...

Page 179: ...sunray hfc4da1 2c china IV diesel engines 180 Terminal ECU K23 EGR position sensor 5V power supply K31 EGR position sensor position signal K39 EGR position sensor ground A04 EGR actuator power supply...

Page 180: ...rdingly Repair the harness Get the Technical Support Replace components Does the problem still exist Electrical fault Check for continuity and insulating property Replace the actuator Check ECU for co...

Page 181: ...ge ECU monitors relay control circuit for conditions as follows It is short to ground It is short to voltage It is open When ECU detects incorrect voltage in low speed or high speed drive circuit DTC...

Page 182: ...ree Repair accordingly Check relay connectors Connector fault Check ECU connectors Connector fault Check continuity and insulating property Electrical fault Repair the harness Repair accordingly Repla...

Page 183: ...circuits as follows Motor control 1 Motor control 2 Besides two processors are applied in throttle valve actuator control system data monitoring These two processors are located in ECU testing data of...

Page 184: ...ngines 185 Fault Tree Check throttle valve actuator connection Connector fault Repair or replace Check throttle valve appearance Throttle valve faults Check ECU connectors Replace the ECU Repair or re...

Page 185: ...nd It is short to voltage It is open When ECU detects incorrect voltage signals DTC occurs and corresponding drive will stop operating Diagnosis Hint Check harness for intermittency and good contact P...

Page 186: ...the Technical Support Repair the harness Repair accordingly Repair accordingly Check starting motor connectors Connector fault Check ECU connectors Connector fault Check for continuity and insulating...

Page 187: ...panel for conditions as follows It is short to ground It is short to voltage It is open When ECU detects incorrect voltage signals DTC occurs Diagnosis Hint Check harness for intermittency and good c...

Page 188: ...lt Tree ECU Y N Y N Y Get the Technical Support Repair the harness Repair accordingly Check connection between instrument panel and ECU Connector fault Check continuity and insulating property Electri...

Page 189: ...It is open When ECU detects incorrect voltage signals DTC occurs Diagnosis Hint Check harness for intermittency and good contact Prior to component maintenance remove all fragments from connector surf...

Page 190: ...1 Fault Tree Get the Technical Support Repair the harness Repair accordingly Check connection between instrument panel and ECU Connector fault Check for continuity and insulating property Electrical f...

Page 191: ...sor displays signals of atmosphere pressure In the case of engine running with wide open throttle reading of atmosphere pressure will be renewed ECU determines whether voltage exceeds normal range via...

Page 192: ...ess Repair accordingly Check sensor connection Connector fault Check sensor resistance for conformity with vehicle status Electrical fault Sensor resistance faults Does the problem still exist Repair...

Page 193: ...lower water level sensor is applied in water level detection in water tank When accumulated water reaches certain level warning lamp on instrument panel will be lightened to remind driver to carry ou...

Page 194: ...ccordingly Eliminate the fault Drain filter Is there still water Check water level sensor for electrical faults Are there still electrical faults Check water level sensor connectors Are there still co...

Page 195: ...his switch is closed in order to provide TCU with voltage for brake application In the case of misoperation of driver during driving brake system will be locked after depressing brake pedal and brake...

Page 196: ...celeration system mechanical parts Mechanical part failures Check accelerator switch adjusting position Check switch position for improper adjustment Adjust accelerator switch position accelerator ped...

Page 197: ...iation between ECU detected signals and standard signals the fault will be stored and expressed as DTC via internal communication module of ECU In the case of external signal intrusion this will lead...

Page 198: ...esel engines 199 Fault Tree Get the Technical Support Repair the harness Repair accordingly Check ECU connectors Connector fault Check continuity and insulating property Control circuit failures Check...

Page 199: ...providing supercharger actuator control motor with pulse width modulation voltage Diagnosis Hint Check for connection and disconnection faults or seizures due to temperature Under extremely hot or co...

Page 200: ...ault Tree ECU ECU Y N Y N ECU Y ECU ECU N Get the Technical Support Repair the harness Repair accordingly Check ECU connectors Connector fault Check for continuity and insulating property Control circ...

Page 201: ...s between differential pressure sensor and ECU include the followings Differential pressure sensor high reference voltage circuit Ground circuit Differential pressure signal circuit When ECU detects i...

Page 202: ...nical Support Repair the harness Repair or replace Check the component connector Connector fault Check ECU connectors Electrical fault Check the sensor Sensor faults Replace the sensor Repair or repla...

Page 203: ...lectrical and Body Accessories The Body Electrical Volume details the technical standards of electrical component removal installation test debugging and diagnosis for SUNRAY long wheelbase vehicles i...

Page 204: ...al of Battery SC 14 Installation of Battery SC 16 Generator SC 18 Removal of Generator SC 18 Installation of Generator SC 21 Instrument Instrument Instrument Instrument and and and and Warning Warning...

Page 205: ...83 Basic parameters LT 83 Wiper Wiper Wiper Wiper and and and and Washer Washer Washer Washer System System System System Wiper WW 86 Mounting position WW 87 Information functions WW 89 Wiper WW 91 D...

Page 206: ...f seat belt SB 132 Removal of seat belt buckle lock SB 134 Power Power Power Power Window Window Window Window Power Window GW 136 Installation position GW 136 Operation Instructions GW 137 Power Wind...

Page 207: ...of front condenser AT 193 Removal of bottom condenser AT 195 Removal of heater water tank AT 196 Removal of after motor AT 198 Removal of compressor AT 202 Installation of compressor assembly AT 204...

Page 208: ...window EC 241 Front A C system EC 242 Rear A C system EC 243 ETACS EC 244 Instrument EC 247 Self diagnosis EC 250 Harness layout EC 251 Main harness EC 251 Engine compartment harness EC 252 Left front...

Page 209: ...ction and and and and Operation Operation Operation Operation Battery 2 Mounting Position 2 Precautions 3 Generator 4 Overview 4 Diagnosis Diagnosis Diagnosis Diagnosis and and and and Testing Testing...

Page 210: ...haracteristics in low electrolyte consumption In the service life of the battery there is no need to replenish with distilled water Moreover other characteristics of the battery are shock resistance h...

Page 211: ...e and negative terminal posts with a metal conductor eg metal tools metal wires metal parts etc in other word the external short circuit of the battery occurs the generated electric arc may result in...

Page 212: ...n behind the pulley into the generator shell The generator is the main power of the vehicle with the function of power supplying to all electric equipments except starter in the normal operation of th...

Page 213: ...egative pole of the charger with that of the battery Do not charge the series connected battery 24V As dual purpose charger one with constant voltage of 16 0V maximum permitted voltage is equal or und...

Page 214: ...e it is necessary to carry out battery boost charge After 3 months of battery service time when the battery capacity is lower than 50 or phenomenons like underpowered vehicle starting dim lighting abn...

Page 215: ...d operating bolt in charging Regulate or replace the regulator Charge according to relevant regulations For mild overcharge clean it with water and recharge it for application Overdischarge Voltage is...

Page 216: ...charge Battery is in the status of liquid loss and the exposure time of terminal cluster is too long Too high electrolyte density Too high electrolyte temperature Impure electrolyte Overcharge method...

Page 217: ...on of polarities For one reversed cell 8V For two reversed cells 4V For the whole reversed cells 12V Manufacturing quality Replace with a new battery Disassemble and reinstall Reverse charging of pola...

Page 218: ...will be internal spark Blocked vent Replace with a new one Deformation Overcharge Overcurrent charging Blocked vent Replace with a new one Battery acid leakage Damaged plastic case due to external im...

Page 219: ...t go out of charging indicator lamp when the engine is in operation Loose drive belt Loose or oxidized generator connector poor connection of ground wire Unable contact of brush with rotor ring stuck...

Page 220: ...converter bridge to electric appliances in the vehicle and then returns through negative power diodes Terminal B is an output one and Terminal D is connected to charging indicator lamp and ignition s...

Page 221: ...h large current from AC generator to battery when the charging current is discovered getting smaller or ever being close to 0 please verify for the existence of faults in charging part In the case of...

Page 222: ...ttery it is necessary to protect your eyes from being hurt by the spilled out acid solution Once the acid solution comes into contact with skin or eyes it is necessary to wash with clean water for 15...

Page 223: ...tallation Installation Installation Installation Removal Removal Removal Removal of of of of Battery Battery Battery Battery 1 Open the engine hood 2 Unscrew mounting bolts of battery negative pole Re...

Page 224: ...h electric leakage onto the vehicle Inspect the transportation tray for battery for the existence of screws and nuts and remove them in order to avoid secondary damage of the battery The sequence of b...

Page 225: ...ation Installation Installation Installation Installation Installation Installation of of of of Battery Battery Battery Battery 1 Open the engine hood 2 Place the battery on its support plate steady 3...

Page 226: ...18 Removal Removal Removal Removal and and and and Installation Installation Installation Installation Removal Removal Removal Removal of of of of Generator Generator Generator Generator 1 Disconnect...

Page 227: ...val Removal Removal Removal and and and and Installation Installation Installation Installation Removal Removal Removal Removal of of of of Generator Generator Generator Generator 5 Unscrew tension bo...

Page 228: ...g Charging Charging Charging System System System System 20 Removal Removal Removal Removal and and and and Installation Installation Installation Installation Removal Removal Removal Removal of of of...

Page 229: ...val Removal Removal and and and and Installation Installation Installation Installation Installation Installation Installation Installation of of of of Generator Generator Generator Generator 1 Connec...

Page 230: ...SC SC SC SC Battery Battery Battery Battery and and and and Charging Charging Charging Charging System System System System 22...

Page 231: ...Instruction Instruction Instruction and and and and Operation Operation Operation Operation Instrument 24 Mounting position 24 Performance characteristics 25 Diagnosis Diagnosis Diagnosis Diagnosis a...

Page 232: ...al instruments which take stepping motors as the structural forms Analog or digital signals of all sensors are converted into digital signals via processing of central processing units CPU to drive th...

Page 233: ...and strong vibration resistance 4 It enables long service life and wide operating range of 40 85 5 It enables low voltage 5V and low current drive all digital control and low consumption 6 It enables...

Page 234: ...l signals via AD and controls the water temperature stepping motor for the indication of corresponding values 2 Tachometer It carries out the algorithmic processing for signals sent by the generator c...

Page 235: ...d subtotal mileage The display interface can be switched via the application of the adjusting lever at the right side The subtotal odometer can be reset via pressing the adjusting lever for 2S 6 Water...

Page 236: ...arning lamp If the indicator lamp keeps lit or it will be lit during vehicle running it indicates that there may be electrical faults in the charging system 10 Exhaust fault indicator lamp In the case...

Page 237: ...in the state of normally on it indicates that there are electronic faults 14 Seat belt warning lamp It will keep lit until the driver s seat belt has been fastened 15 Left turn signal indicator lamp...

Page 238: ...dicator lamp When the upper beam headlamp is connected this indicator lamp will be lit 18 Airbag indicator lamp If the airbag indicator lamp keeps lit or is lit during vehicle running it indicates tha...

Page 239: ...lamp When the front fog lamp is lit corresponding mark of the indicator lamp will be lit When the fog lamp is turned off corresponding indicator lamp goes out 22 Rear fog lamp indicator lamp When the...

Page 240: ...4 Instrument LIN communication A5 Oil water separator B5 NC A6 NC B6 NC A7 NC B7 NC A8 NC B8 NC A9 NC B9 NC A10 Engine fault B10 NC A11 Charging indicator lamp B11 NC A12 Engine oil pressure B12 NC A1...

Page 241: ...l Removal and and and and Installation Installation Installation Installation Removal Removal Removal Removal of of of of the the the the instrument instrument instrument instrument 1 Disconnect the c...

Page 242: ...ystem System System 34 Removal Removal Removal Removal and and and and Installation Installation Installation Installation Removal Removal Removal Removal of of of of the the the the instrument instru...

Page 243: ...ing to enterprise standard approved via specified procedures or customers requirements Tachometer The elementary errors of the tachometer should be equal to or under 10 under low speed and 10 under me...

Page 244: ...IP Instrument Instrument Instrument Instrument and and and and Warning Warning Warning Warning System System System System 36...

Page 245: ...ration Operation Operation ETACS 38 Mounting position 38 Information functions 39 Diagnosis Diagnosis Diagnosis Diagnosis and and and and Testing Testing Testing Testing ETACS 40 System structure 40 I...

Page 246: ...indow rear fog lamp rear defroster front fog lamp step lamp small lamp headlamp hazard warning lamp and locking device ETACS control is achieved based on status of various equipments including signals...

Page 247: ...ions functions SUNRAY ETACS defines 17 kinds of function listed below A Washer Wiper Control B Variable Intermittent Wiper Control C Ignition Key Hole Illumination Control D Front Ceiling Lamp Illumin...

Page 248: ...a centralized control module for body electrical equipments 2 Body electrical control system mainly consists of ETACS sensor input switch input remote control receiving input and interior electrical e...

Page 249: ...ate after the intermittent switch is turned on in T1 0 3S each time of wiping for T2 0 7 0 1S with interval adjustable within 2 6 0 7S VR 0K 18 0 1S VR 50K when the vehicle speed is 0Km h When the veh...

Page 250: ...than 17Km h there is no alarm TI 0 3 0 1 sec 6 Seat Belt Warning Timer Turn the ignition switch to ON position If the driver s seat belt is unfastened the seat belt warning lamp shall flicker with 50...

Page 251: ...lamp shall go out If you insert the key again the tail lamp shall lighten Note Tail lamps mentioned here refer to small lamps 10 Rear Fog Lamp Control With the ignition switch turned to OFF position t...

Page 252: ...or lock signal output by locking device If you hold the latch switch a door unlock signal is output by locking device and then 3 unlock signals are output The driver side door is closed within T3 0sec...

Page 253: ...output by the locking relay T1 0 5 0 1 sec 16 Step Lamp Control The left step lamp shall lighten with the left middle door open and go out with the door closed The right step lamp shall lighten with...

Page 254: ...refer to the left figure 18 Password Learning Input If you press the password learning switch the fault lamp shall lighten entering into password learning mode The learning time is 10 sec in total Pre...

Page 255: ...he door bell shall ring intermittently with interval of T1 0 3 0 1S and it shall stop ringing with the handle released If the vehicle speed is lower than 3 Km h there is no alarm 7 Seat Belt Warning T...

Page 256: ...k signal of T1 0 5 0 1 sec is output by the locking relay 16 Warning Function With all doors and engine hood closed if you use remote controller for locking the vehicle shall be under warning status a...

Page 257: ...e middle door the front ceiling lamp and step lamp shall lighten if you close the door the step lamp shall go out and the front ceiling lamp shall go out gradually 9 Seat belt detection With the ignit...

Page 258: ...relay Output High level Low level A5 Seat belt warning lamp Output High level Low level A6 Rear fog lamp relay Output High level Low level A7 Step lamps Output NC Low level A8 Door locking relay Outpu...

