Ca6350 Service Manual

Operation and Service Manual
FAW Jiabao Series Light Passenger Van

(3rd Edition)
China First Automobile Group Corporation - Jilin Light Vehicle Plant

Operation and Service Manual
FAW Jiabao Series Light Passenger Van

(3rd Edition)
China First Automobile Group Corporation Jilin Light Vehicle Plant

FOREWORD
Dear Users,
Thank you for your purchasing a new FAW Jiabao Series Light Passenger Van!
The purpose of this manual is to provide you with useful information and necessary technical data for the operation,
maintenance, trouble-shooting, and service of your FAW Jiabao Series Light Passenger Van. Since the vehicles made by our
factory are equipped with different model engines, and we provide a specific engine service manual for each model, this
manual only gives a general description concerning the engine. Therefore, please consult the engine service manual that is
specific for your vehicle when having any questions concerning engine operation.
This third edition of the Operation and Service Manual has been published to reflect structural and equipment changes of the
vehicle. The data and information within this manual were up to date at the time of printing. Revisions will be made in the
event of any future changes.
Your valuable comments about our products are warmly welcome. We constantly strive to improve and perfect the FAW Jiabao
Series Light Passenger Van.
Editor
September 2001
China First Automobile Group Corporation
Vehicle Type
Number of
Engine Type
Passengers
Total
Engine Power Weight
Manufacturer’s Product Number
Date of Production y m
Jilin Light Vehicle Plant
Content of Nameplate
Jilin Light Vehicle Plant
Nameplate
Position of Nameplate
Mini-Passenger Car Series

CA6350 Mini-Passenger Car Series
Note
The nameplate is mounted on the inside B-pillar behind the right front passenger door, as shown in Fig. CA6350
Overall Width 1,475 mm
Overall Height 1,830 mm
Front Tread 1,205

Rear Tread 1,200
Wheelbase 2,040 mm
Overall Length 3,902 mm

Contents
Contents
Chapter I. Complete vehicle………………………………………………………………………………………………………………………1
Section 1. General introduction………………………………………………………………………………………………………………………1

Section 2. Vehicle Operation……………………………………………………………………………………………………………………8
Section 3. Equipment and structure of special-purpose vehicles…………………………………………………………………………………20
Section 4. Vehicle service and maintenance……………………………………………………………………………………………………22
Chapter II. Engine ……………………………………………………………………………………………………………………………….36
Section 1. Engine accessories (carbureted engines)…………………………………………………………………………………………………36

Section 2. Engine accessories (EFI engines)………………………………………………………………………………………………42
Chapter III. Chassis……………………………………………………………………………………………………………………………48
Section 1. Clutch………………………………………………………………………………………………………………………………48
Section 2. Transmission………………………………………………………………………………………………………………………51
Section 3. Driveshaft……………………………………………………………………………………………………………………………69
Section 4. Rear axle……………………………………………………………………………………………………………………………70
Section 5. Suspension system………………………………………………………………………………………………………………………77
Section 6. Steering system…………………………………………………………………………………………………………………………83
Section 7. Braking system…………………………………………………………………………………………………………………………93
Section 8. Tires and wheels…………………………………………………………………………………………………………………………111
1
Contents
Chapter IV. Vehicle body…………………………………………………………………………………………………………………………116
Section 1. Front doors and rear sliding doors…………………………………………………………………………………………………116

Section 2. Rear door……………………………………………………………………………………………………………………130
Section 3. Seats…………………………………………………………………………………………………………………………132
Section 4. Instrument panel………………………………………………………………………………………………………………………134
Section 5. Front windshield, rear window, and side windows……………………………………………………………………………………135
Section 6. Bumper…………………………………………………………………………………………………………………………138
Chapter V. Climate control system…………………………………………………………………………………………………………140
Section 1. Heating system…………………………………………………………………………………………………………………………140

Section 2. Air conditioning system……………………………………………………………………………………………………………143
Chapter VI. Vehicle electrical system………………………………………………………………………………………………………157
Section 1. Power supply system…………………………………………………………………………………………………………157

Section 2. Ignition system…………………………………………………………………………………………………………………………168
Section 3. Electronic fuel injection code anti-theft system…………………………………………………………………………………………173
Section 4. Electrical equipment and accessories………………………………………………………………………………………………178
Appendixes………………………………………………………………………………………………………………………………………186
2
Operation and Service Manual - FAW Jiabao Series Light Passenger Van Chapter I. Whole Vehicle
Chapter I. Complete Vehicle

Section 1. General Introduction
I. VIN and engine number location
Fig. 1-1 VIN location Fig. 1-2 Engine number location

a—VIN is located at the front left side of the instrument panel The engine number is located on the right surface of the
cylinder block under the carburetor
b—VIN is located at the surface of wheel cover under the driver’s seat
1
II. Vehicle specifications
Chapter I. Complete Vehicle Operation and Service Manual - FAW Jiabao Series Light Passenger Van
Vehicle type CA6350E4 CA6350E5 CA6350E6 CA1014JE2 CA5010XXYE2 CA6350JE2 CA5010XJBE2 CA5010XJBE6
Engine model LJ465QE1 DA465Q-1A/D DA465Q-1A/D1 DA462-1A/D DA462-1A/D DA465Q-1A/D1
LJ465Q-1AE1 LJ462Q-1AE1 LJ465Q-1AE1
Rated passenger capacity 6-8 persons 2 persons 6-8 persons 6 persons
Curb weight 895kg 865kg 895kg
Rated load capacity —————— 545kg ——————
Gross weight 1410kg

