Chassis Volume: Maintenance Manual of Tojoy Sedan

Maintenance Manual of Tojoy Sedan Clutch and Manual Transmission
Chassis Volume
Chapter I Clutch and Manual Transmission ......................................................................................1
Section I Clutch ..............................................................................................................................1
I. Precautions .........................................................................................................................1
II. Preparation .........................................................................................................................1
III. Common Trouble Diagnosis................................................................................................1
IV. Clutch Hydraulic Oil ............................................................................................................3
V. Master Cylinder of Clutch....................................................................................................4
VI. Clutch Pedal........................................................................................................................6
VII. Clutch Plate, Clutch Friction Wafer and Fly Wheel..............................................................8
VIII. Hydraulic Pipeline .............................................................................................................11
IX. Maintenance Parameters ..................................................................................................12
Section II Manual Transmission....................................................................................................13
I. Precautions .......................................................................................................................13
II. Preparation .......................................................................................................................13
III. Common Trouble Diagnosis..............................................................................................15
IV. System Illustration.............................................................................................................16
V. Gear Oil of Manual Transmission......................................................................................18
VI. Oil Seal .............................................................................................................................19
VII. Gear Shift Control Device .................................................................................................20
VIII. Manual Transmission Assembly........................................................................................23
IX. Gearbox Casing (Left Case) .............................................................................................38
X. Clutch Casing (Right Case)...............................................................................................40
XI. Input Shaft and Gear.........................................................................................................43
XII. Intermediate Shaft.............................................................................................................51
XIII. Differential.........................................................................................................................60
XIV. Shift Control Sub-assembly...............................................................................................63
XV. Gear Shifting Control Sub-assembly .................................................................................65
XVI. Reversing Lamp Switch ....................................................................................................66
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XVII. Maintenance Parameters.............................................................................................66
Chapter II Traveling System..............................................................................................................68
Section I Power Steering System .................................................................................................68
I. Precautions .......................................................................................................................68
II. Preparation .......................................................................................................................69
IV. Power Steering Fluid.........................................................................................................70
V. Steering Wheel..................................................................................................................72
VI. Steering Column ...............................................................................................................76
VII. Steering Gear....................................................................................................................79
VIII. Power Steering Pump .......................................................................................................85
IX. Hydraulic Pipeline .............................................................................................................89
X. Maintenance Data and Specifications ...............................................................................90
Section II Front Axle......................................................................................................................91
I. Precautions .......................................................................................................................91
II. Preparation .......................................................................................................................91
IV. Front Wheel Hub and Steering Knuckle ............................................................................92
V. Front Drive Shaft...............................................................................................................97
VI. Maintenance Parameters ................................................................................................107
Section III Rear Axle ...................................................................................................................108
I. Preparation .....................................................................................................................108
II. Wheel hub.......................................................................................................................108
III Maintenance Parameters ................................................................................................112
Section IV Front Suspension ......................................................................................................113
I. Precautions .....................................................................................................................113
II. Preparation .....................................................................................................................113
III. Front Suspension Assembly............................................................................................114
IV. Front Damper..................................................................................................................116
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V. Lower Suspension Arm ...................................................................................................119
VI. Stabilizer Bar...................................................................................................................122
VII. Connecting Ball Joint of Stabilizer Bar ............................................................................123
VIII. Support Beam of Engine .................................................................................................124
IX. Common Trouble Diagnosis............................................................................................127
X. Maintenance Parameters ................................................................................................128
Section V Rear Suspension........................................................................................................129
I. Precautions .....................................................................................................................129
II. Preparation .....................................................................................................................129
III. Rear Suspension Assembly ............................................................................................130
IV. Rear Damper ..................................................................................................................132
V. Rear Suspension Arm (A) ...............................................................................................136
VI. Rear Suspension Arm (B) ...............................................................................................137
VII. Thrusting Rod .................................................................................................................138
VIII. Rear Stabilizer Bar ..........................................................................................................139
IX. Support Bar of Stabilizer Bar...........................................................................................140
X. Common Trouble Diagnosis............................................................................................141
XI. Maintenance Parameters ................................................................................................141
Section VI Wheel and Tire ..........................................................................................................142
I. Wheel..............................................................................................................................142
II. Tire..................................................................................................................................142
III. Tire Assembly of the Wheel ............................................................................................144
IV. Common Trouble Diagnosis for Tire Assembly of the Wheel ..........................................146
V. Maintenance Parameters ................................................................................................147
Chapter III Braking System .............................................................................................................148
Section I Parking Braking System...............................................................................................148
I. Precautions .....................................................................................................................148
II. Parking Braking System..................................................................................................148
Section II Braking System...........................................................................................................153
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I. Precautions .....................................................................................................................153
II. Preparation .....................................................................................................................153
III. Brake Pedal ....................................................................................................................154
IV. Brake Master Cylinder ....................................................................................................156
V. Brake Fluid......................................................................................................................157
VI. Brake Pipeline.................................................................................................................159
VII. Brake Vacuum Booster ...................................................................................................162
VIII. Front Disc Brake Tongs ..................................................................................................165
IX. Rear Brake......................................................................................................................172
X. Troubleshooting ..............................................................................................................177
XI. Maintenance Parameter..................................................................................................179
Section III Anti-lock Braking System ...........................................................................................181
I. Precautions .....................................................................................................................181
II. Preparation .....................................................................................................................182
III. System Illustration...........................................................................................................182
IV. Anti-lock Braking Mode ...................................................................................................184
V. Speed Sensor .................................................................................................................185
VI. ABS Hydraulic Assembly ................................................................................................187
VII. ABS Control Module .......................................................................................................188
VIII. Exhaust of ABS ...............................................................................................................191
IX. Trouble Diagnosis ...........................................................................................................199
4
Chapter I Clutch and Manual Transmission
Section I Clutch
I. Precautions
■ The hydraulic oil recommended for the clutch is brake fluid “DOT 4”.
■ Please do not reuse the discharged clutch hydraulic oil.
■ Take care not to spill the clutch hydraulic oil onto the painted surface of the body.
■ Please do not use mineral oil such as petrol and kerosene, or it will corrode the rubber spare parts
of the hydraulic system.
■ Please do not disassemble the master cylinder and the hydraulic release bearing.
Caution:
■ Use the dust collector, never the compressed air to clean the clutch friction wafer.
II. Preparation
Special tools used are as follows:
Table of Special Tools
No. Tool Outline Diagram Code Illustration
Fly wheel
1 JAC-T1F011 For Fixing fly wheel
retainer
III. Common Trouble Diagnosis
The performance diagnosis of the clutch assembly and the clutch control system shall be carried out by
experienced drivers or skilled vehicle maintenance technicians.
The following (trouble) diagnosis covers common troubles and possible causes. After proper diagnosis is
performed, adjust it according to the corresponding solutions in the diagnosis table and to the right
chapter or section of the maintenance manual for each specific program or replace the spare part as
required.
The clutch friction wafer and the clutch plate cannot be repaired during the vehicle maintenance, so if
any spare part of them is broken, the whole assembly has to be replaced.
If the rivet of clutch friction wafer is worn or the clutch friction wafer is contaminated by oil or grease, it is
improper to use the clutch friction wafer again.
1
If any spare part needs to be replaced, then a new spare part with quality assurance shall be used for
replacement.
The present diagnosis table is helpful in diagnosing troubles of clutch system caused by conditions as
follows: unable to disengage, incomplete disengagement, incomplete engagement, slipping, noise and
whipping.
The numbers in the diagnosis table are not for the check sequence, and there is no precedence
relationship between two possible causes.
Diagnosis Table for Clutch System
Check Possible Cause Troubleshooting
Unable to The clutch is unable to disengage means that it cannot Replace distorted, wearing and broken spare
disengage function and cut off the power transferred from the parts.
engine. Adjust the clutch system.
Check the following conditions:
1. The release lever of clutch is distorted.
2. The diaphragm spring is distorted.
3. The retaining ring of diaphragm spring is broken.
4. Improper adjustment of the control system of clutch
pedal and the clutch wiredrawing.
5. The clutch friction wafer is engaged with the fly wheel
or clutch plate.
Incomplete The incomplete disengagement will cause the clutch Replace the distorted, wearing, broken spare
disengagement unable to cut off the power transferred from the engine parts or the one that exceeds the specified
normally, and it also becomes difficult to control the size. If the friction wafer cannot fit the
shifting lever because of the continuing rotation of the operation of the spline of gearbox input shaft
clutch friction wafer and the input shaft of gearbox. properly, then the replacement of clutch
Check the following conditions: friction wafer is needed. Replace the gearbox
1. The clutch friction wafer is distorted and swings while input shaft if necessary. If the clutch friction
rotating. wafer exceeds the specified size or is
2. The clutch friction wafer is damaged. damaged, the replacement is needed.
3. The spline of clutch friction wafer does not match with Replace the inapplicable thrust bearing of
the one of gearbox input shaft, or the spline facing is clutch.
damaged. Adjust the clutch system to remove
4. The clutch friction wafer is engaged with the fly wheel unnecessary clearance and solve the
or seizes the clutch plate. mechanical trouble.
5. The thickness of fly wheel/clutch plate/clutch friction Mount the improperly assembled spare part
wafer exceeds the specified size. again.
6. Mechanical troubles with the control system of clutch
pedal and the clutch wiredrawing or improper
adjustment.
Incomplete Incomplete engagement may cause the clutch unable Replace the distorted, wearing and broken
engagement to transfer the engine power to the gearbox input shaft spare parts.
normally and also leads to the slipping of the clutch Replace the clutch friction wafer or defective
friction wafer. Check the following conditions: clutch assembly.
1. The clutch friction wafer is contaminated by oil or Adjust the free play of the clutch pedal in a
grease. correct way.
2. The clutch friction wafer is damaged. Adjust the clutch system to remove
3. The clutch pedal is of no free play. unnecessary clearance and solve the
4. The diaphragm spring/clutch plate/release lever of mechanical trouble.
clutch/spline of clutch friction wafer is distorted or Mount the improperly assembled spare part
damaged. again.
5. Mechanical troubles with the control system of clutch
pedal and the clutch wiredrawing or improper
2
adjustment.
The slipping of clutch friction wafer may cause the Replace the distorted, wearing, broken spare
clutch unable to transfer the engine power normally. parts or the one that exceeds the specified
size and specification.
Check the following conditions: The solutions are the same as those in the
1. The clutch friction wafer is worn. “Unable to disengage” and “Incomplete
2. The clutch friction wafer is contaminated by oil or engagement”.
grease. Stop the engine, cool the clutch casing (if the
3. Incomplete engagement of the clutch. temperature is excessively high), and then
4. The thickness of fly wheel/clutch plate/clutch friction make further diagnosis.
wafer exceeds the specified size, and the friction Mount the given clutch in a correct way.
Slipping
surface is larger than the given specification. Adjust the clutch system in order to remove
5. Excessively high temperature inside the clutch unnecessary clearance and solve the
casing caused by driver’s improper operation. mechanical trouble.
6. The improper clutch is mounted. Mount improperly assembled spare part
again.
The driver shall not put the feet on the clutch
pedal all the time.
Check the following conditions: Mount improperly assembled spare part
1. Improper clutch friction wafer. again.
2. Poor balance.
Noise
3. Troubles with the thrust bearing of clutch.
4. The torsion damp spring of clutch friction wafer is
damaged.
When the clutch friction wafer cannot engage with the Replace the clutch assembly.
fly wheel gently, the following conditions may appear.
Check the following conditions:
1. The damp spring of clutch friction wafer does not
Whipping meet the specification.
2. The clutch friction wafer does not meet the
specification.
3. The clutch friction wafer is contaminated by oil or
grease.
IV. Clutch Hydraulic Oil
1. Check gists
Attention:
■ Please do not use vacuum pump or any other kind of power emptying device to operate on this
system.
■ Check the liquid level of the hydraulic oil for clutch, and make sure that it is at the normal level.
■ Do not let the clutch hydraulic oil drip on the painted surface of the body or other components. If the
hydraulic oil is spilled on it, wipe the surface or the component with a dry cloth immediately.
2. Exhaust air in pipeline
Note: If it becomes spongy while dismantling the clutch pipeline, master cylinder of the clutch, hydraulic
release bearing and the clutch pedal, the air in the system shall be exhausted.
1) Loosen the exhaust bolt of the slave cylinder of clutch.
3
2) Step down the clutch pedal slowly until the air is exhausted completely.
3) Step down the clutch pedal completely, and keep it. Screw down the exhaust bolt.
4) Add hydraulic oil to the clutch hydraulic system.
Attention:
■ Keep the height of fluid level in the stock solution tank between MIN and MAX all along.
5) Repeat the steps above until the discharged clutch hydraulic oil is clean and with no bubbles.
6) Make sure of the normal operation of the clutch.
① Start the engine, step down the clutch pedal, and engage the reverse gear carefully after about 2s. If
there is big noise while engaging, step down the clutch pedal completely for five times to exhaust air
in the system.
② Check the operation condition of the clutch after about 30s. If there is still big noise, please repeat
exhausting.
V. Master Cylinder of Clutch
1. Elements
Disassembly Diagram for Master Cylinder of Clutch
1- Stock solution tank 2- Clamping band 3- Piston 4- Snap ring 5- Push rod 6- Master cylinder body 7-
Lock pin
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2. Dismantlement and Installation
1) Dismantlement
① Discharge the clutch hydraulic oil from the exhaust bolt of clutch.
② Cut off the lock pin between the push rod of clutch master cylinder and the clutch pedal.
Fig. 1.1 001
③ Cut off the connecting hose between the

Fig. 1.1 002
master cylinder of clutch and the brake master
cylinder.
④ Dismantle the oil pipe and the fixing bolt of

Fig. 1.1 003
clutch master cylinder.
⑤ Take out the clutch master cylinder.
2) Check after dismantlement
■ Check whether the clutch pipeline is blocked.
■ Check whether the clutch hose and hard pipe have damages such as breakage and rust.
3) Installation
Pay attention to the following precautions, and install in the reverse order with the dismantlement.
5
■ Apply specified hydraulic oil on the inwall of the pump body and the exterior surface of the piston
assembly. (Brake hydraulic oil D0T 4)
■ Exhaust air in the system. Please refer to the “Clutch Hydraulic Oil”.
■ Adjust the free play of clutch. Please refer to the “On-vehicle Check and Adjustment”.
■ Refer to the “Tightening Torque Table” for the tightening torque.
VI. Clutch Pedal
1. On-vehicle check and adjustment
Check for free play:
■ Press down the clutch pedal by hands until Fig. 1.1 004
you feel certain resistance, and then use the
dividing ruler to check whether the free play is
within the specified range.
The free play of the pedal: 6~13 mm
2. Dismantlement and installation
1) Elements
Clutch Pedal Diagram
6
2) Dismantlement
① Dismantle the lock pin of the clutch pedal to

Fig. 1.1 005
cut off its connecting with the push rod of
clutch master cylinder.
② Dismantle the fixing bolt of clutch pedal, and

Fig. 1.1 006
then take it out.

Fig. 1.1 007
Check whether the clutch pedal is twisted,
damaged or there are any cracks on the welded
junction. If any mentioned condition appears,
please replace the clutch pedal assembly.
4) Installation
Install in the reverse order with the dismantlement.
■ Tightening torque: 20~30Nym
Attention:
■ Do not push the push rod to the clutch master cylinder while adjusting the height of the clutch pedal.
■ Check whether the stroke and free play of the clutch pedal is within the specified range after
adjustment.
■ If the free play of the clutch pedal is not within the specified range, there must be air in the clutch
hydraulic pipeline or troubles with the clutch master cylinder. Exhaust air in the system, and
disassemble the master cylinder or clutch for check.
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VII. Clutch Plate, Clutch Friction Wafer and Fly Wheel
1) Elements
Disassembly Diagram for Clutch
1-Fly wheel 2-Clutch friction wafer 3-Clutch plate 4-Fixing bolt
Attention:
■ Do not let any grease contaminate the surface of clutch friction wafer, plate and fly wheel.
2) Dismantlement
① Dismantle the manual transmission assembly from the vehicle. Please refer to the “Manual
Transmission Assembly”.
② Loosen the fixing bolt of clutch plate evenly. Then dismantle the clutch plate and friction wafer.
Attention:
■ Only loosen one bolt by one to two circles every time in order to prevent damaging the flange of the
clutch casing.
③ Dismantle the fixing bolt of fly wheel from rear end of the cylinder body, and take off the fly wheel.
④ Dismantle the hydraulic release bearing from the clutch casing.
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① Clutch friction wafer
■ Check whether the surface is contaminated by grease or deteriorated because of the looseness of
rivet, single-side contact, or burn. If so, replace the clutch friction wafer.
■ Measure the immersion depth of rivet. If it exceeds the limit, please replace the clutch friction wafer.
Limit: 0.3 mm
Fig. 1.1 008
■ Check whether the return spring is loose or damaged. If
so, please replace the clutch friction wafer.
■ Mount the clutch friction wafer onto the input shaft, and
then check the sliding status and the looseness of the
rotation direction. If the sliding is poor, it shall be cleaned
or replaced on condition that the sliding is still poor after
cleaning. If the looseness is obvious, the clutch friction
wafer or input shaft or both shall be replaced.
② Clutch plate
■ Check whether the end of the diaphragm spring is worn or there is any difference in height. If the
wearing place is obvious or the difference in height is beyond the limit, the clutch friction wafer shall
be replaced.
Limit: 0.5 mm.
■ Check whether the surface of plate is worn, discolored or with cracks.
■ Check whether the rivet of the plate is loose. If so, replace the clutch plate.
③ Hydraulic release bearing
■ Check whether the bearing is burnt, damaged or accompanied with abnormal sound and rough
rotation while working.
■ Check whether the diaphragm spring of hydraulic bearing is worn. If so, please replace it.
④ Fly wheel
Micrometer gauge
■ Use the micrometer gauge to measure the flatness of
Fig. 1.1 009
contact surface between the fly wheel and clutch
friction wafer. If it does not meet the requirement,
please replace the fly wheel.
■ If there is ablative or discolored places on the contact
surface between the clutch plate and friction wafer,
please apply sanding treatment with the abrasive
paper.
Attention:
■ Please measure the flatness on the exterior surface of fly wheel. (Not measure on the anchor pin)
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4) Installation
① Clean the clutch friction wafer and the key slot of input shaft, and remove the grease and worn
sweepings.
② Apply the grease on the key slot of input shaft.
Attention:
■ Recommended grease: SAE J310 or similar products.
■ Make sure that the grease is applied on the specified position, or it may cause noise from the clutch,
poor release or damage. Too much grease also may lead to slipping or whipping.
③ Mount the fly wheel, and tighten it up as specified tightening torque; Use special tools to mount the
clutch friction wafer and clutch plate.
④ Perform step by step as the sequence shown Fig. 1.1 010

in the figure to tighten up the clutch fixing bolt
in turn and evenly.
Attention:
■ Tighten up each bolt by 1~2 circles

sequentially.
Tightening torque: 15~22 Nym
⑤ Mount the hydraulic release bearing.
⑥ Mount the manual transmission on the vehicle. Refer to the “Manual Transmission” for the
installation process.
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VIII. Hydraulic Pipeline
Hydraulic Pipeline Diagram
1-Quick joint 2-Clutch plate and driven disk 3-Oil pipe 4- Hose 5- Left mounting of gearbox 6- Induction
manifold 7-Master cylinder of clutch 8-Clutch pedal
Please pay attention to the following precautions while dismantling and mounting the clutch hydraulic
pipeline.
Attention:
■ Do not let the hydraulic oil for clutch drip on the painted surface of the body or other components. If
the hydraulic oil is spilled on them, wipe the surface or the component with a piece of dry cloth
immediately, and then wash it with water.
■ While mounting the clutch pipeline on the hydraulic release bearing, three-way valve and clutch pipe,
insert it to the end, and check whether the clip is in position.
■ Please use the oil pipe wrench to screw down the oil pipe joint.
■ After installation, please exhaust air in the clutch hydraulic system, and refer to the “Air Exhaust”.
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IX. Maintenance Parameters
1. Technical Parameters
Table of Technical Parameters
Free play of clutch 6~13 mm
2. Lubricating Grease
Lubricating Grease Table
Kingpin of master cylinder SAE J310, NLGI NO. 2
3. Tightening Torque
Tightening Torque Table
Items Torque (Nym)
Fixed nut for the master cylinder of clutch 20~30
Fixed support for oil pipe of hydraulic release

8~12
bearing
Exhaust bolt 7~13
Installation bolt for clutch plate 20~30
Fixing bolt for fly wheel 127~137
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Maintenance Manual of Tojoy Sedan Traveling System
Section II Manual Transmission

I. Precautions
■ Don’t reuse the discharged gear oil of manual transmission.
■ When checking or replacing the gear oil of manual transmission, keep the vehicle level.
■ When dismantling and installing gearbox, keep its interior free of dust and foreign substances.
■ Check and confirm that the installation position is correct before dismantlement or disassembly. If
necessary, make an installation mark and ensure that the mark will not affect the function of the
marked component.
■ Tighten the bolts and nuts by multiple steps and in diagonal direction, namely, tighten the middle
bolts and nuts at first, and then tighten the outer bolts and nuts, according to the regulations. If the
tightening order is specified, do as required.
■ Be careful not to damage the sliding surfaces and matching surfaces of elements.
II. Preparation
See the table below for the adopted special tools.
For installation and

Withdrawal dismantlement of
1 tool for JAC-T1B001 various gears,
bearing bearings and shaft
sleeves

Withdrawal dismantlement of
2 tool for JAC-T1B002 various gears,
bearing bearings and shaft
sleeves
13
Used together with

3 Erector cover JAC-T1B005
erector and erection joint
Used together with

4 Erector-100 JAC-T1B006 erector cover and
erection joint
Used together with

5 Erector-200 JAC-T1B007 erector cover and
erection joint
Used together with

JAC-T1B008 erector, for installation of
JAC-T1B009 bearings of intermediate
6 Erection joint
JAC-T1B011 shaft and input shaft as
JAC-T1B012 well as the shaft sleeves
for gear 1, 2 and 4
Used together with

Installation
7 JAC-T1B016 erector, for installation of
handle
bearing
Erector for
For installation of shift
8 shift shaft oil JAC-T3B001
shaft oil seal of gearbox
seal
Erector for
For installation of
9 differential oil JAC-T3B002
differential oil seal
seal
14
For dismantlement
Detacher for
of spring pin of gear
10 spring pin of JAC-T3B003
shifting fork of
gearbox
gearbox
Erector for
For installation of
right bearing
right bearing of
11 of JAC-T3B005
intermediate shaft
intermediate
of gearbox casing
shaft
Table of Common Trouble Diagnosis
Trouble Cause Troubleshooting

Wear of gear shifting fork shaft Replacement
Skid and Wear of gear shifting fork or synchronizer sleeve Replacement
throw-out of Too soft or damaged retaining spring of shift shaft Replacement
gear Wear of toothed sleeve and gear’s chamfered teeth Replacement of toothed sleeve
of synchronizer and gear of synchronizer
Insufficient gear oil of gearbox Addition
Incorrect free play of clutch pedal Adjustment
Deformation or damage of clutch plate lining Replacement
Damage of clutch plate Replacement of plate
Difficult gear
Wear of synchronizer ring gear Replacement
shifting Wear of toothed sleeve and gear’s chamfered teeth Replacement of toothed sleeve or
of synchronizer gear of synchronizer
Deformation of shift shaft Replacement
Failure of wiredrawing adjustment to proper
Adjustment of wiredrawing
position
Insufficient gear oil of gearbox Addition
Damage or wear of bearing Replacement
Noise
Damage or wear of gear Replacement
Damage or wear of spare parts of synchronizer Replacement
Wear or damage of input shaft oil seal Replacement
Wear or damage of differential oil seal (oil seal wear
Replacement
is caused by poor quality of driving shaft surface)
Oil leakage Oil leakage at oil plug Replacement
Failure of sealant at the lock bolt for gear 1 and 2 Replacement
Failure of sealant at the lock bolt for gear 5 and
Replacement
reverse gear
15
IV. System Illustration
1. Schematic Diagram for Structure
Schematic Diagram for Structure of Gearbox
1-Gearbox casing bolt 2-Baffle plate bolt of reversing lamp switch 3-Baffle plate assembly for reversing
lamp switch 4-Gear 5 gear shifting fork bolt 5-Lock pressure plate bolt 6-Gear 5 synchronizer ring gear
7-Gear 5 gear assembly of intermediate shaft 8-Interlocking pin 9-Reversing lamp switch assembly
10-Left case sub-assembly 11-Gearbox casing bolt 1 12-Intermediate shaft sub-assembly 13-Gear lever
sub-assembly 14-Lock bolt assembly for gear 3 and 4 15-Gear shifting fork assembly for reverse gear
16-Gear shifting fork bolt for reverse gear 17-Lock spring for gear 1 and 2 18-Lock bolt for gear 5 and
reverse gear 19-Lock bolt for gear 1 and 2 20-Lock spring for gear 5 and reverse gear 21-Differential
sub-assembly 22-Closing pin 23-Locknut of intermediate shaft 24-Baffle plate for gear 5 synchronizer
slider 25-Gear 5 synchronizer sub-assembly 26-Gear shifting fork for gear 5 27-Gear 5 synchronizer
slider assembly 28-Input shaft nut 29-Gear 5 gear of intermediate shaft 30-Needle bearing 31-Bearing
pressure plate bolt 2 32-Bearing pressure plate bolt 1 33-Bearing pressure plate of left case 34-Rear
casing assembly 35-Gear 5 gear of input shaft 36-Interlocking bolt for gear 5 and reverse gear 37-Shift
control sub-assembly 38-Stop bolt for gear shifting 39-Left bearing shield ring of intermediate shaft
40-Left bearing shield ring of input shaft 41-Idle gear shaft for reverse gear 42-Gear shaft bolt for reverse
gear 43-Gear shaft bolt washer for reverse gear 44-Idle gear shaft washer for reverse gear 45-Idle gear
assembly for reverse gear 46-Input shaft sub-assembly 47-Lock steel ball for gear 1 and 2 48-Gear
shifting cable support 49-Gear shifting cable support bolt 50-Quick three-way pipe joint 51-Spider for oil
pipe of release bearing 52-Right case sub-assembly 53-No. 1 stud of gearbox 54-No. 2 stud of gearbox
16
2. Gear Transmission Line
Gear 1: Input shaft----gear 1 drive gear of input shaft---gear 1 transmission gear of intermediate
shaft---low-speed synchronizer---intermediate shaft---normally engaged drive gear of intermediate
shaft---differential output
shaft---low-speed synchronizer---intermediate shaft---normally engaged drive gear of intermediate
shaft---high-speed synchronizer---intermediate shaft---normally engaged drive gear of intermediate
shaft---high-speed synchronizer---intermediate shaft---normally engaged drive gear of intermediate
shaft---5-speed synchronizer---intermediate shaft---normally engaged drive gear of intermediate
Reverse gear: Input shaft----drive gear for reverse gear of input shaft---Idle gear for reverse
gear---transmission gear for reverse gear of intermediate shaft (toothed sleeve of low-speed
synchronizer) ---intermediate shaft---normally engaged drive gear of intermediate shaft---differential
output
3. Principle for Gear Shifting
When the complete vehicle is moving forward, the principle for gear shifting of gearbox is as follows: the
gear shifting for speed increase shall be conducted step by step from gear 1 to gear 5; the gear shifting
for speed decrease shall be conducted step by step from gear 5 to gear 1; but shifting into reverse gear
under condition of moving forward is forbidden. To avoid misoperation during gear shifting, the gearbox
is set with locking device which can prevent the gear shifting from gear 5 to reverse gear.
In principle, it is required to shift into reverse gear under condition that the complete vehicle is stationary
and it is forbidden to do so under condition of moving forward; further more, shifting to forward gear
under condition of reverse is also forbidden.
17
V. Gear Oil of Manual Transmission
1. Replacement of Gear Oil of Manual Transmission
1) Discharge
Fig. 1.2.001
① Dismantle the oil drain plug to discharge the
gear oil.
■ Tightening torque: 10~17 N•m
② Check the surface of oil drain plug for iron
chips. If any, remove them in time.
2) Filling
① Dismantle the filling plug to fill new gear oil
until the oil level approaches to the specified
limit which is close to the installation hole.
② Model and filling volume of gear oil: API GL-4
SAE 75W/90
Filling volume: 2.0 L
③ After completion of filling, check the oil level. Fig. 1.2.002