Page 259: ...Low level B5 Front passenger side door lock switch Input NC Low level B6 Hand brake switch Input NC Low level B7 Rear defroster switch Input NC Low level B8 Front fog lamp switch Input NC Low level B9...

Page 260: ...oval Installation Removal Installation Removal Installation Removal Removal Removal Removal of of of of ETACS ETACS ETACS ETACS 1 Disconnect the negative cable of battery 2 Remove the glove box 3 Remo...

Page 261: ...stallation Removal Installation Removal Installation Removal Installation Installation Installation Installation Installation of of of of ETACS ETACS ETACS ETACS 1 Connect the harness connector of con...

Page 262: ...Electrical Parameter Requirement Operating voltage DC12V Operating voltage range DC9V DC16V Quiescent current 10mA Insulating resistance 100M DC500V megger Remote control transmitting frequency 315MHz...

Page 263: ...uration table 58 Introduction to functions 59 Diagnosis Diagnosis Diagnosis Diagnosis and and and and Testing Testing Testing Testing Fault diagnosis 62 Removal Installation Removal Installation Remov...

Page 264: ...system system system SUNRAY front lamps headlamps are installed on both sides of vehicle head for lighting when driving at night Fog lamps are installed on head positions lower than headlamps for road...

Page 265: ...ighting Lighting Lighting Lighting System System System System 57 Instruction Instruction Instruction Instruction and and and and Operation Operation Operation Operation Tail Tail Tail Tail lamps lamp...

Page 266: ...g lamp assembly 2 2 Front ceiling lamp assembly 1 3 Left front courtesy lamp 1 4 Right front courtesy lamp 1 5 License plate lamp assembly 2 6 Left side turn signal lamp 1 7 Right side turn signal lam...

Page 267: ...itch Rotate the cylinder at the end of multifunctional switch lever to the first position to turn on small lamps tail lamps license plate lamps and instrument panel lamp Rotate it to the second positi...

Page 268: ...tch Turn the headlamp switch knob to position lamp press the front fog lamp switch knob and the front fog lamp lightens 6 Rear fog lamp switch Turn the headlamp switch knob to position lamp press the...

Page 269: ...ion Introduction to to to to functions functions functions functions 9 Hazard warning lamp switch If you press the hazard warning lamp switch turn signal lamps on both sides and instrument indicator s...

Page 270: ...sition lamp position Does the front fog lamp lighten when it is turned on Go to Step 2 Check circuit 2 Does the front fog lamp indicator in combination instrument lighten System is normal Go to Step 3...

Page 271: ...he turn signal lamp switch to left right turning position Does left right turn signal indicator in combination instrument flicker as expected System is normal Go to Step 8 5 Connect the temporary vehi...

Page 272: ...ion Yes No 1 Is the fuse blown out Go to Step 4 Go to Step 2 2 Connect the test lamp with two terminals of brake signal lamp switch Does the test lamp lighten Go to Step 5 Go to Step 3 3 Connect the t...

Page 273: ...1 Check if the bulb filament of ceiling lamp is burnt out Is the filament burnt out Go to Step 4 Go to Step 2 2 Is the fuse blown out Go to Step 5 Go to Step 3 3 Connect the test lamp respectively wit...

Page 274: ...Testing Testing Fault Fault Fault Fault diagnosis diagnosis diagnosis diagnosis 5 Glove box lamp failed Step Operation Yes No 1 Is the fuse blown out Go to Step 3 Go to Step 2 2 Check if the bulb fil...

Page 275: ...o Step 2 4 Check the high low beam switch Is it normal Go to Step 5 5 Check switches Are they normal Go to Step 6 6 Check wiring harness of instrument panel as per circuit diagram Go to Step 8 7 Check...

Page 276: ...ct the connector between instrument panel and front body harness Is the voltage normal Go to Step 4 Go to Step 5 4 Check the front body harness from connector to high beam as per circuit diagram Is it...

Page 277: ...ess connectors Are they intact Go to Step 2 2 Is the fuse intact Go to Step 3 Go to Step 8 3 Measure the fuse voltage Is it normal Go to Step 4 Go to Step 7 4 Check connector between instrument panel...

Page 278: ...tch indicator is intact Go to Step 7 Go to Step 2 2 Is the Fuse 9 intact Go to Step 4 Go to Step 3 3 Replace the damaged fuse Go to Step 4 4 Remove the front fog lamp relay and measure the relay volta...

Page 279: ...to Step 3 Go to Step 11 Check connector between instrument panel and rear body harness Is the measured voltage normal Go to Step 4 Go to Step 5 Check rear body harness from connector and rear fog lam...

Page 280: ...ar body harness Is the measured voltage normal Go to Step 4 Go to Step 6 4 Check connector between reversing lamp and wiring harness Is it normal Go to Step 5 Go to Step 10 5 Check rear body harness f...

Page 281: ...o to Step 5 Go to Step 3 3 Measure the fuse voltage Is it normal Go to Step 5 Go to Step 4 4 Check the instrument panel harness 5 Disconnect the brake switch connector and check the brake switch Ensur...

Page 282: ...Step 3 Go to Step 2 2 Replace the damaged fuse Is the hazard warning lamp normal Go to Step 3 3 Remove the hazard warning switch and check if it is normal Go to Step 4 4 Check if the voltage of hazar...

Page 283: ...gnal lamp failed but with normal operation of hazard warning lamp Step Operation Yes No 1 Is the fuse intact Go to Step 3 Go to Step 2 2 Replace the damaged fuse Is the turn signal lamp normal Go to S...

Page 284: ...emoval Installation Removal Installation Removal Removal Removal Removal of of of of headlamp headlamp headlamp headlamp 1 Disconnect the negative cable of battery 2 Remove the front grille front comp...

Page 285: ...Installation Removal Removal Removal Removal of of of of clearance clearance clearance clearance lamps lamps lamps lamps 1 Disconnect the negative cable of battery 2 Hold the side turn signal lamp wit...

Page 286: ...l Installation Removal Installation Removal Installation Removal Removal Removal Removal of of of of front front front front fog fog fog fog lamps lamps lamps lamps 1 Disconnect the negative cable of...

Page 287: ...Installation Removal Installation Removal Installation Removal Removal Removal Removal of of of of ceiling ceiling ceiling ceiling lamps lamps lamps lamps 1 Disconnect the negative cable of battery 2...

Page 288: ...llation Removal Installation Removal Installation Removal Removal Removal Removal of of of of rear rear rear rear tail tail tail tail lamps lamps lamps lamps 1 Disconnect the negative cable of battery...

Page 289: ...al Installation Removal Removal Removal Removal of of of of high mounted high mounted high mounted high mounted brake brake brake brake lamp lamp lamp lamp 1 Disconnect the negative cable of battery 2...

Page 290: ...val Installation Removal Installation Removal Installation Removal Removal Removal Removal of of of of rear rear rear rear fog fog fog fog lamp lamp lamp lamp 1 Disconnect the negative cable of batter...

Page 291: ...12V 60 55W 60 55W H4 12V 60 55W 60 55W Position lamp 12V 16W 16W Turn signal lamp 12V 21W 21W 2 Rear combination lamp Turn signal lamp 12V 21W 21W Brake lamp 12V 21W 21W Reversing lamp 12V 21W 21W Re...

Page 292: ...LT LT LT LT Lighting Lighting Lighting Lighting System System System System 84...

Page 293: ...and Operation Operation Operation Operation Wiper 86 Mounting position 87 Information functions 89 Diagnosis Diagnosis Diagnosis Diagnosis and and and and Testing Testing Testing Testing Wiper 91 Defi...

Page 294: ...iper system system system system Wiper system is the system used for cleaning raindrops on windshield and rear window in order to maintain clear vision The application of spray washer in the system is...

Page 295: ...ng Mounting position position position position of of of of wiper wiper wiper wiper system system system system components components components components 1 Wiper motor Mounting position in the engin...

Page 296: ...ion Operation Operation Mounting Mounting Mounting Mounting position position position position of of of of wiper wiper wiper wiper system system system system components components components compone...

Page 297: ...Operation Operation Operation of of of of wiper wiper wiper wiper system system system system function function function function 1 OFF gear When it is at this gear the wiper is in off state and does...

Page 298: ...case of windshield cleaning pull up the wiper washer lever When the washer is turned on water which is sprayed from the water sprayer cleans the windshield automatically and the wiper shall operate si...

Page 299: ...tem System System System 91 Diagnostic Diagnostic Diagnostic Diagnostic Test Test Test Test Definitions Definitions Definitions Definitions of of of of pins pins pins pins No 1 2 3 4 5 Color Red Green...

Page 300: ...no faults in the wiper motor and verify the existence of good contact of the wiper motor connector Go to Step 7 7 Inspect the ground wire of the wiper motor in the instrument panel wire harness and re...

Page 301: ...onfirm that there are no faults in it Go to Step 10 10 Inspect the instrument panel wire harness between the relay and the wiper motor and repair the instrument panel if necessary Confirm that there a...

Page 302: ...to Step 3 3 Remove the wiper switch and measure the voltage of the switch with a digital multimeter to verify whether the voltage is normal Go to Step 5 Go to Step 4 4 Inspect the instrument panel wir...

Page 303: ...allation Installation Installation Installation Removal Removal Removal Removal of of of of the the the the wiper wiper wiper wiper 1 Disconnect the connecting wire of battery 2 Remove mounting bolts...

Page 304: ...Removal Removal and and and and Installation Installation Installation Installation Removal Removal Removal Removal of of of of the the the the wiper wiper wiper wiper 5 Take down the wiper blade and...

Page 305: ...on Installation Removal Removal Removal Removal of of of of the the the the windshield windshield windshield windshield washing washing washing washing fluid fluid fluid fluid reservoir reservoir rese...

Page 306: ...Installation Installation Installation Installation Removal Removal Removal Removal of of of of the the the the Wiper Wiper Wiper Wiper washing washing washing washing nozzle nozzle nozzle nozzle 1 D...

Page 307: ...nical Technical Technical parameter parameter parameter parameter No load Loaded 4 4N m Low speed High speed Low speed High speed Speed r min Current A Speed r min Current A Speed r min Current A Spee...

Page 308: ...WW Wiper Wiper Wiper Wiper and and and and Washer Washer Washer Washer System System System System 100...

Page 309: ...eration Operation Operation Reversing Radar 102 Mounting position sensor 102 Operating principle 103 Diagnosis Diagnosis Diagnosis Diagnosis and and and and Testing Testing Testing Testing Reversing R...

Page 310: ...or There are 4 sensor probes for Sunray reversing radar With the application of ultrasonic sensor the distance measurement of the obstacle and the vehicle can be carried out In the process of reversin...

Page 311: ...r sends ultrasonic signals to the sensor in order to drive the sensor for ultrasonic wave generation Ultrasonic signals are received by the sensor via obstacle reflection and the internal circuit of t...

Page 312: ...in sensor the buzzer 2HZ beeps once in the case of one or more faulted sensors the buzzer 2HZ beeps twice and then turns into normal distance measurement Distance 0 30 30 60 60 90 90 180 180 Beeping f...

Page 313: ...gnosis Diagnosis Diagnosis and and and and Test Test Test Test Definitions Definitions Definitions Definitions of of of of reversing reversing reversing reversing radar radar radar radar computer comp...

Page 314: ...conditions conditions conditions conditions for for for for the the the the out out out out of of of of operation operation operation operation reversing reversing reversing reversing radar radar rada...

Page 315: ...ditions conditions for for for for the the the the reversing reversing reversing reversing radar radar radar radar false false false false alarms alarms alarms alarms 1 The vehicle is running downward...

Page 316: ...nd and and Installation Installation Installation Installation Removal Removal Removal Removal of of of of the the the the reversing reversing reversing reversing radar radar radar radar computer comp...

Page 317: ...Removal Removal Removal Removal and and and and Installation Installation Installation Installation continued continued continued continued Removal Removal Removal Removal of of of of the the the the...

Page 318: ...val Removal Removal and and and and Installation Installation Installation Installation Removal Removal Removal Removal of of of of the the the the reversing reversing reversing reversing radar radar...

Page 319: ...16V Operating temperature 30 80 Storage temperature 40 85 Operating frequency 58KHz Max detection distance For intermediate probe180cm For left right probe 60cm Technical Technical Technical Technical...

Page 320: ...PT PT PT PT Reversing Reversing Reversing Reversing parking parking parking parking assistance assistance assistance assistance system system system system 112...

Page 321: ...and and and and Operation Operation Operation Operation Radio 114 Mounting position 114 Introduction functions 115 Precautions 119 Diagnosis Diagnosis Diagnosis Diagnosis and and and and Testing Test...

Page 322: ...nds electronic anti vibration reliability USB data reading function and FM AM radio and can supports play formats of CD MP3 and WMA The host featuring with four way audio output function can be connec...

Page 323: ...igh pitch BAL Left right balance FADER Front rear balance CUSTOM Set by customer 2 Press it shortly Under CUSTOM mode sound effect can be achieved by adjusting volume up or down JAZZ Jazz music VOCAL...

Page 324: ...ress and hold it The current radio station is stored onto No 1 position 6 Press it shortly Under radio mode the second radio station is selected under playback mode repeat play starts Press and hold i...

Page 325: ...de the fifth radio station is selected under playback mode it skips the first 10 songs to play Press and hold it The current radio station is stored onto No 5 position 10 Press it shortly CD quit if i...

Page 326: ...tion Introduction Introduction Introduction Introduction to to to to CD CD CD CD player player player player function function function function 13 Press it shortly Auto searching to low end Press and...

Page 327: ...on Instruction Instruction and and and and Operation Operation Operation Operation Precautions Precautions Precautions Precautions 1 Don t place CD player under hot environment 2 Don t remove the CD p...

Page 328: ...struction Instruction Instruction Instruction and and and and Operation Operation Operation Operation Precautions Precautions Precautions Precautions 5 Handle the CD properly 6 The CD is not allowed t...

Page 329: ...co axial cable shielded ground and radio connector shielded circuit Is the resistance higher than the specified Go to Step 8 Go to Step 10 5 Measure the resistance of center conductor signal input be...

Page 330: ...mally Check harness Go to Step 2 2 Test the DC dimmer signal circuit for Open circuit High resistance Short circuit to ground Poor contact Is the fault detected and eliminated Go to Step 6 Go to Step...

Page 331: ...oudspeaker circuit Is there any bang of loudspeaker Go to Step 7 Go to Step 4 4 Test relevant loudspeaker circuit for open circuit or too high voltage Is the fault detected and eliminated Go to Step 1...

Page 332: ...tion Removal Installation Removal Installation Removal Removal Removal Removal of of of of CD CD CD CD player player player player 1 Disconnect the negative cable of battery 2 Remove the outer cover p...

Page 333: ...llation Removal Installation Removal Installation Removal Installation Removal Removal Removal Removal of of of of loudspeakers loudspeakers loudspeakers loudspeakers 1 Disconnect the negative cable o...