Weight
No load Front axle 480kg 475kg 480kg
distribution
Axle-load
Rear axle 415kg 390kg 415kg
Full load Front axle 642kg
Rear axle 768kg
Dimensions Overall Length 3496mm
Width 1445mm
height 1841mm 2041mm
Wheelbase 1940mm
Track Front wheel 1215mm
Rear wheel 1210mm
Front suspension 844mm
Rear suspension 712mm
Min. ground clearance 156mm
Angle of approach 26.1°
Angle of departure 31.7 °
Max. steering angle 37 °
2
Alignment Kingpin inclination angle 11°30′
Kingpin caster angle 5°
Front wheel camber angle 1°
Toe-in 2-5mm
Max. Speed.+ 110km/h 100km/h 110km/h
Max. gradeability ≥29%
Fuel consumption ≤6L/100km

Performance
Min. turning diameter 9m
Emissions CO 2.72g/km
HC+NOx 0.97g/km
Operation and Service Manual - FAW Jiabao Series Light Passenger Van Chapter I. Complete Vehicle
Vehicle type CA5010XJEE2 CA5010XJHE2 CA5010XQCE2 CA5010XYZE2 CA5010XJEE6 CA5010XJHE6 CA5010XQCE6 CA5010XYZE6
Engine model DA462-1A/D DQ465Q-1A/D1
LJ462Q-1AE1 LJ465Q-1AE1
HH462QE
Rated passenger capacity 6 persons 2 persons 6 persons 2 persons
Curb weight 895kg 870kg
Gross weight 1410kg
Weight No Front axle 480kg 470kg

distribution
Axleload
load Rear axle 415kg 400kg
Full Front axle 642kg

load Rear axle 768kg
Dimensions Overall Length 3496mm
Width 1445mm
Height 1841mm 2041mm 1841mm 2041mm
3
Wheelbase 1940mm
Track Front wheel 1215mm
Rear wheel 1210mm
Front suspension 844mm
Rrear suspension 712mm
Min. ground clearance 156mm
Angle of approach 26.1°
Angle of departure 31.7°
Max. steering angle 37 °
Alignment Kingpin inclination 11°30′
angle
Kingpin caster angle 5°
Front wheel camber 1°
angle
Toe-in 2-5mm
Max. speed 100km/h 110km/h
Max. gradeability ≥29%
Fuel consumption ≤6L/100km

Performance
Min. turning diameter 9m
Emissions CO 2.72g/km
HC+NOx 0.97g/km
III. Drivetrain specifications

Engine model DA465Q-1A/D DA465Q-1A/D1 LJ465Q-1AE1 LJ465QE1 DA462-1ª/D LJ462Q-1AE1 HH462QE
4
Type I-4, water-cooled, 4-stroke, overhead camshaft, electronic fuel injection gas engine
Cylinder bore x stroke (mm) 65.5×78 65.5×72 62×72 62×66
Displacement 1.051 0.97 0.87 0.797
Compression ratio 9.0 8.8 8.7
Rated power (kW/rpm) 38.5/5200 35.5/5000 32/5200
Max. torque (N·m/rpm) 83/3000-3500 74/3000-3500 66/3000-3500
Fuel system Multipoint closed loop electronic control fuel injection system
Speed ratio Constant mesh, fully synchronized (1st thru Constant mesh, fully synchronized (1st thru 4th)
Transmission
5th)
Gear 1 3.652 3.505
Arrangement
Gear 2 1.948 2.043
Gear 3 1.424 1.383
Gear 4 1.000 1.000
Gear 5 0.795 ——————————————————————
Reverse gear 3.466 3.536
5
Capacities Tire (general cross ply 165/70R13 (5.00-12ULT)

Fuel tank: 37 L Rim(general cross ply) 5.00×13 (4.00B×12)
Engine lubricating system: 3.5 L Tire pressure(general cross
ply)
Cooling system: 4.0 L Front 200kPa (29 psi)
Transmission: 1.3 L Rear and spare 230kPa (33 psi)
Rear axle: 1.3 L Steering gear
Steering gear: 0.6 L Type Rack and pinion type
Components Braking system
Driveshaft Running braking system
Type Single joint, open type, hollow, double arrangement Dual system hydraulic braking, with braking force
universal joint distribution valve, equipped with vacuum booster
Rear axle Service brake system
Front brake Disc brakes, floating brake calipers (available drum
brake)
Rear brake Drum brakes, self-adjusting
Type Single reduction Parking braking system
Final drive ratio 5.125 Arrangement Lever controlled, cable actuated, acting on two rear
wheels
Axle housing type Welded fabricated Vehicle body All metal enclosed body, 5 doors (2 front doors, 2
sliding doors, and rear liftgate door), three-point seat
belt, panoramic camber windshield
Axle type Semi-floating
Differential type Planetary taper gear
6
Suspension
Front suspension MacPherson strut independent suspension,