④ Tighten the filling plug.
2. Check of Gear Oil of Manual Transmission

Fig. 1.2.003
■ Confirm there is no gear oil leakage at and
around the manual transmission.
① Dismantle the filling plug.
Check the oil level through the installation hole of
filling plug, as shown in Fig. 1.2.002 and Fig.
1.2.003.
② Tighten the filling plug.
Attention:
■ When checking the oil level, don’t start the
engine.
18
VI. Oil Seal
1) Dismantlement
① Discharge the gear oil of gearbox. Please refer to “Gear Oil of Manual Transmission”.
② Dismantle the front drive shaft from drive axle. Fig. 1.2.004
Please refer to “Front Drive Shaft”.
③ Use slotted screw driver to dismantle the

differential side oil seal.
Attention:
■ Don’t bruise the differential casing.
2) Installation
① Mount the differential side oil seal onto the clutch casing and gearbox casing with special tools.
Attention:
■ Coat a proper quantity of grease on the lip of new oil seal.
② Install all dismounted spare parts in the reverse order with dismantlement.
③ Fill the gear oil of manual transmission and check the oil level. Please refer to “Check of Gear Oil of
Manual Transmission”.
3) Check the drive shaft for flexibility after installation.
19
VII. Gear Shift Control Device
1. Element
1
2
Diagram for Gear Shift Control Device
1-Gear shift wiredrawing 2-Gear shift control device 3-Gear shift handle
1) Dismantlement
① Dismantle the storage battery. Please refer to “Storage Battery”.
② Dismantle the air filter assembly. Please refer to “Air Filter Assembly”.
③ Set the gear shift handle at neutral position.
④ Dismantle the gear shift handle.
⑤ Dismantle the rear section of auxiliary facia console. Please refer to “Auxiliary Facia Console”.
20
⑥ Dismount the gear shift wiredrawing and Fig. 1.2.005

spring bearing (inner and outer).
Please refer to Fig. 1.2.005-Fig. 1.2.008.
Fig. 1.2.006
Fig. 1.2.007
Fig. 1.2.008
21
⑦ Dismantle the fixed bolt of gear shift

Fig. 1.2.009
wiredrawing on the side of engine
compartment plate.
■ Tightening torque: 20~30Nym
⑧ Dismantle the fixed bolt of gear shift control

Fig. 1.2.010
device.
⑨ Dismount the gear shift control device

assembly out of the vehicle.
2) Installation Fig. 1.2.011
Pay attention to the following points and install in

the reverse order with dismantlement.
■ Mount the gear select wiredrawing and gear

shift wiredrawing correctly.
■ Pay attention to the installation direction of Fig. 1.2.012

spring bearing.
■ When the gear shift handle is set at the side of

gear 1-gear 2 or at the side of gear 5-reverse
gear, confirm that the gear shift handle can be
shifted to neutral position smoothly.
■ When the gear shift handle is shifted to each

gear, ensure that the gear shifting is smooth.
22
VIII. Manual Transmission Assembly
1) Dismantlement
① Cut off the negative connection of storage battery.
② Dismantle the storage battery and its support. Fig. 1.2.013

Please refer to “Storage Battery”.
③ Dismantle the air filter assembly. Please refer to

“Air Filter Assembly”.
④ Drain the hydraulic oil in the clutch and cut off

the oil pipe of clutch from the quick joint of
hydraulic release bearing of clutch. Please refer
to “Clutch Pipeline”.
Attention:
■ During dismantlement, don’t press on the clutch pedal.
⑤ Cut off the wire harness connectors of speed sensor, reversing lamp switch and crankshaft position
sensor form the gearbox.
⑥ Dismantle the crankshaft position sensor. Please refer to “Crankshaft Position Sensor”.
■ Tightening torque: 8~12 Nym
⑦ Dismantle the oil pipe clip of clutch from the support rack of left mounting of manual transmission to
cut off the oil pipe of master cylinder of clutch.
⑧ Cut off the gear shift wiredrawing of gearbox. Please refer to “Gear Shift Control Device”.
⑨ Mount the lifting frame on the hook of engine.
⑩ Dismantle the starter. Please refer to “Starter”.

⑪ Discharge the gear oil. Please refer to “Replacement of Gear Oil of Manual Transmission”.
⑫ Dismantle the front drive shaft. Please refer to “Drive Shaft”.
Attention:
■ After dismantling the front drive shaft, please put a suitable plug in the side oil seal.
⑬ Dismantle the deflector of engine.

⑭ Dismantle the engine support beam. Please refer to “Engine Support Beam”.
23
⑮ Dismantle the lower supporting rack and lower division plate of gearbox.
■ Tightening torque: M6 5~6 N•m
M8 12~15 N•m
⑯ Dismantle the support rack of left mounting of gearbox.

⑰ Use jack to lift the gearbox assembly and dismantle the fixed bolt between gearbox and engine.
⑱ Dismount the gearbox assembly from the vehicle.
2) Installation
Pay attention to the following points and install in the reverse order with dismantlement.
■ When mounting the gearbox assembly onto the engine, pre-tighten the fixed bolts at first, and then
tighten them complying with the following standard.
Tightening direction: 1: gearbox sidetengine side (1, 3, 5, 6, 7)
2: engine sidetgearbox side (2, 4)
Tightening torque: 1 50~70 Nym Fig. 1.2.014

3 1
2 50~70 Nym 5
3 50~70 Nym
7
6
4 50~70 Nym
4
5 50~70 Nym
2
6 50~70 Nym
7 50~70 Nym
■ Fill hydraulic oil of clutch and discharge the air in the pipeline of hydraulic system of clutch. Please
refer to “Clutch Pipeline”.
■ After installation, check the gear oil level of manual transmission, then check for the gear oil leakage
of gearbox and check the mechanical installation for looseness. Please refer to “Check of Gear Oil
of Manual Transmission”.
24
2. Disassembly and Assemblage
1) Disassembly
① Dismantle the oil drain plug to discharge the gear oil. Please refer to “Replacement of Gear Oil of
Manual Transmission”.
② Dismantle the filling plug. Fig. 1.2.015
③ Cut off the oil pipe of clutch from the clutch

Fig. 1.2.016
casing, and dismantle the hydraulic release
bearing.
④ Dismantle the speed sensor and reversing

lamp switch from the gearbox.
⑤ Dismantle the support of shift wiredrawing. Fig. 1.2.017
⑥ Dismantle the rear casing and the baffle plate

Fig. 1.2.018
of reversing lamp switch.
Attention:
■ As the oil delivery groove crosses the input

shaft, it shall be dismantled toward the axial
direction of input shaft.
25
⑦ Dismantle the locknut of intermediate shaft. Fig. 1.2.019

Attention:
■ When dismantling the locknut, don’t use any

pneumatic tool to prevent the gear from
damage.
⑧ Dismantle the gear 5 shifting fork bolt. Fig. 1.2.020
⑨ Dismount the gear 5 synchronizer and gear 5 Fig. 1.2.021

shifting fork.
⑩ Dismantle the nut of input shaft and use Fig. 1.2.022

calipers to dismount the outer circlip of rear
bearing of intermediate shaft.
26
⑪ Take off the gear 5 gear of intermediate shaft Fig. 1.2.023

and input shaft.
⑫ Dismantle the screw of interlocking plate to Fig. 1.2.024

take off the interlocking plate.
⑬ Dismantle the screw of bearing pressure Fig. 1.2.025

plate.
⑭ Take off the bearing pressure plate. Fig. 1.2.026
27
⑮ Dismantle the circlip of left bearing of Fig. 1.2.027

intermediate shaft.
⑯ Dismantle the circlip of left bearing of input Fig. 1.2.028

shaft.
⑰ Dismantle the bolt of gear shaft for reverse Fig. 1.2.029

gear and the gear limit bolt. Bolt of gear shaft for reverse
gear
Gear limit bolt
⑱ Dismantle the shift control sub-assembly. Fig. 1.2.030
28
⑲ Dismantle the fixed bolt of clutch casing. Fig. 1.2.031
⑳ Take off the gearbox casing. Fig. 1.2.032
Dismantle the fixed bolt of shifting fork for Fig. 1.2.033
reverse gear.
Fig. 1.2.034
Take off the shifting fork for reverse gear.
29
Take off the gear shaft and gear for reverse Fig. 1.2.035
gear.
Take off the intermediate shaft sub-assembly

and the input shaft sub-assembly.
Attention:
■ Take off the intermediate shaft sub-assembly

and input shaft sub-assembly, together with
shifting fork assembly for gear 1 and 2, gear
lever for gear 5 and reverse gear as well as
shifting fork for gear 3 and 4.
Fig. 1.2.036
Take off the differential sub-assembly from the
clutch casing.
Fig. 1.2.037
Dismantle the differential side oil seals on the
clutch casing and gearbox casing with slotted
screw driver.
Attention:
■ Don’t bruise the gearbox casing and clutch

casing.
Fig. 1.2.038
Dismantle the differential bearing outer rings
from the clutch casing and gearbox casing
with copper bar.
Attention:
■ Don’t bruise the clutch casing and gearbox

casing.
30
z Dismantle the oil delivery groove from the Fig. 1.2.039

gearbox casing.
2) Assemblage
① Mount the oil deliver groove on gearbox casing.
② Mount the differential side bearing outer ring with punch until it is level with the end faces of clutch
casing and gearbox casing.
③ Mount the differential side oil seals onto the clutch casing and gearbox casing according to the
following steps.
a. Coat gear oil of gearbox on the lip of new oil

Fig. 1.2.040
seal.
b. Mount the oil seal with punch. Fig. 1.2.041
JAC-T3B002
31
④ Mount the differential sub-assembly onto the Fig. 1.2.042

clutch casing.
⑤ Mount the sub-assemblies of input shaft,

Fig. 1.2.043
intermediate shaft and gear shifting fork.
Attention:
■ The shifting fork must be clamped in the

groove of synchronizer toothed sleeve.
■ The two gear levers must be fitted into their

corresponding holes.
■ Don’t scratch the input shaft oil seal when Fig. 1.2.044
assembling the input shaft sub-assembly.
⑥ Mount the gear and gear shaft for reverse

Fig. 1.2.045
gear.
32
⑦ Mount the gear shifting fork for reverse gear.

Fig. 1.2.046
⑧ Mount the gearbox casing onto the clutch

Fig. 1.2.047
casing.
Attention:
■ The sealant must be coated evenly and there

shouldn’t be any adhesive failure or
breakdown.
■ The installation must be conducted within 15

min after coating of sealant.
⑨ Mount the gear shaft bolt for reverse gear.

Fig. 1.2.048
⑩ Mount the self-locking mechanism of gearbox. Fig. 1.2.049

Note: The assemblage order is steel ball, spring
and bolt.
Attention:
■ Don’t reuse damaged spare parts.
33
⑪ Mount the gear shift control device. Fig. 1.2.050

Attention:
■ Pay attention to the installation direction.
⑫ Mount the interlocking bolt for gear 5 and Fig. 1.2.051

reverse gear and the limit bolt for gear shifting.
⑬ Mount the circlips of left bearings of input shaft

and intermediate shaft.
⑭ Mount the bearing pressure plate.

Fig. 1.2.052
⑮ Mount the interlocking pressure plate bolt. Fig. 1.2.053
34
⑯ Mount the interlocking pin and interlocking

pressure plate. Fig. 1.2.054
Fig. 1.2.055
⑰ Mount the gear 5 gear. Fig. 1.2.056
Attention:
■ When mounting the gear 5 gear of input shaft,

make the side with circular slot mark
downwards.
⑱ Mount the input shaft nut. Fig. 1.2.057
Attention:
■ Don’t reuse the spare parts that can’t be used

any more.
35
⑲ Mount the gear 5 gear needle and gear of Fig. 1.2.058

intermediate shaft.
⑳ Mount the baffle plate of gear 5 synchronizer Fig. 1.2.059

slider assembly.
Mount the intermediate shaft nut. Fig. 1.2.060
Attention:
■ Don’t reuse the spare parts that can’t be used

any more.
Fig. 1.2.061
Mount the gear 5 shifting fork bolt.
36
Mount the rear casing onto the gearbox Fig. 1.2.062
casing.
Attention:
■ The installation must be conducted within 15

min after coating of sealant.
For the remaining steps, assemble in the

reverse order with disassembly.
37
IX. Gearbox Casing (Left Case)
Disassembly Diagram for Gearbox Casing
1-Left bearing outer ring of differential 2-Oil delivery groove assembly bolt of gearbox casing cover 3-Oil
delivery groove assembly of gearbox casing cover 4-Oil delivery groove bolt 5-Oil delivery groove
assembly 6-Adjusting gasket of differential 7-Oil inlet plug screw 8-Differential oil seal 9-Gearbox
casing
38
1. Adjustment of Axial Clearance of Differential

Casing Fig. 1.2.063 Soldering tin
Attention:
■ Select an adjusting gasket to adjust the axial

clearance of differential casing.
1) Place suitable soldering tin on the gearbox

casing (the specific position is as shown in the
figure), and then mount the differential.
2) Mount the clutch casing and tighten the bolt to

the specified torque.
3) If the soldering tin is not flattened, use thicker soldering tin to repeat the steps 1) and 2).
4) Measure the thickness (T) of the flattened

soldering tin with micrometer and select the Fig. 1.2.064
adjusting gasket based on the following
formula.
Thickness of gasket:
(T-0.05 mm) to (T-0. 17 mm)
39
X. Clutch Casing (Right Case)
Disassembly Diagram for Clutch Casing
1-Bleeding plug screw 2-Right bearing outer ring of differential 3-Differential oil seal 4-Right bearing
outer ring of intermediate shaft 5-Oil deflector of intermediate shaft 6-Speed sensor assembly
7-Speed sensor bolt 8-Mounting bolt of release bearing 9-Hydraulic release bearing 10-Clutch
casing
40
Fig. 1.2.065
Essentials of Dismantlement and Installation:
1. Right Bearing of Intermediate Shaft
1) Installation Fig. 1.2.066 JAC-T3B005
Press in the bearing vertically.
Attention:
■ Make the side with model countermark

upwards.
2. Hydraulic Release Bearing (Input Shaft Oil Fig. 1.2.067

Seal)
1) Dismantlement
① Dismantle the hydraulic release bearing from

the clutch casing.
② Dismantle the input shaft oil seal with punch. Fig. 1.2.068
41
2) Installation
Fig. 1.2.069
① Fix the hydraulic release bearing casing.
② Mount the input shaft oil seal with special

punch.
3. Speed Sensor
Fig. 1.2.070
1-Speed gear 2-Speed sensor 3-O-ring
1) Dismantlement
Fig. 1.2.071
① Dismantle the fixed bolt of speed sensor.
② Take off the sensor.
2) Check After Dismantlement
■ Check the O-ring for aging and elastic

deformation.
3) Installation
Pay attention to the following steps and install in

the reverse order.
■ Coat the O-ring with gear oil of gearbox.
42
XI. Input Shaft and Gear
1. Element
Disassembly Diagram for Input Shaft and Gear
1-Left bearing of input shaft 2-Gear adjusting gasket for gear 4 of input shaft 3-Gear 4 gear assembly
of input shaft 4-Gear needle bearing for gear 4 of input shaft 5-Gear shaft sleeve for gear 4 of input
shaft 6-Ring gear of high-speed synchronizer 7-High-speed synchronizer sub-assembly
8-High-speed synchronizer slider assembly 9-Gear 3 gear assembly of input shaft 10-Gear needle
bearing for gear 3 of input shaft 11-Input shaft 12-Right bearing of input shaft
2. Disassembly and Installation Fig. 1.2.072

JAC-T1B001
1) Disassembly
Note: The disassembly shall be conducted on the

hydraulic bench.
① Dismantle the right bearing of input shaft.
Mount the special tools onto the right bearing of

input shaft.
43
② Dismantle the left bearing and gear adjusting Fig. 1.2.073

gasket for gear 4. Mount the special tools onto
the gear 4 gear.
JAC-T1B002
③ Take off the gear 4 gear assembly. Fig. 1.2.074
④ Take off the gear 4 needle bearing. Fig. 1.2.075
⑤ Take off the ring gear of high-speed

Fig. 1.2.076
synchronizer at the side of gear 4 gear.
44
⑥ Dismantle the gear shaft sleeve for gear 4.

Fig. 1.2.077
JAC-T1B001
Mount the special tools onto the gear 3 gear.
⑦ Take off the gear shaft sleeve for gear 4.

Fig. 1.2.078
⑧ Take off the high-speed synchronizer Fig. 1.2.079

sub-assembly at the side of gear 3 gear.
⑨ Take off the gear 3 gear assembly. Fig. 1.2.080
45
⑩ Take off the gear 3 needle bearing. Fig. 1.2.081
2) Check After Disassembly Fig. 1.2.082

① Input Shaft and Gear
Check the following items. If necessary, please

replace the spare parts with trouble.
■ Check the input shaft for damage, peeling,

dent, uneven wear, bending and other
abnormalities.
■ Check the gear for excess wear, damage, Fig. 1.2.083

peeling and other abnormalities.
② Synchronizer Fig. 1.2.084

■ Check the contact surface of the ring gear and

sub-assembly for damage and excess wear.
■ Check whether the rotation between the ring

gear and sub-assembly is smooth.
46
■ If the convex side of the ring gear or the Fig. 1.2.085

inserted working side is with crack, damage or
excess wear, please replace it.
■ Check the clearance between the upper ring

gear and gear of synchronizer.
Have the synchronizer ring gear cling to the

matching conical surface of gear. Check the
clearance between the conjoint tooth of gear and
the end face of ring gear. If the clearance reaches
or exceeds the limit, it is essential to replace the
spare parts.
Standard value: 0. 8~1.2 mm
Limit value: 0.5 mm
③ Bearing
Fig. 1.2.086
■ Check the bearing for damage or poor

rotation.
3) Assemblage Fig. 1.2.087

Attention:
■ Coat all spare parts with gear oil of gearbox.
① Assemble the high-speed synchronizer

sub-assembly in advance.
47
Attention:
Fig. 1.2.088
■ Installation direction of high-speed A
synchronizer hub
A: at the side of gear 4 gear
B: at the side of gear 3 gear
■ Installation direction of high-speed

Fig. 1.2.089
synchronizer sleeve
② Mount the gear 3 needle bearing.

Fig. 1.2.090
③ Mount the gear 3 gear assembly.

Fig. 1.2.091
48
④ Mount the high-speed synchronizer

Fig. 1.2.092
sub-assembly.
⑤ Mount the ring gear of high-speed

Fig. 1.2.093
synchronizer at the side of gear 4 gear.
⑥ Mount the gear shaft sleeve for gear 4. Fig. 1.2.094

JAC-T1B005
JAC-T1B006
JAC-T1B009
⑦ Mount the gear 4 gear assembly. Fig. 1.2.095
49
⑧ Mount the gear 4 needle bearing.

Fig. 1.2.096
⑨ Mount the gear adjusting gasket for gear 4.

Fig. 1.2.097
⑩ Mount the left bearing of input shaft. Fig. 1.2.098

JAC-T1B005
JAC-T1B006
JAC-T1B009
⑪ Mount the right bearing of input shaft. Fig. 1.2.099

JAC-T1B005
JAC-T1B006
JAC-T1B008
50
XII. Intermediate Shaft
1. Element
Disassembly Diagram for Intermediate Shaft
1-Gear shaft sleeve for gear 5 of intermediate shaft 2-Gear washer for gear 5 of intermediate shaft
3-Left bearing of intermediate shaft 4-Gear 4 gear of intermediate shaft 5-Gear spacer for gear 3 and
4 of intermediate shaft 6-Gear 3 gear of intermediate shaft 7-Gear 2 gear assembly of intermediate
shaft 8-Gear needle bearing for gear 2 of intermediate shaft 9-Gear shaft sleeve for gear 2 of
intermediate shaft 10-Ring gear sub-assembly of gear 2 synchronizer 11-Low-speed synchronizer
sub-assembly 12-Low-speed synchronizer slider assembly 13-Ring gear sub-assembly of gear 1
synchronizer 14-Gear 1 gear of intermediate shaft 15-Gear needle bearing for gear 1 of intermediate
shaft 16-Gear shaft sleeve for gear 1 of intermediate shaft 17-Intermediate shaft 18-Right bearing
inner ring of intermediate shaft 19-Right bearing shield ring of intermediate shaft
2. Disassembly and Assemblage Fig. 1.2.100

JAC-T1B001
1) Disassembly
Note: Conduct disassembly on the hydraulic

bench.
① Dismantle the gear shaft sleeve for gear 5,

gear washer for gear 5, left bearing and gear 4
gear.
51
② Take off the gear 3 gear. Fig. 1.2.101
③ Take off the gear spacer for gear 3 and 4.

Fig. 1.2.102
④ Take off the gear 2 gear assembly and ring

Fig. 1.2.103
gear sub-assembly of gear 2 synchronizer.
⑤ Take off the gear 2 needle bearing. Fig. 1.2.104
52
⑥ Dismantle the gear shaft sleeve for gear 2,

Fig. 1.2.105
ring gear sub-assembly of gear 1 synchronizer
JAC-T1B002
and gear 1 gear assembly.
⑦ Take off the gear 1 needle bearing.

Fig. 1.2.106
⑧ Dismantle the gear shaft sleeve for gear 1. Fig. 1.2.107

Mount the special tools onto the gear shaft sleeve
for gear 1.
JAC-T1B001
⑨ Dismantle the circlip with outside caliper and Fig. 1.2.108

take off the right bearing shield ring of
intermediate shaft and the right bearing.
53
2) Check After Disassembly
① Intermediate Shaft and Gear
Check the following items. If necessary, please replace the spare parts with trouble.
■ Check the intermediate shaft for damage, Fig. 1.2.109

peeling, dent, uneven wear, bending and other
abnormalities.
■ Check the gear for excess wear, damage,

Fig. 1.2.110
peeling and other abnormalities.
② Synchronizer
Fig. 1.2.111
■ Check the contact surface of the ring gear and

sub-assembly for damage and excess wear.
■ Check whether the rotation between the ring

gear and sub-assembly is smooth.
54
■ If the convex side of the ring gear or the Fig. 1.2.112

inserted working side is with crack, damage or
excess wear, please replace it.
■ Check the clearance between the upper ring gear and gear of synchronizer.
Have the synchronizer ring gear cling to the matching conical surface of gear. Check the clearance
between the conjoint tooth of gear and the end face of ring gear. If the clearance reaches or exceeds the
limit, it is essential to replace the spare parts.
Standard value: 0. 8~1.2 mm
Limit value: 0.5 mm
③ Bearing
Check the following items. If necessary, please replace the spare parts with trouble.
■ Check the bearing for damage or poor Fig. 1.2.113

rotation.
3) Assemblage
Attention:
■ Coat the junction surface of each spare part with gear oil of gearbox before assemblage.
① Assemble the low-speed synchronizer sub-assembly
55
a. Mount the synchronizer hub onto the Fig. 1.2.114

synchronizer sleeve.
Attention: Fig. 1.2.115

■ Installation direction of low-speed
synchronizer hub
■ Installation direction of low-speed Fig. 1.2.116

synchronizer sleeve
b. Mount the slider assembly onto the Fig. 1.2.117

synchronizer sub-assembly.
56
② Assemble the gear 1 gear and ring gear Fig. 1.2.118

sub-assembly of gear 1 synchronizer.
a. Mount the upper ring gear.
b. Mount the elastic ring.

Fig. 1.2.119
Attention:
■ The elastic ring must be mounted completely.
c Mount the lower ring gear. Fig. 1.2.120

■ Pay attention to the installation position.
③ Assemble the low-speed synchronizer Fig. 1.2.121

sub-assembly and gear 1 gear assembly.
④ Mount the gear 1 gear spacer.
57
⑤ Mount the gear 1 gear assembly and low-speed synchronizer sub-assembly.
⑥ Mount the right bearing and its shield ring.

Fig. 1.2.122
⑦ Mount the gear 2 gear spacer. Fig. 1.2.123

JAC-T1B005
JAC-T1B007
JAC-T1B0011
⑧ Mount the gear 2 needle bearing. Fig. 1.2.124
⑨ Mount the gear 2 synchronizer sub-assembly Fig. 1.2.125

and gear 2 gear assembly.
58
⑩ Mount the gear 3 gear. Fig. 1.2.126
⑪ Mount the gear spacer for gear 3 and 4.

Fig. 1.2.127
⑫ Mount the gear 4 gear. Fig. 1.2.128
⑬ Mount the left bearing of intermediate shaft.

Fig. 1.2.129
JAC-T1B005
JAC-T1B006
JAC-T1B008
59
XIII. Differential
1. Element
Diassembly Diagram for Differential
1-Shield ring of planetary gear shaft 2-Planetary gear 3-Half shaft of differential 4-Planetary gear
shaft 5-Right inner ring of differential bearing 6-Induction ring gear 7-Differential bolt 8-Differential
casing 9-Differential casing pad 10-Main reduction gear 11-Left inner ring of differential bearing
60
1) Disassembly Fig. 1.2.130

① Dismantle the differential side bearing with JAC-T1B001
punch and suitable puller.
② Dismantle the shield ring on the differential

casing with snap ring pliers.
③ Dismantle the planetary gear and half shaft of

Fig. 1.2.131
differential on the differential casing.
Note: Rotate the planetary gear for dismantlement.
④ Dismantle the differential bolt in the reverse Fig. 1.2.132

order of that as shown in the figure, and cut off
the differential casing and main reduction
gear.
① Planetary Gear, Pad, Half Shaft of Differential, Induction Ring Gear and Casing
Check the planetary gear, pad, half shaft of differential, induction ring gear and casing. If necessary,
61
② Bearing
Fig. 1.2.134
Check the bearing for damage and poor rotation. If
necessary, please replace the spare parts with
trouble.
Attention:
■ When replacing bearing, replace complete

sets of left and right inner rings of bearing.