Page 334: ...System System System 126 Removal Installation Removal Installation Removal Installation Removal Installation Removal Removal Removal Removal of of of of loudspeakers loudspeakers loudspeakers loudspea...

Page 335: ...nce Parameter Frequency range KHz 531 1629 Intermediate frequency KHz 455 5 S N sensitivity dBuV 40 S N ratio dB 40 Selectivity dBuV 40 Intermediate frequency rejection ratio dBuV 50 Image rejection r...

Page 336: ...1KHz 15 CD read time S TCD 784 10 CD quit time S TCD 784 8 Time to next track S TCD 784 3 Time between first and last track S TCD 784 5 Pause and play time S TCD 784 6 Error correction during reading...

Page 337: ...struction Instruction and and and and Operation Operation Operation Operation Seat Belt 130 Overview 130 Diagnosis Diagnosis Diagnosis Diagnosis and and and and Testing Testing Testing Testing Seat Be...

Page 338: ...ruction and and and and Operation Operation Operation Operation Seat Seat Seat Seat Belt Belt Belt Belt The seat belts are assembled on each seats for Sunray The seat belt is designed to limit the mov...

Page 339: ...river s seat belt do the corresponding seat belt indicator lamps illuminate and extinguish Go to Step 2 3 Replace the instrument panel combination instrument Has the replacement operation been complet...

Page 340: ...val Installation Removal Installation Removal Installation Removal Removal Removal Removal of of of of seat seat seat seat belt belt belt belt 1 Disconnect the connecting wire of battery 2 Remove the...

Page 341: ...SB SB SB SB Seat Seat Seat Seat Belt Belt Belt Belt 133 4 Remove the B pillar inner trim panel...

Page 342: ...emoval Installation Removal Installation Removal Installation Removal Removal Removal Removal of of of of seat seat seat seat belt belt belt belt 5 Remove the covers of top mounting bolts 6 Remove the...

Page 343: ...moval Removal Removal Removal of of of of seat seat seat seat belt belt belt belt buckle buckle buckle buckle lock lock lock lock 1 Disconnect the connecting wire of battery 2 Remove the front seat in...

Page 344: ...d and and Operation Operation Operation Operation Power Window 136 Installation position 136 Operation Instructions 137 Diagnosis Diagnosis Diagnosis Diagnosis and and and and Testing Testing Testing...

Page 345: ...The main switch on front door trim at the driver s side enables the driver to lift or lower windows at the passenger s side Power window system includes power window switches on each door trims body c...

Page 346: ...passenger s side 2 Power window motor Permanent magnetic reversible motor enables window regulator upper window bracket to move by the rope wheel mechanism Connect the battery positive and negative to...

Page 347: ...relay is the battery voltage Go to Step 7 Go to Step 5 5 Turn the ignition switch on and check if Terminal 3 of power window relay grounds Go to Step 11 Go to Step 6 6 Check if the harnesses of ETACS...

Page 348: ...indow motor connector and turn the ignition switch on When the power window main switch goes up the voltage between Terminal 2 of left front door power window motor connector D08 and ground is the bat...

Page 349: ...en going down Terminal 3 and 8 Terminal 1 and 4 are conductive when no operation Go to Step 5 Go to Step 4 4 Replace the right front door power window switch 5 Check if the harnesses of right front do...

Page 350: ...ting Testing Troubleshooting Troubleshooting Troubleshooting Troubleshooting 4 The auto down function for left front door power window fails Step Operation Method Yes No 1 The normal replacement and c...

Page 351: ...moval Installation Removal Removal Removal Removal of of of of window window window window regulator regulator regulator regulator motor motor motor motor 1 Disconnect the connecting wire of battery 2...

Page 352: ...moval Installation Removal Removal Removal Removal of of of of window window window window regulator regulator regulator regulator switch switch switch switch 1 Disconnect the connecting wire of batte...

Page 353: ...al Installation Installation Installation Installation Installation of of of of window window window window regulator regulator regulator regulator motor motor motor motor 1 Install the motor 2 Connec...

Page 354: ...l Installation Installation Installation Installation Installation of of of of window window window window regulator regulator regulator regulator switch switch switch switch 1 Install the window swit...

Page 355: ...GW GW GW GW Power Power Power Power Window Window Window Window 146...

Page 356: ...ro Applied models SUNRAY products manufactured by JAC Subject Page Instruction Instruction Instruction Instruction and and and and Operation Operation Operation Operation Electric rear view mirro 148...

Page 357: ...Operation Operation Operation Rear Rear Rear Rear view view view view mirror mirror mirror mirror Sunray rear view mirrors is devided into interior rear view mirror and exterior interior rear view mi...

Page 358: ...lation Installation Installation Removal Removal Removal Removal of of of of rear rear rear rear view view view view mirror mirror mirror mirror 1 Disconnect the connecting wire of battery 2 Remove th...

Page 359: ...n Installation Installation Installation Removal Removal Removal Removal of of of of rear rear rear rear view view view view mirror mirror mirror mirror switch switch switch switch 1 Disconnect the co...

Page 360: ...and and and and Operation Operation Operation Operation H H H Horn orn orn orn 152 Mounting position 152 Diagnosis Diagnosis Diagnosis Diagnosis and and and and Testing Testing Testing Testing H H H H...

Page 361: ...HORN HORN 152 Instruction Instruction Instruction Instruction and and and and Operation Operation Operation Operation Mounting Mounting Mounting Mounting position position position position of of of o...

Page 362: ...system Go to Step 6 Go to Step 7 6 Disconnect the body control module Is the horn always on Go to Step 7 Go to Step 11 7 Disconnect the horn relay Is the horn always on Go to Step 10 Go to Step 9 8 Ch...

Page 363: ...Reconnect the horn relay 2 Disconnect the horn connector 3 Connect a test lamp between the horn control circuit and a sound ground 4 Press the horn button and hold it Is the test lamp lit Go to Step 1...

Page 364: ...rn for proper mounting torque 2 Check if there is any fragment at the connecting part between horn and vehicle Is any fault detected and elimilated Go to Step 9 Go to Step 6 6 Perform procedures below...

Page 365: ...stallation Removal Installation Removal Installation Removal Removal Removal Removal of of of of horn horn horn horn 1 Disconnect the negative cable of battery 2 Remove the front bumper 3 Remove the m...

Page 366: ...165 Operating principle 165 Air distribution system introduction 167 Leak test 168 A C system performance testing 169 Refrigerant recovery 172 A C System Performance Table 174 System Testing 176 Remov...

Page 367: ...m system system system SUNRAY adopts dual A C system with the front and rear A C controlled independently In this system the front and rear A C use independent condenser and evaporator but share the s...

Page 368: ...kin 2 In case of the refrigerant gets into your eyes or having contact with skin please flush the affected areas with fresh water and go to the doctor for help Please don t rub your eyes with hand or...

Page 369: ...34a refrigerant and R 12 refrigerant are incompatible so even little amount of R 12 refrigerant is not allowed to be mixed into R 134a refrigerant 7 When handling refrigerant please note that the surr...

Page 370: ...lation of A C system after removal please apply refrigerant oil onto the O ring As for screwed joints install them by hand and then use two wrenches for tightening As for the flanged joints install nu...

Page 371: ...most of places using A C 2 TO FACE FEET mode Air is adjusted and vented out through upper air vent and floor air vent The air from floor air vent is hotter than that from upper air vent However when t...

Page 372: ...button Press this button and the indicator shall lighten indicating the internal circulation mode is applied press this button again and the external circulation mode is selected 7 Front control pane...

Page 373: ...b within the range shown in the right figure and the interior temperature can be controlled within the indicated range 10 Rear control panel cold warm select knob Rotate the knob within the red zone t...

Page 374: ...rature gas after passing through compressor which transforms into high pressure and low temperature liquid after being cooled by condenser radiating pipe the liquid after being dehumidified and buffer...

Page 375: ...Conditioner 166 Diagnosis Diagnosis Diagnosis Diagnosis and and and and Testing Testing Testing Testing Operating Operating Operating Operating principle principle principle principle 5 Condensation p...

Page 376: ...system system system introduction introduction introduction introduction 1 Mixing flow The outside air is mixed through Instrument panel air vent Floor air vent 2 Ventilation The outside air comes in...

Page 377: ...uorescence leak detector IMPORTANT Be sure to wear dark color goggles with UV lamp so the color of dye can be deepened The application of fluorescent dye can facilitate the detection of leak position...

Page 378: ...ng A C A C A C A C system system system system performance performance performance performance testing testing testing testing 1 Test the vehicle under direct sunlight 2 Don t test the vehicle under a...

Page 379: ...C A C A C A C system system system system performance performance performance performance testing testing testing testing 5 Set the cooling temperature to the coldest status 6 Open the instrument pane...

Page 380: ...ood is closed 10 Connect the precision pressure gauge to A C system 11 As for the precise testing of humidity relative humidity the pressure and temperature of air supply outlet shall vary with humidi...

Page 381: ...g Testing R R R Refrigerant efrigerant efrigerant efrigerant recovery recovery recovery recovery 1 Park the vehicle in well ventilated areas 2 Connect to the refrigerant recovery machine 3 Turn on the...

Page 382: ...g partial vacuum of A C system with pressure at about 34 kPa 10 Hg 7 Once partial vacuum is realized it is recommended to turn off the refrigerant recovery machine and two manual valves and record the...

Page 383: ...191 1296 86 30 47 8 60 42 236 225 1494 95 35 54 12 49 50 265 266 1653 104 40 62 16 45 58 300 304 1864 113 45 69 20 47 63 334 323 2155 40 59 15 37 3 00 25 171 139 956 68 20 38 3 50 28 197 164 1129 77 2...

Page 384: ...5 psi You can also determine the boiling point of refrigerant 134a based on different pressure For example under the pressure of 188 2 kPa 27 3 psi the boiling point of refrigerant R134a is 0 32 F 15...

Page 385: ...the outlet hose at the heater core Set the maximum speed of blower Set the warmest temperature Record temperature at the position listed below Central air vent on instrument panel Outlet hose at the h...

Page 386: ...AT AT AT ATAir Air Air Air Conditioner Conditioner Conditioner Conditioner 177 10 Run the system to check the maintenance result Is the fault detected and eliminated System is normal Go to Step 2...

Page 387: ...Is the inlet hose of heater warmer than the outlet hose Go to Step 11 Go to Step 5 5 Test the operation of A C compressor Does the A C compressor run Go to Step 7 Go to Step 6 6 Replace the A C compr...

Page 388: ...p 4 Go to Step 11 4 Touch the blower casing to check for vibration when the blower motor operating at different speed Is there any overvibration Go to Step 6 Go to Step 5 5 Listen to the sound of blow...

Page 389: ...the engine run for several minutes Stop the engine for 1 minute Restart the engine Is any noise detected by using this procedure Go to Step 6 Generation of liquid slugging noise is a common phenomeno...

Page 390: ...he blower motor speed reduces is there still tick click chirp squeak or scraping but with lower sound Go to Step 6 Go to Step 4 4 Is whish howling obvious under every mode but not so under every tempe...

Page 391: ...operation finished Go to Step 15 5 Check if the carpet is moist Is the carpet moist Go to Step 6 Go to Step 14 6 Check the existence of the conditons below Leak at front windshield periphery Drain pi...

Page 392: ...etected and eliminated Go to Step 15 Go to Step 5 5 Turn the ignition switch to OFF position Connect the blower motor Air heater ventilation and A C system control module Turn the ignition switch to O...

Page 393: ...AT AT AT ATAir Air Air Air Conditioner Conditioner Conditioner Conditioner 184 Is the fault eliminated...

Page 394: ...control position of blower 20 blower speeds should be effective Is every blower speed effective Go to Step 8 Go to Step 5 5 Plug a 2 pin connector into the back of blower motor Use integrated radio t...

Page 395: ...Observe the internal circulation damper Set the internal circulation switch to OFF position Does the internal circulation damper transfer from internal circulation to ventilation Go to Step 5 Go to I...

Page 396: ...ernal Air Circulation Fault Diagnosis Help in Automatic Air Heater Ventilation and A C System 5 Set the temperature switch to OFF position When heating or defrosting is applied is it still cold Go to...

Page 397: ...et the mode switch to OFF position Does the blower stop operation Go to Step 2 Go to Step2 2 Set the mode switch to VENT position Turn the blower motor switch to each speed position Is the blower moto...

Page 398: ...positions Does the drive shaft of internal circulation actuator rotate Go to Step 11 Go to Step 4 4 Turn the ignition switch to OFF position Disconnect the internal circulation actuator Turn the igni...

Page 399: ...culation damper seals Dislocation of internal circulation damper seals Is the fault detected and eliminated Go to Step 15 Go to Step 10 10 Check the harness connector of internal circulation actuator...

Page 400: ...Installation Removal Installation Removal Installation Removal Removal Removal Removal of of of of front front front front A C A C A C A C assembly assembly assembly assembly 1 Recover refrigerant 2...

Page 401: ...allation Removal Installation Removal Installation Removal Installation Removal Removal Removal Removal of of of of front front front front A C A C A C A C assembly assembly assembly assembly 5 Remove...

Page 402: ...moval Installation Removal Installation Removal Installation Removal Removal Removal Removal of of of of top top top top evaporator evaporator evaporator evaporator tank tank tank tank 1 Recover refri...

Page 403: ...ation Removal Installation Removal Installation Removal Removal Removal Removal of of of of top top top top evaporator evaporator evaporator evaporator tank tank tank tank 5 Disconnect the A C drain p...

Page 404: ...stallation Removal Installation Removal Installation Removal Installation Removal Removal Removal Removal of of of of front front front front condenser condenser condenser condenser 1 Recover refriger...

Page 405: ...tioner Conditioner 196 Removal Installation Removal Installation Removal Installation Removal Installation Removal Removal Removal Removal of of of of front front front front condenser condenser conde...

Page 406: ...nstallation Removal Installation Removal Installation Removal Removal Removal Removal of of of of bottom bottom bottom bottom condenser condenser condenser condenser 1 Recover refrigerant 2 Disconnect...

Page 407: ...val Installation Removal Installation Removal Installation Removal Removal Removal Removal of of of of heater heater heater heater water water water water tank tank tank tank 1 Recover refrigerant 2 D...

Page 408: ...moval Installation Removal Installation Removal Installation Removal Installation Removal Removal Removal Removal of of of of heater heater heater heater water water water water tank tank tank tank 5...

Page 409: ...tion Removal installation Removal installation Removal installation of of of of temperature temperature temperature temperature control control control control motor motor motor motor 1 Disconnect neg...

Page 410: ...Removal Removal Removal Removal i i i installation nstallation nstallation nstallation of of of of mode mode mode mode damper damper damper damper motor motor motor motor 1 Disconnect negative cable o...

Page 411: ...Removal Removal Removal i i i installation nstallation nstallation nstallation of of of of speed speed speed speed governing governing governing governing module module module module 1 Disconnect nega...

Page 412: ...ation nstallation nstallation nstallation of of of of internal external internal external internal external internal external air air air air damper damper damper damper motor motor motor motor 1 Disc...