coil spring, equipped with anti-sway bar,
hydraulic shock absorbers
Rear suspension Longitudinal semi-elliptic leaf springs,
hydraulic shock absorbers
7
IV Repair regulations
1. When repairing electric parts, the negative battery cable should first
be disconnected from the battery, in order to avoid electric shock or a
short in the vehicle’s electrical system; unscrew the nut on negative
battery terminal, to separate the ground wire from the battery post.
2. When jacking up the front or rear of the vehicle with a jack, be sure
to position the jack at the middle of front suspension or rear axle
housing, before raising the jack. (see Figures 1.1-3, 1.1-4)
3. When repairing a vehicle after raising the front or rear of the
vehicle, always place a jack stand under each side of the vehicle for
added safety. (see Figures 1.1-5, 1.1-6)
Note: When putting jack stands under the vehicle, take care to avoid Fig. 1.1-4 Hydraulic positioned used under the
hitting or rubbing any sensitive components (ie, fuel hoses, ect.). Tire rear end
chocks should be placed under the front and back sides of the left and
right wheels still on the ground, to prevent the vehicle from moving
forward or backward
Fig. 1.1-5 Jack stand placed under the front end
Fig. 1.1-3 Hydraulic jack positioned under the front end
8
9
Fig. 1.1-6 Jack stand placed under the rear end.
4. When raising a vehicle on a car lift, make sure the lift arms do not make
contact with brake lines, fuel hoses, brackets, or other fragile parts.
The correct positioning of the arms of a car lift under the vehicle is shown in Fig. 1.1-8 Rear end lift arm position
figures 1.1-7 and 1.1-8. After raising the vehicle slightly off the ground, 5. When repairing the vehicle, disassembled parts should be
verify that the vehicle is solidly positioned on the lift arms, and then neatly arranged together on a parts tray in the manner in which
proceed to raise the vehicle as required for repairs. they were removed, for an orderly repair and to avoid confusion.
After the vehicle is raised to the required position, the safety lock of the car 6. Each bolt must be reinstalled in its original position. Bolts and
lift should be engaged. nuts with specified torque requirements must be fastened with a
torque wrench.
7. Any oil seals, gaskets, and o-rings removed during disassembly
should be replaced with new during reassembly.
8. When repairing the vehicle, refer to the instructions and
specifications within this manual.
Fig. 1.1-7 Front end lift arm position
10
Section 2 Vehicle operation