Pay attention to the following points and assemble
Bearing
in the reverse order with disassembly.
■ Ensure the shield ring is mounted in the slot

correctly.
■ Mount the differential side bearing with punch.
■ Coat the differential bolt with sealant. Fig. 1.2.136
62
XIV. Shift Control Sub-assembly
Disassembly Diagram for Shift Control Sub-assembly
1-Selector rod 2-Clamping band 3-Control casing 4-Bolt 5-Shift stopper 6-Return spring seat
7-Return spring 8-Interlocking plate 9-Control shaft 10-Control shaft head 11-Lock pin 12-Gear
lever 13-Oil seal of control shaft 14-Spring pin 15-Needle bearing
Essentials of Disassembly:
1. Lock Pin
1) Dismantlement
Knock out the lock pin with special tool Fig. 1.2.137
JAC-T3B003 towards the direction as shown in the
Lock pin
figure.
Control head
Knock-out
direction
63
2) Installation Fig. 1.2.138 Press-in direction
Press in the lock pin from the direction as shown in

the figure.
2. Needle Bearing
Fig. 1.2.139
1) Installation Control casing
Needle
Press in the needle bearing to the position as bearing
shown in the figure to make the model

Position of model
countermark towards the direction as shown in the countermark
figure.
3. Oil Seal of Control Shaft Fig. 1.2.140

1) Installation
Note: Coat the oil seal lip with gear oil of gearbox.
Install it with special tool JAC-T3B001.
4. Spring Pin Shifting fork Fig. 1.2.141

Guide rail
1) Installation
Please install it with special tool JAC-T3B003

according to the directions as shown in the figure. Press-in direction
Opening
Spring pin
64
XV. Gear Shifting Control Sub-assembly
Disassembly Diagram for Gear Shifting Control Sub-assembly
1-Shifting fork for gear 5 2-Shifting fork for gear 3 and 4 3-Shifting fork for gear 1 and 2 4-Shifting
fork for reverse gear 5-Shifting fork shaft for gear 1 and 2 6-Shifting fork shaft for gear 3 and 4
1. Check: Fig. 1.2.142

Check the contact surface and sliding surface of
shifting fork shaft for wear, damage and bending. If
necessary, please replace it.
65
XVI. Reversing Lamp Switch
1. Element Position Fig. 1.2.143
2. Check
Check the continuity between the ports.
Check Table for Reversing Lamp Switch
Gear Continuity
Reverse gear Yes
Except the reverse gear No
XVII. Maintenance Parameters
Table of Tightening Torque
No. Name Qty. Tightening Torque (N • m)

1 Lock bolt for gear 5 and reverse gear 1 10~16
2 Lock bolt for gear 1 and 2 1 10~16
3 Gear shifting fork bolt for reverse gear 1 18~28
4 Gear shifting fork bolt for gear 5 1 8~10
5 Mounting bolt of speed sensor 1 5~7
6 Gear shaft bolt for reverse gear 1 18~28
7 Bearing pressure plate bolt 7 8~12
8 Nuts of intermediate shaft and input shaft 2 80~100
9 Gearbox casing bolt 16 18~28
10 Reversing lamp switch assembly 1 15~20
11 Oil fill plug screw 1 10~17
12 Bleeding plug screw 1 10~17
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13 Shift control casing bolt 4 8~12

14 Clutch casing bolt 6 8~12
15 Baffle plate bolt of reversing lamp 2 8~12
16 Lock bolt for gear 3 and 4 1 15~20
Mounting bolt of release bearing M6 X 1.0 X
17 3 7~10
20
18 Mounting bolt of cable support 2 19~25
19 Stop bolt for gear shifting 1 10~16
20 Interlocking bolt for gear 5 and reverse gear 1 10~16
2. Transmission Ratio
Table of Transmission Ratio of Each Gear
Max.
Speed Ratio of Each Gear Gear Main
Type of Input
Ratio of Reduction
Gearbox Torque Reverse
Gear 1 Gear 2 Gear 3 Gear 4 Gear 5 Odometer Ratio
(N.m) gear
MF514A02 160 3.583 2.043 1.412 1.105 0.881 3.615 26 4.250
MF514D02 160 3.583 2.043 1.412 1.105 0.881 3.615 26 4.059
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Chapter II Traveling System
Section I Power Steering System

I. Precautions
1. The vehicle shall be at level and dry ground when checking its steering system.
2. The bolts of the steering system elements shall be tightened according to the specified torque.
3. The wheel location shall be checked after the check of steering gear and other steering mechanisms
is finished.
4. The following points shall be paid attention to during the steering gear disassembly:
1) The device outside shall be cleaned completely before disassembly.
2) The disassembly shall be carried out in the clean work area, in order to avoid the inner spare parts
being polluted by dust and other foreign matters.
3) Please put the disassembled spare parts on the parts shelf in order, to make the assembly much
easier and more correct.
4) The nylon cloth is recommended to be used for cleaning the spare parts, for the rag dust remaining
on the ordinary rag used in workshop will affect the operation of spare parts.
5) Please don’t use the disposable spare parts.
6) Please lubricate the specified spare parts with lubricating grease before assemblage.
68
II. Preparation
1. Special Tools
Steering For dismantling the

1 wheel JAC-T1D002 steering wheel
puller
2. General Tools
Table of General Tools
No. Tool Outline Diagram Illustration
For dismantling and mounting

Power
1 the bolts and nuts
tool
Trimming For dismantling the trimming

2 plate cover of steering column
detacher
69

Trouble Possible Cause Troubleshooting
The driving belt is loose or worn Check the driving belt
Check if the hydraulic oil pipe is damaged
The hydraulic oil pipe is blocked and blocked, or if its direction is wrong,
replace the oil pipe assembly if necessary
The steering fluid becomes smudgy Clean the whole steering system
Hard or excessively There is air mixing in the oil circuit Exhaust air in the system
easy steering The suspension ball joint is
Check the element of suspension ball joint
deadlocked
The steering gear is damaged Replace the steering gear
The steering column is damaged Check the steering connecting element
The power steering pump is
Replace the power steering pump
damaged
The ball joint of tie rod is damaged Replace the tie rod if necessary
The suspension ball joint is
Check the element of suspension ball joint
damaged
The dustproof boot for steering Check the element, and replace it if
gear is damaged necessary
Insensitive steering
The fixed bolt of steering gear is Check and replace it with a new fixed bolt if
(when rotating the
loose necessary
steering wheel, the
The fixed bolt of steering column is Check and replace it with a new fixed bolt if
direction is not
loose necessary
changed)
The fastening bolt connecting the
Check and replace it with a new fastening
steering column and steering
bolt if necessary
mechanism pinion is loose
The steering gear clearance is too
Replace the steering gear
large
IV. Power Steering Fluid

Fig. 2.1.001
1. Check of the Fluid Level
1) Check the fluid level when the engine is shut
off. MAX
2) Make sure the level is between MIN and MAX. MIN
Attention:
■ The level shall not exceed the maximum value
(MAX line), in order to avoid the leakage of the
power steering fluid.
Recommended oil: PSF3
3) Please don’t reuse the discharged power
steering fluid.
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2. Check of the Leakage of Steering Fluid
1) Check if the hydraulic joint has oil leakage, Fig. 2.1.002

crack, damage, looseness, and wear.
① Operate the engine to make the liquid
temperature of the stock solution tank reach Rupture of Oil pipe nut
the hose
50 ~ 80 ℃ (122 ~ 176 ℉), and keep the
engine operating at idle speed. Hose clamp
② Turn the steering wheel to the left and right

Rupture of the oil
limits for several times. pipe Eyebolt
③ Keep the steering wheel at the position of locked point for 5s, and check if there is oil leakage
meanwhile.
④ If the oil leakage is found at the joint, please unscrew the oil pipe nut and then retighten it to the
specified torque.
Attention:
■ Please don’t tighten the joint nut excessively, to avoid the damage of O-ring, gasket and joint.
⑤ If there is oil leaking from the power steering pump, please check the power steering pump. Refer to
“Power Steering Pump” please.
⑥ Check if there is oil aggregating on the dustproof boot of steering gear.
3. Air Exhaust of the Hydraulic System
If the air is not exhausted completely, the following symptoms will appear -
■ There is air bubble in the stock solution tank.
■ There is abnormal sound in the power steering pump.
Note: There will be liquid noise during the power steering pump operation, which will not influence the
performance or durability of the system.
1) Shut off the engine, and turn the steering wheel to the left and right limits for several times.
Attention:
■ When filling the stock solution tank with oil, rotate the steering wheel to make the level not lower
than the MIN line.
2) Start the engine and make it operate at idle-speed, meanwhile keep the steering wheel staying at
the locked position for 3s, and check if there is oil leakage
3) Repeat the step 2 for several times every 3s.
Attention:
■ Please don’t keep the steering wheel staying at the locked point for more than 10s, to avoid
damaging the power steering pump.
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4) Check if there is air bubble or white impurity in the oil.
5) If the air bubble or white impurity has not been exhausted completely, please shut off the engine.
When the air bubble or white impurity has been exhausted completely, then please carry out the
step 2) and step 3).
6) Shut off the engine, and check the oil level.
Attention:
■ Check if the oil level of the stock solution tank varies within 5 mm when the engine is in operation
and stop status.
■ If the variation is not in the range, the system shall be exhausted repeatedly.
4. Replacement of Power Steering Fluid
1) Lift the front wheels, and fix them with rigid support.
2) Dismantle the oil return pipe from the stock solution tank, and block the return opening of the stock
solution tank.
3) Connect the oil return pipe with general oil pipe, and discharge the power steering fluid into the
container.
4) Start the engine, turn the steering wheel to the left and right, and discharge the power steering fluid.
Attention:
■ The power steering fluid shall be added timely to keep the fluid level between MIN and MAX all the
while, which can avoid the dry grinding of the power steering pump.
■ The operating time of the engine should not be too long, when the fluid level is down to MIN position,
the engine should be shut off.
5) Connect the oil return pipe, and then add new power steering fluid to the standard position.
6) If the quality of the replaced power steering fluid does not meet the ideal requirement, it can be
achieved according to the step 2) ~ step 5).
Attention:
■ The air in the system shall be exhausted after replacement. Please refer to “Air Exhaust of the
Hydraulic System”.
V. Steering Wheel
1. On-vehicle Check
1) Check the installations
① Check the installations of steering gear assembly, front suspension, axle and steering column.
② Check if there is moving clearance during the up-and-down, left-and-right, and axial movements of
the steering wheel.
③ Check if the fixed nut and bolt of steering gear assembly are loose.
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2) Check the free play of the steering wheel
① Rotate the steering wheel to make the front wheels straight forwards. Start the engine, and rotate
the steering wheel slightly until the front wheels begin to move. Measure the movement of the
steering wheel on the excircle.
■ The free play of steering wheel: 30 mm
② When the measured value exceeds the standard value, check the installations of each steering
column joint and steering gear. Make adjustment according to the situation or replace the relevant
spare parts.
③ If the free play is still a limited value, then make the steering wheel in the middle position with the
engine being shut off, and apply a force of 5 N to steering wheel circle, and check the free play.
■ Standard value: <15 mm
④ If the standard value is exceeded, the steering gear should be dismantled to check the total torque
of the pinion.
3) Check the middle position
① Make sure the steering gear assembly, steering column, and steering wheel are mounted correctly.
② Check the middle position after the wheel location. Please refer to “Check of the Front Wheel
Location”.
③ Park the vehicle straight forwards, and ensure the steering wheel is in middle position.
④ Unscrew the locknut of tie rod and turn the adjusting rod to the left and right slightly to ensure the
steering wheel is in middle position.
4) Check static steering force of the steering wheel
① Park the vehicle on the level and dry ground, and pull up the parking brake handle.
② Start the engine.
③ Keep the engine operating, and raise the temperature of power steering fluid to the operating
temperature.
Note: The tyre pressure value shall be within the standard value.
④ Turn the steering wheel 360° from the middle position, and check the steering force of steering
wheel to see if there is obvious fluctuation.
■ The steering force of steering wheel: <34N allowable fluctuation: <5.9N
⑤ If the steering force of steering wheel exceeds the specified value, please check or adjust the
following items:
a. Check if the ball joint of lower suspension arm and ball joint of steering tie rod are damaged.
b. Check or adjust the preloading of the steering gear and the rotational torque of the ball joint of
steering tie rod.
c. Check or adjust the rotational torque of the ball joint of lower suspension arm.
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5) Check the self-return of the steering wheel

Attention:
■ Make slow or sudden turns to see if there is difference in applied force and return in left and right
directions.
■ This step must be carried out on the safe road and in the safe traffic conditions, and safety must be
paid more attention to.
① Rotate the steering wheel 90°, and drive the

vehicle at 35 km/h for several seconds, and Fig. 2.1.003
then release the steering wheel, the return
shall reach more than 70% at least.
Attention:
■ When the steering wheel is rotated rapidly,
there will be sense of “heaviness” temporarily,
which is due to the deficiency of oil supply for
the power steering pump in idle period, it is not
the trouble.
6) Check the steering angle of the front wheel
① Check the steering angle of the front wheel after the front wheel toe-in check. Put the front wheel on
the radius gauge to check the maximum steering angle of the inner and outer wheels of the left &
right wheel.
■ Inner wheel: 38° 52' Outer wheel: 33° 07'
② Rotate the steering wheel to the left and right limits to measure the steering angle, when the engine
is at idle speed.
■ If the measured value is not in the standard range, the tie rod shall be adjusted.
The adjusting method of the steering angle is as follows:
■ Unscrew the locknut of the left & right tie rods, and rotate the left & right tie rods with spanner
separately adjusting the steering angle to standard value, and then screw down the locknut to the
specified tightening torque.
Attention:
■ The length of left & right tie rods shall keep the same during the length regulation.
■ Tightening torque: 50~55 N • m
7) Check the dust cover of ball joint
① Press the dust cover with finger to check if there is crack or damage.
② If the dust cover is cracked or damaged, the tie rod ball joint shall be replaced.
Attention:
■ When the dust cover is cracked or damaged, it may damage the ball joint.
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8) Check the rotational torque of the ball joint of the steering tie rod
① Swing the tie rod rapidly for 10 times.
② Measure the swinging resistance of the tie rod with spring balance.
■ Standard value: 2 ~ 5 Nym

Fig. 2.1.004
■ If the measured value is not within the
standard value, please replace it.
1) Dismantlement
① Cut off the negative battery terminal and keep
this state for more than 3 min.
② Dismantle the driver airbag module from the steering wheel.

Please refer to “Driver Airbag Module”.
③ Remove the fixed nut of steering wheel after the steering locking.
■ Tightening torque: 35 ~ 45 N-m

Fig. 2.1.005
④ Pull out the steering wheel from the steering
shaft.
Note: If it can not be pulled out easily, please use
the steering wheel puller.
2) Installation
Install in the reverse order with dismantlement.
Attention:
■ The installation must be carried out when the wheel is running straight forwards and the steering
wheel is in middle position. In addition, the steering wheel and fixed nut can be marked alternatively
before dismantlement, and the marks shall be corresponding during installation.
■ For the installation position of the clock spring (hairspring), please refer to “Clock Spring”.
■ Excessive torsion shall be avoided when the clock spring is tightened.
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VI. Steering Column

1. Element
Diagram for Steering Column Assembly

Attention:
■ Please don’t apply axial force excessively to the steering column assembly during dismantlement
and installation.
■ Please don’t move the steering gear when dismantling the steering column.
1) Dismantlement
① Park the vehicle straight forwards.
② Cut off the negative battery terminal, and keep this state for more than 3 min.
③ Dismantle the driver airbag module from the steering wheel. Please refer to “Driver Airbag Module”.
④ Dismantle the steering wheel. Please refer to “Steering Wheel”.
⑤ Dismantle the upper and lower protecting covers of steering column and the lower part of console at
driver’s side. Please refer to “Console Assembly”.
⑥ Dismantle the combined switch assembly and the clock spring from the steering column. Please
refer to “Clock Spring”.
⑦ Cut off each wire harness joint mounted onto the steering column, and then remove the wire
harness from the steering column.
⑧ Dismantle connecting bolt of steering column connecting shaft, and separate the steering column
and steering gear.
■ Tightening torque: 15 ~ 20 Nym Fig. 2.1.006
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⑨ Dismantle the fixed bolt of the steering column

Fig. 2.1.007
assembly, and lower the steering column to
take off the steering column assembly.
■ Tightening torque: 13 ~ 18 Nym
2) Check after Dismantlement
① Check if the steering column has the damages such as crack and deformation, if it has, please
replace it.
② Check if the spline of steering column is worn or has broken tooth, if it has, please replace it.
3) Disassembly
Disassembly Diagram for Steering Column
1-Special bolt 2-Steering lock support 3-Steering lock assembly 4-Snap ring 5-Steering shaft
assembly 6-Spring 7-Steering column assembly
77
① Disassembly
a. Unscrew the connecting bolt of steering column and connecting shaft universal joint, and then
dismount the universal joint.
b. Dismantle the steering lock if necessary.
Attention:
■ The special bolt must be replaced when the steering lock is remounted.
c. Dismantle the adjustable steering column

Fig. 2.1.008 Reversal thread screw tap
and support if necessary.
Special bolt
② Disassembly gists Steering lock
support
Dismantlement of the special bolt:
a. Drill the special bolt with electric drill to put in
the screw tap.
b. Dismount the special bolt with reversal thread
Steering lock body
screw tap.
4) Check after disassembly

① Check the crack and damage of the adjustable support and spring.
② Check if the operation of the steering lock mechanism is normal.
5) Assemblage
Assemble the steering lock assembly, steering lock support and special bolt.
Attention:
Fig. 2.1.009
■ When the steering lock assembly and steering
lock support are being mounted on the
steering column assembly, they shall aim at
the locking gap of steering column to lock up
the steering lock temporarily.
■ When making sure the operation of the
steering lock is correct, fasten the special bolt Gap
until the bolt head is locked out.
6) Installation
Attention:
■ Please don’t reuse the disposable spare parts.
■ Keep the steering wheel in middle position to mount the steering column assembly.
■ Please pay attention to the mounting position when mounting the connecting shaft on the steering
column.
78
7) Check after Installation
Park the vehicle straight forwards, and turn the steering wheel to the left and right for several times to
make sure the steering wheel is operated flexibly.
VII. Steering Gear
1. Element
Diagram for Steering Gear Assembly
Attention:
■ Rotating the steering wheel while separating the steering column and steering gear may damage
the clock spring, therefore the steering wheel must be fixed to avoid its rotation.
1) Dismantlement
Fig. 2.1.010
Attention:
■ The oil in steering system shall be collected

firstly before dismantlement.
① Park the vehicle straight forwards.
② Dismantle connecting bolt of steering column
and steering gear from the cab, and separate the
steering column and steering gear.
■ Tightening torque: 15 ~ 20Nym
③ Dismantle the air filter assembly. Please refer to

Fig. 2.1.011
“Air Filter Assembly”.
④ Dismantle the oil pipe of steering gear.
79
⑤ Dismantle the tie rod locknut.

Fig. 2.1.012
■ Tightening torque: 50 ~ 55 N•m
⑥ Dismantle the ball joint of steering tie rod from

Fig. 2.1.013
steering knuckle with special tool, as is shown
in the figure.
Locknut
⑦ Dismantle the engine support beam assembly
and the gearbox rear suspension. Please refer Rope
to “Engine Support Beam”.
Attention:
Ball joint
■ Please use the jack to support.
⑧ Dismantle the steering gear fixed bolt from the

Fig. 2.1.014
firewall.
■ Tightening torque: 60 ~ 80 N • m
⑨ Move the steering gear assembly to the right,

and take it out from the left side of frame.
Attention:
■ Take it out carefully and slowly in order not to

damage the tie rod dustproof boot.

① Steering Gear
■ Check if the oil pipe joint is loose and damaged.
■ Check if the fixed liner of steering gear has damages such as abrasion, and crack.
■ Check if the pinion and rack operate well and if they are worn.
■ Check the preloading of the gear.
80
a. Rotate the gear with the speed of 4~6s per circle, and measure the gear preloading in the whole
stroke of the rack.
■ Standard value: 0.6 ~ 1.3 Nym
b. If the measured value is beyond the specification, the block shall be regulated, and then the gear
preloading shall be checked again.
c. If the specified gear preloading still can’t be obtained through block regulation, the block
sub-assembly shall be checked or replaced.
② Steering tie rod
Check the rotational torque of the steering tie rod.
a. Swing the tie rod rapidly for 10 times.
b. Measure the swinging resistance of the tie rod with spring balance.
■ Standard value: 2 ~ 5 Nym
If the measured value is not within the stated value, please replace it.
Attention:
■ If there is no excessive clearance while swinging the tie rod slowly, it can be used even the
measured value is lower than the standard value. If the measured value is lower than 4.3 N, the tie
rod must be replaced.
③ Tie rod dustproof boot
■ Check if the dustproof boot is damaged, if it is, please replace it.
■ Check if the dustproof boot is mounted to the right position.
3) Installation
Note: Please don’t reuse the damaged spare parts.
Attention:
■ Pay attention to the mounting position while connecting the steering gear and steering column.
■ Exhaust air in the steering hydraulic system after installation. Please refer to “Hydraulic Pipeline”.
■ Keep the tyre on the level ground in no load condition when dismantling the steering gear assembly,
and tighten the nut and bolt for the last time.
■ Check the wheel location. Please refer to “Location of Front Wheels”.
■ Turn the steering wheel to the left and right limits for several times to make sure the steering wheel
is operated flexibly.
81

1) Element
Disassembly Diagram for Steering Gear

1-Locknut 2-Block 3-Rack support spring 4- Rack support seat 5-Liner 6-Self-locking nut 7-Bearing
8-Steering gear casing 9-Open spring 10- Rack stop block 11-Gear liner assembly 12-Oil seal
13-Support pad 14-Oil pipe 15-Steering gear pinion with valve body assembly 16-Valve body casing
17-Gasket ring 18-Rack 19-Dust cover 20- Tie rod ball joint 21-Tie rod locknut 22-Clamp 23-Dustproof
boot 24-Clamping band 25-Tie rod 26-Joint washer
2) Disassembly
① Dismantle the tie rod ball joint from the tie rod.
② Dismantle the clamping band and clamp of dustproof boot, and take out the dustproof boot from the
tie rod.
③ Dismantle the oil pipe from the gear casing.
④ Move the rack slowly to discharge the oil from the gear casing.
⑤ Dismantle the end cap.
82
⑥ Rotate the rack clockwise to the lock position, and dismantle the self-locking nut.
⑦ Loosen the joint washer between the tie rod and rack with chisel, and dismantle the tie rod from the
rack.
⑧ Dismantle the block locknut to dismount the block.
⑨ Dismantle the rack support spring, support seat and liner from the gear casing.
⑩ Dismantle the valve casing.
⑪ Rotate the rack stop block clockwise until the end of open spring pops a gear casing slot.
⑫ After the end of open spring pops the rack casing groove, rotate the rack stop block anti-clockwise,
and then dismantle the open spring.
⑬ Move the rack stop block, rack liner and rack from the gear side and then dismantle them.
Attention:
■ The casing oil seal shall be replaced when the rack is dismounted.
⑭ Dismantle the O-ring and oil seal from the rack liner.
⑮ Dismantle the valve body, oil seal and ball bearing from the valve casing. And dismantle the ball
bearing and needle bearing from the gear casing.
Attention:
Take care not to damage the gear valve body in the gear casing.
3) Assemblage
Pay attention to the following items and assemble in the reverse order with disassembly.
■ Smear the sealant on the surface when mounting the block, and then tighten it to the specified
torque.
■ Tightening torque: 50 ~ 70 Nym.
83
4. Tie Rod
Disassembly Diagram for Tie Rod
1-Tie rod 2-Clamping band 3-Dustproof boot 4-Ball joint 5-Locknut
1) Dismantlement
① Fix the pinion and rack onto the bench clamp.
Attention:
■ Enwind a piece of cloth around the surface of the rack when mounting the rack. Tighten it carefully
in order not to damage the rack.
② Cut off the dustproof boot clamping band to dismount the dustproof boot
③ Dismount the tie rod.
① Check if the tie rod is damaged or deformed.
② Check if the dustproof boot is damaged or deformed.
③ Check the swinging torque of tie rod.
④ Check the swing and the axial clearance of tie rod ball joint.
3) Installation
① Mount the tie rod on the rack and tighten it, and then fix it in the slot with punch.
■ Tightening torque of tie rod and rack: 80 ~ 100 Nym
② Mount the dustproof boot on the gear casing, and then fix it with clamping band.
84
Attention:
■ The fixing strap for dustproof boot must be assembled after the regulation of toe-in.
■ Please don’t’ reuse the disposable spare parts.
③ Regulate the length of tie rod and tighten the locknut.
■ The length of tie rod (standard value): 175.3±1 mm
■ Tightening torque of the tie rod locknut: 50 ~ 55 N • m
VIII. Power Steering Pump
1. On-vehicle Check
1) Check of the released oil pressure
Attention:
■ Please confirm the belt tension rate before implementation. Refer to “Drive Belt”.
① Dismantle the flowline form the power steering pump, and connect the pressure gauge.
Diagram for Power Steering Pump Assembly
1-Thermometer 2- Stock solution tank 3-Power steering pump 4-Pressure gauge 5-Cut-off valve 6-Joint
85
② Open the valve, and exhaust air in the hydraulic pipeline. Please refer to “Air Exhaust of the
Hydraulic System”.
③ Start the engine, and turn the steering wheel for several times to make the oil temperature reach
about 50 ℃.
Attention:
■ The belt and the hoses of other spare parts must be kept clean when starting the engine.
④ Turn off the pressure gauge when the engine is at idle speed, and measure the released oil
pressure. Please refer to “Technical Specifications”.
Attention:
■ Please don’t let the valve be closed for more than 10s.
⑤ Open the valve slowly after measurement. If the released oil pressure is not within the standard
range, please replace the power steering pump.
⑥ Cut off the pressure gauge from the hydraulic pipeline after check, and then fill new oil and exhaust
air in the pipeline. Please refer to “Air Exhaust of the Hydraulic System”.
1) Dismantlement
① Discharge the power steering fluid from the Fig. 2.1.015

stock solution tank.
② Dismantle the belt of power steering pump.