Page 413: ...emoval Removal Removal Removal i i i installation nstallation nstallation nstallation of of of of compressor compressor compressor compressor assembly assembly assembly assembly 1 Recover refrigerant...

Page 414: ...val Removal i i i installation nstallation nstallation nstallation of of of of compressor compressor compressor compressor assembly assembly assembly assembly 5 Loosen mounting nuts from tension pulle...

Page 415: ...on Installation Installation Installation of of of of compressor compressor compressor compressor assembly assembly assembly assembly 1 Refill compressor with compressor oil and tighten the oil filler...

Page 416: ...oval Installation Removal Removal Removal Removal of of of of front front front front A C A C A C A C control control control control panel panel panel panel 1 Disconnect negative cable of battery 2 R...

Page 417: ...oval Installation Removal Removal Removal Removal of of of of front front front front A C A C A C A C control control control control panel panel panel panel 1 Disconnect negative cable of battery 2 R...

Page 418: ...clutch of 110mm diameter Air heater Front heater assembly Rear heater assembly Type All aluminum welding heater Power 4000W 4500W Blower Front A C blower Rear A C blower 2 Operating voltage DC 12 V DC...

Page 419: ...AT AT AT ATAir Air Air Air Conditioner Conditioner Conditioner Conditioner 210...

Page 420: ...231 Audio system 231 Cigarette lighter and fuel heater 233 Rear ceiling lamp and front fog lamp 234 Rear fog lamp 235 High beam and low beam 236 Turn signal lamp and hazard warning lamp 237 Small lam...

Page 421: ...Start to understand every system form understanding its circuit diagram for circuit diagram indicates all operating paths of every component For example it indicates power supply and negative ground...

Page 422: ...m Diagram Diagram Diagram 211 Harness layout drawing Mounting and fixed position of main harness and wire connector and route of main harness are indicated in this part With the help of these harness...

Page 423: ...EC Circuit Circuit Circuit Circuit Diagram Diagram Diagram Diagram 212 Notation The following electrical notations electrical symbols and abbreviations are adopted in this manual Notation of circuit...

Page 424: ...EC EC EC EC Circuit Circuit Circuit Circuit Diagram Diagram Diagram Diagram 213...

Page 425: ...EC EC EC EC Circuit Circuit Circuit Circuit Diagram Diagram Diagram Diagram 214...

Page 426: ...Y Light green Lg White W Identification of wire connector codes Wire connector identification code consists of harness position identification code and wire connector identification code For example N...

Page 427: ...EC EC EC EC Circuit Circuit Circuit Circuit Diagram Diagram Diagram Diagram 216 Electrical symbols of circuit diagram...

Page 428: ...EC EC EC EC Circuit Circuit Circuit Circuit Diagram Diagram Diagram Diagram 217...

Page 429: ...EC EC EC EC Circuit Circuit Circuit Circuit Diagram Diagram Diagram Diagram 218...

Page 430: ...EC EC EC EC Circuit Circuit Circuit Circuit Diagram Diagram Diagram Diagram 219...

Page 431: ...EC EC EC EC Circuit Circuit Circuit Circuit Diagram Diagram Diagram Diagram 220...

Page 432: ...EC EC EC EC Circuit Circuit Circuit Circuit Diagram Diagram Diagram Diagram 221...

Page 433: ...EC EC EC EC Circuit Circuit Circuit Circuit Diagram Diagram Diagram Diagram 222...

Page 434: ...EC EC EC EC Circuit Circuit Circuit Circuit Diagram Diagram Diagram Diagram 223...

Page 435: ...EC EC EC EC Circuit Circuit Circuit Circuit Diagram Diagram Diagram Diagram 224...

Page 436: ...EC EC EC EC Circuit Circuit Circuit Circuit Diagram Diagram Diagram Diagram 225...

Page 437: ...EC EC EC EC Circuit Circuit Circuit Circuit Diagram Diagram Diagram Diagram 226...

Page 438: ...EC EC EC EC Circuit Circuit Circuit Circuit Diagram Diagram Diagram Diagram 227...

Page 439: ...EC EC EC EC Circuit Circuit Circuit Circuit Diagram Diagram Diagram Diagram 228...

Page 440: ...EC EC EC EC Circuit Circuit Circuit Circuit Diagram Diagram Diagram Diagram 229...

Page 441: ...EC EC EC EC Circuit Circuit Circuit Circuit Diagram Diagram Diagram Diagram 230...

Page 442: ...EC EC EC EC Circuit Circuit Circuit Circuit Diagram Diagram Diagram Diagram 231...

Page 443: ...EC EC EC EC Circuit Circuit Circuit Circuit Diagram Diagram Diagram Diagram 232...

Page 444: ...EC EC EC EC Circuit Circuit Circuit Circuit Diagram Diagram Diagram Diagram 233...

Page 445: ...EC EC EC EC Circuit Circuit Circuit Circuit Diagram Diagram Diagram Diagram 234...

Page 446: ...EC EC EC EC Circuit Circuit Circuit Circuit Diagram Diagram Diagram Diagram 235...

Page 447: ...EC EC EC EC Circuit Circuit Circuit Circuit Diagram Diagram Diagram Diagram 236...

Page 448: ...EC EC EC EC Circuit Circuit Circuit Circuit Diagram Diagram Diagram Diagram 237...

Page 449: ...EC EC EC EC Circuit Circuit Circuit Circuit Diagram Diagram Diagram Diagram 238...

Page 450: ...EC EC EC EC Circuit Circuit Circuit Circuit Diagram Diagram Diagram Diagram 239...

Page 451: ...EC EC EC EC Circuit Circuit Circuit Circuit Diagram Diagram Diagram Diagram 240...

Page 452: ...EC EC EC EC Circuit Circuit Circuit Circuit Diagram Diagram Diagram Diagram 241...

Page 453: ...EC EC EC EC Circuit Circuit Circuit Circuit Diagram Diagram Diagram Diagram 242...

Page 454: ...EC EC EC EC Circuit Circuit Circuit Circuit Diagram Diagram Diagram Diagram 243...

Page 455: ...EC EC EC EC Circuit Circuit Circuit Circuit Diagram Diagram Diagram Diagram 244...

Page 456: ...EC EC EC EC Circuit Circuit Circuit Circuit Diagram Diagram Diagram Diagram 245...

Page 457: ...EC EC EC EC Circuit Circuit Circuit Circuit Diagram Diagram Diagram Diagram 246...

Page 458: ...EC EC EC EC Circuit Circuit Circuit Circuit Diagram Diagram Diagram Diagram 247...

Page 459: ...EC EC EC EC Circuit Circuit Circuit Circuit Diagram Diagram Diagram Diagram 248...

Page 460: ...EC EC EC EC Circuit Circuit Circuit Circuit Diagram Diagram Diagram Diagram 249...

Page 461: ...EC EC EC EC Circuit Circuit Circuit Circuit Diagram Diagram Diagram Diagram 250...

Page 462: ...ronic accelerator pedal MD03 Connected to right door harness 1 M16 Instrument 1 MD04 Connected to right door harness 2 M17 Instrument 2 MV01 Connected to airbag harness M18 Ignition switch MB01 Connec...

Page 463: ...EC EC EC EC Circuit Circuit Circuit Circuit Diagram Diagram Diagram Diagram 252 Main harness 1...

Page 464: ...EC EC EC EC Circuit Circuit Circuit Circuit Diagram Diagram Diagram Diagram 253 Main harness 2...

Page 465: ...enerator positive pole E03 Connected to starter control E04 Connected to starter positive pole E05 Connected to oil pressure switch E06 Connected to reversing lamp switch E07 Connected to water temper...

Page 466: ...specification Identification code Name D01 Left window regulator motor D02 Left electric rear view mirror D03 Window regulator main switch D04 Left door loud speaker D06 Left door lock actuator D08 E...

Page 467: ...ront door harness specification Identification code Name D11 Right power window motor D12 Right electric rear view mirror D13 Power window auxiliary switch D14 Right door loud speaker D16 Right door l...

Page 468: ...ification code Name L01 Front ceiling lamp L02 Left rear combination lamp L03 High mounted brake lamp L04 Reversing radar ECU L05 Antenna amplifier L06 Rear blower LR01 Connected to reversing radar ha...

Page 469: ...ram Diagram Diagram Diagram 258 Right tail lamp harness specification Identification code Name N01 Intermediate ceiling lamp N02 Rear ceiling lamp N03 Right rear combination lamp N04 Right rear fog la...

Page 470: ...rcuit Circuit Circuit Diagram Diagram Diagram Diagram 259 Left back door harness specification Identification code Name T03 Left license plate lamp T04 Right license plate lamp LT01 Connected to left...

Page 471: ...cuit Circuit Circuit Circuit Diagram Diagram Diagram Diagram 260 Rear loud speaker harness specification Identification code Name S01 Left rear loud speaker S02 Right rear loud speaker SM01 Connected...

Page 472: ...arness specification Identification code Name B01 ABS system control module B02 Left front wheel speed sensor B03 Right front wheel speed sensor B04 Right front wheel speed sensor B05 Right rear wheel...

Page 473: ...EC EC Circuit Circuit Circuit Circuit Diagram Diagram Diagram Diagram 262 Fuel tank harness specification Identification code Name G01 Fuel sensor G02 Condenser fan motor GM01 Connected to main harne...

Page 474: ...ram Diagram Diagram 263 Reversing radar harness specification Identification code Name R01 Left rear fog lamp R02 Left external probe R03 Left intermediate probe R04 Right intermediate probe R05 Right...

Page 475: ...ody Accessories The Chassis Volume details the technical standards on removal installation testing debugging and diagnosis for systems and components of SUNRAY long wheelbase vehicle chassis When repl...

Page 476: ...mation 17 Fault Symptom Table 18 Removal Installation Manual Transmission 19 Specifications 43 Tightening Torque 43 Care and Maintenance 44 Brake Brake Brake Brake System System System System Brake Sy...

Page 477: ...t 107 Inspection and Confirmation 107 Fault Symptom Table 108 Removal Installation Removal of Transmission shaft 109 Installation of Transmission shaft 110 Front Front Front Front Suspension Suspensio...

Page 478: ...d Tires Tires Tires Tires Wheels and Tires 174 Explosive View of Wheels and Tires 175 Precaution for Tire Usage 175 Diagnosis and Testing Removal Installation Instruction of Tire Assembly 176 Fault Sy...

Page 479: ...n Clutch 1 Explosive View of Clutch 1 Introduction of Clutch 1 Diagnosis Diagnosis Diagnosis Diagnosis and and and and Testing Testing Testing Testing Clutch 2 Operating Principle 2 Inspection and Mai...

Page 480: ...tem diagram Diagram of Clutch Control System 1 Clutch 2 Clutch release cylinder 3 Release fork 4 Release bearing 5 Clutch line 6 Clutch master cylinder 7 Clutch pedal 8 Fluid reservoir Schematic Diagr...

Page 481: ...s and altitude difference out of the limit value replace the clutch pressure plate Limit value 0 5mm Inspect the surface of the pressure plate for wears cracks and discoloration Inspect rivets of the...

Page 482: ...ft into the reverse gear after 2 seconds In the case of large noise during gear selection step the clutch pedal to the floor for 5 times in order to carry out system air bleeding Wait for 30 seconds a...

Page 483: ...ce it Replace inapplicable clutch thrust bearing Adjust clutch system remove unnecessary clearances and eliminate mechanical failures Reinstall improperly assembled parts Incomplete engagement Incompl...

Page 484: ...clutch friction lining In the case of poor balance in some parts replace clutch assembly Adjust clutch pedal control system Reinstall improperly assembled parts Shudder There may be clutch shudder in...

Page 485: ...ation Clutch Clutch Clutch Clutch 1 Disconnect the negative cable of battery 2 Lift the vehicle 3 Remove the clutch slave cylinder Remove bleed bolts of clutch slave cylinder and drain system brake fl...

Page 486: ...e the removed transmission backward 8 Insert special tools in the center of pressure plate Remove mounting bolts of the pressure plate assembly and pay attention to the installation position Attention...

Page 487: ...ontinued Clutch Clutch Clutch Clutch 11 Remove the release bearing Attention Do not make the lubricating grease to contact with the clutch assembly 12 Remove the release fork Remove the dust boot at t...

Page 488: ...tallation and pay attention to safety 2 Insert the special tool into the saddle bore of guide bearing at the rear end of crankshaft Set the new friction lining and pressure plate into the special tool...

Page 489: ...nd tighten connecting bolts between the transmission and engine with attention to the tightening torque Install the starter into the transmission assembly 8 Install the mount pad in the rear of transm...

Page 490: ...s instrument panel Attention Attention Attention Attention Pay attention not to damage the instrument clip during its removal 3 Drain brake fluid in the brake fluid reservoir 4 Remove three mounting...

Page 491: ...ion of output and input hoses of the master cylinder confirm that they are well tightened 3 Inspect the master cylinder oil pipe for deformation or crush 4 Align the master cylinder to screw holes and...

Page 492: ...rt name Tightening torque Nm Quantity Clutch master cylinder bolt and nut cap 23 29 3 Nut for installing the master cylinder to the vehicle body 23 29 4 Clutch slave cylinder bolt 120 140 3 Clutch hos...

Page 493: ...on Operation Operation Manual Transmission 16 Explosive View of Manual Transmission 16 Introduction of Manual Transmission 16 Diagnosis Diagnosis Diagnosis Diagnosis and and and and Testing Testing Te...

Page 494: ...inciples of motion 1st gear Engine Clutch Input shaft 1 Main gear of countershaft 15 Countershaft 11 1st driving gear 6 1st 2nd gear synchronizer 5 Output shaft 10 2nd gear Engine Clutch Input shaft 1...

Page 495: ...to 1st gear step by step for speeding down reverse gear can be shifted to in 3 seconds of pause after the clutch pedal is depressed under motionless state of vehicle don t apply reverse gear under run...

Page 496: ...r If excessive clearance is felt please check fork shaft groove and guide spring for any wear or failure Difficulty in gear shifting loud impact sound in gear shifting or difficulty in shifting to cer...

Page 497: ...ission 1 Remove manual transmission Oil drainage Attention Remove oil drain plug with wrench and drain oil through this plug instead of other parts 2 Remove release bearing from input shaft front cap...

Page 498: ...transmission transmission transmission transmission 5 Remove clutch housing Place it upside down on cardboard horizontally 6 Remove input shaft oil seal from transmission 7 Remove top cover from tran...

Page 499: ...transmission transmission transmission transmission 9 Use pneumatic gun or wrench to remove output shaft bolt of transmission and knock out flange nut 10 Remove rear cover of transmission Attention I...

Page 500: ...ntinued Manual Manual Manual Manual transmission transmission transmission transmission 13 Remove side cover from transmission Turn over the transmission Remove bolts from side cover 14 Remove side co...