I. Operation description
(I) Keys
Two keys are provided with each vehicle (For keys with the code anti-
theft system, see Chapter 6).
The vehicle key has the following functions:
1. To control the power supply of vehicle’s electrical equipment.
2. To unlock and lock vehicle door. Fig. 1.2-1 Fig. 1.2-2
3. To unlock and lock the fuel tank cap
(II) Door lock and door window
a) Front door lock
Unlocking and locking from outside the vehicle (Fig. 1.2-2). Turning
the key clockwise can unlock the left front door lock. Turning key
counterclockwise can unlock right front door lock. Performing these
two operations in reverse will lock the doors.
Unlocking and locking from inside the vehicle (Fig. 1.2-2). Lift the Fig. 1.2-3
inner door lock knob, pull the inner door handle, and the vehicle door
is unlocked; shut vehicle door, press inner lock button, and the vehicle 2. Sliding door lock
door is locked. After unlocking from outside the vehicle, pull the outer handle
Note: When the vehicle is running, the inner lock knob must be backward, and the middle door will open.
pressed, to avoid accidentally pulling inner handle and opening the Unlocking and locking from inside the vehicle (Fig. 1.2-4). Lift the
vehicle door. inner door lock knob, pull the handle backwards, and the middle door
The door can be locked from outside the vehicle without the key. is opened. Pull the inner handle forward to close vehicle door, press
First, open vehicle door and press the inner lock button, then lift the inner lock button, and the vehicle door is locked.
outer door handle and close the door, thus locking the door, as shown
in Fig. 1.2-3. Afterward, pull the outer handle to verify it is locked.
11
1. Front seat
(1) Latching
Hang the 2 lock loops at the front of the seat on the latch hooks, and
push the handles up to lock, thus latching the seat securely, as
shown in Fig. 1.2-6 and Fig. 1.2-7.
3.RearFig.
door1.2-4
lock Fig. 1.2-5 position.
(III) Seat and body
Unlocking and locking outside vehicle is shown as Fig. 1.2-5.
3. Rear liftgate door lock The front seat cushion and backrest are a single assembly, therefore
Insert the key into the lock, turn counterclockwise 90°, remove the when repairing the engine, the seat should be tilted. Release the latch
key, then hold the outer handle while pressing the button with your and tilt the seat back to gain access to the engine compartment. Be
thumb and pull backward, the rear door is opened; after the door is sure to securely latch the seat before operating the vehicle.
closed, insert key into the lock, turn clockwise 90°, the rear door is
locked.
4. Raising and lowering the front door window glass
Turn the window crank of the right front door clockwise to raise the
glass; turn the window crank of the left front door counterclockwise to
raise the glass. Performing these two operations in reverse will lower
the glass.
5. Side door window
To open the sliding window, push the button to make the window Fig. 1.2-7
reach the locking position. To open the push-pull side window, press (2) Fore and aft adjustment
button, and at the same time, pull the handle backwards, to the desired Lift the handle under the front of the seat to release the latch and
12
adjust the seat fore and aft. (see Fig. 1.2-8) Note: For your safety, do
not attempt to adjust the seat’s fore and aft position while driving.
13
3. Body
CA1010, and CA1010A Mini-Cargo Car Series with single row seat,
The body is full metal rear body. Body safety frame is fixed on cab
rear wall board, the body can be opened on three sides. Body panels
are connected with self-locking catch and staple, designed for quick
assembly and disassembly. Pulling the handle outwards can make the
Fig. 1.2-7 staple and catch separate to open the body; buckle staple and catch
(3) Seat back adjustment together, push handle, and the body is closed and locked.
The seat back is tiltable. To adjust, raise the handle at the side of the (IV) Fuel tank cap
seat, select backrest angle, and release the handle, thus locking the The fuel tank cap is located on the right side of the vehicle. Inserting
backrest in position. (fig. 1.2-9) key and turning counterclockwise locks the cap, vice versa opens it
2. Rear seating (see Fig. 1.2-11). After opening the lock, turning the fuel cap
The second row seat back can tilt forward, to allow easier passenger counterclockwise will open it. Turning clockwise, and hearing a
entry to the third row seat. (see fig. 1.2-10). The seat back may be ratcheting sound, verifies the cap has been properly tightened.
tilted to the same degree as the front seat backs. (V) Seat belts
The third row seat may be folded forward by raising the handle, This vehicle uses automatic locking seat belts.
pulling the seat back forward to a horizontal position, and then tilting When fastening the seat belts, insert the tongue into the buckle, until
then tilting the entire seat 90°. you hear a click, indicating the seat belt is locked. Pressing the red
button on the buckle will unfasten the seat belt.
Fig. 1.2-10
Fig. 1.2-11 Fig. 1.2-12
Note: (VII) Instrument panel and control mechanism, see Fig. 1.2-15.(“hard
·The seat belt is designed for your safety based on the shape of the plastic” instrument panel pictured below)
human body. Therefore, the seat belt must be used as it was designed
for proper performance. The lower strap should not rest above the
abdomen, and the upper shoulder strap should cross over chest and
shoulder.
·The seat belt should be kept clean. In particular, avoid any oil or
chemicals from touching the straps. If the straps become dirty, they
may be washed with a mild soap and warm water.
·If a seat belt is damaged, it should be replaced immediately.
·Each seat belt is designed for one person. Children can NOT share a
seat belt with another person. Fig. 1.2-15 Instrumentation
·Customers should not attempt to modify the seat belts in any way, so 1. Brake fluid reservoir 2. Lighting and turn signal switch 3. Choke pull knob 4. Windshield
as to maintain their proper operation and performance. wiper and washer switch 5. Hazard lamp switch 6. Speedometer 7. Warning indictor lamp
(VI) Jack, spare tire location 8. Water temperature gauge 9. Fuel level gauge 10. Ash tray 11. Glove box 12. Blower and
1. Jack air conditioner switch 13. Climate control panel 14. climate control vent 15. Ignition switch
The jack is located under the left front seat. To access the jack, raise 16. Fog lamp switch 17. Rear wiper switch (optional) 18. Cigarette lighter (optional) 19.
the seat and engine cover, turn the jack handle spindle Radio/cassette player
counterclockwise and remove. When storing the jack, turn the jack (VIII) Instrumentation, see fig. 1.2-6
handle spindle clockwise to secure the jack tightly in its mounting 1. Speedometer
position (see Fig. 1.2-13). Indicates the vehicle speed and records kilometer accumulation.
The jack handle is stored on the left lower side of the instrument panel 2. Fuel level gauge
(Fig. 11.2-14). When the ignition switch is turned to the ON position, the fuel level
2. Spare Tire gauge indicates the fuel quantity within the fuel tank.
To access the spare tire, open the rear liftgate door, unscrew the
mounting bolt, and lift up on the spare tire.
Fig. 1.2-13 Fig. 1.2-14
When the fuel gauge points to F, the fuel tank is full; when it points to starting the engine, the indicator lamp should turn off indicating good oil
E, the fuel tank is near empty (see Fig. 1.2-17). pressure for safe operation. If the oil pressure lamp is still on after
starting the engine or turns on during operation, turn the engine off to
avoid possible engine damage, and check the engine oil level
immediately (Fig. 1.2-19a).
5. Charge indicator lamp (red)
When the ignition switch is turned to the ON position and the engine is
(a) carbureted engines (b) EFI engines not running, the indicator lamp will turn on. After starting the engine, the
Fig. 1.2-16 indicator lamp should turn off to indicate proper operation of the
3. Water temperature gauge vehicle’s electrical charging system. If the lamp is still on during vehicle
When the ignition switch is turned to the ON position, the pointer will operation, this indicates a fault in the vehicle’s electrical charging
indicate the engine’s present coolant temperature. When the pointer system, which should be repaired immediately (see fig. 1.2-19b).
fluctuates in C range, engine water temperature is normal; when the
pointer reaches the H range, this indicates an abnormally high engine
temperature and the engine should be turned off as soon as safely
possible to avoid potential engine damage (see Fig. 1.2-18).
Fig. 1.2-19
6. Left-turn indicator lamp (green), see Fig. 1.2-19c.
7. Right-turn indicator lamp (green), see Fig. 1.2-19d.
8. High beam indicator lamp (blue), see fig. 1.2-19e.
Fig. 1.2-17 Fig. 1.2-18 9. Parking brake indicator lamp (red), see fig. 1.2-19f.
4. Low engine oil pressure indicator lamp (red) 10. Low brake fluid indicator lamp (red).
When the ignition switch is turned to the ON position, and the engine When the ignition switch is turned to the ON position and the engine is
is not running, the indicator lamp will turn on to indicate a lack of oil not running, the indicator will turn on; after starting the engine starts, the
pressure; after lamp should turn off.
Note:
If the lamp is still on after starting the engine or turns on during ·Do not crank the engine for longer than 5 seconds each time. If the
operation, park the vehicle as soon as safely possible and check the engine does not start within 5 seconds, wait 5-10 seconds before trying
brake fluid reservoir level, filling as required. If the braking fluid again. If the engine can not be successfully started, have the fuel and
reservoir is full and the lamp is still on, have the brake system ignition systems examined by an authorized FAW dealer.
repaired immediately (see Fig. 1.2-19g). ·In the event of engine failure, do not leave the key in the ON position
11. (EFI engines) Engine fault indicator lamp (red) for extended periods, or the battery will be drained.
When the ignition switch is turned to the ON position, and the engine (X) Combination switch
is not running, the indicator will turn on; after starting the engine, the 1. Lighting switch
indicator lamp should turn off. If the indicator lamp is still on or turns The lighting switch is located on the left side of the steering wheel.
on during operation, the EFI system should be repaired immediately When it is turned to the OFF position, all lighting is turned off; when
(see Fig. 1.2-19h). turned to the first (middle) position, front and rear marker lamps,
(IX) Ignition switch instrument lamps, and the rear license plate lamp will turn on; when
The ignition switch has 4 positions (see Fig. 1.2-20). turned to the second position, all lamps including headlamps will turn on
1. OFF: The key can only be removed and inserted in this position, (see Fig. 1.2-21a).
and the vehicle’s electrical system is turned off. 2. Passing signal lamp, turn signal switch
2. ACC: In this position, the power supply to electrical accessories is This handle’s middle position is its neutral position. Push the handle
turned on, and electrical equipment such as the radio/cassette player forward to turn on the right turn signals; pull the handle backward to turn
can be used. on the left turn signals; raise the handle to momentarily turn on the high
3. ON: In this position, the engine’s ignition system is turned on. beam headlamps for passing, release the handle will allow it to
4. ST: Turning the key to this position will start the engine. Release as automatically return to the neutral position.
soon as the engine starts, and the key will automatically return to the
ON position .
Fig. 1.2-20
Fig. 1.2-21
Chapter I. Whole Vehicle Operation and Service Manual on FAW Jiabao Series Light Passenger Van
3.High/low beam headlamp switch