Please refer to “Drive Belt”.
③ Dismantle the high pressure induction

manifold and flowline from the power steering
pump.
④ Dismantle the fixed bolt and then dismount the

Fig. 2.1.016
power steering pump.
■ Tightening torque: 40 ~ 60 Nym
2) Installation
① Install in the reversed order with

dismantlement.
② Carry out the following steps after installation.
■ Regulate the tension rate of the belt. Please refer to “Tension Rate Adjustment”.
■ Do air exhaust. Please refer to “Air Exhaust of the Hydraulic System”.
86
1) Element
Disassembly Diagram for Power Steering Pump

1-Hexagon bolt 2-End cap 3-O-ring 4-Needle bearing 5-Armature 6-Induction manifold 7-Pin
8-Compression spring 9-Oil seal 10-Shaft 11-Ball bearing 12-Valve core 13-Valve bolt 14-Spring guide
pin 15-Washer 16-Casing 17-Gasket ring 18-Fuel distributor 19-Blade 20-Needle 21-Stator
2) Check Before Disassembly
The power steering pump can be disassembled only when the following troubles appear:
■ The power steering pump leaks oil.
■ The power steering pump pulley has been damaged or deformed.
■ The performance of the power steering pump is not good.
3) Disassembly
Attention:
■ Please fix the power steering pump in the calipers if necessary.
① Dismantle the induction manifold and O-ring from the power steering pump.
② Dismantle the rear end cap, O-ring, needle, and stator.
87
③ Dismantle the armature, blade as well as fuel distributor.
④ Dismantle the inner and outer O-rings and gasket ring.
⑤ Dismantle the snap ring with pliers. Take out the ball bearing and shaft.
⑥ Dismantle the oil seal from the body of power steering pump.
⑦ Dismantle the valve screw to take out the valve core and compression spring.
① Check of the power steering pump casing and rear end cap.
■ Check if the casing and rear end cap are damaged. If they are, please replace the power steering
pump assembly.
② Check of the Flow Control Valve
■ Check if the flow control valve and spring are damaged (the specific checking procedures are as
follows), if they are, please replace them.
The check procedures of flow control valve:
a. Press the valve rod with hand, if it can move up and down freely, which shows that the valve core is
not seized or damaged, vise versa, it shows that the valve core has been seized or damaged.
b. Check if the valve core surface is scratched.
c. Take out the spring in the valve cavity, and check if it is deformed.
5) Assemblage
Pay attention to the following items and assemble in the reverse order with disassembly.
■ Clean the spare parts.
■ Smear the standard power steering fluid on the surface of the dismounted spare parts, of which the
oil seal and O-ring are included.
■ Fill new oil and exhaust air in the system. Please refer to “Air Exhaust of the Hydraulic System”.
88
IX. Hydraulic Pipeline

1. Diagram for Hydraulic Pipeline
Oil Circuit Diagram for Power Steering Hydraulic Pipe

1-Oil return pipe 2- Power steering pump 3-High pressure pipe 4-Power steering stock solution tank
5-Flowline 6-Oil return hose 7-Power steering gear 8-Steering tie rod 9-Radiator pipe
1) Insert the hose firmly until it touches the Fig. 2.1.017

tubular axle. Tubular axle
Attention:
■ Please don’t use the oil for lubrication.
Pipe Hose
2) The projection part of the eyebolt shall face to

Fig. 2.1.018
the notch of the pump side when mounting the Eyebolt
eyebolt, and then tighten it to the specified Eyebolt joint
torque.
Copper
washer
Sealing part
Power steering pump
89
X. Maintenance Data and Specifications

1. Technical Specifications
Table of Technical Specifications
Types of steering column and Energy-absorbing, cross shaft universal joint connection,
connecting shaft adjustable gradient of steering column
Type of steering gear Pinion and rack
Rack stroke 134 mm
Type of oil pump Impeller type
Flow of oil pump 8.5 mL/rev
Starting pressure of oil pump
1.5~ 2.0 MPa
pressure valve
Free play of steering wheel 0~ 30 mm
Max. wheel steering angle Inner: 38° 52°; Outer 33° 07
Steering force 23 N or smaller
Belt flexibility (under the applied
7 ~ 10 mm
force of 98N)
Pressure drop of oil pump 5.9 MPa
Rotational torque of steering pinion 0.6~ 1.3 N•m
Swinging torque of steering pull rod 2 ~ 5 N•m
2. Recommended Accessories
Table of Recommended Accessories
Item Recommended Lubricating Oil Fill Volume
Horn contact of steering wheel LONG TIME PD2 Proper
Power steering fluid Type PSF-3 0. 9L
Torque Torque
Item Item
(N•m) (N•m)
Steering wheel locknut 35~45 Steering gear mounting bolt 60 ~ 80
Assembly support of steering column
13~18 Steering pull rod locknut 50 ~ 55
and steering connecting shaft
Steering shaft and connector 15~20 Slotted nut of steering pull rod ball joint 15 ~ 34
Steering pinion and connector 15~20 Rack clearance adjusting nut 50 ~ 70
Bolt of oil pump support 20 ~ 27 Steering pull rod and rack connection 80 ~ 100
Valve body shell and rack shell
20 ~ 30 Oil pump adjusting bolt 25 ~ 33
assembly
Mounting clamping band of pressure Mounting bolt of pressure pipe and oil
8 ~ 12 55 ~ 60
pipe and oil return pipe pump
Pressure pipe and oil return pipe
12 ~ 18 Oil cooling pipe mounting bolt 8 ~ 12
connected with steering gear
Self-locking nut of steering pinion and Clamp plate of suction pipe support
20 ~ 30 3~5
rotary valve (with joint of oil pump suction pipe)
Block 50 ~ 70
90
Section II Front Axle

I. Precautions
1. The following items shall be paid attention to during the front axle maintenance
1) The spare parts needing minor repair, such as, the steering knuckle can not be dismantled.
2) Try to operate on a dustless workbench.
3) Before the disassembly and assemblage, please clean the external surface of the spare part.
4) During working, be careful to avoid smearing the spare parts and prevent entry of foreign matters.
5) The disassembled spare parts shall be reassembled in order. If the work is paused, the spare parts
shall be covered by clean hood.
6) As rags will be left on the spare parts if the fabrics are used, it is a must to use the paper cloth.
7) The disassembled spare parts (excluding rubber spare parts) shall be cleaned by the kerosene or
dried and wiped by the paper cloth.
2. Precautions for checking and repairing the system or replacing the spare parts
1) The stated torque check shall be done to the fasteners after the assemblage.
2) The necessary alignment check shall be conducted after the system assemblage.
3) The disposable spare parts can’t be reused.
4) Before repairing and replacing the spare parts, thorough check is required.
II. Preparation
Select proper maintenance tools for dismantlement and installation.
1. General tool
Table of General Maintenance Tool

1 Power tool dismantlement of bolts
and nuts
91
2. Special tool
Table of Special Maintenance Tool

Drawing
die for For dismantlement
1 steering JAC-T1D003 of the connecting
driving ball joint
rod

Offtracking of Wear of the steering knuckle of the drive shaft Replacement
the vehicle Wear, friction or click of the wheel bearing Replacement
Defects of the front suspension and the steering system Adjustment or
replacement
Vibration Wear, damage or bending of the drive shaft Replacement
Abnormal sound of the drive shaft and wheel hub spline Replacement
Wear, friction or click of the wheel bearing Replacement
Run-out Unbalanced wheel Adjustment or
replacement
Defects of the steering knuckle of the front axle Adjustment or
replacement
Loud noise Wear, damage or bending of the drive shaft Replacement
Wear of the wheel hub spline of the drive axle Replacement
Wear of the wheel hub spline of the drive shaft Replacement
Wear, burning or abnormal sound of the wheel bearing Replacement
Looseness of hub nuts Adjustment or
replacement
replacement
IV. Front Wheel Hub and Steering Knuckle
1. On-vehicle check
Check whether every element’s fixing (clearance) and wear status is normal.
1) Check of the wheel bearing
■ Push the wheel hub and the bearing assembly axially with hand; check whether there is any
looseness for the wheel bearing. If any, it is suggested that the bearing shall be replaced or
reassembled.
■ Rotate the wheel hub, and check whether there is any abnormal noise or other abnormalities. If any,
it is suggested that the bearing shall be replaced.
92

1) Element
Disassembly Diagram for the Front Axle

1-Lower suspension arm 2-Ball joint 3-Fixing bolt of the brake tongs 4-Dust guard 5-Wheel hub
assembly 6-Locknut 6-Cotter pin 7-Cotter pin 8-Gasket 9-Brake disk 10-Brake tongs 11-Steering knuckle
12-Shock absorber 13-Nut 14-Snap ring 15-Wheel bearing 16-Locknut of the lower suspension arm
2) Dismantlement
① Lift the vehicle and dismantle the tire of the front

Fig. 2.2.001
wheel. Please refer to “Wheel and Tire”.
② Dismantle the speed sensor from the steering knuckle.
Please refer to “Speed Sensor”.
Attention:
■ Do not pull the wire harness of the speed sensor.
■ While in installation, check the clearance between the
speed sensor and the wheel hub.
Standard value of clearance: 0.5 mm

③ Loosen the fixing bolt of the brake hose and remove the brake hose. Please refer to “Braking
Pipeline”.
④ Dismantle the front brake tongs assembly from the steering knuckle and hang and fix it. Please refer
to “Front Brake Tongs”.
93
Attention:
■ Do not step on the brake pedal after the

Fig. 2.2.002
dismantlement of the brake tongs.
⑤ Dismount the stop bolt of the brake disk from
the wheel hub and remove the brake disk.
⑥ Dismantle the cotter pin and loosen the

Fig. 2.2.003
locknut of the wheel hub.
⑦ Knock the drive shaft gently with a hammer (or
other appropriate tools) and a wooden block to
separate the wheel hub and the steering
knuckle assembly. Then dismount the locknut
of the wheel hub.
Attention:
■ While putting down the drive shaft, make sure that the casing (universal joint component), axle and
other spare parts are supported.
■ If operations mentioned above still fail to separate the wheel hub and the drive shaft, resort to
pullers (or appropriate tools).
⑧ Dismantle the ball joint of the steering tie rod

Fig. 2.2.004
from the steering knuckle.
Attention:
■ Use special or appropriate tools to avoid

damaging the dust wrapper of the ball joint.
94
⑨ Dismount the shock absorber and the fixing

Fig. 2.2.005
bolt from the steering knuckle.
■ Tightening torque:75~90 Nym
⑩ Dismantle the drive shaft from the wheel hub. Fig. 2.2.006
Attention:
■ The universal joint of the drive shaft shall be

positioned without too large angle to avoid
excessive stretching and the falling off of the
ball case.
⑪ Dismantle the ball joint of the lower

Fig. 2.2.007
suspension arm from the steering knuckle.
Please refer to “Lower Suspension Arm”.
Attention:
■ Use special tools to avoid damaging the dust

wrapper of the ball joint.
⑫ Remove the wheel hub and the steering knuckle assembly.
Attention:
■ Check whether there is any deformation, crack or any other damages of the element. If any, please
get it replaced.
■ Check whether there is any damage, too large axial clearance, or torsion for the dust wrapper of the
external ball joint of the tie rod. Please refer to” Tie Rod”.
4) Installation
■ Install in the reverse order with dismantlement. As for tightening torque, please refer to
“Maintenance Parameters”.
95
Attention: Please do not use damaged spare parts.

■ While installing the ball joint of tie rod, fix the nuts to avoid rotation and then screw them down.
■ Under no load conditions, screw down every spare parts which are dismounted in the process of
dismantling front wheel hub and the steering knuckle finally.
■ Check wheel alignment. Please refer to “Front Wheel Alignment Check”.
■ Check whether the wire harness of the wheel sensor is correctly connected. Please refer to “Speed
Sensor”.
1) Disassembly
Fig. 2.2.008
① Remove the snap ring with the inner snap ring
pliers.
② Dismount the wheel hub and the dust cover
③ Dismount the inner ring of the wheel bearing
from the wheel hub.
④ Dismount the outer ring of the wheel bearing
Attention:
■ Operate it according to the regulation; avoid the slide of the bearing which may cause physical
injury.
■ Tightening torque: 80 Nym~100 Nym
■ If the repeated attempts to separate the steering knuckle and the wheel bearing all fail, please
replace the steering knuckle assembly.
2) Check after the disassembly
① Steering knuckle
■ Check whether there is any scratch, crack or other damages on the contact surface of the steering
knuckle and the wheel bearing.
■ If any of the situations mentioned above occurs, please repair and replace it according to the actual
situation.
② Brake disc
Check whether there is any crack or other damages on the surface of the brake disk.
③ Snap ring
■ Check whether there is any crack or other damages on the snap ring.
Attention:
■ Please do not use damaged spare parts.
④ Wheel hub
■ Check whether the wheel hub bolt is stretched.
■ Check whether there is any scratch, crack or other damages on the contact surface of the wheel
hub and the wheel bearing.
96
■ If any of the situations mentioned above occurs, please repair or replace it.
3) Assemblage
① Apply appropriate amount of grease on the contact surface of the steering knuckle and the wheel
bearing.
② Press the new wheel bearing in the steering joint and install the new snap ring.
Attention:
■ Please do not press the inner ring of the wheel bearing to avoid damaging the wheel bearing
assembly.
■ The model of the left and right wheel bearing shall be the same.
■ Please avoid repeated usage of damaged spare parts.
③ Install the dust guard.
④ Press the wheel hub into the steering knuckle.
Attention:
■ Please do not press the outer ring of the wheel bearing to avoid damaging the wheel bearing
assembly.
4) Check after the assemblage
■ Check whether the wheel hub and wheel bearing is assembled appropriately.
■ Measure the axial clearance of the bearing.
Limit value: 0. 064~0. 088 mm
Attention:
■ If the axial clearance exceeds the limit value, please reassemble it.
4. Replacement of the wheel bearing
As for the dismantlement and installation, please refer to procedures mentioned in “Front Wheel Hub
and Steering Knuckle”.
Attention:
■ Please do not use damaged spare parts.
■ The model of the left and right wheel bearing shall be the same.
■ Please conduct necessary road test.
V. Front Drive Shaft
1. On-vehicle check and maintenance
1) Check whether there is any looseness or other damages on the drive shaft and the universal joint.
2) Check whether there is any crack or other damages on the dust wrapper.
Attention:
97
■ If there is any noise or vibration on the drive shaft, please replace the drive shaft assembly.
2. Replacement of the dust wrapper of the drive shaft
1) Lift up the vehicle and dismantle the tire of the front wheel. Please refer to “Wheel and Tire”.
2) Dismantle the speed sensor from the steering knuckle. Please refer to “Speed Sensor”.
Attention:
■ Please do not pull the wire harness of the speed sensor.
3) Dismantle the front brake tongs assembly from the steering knuckle and hang and fix it. Please refer
to “Front Brake Tongs”.
Attention:
■ Do not step on the brake pedal after the dismantlement of the brake tongs.
4) Dismantle the cotter pin and loosen the locknut of the wheel hub.
5) Knock the drive shaft gently with a hammer (or appropriate tools) and a wooden block, separate the
wheel hub and the steering knuckle assembly and then dismount the locknut of the wheel hub.
Attention:
■ Make sure that the casing (universal joint component), shaft and other spare parts are supported
while putting down the drive shaft.
■ If operations mentioned above still fail to separate the wheel hub and the drive shaft, please resort
to pullers (or appropriate tools).
6) Dismantle the ball joint of the steering tie rod from the steering knuckle.
Attention:
■ Special tools shall be used to avoid damaging the dust wrapper of the ball joint.
7) Loosen the fixing bolt and nut of the shock absorber and the steering knuckle.
8) Separate the drive shaft from the wheel hub and the bearing assembly.
Attention:
■ The universal joint of the drive shaft shall be positioned without too large angle to avoid excessive
stretching and the falling off of the ball case.
9) Dismantlement of the clamping band of the dust wrapper.
98
10) Screw the puller of the drive shaft (or other appropriate Fig. 2.2.009
tools) into the screw hole of the universal joint
subassembly and pull out the universal joint
subassembly from the shaft.
Attention:
■ If it is impossible to pull out the universal joint
subassembly; firstly, remove the drive shaft assembly
from the vehicle and then try again.
11) Dismount the snap ring from the drive shaft and remove the dust wrapper.
12) Wipe off the grease on the universal joint subassembly with a piece of paper towel.
13) Smear appropriate amount of grease in the teeth-shaped hole of the universal joint subassembly
until the grease begins to flow out from the circular groove and the teeth-shaped hole. After grease
smearing, wipe off the old grease flown out with a piece of cleaning cloth.
14) Wrap the spline with tapes to avoid damaging the dust
Fig. 2.2.010
cover. Install the new dust wrapper and its clamping
band on the drive shaft.
Attention:
■ Avoid repeated usage of the dust wrapper and its
clamping band.
Subassembly
15) Dismantle the tape wrapped on the shaft.

16) Put the snap ring on the grove on the shaft edge. Align the intermediate shaft on the shaft edge with
the universal joint subassembly. Then mount the shaft on the universal joint subassembly with the
snap ring.
Attention:
Fig. 2.2.011
■ Avoid repeated usage of the snap ring. Subassembly
■ It is suggested that special tools shall be used in the

installation of the snap ring.
17) Install the universal joint subassembly on the drive
shaft with a plastic hammer.
Attention:
■ Make sure that the universal joint subassembly is
properly engaged while rotating the drive shaft.
99
18) Smear appropriate amount of grease evenly in the dust

Prevent the deformation of
wrapper from its side with large diameter. Fig. 2.2.012 the dust wrapper
19) Install the dust wrapper in the groove as shown in the

figure.
Attention:
■ If there is any grease on the fixed surface of the dust
wrapper (indicated by *), the dust wrapper may fall off.
Wipe off all the grease on the surface of the dust wrapper.
Slotted screwdriver
20) Insert the slotted screwdriver from its side with large
diameter and exhaust all the air within. Adjust the
installation length of the dust wrapper to avoid its
deformation.
Attention:
Fig. 2.2.013
■ If the installation length of the dust wrapper is too long, it
may be broken.
■ Use the slotted screwdriver with care to avoid internal
damage of the dust wrapper.
21) Fix the new clamping band of the dust cover with tools.
Attention:
■ Avoid repeated usage of the clamping band of the dust wrapper.
22) Fix the universal joint subassembly and the drive shaft and then determine the correct position for
rotating the dust wrapper.
Attention: If the dust wrapper is installed at the wrong position, please reinstall it by new clamping band
of the dust wrapper.
23) Make sure that the snap ring on the side of the axle of the transmission is fully engaged.
24) Insert the drive shaft into the wheel hub and the bearing assembly, and then screw down the locknut
of the wheel hub.
25) Install fixing bolt and nut of the shock absorber and the steering knuckle.
26) Install the ball joint of the steering tie rod and screw down the locknut according to the standard
tightening torque.
Attention:
■ In the installation, fix the bolt first to avoid rotation and then screw down the nut.
27) Install the brake tongs component and fix the brake hose. Please refer to “Front Brake” and “Braking
Pipeline”.
28) Install the speed sensor on the steering knuckle. Please refer to “Speed Sensor”.
100
29) Screw down the locknut till reaching the standard torque.
30) Install the cotter pin.
Attention:
■ Avoid repeated usage of the cotter pin.
31) Install the tire and screw it down according to the standard torque. Please refer to “Maintenance
Parameters”.
1) Element
Diagram for Drive Shaft Assembly
2) Dismantlement
① Lift up the vehicle and dismantle the tire of the front wheel. Pease refer to “Wheel and Tire”.
② Dismantle the speed sensor from the steering knuckle. Please refer to “Speed Sensor.”
Attention:
③ Dismantle the front brake tongs assembly from the steering knuckle and hang and fix it. Please refer
to “Front brake Tongs”.
Attention:
■ Do not step on the brake pedal while dismantling the brake tongs.
④ Dismantle the brake disc.
⑤ Dismount the cotter pin and loosen the locknut of the wheel hub.
⑥ Knock the drive shaft gently with a hammer (or appropriate tools) and a wooden block to separate
the wheel hub and the steering knuckle assembly, then dismantle the locknut of the wheel hub.
101
Attention:
■ Make sure that the casing (universal joint component), shaft and other spare parts are supported
while putting down the drive shaft.
■ If operations mentioned above still fail to separate the wheel hub and the drive shaft, please resort
to pullers (or appropriate tools).
⑦ Dismount the ball joint of the steering tie rod from the steering knuckle.
Attention:
■ Special tools shall be used to avoid damaging the dust wrapper of the ball joint.
⑧ Loosen the fixing bolt and nut of the shock absorber and the steering knuckle.
⑨ Dismantle the drive shaft from the wheel hub and the bearing assembly.
⑩ Dismantle the drive shaft from the side of the transmission.
Attention:
■ In drive shaft dismantlement, the universal joint of the drive shaft shall be positioned without too
large angle. Avoid excessive stretching of the slip joint.
① Rotate the universal joint to check whether it operates flexibly or is seriously unloosened.
② Check whether there is any crack, damage or grease leakage of the dust wrapper.
③ If any situation inconsistent with the regulation occurs, please disassemble the drive shaft and
replace the defective spare parts.
4) Installation
Attention:
■ While installing the drive shaft, replace the oil seal at the side of the new transmission.
① Front drive shaft
■ Install in the reverse order with dismantlement. As for the tightening torque, please refer to
“Maintenance Parameters”
Attention: Avoid repeated usage of disposable spare parts.
■ While inserting the drive shaft into the side of the transmission, avoid damaging the oil seal.
Attention:
■ Make sure that the snap ring on this side is fully engaged.
■ Apply gear oil on the spline of the drive shaft.
■ Before installing the drive shaft, make the opening of the snap ring downward.
4. Disassembly and assemblage

1) Element
102
Disassembly Diagram for the Drive Shaft

1-Snap spring 2-Casing 3-Snap ring 4-Tripod assembly 5-Dust wrapper 6-Clamping band of the dust
wrapper 7-Locknut 8-Cotter pin 9-Washer 10-Dust guard 11-Ring gear of the speed sensor
2) Disassembly
① Side of the transmission
a. Fix the drive shaft into the caliper.
Attention:
■ While fixing the drive shaft in the caliper, please use aluminum or copper sheet to protect the drive
shaft.
b. Dismount the clamping band of the dust wrapper and then dismantle the dust wrapper from the
casing.
103
c. Mark the casing and the drive shaft with assembly signs Fig. 2.2.014 Matching mark
and then pull the casing out from the driving shaft.
Attention:
■ Please mark with paint or similar materials. Do not

scratch the surface.
d. Dismount the snap ring and then dismantle the tripod

assembly from the drive shaft. Fig. 2.2.015
e. Dismount the dust wrapper from the drive shaft.
f. Wipe off the old grease on the casing with a piece of

paper cloth.
② Side of the wheel Snap ring
a. Fix the drive shaft in the calipers.
Attention:
■ While fixing the drive shaft in the calipers, please use aluminum or copper sheet to protect the drive
shaft.
b. Dismount the clamping band of the dust wrapper and then dismantle the dust wrapper from the
universal joint subassembly.
c. Screw the puller (or appropriate tools) of the drive shaft in the screw thread of the universal joint
subassembly and then separate the universal joint subassembly from the drive shaft.
Attention:
■ If the attempts to dismantle the universal joint subassembly all fail, please replace the drive shaft
assembly.
d. Dismount the snap ring from the drive shaft and remove the dust wrapper.
e. Dismantle the dust guard and the speed sensor from the drive shaft.
f. Rotate the ball case and wipe off the old grease on the universal joint subassembly with a piece of
paper cloth.
3) Check after disassembly
① Drive shaft
Check whether there is any run-out, crack or other damages of the drive shaft. If any, please replace the
drive shaft assembly.
a. Universal joint subassembly (side of the wheel)
Check the following items:

104
■ Check whether the universal joint subassembly is excessively rotated and whether the drive shaft is
too loose.
■ Whether there is any foreign matter in the universal joint subassembly.
■ Whether there is any sign of pressure impact, crack or internal damage of the universal joint
subassembly.
If any situation inconsistent with the regulation occurs, please replace the universal joint subassembly.
b. Casing and tripod assembly (side of the transmission)
If there is any scratch or abrasion on the rolling contact surface of the casing and the tripod assembly,
please replace the casing and the tripod assembly.
Note:
The casing and tripod assembly are used in the same device.
② Dust wrapper and speed sensor
■ Check whether there is any crack or other damages. If any, please replace it.
4) Assemblage
① Side of the transmission
a. Wrap the spline on the drive shaft with tapes to avoid damaging the dust wrapper. Install the new
dust wrapper and its clamping band on the shaft.
Note: Please avoid repeated usage of dust

Fig. 2.2.016
wrapper and its clamping band.
b. Dismount the tapes around the spline of the

drive shaft.
Tape
c. While installing the tripod assembly, align it Cross shaft component

Fig. 2.2.017
with the paint matching mark, and with the
chamfer angle toward the shaft.
Matching mark
Matching
mark
Spline
Drive shaft
105
d. Fix the tripod assembly on the casing with the snap ring.
e. Smear the tripod assembly and the slide surface with the Fig. 2.2.018
recommended grease.
f. Install the casing on the tripod assembly and then smear
the recommended grease.
Snap ring
g. Install the clamping band in the groove as shown in the

Prevent the deformation of
figure. Fig. 2.2.019 the dust wrapper
Attention:
■ If there is any grease on the fixed surface of the dust
wrapper, the dust wrapper may fall off. Wipe off all the
grease on the surface.
h. Insert the slotted screwdriver from the side with large
diameter of the dust wrapper and exhaust all the air
within. Adjust the installation length of the dust wrapper Slotted screwdriver
to prevent its deformation.