Page 501: ...ion transmission transmission 17 Remove gear selector fork from transmission Attention Attention Attention Attention Please notice the position of steel balls This transmission has 7 steel balls and 1...

Page 502: ...tinued Manual Manual Manual Manual transmission transmission transmission transmission 21 Remove output input shaft of transmission and place it on cardboard horizontally 22 Remove output shaft of tra...

Page 503: ...Continued Continued Manual Manual Manual Manual transmission transmission transmission transmission 25 Use a rubber hammer or copper rod to knock on the reverse gear shaft gently 26 Pull out the reve...

Page 504: ...l Installation Continued Continued Continued Continued Manual Manual Manual Manual transmission transmission transmission transmission 29 Loosen the 5th gear circlip with circlip pliers and remove the...

Page 505: ...Instruction and and and and Operation Operation Operation Operation Exploded Exploded Exploded Exploded View View View View of of of of Reverse Reverse Reverse Reverse Gear Gear Gear Gear Shaft Shaft...

Page 506: ...n Transmission 28 Instruction Instruction Instruction Instruction and and and and Operation Operation Operation Operation Exploded Exploded Exploded Exploded View View View View of of of of Output Out...

Page 507: ...sembly of output shaft 1 34 O ring 1 9 Circlip 1 35 Conical spring washer 1 10 Thrust washer of 2nd gear 1 36 Output shaft nut 1 11 2nd gear assembly of output shaft 1 37 Steel ball 1 12 Needle roller...

Page 508: ...mission Transmission 30 Instruction Instruction Instruction Instruction and and and and Operation Operation Operation Operation Exploded Exploded Exploded Exploded View View View View of of of of Top...

Page 509: ...selector rocker arm assembly 1 15 Large washer 2 3 Flat washer 1 16 Spring washer 8 4 Oil seal 1 17 Hexagon bolt 1 5 Inner gear selector rocker arm 1 18 Flat washer 6 Spring pin 1 19 Washer 1 7 Rever...

Page 510: ...and and and and Operation Operation Operation Operation Exploded Exploded Exploded Exploded View View View View of of of of Input Input Input Input Shaft Shaft Shaft Shaft Assembly Assembly Assembly A...

Page 511: ...of of of of Transmission Transmission Transmission Transmission Rear Rear Rear Rear Cover Cover Cover Cover Instruction Instruction Instruction Instruction and and and and Operation Operation Operati...

Page 512: ...w View of of of of Countershaft Countershaft Countershaft Countershaft Assembly Assembly Assembly Assembly S N Name Qty S N Name Qty 1 Circlip 1 6 Circlip 1 2 Cylinder roller bearing 1 7 5th gear of c...

Page 513: ...d and Operation Operation Operation Operation Exploded Exploded Exploded Exploded View View View View of of of of Housing Housing Housing Housing Assembly Assembly Assembly Assembly S N Name Qty 1 Fle...

Page 514: ...Fork Fork Fork Fork Assembly Assembly Assembly Assembly S N Name Qty S N Name Qty 1 5th reverse gear shift block 1 9 1st 2nd gear shift fork shaft 1 2 5th reverse gear shift fork shaft 1 10 1st 2nd g...

Page 515: ...ploded View View View View of of of of Transmission Transmission Transmission Transmission Front Front Front Front Cover Cover Cover CoverAssembly Assembly Assembly Assembly S N Name S N Name Qty 1 Cl...

Page 516: ...ission Transmission Transmission 38 Instruction Instruction Instruction Instruction and and and and Operation Operation Operation Operation Transmission Transmission Transmission Transmission Assembly...

Page 517: ...ntinued Continued Continued Transmission Transmission Transmission Transmission Installation 1 Place transmission housing onto a clean cardboard 2 Install reverse gear and reverse gear shaft onto tran...

Page 518: ...nsmission Transmission 5 Install the fixed circlip of 5th driving gear of transmission countershaft in place 6 Install output shaft of transmission into transmission housing 7 Install guide bearing of...

Page 519: ...tric position on input shaft support bearing Install inside and outside circlips into input shaft of transmission Install the countershaft bearing into transmission Please notice the mounting directio...

Page 520: ...stall gear shift control mechanism onto the top cover of transmission Attention Attention Attention Attention In order to avoid deformation during installation of transmission cover please tighten bol...

Page 521: ...ear cover transmission cover bolts 25 35 Bracket bolt 25 35 Side cover bolt 14 24 5 Vent plug 10 8 18 6 Oil filler plug and oil drain plug 39 2 58 8 Output shaft nut 160 210 Gear shift shaft dowel hol...

Page 522: ...ge gear oil inside transmission Normal service condition Severe service condition Other inspections Note Severe service condition includes items listed below 1 Running in dusty areas or frequently exp...

Page 523: ...pection and confirmation 52 Fault Symptom Table 53 Removal Installation Removal Installation Removal Installation Removal Installation Removal installation of brake disc 50 Removal installation of bra...

Page 524: ...m 46 Instruction Instruction Instruction Instruction and and and and Operation Operation Operation Operation SUNRAY vehicles brake system adopts cross type brake line and the front disc rear drum brak...

Page 525: ...to make the vacuum inside the vacuum booster equivalent to atmospheric pressure With the brake pedal depressed to the end and engine started check if the clearance between brake pedal and floor decrea...

Page 526: ...t points 10mm distant from the disc edge Runout limit 0 05mm If the disc runout exceeds the specified value please replace or reprocess it accordingly 3 Thickness inspection Check the thickness of bra...

Page 527: ...e of auto regulating mechanism Adjust Overheating of brake rotary parts due to sluggish of brake shoe Adjust Restriction of brake line Adjust Pedal travel increase decrease of clearance between pedal...

Page 528: ...liper to certain degree ready for removal instead of removing it completely 3 Remove the brake caliper Hang up the brake caliper properly in order to avoid damage of brake hose Caution Caution Caution...

Page 529: ...ng nut 3 Reinstall the brake caliper 4 Install the brake hose onto the shock absorber 5 Check the front disc runout as required 6 Set the axial clearance of wheel bearing Tighten the adjusting nut of...

Page 530: ...emove the plastic cap of brake caliper sliding pin 3 Make the brake disc exposed Remove the guide pin bolt of brake caliper Upturn the brake caliper Note Note Note Note The ablated or damaged piston b...

Page 531: ...ning 2 Check if two brake linings are of the same type 3 During the installation of new brake lining please remove the interleaving paper from the acoustic lining 4 Reinstall inner outer brake lining...

Page 532: ...bly Removal 1 Have the vehicle lifted and remove the front wheel Note Note Note Note Clamp the brake hose with SST in order to avoid damage of brake hose 2 Clamp the brake hose 3 Remove the brake hose...

Page 533: ...tallation Removal Installation Installation 1 Reinstall the brake caliper 2 Connect the brake hose to the brake caliper 3 Fix the brake hose onto the shock absorber 4 Bleed air out of brake line in ac...

Page 534: ...wheel wheel wheel brake brake brake brake shoe shoe shoe shoe Removal 1 Release the parking brake lever have the vehicle lifted and remove the rear wheel 2 Remove the automatic regulator 3 Mark prope...

Page 535: ...return spring 8 Remove the trailing shoe Remove the lock pin and its spring cap Remove the trailing shoe from the wheel cylinder and support Disconnect the parking brake cable 9 Disassemble the leadi...

Page 536: ...um pin 6 Reinstall the leading shoe 7 Install the upper lower return spring of brake shoe 8 Install the brake shoe lock pin and the fixed pin and clip of spring Note Note Note Note Please don t make t...

Page 537: ...gulator 3 Depress the brake pedal to ensure proper automatic regulation 4 Pull up the parking brake lever until it gets stuck at the 3rd tooth Note Note Note Note Ensure thread length on both sides ar...

Page 538: ...1 Loosen the parking brake lever 2 Remove the wavy dust shield of parking brake 3 Remove the parking brake lever assembly Remove the spring clip and the clevis pin for fixing cable Remove the mountin...

Page 539: ...al 1 Loosen the parking brake lever 2 Remove the spring clip and the clevis pin from the main cable and remove the cable from the parking brake lever 3 Separate the main cable from the equalizer Remov...

Page 540: ...Remove the main cable from the equalizer Remove the spring clip and the clevis pin Remove the return spring from the equalizer 3 Remove the rear brake drum 4 Remove the rear cable from the brake shoe...

Page 541: ...of of of brake brake brake brake pedal pedal pedal pedal Removal 1 Disconnect the negative cable of battery 2 Remove the clevis pin and spring clip from the vacuum booster control rod of brake pedal...

Page 542: ...ation 5 Remove the brake pedal Push the spider to the direction of clutch pedal Remove the brake pedal 6 Remove the pedal bushing and spring Remove the pedal bushing Remove the spring Installation 1 R...

Page 543: ...servoir cap Disconnect the fluid level alarm harness connector Remove the fluid reservoir cap 3 Remove the clutch master cylinder pipe and drain the brake fluid out of the master cylinder fluid reserv...

Page 544: ...tion Caution Caution Caution Don t the make the brake fluid splashing onto the paint surface In case of any please wash the surface with clean water immediately Removal 1 Disconnect the negative cable...

Page 545: ...Removal Installation 5 Remove the seal ring between generator and vacuum pump Installation 1 Reinstall the seal ring between generator and vacuum pump 2 Reinstall the vacuum booster 3 Reinstall the oi...

Page 546: ...nt surface In case of any please wash the surface with clean water immediately Removal 1 Disconnect the negative cable of battery 2 Disconnect the harness connector of the brake fluid level warning sw...

Page 547: ...allation Removal Installation Removal Installation 7 Remove the brake switch Remove the harness connector 8 Remove the booster and master cylinder assembly 9 Separate the booster from the master cylin...

Page 548: ...he master cylinder onto the booster Ensure proper position and clean joint surface for sealing washer of vacuum pump 5 Reconnect the brake line 6 Reconnect the brake line with the master cylinder 7 In...

Page 549: ...e lifted 3 Connect the oil drain pipe to the air vent of four wheels 4 Loosen the bleeder screw Note Note Note Note Keep the brake fluid reservoir cap clean 5 Open the brake fluid reservoir cap 6 Blee...

Page 550: ...ion Instruction Instruction Instruction and and and and Operation Operation Operation Operation ABS system 74 Diagnosis Diagnosis Diagnosis Diagnosis and and and and Testing Testing Testing Testing AB...

Page 551: ...m 74 Instruction Instruction Instruction Instruction and and and and Operation Operation Operation Operation Anti lock Anti lock Anti lock Anti lock brake brake brake brake system system system system...

Page 552: ...ction Instruction Instruction and and and and Operation Operation Operation Operation Operating Operating Operating Operating principle principle principle principle Connection Connection Connection C...

Page 553: ...occurrence of more faults and traffic accidents 6 ABS hydraulic governor with ECU consists of the following parts ABS ECU Including reflux pump motor relay and solenoid valve relay Solenoid valves 8 I...

Page 554: ...step 3 Read diagnostic trouble code DTC With DTC Go to Step 4 No DTC Go to Step 9 4 Record DTC and clear fault memory Go to the next step 5 Verify and reproduce fault Simulation of fault occurrence s...

Page 555: ...ck pins for incomplete insertion into connector shells ABS components are sensitive to electromagnetic interference EMI If any intermittent fault is suspicious please check whether the optional equipp...

Page 556: ...keep the brake pressure stable and avoid boosting or reducing of hydraulic pressure 2 Pressure reducing Under the pressure maintenance mode wheel skidding can still be detected by ABS control module t...

Page 557: ...ld be lit If the system is normal the warning lamps shall go out in about 3 seconds ON ON 2 The system is normal after self checking OFF OFF 3 There is current DTC not removed in ABS ABS stops operati...

Page 558: ...c self checking is qualified with the vehicle speed no less than 15Km h 2 Cross validation Install the removed ABS onto a normal vehicle equipped with the same ABS model with ABS harness connectors co...

Page 559: ...ur skin if any fluid touches your skin 1 Manual brake bleeding procedures Step Operation 1 Fill the brake fluid reservoir 2 Repeat the procedures below for bleeding of each wheel cylinder in order of...

Page 560: ...ve as per prompt of diagnostic instrument 6 Firstly test the oil inlet valve and oil outlet valve of left front wheel during which the repair man in the vehicle should depress the brake pedal with for...

Page 561: ...CU C0065 Left front oil inlet valve circuit fault of hydraulic governor ABS hydraulic governor with ECU C0070 Right front oil outlet valve circuit fault of hydraulic governor ABS hydraulic governor wi...

Page 562: ...TC and check for any fault 3 Check power UZ circuit of ignition switch 4 Check brake line for any leak ABS poor effect 1 Read DTC and check for any fault 2 Check brake line for any leak 3 Apply diagno...

Page 563: ...tore data by snapshot once fault occurs The stored data can be displayed at lower speed to facilitate diagnosis Oscilloscope can also be applied for signal detection 4 Apply the Component Test functio...

Page 564: ...8 tooth gear ring mounted on its axle shaft This vehicle model mainly adopts the active wheel speed sensors that are activated by 12V DC power voltage supplied by ABS ECU Wheel speed sensor adopts Hal...

Page 565: ...hen turning over 6 8Km h of the reference speed Long time monitoring of signal interference 1 In case signals of one or two wheel speed sensors fail fault shall be detected in 20s with brake pedal dep...

Page 566: ...Step 1 Fault confirmation a Connect the diagnostic instrument read and record DTC b Clear of DTC Apply diagnostic instrument to clear DTC as per prompt of the instrument Remarks DTC cannot be cleared...

Page 567: ...e the connector from wheel speed sensor b One terminal of sensor is connected with 12V battery and the other terminal connected with red pen of oscilloscope Attention Ground cable of oscilloscope must...

Page 568: ...C0085 C0090 C0095 To be conducted at the same time of ABS ECU initialization and self checking Vehicle under stationary state or speed 15Km h 1 With the ignition switch turned on ABS ECU detects relev...

Page 569: ...ate the left front wheel by hand Boosting phase Use diagnostic instrument to access the boosting phase Normal state The repair man outside cannot rotate the left front wheel by hand Pressure maintenan...

Page 570: ...otor relay stop operation no voltage drop is detected by reflux pump monitoring 1 Reflux pump motor circuit inside ABS 2 Open circuit of reflux pump motor relay 3 Fault of reflux pump motor relay 4 Fa...

Page 571: ...Remove connectors from ABS hydraulic governor with ECU c Use multimeter to measure the voltage at the power terminal and grounding terminal of reflux pump Remarks If no jumper box is applied the norm...

Page 572: ...ted The time of voltage supplied for solenoid valve detected to be 0 8 Uz 8 0V exceeds 0 8s 1 Solenoid valve relay circuit inside ABS 2 Inadequate power supply 3 Short circuit 4 Open circuit Occurrenc...

Page 573: ...se Normal state The repair man outside cannot rotate the left front wheel by hand Pressure reducing phase Use diagnostic instrument to access the pressure reducing phase Normal state The repair man ou...