Turn the lighting switch to the second position. When the handle is on 5. Rear windshield wiper
middle position, the low beam lamps are activated; when the handle is The wiper and washer switches are located on the instrument panel (see
pressed down, the high beam headlamps are activated (see Fig. 1.2- Fig. 1.2-24). Pressing the wiper switch activates the rear wiper. Pressing
22). the switch again turns off the rear wiper.
4. Windshield wiper and washer switch The rear windshield washer is activated by depressing the washer switch
The windshield wiper/washer switch is located on the right side of the (when the rear wipers are activated). Releasing the switch will turn off
steering column. The wiper switch has 3 positions; INT position for the washer.
intermittent operation, LO position for low speed operation, HI
Rear wiper switch (white)
position for high speed operation. In the OFF position, the wipers are
turned off (see Fig. 1.2-23).
The windshield wiper and washer are both activated with one control
handle. When the handle is raised, the washer is activated, spraying
windshield washer fluid on to the windshield; after releasing, the
handle resets automatically (see Fig. 1.2-23).
Rear washer switch (white)
Fig. 1.2-24
Windshield
washer
Note:
(1) Spraying time per wash does not exceed 5 seconds; the interval time
is not less than 25 seconds.
(2) When windshield is dry, do not scrape dirt with the wipers, to avoid
scratching the windshield and wearing out the wiper blades prematurely.
Fig. 1.2-22 Fig. 1.2-23
(XI) Horn
The horn switch is located on the steering wheel. Press any point on
the button to activate the horn (see Fig. 1.2-25).
Fig. 1.2-25 Fig. 1.2-26 Fig. 1.2-27 Fig. 1.2-28

(XV) Glove box
(XII) Interior lamp switch Pulling lock button in the direction indicated by arrow in Fig. 1.2-29 will
ON position turns the lamp on, OFF position turns the lamp off (see open the glove box door; gently pushing the glove box door shut will
Fig. 1.2-26). engage the latch.
(XIII) Hazard lamp switch (XVI) Cigarette lighter and ash tray
The hazard lamp switch is a red button located on the combination When the ignition switch is in the ON or ACC position, the cigarette
switch cover under the steering wheel. When this switch is pulled out, lighter can be used. To activate the cigarette lighter, push in on the
the front, rear, and side turn signal lamps are activated as a warning to cigarette lighter knob and, after several seconds, the cigarette lighter will
other motorist to indicate that the vehicle has an emergency or has pop back out automatically along with a “clicking” sound, indicating that
stopped for repairs (see fig. 1.2-27). you may now pull it out to light a cigarette.
(XIV) Choke pull knob (carbureted engines) Note: If the cigarette lighter has not popped out after thirty seconds from
When the engine is cold, first pull out the choke knob and then start the time it was pushed in, the cigarette lighter is faulty and should be
the engine. After the engine has successfully started, push the choke replaced.
button in completely (see Fig. 1.2-28). Open the ash tray by pulling slowly outwards from the bottom. To
remove for cleaning, pull the ash tray out, press down on the top ash
shield, and pull completely out. After cleaning, push the ash tray back in
to its normal position (see Fig. 1.2-31).
(XVIII) Climate control system