Attention:
■ If the installation length of the dust wrapper is too long, it may be broken.
■ Use the slotted screwdriver with care to avoid damaging the internal part of the dust wrapper.
i. Use special tools to fix the new clamping band of the dust wrapper.
Attention:
■ Please avoid repeated usage of the clamping band of the dust wrapper.
J. Fix the casing and the drive shaft and then determine the correct position for rotating the dust
wrapper.
Note: When the dust wrapper is installed at the wrong position, please use new clamping band of the
dust wrapper to reinstall it.
k. Install the speed sensor and the dust wrapper on the casing.
② Side of the wheel
Assemble it according to the procedures 14 – 23 in “Replacement of the Dust Wrapper of the Drive
Shaft”
Attention:
■ In the installation, make sure that the universal joint subassembly and the drive shaft are in the
same line.
■ While installing, make sure that the speed sensor is fully engaged with the casing.
■ First press in the dust wrapper; and then install the speed sensor.
106
VI. Maintenance Parameters
1. Tightening torque
Tightening Tightening
Item Item
torque (N • m) torque (N • m)
Connecting nut of the rear
Locknut of the drive shaft 220~60 cantilever and the rear steering 130-150
knuckle
Connecting nut of the steering
Nut of the support rack of the
knuckle and the shock 75-90 17-26
antisway bar
absorber assembly
Connecting nut of the ball joint
Connecting nut of the antisway bar
of the lower suspension arm 60-72 35-45
and the pull-rod
and the steering knuckle
Wheel nut 90-110 100-120
cantilever and the body
Locknut of the rear wheel hub
180-220 Eccentric nut of the rear cantilever 80-100
bearing
shock absorber and the rear 75-90 Stop bolt of the brake disc 10~15
steering knuckle
107
Section III Rear Axle

I. Preparation
Dismantlement and installation shall be conducted with appropriate maintenance tools.
Table of Maintenance Tools
For the installation and

1 Power tool dismantlement of bolts
and nuts
II. Wheel hub
1. On-vehicle Check
Check whether every element‘s fixing (clearance) and wear status is normal.
1) Check of the wheel bearing
■ Push the wheel hub and the bearing assembly axially with hand; check whether there is any
looseness for the wheel bearing. If any, it is suggested that the bearing shall be replaced or
reassembled.
■ Rotate the wheel hub, and check whether there is any abnormal noise or other abnormalities. If any,
it is suggested that the bearing shall be replaced.
108
Diagram for Rear Wheel Hub Assembly
1-Dust guard 2-Axle head nut 3-Nut gasket 4-Rear hub assembly 5-Buffering and locating block 6-Rear
steering knuckle
1) Dismantlement Fig. 2.3.001

① Wheel hub and bearing assembly
a. Lift up the vehicle and dismantle the tire of the

wheel. Please refer to “Tire and Wheel”.
b. Dismantle the dust guard of the wheel hub.
C Dismantle the axle head nut and the nut

Fig. 2.3.002
gasket.
109
d. Dismantle the stop bolt of the brake drum and Fig. 2.3.003
remove the brake drum.
e. Dismantle the rear wheel bearing assembly

Fig. 2.3.004
from the rear steering knuckle.
Attention:
■ Slowly remove the wheel bearing assembly

axially.
② Rear steering knuckle
a. Dismantle the wheel hub and the bearing assembly from the rear steering knuckle. Please refer to
“Wheel Hub and Bearing Assembly”.
b. Dismantle the speed sensor. Please refer to “Speed Sensor”.
Attention:
c. Dismantle the rear brake and the parking braking wiredrawing. Please refer to “Rear Brake” and
“Parking Braking System”.
d. Dismantle the hard tube of the rear brake. Please refer to “Brake Pipeline”.
Attention:
■ Collect the brake fluid with care to avoid Fig. 2.3.005

environmental pollution.
■ If there is any brake fluid on the brake

assembly, clean it with a piece of paper cloth.
e. Dismantle the fixing bolt of the brake bottom

plate and the rear steering knuckle, and
remove the rear brake bottom plate and the
buffering and locating block.
110
f. Dismantle the rear cantilever (A), the rear

Fig. 2.3.006
thrusting rod and the rear cantilever (B).
Please refer to “Rear Cantilever and Thrusting
Rod”.
g. Dismantle the fixing bolts and nuts of the rear

shock absorber and the rear steering knuckle.
h. Dismantle the rear steering knuckle.
2) Check after the dismantlement
① Check whether there is any deformation, crack or damages of the element. If any, get it replaced.
② Check whether there is any wear, noise or other damages of the bearing of the rear wheel hub.
③ Check whether there is any wear, scratch or crack on the inner surface of the wheel hub.
3) Installation
① Wheel hub and bearing assembly
■ Install in the reverse order with dismantlement.
Note: Do not use damaged spare parts.
■ Check whether the speed sensor is correctly connected.
■ In the assemblage, fix the dust guard first and then press in it axially with the stress exerted on the
outer edge of the dust guard of the steering knuckle.
■ Screw down the axle head nut to make its gasket press the inner ring of the wheel bearing until it
contacts the end of the spline.
■ The model of the left and right bearings shall be the same.
② Steering knuckle
Note: Do not use damaged spare parts.
■ Determine the mounting position of the buffering and locating block.
■ Finally screw down every spare parts dismounted in the dismantlement process of rear steering
knuckle under no load condition.
■ Check the wheel alignment.
■ Exhaust air in the braking system. Please refer to “Brake Fluid”.
111
III Maintenance Parameters
Item Tightening torque (N • m)

Axle head nut 220~260
Stop bolt of the brake drum 10~15
Connecting bolt between the brake bottom plate
56~70
and the rear steering knuckle
Connecting bolt between the rear shock absorber
75~90
and the rear steering knuckle
112
Section IV Front Suspension

I. Precautions
■ When mounting rubber liner, it is necessary to carry out the final tightening on condition that the tires
contact the ground and there is no load. As the engine oil will shorten the service life of rubber liner,
do clean up the overflowing engine oil.
－ No-load condition means that the fuel, engine coolant and lubricant have been filled normally, and
the spare tire, jack, driver tools and foot pad are in their designated positions.
■ After repairing the spare parts of suspension, do check the wheel alignment.
■ Reuse of locknut is forbidden. Always use new nut for installation.
II. Preparation
1. Special Tools
Drawing die
For dismantlement of
1 for steering JAC-T1D003
connecting ball joint
driving rod
Damping For dismantlement and
2 spring JAC-T1D004 installation of damping
detacher spring
113
III. Front Suspension Assembly
1. On-vehicle Check
Confirm whether the fixing (clearance) and wear of each element are normal.
1) Check of Tie Rod Clearance
① Stop the front wheels, making them straight forwards.
Note: Don’t press on the brake pedal.
② Place the crowbar (or similar tool) between the tie rod and steering knuckle.
③ Check the clearance by up-and-down leverage.
Attention:
■ Don’t damage the dust cover of ball joint.
■ Don’t apply too much force to avoid damaging the installation position.
2) Check of Damper
Check the installation position for oil leakage, damage and breakage.
2. Check of Front Wheel Alignment
1) Illustration
Check the wheel alignment under no-load condition.
Note: No-load condition means that the fuel oil, lubricating oil and engine coolant have been filled
normally, and the driver tools, spare tire and jack are in their designated positions.
2) Prior Check
① Check whether the tire pressure is normal and check the tire for wear. Please refer to ”Wheel and
Tire”.
② Check the wheel for run-out. Please refer to ”Wheel and Tire”.
③ Check the shaft end clearance of wheel bearing. Please refer to “Check of Wheel Assembly”.
④ Check the shaft end clearance of tie rod. Please refer to “Steering Gear”.
⑤ Check each fixed point of axle and suspension for looseness and deformation.
⑥ Check each suspension component, steering knuckle, damper and tie rod for crack, deformation
and other damages.
⑦ Check the car body height.
114
3. Check of Front Wheel Toe-in
Attention:
■ It is necessary to conduct wheel alignment on level ground and under no-load condition.
■ Front wheel toe-in value: -3~+3 mm
If the toe-in value is beyond the standard range, please conduct adjustment according to the following
steps:
1) Check the toe-in value setting on the four-wheel aligner.
2) Put the steering wheel in the right position and

Fig. 2.4.001
fix it.
3) Loosen the end locknut of tie rod.

Fig. 2.4.002
4) Rotate the left and right tie rods clockwise or
anticlockwise to adjust the toe-in value to
standard value.
Note: The rotation of left and right tie rods shall be

equivalent.
5) Lock the end locknut of tie rod well.
4. Check of Camber Angle, Castor Angle and Kingpin Inclination
■ Camber angle of front wheel: 0°±30'
■ Castor angle: 2°±30'
■ Kingpin inclination: 12°±30'
Attention:
■ The camber angle and castor angle have been set well before the car leaves the factory, so don’t
adjust them.
■ If the camber angle, castor angle and kingpin inclination are beyond the standard range, please
check the front suspension, steering knuckle, damper and tie rod for wear and damage. If the above
situations exist, please replace the suspect spare parts.
115
IV. Front Damper
1. Element
Disassembly Diagram for Front Damper
1-Trimming cover 2-Self-locking nut 3-Upper seat of spring 4-Upper vibration isolator of spring
5-Dust cover 6-Lower vibration isolator of spring 7-Helical spring 8-Front damper
1) Dismantlement
① Dismantle the front tires. Please refer to “Wheel and Tire”.
② Cut off the connector of speed sensor. Please Fig. 2.4.003

refer to “Speed Sensor”.
Attention:
■ Don’t pull the wire harness of speed sensor.
③ Dismantle the brake hose clip to cut off the

brake hose. Please refer to “Hydraulic
Pipeline”.
116
④ Dismantle the fixed nut of upper seat of damper.

■ Tightening torque: 20~30 Nym Fig. 2.4.004
⑤ Dismantle the connecting nut between the damper and
the ball joint of suspension arm.
⑥ Dismantle the fixed bolts and nuts of damper and
steering knuckle.
⑦ Dismantle the damper assembly.

Fig. 2.4.005
2) Installation
■ Install in the reverse order with dismantlement. With respect to the tightening torque, please refer to
Note: Don’t use damaged spare parts.
■ Conduct the final tightening to each spare part that is dismounted during the dismantlement of
damper under no-load condition.
■ Check the wheel alignment. Please refer to “Check of Front Wheel Alignment”.
1) Element
Disassembly Diagram for Damper

1-Trimming cover 2-Self-locking nut 3-Upper seat of helical spring 4-Upper seat pad of helical
spring 5-Upper vibration isolator of helical spring 6-Buffer block of damper 7-Helical spring
8-Lower vibration isolator of helical spring 9-Dust cover 10-Damper casing
117
2) Disassembly
Attention:
■ Don’t damage the piston push rod of damper when dismantling the spare parts of damper.
① Dismount the trimming cover with slotted screw driver. Fig. 2.4.006 JAC-T1D004
② Compress the helical spring with spring compressor till it
is loosened completely.
Attention:
■ Compress the helical spring after confirming that the

compressor has been mounted properly.
■ Don’t use any pneumatic tool when tightening the bolt of

spring compressor.
③ Fix the end of piston pull rod to dismantle its locknut.
Attention:
■ Confirm that the compressed helical spring is loose.
④ Dismantle the upper seat of helical spring, upper vibration isolator of spring, dust cover and buffer
block.
⑤ Dismantle the helical spring with compressor, and then release the compressor slowly.
⑥ Dismantle the lower vibration isolator of spring and take off the damper casing.
① Damper
■ Check the damper for deformation, crack and damage. If any, please replace it.
■ Check the piston pull rod for damage, wear and deformation. If any, please replace it.
■ Check the piston for oil leakage. If any, please replace it.
② Vibration Isolator of Spring, Buffer Block and Dust Cover
Check them for crack and check the rubber spare parts for wear. If any, please replace them.
③ Helical Spring
Check the helical spring for crack, wear and damage. If any, please replace it.
④ Upper Seat of Spring
Check it for crack, wear, deformation and other damages. If any, please replace it.
118
4) Assemblage
Assemble in the reverse order with disassembly. With respect to the tightening torque, please refer to
■ Don’t damage the piston pull rod when mounting the spare parts onto the damper.
■ Make the large-diameter end of the helical

Fig. 2.4.007 Helical spring
spring downwards to align with the lower seat
of spring.
■ Confirm that the compressor has been

mounted onto the helical spring completely,
and then begin to compress the helical spring.
Lower spring seat
■ When loosening the compressor, check Place the spring in the
designated position
whether the installation position of the helical
spring is correct.
■ Check whether the assemblage mark is

correct.
V. Lower Suspension Arm
1. Element
Diagram for Lower Suspension Arm Assembly
119
1) Dismantlement
① Lift the vehicle to dismantle the tires. Please refer to “Wheel and Tire”.
② Dismantle the fixed bolt of front support of lower suspension arm.
③ Dismantle the rear fixed support bolt of lower Fig. 2.4.008

suspension arm.
Step 2
Step 3
④ Dismantle the locknut of ball joint of lower Fig. 2.4.009

suspension arm.
Note: During dismantlement, fix the ball joint of

lower suspension arm at first, and then loosen the
locknut to avoid rotation.
⑤ Dismantle the lower suspension arm

assembly.
⑥ Dismantle the bolt between the front rubber

sleeve and fixed support of lower suspension
arm.
⑦ Take off the fixed support.
① Visual Check
■ Check the liner for wear and damage. If any, please replace it.
120
■ Check the lower suspension arm for deformation and other damages. If any, please replace it.
■ Check all fixed bolts and nuts. If any, please replace them.
2) Installation
■ Install in the reverse order with dismantlement. With respect to the tightening torque, please refer to
■ Tighten the bolt between the front rubber sleeve and fixed support of lower suspension arm in
advance to avoid distortion or deformation of the rubber sleeve.
■ Conduct the final tightening to each spare part that is dismounted during the dismantlement of lower
suspension arm under no-load condition.
■ Check the wheel alignment. Please refer to “Check of Front Wheel Alignment”.
121
VI. Stabilizer Bar
1. Element
Diagram for Stabilizer Bar Element
2. Dismantlement and Installation Fig. 2.4.010
1) Dismantlement
① Dismantle the connecting ball joints of left and

right front stabilizer bars.
Fig. 2.4.011
② Dismantle the fixed nuts of support racks of
left and right stabilizer bars, and take off the
support racks and liners.
③ Dismantle the stabilizer bar assembly.
Check the stabilizer bar, connecting ball joint of stabilizer bar, support rack of stabilizer bar and liner of
stabilizer bar for deformation and wear. If any, please replace them.
3) Installation
122
Note: Don’t reuse disposable spare parts.
■ Pay attention to the installation direction when mounting the liner and support rack of stabilizer bar.
stabilizer bar under no-load condition.
VII. Connecting Ball Joint of Stabilizer Bar
1. Element
Diagram for Connecting Ball Joint Element of Stabilizer Bar
1) Dismantlement
① Dismantle the locknut at one end of the Fig. 2.4.012

connecting ball joint of stabilize bar from the
front damper. Step 1
② Dismantle the locknut at the other end of the

connecting ball joint of stabilize bar from the Step 2
stabilizer bar.
123
① Check of Ball Joint
■ Move the ball joint stud manually to confirm its flexibility.
② Visual Check
■ Check the dust cover of ball joint for crack and other damages. If any, please replace it.
2) Installation
■ Before locking the locknut, fix the ball joint stud to avoid rotation.
VIII. Support Beam of Engine
1. Element
Direction of the vehicle‘s

forward movement 5
1
Schematic Diagram for Position of Engine Suspension
1-Front mounting 2-Left mounting 3-Rear mounting 4-Support beam of engine 5-Right mounting
124
1) Dismantlement
① Support the oil pan of engine with jack.
Attention:
■ A cushion shall be put between the oil pan of engine and the jack.
② Dismantle the fixed bolt of support beam of engine.
③ Dismantle the fixed bolts and nuts between fixed support of engine suspension and the front & rear
engine suspensions.
④ Take off the support beam of engine.
⑤ Dismantle the cushions for front and rear engine suspensions.
■ Check the cushion and liner for crack, wear and aging.
■ Check the fixed support for deformation and damage.
2) Installation
Fig. 2.4.013
① Install the front and rear cushions for engine
suspension.
Fig. 2.4.014
125
Installation of Liner of Engine Support Beam

Fig. 2.4.015
a. Fit the upper and lower liners in the installation
holes of engine support beam respectively, as
shown in the figure.
Attention:
■ After assemblage, the liner shall be

compressed evenly in the installation hole and
its surface shall be flat.
b. Press the steel bushing into the liner in

parallel.

■ The steel bushing and liner shall be matched
tightly, and the surface shall be flat.
②Install the support beam of engine Fig. 2.4.017

Attention:
Fig. 2.4.018
■ The bolts and nuts between the cushion of
engine suspension and the fixed support for
that shall be tightened in advance. The final
tightening shall be conducted after the engine
assembly is mounted completely.
126
IX. Common Trouble Diagnosis
Common Trouble Diagnosis

Improper front wheel alignment Adjustment
Rotation over the ball joint of lower support
Replacement
Hard steering frame
Too low tire pressure Air inflation
No power steering Repair or replacement
Centering of steerable wheel Improper front wheel alignment Adjustment
Trouble of damper Repair or replacement
Poor return Wear or damage of stabilizer bar Replacement
Wear or damage of helical spring Replacement
Wear of lower suspension arm liner Replacement
Abnormal wear of tire Too low or too high tire pressure Press adjustment
Insufficient steering resistance of lower
Offtracking of vehicle Replacement
suspension arm ball joint connection
Looseness or wear of lower suspension
Replacement
arm liner
Offtracking of vehicle to one Replacement
side
Bending of lower suspension arm Replacement
Replacement
Looseness or wear of lower suspension
Shimmy of steerable wheel Replacement
arm liner
Wear or damage of stabilizer bar Replacement
Sagging of vehicle
127
X. Maintenance Parameters
Technical Specifications
Item Parameters and Specifications
McPherson independent suspension with helical
Type of front suspension
spring
Type Two-way hydraulic telescopic damper
Stroke 139 mm
Damper
Damping force Extension 975±166 N
(0.3 m/s) Contraction 265±60 N
Color identification:
Helical spring Manual transmission Free height: 322 mm
white_wire 1
Wheel toe-in (front) 0+ 3 mm
Camber angle 0°±30'
Wheel
Kingpin inclination 12° ±30'
alignment
Castor angle 2° ±30'
Offset of king pin 5.94 mm
Steel wheel 0.6 mm
Radial
Aluminum wheel 0.3 mm
Wheel runout
Steel wheel 1.0 mm
Axial
Tightening
Tightening Torque
Item Item Torque
(N • m)
(N • m)
Nut of upper seat of front Bolt between the front liner and front
20~30 100~120
damper support of lower suspension arm
Front damper and front
75~90 Fixed support of stabilizer bar 17~26
steering knuckle
Self-locking nut of front Installation of front and rear cushions for
60~70 40—50
damper engine suspension
Connecting ball joint of
35~55 Support beam of engine 70~90
stabilizer bar
Front support of lower
60~80
suspension arm
Rear support of lower Installation of front and rear engine
60~80 60~80
suspension arm suspension supports and cushions
Locknut of ball joint of lower
60~72
suspension arm
128
Section V Rear Suspension

I. Precautions
1. Precautions for Maintenance
■ When mounting suspension, it is necessary to carry out the final tightening on condition that the
tires contact the ground and there is no load.
－ No-load condition means that the fuel, engine coolant and lubricant have been filled normally, and
the spare tire, jack, driver tools and foot pad are in their designated positions.
■ After repairing the spare parts of suspension, do check the wheel alignment.
■ Reuse of locknut is forbidden. Always use new nut for installation.
II. Preparation
1. General Maintenance Tools
Table of General Maintenance Tools
For installation and dismantlement

1 Power tool
of bolt and nut
2. Special Tools
No. Tool Outline Diagram No. Illustration
Drawing die
For dismantlement of
1 for steering JAC-T1D003
connecting ball joint
driving rod
Damping For dismantlement and
2 spring JAC-T1D004 installation of damping
detacher spring
129
III. Rear Suspension Assembly
1. Element
Disassembly Diagram for Rear Suspension Assembly
1-Thrusting rod 2-Support rack of thrusting rod 3-Rear suspension arm (A) 4-Rear stabilizer bar
5-Rear suspension arm (B) 6-Rear steering knuckle 7-Rear frame
2. On-vehicle Check
Confirm whether the fixing (clearance, looseness) and elements (wear, damage) are normal.
1) Check of Damper
Check the installation position for oil leakage and damage.
2) Check of Axial Clearance of Wheel Bearing
① Lift the vehicle and check the axial clearance when the vehicle is stationary.
Note: If there is axial clearance, dismount the wheel hub cover and release the parking brake handle.
Afterwards, continue the following steps.
② Check the axial clearance at the end of wheel bearing.
130
a. Place the micrometer on the surface of wheel hub, and then rotate the wheel hub to check the axial
clearance.
■ Standard clearance: 0~0.22 mm
b. If the axial clearance is beyond the specified range, tighten the nut of wheel bearing with the
specified torque. Afterwards, check the axial clearance again.
c. If it is impossible to adjust the axial clearance to be within the specified range, replace the bearing of
rear wheel.
3. Check of Rear Wheel Alignment
Attention:
■ The camber angle has been set well before the car leaves the factory, so it can’t be adjusted.
■ If the camber angle is beyond the standard range, please check or replace the deformed or
damaged spare parts.
Camber angle of rear wheel: -0° 30'~0° 30'
1) Illustration
Measure the wheel alignment under no-load condition.
Note: No-load condition means that the levels of fuel and various fluids of engine reach their standard
values, and the spare tire, jack, driver tools and foot pad are in their designated positions.
2) Prior Check
① Check whether the tire pressure is normal and check the tire for wear. Please refer to ”Wheel and
Tire”.
② Check the wheel for run-out. Please refer to ”Wheel”.
③ Check the shaft end clearance of wheel bearing. Please refer to “Check of Wheel Bearing”.
④ Check the clearance of each suspension element and check each fixed point for looseness.
⑤ Check the maneuverability of the damper.
⑥ Check each suspension arm for crack, deformation and other damages.
⑦ Check the body height.
3) Wheel Toe-in
Take the following steps to measure the wheel toe-in. In case of failure to comply with the specified value,
please check and replace the worn or deformed spare parts of rear suspension.
① Park the vehicle on the four-wheel aligner and obtain the data of rear wheel alignment.
131
② If the indicated data are beyond the standard Fig. 2.5.001

range, rotate the adjusting bolt of rear
suspension arm (A) for adjustment.
Rear wheel toe-in value: 1~5 mm.
Attention:
■ During adjustment, the rotation of the

adjusting bolts on both sides of rear
suspension shall be the same.
Note: One grid of clockwise adjustment leads to

2.4 mm of toe-in change. (The unilateral toe-in
angle is about 14°)
Attention:
■ The eccentric bolt can only be adjusted within 90° leftwards and rightwards respectively.
■ The necessary check by road test shall be conducted.
IV. Rear Damper
1. Element
Diagram for Rear Damper Assembly
1) Dismantlement
① Lift the vehicle to dismantle the tires. Please refer to “Tire Assembly”.
② Dismantle the brake hard pipe snap-in to remove the brake hard pipe. Please refer to “Brake
Pipeline”.
③ Dismantle the C-pillar upper trim board. Please refer to “Interior Trimming of Body”.
132
④ Dismantle the locknut of upper seat of damper. Fig. 2.5.002

⑤ Dismantle the fixed bolts and nuts of damper

Fig. 2.5.003
and rear steering knuckle.
Attention:
■ During dismantlement, prevent the damper

assembly from falling suddenly to avoid
physical injury.
⑥ Dismantle the rear damper assembly.
① Check for deformation, crack and other damages. If any, Please conduct replacement.
② Check for oil leakage. If any, Please conduct replacement.
3) Installation
① Install in the reverse order with dismantlement. With respect to the tightening torque, please refer to
② Conduct the final tightening to each spare part that is dismounted during the dismantlement of rear
damper assembly under no-load condition.
③ Check the wheel alignment. Please refer to “Check of Rear Wheel Alignment”.
133
1) Disassembly
Disassembly Diagram for Rear Damper
1-Self-locking nut 2-Upper seat of helical spring 3-Upper vibration isolator of helical spring 4-Buffer
block of damper 5-Helical spring 6-Dust cover of damper 7-Lower vibration isolator of helical spring
8-Damper casing
Attention:
■ Don’t damage the piston push rod of damper when dismantling the spare parts of damper.
① Dismount the trimming cover with slotted Fig. 2.5.004 JAC-T1D004

screw driver.
② Compress the helical spring with spring

compressor till it is loosened.
Attention:
■ Compress the helical spring after confirming

that the compressor has been mounted
properly.
■ Don’t use any pneumatic tool when tightening the bolt of compressor.
③ Fix the end of piston pull rod to dismantle its self-locking nut.
Attention:
■ Confirm that the compressed helical spring is loose.
④ Dismantle the upper seat of helical spring, upper vibration isolator of spring, dust cover and buffer
block.
⑤ Dismantle the helical spring with compressor, and then loosen the compressor slowly.
⑥ Dismantle the lower vibration isolator of spring and take off the damper casing.
134

① Damper
■ Check the damper for oil leakage. If any, please replace it.
■ Check the piston push rod for damage, wear and deformation. If any, please replace it.
■ Check the lower seat of helical spring for crack and deformation. If any, please replace it.
② Buffer Block, Dust Cover and Vibration Isolator
■ Check the buffer block, dust cover, upper vibration isolator of spring and lower vibration isolator of
spring for wear and damage. If any, please replace them.
③ Helical Spring
■ Check the free play of the helical spring. In case of inconformity, please replace it as required.
④ Upper Seat of Helical Spring
■ Check it for crack, wear, deformation and other damages. If any, please replace it.
3) Assemblage
Attention:
■ Don’t use damaged spare parts.
Assemble in the reverse order with disassembly. With respect to the tightening torque, please refer to
■ Don’t damage the piston push rod when mounting the spare parts onto the damper.
■ When mounting the lower vibration isolator of
spring, it is necessary to align the boss of Fig. 2.5.005
vibration isolator with the spring seat hole on Lower seat of
spring
the damper and mount it properly.
■ Make the large-diameter end of the helical Hole (3 places)
spring downwards to align with the lower seat

of spring. Boss (3 places)
■ Confirm that the compressor has been

mounted onto the helical spring completely,
and then begin to compress the helical spring.
■ When releasing the compressor, check whether Fig. 2.5.006

the installation position of the helical spring is
correct.
■ Check whether the assemblage mark is correct.
135
V. Rear Suspension Arm (A)
1. Element
Diagram for Rear Suspension Arm (A) Element
1) Dismantlement
① Dismantle the support bar assembly of rear stabilizer bar. Please refer to “Support Bar of Rear
Stabilizer Bar”.
② Dismantle the connecting bolt between the rear suspension arm (A) and the rear steering knuckle.
③ Dismantle the eccentric bolt of rear suspension arm (A).
Attention:
■ The matching mark shall be made in advance.
④ Take off the rear suspension arm (A) assembly.
■ Check the rear suspension arm (A) for deformation and check the liner for wear and other damages.
If any, please replace it.
■ Check the thread of eccentric bolt for distortion. If any, please replace it.
3) Installation
■ Tighten the connecting bolt and eccentric bolt in advance.
suspension arm (A) under no-load condition.
■ Check the rear wheel alignment of the vehicle. Please refer to “Rear Suspension Assembly”.
136
VI. Rear Suspension Arm (B)
1. Element
Diagram for Rear Suspension Arm (B) Element
1) Dismantlement
① Dismantle the connecting bolt between the rear suspension arm (B) and the rear steering knuckle.
② Dismantle the connecting bolt between the rear suspension arm (B) and the body.
③ Take off the rear suspension arm (B) assembly.
■ Check the rear suspension arm (B) for deformation and check the liner for wear and other damages.
If any, please replace it.
3) Installation
■ Tighten the connecting bolt in advance.
■ Conduct the final tightening to each spare part that is dismounted during the dismantlement of rear
suspension arm (B) under no-load condition.
137
VII. Thrusting Rod
1. Element
Diagram for Thrusting Rod Element
1) Dismantlement
① Dismantle the fixed bolt of rear parking wiredrawing. Please refer to “Parking Braking System”.
② Dismantle the fixed bolt of front fixed support of thrusting rod.
③ Dismantle the connecting bolt between the

Fig. 2.5.007
thrusting rod and the rear steering knuckle.
■ Check the thrusting rod for deformation and check the liner for wear and other damages. If any,
please replace it.
3) Installation
■ Tighten the connecting bolt in advance.
thrusting rod under no-load condition.
138
VIII. Rear Stabilizer Bar
1. Element
Disassembly Diagram for Rear Stabilizer Bar
1-Rear stabilizer bar 2-Bolt 3-Shaft sleeve 4-Washer 5-Locknut

1) Dismantlement
① Dismantle the self-locking nut of support bar of

stabilizer bar and take off the isolating shaft sleeve
of support bar and washer.
139
② Dismantle the bolts of support racks of left and

right stabilizer bars and take off the support Fig. 2.5.009
racks and liners.
③ Dismantle the stabilizer bar.
Check the stabilize bar, isolating shaft sleeve of

support bar and support rack of stabilizer bar for
deformation, crack and wear. If any, please replace
them.
3) Installation
■ Install in the reverse order with dismantlement. With regard to the tightening torque, please refer to
■ When mounting the support rack of stabilizer bar, please pay attention to the installation direction.
IX. Support Bar of Stabilizer Bar
1. Element
Diagram for Support Bar Element of Stabilizer Bar
For the dismantlement and installation, please

refer to “Stabilizer Bar”.
Attention:
■ The end of rear stabilizer bar shall be mounted

between the two rubber sleeves at the upper
part of the support bar in advance.
■ It is required that the distance A from the lower

end of bolt to the locknut be 28~30 mm.
140
X. Common Trouble Diagnosis

Common Trouble Diagnosis
Looseness of assemblage Fastening
Fatigue or damage of wheel bearing Replacement
Abnormal sound
Damage of damper assembly Replacement of damaged component
Tire quality defect Replacement
Too high tire pressure Pressure adjustment
Damage of damper assembly Replacement of damaged component
Difficult control Looseness of tire nut Fastening
Shortening or breakage of helical spring Replacement
Tire quality defect Replacement
Body tilt Shortening or breakage of helical spring Replacement
XI. Maintenance Parameters
Rear Suspension System Two-connecting rod
Type Two-way hydraulic telescopic damper
Stroke 209.5 mm
Damper
Extension 480 ± 92 N
Damping force
Contraction 165 ± 44 N
Type Standard
Helical spring Free height 336.5 mm
Color Black
Toe-in 3±2 mm
Wheel alignment
Camber angle 0° ± 30'
Tightening Torque Tightening Torque
Item Item
(Nym) (Nym)
Rear suspension arm (A) and Rear suspension arm (B) and
110~120 80~100
body body
Rear suspension arm (A) and Rear suspension arm (B) and
100~120 100~120
rear steering knuckle rear steering knuckle
Thrusting rod and rear steering
Support rack of thrusting rod 40~50 100~120
knuckle
Mounting nut of upper seat of Rear damper and rear steering
20~30 75~90
rear damper knuckle
Support rack of rear stabilizer
Locknut of rear damper 45~55 17~26
bar
141
Section VI Wheel and Tire

I. Wheel
Attention:
■ Please use original wheels.
1. Check
■ Check whether there is any abrasion or inappropriate charge of the wheel.
■ Check whether there is any crack or other damages on the wheel. If deformation is found, please
check the run-out of the wheel.
1) Dismantle the tire from the wheel and mount it

on the wheel balancer. Fig. 2.6.001
2) Set the dial indicator according to the figure.