Page 574: ...Depress and release brake pedal to check brake lamp With brake pedal depressed Brake lamp shall be lit With brake pedal released Brake lamp shall go out Remarks Please ensure the brake lamp and its ci...

Page 575: ...oubleshooting Troubleshooting Troubleshooting Troubleshooting procedures procedures procedures procedures S N Operating Step Operation Detection Result Next Step 1 ABS hydraulic governor with ECU unde...

Page 576: ...is DTC shall be recorded and ABS shall be turned off by software 2 If voltage below 7 6V or above 16 9V is continuously monitored this DTC shall be recorded and ABS and EBD shall be turned off by hard...

Page 577: ...turned to the coldest mode blower turned to the maximum speed mode Parking With all electrical equipments turned off rotation speed increased to 3500rpm and hold on for 30s During application of serv...

Page 578: ...tem 1 Remove the negative cable of battery 2 Drain the brake fluid in the hydraulic brake system completely 3 Loosen the oil pipe of brake master cylinder 4 Remove the ABS connector 5 Remove the brake...

Page 579: ...llation of aluminum alloy parts the brake pipe should be fit in place smoothly by correct alignment otherwise the original part bodies may be damaged easily 3 Insert the ABS plug into relevant socket...

Page 580: ...peed speed speed sensor sensor sensor sensor 1 Disconnect the negative cable of battery 2 Lift the vehicle 3 Disconnect the plug of wheel speed sensor and remove the harness fixture of sensor 4 Remove...

Page 581: ...nd and and and Operation Operation Operation Operation Transmission Shaft 106 Explosive View of Transmission Shaft 106 Introduction of Transmission Shaft 106 Diagnosis Diagnosis Diagnosis Diagnosis an...

Page 582: ...nd rear axle together and to transmit power from transmission to rear axle Transmission shaft made of hollow steel tube is equipped with intermediate support to reduce resonance during power transmiss...

Page 583: ...ntenance and repair of universal joint Maintenance of universal joint Use grease nipple that is aligned to the oil filler of universal joint to add grease until clean grease is extruded out Repair of...

Page 584: ...es Procedures Procedures Procedures for for for for Transmission Transmission Transmission Transmission Shaft Shaft Shaft Shaft Vibration Check radial runout of shaft Normal Abnormal Check shaft balan...

Page 585: ...t shaft shaft 1 Lift the vehicle Note Note Note Note Mark properly in pair on transmission shaft front flange and transmission flange 2 Remove transmission shaft front flange from transmission flange...

Page 586: ...Install the transmission shaft front flange onto transmission 2 Install transmission shaft intermediate support onto the intermediate support seat located on body bottom plate Note Note Note Note Don...

Page 587: ...d and Operation Operation Operation Operation Front Suspension 112 Front Suspension 112 Diagnosis Diagnosis Diagnosis Diagnosis and and and and Testing Testing Testing Testing Front Suspension 114 Ins...

Page 588: ...pension Suspension Suspension This front axle is a steering axle at front of the vehicle mainly consisting of the front overhang subframe assembly lower swing arm assembly front anti roll bar link ass...

Page 589: ...rake hose mounting flat spring nut 2 10 Front anti roll bar assembly 1 11 Front anti roll bar mounting bushing 2 12 Front anti roll bar mounting bracket 2 13 Front anti roll bar link assembly 2 14 Typ...

Page 590: ...s is worn and its clearance exceeds the specified one please replace this worn part together with its matching part according to relevant requirements Measure the starting torque of the front wheel hu...

Page 591: ...pressure Adjust the tire pressure Fault in the shock absorber Repair or replace Vehicle deviation Improper front wheel alignment Adjust Insufficient steering resistance of the lower swing arm ball joi...

Page 592: ...ubframe Subframe Subframe Subframe Removal 1 Disconnect the negative cable of battery 2 Place the steering wheel in the center and lock it up in the position of straight ahead 3 Remove track bolts for...

Page 593: ...omplete removal of the brake caliper has been done 7 Remove the brake caliper Hang the brake caliper up to avoid brake hose damage 8 Remove cotter pin and castle nuts for fixing the steering tie rod o...

Page 594: ...ench Remove the disc washer Caution Caution Caution Caution Pay attention not to damage the lower swing arm ball joint for connecting the shock absorber and the front suspension 13 Lay down the lower...

Page 595: ...shock absorber from the cab Reinstall the disc washer Support nuts and washers of the piston rod with the L shaped wrench Install nut caps 6 Reinstall the wheel hub assembly 7 Reconnect the brake hos...

Page 596: ...of of of Subframe Subframe Subframe Subframe Disassembly 1 Remove the two mounting bolts at the mounting position of the front anti roll bar 2 Remove the steering gear box 3 Remove the lower swing ar...

Page 597: ...rame Subframe Continued Continued Continued Continued Assembly 1 Install the compression travel stop block 2 Reinstall the lower swing arm assembly Install feedthrough bolts and nuts between the lower...

Page 598: ...ontinued Continued Continued Continued 4 Reinstall the steering gear box Make sure to install mounting bolts in the direction of underside of the cross rail Caution Caution Caution Caution Make sure t...

Page 599: ...Arm Arm Arm Removal 1 Loosen wheel nuts lift the vehicle and remove wheels 2 Loosen mounting nuts of the front lower swing arm Note Note Note Note In the process of steering tie rod removal from the...

Page 600: ...arm Remove nuts and bolts between the lower swing arm and the cross rail Remove nuts and bolts between the lower swing arm and the front suspension Remove the disc washer Installation 1 Reinstall the...

Page 601: ...into the lower swing arm the mounting of the front axle is not allowed to exceed the specified value to avoid damage of the lower swing arm ball joint dust cover 4 Reinstall the ball joint into the l...

Page 602: ...oosen wheel nuts lift the vehicle and remove wheels 2 Remove the fixed cotter pin and castle nuts between the steering tie rod end and the steering knuckle Note Note Note Note In the process of steeri...

Page 603: ...bsorber form the steering knuckle 7 Lower the lower swing arm assembly and remove the helical spring 8 Remove the gasket from the top of the spring Installation 1 Reinstall the helical spring Ensure f...

Page 604: ...8 128 128 128 Removal Removal Removal Removal and and and and Installation Installation Installation Installation of of of of Helical Helical Helical Helical Spring Spring Spring Spring 4 Connect the...

Page 605: ...move wheels 2 Remove the brake hose from the shock absorber 3 Support the lower swing arm 4 Support the wheel hub assembly 5 Remove the shock absorber from the cab Remove the cap Remove nuts and washe...

Page 606: ...ation Installation of of of of Front Front Front Front Shock Shock Shock Shock Absorber Absorber Absorber Absorber 10 Fix the shock absorber firmly from the cab Reinstall the disc washer Install nuts...

Page 607: ...g arm bushing assembly 2 Front cross rail bushing assembly 2 Front wheel hub inner and outer bearings 2 sets for each Left and right friction linings 2 pieces for each 3 Maintenance Parameter Table of...

Page 608: ...ear axle 134 Explosive View of Rear Axle 134 Introduction of Rear Axle 135 Diagnosis Diagnosis Diagnosis Diagnosis and and and and Testing Testing Testing Testing Rear axle 136 Operating principle 136...

Page 609: ...int assembly of propeller shaft through driving gear flange at one end of spline with its middle part supported by two conical bearings installed reversely for bearing axial force and tangential force...

Page 610: ...riven gear 25 Differential housing Left 26 Differential housing bolt 27 Heavy spring washer 28 Bearing cap 29 Heavy spring washer 30 Bearing cap bolt 31 Rear axle housing assembly 32 Normally closed v...

Page 611: ...he lube oil level inside housing also Please change lube oil during the first Stage II maintenance of new vehicle Change the lube oil for rear axle housing after running for 40000Km or 24 months Drain...

Page 612: ...l position have the vehicle jacked up after the parking brake lever is applied Turn the flange clockwise to the end and mark in pair properly on the flange dust cover and final drive housing turn the...

Page 613: ...reduction of adjusting washers but decease with the adding of adjusting washers 2 Adjustment of differential bearing preload Adjustment of differential bearing Adjust the differential bearing to gain...

Page 614: ...rrect backlash adding washers Deflected to dedendum High driving gear driven gear too close 1 Driven gear close to driving gear 2 Driving gear away from driven gear to obtain correct backlash reducing...

Page 615: ...bolt or reapply sealant Looseness of bearing support fastening bolt Tighten bolt to the specified torque Looseness of drain plug or damage of lining Tighten plug or replace lining Axle housing deform...

Page 616: ...wheel nut 3 Jack up the rear axle Removal of axle shaft 1 Loosen axle shaft nut 2 Remove axle shaft If it is difficult to remove please use copper hammer to knock on the axle shaft flange gently unti...

Page 617: ...nd of axle shaft sleeve Note Note Note Note During assembly apply lithium base grease onto the outer ring of axle shaft oil seal and then press it into rear hub 5 Disassemble together with the inner r...

Page 618: ...k 4 Remove hose steel tube and electric wiring harness 5 Remove brake assembly 6 Remove rear axle Jack up the axle housing Remove U bolt and upper lower back plates lower the jack and pull out the axl...

Page 619: ...stallation Continued Continued Continued Continued Rear Rear Rear Rear axle axle axle axle 4 Remove differential assembly 5 Remove driving gear assembly by using puller and remove adjusting washer at...

Page 620: ...r axle axle axle axle 3 Measure and record planetary gear backlash Attention Attention Attention Attention Please hold the planetary gear spider during backlash measurement 4 Remove planetary gear spi...

Page 621: ...emoval Installation Continued Continued Continued Continued Rear Rear Rear Rear axle axle axle axle Removal of driving gear 1 Remove driving gear flange nut 2 Remove retaining ring for shaft and remov...

Page 622: ...Remove bearing from driving gear 6 Remove oil seal from bearing support 7 Remove inner and outer rings of bearing Inspection during removal Check driving gear flange for wear or damage Check bearing f...

Page 623: ...ar hub inner bearing 2 Rear hub outer bearing 2 Driving gear inner bearing 1 Driving gear outer bearing 1 Axle shaft oil seal 2 Driving gear nut 1 Differential bearing 2 Left right friction Respective...

Page 624: ...on Specification Item Wear limit Wear of rear axle leaf spring retainer location hole 1mm Outer bearing journal radial runout of left right axle shaft sleeve 0 1mm Middle unprocessed surface of axle s...

Page 625: ...eration Operation Operation Steering System 152 Explosive View of Steering System 152 Introduction of Steering System 153 Diagnosis Diagnosis Diagnosis Diagnosis and and and and Testing Testing Testin...

Page 626: ...and low speed steering with large steering angle the assistance is obvious It enhances the steering sensitivity It reduces the impact on the steering wheel in the case of ground kick back In the case...

Page 627: ...t and then goes through the pre open clearance of the rotary valve At this moment because there is no movement of the rotary valve the hydraulic oil returns to the oil reservoir and the oil pressures...

Page 628: ...Notice In the operation of power steering pump there may be liquid noise which does not affect system performance or durability 1 Turn off the engine and make full lock turns of the steering wheel to...

Page 629: ...exceeds 30mm turn off the engine keep front wheels in straight running and apply a force of 5N on the steering wheel circle for the inspection of the free play The free play should not exceed 10mm If...

Page 630: ...tie rods rotate the left and right steering tie rods respectively with a wrench to adjust the steering angles to the standard values and then tighten the lock nuts with a tightening torque of 45 55N m...

Page 631: ...cover 6 Free upward and downward adjustment and locking device of the steering wheel Inspection of Steering Column Inspect the steering column for cracks deformations or other damages in the case of...

Page 632: ...ly Install the new piston ring onto the piston of the rack piston assembly apply some power steering hydraulic oil on the new piston ring and press it out downward with fingers Inspection of Valve Ass...

Page 633: ...re Internal pressure relief No pressure in steering system Seizure in slide valve assembly of the steering pump serious wear in parts Inspect the safety valve relief valve change the oil and replace t...

Page 634: ...ow in the power steering pump further inspect the hydraulic oil filter and pipeline for blockage Poor performance of the power steering gear Inspect the power steering gear for damage Inspect the v be...

Page 635: ...evel in the power steering oil reservoir oil leakage or air entrainment in the system blocked filter element in the power steering oil reservoir may lead to insufficient oil suction of the power steer...

Page 636: ...g of power steering pump belt or loose mounting position of the pump 6 Loose bolts in joints of oil pipes which may lead to steering oil leakage and insufficient flow in the system Troubleshooting for...

Page 637: ...llation Installation Power assisted Power assisted Power assisted Power assisted Steering Steering Steering Steering System System System System 1 Disconnect the negative cable of the battery 2 Remove...

Page 638: ...d ball joint and steering knuckle Do not reuse the cotter pin 7 Remove the tie rod ball joint from the steering knuckle Note Note Note Note After the separation of the steering tie rod and steering kn...

Page 639: ...nued Continued Power assisted Power assisted Power assisted Power assisted Steering Steering Steering Steering System System System System 9 Disconnect the booster oil pipe from the steering gear box...

Page 640: ...ball joint in place Install the ball joint in place Tighten lock nuts of the ball joint Caution Caution Caution Caution Keep the steering wheel in the straight ahead position throughout 5 Install ball...

Page 641: ...Installation Installation of of of of Steering Steering Steering Steering Wheel Wheel Wheel Wheel Removal 1 Remove the negative cable of the battery 2 Remove the upper and lower protective plates of t...

Page 642: ...teering Steering Steering Wheel Wheel Wheel Wheel Continued Continued Continued Continued 6 Remove mounting nuts of the steering wheel and remove the steering wheel Installation Warning Warning Warnin...

Page 643: ...g Steering Steering Steering Column Column Column Column Removal 1 Disconnect the negative cable of the battery 2 Remove the upper and lower protective plates of the steering column 3 Remove the multi...

Page 644: ...Steering Steering Steering Steering Column Column Column Column Continued Continued Continued Continued 6 Remove four mounting nuts for fixing the lower part of the steering column onto the partition...

Page 645: ...10 Fix the lower part of the steering column onto the partition panel 11 Reconnect the harness plug of the ignition switch 12 Reinstall the combination switch 13 Fix the wire with cable ties Caution...

Page 646: ...Instruction and and and and Operation Operation Operation Operation Wheels and Tires 174 Explosive View of Wheels and Tires 175 Precaution for Tire Usage 175 Diagnosis Diagnosis Diagnosis Diagnosis an...

Page 647: ...vehicles vehicles adopts adopts adopts adopts tire tire tire tire models models models models of of of of GITI GITI GITI GITI 1 1 1 19 9 9 95 5 5 5 70 70 70 70R15LT R15LT R15LT R15LT and and and and 1...

Page 648: ...please replace it Tire rotation Perform tire rotation after the vehicle running for 8000Km tire rotation shall also be conducted when changing with a new tire Replacement Replacement Replacement Repla...