There are 6 ventilation vents, including 2 defroster vents and 4
adjustable dash-mounted vents (see Fig. 1.2-33, 1.2-34).
Fig. 1.2-29 Fig. 1.2-30 Fig. 1.2-33 Fig. 1.2-34

(XVII) Sun visors (XIX) Heater and air conditioning (if equipped) system
The vehicle is equipped with driver’s and passenger’s front sun 1. Name and function
visors. Simply pull down the sun visor as required to block undesired As shown in Fig. 1.2-35.
sunlight, and push back up when not in use (see Fig. 1.2-32).
Fig. 1.2-35
Fig. 1.2-31 Fig. 1.2-32
① Fan switch: Includes 4 heater fan speed positions. Turning Note:

on the fan supplies power to the climate control system.  Pre-cooling: When you park in direct sunlight, you should
② Air conditioner switch: A/C (ON-OFF) Pressing the fan lower one of the windows temporarily when the air conditioner
switch AND rotating the switch to a fan-on position is first turned on for several minutes. This will force most of the
activates the air conditioner. hot and stale air out of the vehicle.
③ Inside/outside air intake lever: In the “ ” position, the  When operating the vehicle in urban areas (stop and go traffic),
climate control system uses outside air. In the “ ” air conditioning efficiency is reduced. You may compensate for
position, the system uses recirculated air for more efficient this effect by operating the vehicle in lower gears (higher
air conditioning. rpm’s) for better cooling.
④ Temperature control lever: This lever actuates the heater  When operating the vehicle with the air conditioner on for
water control valve to control the temperature. extended periods, you should periodically open a window
⑤ Mode selector lever: Controls the direction of the airflow slightly to ventilate the vehicle.
within the vehicle (ie, panel, panel and floor, floor, (XX) Parking braking handle
defroster. When parking the vehicle, you should always apply the parking braking.
⑥ Indicates all airflow from the instrument panel vents. When the parking braking handle is pulled up, braking action is applied
⑦ Indicates airflow evenly distributed from the instrument at the rear wheels. To release the parking brake, pull the handle upward
panel vents and the floor vents and press the button at the top of parking braking handle with your
⑧ Indicates all airflow from the floor vents. thumb, and push the handle down. Note: different vehicle types have
⑨ Indicates all airflow from the defroster vents. different parking braking handle positions, as shown in Fig. 1.2-36.
Move lever to, move lever ④ to the “COOL” position, move lever
③ to the “ ” position, turn the fan switch ① to your desired speed
position, press the AC/fan switch ②, and the air conditioner will
activate.
Note: When lever is turned to the “ ” position, the air conditioner
will turn off automatically. The lever must be in the “recirculate”
position for the air conditioning to operate.
3. Heater control
Move lever to your desired position, handle to “HOT” position, lever Fig. 1.2-36
to the “ ”position, turn the fan switch ① to your desired speed
position, and the heater will activate.
4. Quick defrost control
Move lever to the position, lever to the “HOT” position, lever to the
“ ” position, turn the fan switch ① to the highest speed position,
and quick defrosting can be done.
(XXII) Gear shift lever