As for the run-out of the wheel, please refer
to “Maintenance Parameters”. If the total
run-out value exceeds the limit, please get it Transverse
Radial
replaced. runout
runout
II. Tire
Attention:
■ For new tires in the running in period, avoid sudden start, sharp turn and emergency braking. Do not
drive in bad working conditions so as to prevent immature damage of new tires.
■ The new tire shall be balanced before its use. As for details, please refer to “Wheel Balance”.
1. Check
1) Check of tire pressure
■ Check the charge pressure of the tire. If it is not within the range of the standard value, please make
certain adjustments.
Standard value: 220±10 Kpa
Attention:
■ Qualified tyre gauge should be used to check tyre pressure.
■ Tire pressure should be checked in the cold state at least once a month.
Cold state refers to the vehicle situation that it has not been operated for more than three hours at the
least; or the one that it has not been operated for three hours and with the previous mileage of less than
1.6 km.
■ Tire pressure should be checked frequently in a dramatically-changed ambient temperature.
142
■ Inappropriate tire pressure will lead to:

a. Inadequate tire pressure will lead to rapid Fig. 2.6.002
wear on the shoulder of the tire, tire flexing
and increase the rolling resistance.
b. Excessive tire pressure will lead to rapid wear

on the middle part of crown and weaken the Fig. 2.6.003
cushioning capacity of the tire.
2) Check of the tire tread Fig. 2.6.004
① Check the depth of the tire tread.

Note: Tire specification: 175/65R14 82H
■ When the depth of the tire tread reaches, or is
smaller than, the limit, the wear mark will
appear on the tire tread. While this occurs,
please replace the tire.
② Check whether there is any foreign matter in Fig. .6.005

the tire tread. If any, remove them.
3) Change of tire position
■ When the vehicle has run 8,000 km, the
position of its tires should be changed. Tire
replacement should be accompanied by
change of tire position.
Note: The recommended change of tire position
is shown in the figure.
143
4) Replacement
① After the vehicle has normally run 50,000 km, its tires should be replaced.
② In case of one of the following situations, the tire should also be replaced:
■ There are at least three worn-out marks on the tire tread.
■ There are cord fabrics or cord threads on the tire rubber.
■ There are cracks on the tread or shoulder of the tire; or the cord layer appears.
■ The tire has bulges, knurls or layer separation.
■ The tire is punctured, scratched or damaged to such an extent that it can not be repaired.
III. Tire Assembly of the Wheel

① Dismantle wheel nuts.

② Dismantle the tire assembly of the wheel.
2) Installation
① Install the wheel cover. Fig. 2.6.007
Attention:
■ The valve cock of the wheel cover should be
aligned with the wheel rim and then get it
pretightened.
② Install the tire assembly of the wheel and tire
nuts.
Attention:
■ If the manual installation, it shall be pretightened in turn to ensure wheel alignment; and then it shall
be evenly screwed down in a diagonal order.
■ If the automatic fastening, the tightening torque should be adjusted to ensure one-pass fastening.
2. Wheel balance
1) Dismantlement
① Dismantle tires to be adjusted.
144
② Dismantle old weights on both sides of the wheel and remove foreign matters on the tire tread.
Note: In case of a new tire, remove all tapes from it.
Attention:
■ During the dismantlement, take care to avoid any scratch to the wheel.
2) Adjustment of wheel balance
① With the center hole as the direction, install the driving wheel on the wheel balancer and start the
wheel balancer.
② When unbalanced values of both the outside and the inside are shown on the display of the wheel
balancer, multiply the unbalanced value of the outside with 5/3 to determine the mass of the weight
in actual use. Then select the weight of the outside with a value closest to the calculated one and
install them in the specified outside position or in the specified angle to the wheel.
Attention:
■ After the installation of outer weights, install the inner weights as well.
■ Before the installation of weights, make sure a clean and tidy matching surface for the wheel.
a. Install the weight at the position indicated by

the figure. Fig. 2.6.008
b. While installing weight on the driving wheel, as Bonding weight
shown in Fig. 2.6.008 on the right, position it in Center of gravity
the groove area on the inner wall of the driving Alignment

with the
groove
wheel to align the center of the weight with the
position (or angle) indicated by the wheel Position (angle) indicated by
the wheel balancer
balancer.
Attention:
■ Avoid repeated usage of weights and use new weights every time.
■ Weights installed should be no more than three.
■ Use original weights only.
c. If the calculated mass of the weight is more than 50 g, install the two weights in a line.
145
Attention:
■ Do not put one weight on the other. Fig. 2.6.009
③ Restart the wheel balancer.
④ Knock weights in from the inside of the driving
wheel in accordance with the position (or
angle) indicated by the wheel balancer.
Position (angle) indicated by
the wheel balancer
Attention:
■ The weights installed should be no more than two.
⑤ Start the wheel balancer. Make sure that the remaining unbalanced values on both the inner and
outside are no more than 5 g.
■ If the remaining unbalanced value on any side is more than 5 g, repeat the procedure of installing
the weights.
IV. Common Trouble Diagnosis for Tire Assembly of the Wheel

Offtracking of Wear of the steering knuckle of the drive shaft Replacement
the vehicle Wear, friction or click of the wheel bearing Replacement
replacement
Vibration Wear, damage or bending of the drive shaft Replacement
Abnormal sound of the drive shaft and wheel hub spline Replacement
Wear, friction or click of the wheel bearing Replacement
Run-out Unbalanced wheel Adjustment or
replacement
Defects of the steering knuckle of the front axle Adjustment or
replacement
Loud noise Wear, damage or bending of the drive shaft Replacement
Wear of the wheel hub spline of the drive axle Replacement
Wear of the wheel hub spline of the drive shaft Replacement
Wear, burning or abnormal sound of the wheel bearing Replacement
Looseness of hub nuts Adjustment or
replacement
replacement
146
V. Maintenance Parameters
1. Technical specifications
Item Parameter
Run-out of the wheel Radial direction Steel wheel 0.6 mm
Axial direction Steel wheel 1.0 mm
Tire pressure (cold state) 220±10 KPa
Tire specification 175/65R14 82H
Item Tightening Torque
Wheel nuts 90~110 Nym
147
Maintenance Manual of Tojoy Sedan Braking System
Chapter III Braking System
Section I Parking Braking System
I. Precautions
■ The parking braking system should be checked and adjusted under normal braking conditions.
■ When the parking braking system is checked, the vehicle should be parked on the level ground with
the wheels fixed by the corner blocks.
II. Parking Braking System Fig.3.1.001
1. On-vehicle check
1) Stroke of the parking control handle
■ Pull up the parking braking control handle with

a force of 196 N. Make sure that the ratchet is
in the specified groove (check it through
hearing and calculating the ratchet sound).
Standard value: 5~7 teeth
2) Check of elements
① Check whether every elements are fixed normally.
② Check whether there is any bending, damage or crack on the parking braking control handle. If any,
get it replaced.
③ Check whether there is any abrasion or damages on the parking braking wiredrawing. If any, get it
replaced.
④ Check whether the switch of the parking braking warning lamp is normal. If it is out of work, please
check or get it replaced.
3) Adjustment
Attention:
■ Adjust the parking braking system under normal braking conditions.
① Dismantle the rear part of the auxiliary facia console. Please refer to “Auxiliary Facia Console”.
② Release the parking braking control handle and insert both the left and the right wiredrawing joints
into the mounting hole of the balance plate of the braking control handle.
③ After the mounting of the wiredrawing, screw down the adjusting nut to ensure the specified
distance between the adjusting nut and the end of the wiredrawing.
148
Disassembly Diagram for the Parking Control Handle Assembly

1-Parking control handle assembly 2-Parking wiredrawing joint 3-Adjusting nut
4-Thread brace rod
■ L: 35~40 mm
④ After the adjustment, pull up the braking control handle with a force of 196 N vertical to the handle at
the position 25 mm from the end of the handle and adjust the adjusting nuts to enable the pull-up of
5~7 teeth for the handle. Otherwise, L should be adjusted through the adjustment of the adjusting
nut.
Note: If the number of the teeth pulled up is less than 5, reduce L; vice versa.
Attention: After the adjustment, check whether there is any drag of the wheel while the parking braking
control handle is completely released.
2. Element
Disassembly Diagram for the Parking Braking Wiredrawing

1- Parking control handle assembly 2-Fixed junction clip of both the left and the right wiredrawings
3-Right parking braking wiredrawing assembly 4-Left parking braking wiredrawing assembly
5-Clamp spring
149
1) Dismantlement and installation

Fig.3.1.002
① Dismantlement
a. Dismantle the rear part assembly of the
auxiliary facia console. Please refer to
“Auxiliary Facia Console”.
Fig.3.1.003
b. Loosen the adjusting nut and dismantle the

parking wiredrawing on both the left and the
right side from the inside of the wiredrawing
bayonet.
c. Disconnect the wire harness of the parking

braking switch and dismantle the parking Fig.3.1.004
braking control handle assembly.
d. Dismantle the tire of the rear wheel. Please
refer to “Wheel and Tire”.
e. Dismantle the rear brake shoe. Please refer to
“Rear Brake”.
i
f. Dismantle the parking braking wiredrawing
from the pull rod of the brake shoe.
Fig.3.1.005
150
g. Dismantle the fastening bolt of the parking

Fig.3.1.006
braking wiredrawing. Left
h. Withdraw the parking braking wiredrawing

assembly from the mounting hole at the
bottom of the body.
Fig. 3.1.007
Right
② Check after dismantlement
■ Check whether the buttons are normal. If they can not return to the original position, please get them
replaced.
■ Check whether there is any wear at the ratchet of the parking braking control handle.
■ Check whether there is any deformation, wear, bending or looseness in the parking braking
wiredrawing. If any, please get it replaced.
③ Installation
■ Make sure that the wiredrawing runs in a smooth way while installing the wiredrawing.
■ Check and adjust the stroke of the parking control handle. Please refer to “Adjustment”.
151
Section II Braking System

I. Precautions
1. ”D0T4" brake fluid is recommended for use.
2. Please do not reuse the discharged brake fluid.
3. Pay attention not to spilling the brake fluid on the painted surface in order to prevent it from
damaging the paint. Please wash the painted surface with water immediately if the brake fluid is spilt
on it.
4. Please wash all the spare parts of the brake wheel cylinder with clean brake fluid.
5. Please do not use mineral oil such as petrol and kerosene in order to prevent it from damaging the
rubber spare parts of hydraulic system.
6. Please use special flare nut wrench to dismantle or mount the oil pipes.
7. The tightening torque must be checked while mounting the brake oil pipe.
8. The brake joint surface shall be run in after the brake drum (disc) and brake shoe are repaired or
replaced, or when the spongy brake appears after a short traveling distance. Please refer to "Steps
of Front Brake Running In".
II. Preparation
Special maintenance tools must be used for dismantlement and installation if necessary.
Table of Maintenance Tools
For dismantling and

Flare nut
1 mounting brake oil
wrench
pipes
For dismantling and

2 Power tool
mounting bolts and nuts
153
III. Brake Pedal
1. Check and Adjust Fig. 3.2.001 Locknut
The Adjustment of clearance between the brake

pedal and brake limit switch bolt:
1) Dismantle the lower part of the console. Please

refer to "Console".
2) Cut off the connector of stop lamp switch, and

Brake pedal dog
screw off the locknut of stop lamp. Then loosen plate
the brake pedal, and turn the switch to make
the clearance between the switch and brake
pedal is within 0.5 ~ 1.0 mm.
2. Free Play of Brake Pedal

1) Press the brake pedal 2 ~ 3 times when the Fig. 3.2.002
engine is shut down.
2) Press the pedal with hand when the vacuum of
the brake vacuum booster is confirmed to be
eliminated.
3) Check if the free play of the pedal is within the
standard range before the occurrence of
resistance.
■ Standard value: 3 ~ 8 mm
4) If the free play is beyond the standard range, it

shall be adjusted.
Attention:
■ If the free play cannot be adjusted within the

standard range, please replace the damaged
spare parts.

Fig. 3.2.003
1) Dismantlement
① Dismantle the lower part of the console. Please
refer to "Console".
② Cut off the connector of the stop lamp switch.
③ Dismantle the connecting lockpin of the brake

vacuum booster to disconnect it with the brake
vacuum booster.
154
④ Dismantle the fixed bolt of brake pedal and

body, as well as the fixed nut of brake vacuum Fig. 3.2.004
booster.
■ Tightening torque: 20~ 25 N•m
⑤ Take out the brake pedal.

① Brake pedal
■ Check if the movable pin of brake pedal is worn
or deformed.
■ Check if the brake pedal has the damages
such as crack and distortion.
② Lockpin and liner
■ Check if the lockpin and liner are damaged or
deformed, if they are, please replace them.
③ Stop lamp switch
a. Check the two terminals of the stop lamp switch Fig. 3.2.005
with multimeter to see if they are conducted
when pressing on or releasing the stop lamp
strut. Non-conduction Conduction
b. As the figure shows, when the strut is pressed
more than 4 mm, there is non-conduction
between the terminals, but when it is released,
there is conduction between the terminals,
which shows that the stop lamp switch works
normally.
3) Installation
Attention:
■ Check if the brake pedal operates smoothly.
■ Check and adjust the brake pedal free play
after installation.
■ Check the clearance between the brake pedal
and stop lamp limit switch.
155
IV. Brake Master Cylinder
1. On-vehicle Check
Check if the master cylinder mounting surface, stock solution tank mounting surface and brake pipe
connector leak.
Attention:
■ Don't splash the brake fluid on the painted surface, or else it will damage the oil paint. If there is
brake fluid on the painted surface, please clean it with water immediately.

① Discharge the brake fluid. Please refer to
"Discharge and Fill”.
② Dismantle the air filter assembly. Please refer

to “Air Filter Assembly”.
③ Dismantle connector of brake fluid level switch.
④ Cut off the brake hard pipe of the master Fig. 3.2.007
cylinder with flare nut wrench.
⑤ Dismantle the connecting pipe of brake Fig. 3.2.008

master cylinder and clutch master cylinder as
well as the fixed nut of master cylinder, and
then dismount the master cylinder
sub-assembly.
156
2) Installation
Attention:
■ Please refill the brake fluid "D0T4".
■ Please don't reuse the discharged brake fluid.
■ Apply the lubricating grease to the axis pin of master cylinder before installation: SAE J310 or the
similar product.
① Mount the master cylinder on the brake vacuum booster, and tighten the nut.
Attention:
■ Please don't damage the slip surface of piston push rod, and don't let the foreign matters drop on its
surface.
② Mount the brake hard pipe on the master cylinder sub-assembly, and pretighten it.
③ Tighten the brake oil pipe nut with flare nut wrench or the similar tools. Please refer to "Hydraulic
Pipeline Diagram".
④ Mount the connector of the brake fluid level switch.
⑤ Fill new brake fluid and exhaust air. Please refer to "Exhaust Air in the Hydraulic Pipeline".
V. Brake Fluid
Fig. 3.2.009
1. Check of the Brake Fluid Level
■ Make sure the level of brake fluid in the stock

solution tank is within the specified range
(between marks of MAX and MIN).
MAX
■ Check visually if there is leakage around the
stock solution tank.
MIN
■ Please check if the braking system leaks if the
oil level is too low.
■ Release the parking brake handle, and observe

if the brake alarm lamp goes out. If the lamp
does not go out, please check if the braking
system leaks.
2. Discharge and Fill

Attention:
■ Please refill the brake fluid "D0T4".
■ Please don't splash the brake fluid on the painted surface, to avoid damaging the oil paint. If there is
157
1) Insert the ethylene tube into the exhaust valve. Fig. 3.2.010
2) Press the brake pedal, release the exhaust

valve, and then discharge the brake fluid
slowly.
3) Clean the inside of the stock solution tank, and Fig. 3.2.011
fill new brake fluid.
4) Release the exhaust valve, press the brake

pedal slowly to the end, and release it. Repeat
the steps every 2s or 3s until the new brake
fluid flows out, and press the brake pedal still to
shut off the exhaust valve. Repeat the same
operation for each wheel.
5) Exhaust air. Please refer to "Exhaust Air in the

Brake Pipeline".
3. Exhaust air in the brake pipeline.
Attention:
■ Pay attention to the level of brake fluid in the stock solution tank of master cylinder when exhausting
the air.
1) Insert the ethylene tube into the exhaust valve of right rear brake wheel cylinder.
2) Press the brake pedal to the end 4 or 5 times.
3) Press the brake pedal still, release the exhaust valve to exhaust the air in brake pipeline, and then
tighten the exhaust valve immediately.
4) Repeat step 2) and step 3) until all the air is exhausted from the brake pipeline.
5) Tighten the exhaust valve.
6) Repeat the above steps and fill up half of the stock solution tank of master cylinder at least, and
exhaust the air in brake pipeline according to the following sequence.
■ The air exhaust sequence of the four wheels: Right rear brake wheel cylinder, left front brake wheel
cylinder, left rear brake wheel cylinder, and right front brake wheel cylinder
158
VI. Brake Pipeline
1. Diagram for Hydraulic Pipeline
Diagram for Hydraulic Pipeline of Braking System
1-Rear right wheel 2-Rear wheel cylinder 3-Speed sensor 4-Brake pedal 5-Vacuum booster with brake
master cylinder assembly 6- Right front wheel cylinder 7- Right front wheel 8- Left front wheel cylinder 9-
Left front wheel 10-ABS module 11- Left rear wheel cylinder 12- Left rear wheel
Attention:
■ None of the brake hoses and brake pipes shall be excessively bent, twisted or stretched.
■ Make sure there is no interference with other spare parts during steering.
■ The brake pipeline and hose are significant safety spare parts, if there is leakage of brake fluid, the
fixing device shall be tightened all the while. If there are damaged spare parts, please replace them
with new and applicable ones.
■ Please don't splash the brake fluid on the painted surface, to avoid damaging the oil paint. If there is
■ When the brake pipeline and hose are cut off, please seal the open end properly to avoid the
entering of dust.
■ The brake fluid "D0T4" shall be refilled.
159
1. Front Brake Pipe and Hose

Fig. 3.2.012
1) Dismantlement
① Dismantle the wheel tyre. Please refer to

"Wheel and Tyre".
② Dismantle the brake hose bolt.
Attention:
■ Take care not to let the bolt gasket drop off.
③ Dismantle the connector of brake hose and Fig. 3.2.013

brake hard pipe with flare nut wrench to take
off the clamping piece.
④ Dismantle the fixed bolt of brake hose clip

from the damper.
⑤ Dismount the brake hose and brake pipe.
2) Installation
① Mount the fixed bolt of brake hose clip and copper gasket.
Attention:
■ Please don't reuse the gasket.
■ Pay attention to the mounting direction of the brake hose connector.
② Pretighten the locknut of brake hose and brake hard pipe, mount the card and then tighten it with
flare nut wrench.
Note: Pretighten it with hand as much as possible.
③ Tighten the fixed bolt of brake hose clamping piece.
④ Please refer to "Exhaust Air in the Brake Pipeline".
160
2. Rear Brake Pipeline and Brake Hose Fig. 3.2.014
1) Dismantlement
① Dismantle the hard pipe of the rear brake

wheel cylinder with flare nut wrench.
② Dismantle the rear brake hose and brake hard Fig. 3.2.015
pipe to dismount the clamping piece.
③ Dismantle the brake hose and brake hard

pipe.
3) Installation
① Pretighten the connector of brake hose and brake hard pipe, mount the snap-gauge, and then
tighten it with flare nut wrench.
② Mount the hard pipe of the rear brake wheel cylinder.
③ Fill new brake fluid and exhaust air. Please refer to "Exhaust Air in the Brake Pipeline".
3. Brake Hard Pipe of Brake Master Cylinder and ABS Pump or Brake Distribution Valve

① Dismantle the air filter assembly. Please refer
to "Air Filter".
② Dismantle the oil pipe connector of brake

master cylinder.
161
③ Cut off the connector of brake master cylinder Fig. 3.2.017

and ABS pump or brake distribution valve, and
then cut off other connectors in turn.

4个
Attention:
■ The brake fluid in the ABS pump shall not be

discharged completely.

① Pretighten the connector of oil pipe of brake
master cylinder and ABS pump or brake
distribution valve.
② Pretighten other oil pipe connectors in turn.
③ Pretighten the above connectors with flare nut 6个

wrench.
④ Mount the air filter assembly.
⑤ Fill new brake fluid and exhaust air. "Exhaust

Air in the Brake Pipeline".
Attention:
■ If the connector of brake pipe and brake hose leaks, please tighten it; or if there are spare parts
damaged, please replace them.
① Check if the brake hose, brake pipe and connector leak fluid, or if they are damaged, twisted,
deformed, or in contact with other spare parts and loose.
② Apply certain brake force for several seconds when the engine is in operation, and then check if the
spare parts leak fluid.
VII. Brake Vacuum Booster
1. On-vehicle Check
1) Operation Check
Shut down the engine, and press the brake pedal for several times, to keep the vacuum pressure of the
brake vacuum booster the same with atmospheric pressure. Press the brake pedal to the end to start the
engine, and when the vacuum meets the standard, make sure the clearance between brake pedal and
floor is shortened.
162
Attention:
■ The interval of stepping down the brake pedal is Fig. 3.2.019
5s.
2) Check of Air Tightness

Fig. 3.2.020
■ The engine shall be shut down when it Good Poor
operates at idle speed for 1 min and the brake
vacuum booster becomes vacuum. Press the
brake pedal normally to relieve the vacuum.
Make sure the clearance between brake pedal
and floor increases gradually. Third
■ Press the pedal when the engine is in Second
operation, and then step down the pedal for First
30s to shut down the engine, after that make
sure the pedal stoke does not change.
Attention:
■ The interval of stepping down the pedal is 5s.
Attention:
■ Please don't bend the brake pipe when
dismantling the brake vacuum booster.
■ Please replace the damaged lockpin.
■ Please don't damage the thread of brake
vacuum booster fixed bolt.
1) Dismantlement
① Dismantle the air filter assembly. Please refer Fig. 3.2.021
to "Air Filter".
② Dismantle the vacuum hose from the brake
vacuum booster.
163
③ Dismantle the lockpin from the brake pedal. Fig. 3.2.022
④ Dismantle the connecting nut of the brake Fig. 3.2.023

pedal and brake vacuum booster.
⑤ Dismantle the vacuum booster from the

engine compartment.
2) Check after Dismantlement Fig. 3.2.024

Length of input rod
① Check of the length of push rod
a. Apply the vacuum pressure of -66.7 KPa to

the brake vacuum booster with hand-operated
vacuum pump. Preload
b. Check the length of push rod.
② Vacuum hose
Check if it is damaged or cracked. If it is, please

replace it.