Page 649: ...e weights in the same straight line Attention Attention Attention Attention For balance weight cannot be reused please apply new one every time No more than two pieces of balance weight can be install...

Page 650: ...or replace Adjust or replace Up and down vibration of steering wheel Excessive deflection of wheel and rim Looseness of wheel nut Wheel unbalance Fracture or wear of engine mounting rubber Fracture or...

Page 651: ...osen tire nut and have the vehicle jacked to remove the tire 2 Remove brake hose from shock absorber Note Note Note Note Loosen the brake caliper top bolt properly for removal of brake caliper 3 Remov...

Page 652: ...er 3 Install brake hose onto shock absorber 4 Install wheel plane bearing 5 Determine wheel bearing end play Tighten wheel bearing adjusting nut and rotate the wheel at the same time to make bearing i...

Page 653: ...y already removed removed removed removed Removal 1 Mark properly on flange and brake disc to facilitate positioning during reinstallation 2 Remove flange from brake disc 3 Remove oil seal 4 Remove in...

Page 654: ...sc Caution Caution Caution Caution The adopted bearing races and rollers should be from the same manufacturer 2 Reinstall the inner and outer races of bearing 3 Apply grease onto race and roller beari...

Page 655: ...cts manufactured by JAC Subject Page Instruction Instruction Instruction Instruction and and and and Operation Operation Operation Operation Four Wheel Alignment 184 Preparation before four wheel alig...

Page 656: ...t axis and angle Function of four wheel alignment Four wheel alignment functions for measurement of alignment angle of chassis In case of a little change in chassis parameters it is only needed to adj...

Page 657: ...rline is located inside of plumb line Excessive camber may lead to outside wear of tire and too small camber may lead to inside wear of tire In case of inconsistency between two wheel cambers the vehi...

Page 658: ...xis and the plumb line viewed from the front of vehicle Kingpin inclination angle mainly functions for the realization of auto return after steering and the increase of adhesion force of vehicle Kingp...

Page 659: ...parameters provided by four wheel aligner with the standard data and calculate the actual data for adjustment 8 Lift the vehicle As the rear wheels are of nonadjustable rear axle only front wheel camb...

Page 660: ...lation transmission JAC T8F003 Flywheel stopper Fixing flywheel for easy removal engine JAC T8F004 Cooling system tester Checking cooling system for leakage engine JAC T8F005 Oil filter wrench Removin...

Page 661: ...ng engine JAC T8F017 V block for camshaft measurement Measuring camshaft damage engine JAC T8F018 Hose clamp pliers Removing a clamp from a hose JAC T8F019 Piston ring extractor Removing and installin...

Page 662: ...g installer Installing countershaft front bearing transmission JAC T8B007 Input shaft protective sleeve Protecting front gear of input shaft transmission JAC T8B008 Output shaft protective sleeve Prot...

Page 663: ...ses five volumes Engine Control Engine Mechanical Chassis Body Electrical and Body Accessories The Body Accessories Volume details the removal methods of body accessories including interior and exteri...

Page 664: ...Cover Cover Cover Cover Front compartment cover BD 24 Front compartment cover BD 25 Radiator core bracket BD 28 Compartment cover release cable BD 29 Right front door BD 31 Left front door BD 34 Door...

Page 665: ...SE 116 Front row twin bench type seat SE 119 Front row individual seat SE 120 back row seats SE 121 Sealing Sealing Sealing Sealing Elements Elements Elements Elements Inner acoustic baffle of front...

Page 666: ...Instruction Instruction and and and and Operation Operation Operation Operation SST for Glass 2 Front windshield 3 Removal Installation Removal Installation Removal Installation Removal Installation...

Page 667: ...tion Function Function Function Function Door hinge adjusting wrench For adjustment removal or installation of door hinge Ceiling remover For removal of ceiling Sealant remover For cutting door window...

Page 668: ...ront Front Front windshield windshield windshield windshield Front windshield is mainly composed of laminated glass and relevant accessories interior rear view mirror base antenna and antenna terminal...

Page 669: ...shield windshield windshield Removal 1 Remove glass molding Prepare repair kit with the following articles included Sealant carbamic acid ethyl ester adhesive Cleaner Primer Cloth Wool brush Felt Mat...

Page 670: ...ng cutting Attention Attention Attention Attention In case of the windshield to be reused it is prohibited to use cutter or electric cutting tools 6 Cut one side and top side of glass sealant Cut the...

Page 671: ...ut also can soften the surface coat of synthetic paint therefore ZK polypropylene surface paint mixed with hardener should be applied around the window 3 Install the new height adjusting brackets onto...

Page 672: ...gle triangle triangle triangle glass glass glass glass Removal 1 Remove the rear view mirror from the window 2 Remove the glass Compress the glass continuously and forcibly from the inside upper corne...

Page 673: ...angle triangle triangle glass glass glass glass 2 Reinstall the window Pass the cable through the window groove and stick the lower edge of seal along the edge of window groove Compress the outside of...

Page 674: ...on Removal Installation Removal Installation Front Front Front Front door door door door glass glass glass glass 1 Disconnect the negative cable of battery 2 Remove the interior trim panel of door 3 D...

Page 675: ...oval Installation Removal Installation Continued Continued Continued Continued Front Front Front Front door door door door window window window window 5 Pull out the glass seal from top to bottom 6 Re...

Page 676: ...Front Front Front door door door door glass glass glass glass seal seal seal seal Removal 1 Disconnect the negative cable of battery 2 Peel off the window glass seal Note Note Note Note Peel off the...

Page 677: ...Front Front Front door door door door glass glass glass glass regulator regulator regulator regulator Removal 1 Disconnect the negative cable of battery 2 Peel off the window glass seal Note Note Not...

Page 678: ...tallation Removal Installation Continued Continued Continued Continued Front Front Front Front door door door door glass glass glass glass regulator regulator regulator regulator 5 Remove the mounting...

Page 679: ...eft Left Left side side side side wall wall wall wall glass glass glass glass Removal 1 Prepare necessary tools 2 Peel off the window glass seal Note Note Note Note Peel off the window glass seal comp...

Page 680: ...s for cutting glasses please wear gloves and goggles to avoid possible injury caused by glass fragments generated during cutting Attention Attention Attention Attention In case of the windshield to be...

Page 681: ...the body for side trimming 3 Wipe the glass clean Trim the polyurethane sealant remained on window carefully with polyurethane sealant in thickness of 1mm left on the glass for side trimming Caution C...

Page 682: ...Removal Installation Right Right Right Right side side side side wall wall wall wall glass glass glass glass Removal 1 Side wall glass 2 Remove the curtain 3 Remove the side pillar trim panel 4 Remov...

Page 683: ...allation Removal Installation Removal Installation Continued Continued Continued Continued Right Right Right Right side side side side wall wall wall wall glass glass glass glass 5 Remove the mounting...

Page 684: ...Installation Removal Installation Rear Rear Rear Rear side side side side wall wall wall wall glass glass glass glass Removal 1 Rear side wall glass 2 Remove the curtain 3 Remove upper and lower trim...

Page 685: ...tion Removal Installation Removal Installation Removal Installation Rear Rear Rear Rear side side side side wall wall wall wall glass glass glass glass 5 Remove the mounting bolts for glass and take t...

Page 686: ...th Wool brush Felt Mat Nozzle Note Note Note Note An additional tube of sealant may be applied 2 Install the precise cutting blade 24mm hook type blade onto the cutter Warning Warning Warning Warning...

Page 687: ...f 1mm left on the glass for side trimming Caution Caution Caution Caution Glass primer contains solvent that can make the primer hardened after volatilization but also can soften the surface coat of s...

Page 688: ...tion Instruction Instruction Instruction and and and and Operation Operation Operation Operation Front compartment cover 24 Removal Installation Removal Installation Removal Installation Removal Insta...

Page 689: ...ront Front Front Front Compartment Compartment Compartment Compartment Cover Cover Cover Cover 24 Instruction Instruction Instruction Instruction and and and and Operation Operation Operation Operatio...

Page 690: ...25 Removal Installation Removal Installation Removal Installation Removal Installation Front Front Front Front compartment compartment compartment compartment cover cover cover cover 1 Open the front...

Page 691: ...over Cover Cover Cover 26 Removal Installation Removal Installation Removal Installation Removal Installation Continued Continued Continued Continued Front Front Front Front compartment compartment co...

Page 692: ...stment Inspection Adjustment Front Front Front Front compartment compartment compartment compartment cover cover cover cover 1 The adjustment direction of front compartment cover is shown in the figur...

Page 693: ...r Cover 28 Removal Installation Removal Installation Removal Installation Removal Installation Radiator Radiator Radiator Radiator core core core core bracket bracket bracket bracket 1 Remove the lock...

Page 694: ...29 Removal Installation Removal Installation Removal Installation Removal Installation Compartment Compartment Compartment Compartment cover cover cover cover release release release release cable cab...

Page 695: ...ver Cover Cover Cover 30 Removal Installation Removal Installation Removal Installation Removal Installation Continued Continued Continued Continued Compartment Compartment Compartment Compartment cov...

Page 696: ...Cover 31 Removal Installation Removal Installation Removal Installation Removal Installation Right Right Right Right front front front front door door door door 1 Disconnect the negative cable of bat...

Page 697: ...ment Cover Cover Cover Cover 32 Removal Installation Removal Installation Removal Installation Removal Installation Continued Continued Continued Continued Right Right Right Right front front front fr...

Page 698: ...ont Compartment Compartment Compartment Compartment Cover Cover Cover Cover 33 Inspection Adjustment Inspection Adjustment Inspection Adjustment Inspection Adjustment Right Right Right Right front fro...

Page 699: ...er Cover 34 Removal Installation Removal Installation Removal Installation Removal Installation Left Left Left Left front front front front door door door door 1 Disconnect the negative cable of batte...

Page 700: ...mpartment Cover Cover Cover Cover 35 Removal Installation Removal Installation Removal Installation Removal Installation Left Left Left Left front front front front door door door door 5 Remove mounti...

Page 701: ...mpartment Compartment Compartment Cover Cover Cover Cover 36 Inspection Adjustment Inspection Adjustment Inspection Adjustment Inspection Adjustment Left Left Left Left front front front front door do...

Page 702: ...over Cover Cover Cover 37 Removal Installation Removal Installation Removal Installation Removal Installation Left Left Left Left front front front front door door door door outer outer outer outer ha...

Page 703: ...er Cover Cover Cover 38 Removal Installation Removal Installation Removal Installation Removal Installation Continued Continued Continued Continued Left Left Left Left front front front front door doo...

Page 704: ...ver Cover Cover 39 Removal Installation Removal Installation Removal Installation Removal Installation Left Left Left Left front front front front door door door door lock lock lock lock cylinder cyli...

Page 705: ...Compartment Compartment Cover Cover Cover Cover 40 Removal Installation Removal Installation Removal Installation Removal Installation Continued Continued Continued Continued Left Left Left Left front...

Page 706: ...er Cover Cover Cover 41 Removal Installation Removal Installation Removal Installation Removal Installation Left Left Left Left front front front front door door door door lock lock lock lock body bod...

Page 707: ...Compartment Compartment Cover Cover Cover Cover 42 Removal Installation Removal Installation Removal Installation Removal Installation Continued Continued Continued Continued Left Left Left Left front...

Page 708: ...r Cover 43 Removal Installation Removal Installation Removal Installation Removal Installation Continued Continued Continued Continued Left Left Left Left front front front front door door door door l...

Page 709: ...Cover Cover Cover Cover 44 Removal Installation Removal Installation Removal Installation Removal Installation R R R Right ight ight ight front front front front door door door door lock lock lock lo...

Page 710: ...Removal Installation Removal Installation Removal Installation Removal Installation Continued Continued Continued Continued R R R Right ight ight ight front front front front door door door door lock...

Page 711: ...ver Cover Cover Cover 46 Removal Installation Removal Installation Removal Installation Removal Installation Door Door Door Door seal seal seal seal 1 Remove the step plate 2 Peel off door seal from t...

Page 712: ...allation Double open Double open Double open Double open back back back back door door door door Removal 1 Disconnect the negative cable of battery 2 Disconnect the harness of left door 3 Remove bolts...

Page 713: ...lation Removal Installation Continued Continued Continued Continued Double open Double open Double open Double open back back back back door door door door 5 Remove bolts for right door hinge 6 Remove...

Page 714: ...mpartment Compartment Compartment Cover Cover Cover Cover 49 Removal Installation Removal Installation Removal Installation Removal Installation Double open Double open Double open Double open back ba...

Page 715: ...over Cover Cover 50 Removal Installation Removal Installation Removal Installation Removal Installation Back Back Back Back door door door door outer outer outer outer handle handle handle handle Remo...

Page 716: ...ment Cover Cover Cover Cover 51 Removal Installation Removal Installation Removal Installation Removal Installation Continued Continued Continued Continued Back Back Back Back door door door door oute...

Page 717: ...mpartment Compartment Compartment Cover Cover Cover Cover 52 Removal Installation Removal Installation Removal Installation Removal Installation Back Back Back Back door door door door latch latch lat...

Page 718: ...Cover Cover Cover Cover 53 Removal Installation Removal Installation Removal Installation Removal Installation Outer Outer Outer Outer lock lock lock lock of of of of back back back back door door do...

Page 719: ...ver Cover Cover Cover 54 Removal Installation Removal Installation Removal Installation Removal Installation Continued Continued Continued Continued Outer Outer Outer Outer lock lock lock lock of of o...

Page 720: ...over Cover 55 Removal Installation Removal Installation Removal Installation Removal Installation Inner Inner Inner Inner lock lock lock lock of of of of back back back back door door door door Remova...

Page 721: ...Removal Installation Removal Installation Removal Installation Removal Installation Continued Continued Continued Continued Inner Inner Inner Inner lock lock lock lock of of of of back back back back...

Page 722: ...partment Compartment Compartment Compartment Cover Cover Cover Cover 57 Removal Installation Removal Installation Removal Installation Removal Installation Back Back Back Back door door door door seal...

Page 723: ...BD BD BD BD Front Rear Front Rear Front Rear Front Rear Doors Doors Doors Doors and and and and Front Front Front Front Compartment Compartment Compartment Compartment Cover Cover Cover Cover 58...

Page 724: ...Installation Removal Installation Removal Installation Instrument panel 61 Roof lining 69 Trim panel of A pillar 74 Trim panel of B pillar 75 Trim panel of C pillar 78 Side wall window trim panel 80 T...

Page 725: ...terior Interior Exterior Interior Exterior Trims Trims Trims Trims 60 Instruction Instruction Instruction Instruction and and and and Operation Operation Operation Operation Instrument Instrument Inst...

Page 726: ...al Installation Removal Installation Instrument Instrument Instrument Instrument panel panel panel panel 1 Remove the negative cable of battery 2 Remove the upper cover of steering wheel 3 There are t...

Page 727: ...Installation Removal Installation Continued Continued Continued Continued Instrument Instrument Instrument Instrument panel panel panel panel 5 Remove the instrument cover 6 Remove four mounting screw...