The gear shift positions of the 5-speed transmission are shown in Fig.
1.2-38. The 4-speed transmission’s gear shift pattern is identical to the 5-
speed transmission less the 5th gear position.
Note: When the vehicle is moving forward, reverse gear cannot be
engaged. When moving in reverse, forward gears can not be selected.
Changes in gear directions should only be made after the vehicle has
come to a complete stop.
Fig. 1.2-37
(XXI) Pedal
1. Clutch pedal
The clutch pedal is used for controlling the power transfer between
the engine and the transmission. By depressing the pedal, you Fig. 1.2-38
interrupt the power transfer, allowing you to make a gear selection;
release the pedal, and the power transfer is re-engaged. See in Fig.
1.2-37. II New vehicle examination and break-in
Note: When driving, do not rest your foot on the clutch pedal, to (I) Examination and breaking-in of the new vehicle
avoid premature clutch and clutch bearing wear. The user should examine the following items after receiving the new
2. Brake pedal vehicle:
Depressing the pedal will produce braking force at all four wheels. 1. Connections and tightness of all components, particularly the engine,
See in Fig. 1.2-37. transmission, steering, brakes, suspension, wheels, etc.
Note: 2. Radiator and overflow reservoir coolant levels.
 Rain and snow on road surfaces will influence the vehicle’s 3. Engine, transmission, and rear axle oil levels.
braking ability. 4. Presence or absence of blow-by, water and oil leakage.
 If brake squeal occurs during braking, the brake system 5. Fuel level.
should be repaired. 6. Tire air pressure.
 If the brake pedal suddenly drops to a lower position, 7. Installation of engine accessories and engine belt tightness.
develops a soft “spongy” feel, or the vehicle’s braking 8. Operational condition of electric equipment, lighting, horn, and
distance increases noticeably, the brake system should be instruments.
immediately repaired. 9. Operational condition of the brake system, the presence or absence of
3. Accelerator pedal oil leaks at pipe fittings, and the brake fluid reservoir level.
The accelerator pedal is used for controlling the throttle. When 10. Operational condition of the clutch.
driving, depress the accelerator pedal to increase engine speed, thus 11. Operational condition of the steering system.
increasing the power output and vehicle speed. See ③ in Fig. 1.2-37.
12. Presence or absence of abnormal engine and transmission system 5. During the first 200km, vary the speed and engine load while keeping
sounds. a close watch on the engine gauges, particularly the water temperature
13. Tool kit and accessories are complete. and oil pressure gauges.
(II) New vehicle break-in 6. Check the temperature of the wheel hubs and rear brake drums often
The operating life, reliability, durability, and economical efficiency of for excessive heat, to verify wheel bearings are functioning properly.
the vehicle depend greatly on initial operating conditions. Before a 7. When operating the vehicle, always drive the vehicle in the proper
new vehicle is driven normally, it must pass through a breaking-in gear for the given speed.
period. During the engine break-in period, avoid extended periods of 8. When the break-in mileage reaches 500km, examine the tightness of
heavy loading and high rpm’s, to give new parts an ideal break-in steering system, suspension and transmission driveshaft, and tighten if
environment, so as to improve their surface quality and combination necessary. Inspect the brake lines for leakage and repair if necessary.
precision, and avoid premature abrasion. During break-in period, maintain the vehicle according to the following
The break-in mileage of new vehicles is 1,000km. If conditions are guidelines, and then commence normal operation.
permitting, the customer may extend the break-in mileage to 2,500km 1. Carry out regular maintenance as outlined by FAW after the initial
for superior results. 1,000km break-in period.
The following regulations should be followed during the break-in 2. Change engine, transmission, and rear axle oils.
period: III Fuel, coolant, lubricants
1. Drive on flat and good road surfaces. (I) Fuel
2. Avoid quick starts, rapid acceleration, and high speeds. #90 (GB17930-1999) unleaded gasoline or higher should be used.
3. Closely observe your speed, making sure not to exceed the Note: Vehicles equipped with EFI engines should use #93 (GB17930-
maximum break-in speeds for each gear (see Table 1.2-1). 1999) unleaded gasoline or higher.
Running Vehicle speed not exceeding (km/h) (II) Coolant
mileage 1st 2nd 3rd 4th 5th For long engine life, an antifreeze solution should be used year-round.
(km) gear gear gear gear gear The factory installed coolant is a 50/50 mixture of antifreeze (ethylene
0-200 13 22 34 48 64 glycol) and water. This allows protection exceeding 5℃ below the
200-800 13 22 34 48 64 lowest average air temperature. Engine coolant should be changed every
800-1,500 20 33 51 73 97 2 years.
1500-2,500 27 44 69 95 105 (III) Brake fluid
Note: For 4-speed transmissions, refer to the speed limitations listed Use #9208 (DOT 3) brake fluid.
above for gears 1-4. (IV) Lubricants
4. During the first 200km, the vehicle must be operated “empty” (no 1. Lubricating oil
passengers or cargo); between 200-1,000km, the combined Engine 10W30 SE(GB11121-1995) gasoline engine oil
passenger/cargo weight carried by the vehicle must not exceed 70% of Transmission 75W-90 or 80W-90 (GL-4 or GL-5) gear oil
the vehicle’s specified load capacity. Rear axle 75W90 or 80W-90 (GB13985-92) hypoid gear
oil
2. Chassis grease
Lithium-based grease
Section 3 Equipment and structure II. CA5010XJE monitor van series

of special-purpose vehicles 1. Front van doors have a “monitor” emblem (see Fig. 1.3-4).
I. CA5010XJB police van series 2. The cab is equipped with a public address system.
1. The upper part of the body is white, the lower part is blue, the front 3. The center and rear seating are located on the left side, with a metal
doors have a standard “police” emblem, the emblem and the lower working table on the right side (see Fig. 1.3-5).
body are both BP dark (phthalocyanine) blue color in GB/T3181-95,
see Fig. 1.3-1
Fig. 1.3-4
Fig. 1.3-1
2. The upper side of the body is equipped with light bar, siren,
and loudspeaker operated from within the cab.
3. There are two rows of passenger seating (both can fold and
tilt), and a work table located between the front seats (see Fig. Fig. 1.3-5
1.3-2).
A handcuff loop is provided on the upper side of the back seat, III. CA5010 XYZ postal van series
and a leg shackle loop is provided on the lower side (see fig.3-3) 1. The entire vehicle is painted phthalocyanine green. The front doors
Fig. 1.3-2 Fig. 1.3-3 have a yellow “postal” emblem, with an EMS (express mail service)
emblem on the rear side (see Fig. 1.3-6).
2. A “mail” lamp is mounted on the van roof.
3. A tiltable partition is provided between the front cab area and the rear
mail cargo area.
Protective railing is installed over the middle door window, rear V. CA5010XJH ambulance van series
quarter windows, and rear window glass. The floor has a durable red 1. The vehicle body is white, with a “ red heart and white cross” emblem
severe duty floor mat for long life (see Fig. 1.3-7). on the front doors (see Fig. 1.3-10).
2. The upper side of the body is equipped with light bar, siren, and
loudspeaker operated from within the cab.
3. The front cab area and rear ward area is separated by a bulkhead.
There is a flip-down seat on the right side. The side windows are
equipped with white curtains. An aluminum alloy stretcher is provided
(see Fig. 1.3-11).
Fig. 1.3-6 Fig. 1.3-7
IV. CA5010XXY cargo van series
1. “Van” emblem on the upper, center side panel (see fig. 1.3-8).
2. A tiltable partition is provided between the front cab area and the
rear cargo area. The center and rear quarter windows are deleted.
The floor has a durable red severe duty floor mat for long life (see
Fig. 1.3-9).
Fig. 1.3-10
Fig. 1.3-8 Fig. 1.3-11