Input rod
① Unscrew the locknut to adjust the length of
push rod in the standard range, and then
pretighten it. See the figure (3.2.025).
■ Standard value B: 157 mm

Locknut
② Mount the brake vacuum booster onto the fire
wall according to the specified tightening
torque.
164
③ Mount the brake pedal lockpin. Please refer to "Brake Pedal".
④ Mount the vacuum hose.
Attention:
■ Insert the vacuum hose at least 20 mm during installation.
■ Please don't use the lubricating oil during installation.
⑤ Please refer to "Adjustment of Brake Pedal". Adjust the free play of the brake pedal.
⑥ Tighten the push rod locknut according to the specified torque.
⑦ Mount the air filter assembly. Please refer to "Air Filter".
⑧ Fill new brake fluid and exhaust the air. Please refer to "Exhaust Air in the Hydraulic Pipeline".
VIII. Front Disc Brake Tongs Fig. 3.2.025

1. On-vehicle Check
1) Wear check of the brake shoe
■ Check the thickness of brake shoe from the

access hole of brake wheel cylinder. Check
with graduated scale if necessary.
Standard thickness: 9.0 mm
Wear limit thickness: 2.0 mm
165
2. Element
Disassembly Diagram for Brake Tongs
1- Brake tongs body 2- Dust wrapper of slide pin 3-Piston 4-Dust cover of piston 5-Piston guide ring
6-Caliper support rack 7-Exhaust screw 8-Spring pad 9-Brake shoe 10- Brake shoe muffler plate
Attention:
■ The brake wheel cylinder and brake shoe shall be cleaned thoroughly, to minimize the damage
caused by the particle in air and other substances.
■ Please don't step down the brake pedal when dismantling the brake wheel cylinder, in order to avoid
the piston being ejected.
■ Please don't damage the dust wrapper of the piston.
■ Please don't dismantle the support rack of the brake wheel cylinder and the bolt on brake hose
unless disassembling or replacing the brake wheel cylinder. The brake wheel cylinder can be hung
with rope to avoid pulling the brake hose.
■ If the brake shoe muffler plate is seriously worn, please replace it with new muffler plate.
■ The muffler plate shall be replaced when the brake shoe is replaced.
■ Make sure there is no brake fluid on the brake disc.
166
3. Dismantlement and Installation of Brake Shoe

Fig. 3.2.027
1) Dismantlement
"Wheel and Tyre".
② Dismantle the sliding pin of lower brake wheel
cylinder.
③ Lift the brake wheel cylinder with rope, and
then dismantle the brake shoe, and brake
shoe muffler plate.
2) Installation
① Mount the inner and outer muffler plates on Fig. 3.2.028
their brake shoes separately.
Attention:
■ Mount the muffler plate based on its fixed
direction.
② Mount the brake shoe onto the support rack of
brake wheel cylinder.
③ Keep pressing the piston when mounting the
brake shoe, and then mount the brake wheel
cylinder onto its support rack.
Note: The piston can be pressed continuously with
the disc-type brake piston tools.
■ Pay attention to the level of brake fluid in the
brake stock solution tank.
④ Mount the sliding pin of lower brake wheel
cylinder, and tighten it.
⑤ Fix the brake disc with tyre nut, and step down
the brake pedal until it works.
⑥ Check the brake rotation resistance.
⑦ Mount the wheel tyre.
4. Dismantlement and Installation of Brake
Tongs Sub-assembly
1) Dismantlement
"Wheel and Tyre".
② Dismantle the brake hose bolt, and then cut
off the brake hose.
167
■ Take care not to let the bolt gasket drop off.
③ Dismantle the bolt of the support rack of the

brake wheel cylinder, and then dismantle the
brake tongs sub-assembly.
2) Installation
Attention:
■ Refill the brake fluid "D0T4".
① Mount the brake tongs sub-assembly on the steering knuckle, and then tighten the fixed bolt of the
support rack of the brake wheel cylinder to the specified torque.
Attention:
■ The engine oil and water on the joint surfaces of steering knuckle and brake tongs sub-assembly,
fixed bolt of the brake hose, and fixed bolt gasket shall be avoided.
② Mount the brake hose on the brake tongs sub-assembly, and tighten the fixed bolt of brake hose to
the specified torque.

■ Please don't reuse the fixed bolt gasket of the
brake hose.
■ Limit, align and connect the brake hose and

brake tongs sub-assembly.
③ Fill brake fluid and exhaust air. Please refer to

"Brake Fluid".
④ Check the rotation resistance of the brake.
⑤ Mount the wheel tyre.
168
5. Disassembly and Assemblage of Brake Tongs Sub-assembly
1) Disassembly
① Dismantle the sliding pin of brake wheel cylinder, and dismantle the brake wheel cylinder from its
support rack. Dismantle the brake shoe and its muffler plate from the support rack of brake wheel
cylinder.
Attention:
■ Please don't let the brake shoe and its muffler plate drop off from the support rack of brake wheel
cylinder.
② Dismantle the sliding pin and sliding pin dust wrapper from the support rack of brake wheel cylinder.
③ As the figure shows, put a proper wood block, Fig. 3.2.031

and blow air evenly to the fixed bolt hole of the
brake hose, to dismantle the piston and its
dust wrapper.
Attention:
■ Take care not to let the finger clamped by the

piston.
④ Dismantle the piston seal ring from the brake Fig. 3.2.032
wheel cylinder with slotted screwdriver. Piston seal ring
Attention:
■ Don't damage the inner wall of the brake wheel

cylinder body.
2) Check after Disassembly
① Brake wheel cylinder body
Attention:
■ Clean the cylinder body with new brake fluid. Please don't use petrol or kerosene.
■ Check if the inner wall of brake wheel cylinder body is worn or damaged. If it is, please replace the
brake wheel cylinder.
② Support rack of the brake wheel cylinder
■ Check if the support rack is worn, cracked or damaged. If it is, please replace it.
③ Piston
■ Check if the piston surface is rusty, worn, or damaged. If it is, please replace it.
169
■ Please don't grind the piston surface with sand paper.

④ Sliding pin, pin bolt or pin dust wrapper.
■ Check if the sliding pin, pin bolt and pin dust wrapper are worn and cracked. If they are, please
replace them.
3) Assemblage
Fig. 3.2.033
Attention: Piston seal ring
■ The specified rubber grease shall be used
during assemblage.
① Apply rubber grease to the piston seal ring, and
mount the piston seal ring in the cylinder body.
Attention:
■ Please don't reuse piston seal ring.
② Apply brake fluid to the piston, and apply
rubber grease to the piston dust wrapper.
Cover the piston port with piston dust wrapper,
and then slowly fixed the side of cylinder body
which is on the piston dust wrapper in the
groove of the cylinder body.
Attention: Piston dust Fig. 3.2.034

cover
■ Please don't reuse piston dust wrapper. Piston
③ Put hand in the cylinder body and insert the

piston edge of the piston dust wrapper in the
piston groove.
Attention:
■ Apply an even force to press down the piston in
order to avoid rubbing the inner wall of the
cylinder body.
④ Mount the sliding pin and sliding pin dust
wrapper on the support rack of brake wheel
cylinder separately.
⑤ Mount the shoe muffler plate on the brake
shoe.
Attention:
■ Mount it based on the fixed direction of the
muffler plate.
⑥ Mount the brake shoe sub-assembly on the
support rack of brake wheel cylinder.
170
⑦ Keep pressing the piston when mounting the Fig. 3.2.035

brake shoe, and then mount the brake wheel
cylinder on the support rack of brake wheel
cylinder.
⑧ Tighten the pin bolt.
6. Check of the Brake Disc
1) Visual Check
■ Check if the surface of brake disc is unevenly worn, cracked and seriously damaged. If it is, please
replace it.
2) Check of the Runout

Fig. 3.2.036
① Fix the brake disc on the wheel hub.
② Check the runout with dial gauge. (It can be
measured at the place which is 10 mm away
from the inside edge of brake disc)
■ Runout limit: 0.05 mm
Note: Make sure the axial clearance of wheel
bearing is within the specified value before
measurement. Refer to "Check of the Wheel
Bearing". Fig. 3.2.037
③ If the runout is beyond the specified value,
please replace it or do some necessary
processes.
3) Check of Thickness
■ Check the thickness of brake disc with dial
gauge. If the thickness is lower than the wear
limit, please replace the brake disc.
Standard thickness: 19 mm
Wear limit: 17 mm
7. Steps of Brake Running In
If the spongy brake appears after the brake disc is repaired or replaced and the brake is replaced, or
after a short distance travel, please run in the joint surface of brake disc and brake shoe according to
following steps.
■ If the brake effect is not good before running in, please pay attention to controlling the speed.
171
■ These steps shall be carried out only when the pavement and traffic conditions are safe. Pay
attention to your safety.
1) Drive the vehicle on the smooth road.
2) Control the force of stepping down the brake pedal to brake the vehicle within 3s ~ 5s.
3) Drive some distances continuously to make the braking system cool down.
4) Repeat steps 1~ 3 until the brake shoe and brake disc are run in completely.
IX. Rear Brake Fig. 3.2.038

1. On-vehicle Check
1) Wear check of brake shoe
■ Check the thickness of brake shoe from the

access hole of brake bottom plate.

1) Dismantlement

"Wheel and Tyre".
② Release the parking brake.
③ Dismantle the rear wheel hub dust cover,

locknut and gasket of the wheel bearing
assembly, and take off the wheel bearing
assembly. Please refer to “Wheel Hub and
Bearing”.
④ Dismantle the stop bolt of the rear brake drum,

and take off the brake drum.
⑤ Dismantle the rear brake hard pipe. Please Fig. 3.2.040

refer to "Brake Pipeline".
⑥ Dismantle the speed sensor. Please refer to

"Speed Sensor".
172

■ Please don't pull the speed sensor harness.
⑦ Dismantle the rear brake shoe and parking
brake wiredrawing.
⑧ Dismantle fixed bolt of brake bottom plate

Fig. 3.2.042
■ Tightening torque: 45~ 55 N•m
⑨ Take off the rear brake from the rear steering
knuckle.
2) Check after Dismantlement Fig. 3.2.043

Inner diameter
① Brake drum
■ Check if the inner diameter and circular runout
of brake drum are within the standard value. If
they are not, please process or replace it.
Standard value: 204 mm
Circular runout: < 0.05 mm
② Brake shoe
Fig. 3.2.044
■ Check the thickness of brake shoe and its
connection with brake drum. If they do not
conform to the standard, please replace the
brake shoe.
Standard thickness of brake shoe (A): 5 mm
Allowable limit thickness (A): 1 mm
173
③ Brake bottom plate
Check if the brake bottom plate has wear and other damages.
3) Installation
■ Tighten the fixed bolt of brake bottom plate according to the diagonal sequence.
■ The diameter of brake shoe shall be adjusted within φ 204 ± 0.25 mm in order to conveniently mount
the brake drum.
■ The inner surface of brake drum shall be cleaned during installation, and the grease shall be
avoided for the contact surface of brake shoe and brake drum. If the contact surface is stained with
grease, it shall be cleaned with acetone, if it is stained seriously, please replace it with a brake shoe
assembly with same model.
■ The brake pedal shall be stepped down for several times after mounting the brake drum to place the
brake shoe in position.
Attention:
■ The brake is equipped with automatic clearance adjusting device. The brake shoe clearance will be
adjusted automatically to the normal value in the above braking processes.
■ The parking wiredrawing shall be adjusted. Please refer to "Parking Brake System".
■ Exhaust the air in braking system. Please refer to "Brake Fluid".
174
1) Element
Disassembly Diagram for Rear Brake
1-Adjusting spring 2-Dial plate 3-Rear brake wheel cylinder 4-Washer 5-Bolt 6-Upper return spring
7-Adjusting rod 8-Brake shoe and arm assembly 9-Compression spring of brake shoe 10-Compression
spring pull rod 11-Support bar protecting sleeve 12-Support bar 13-Lower return spring 14-Brake bottom
plate 15-Access hole plug 16-Brake shoe assembly
2) Disassembly Fig. 3.2.045
① Dismantle the adjusting spring.
Fig. 3.2.046
② Dismantle the compression spring of brake

shoe and the compression spring pull rod.
175
③ Stretch the shoe, dismantle the upper and Fig. 3.2.047

lower return springs and adjusting rod.
④ Dismantle the parking wiredrawing from the
brake shoe arm, and take off the brake shoe.
⑤ Dismantle the fixed bolt of brake wheel
cylinder, and take off the brake wheel cylinder
from the brake bottom plate.
3) Check after Disassembly Fig. 3.2.048

① Brake wheel cylinder
Check if the brake wheel cylinder outside has wear
or other damages, and if the piston is flexible as
well as if the contact surface of piston and brake
shoe is worn or leaks oil. If the above conditions
exist, please replace the wheel cylinder assembly.
② Return spring, arm, and adjusting rod Fig. 3.2.049

Check the elasticity of spring, and check if the arm
and adjusting rod have deformation and other
damages.
Pay attention to the following items and install in

the reverse order with dismantlement.
■ Mount the upper return spring first, and then
mount the lower return spring. Forward
■ Apply the lubricating grease in the shadow
area as shown by the arrow.
■ Pay attention to the mounting direction of the
adjusting rod.
176
X. Troubleshooting
1. Rear Braking System
Table of Common Troubleshooting for Rear Braking System

1. The pipeline connector and cup of brake wheel cylinder 1. Tighten or replace it after cleaning
leak fluid 2. Exhaust
2. The residual air in the pipeline is not exhausted 3. Readjust
completely 4. Frictionize or replace
Insufficient 3. The clearance between brake shoe and brake drum is 5. Replace, reduce the temperature, and
brake force too large exhaust the air
4. The brake shoe surface is stained with oil or is
hardened
5. The brake drum is overheated, and there is
air-resistance in the pipeline
1. The oil return hole of rear brake wheel cylinder is 1. Do troubleshooting or replace
blocked or the cup is expansive 2. Readjust
2. The clearance between brake shoe and brake drum is 3. Replace
The brake
too small 4. Modify or replace
is hard to
3. The elasticity of the brake shoe return spring wanes or
release
the brake shoe return spring is broken
4. The brake shoe or bottom plate is deformed, and the
return is resisted.
1. The rear brake shoe is seriously worn 1. Replace
2. The brake drum is out of circularity. 2. Honing, and check of the balance
3. When the rear brake surface is too smooth, the friction performance
coefficient is small, while the brake pressure is high, 3. Clean the foreign matter, and grind the
Noise there will be frictional noise when the smooth surface rear brake shoe with sandpaper
frictionizes as sliding, or due to the foreign matter
seized in the friction pair pressing the friction surface
1. The brake clearance and the pedal free play are too 1. The brake clearance shall be readjusted
small, when releasing the brake pedal, the brake force in that case
has not disappeared, causing the friction pair to be 2. Adjust it according to the specification if
frictionized in long term; the initial starting is difficult, the necessary.
operation is powerless, and the wheel drum is hot when 3. The troubleshooting can be done by
touching its surface overhauling or replacing the return spring
The brake 2. The brake handle is not released completely due to
drum improper adjustment or operation mistake, Which
heating due causes the friction pair to be heated for having been
to braking frictionized for a long time
drag 3. The heat generated by brake results in the return spring
deformation, the elasticity reduction or disappearance,
and if it cannot make sure the rear brake shoe
assembly return timely after braking, it cannot stop the
brake drum heating for the brake cannot being released
timely either
The common wiredrawing or rusty sleeve, broken, falling off Check if the surfaces of brake control
stiff spring or disappeared elasticity cause that the parking wiredrawing and braking system components
Parking brake control wiredrawing or brake wiredrawing cannot be are damaged, if the handle is controlled
brake pulled flexibly in their jackets, therefore the parking brake flexibly and clamped; Check if the wiredrawing
failure can not be released and it will fail to work connector and the fixed part is loose or
damaged, repair or replace the parts if
necessary.
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2. Braking System
Table of Common Troubleshooting for Braking System

Trouble Possible Causes Troubleshooting
The air pressure of left and right tyres is insufficient Adjust
The adjustment of front wheel is incorrect Adjust
Off tracking at one side The brake shoe is of poor contact Adjust
when the vehicle is There is lubricating grease or oil on the surface of brake shoe replace
braked The brake drum is eccentric or is not worn evenly replace
The brake wheel cylinder is not mounted properly Adjust
The automatic adjusting device has trouble Adjust

The brake fluid is very little or is polluted Add or replace
There is air in the braking system Exhaust air in the system

The brake booster has trouble Adjust
The brake shoe is of poor contact Adjust
Insufficient brake force There is lubricating grease or oil on the surface of brake shoe Replace
The drag of brake shoe results in overheated rotary spare parts of Adjust
the brake
The brake pipeline is restricted Adjust
The proportional valve has trouble Replace
There is air in the braking system Exhaust air in the system
Pedal stroke increase The brake fluid leaks Adjust

(the distance from The automatic adjusting device has trouble Adjust
pedal to floor shortens) The clearance between push rod and brake master cylinder is too Adjust
large
The parking brake is not released completely
The parking brake is adjusted improperly Adjust

The brake pedal return spring is worn Replace
The oil return hole of brake master cylinder is restricted Adjust
The brake return spring of the rear drum is damaged Replace
Braking drag
The sliding spare parts is short of lubrication Lubricate
The one-way valve of brake master cylinder or piston return spring Replace
has deficiency
The clearance between push rod and brake master cylinder is too Adjust
small
The rear brake shoe is damaged Adjust
Inadequate parking There is lubricating grease or oil on the surface of rear brake shoe Replace
brake function The parking brake cable is seized Adjust
The stroke of parking brake handle is too large Adjust
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XI. Maintenance Parameter
Item Specification Item Specification

Type Tandem Type Rear wheel mechanical
Brake master
brake
cylinder Parking brake
Cylinder diameter 22.22 mm Brake type Lever-type
Type Vacuum booster Cable layout V-type layout
Effective 228. 6mm Model Magneto-electricity
Brake booster diameter
Transmission 6.1:1 Resistance 1 ~ 2 KQ
ratio
Speed sensor
Type Floating caliper / with Output voltage AC
ventilated disc
Brake disc 241 mm Air clearance 0. 2 ~ 1.1 mm
diameter
Front brake Brake disc 19 mm Type Alarm lamp module
diameter
ABS, EBD
Friction block 9 mm Operating voltage 12V
alarm lamp
thickness
Cylinder diameter 51 mm Operating current 80 mA
Type Leading and driven Diameter of brake 17.46 mm
brake wheel cylinder
Rear brake Rear brake
Brake drum 204 mm Clearance Automatic
diameter adjustment
2. Technical Parameters
Table of Technical Parameters
Item Standard Item Standard Limit

value value
Height of the brake pedal 151.7 mm Thickness of the front disc brake 9.0 mm 2.0
shoe mm
Stroke of the brake pedal 125.6 mm Thickness of the front disc 19 mm 17 mm
The distance between stop lamp switch outside and 0.5 ~ 1.0 Front disc runout 0.05 mm
pedal dog plate mm
Free play of the brake pedal 3 ~ 8mm Thickness of the rear drum 5 mm 1 mm
brake lining
The distance from booster push rod to brake master 0 Brake drum diameter 204 mm 206
cylinder mm
The stroke of parking brake lever (when the dog plate 5 ~ 7 teeth Clearance between brake wheel 0.15
assembly applying the force of 196N) cylinder and piston mm
The length of booster push rod B 157 mm
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Section III Anti-lock Braking System

I. Precautions
While repairing the anti-lock braking system (ABS), pay attention to the following items to avoid
damaging the ABS.
1. Disconnect the connector on the ABS control module before the electrical welding.
2. As the spare parts of the ABS are extremely sensitive to electromagnetic interference (EMI), much
attention shall be paid to the direction, position, installation and location of all the spare parts of the
ABS. Equal care shall be given to check whether there is any interference on the wiring, the joint,
the clip and the bracket.
3. Do not start the engine with a quick charger or charge the connected storage battery. This can
cause the failure of the storage battery or damage the spare parts of the ABS.
4. It is a must to close the ignition switch first; then disconnect the negative pole of the storage battery,
and disconnect the connector of the ABS control module assembly.
5. Do not attempt to repair any spare parts of the ABS and all of them shall be replaced if the repair is
required.
6. Do not hang the spare parts of the suspension system on the wire harness of the speed sensor to
avoid damaging the wire harness of the speed sensor.
7. Do not expose the ABS control module in an environment with a temperature higher than 105 ℃.
8. Do not use petroleum-based fluid in the brake master cylinder and do not use the container which
was used to hold petroleum-based fluid. The oil may lead to swelling and deformation of the rubber
spare parts of the hydraulic brake system.
9. In ABS operation, it is normal that the brake pedal may vibrate gently and mechanical noise can be
heard.
10. Turn the ignition switch to the ON position and start the vehicle. The brake pedal may vibrate and
the work noise of the motor of the ABS hydraulic assembly can be heard. These are all normal.
11. While the vehicle travels on bumpy, sandy or snow-covered (relatively deep new snow) pavement,
the braking length may be longer than that of the vehicle without ABS.
12. While any trouble of the braking system occurs, figure out it is caused by the ABS or the common
braking system. As for the latter, check whether there is any trouble in components such as the
vacuum booster, the hydraulic braking system and the brake.
13. If the tire dimensions and models are not used correctly in combination or if the brake shoes are not
the original spare parts of JAC, the braking length and the steering stability may be influenced
negatively.
181
II. Preparation
Common maintenance tools and special tools may be used in the maintenance.
X-431
For trouble
1 diagnostic JAC-T1Z001
diagnosis of ABS
tester
III. System Illustration
1. System Diagram
ABS Diagram
1- Left front brake assembly 2-Vacuum booster with brake master cylinder assembly 3-ABS assembly
4-Brake pedal assembly 5-Right front brake assembly 6-Braking pipeline 7- Right rear brake assembly
8- Left rear brake assembly
182
2. Functions of the ABS
The ABS can prevent wheel lock by controlling the hydraulic brake pressure of the four wheels in case of
emergency braking or braking on dangerous pavements. The ABS has follows advantages:
(1) It enables the vehicle to turn safely while encountering a barrier in an emergency braking situation.
(2) It enables the vehicle to be parked stably at the driver’s option in case of emergency braking on a
curve.
Attention:
■ If the electrical system is disconnected, the fail safe mode will be started and the ABS will become
inoperative and the ABS warning lamp will be on.
■ Special diagnostic tester provided by JAC can be used to diagnose the ABS electrical system.
■ In the braking process, the brake pedal may vibrate gently and mechanical noise can be heard.
These are normal in ABS operation.
3. Functions of EBD
Electronic brake force distribution (EBD) is a kind of proportional system which is used to maintain
vehicle stability in the braking period. Under normal braking conditions, equal wheel speed is required to
ensure effective balanced braking. Under conditions where the braking is hard to achieve, given that the
vehicle weight is shifted to the front wheel and the brake force required by the rear wheel is relatively
small, EBD will provide effective braking and vehicle stability by taking advantage of the brake pressure
required by the rear pressure increasing valve and the pressure reducing valve in maintaining the
stability of the rear wheel.
4. Protective Functions to Troubles
If the ABS has electrical trouble, the ABS warning lamp will be on. If the EBD has electrical trouble, the
brake warning lamp and the ABS warning lamp will be on.
Meanwhile, the ABS will change to one of the following situations of the protective functions to troubles.
1) For ABS troubles, activate EBD only and the vehicle status is the same with that of the vehicle
without ABS.
2) For EBD troubles, both the EBD and the ABS are out of use and the vehicle status is the same with
that of the vehicle without ABS and EBD.
183
5. Basic Diagram for the ABS Hydraulic System
Left Right
front/LF front /RF
Right Left
rear/RR rear/LR
Basic Diagram for the ABS Hydraulic System
1-Master cylinder 2-Inlet valve /LF 3-Outlet valve /LF 4- Inlet valve /RR 5- Outlet valve /RR 6-Damper 7-
Oil return pump 8-Accumulator 9- Inlet valve /RF 10- Outlet valve /RF 11- Inlet valve /LR 12- Outlet valve
/LR
IV. Anti-lock Braking Mode
While the wheel slips in the braking period, the ABS will enter into the anti-locking braking mode. During
the anti-lock braking period, hydraulic circuit pressure of all the wheels will be within the control to
prevent wheel slip. Each wheel is equipped with independent hydraulic pipelines and valves.
The ABS can reduce, maintain or increase the braking hydraulic pressure of all the wheels. Whereas,
the ABS can not increase the hydraulic pressure to the extent which exceeds the pressure transmitted
by the main cylinder during the braking period. During the anti-lock braking period, a series of rapid
vibration of the brake pedal can be felt. The position of each valve changes rapidly in accordance with
the required wheel speed and as a result, vibration occurs. Pedal vibration occurs in the anti-lock braking
period and stops under normal braking conditions or while the vehicle is completely stopped. The action
noise caused by the rapid circulated usage of the solenoid valve can be heard. When the ABS is started
on dry pavement, the tire on the edge of skidding will produce high-pitched noise intermittently. Those
noises and pedal vibration are normal in the ABS braking operation period. The operation of the brake
pedal shall be the same with the operation without the ABS. Balanced pedal force can ensure vehicle
stability and the shortest parking distance as well.
184
1. Pressure maintenance
While the ABS control module detects wheel slip, it will close the inlet valve and the outlet valve of the
hydraulic assembly so as to isolate the system. By doing this, it can maintain a stable pressure on the
brake to avoid reducing or increasing the hydraulic pressure.
2. Pressure reduction
Under the pressure maintenance mode, if the ABS control module can still detect wheel slip, it will
reduce the pressure of the influenced wheel by closing the inlet valve and opening the outlet valve.
Redundant fluid/pressure will be stored temporarily in the accumulator of the hydraulic assembly until
the motor pump can transport the brake fluid back into the stock solution tank of the master cylinder.
3. Pressure increase
Under pressure maintenance or pressure reduction mode, when the ABS control module detects fewer
wheel slip, the ABS control module will increase the wheel pressure by taking advantage of the pressure
of the master cylinder with the opened inlet valve and closed outlet valve. Partial or whole pressure from
the brake master cylinder will be applied on the wheel.
4. Working process of the ABS
In the traveling process, every speed sensor will produce a voltage signal which is proportional to the
wheel speed. The ABS control will receive the wheel speed data and judge whether one or more wheels
decelerate too quickly compared with the reference vehicle speed, and this is called slip. The ABS
controller will activate the module in accordance with the requirement, and the module will control the
brake pressure of every wheel to achieve optimization.
V. Speed Sensor
The speed sensor consists of the sensor body and the ring gear, and every wheel is equipped with one
group. This vehicle type can be operated with the driving speed sensor and the external power supply
(12 V). The sensor can provide a constant amplitude signal regardless of the wheel speed.
Fig.3.3.001
1. Element
2. Dismantlement
1) Front wheel
① Lift the vehicle.
② Disconnect the sensor connector.
185
③ Unscrew the fixing bolt of the sensor and remove the sensor slowly.
■ Tightening torque: 8~10 N.m
Attention:
■ Please do not pull the wire harness of the speed sensor forcedly.
■ While in installation, pay attention to the clearance between the speed sensor and the signal ring
gear.
Standard value: 0.2~1.1 mm
2) Rear wheel
① Lift the vehicle and dismantle the tire of the rear wheel.
Attention:
Fig.3.3.002
■ Unscrew the fixing bolt of the tire before lifting
the vehicle.
② Disconnect the sensor connector.
③ Unscrew the fixing bolt of the speed sensor

and remove the speed sensor slowly.
Attention:
■ Do not pull the wire harness of the speed

sensor forcedly.
■ While in installation, pay attention to the

clearance between the speed sensor and the
signal ring gear.
Standard value: 0.2~1.1 mm
3. Check after dismantlement
1) Check whether there is any foreign matter in the mounting hole of the sensor and whether there is
any foreign matter like sweepings on the surface of the brake disc.
2) Before installation, clean the mounting hole of the sensor and the surface of the brake disc.
4. Installation
Install in the reverse order with dismantlement, and screw down the bolt to the specified toque.
Attention:
■ There shall be no twisting for the wire harness after installation.
186
VI. ABS Hydraulic Assembly