Page 728: ...stallation Continued Continued Continued Continued Instrument Instrument Instrument Instrument panel panel panel panel 9 Remove four mounting screws of the clock spring and take down the clock spring...

Page 729: ...stallation Removal Installation Removal Installation Continued Continued Continued Continued Instrument Instrument Instrument Instrument panel panel panel panel 13 Remove two mounting screws of A C co...

Page 730: ...on Removal Installation Removal Installation Removal Installation Continued Continued Continued Continued Instrument Instrument Instrument Instrument panel panel panel panel 17 Remove four mounting sc...

Page 731: ...rument Instrument Instrument Instrument panel panel panel panel 21 Loosen two mounting screws of instrument panel 22 Remove the mounting bolt on the left side of instrument panel 23 Remove the mountin...

Page 732: ...lation Continued Continued Continued Continued Instrument Instrument Instrument Instrument panel panel panel panel 25 Remove two mounting bolt on the right side of instrument panel 26 Remove the shift...

Page 733: ...trument panel panel panel panel Installation 1 During the installation of instrument panel the clock spring should be installed under the premise that the wheels face forward and it should be rotated...

Page 734: ...nterior Exterior Interior Exterior Interior Exterior Trims Trims Trims Trims 69 Instruction Instruction Instruction Instruction and and and and Operation Operation Operation Operation Roof Roof Roof R...

Page 735: ...ims 70 Removal Installation Removal Installation Removal Installation Removal Installation Roof Roof Roof Roof lining lining lining lining Removal 1 Remove the negative cable of battery 2 Remove curta...

Page 736: ...rior Trims Trims Trims Trims 71 Removal Installation Removal Installation Removal Installation Removal Installation Roof Roof Roof Roof lining lining lining lining 5 Remove interior ceiling lamp 1 6 R...

Page 737: ...ion Removal Installation Removal Installation Roof Roof Roof Roof lining lining lining lining 9 Remove front interior ceiling lamp 10 Remove clips of rear roof lining and take down the rear roof linin...

Page 738: ...or Trims Trims Trims Trims 73 Removal Installation Removal Installation Removal Installation Removal Installation Roof Roof Roof Roof lining lining lining lining Installation Two service persons are n...

Page 739: ...Installation Removal Installation Right Left Right Left Right Left Right Left upper upper upper upper trim trim trim trim panel panel panel panel of of of of A pillar A pillar A pillar A pillar Remova...

Page 740: ...upper lower upper lower upper lower upper lower trim trim trim trim panel panel panel panel of of of of B pillar B pillar B pillar B pillar Removal 1 Remove curtains 2 Remove two mounting screws for r...

Page 741: ...m Trim Panel Panel Panel Panel Left Left Left Left upper lower upper lower upper lower upper lower trim trim trim trim panel panel panel panel of of of of B pillar B pillar B pillar B pillar Removal 1...

Page 742: ...rims 77 Removal Installation Removal Installation Removal Installation Removal Installation Left Left Left Left upper lower upper lower upper lower upper lower trim trim trim trim panel panel panel pa...

Page 743: ...or for for C pillar C pillar C pillar C pillar Trim Trim Trim Trim Panel Panel Panel Panel Left Right Left Right Left Right Left Right trim trim trim trim panel panel panel panel of of of of C pillar...

Page 744: ...n Removal Installation Removal Installation Removal Installation Continued Continued Continued Continued Left Right Left Right Left Right Left Right trim trim trim trim panel panel panel panel of of o...

Page 745: ...ation Right Right Right Right side side side side wall wall wall wall window window window window trim trim trim trim panel panel panel panel Removal 1 Remove curtains 2 Remove upper trim panel 1 and...

Page 746: ...emoval Installation Removal Installation Removal Installation Removal Installation Continued Continued Continued Continued Right Right Right Right side side side side wall wall wall wall window window...

Page 747: ...val Installation Left Left Left Left side side side side wall wall wall wall window window window window trim trim trim trim panel panel panel panel Removal 1 Remove curtains 2 Remove upper trim panel...

Page 748: ...3 Removal Installation Removal Installation Removal Installation Removal Installation Continued Continued Continued Continued Left Left Left Left side side side side wall wall wall wall window window...

Page 749: ...r Upper lower Upper lower trim trim trim trim panel panel panel panel of of of of right right right right D pillar D pillar D pillar D pillar Removal 1 Remove curtains 2 Remove mounting screws for upp...

Page 750: ...ower Upper lower Upper lower trim trim trim trim panel panel panel panel of of of of left left left left D pillar D pillar D pillar D pillar Removal 1 Remove curtains 2 Remove mounting screws for uppe...

Page 751: ...nels 1 1 1 1 2 2 2 2 3 3 3 3 and and and and 4 4 4 4 and and and and right right right right trim trim trim trim panels panels panels panels 1 1 1 1 2 2 2 2 and and and and 3 3 3 3 Removal 1 Remove cu...

Page 752: ...allation Removal Installation Continued Continued Continued Continued Left Left Left Left trim trim trim trim panels panels panels panels 1 1 1 1 2 2 2 2 3 3 3 3 and and and and 4 4 4 4 and and and an...

Page 753: ...allation Removal Installation Left Left Left Left trim trim trim trim panel panel panel panel of of of of front front front front door door door door trim trim trim trim panel panel panel panel Remova...

Page 754: ...89 Removal Installation Removal Installation Removal Installation Removal Installation Left Left Left Left door door door door Removal 1 Pry up the left door lower trim panel with tool carefully 2 Pr...

Page 755: ...al Installation Removal Installation Removal Installation Removal Installation Right Right Right Right door door door door Removal 1 Remove inner handle cover of door 2 Remove the right door lower tri...

Page 756: ...n Removal Installation Removal Installation Interior Interior Interior Interior rear view rear view rear view rear view mirror mirror mirror mirror Removal 1 Pull the interior rear view mirror downwar...

Page 757: ...Installation Removal Installation Removal Installation Removal Installation Sun Sun Sun Sun visor visor visor visor Removal 1 Remove mounting screws of right sun visor 2 Take down the sun visor 3 Rem...

Page 758: ...s Curtains Curtains Removal 1 Pry out the curtain slide rail with screwdriver and make it separated from the clips mounted on the trim panel 2 Clips are positioned at the middle of each pillar and at...

Page 759: ...tion Removal Installation Removal Installation Luggage Luggage Luggage Luggage rack rack rack rack Removal 1 Two service persons are necessary for removal of luggage rack in order to avoid personal in...

Page 760: ...erior Exterior Trims Trims Trims Trims 95 Removal Installation Removal Installation Removal Installation Removal Installation Continued Continued Continued Continued Luggage Luggage Luggage Luggage ra...

Page 761: ...ms 96 Removal Installation Removal Installation Removal Installation Removal Installation Step Step Step Step plate plate plate plate assembly assembly assembly assembly Removal 1 Remove mounting scre...

Page 762: ...l Installation Removal Installation Removal Installation Removal Installation Front Front Front Front bumper bumper bumper bumper Removal 1 Remove the negative cable of battery 2 Remove screws of fron...

Page 763: ...ms Trims 98 Removal Installation Removal Installation Removal Installation Removal Installation Front Front Front Front bumper bumper bumper bumper 5 Remove mounting screws of bumper 6 Remove four mou...

Page 764: ...99 Removal Installation Removal Installation Removal Installation Removal Installation Rear Rear Rear Rear bumper bumper bumper bumper 1 Remove the negative cable of battery 2 Remove mounting screws...

Page 765: ...100 Removal Installation Removal Installation Removal Installation Removal Installation Continued Continued Continued Continued Rear Rear Rear Rear bumper bumper bumper bumper 5 Disconnect the harness...

Page 766: ...Trims Trims Trims 101 Removal Installation Removal Installation Removal Installation Removal Installation Front Front Front Front grille grille grille grille Removal 1 Remove mounting screws for fron...

Page 767: ...Trims Trims Trims 102 Removal Installation Removal Installation Removal Installation Removal Installation Fender Fender Fender Fender Removal 1 Remove the negative cable of battery 2 Remove the front...

Page 768: ...s Trims Trims Trims 103 Removal Installation Removal Installation Removal Installation Removal Installation Continued Continued Continued Continued Fender Fender Fender Fender 5 Remove front bumper 6...

Page 769: ...rims 104 Removal Installation Removal Installation Removal Installation Removal Installation Continued Continued Continued Continued Fender Fender Fender Fender 9 Remove mounting bolts for fender 10 R...

Page 770: ...105 Removal Installation Removal Installation Removal Installation Removal Installation Continued Continued Continued Continued Fender Fender Fender Fender 13 Remove mounting screws for fender 14 Rem...

Page 771: ...n Removal Installation Removal Installation Removal Installation Front Front Front Front door door door door skirt skirt skirt skirt trim trim trim trim panel panel panel panel Removal 1 Remove front...

Page 772: ...llation Removal Installation Removal Installation Front Front Front Front side side side side wall wall wall wall skirt skirt skirt skirt trim trim trim trim panel panel panel panel Removal 1 Remove f...

Page 773: ...al Installation Middle Middle Middle Middle side side side side wall wall wall wall skirt skirt skirt skirt trim trim trim trim panel panel panel panel Removal 1 Remove mounting screws for middle side...

Page 774: ...stallation Removal Installation Removal Installation Rear Rear Rear Rear wheel wheel wheel wheel skirt skirt skirt skirt trim trim trim trim panel panel panel panel Removal 1 Remove mounting screws 2...

Page 775: ...s 110 Removal Installation Removal Installation Removal Installation Removal Installation Rear Rear Rear Rear tire tire tire tire mud mud mud mud guard guard guard guard Removal 1 Remove mounting scre...

Page 776: ...n Instruction Instruction and and and and Operation Operation Operation Operation Driver s seat 112 Front row twin bench type seat 114 Front row individual seat 115 Removal Installation Removal Instal...

Page 777: ...driver driver s s s s seat seat seat seat 1 Vertical adjustable headrest 2 Angle adjustable armrest 3 Front and rear height adjustable seat Eight adjusting ways for driver s seat can be achieved viz...

Page 778: ...nstruction Instruction and and and and Operation Operation Operation Operation Driver Driver Driver Driver s s s s seat seat seat seat 1 Armrest 2 Backrest cushion 3 Headrest assembly 4 Headrest latch...

Page 779: ...and Operation Operation Operation Operation Front Front Front Front row row row row twin twin twin twin bench type bench type bench type bench type seat seat seat seat 1 Armrest 2 Backrest cushion 3...

Page 780: ...nd and and and Operation Operation Operation Operation Front Front Front Front row row row row individual individual individual individual seat seat seat seat 1 Backrest cushion 2 Headrest assembly 3...

Page 781: ...ation Removal Installation Driver Driver Driver Driver s s s s seat seat seat seat 1 Disconnect the negative cable of battery 2 Remove two mounting nuts on the left side of seat 3 Remove two nuts on t...

Page 782: ...tion Removal Installation Sliding Sliding Sliding Sliding rail rail rail rail and and and and seat seat seat seat 1 Push the sliding rail rearwards and remove four mounting bolts 2 Pull the sliding ra...

Page 783: ...ing rail rail rail rail and and and and seat seat seat seat 1 Install the sliding rail onto the vehicle and install seven mounting bolts in reverse order of removal 2 Install the seat onto sliding rai...

Page 784: ...ow row twin twin twin twin bench type bench type bench type bench type seat seat seat seat Removal 1 Remove four mounting bolts below front row seat 2 Remove the front row twin bench type seat from ve...

Page 785: ...w row row row individual individual individual individual seat seat seat seat Removal 1 Remove four mounting bolts below front row seat 2 Remove the front row individual seat from vehicle Installation...

Page 786: ...k Back Back row row row row seats seats seats seats Removal 1 Remove four mounting bolts below back row seats 2 Remove the back row twin bench type seat from vehicle Installation 1 Install the back ro...

Page 787: ...s Elements Applied models SUNRAY products manufactured by JAC Subject Page Removal Installation Removal Installation Removal Installation Removal Installation Inner acoustic baffle of front wall 124 O...

Page 788: ...ation Inner Inner Inner Inner acoustic acoustic acoustic acoustic baffle baffle baffle baffle of of of of front front front front wall wall wall wall 1 Disconnect the negative cable of battery 2 Remov...

Page 789: ...l heat shield of engine hood 4 Remove heat shields of left and right fenders 5 Remove heat shields of left and right wheels 6 Remove front and right acoustic baffles of front wall Removal Installation...

Page 790: ...Installation Removal Installation Rear Rear Rear Rear door door door door seal seal seal seal 1 Remove middle seal of rear door frame 2 Remove seal of rear door frame Removal Installation Removal Ins...

Page 791: ...compartment compartment compartment compartment seal seal seal seal 1 Remove the rear end seal of front compartment 2 Remove the front section seal assembly of front compartment Removal Installation...

Page 792: ...ody Body Repair Repair Repair Repair Parameters Parameters Parameters Parameters Applied models SUNRAY products manufactured by JAC Subject Page Engine Compartment Repair Parameters 130 Windshield Rep...

Page 793: ...ody Repair Repair Repair Repair Parameters Parameters Parameters Parameters 130 Engine Engine Engine Engine Compartment Compartment Compartment Compartment Repair Repair Repair Repair Parameters Param...

Page 794: ...Body Body Body Body Repair Repair Repair Repair Parameters Parameters Parameters Parameters 131 Windshield Windshield Windshield Windshield Repair Repair Repair Repair Parameters Parameters Parameters...

Page 795: ...Body Body Body Body Repair Repair Repair Repair Parameters Parameters Parameters Parameters 132 Front Front Front Front Door Door Door Door Repair Repair Repair Repair Parameters Parameters Parameters...

Page 796: ...dy Body Repair Repair Repair Repair Parameters Parameters Parameters Parameters 133 Rear Rear Rear Rear Double Door Double Door Double Door Double Door Repair Repair Repair Repair Parameters Parameter...

Page 797: ...air Parameters Parameters Parameters Parameters 134 Girder Girder Girder Girder Repair Repair Repair Repair Parameters Parameters Parameters Parameters Side member repair parameters Diagonal L1 5068mm...

Page 798: ...ng bearing together with relevant installer transmission JAC T8F003 Flywheel stopper For fixing flywheel to facilitate removal engine JAC T8F004 Cooling system detector For checking engine cooling sys...

Page 799: ...moval installation of camshaft bushing engine JAC T8F017 V block for camshaft measurement For measuring damage of camshaft engine JAC T8F018 Hose clamp pliers For removing hose clamp JAC T8F019 Piston...

Page 800: ...ront bearing transmission JAC T8B007 Input shaft protective sleeve For protecting input shaft front end teeth transmission JAC T8B008 Output shaft protective sleeve For protecting output shaft front e...

Page 801: ...SUNRAY SUNRAY SUNRAY SUNRAY Special Special Special Special Service Service Service Service Tools Tools Tools Tools...

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