Fig.3.3.003
1) Dismantlement
① Close the ignition switch and disconnect the
negative terminal of the storage battery.
② Dismount the connector of the ABS control
module.
③ Step down the pedal for a distance larger than
60 mm; fix it with the pedal bracket.
Fig.3.3.004
■ Close the centre valve of the hydraulic
assembly to prevent the brake fluid leakage
from the outlet when the system is opened.
④ Dismount the brake hard pipe connected with
the master cylinder from the hydraulic
assembly and make marks; then block the
outlet with a plug immediately.
⑤ Dismount the hard pipes leading to wheels
and make marks; then block the outlet with a
plug immediately.
⑥ Dismount the bolt from the support rack of the
ABS hydraulic assembly.
⑦ Dismantle the whole ABS hydraulic assembly
from the rack.
2) Installation
Install the ABS hydraulic assembly in the reverse order with dismantlement.
Attention:
■ The connector of the braking pipeline connected with the ABS hydraulic assembly shall be screwed
down to the specified torque.
Tightening torque: 13~17 N.m
■ Dismantle the plug of the hydraulic opening on the hydraulic assembly only when the brake hard
pipe is prepared to be installed, so as to avoid foreign matters entering the braking system. As for
the following procedures, please refer to “Braking Pipeline”.
① Install the ABS hydraulic assembly on the rack and screw it down to the specified torque.
② Dismount the plug on the hydraulic opening, and install the brake hard pipe and make sure that the
hard pipe is correctly connected.
③ Connect the hydraulic assembly to the brake hard pipe of the master cylinder.
④ Assemble the brake hard pipe and screw it down to the specified torque.
187
⑤ Fill new brake fluid into the stock solution tank till the fluid level reaches the MAX position; and then
exhaust air with the specified method.
⑥ When the ignition switch is turned to the ON position, the ABS warning lamp shall be on and then be
off.
⑦ Clear trouble codes in memory; and then read it again to see whether there is still any trouble code.
⑧ Finally, conduct the final drive to check whether the ABS functions are normal.
Note:
If there is any trouble with the ABS hydraulic assembly, replace the assembly.
VII. ABS Control Module Fig.3.3.005
1. Element. This kind of vehicle type adopts

BOSCH ABS 8 FWD –X ABS, in which the ABS
control module and the hydraulic assembly are
integrated.
2. Illustration of the pins of the ABS control module
Illustration Table of Pins of the ABS Control Module
Pin Pin
Illustration Illustration
No. No.
Power supply end of the motor
1 20 Signal terminal of the speed sensor (left rear)
(anode)
2 N. C. 21 N. C.
Speed sensor output (right rear
3 22 Signal terminal of the speed sensor (left front)
wheel )
4 Driving ABS warning lamp 23 N. C.
5 N. C. 24 N. C.
Signal terminal of the speed sensor
6 25 Power supply end of the valve relay
(right front)
7 N. C. 26 CAN-high
8 N. C. 27 Speed sensor output (right front wheel )
9 N. C. 28 N. C.
10 N. C. 29 N. C.
11 N. C. 30 Input of the stop lamp switch
12 N. C. 31 Signal terminal of the speed sensor (right rear)
Power supply end of the ABS control module
13 Grounding terminal of the motor 32
(ignition power supply line)
14 CAN-low 33 Power supply end of the speed sensor (left rear)
15 N. C. 34 Power supply end of the speed sensor (left front)
16 Driving EBD warning lamp 35 N. C.
17 Diagnosis of K line 36 N. C.
Power supply end of the speed
18 37 N. C.
sensor (right front)
Power supply end of the speed
19 38 Grounding wire of the ABS control module
sensor (right rear)
188
Diagram for Pin Position of the ABS Control Module
3. Check of the ABS control module
Attention:
■ First conduct basic check to the braking system.
1) Basic check of the braking system
① Check the brake fluid level; if the fluid level is too low, fill new brake fluid.
② Check whether there is any leakage near the braking pipeline and the ABS hydraulic assembly. If
any, conduct the following check:
a. If there is any looseness of the connecting part of the ABS hydraulic assembly; screw down the oil
pipe nut of the pipeline to the specified torque (18~30 N.m). Check the leakage again and make
sure that there is no leakage of the brake fluid.
b. If the connecting part of the oil pipe nut and the thread part of the actuator are broken, replace the
damaged spare parts. Check the leakage again and make sure that there is no leakage of the brake
fluid.
c. If there is leakage in any places rather than the connecting part of the actuator, please wipe the fluid
with a piece of clean cloth and check the leakage again. If leakage is still found, replace the
damaged spare parts.
d. If there is any leakage on the hydraulic assembly, wipe the fluid with a piece of clean cloth and then
check the leakage again. If leakage is still found, replace the hydraulic assembly.
Attention:
■ Do not disassemble the ABS hydraulic assembly unless there is a special requirement.
③ Check whether there is any wear for the brake shoes.
④ Check whether there is any looseness of the terminal of the power circuit and check the storage
battery.
■ Check whether there is any looseness on the anode and cathode of the storage battery. Meanwhile,
check whether the voltage of the storage battery is normal.
189
2) Check of the ABS warning lamp and the brake warning lamp
① If the ignition switch is turned to the ON position, the ABS warning lamp will be lightened for 1 s and
the brake warning lamp will be lightened as well. If they are not lightened, please refer to “Common
Troubles and Analysis Procedure for the ABS”.
② Check whether the ABS warning lamp is off when the ignition switch is turned to the ON position for
about 1 s. If it is not off, please refer to “Common Troubles and Analysis Procedure for the ABS”.
③ If the ABS warning lamp does not become off when the engine starts and runs for more than 10 s,
please refer to “Common Troubles and Analysis Procedure for the ABS”.
Attention:
■ The brake warning lamp will be lightened in the operation of the parking braking (when the switch is
turned to the ON position) and the brake fluid level sensor (inadequate brake fluid).
3) Check ABS control module with diagnostic tester
Check the control data and the memorial trouble code of the control module with the diagnostic tester. If
any abnormality is found, repair it according to the trouble prompts. Please refer to “Trouble Diagnosis”.
4) Table of the ABS trouble code
Table of the ABS Trouble Code
Trouble Trouble
Illustration Illustration
code code
Trouble of the left front charged solenoid
C0011 Trouble of the ABS warning lamp C0061
valve
C0012 Trouble of the brake warning lamp C0062 Trouble of the left front relief solenoid valve
Contact of the system breaker and open circuit of Trouble of the right front pressure solenoid
C0014 C0063
the coil valve
C0017 Grounding trouble of the motor pump C0064 Trouble of the right front relief solenoid valve
C0018 Short circuit of the motor pump and the storage
Trouble of the left rear charged solenoid
battery or open circuit of the motor grounding /with C0065
valve
high electrical resistance value
C0021 Speed of left front wheel= 0 kph C0066 Trouble of the left rear relief solenoid valve
Trouble of the right rear charged solenoid
C0022 Speed of right front wheel= 0 kph C0067
valve
C0023 Speed of left rear wheel= 0 kph C0068 Trouble of the right rear relief solenoid valve
C0024 Speed of right rear wheel= 0 kph C0091 Failure of the brake pedal in deceleration
Too great change of speed for the left front wheel Failure of the brake pedal in deceleration in
C0025 C0093
speed the previous ignition period
Trouble of no deceleration with effective
C0026 Too great change of speed for the right front wheel C0094
brake pedal
C0027 Too great change of speed for the left rear wheel C0095 Open circuit of the brake switch
Trouble related to the left rear charged
C0028 Too great change of speed for the right rear wheel C0118
solenoid valve
The opening of the circuit of the left front wheel
Trouble related to right rear charged solenoid
C0032 speed or the grounding/short circuit of the storage C0121
valve
battery
190
C0033 The opening or grounding of the right front wheel C0122 Trouble related to relief or front pressure
speed circuit/ short circuit of the storage battery solenoid valve
C0034 The opening or grounding of the left rear wheel C0127 Trouble of no deceleration with effective
speed circuit/ short circuit of the storage battery brake pedal in the previous ignition period
C0035 The opening or grounding of the right rear wheel C0151 The relief time of the left front wheel is too
speed circuit/ short circuit of the storage batter long
C0036 Too low voltage C0152 The relief time of the right front wheel is too
long
C0037 Too high voltage C0153 The relief time of the left rear wheel is too
long
C0042 Open circuit of the motor pump C0154 The relief time of the right rear wheel is too
long
C0043 Stop of the motor pump C0191 Starting current of the pumpless motor
C0055 Internal trouble C0192 Current overload of the pump motor
C0056 The system relay is connected always C0194 Short circuit current of the pump motor
VIII. Exhaust of ABS

1. Exhaust conditions of the ABS
If one of followings occurs, conduct the exhaust procedure of the ABS immediately.
1) The braking pipeline can not reach the required pedal height or feeling by exhausting air in the
traditional way.
2) Replace the ABS hydraulic assembly.
3) Excessive amount of fluid has been consumed.
4) Doubt of air intake.
■ This procedure adopts the diagnostic tester to drive the system valve, to operate the pump motor
and exhaust air in the secondary circuits. Those circuits are always closed and are only opened in
the initialization period of the vehicle starting and the ABS operation period. The automatic exhaust
procedure will open those secondary circuits to make all the air flow out and get it collected in the
hydraulic assembly where it can be exhausted from the system.
2. Exhaust of ABS
1) Required items
① Diagnostic tester with proper software.
② Brake fluid.
③ Lifting jack.
④ Exhaust bottle with hoses which can be used to recycle vehicle fluid.
⑤ Proper safety equipment including safety glasses.
⑥ Two maintenance personnel are required: One steps down the brake pedal and controls the
diagnostic tester, and another one maintains the hydraulic oil level in the primary chamber of the
brake master cylinder and switches on or off the exhaust screw according to the diagnosis process.
191
2) Preliminary Check
① Check the charging status of the storage battery and repair the storage battery and the charging
system as required.
② Connect the diagnostic tester and select current and historical trouble code. Before implementing
the ABS exhaust procedure, clear all the trouble diagnostic codes. If those codes can not be cleared,
conduct the troubleshooting first.
③ Check whether there is any damage or leakage of the appearance. Conduct maintenance if
required.
3) Operation before exhaust
① Start the engine.
② Connect the diagnostic tester and establish communication with the ABS.
③ Lift the vehicle and make it properly supported.
4) On-vehicle exhaust
Attention:
The automatic exhaust procedure can be stopped at any time by pressing the EXIT key on the
diagnostic tester.
① Select “Automatic Exhaust Procedure” on the diagnostic tester and implement the procedure
according to the illustration. (Please refer to the actual diagnosis procedure)
② In the basic and automatic exhaust process, step down the brake pedal and maintain the brake fluid
level of the brake master cylinder.
③ While exhausting air for one wheel, make sure that the hose is connected with the exhaust screw
and that the air is exhausted into the chamber of the brake fluid. This chamber must be 30 mm
higher than the hose bolt filled with brake fluid so as to prevent the reentry of air into the braking
pipeline.
④ The first step is the basic exhaust. This step must be carried out before the automatic exhaust so as
to obtain good pedal height and pedal feeling and to ensure the optimal performance of the ABS.
⑤ The first step of automatic exhaust procedure is to rotate the pump and the relief valve for about 30
s. The exhaust bolts are not required to be switched on or off at this step. The brake pedal keeps on
decreasing or increasing pressure alternatively in the whole process.
⑥ In the next step, the diagnostic tester will require the maintenance personnel to open one of the
exhaust bolts. Then the diagnostic tester will conduct periodic check of the pressure valve and the
pump motor for about 30 s. The brake pedals are required to decrease or increase pressure
alternatively in the whole process.
⑦ As for the remaining exhaust bolts, the diagnostic tester will repeat procedure 6 to exhaust air.
⑧ When the automatic exhaust procedure ends, the diagnostic tester will display corresponding
information.
⑨ Step down the brake pedal, and measure and feel the pedal height. Repeat procedures from 1 to 8
until the pedal is acceptable.
192
Attention:
■ In the repeated operation, the automatic exhaust procedure may stop temporarily and the “Cool
Down” waiting mode may be activated.
5) Automatic exhaust mode
It will not start again until ovetiming is indicated by the running time meter. In addition, this process can
not be skipped.
On-vehicle diagnosis procedure:
① Enter into the special trouble diagnosis LAUNCH

system of Jianghuai sedans. Special Trouble diagnosis system of
Jianghuai sedans
Developed by Launch Tech Company
Limited
Please register in time
Start
Original BDX
Exit Help
version information
Start 17:53
② Select the whole V10.01 system

exclusively for Jianghuai sedans.
Please diagnose the software version
The whole V10.01 system exclusively for

Jianghuai sedans
This procedure can diagnose all the

electrical control systems of the Jianghuai
automobiles produced in 2007 or before.
Page up Page down Enter

③ Enter into the automatic exhaust Back Help
procedure and operate it according to Start 18:37
prompts.
193
Exhaust mode
Start the exhaust mode
Please operate it in strict observance of

the system prompts
Yes No
Start 18: 46
④ The first step of the system exhaust.
Exhaust mode
The first step:

Please close all the exhaust bolts and
then step down the brake pedal.
Continue the process by pressing the
“Yes” button.
Yes No
⑤ The exhaust process in progress. Start 18: 47
Exhaust mode
The exhaust mode is in active use.

Start the pump and keep it run for 20 s.
The home page of the diagnosis

⑥ The first step is completed.
Start 18:47
194
Exhaust mode
The first step is completed.
Enter
Start 18:48
⑦ The second step of the exhaust.
Exhaust mode
The second step:

Start to exhaust air in the right rear wheel.
Please connect the oil drain pipe; open
the right rear exhaust bolt and then step
down the brake pedal.
Enter
Start 18:48
⑧ The exhaust process in progress.
Exhaust mode

Start the pump and keep it run for 20 s.

Start 18:48
⑨ The third step.
195
Exhaust mode
The third step: Start to exhaust air in the

left rear wheel. Please connect the oil
drain pipe and open the left rear exhaust
bolt; and then step down the brake
pedal.
⑩ The exhaust process in progress. Enter

Start 18:49
Exhaust mode
The exhaust mode is in active use. Start

the pump and keep it run for 20 s.
Enter
Start 18:49
The third step is completed.
Exhaust mode
The third step is completed.
Enter
The fourth step. Start 18:49
196
Exhaust mode
The fourth step: Start to exhaust air

in the left front wheel. Please connect
the oil drain pipeline, open the left
front exhaust bolt; and then step
down the brake pedal.
Enter
The exhaust process in progress.

Start 18:49
Exhaust mode

Start the pump and keep it run for 20
s.
Start 18:49
The fourth step is completed.
Exhaust mode
The fourth step is completed.
Enter
Start 18:50
The fifth step
197
Exhaust mode
The fifth step:

Start to exhaust air in the right front
wheel. Please connect the oil drain pipe;
open the right front exhaust bolt and
then step down the brake pedal.
Enter
The exhaust process in progress.
Start 18:50
Exhaust mode
The exhaust mode is in active use. Start

the pump and keep it run for 20 s.
Start 18:50
The exhaust process is completed.
Exhaust mode
The exhaust process is completed.
Enter
Start 18:51
198
IX. Trouble Diagnosis
1. Brief introduction to the trouble diagnosis
1) Conduct the trouble diagnosis and achieve a thorough understanding of various systems of the
vehicle (control and mechanism).
2) Be familiar with the clients’ complaints before the check; and then inquire their dissatisfaction
carefully after obtaining a thorough understanding of troubles.
3) Conduct trouble check at the beginning stage for the thorough trouble repairing. For intermittent
trouble, it is of great significance to reappear the troubles according to the communications with the
clients and the past cases. Do not carry out check according to special cases. Most of the
intermittent troubles are caused by poor contact; if it is the case, it is an effective method to sway the
suspicious wire harness or connectors.
4) After the diagnosis, “clear the trouble code” must be implemented.
199
2. Diagnostic flow chart
The diagnostic flow is as follows:

Determine the
trouble
Get to know the “Precautions” and how to

diagnose; find out the trouble quickly
Conduct preliminary
check
Whether the ABS trouble

lamp is lightened
Yes
No
Check the ABS actuator, wire
Whether the diagnostic tester harness between the electrical units No
displays the trouble code and the data connector
Yes
Conduct the diagnostic
Conduct automatic procedure for troubles
diagnosis
Abnorm
Check and repair the

defective spare parts
Abnorm
Affirm the troubles

Clear the automatic diagnostic results, and
drive the vehicle with a speed no less than 30
km/h for a minute at least.
Normal
Normal
Conduct the automatic

diagnosis again
Check results
200
3. Diagnostic information and flow
1) Automatic diagnosis
ABS control module can conduct automatic diagnosis for the system and detect system troubles. Once
the trouble is found, the automatic diagnosis will set the diagnostic trouble code (DTC), lighten the ABS
warning lamp and meanwhile, close the ABS.
2) Display the diagnostic trouble code
Use special scan tools (diagnostic tester) to display the diagnostic trouble code.
3) Clear the diagnostic trouble code
Use scan tools (diagnostic tester) to clear diagnostic trouble codes in the memory of the ABS control
module.
Attention:
■ After the completion of the clear procedure, check whether the system operation is normal and
whether the diagnostic trouble code will not reappear.
■ The diagnostic trouble code can not be cleared by dismantling the connector of the ABS control
module, disconnecting the storage battery wire or switching off the engine.
4) Intermittent troubles including those caused by poor contact are mainly caused by the following
situations:
① Wrong electrical wiring.
② Wrong electrical connection.
③ Seizure of the relay and the solenoid valve.
5) Initialization sequence
The ABS control module will conduct initialization test at the beginning of every ignition period.
Initialization sequence is solenoid valve and motor pump in succession, so as to check whether the
operation of spare parts is normal. If any trouble is detected, the ABS control module will set
corresponding diagnostic trouble code. While the initialization sequence is conducted, some sounds can
be heard and some movements may be felt. These are part of the normal system operation. If the ABS
control module finds out that there is no signal input in the brake switch (with the feet releasing from the
brake pedal), it will start the initialization process immediately. If there is any signal input in the brake
switch (with the feet stepping down the brake pedal), the initialization process will not be started until
there is no signal input in the brake switch (with the feet releasing from the brake pedal) or until the
vehicle speed reaches 16 km/h.
4. Check of the diagnostic circuit
1) System illustration
The diagnostic circuit can detect problems caused by ABS/EBD system troubles. The diagnostic circuit
check will guide the maintenance personnel to enter into the next step of trouble diagnosis.
201
2) Diagnostic procedure
The maintenance procedure for ABS / EBD system is as the follows:
① Check whether there is any mechanical trouble related to the braking system of the vehicle.
■ Check whether the fluid level of the braking stock solution tank is correct.
■ Check whether the brake fluid of the master cylinder is polluted.
■ Check whether there is any leakage of the brake master cylinder/ ABS hydraulic assembly.
■ Check the braking spare parts of all the wheels.
■ Check whether there is any braking drag.
■ Check the braking stability (no pre-tensioning and no forward rotation).
■ Check whether there is any wear/damage for the brake shoe.
■ Check whether there is any damage for the wheel bearing.
■ Check the wheel (speed) sensor and the wire harness.
■ Check whether there is any damage of the wheel sensor connector/ring gear. Check the depth/
wear status of the tire tread.
■ Conduct road test for the vehicle and make modifications according to the actual situation.
② Check the diagnostic circuit and carry it out in accordance with applicable trouble diagnosis
procedure. While all the systems’ trouble codes have been cleared, the ABS diagnostic trouble
codes shall be cleared.
Table of Trouble Diagnosis
Step Diagnosis Yes No

1 1. If possible, connect or install all the spare parts that were To step 2 To step 4
disconnected or dismantled before.
2. Turn the ignition switch to the ON position and turn off the
engine.
3. Install proper diagnostic tester on the DLC and make it
communicate with the ABS control module.
2 Are there any trouble codes that are saved currently or before? To step 3 To step 7
3 1. Record current trouble code.
2. Record diagnostic trouble code in the past.
3. Record historical data such as the times set by various
diagnostic trouble codes, times by the automatic diagnosis trouble
codes for the first time, times by automatic diagnosis trouble codes
last time, speed set at diagnosing trouble code and other
augmented data which can help the diagnosis.
4. Do not clear the diagnostic trouble code before recording
information from the diagnostic tester.
4 Can the diagnostic tester communicate with other modules on the To step 5 To step 6
same data line?
5 To “No Communication with the ABS Control Module” in the
trouble procedure of the ABS control module.
202
6 To the unit of the data chaining connector of the electrical terminal.

7 1. Stop the engine. To step 8 To step 9
2. Wait for 10 s.
3. Start the engine.
4. Watch the ABS warning lamp after starting.
8 Is there any lamp still on? To step 9 To step 10
9 To the “Switch on” trouble procedure of the corresponding lamp
10 To “Out-of-work” trouble procedure of the corresponding lamp
5. Common Troubles and Analysis Procedure for the ABS
1) No communication with the ABS control module
Typical causes for the inability of communicating with ABS control module:
■ Poor contact of the diagnostic terminal.
■ Ungrounded ABS control module.
■ No voltage by the storage battery for the ABS control module.
■ No voltage by the ignition switch for the ABS control module.
■ Open circuit/short circuit of the data circuit.
■ Over high electrical resistance of the data circuit.
2) The ABS warning lamp is not lightened/no diagnostic trouble code
The typical causes for the failure of the ABS warning lamp and no setting of diagnostic trouble code are
as follows:
■ ABS warning lamp trouble/ loosened socket.
■ Disconnection of the fuse on the console.
■ The driving module of the warning lamp of the device has trouble.
■ ABS control module trouble.
■ Open circuit or short circuit between the ABS control module and the device.
3) ABS warning lamp is lightened/ no diagnostic trouble code
Typical causes for the lightening of the ABS warning lamp without setting of the diagnostic trouble code
are as follows:
■ Open circuit between the device and the ABS control module.
■ Ungrounded ABS control module.
■ Short circuit between the device and the ABS control module.
■ The driving module of the device warning lamp has trouble.
203
4) The lightening of the brake warning lamp
Typical causes for the lightening of the brake warning lamp without setting of diagnostic trouble code are
as follows:
■ Parking braking switch trouble.
■ Too low brake fluid level or the brake fluid switch trouble.
■ Trouble situations with diagnostic trouble codes C0055, C0065 or C0067 (refer to the table of
diagnostic trouble code) occur.
■ Any situation mentioned below in the ABS will lead to the failure of EBD.
a. Failure of two coaxial speed sensors.
b. Open circuit of the storage battery and the short circuit of grounding.
c. Grounding of the motor and the short circuit of the storage battery.
e. Open circuit of the grounding of the ABS control module and the short circuit of the storage battery.
f. Open circuit of the ignition switch and the short circuit of the grounding.
■ Open circuit of the device and the ABS control module.
■ Trouble of the warning lamp circuit.
■ Device trouble.
■ Trouble of the ABS control module.
5) The brake warning lamp is not lightened /no diagnostic trouble code setting
Typical causes that the brake warning lamp is not lightened and no setting of diagnostic trouble code are
as follows:
■ Lamp trouble/ looseness of the socket.
■ Disconnection of the console fuse.
■ Device trouble.
■ Grounding of the circuit between the ABS control module and the device.
204

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Maintenance Manual of Tojoy Sedan Clutch and Manual Transmission

Chapter I Clutch and Manual Transmission ......................................................................................1

Section I Clutch ..............................................................................................................................1

II. Preparation .........................................................................................................................1

III. Common Trouble Diagnosis................................................................................................1

IV. Clutch Hydraulic Oil ............................................................................................................3

V. Master Cylinder of Clutch....................................................................................................4

VI. Clutch Pedal........................................................................................................................6

VII. Clutch Plate, Clutch Friction Wafer and Fly Wheel..............................................................8

VIII. Hydraulic Pipeline .............................................................................................................11

IX. Maintenance Parameters ..................................................................................................12

Section II Manual Transmission....................................................................................................13

II. Preparation .......................................................................................................................13

III. Common Trouble Diagnosis..............................................................................................15

IV. System Illustration.............................................................................................................16

V. Gear Oil of Manual Transmission......................................................................................18

VI. Oil Seal .............................................................................................................................19

VII. Gear Shift Control Device .................................................................................................20

VIII. Manual Transmission Assembly........................................................................................23

IX. Gearbox Casing (Left Case) .............................................................................................38

X. Clutch Casing (Right Case)...............................................................................................40

XI. Input Shaft and Gear.........................................................................................................43

XII. Intermediate Shaft.............................................................................................................51

XIV. Shift Control Sub-assembly...............................................................................................63

XV. Gear Shifting Control Sub-assembly .................................................................................65

XVI. Reversing Lamp Switch ....................................................................................................66

XVII. Maintenance Parameters.............................................................................................66

Chapter II Traveling System..............................................................................................................68

Section I Power Steering System .................................................................................................68

II. Preparation .......................................................................................................................69

III. Common Trouble Diagnosis..............................................................................................70

IV. Power Steering Fluid.........................................................................................................70

VI. Steering Column ...............................................................................................................76

VII. Steering Gear....................................................................................................................79

VIII. Power Steering Pump .......................................................................................................85

IX. Hydraulic Pipeline .............................................................................................................89

X. Maintenance Data and Specifications ...............................................................................90

Section II Front Axle......................................................................................................................91

II. Preparation .......................................................................................................................91

III. Common Trouble Diagnosis..............................................................................................92

IV. Front Wheel Hub and Steering Knuckle ............................................................................92

V. Front Drive Shaft...............................................................................................................97

VI. Maintenance Parameters ................................................................................................107

Section III Rear Axle ...................................................................................................................108

II. Wheel hub.......................................................................................................................108

III Maintenance Parameters ................................................................................................112

Section IV Front Suspension ......................................................................................................113

II. Preparation .....................................................................................................................113

III. Front Suspension Assembly............................................................................................114

IV. Front Damper..................................................................................................................116

V. Lower Suspension Arm ...................................................................................................119

VI. Stabilizer Bar...................................................................................................................122

VII. Connecting Ball Joint of Stabilizer Bar ............................................................................123

VIII. Support Beam of Engine .................................................................................................124

IX. Common Trouble Diagnosis............................................................................................127

X. Maintenance Parameters ................................................................................................128

Section V Rear Suspension........................................................................................................129