VI. CA 5010XQC prison van series
1. The upper body is white, the lower is dark (phthalocyanine) blue in
GB/T3081-95 (see fig. 1.3-12).
Fig. 1.3-9
2. The upper side of the body is equipped with light bar, siren, and
loudspeaker operated from within the cab. Section 4 Vehicle service and maintenance
3. A prisoner’s cage separates the rear cabin into an isolated jail cell
(see Fig. 1.3-13). 1. Routine maintenance
Routine maintenance, daily preventative maintenance before and after
operating the vehicle, is the foundation of long vehicle life. Keeping the
vehicle clean and being observant are very important. Besides cleaning
the interior and exterior of the vehicle, including the glass, important
preventive maintenance areas are:
1. To check condition of the vehicle lighting, instruments, wiper blades,
brake system.
2. Check for any abnormal engine or chassis sounds.
3. Check for any water, oil, or gas leakage; check fluid levels (ie, oil,
coolant, fuel), and tire air pressure. Add as required.
4. Check the condition and mounting of the wheels, steering,
transmission, and suspension mounting.
Fig. 1.3-12 Fig. 1.3-12 II. Schedule of regular maintenance

Time interval: Mileage 1 10 20 30 40 50 60
Number of months or kilometers, whichever ( X 1,000km)
comes first Number of months Break-in 6 12 18 24 30 36
(Month) period
Engine Fan belt : tension, damage J·T J·T·G G J·T·G
Timing belt: tension, damage J·T·G J·T·G J·T·G J·T·G
Valve clearance J·T J·T J·T J·T
Cylinder head, intake, and exhaust manifold mounting bolts: degree of tightness N N N N
Engine oil filter G G G G G G G
Engine oil G Every 5000 km, replace once
Coolant J·B J·B J·B J·B G J·B J·B
Cooling system hoses and connections: leakage, damage, degree of tightness J·T·G
Exhaust piping and accessories: leakage, damage, degree of tightness J·T·G J·T·G J·T·G J·T·G
Ignition ignition wires: deterioration, damage J·T·G J·T·G J·T·G J·T·G
system Distributor cap and rotor: abrasion, cracks J·T·G J·T·G J·T·G J·T·G
Spark plugs J·T·G R J·T·G R J·T·G R J·T·G
Ignition timing J·T·G G G G G G G
Vacuum advance unit J·T J·T J·T J·T J·T J·T J·T
J·T J·T J·T·G J·T·G
Fuel Air filter element Q Q Q Q G Q Q
system Throttle stay and carburetor shaft Every 10000km , I.T.R.G.
Fuel pipe and joint: leakage, damage J·T·G J·T·G
Gasoline filter G
Idle speed and idle mixture J·T J·TT J·T J·T
Crankcase breather hose and connector J·T J·T·G J·T·G J·T·G
PCV valve J·T J·T·G J·T·G J·T·G
Fuel evaporation control system hose and connector J·T J·T·G
Electrical Harness and lighting fitting J·T
equipment
Chassis Clutch pedal free travel J·T J·T J·T J·T
and body Brake drums, shoes, rotors, pads: abrasion, damage J·T J·T·G
Brake lines: leakage, damage J·T J·T·G
Brake fluid J·B J·B G J·B
Brake pedal free travel J·T J·T J·T J·T J·T J·T J·T
Brake rod and stay: travel, damage J·T J·T J·T J·T J·T J·T J·T
Tires: abrasion, pressure J·T J·T J·T J·T J·T J·T J·T
Wheels, wheel nuts: damage, tightness J·N J·N J·N J·N J·N J·N J·N
Shock absorbers: oil leakage, damage J·T J·G J·G J·G
Driveshaft J·T J·G J·G J·G
Transmission and rear axle: oil leakage, oil level G J·T·G J·T·G G J·T·G J·T·G
Spring plate J·T·G R R R
Steering: tightness, damage, noise J·T J·T·G J·T·G J·T·G
Door hinges R R R
Test drive Carry out a test drive after each maintenance
Note: Letters in the table stand for meanings, B—supplement, J—check ,T—regulate, Q—clean, sweep, R—lubricate , G—replace(If it coexists with other items replace if necesary)
Chapter I. Complete Vehicle Operation and Service Manual – FAW Jiabao Series Light Passenger Van
III. Maintenance items

(I) Engine
1. Fan belt
(1) Check and adjustment
1) Check for cracks, breaks, distortion, abrasion, and cleanliness of
the belt. Check belt tension. Press the belt with your thumb (about
10kg force); if belt deflection is 6-9mm, belt tension is correct, as
shown in Fig. 1.4-1.
Fig. 1.4-2
4) Tighten the alternator adjusting bolt and lower mounting bolts.
Note: Never perform the above procedure when the engine is running.
(2) Replacing the fan belt
1) Loosen the alternator adjusting bolt and lower mounting bolts, and
move alternator inwards to release tension on the belt.
2) Remove the belt and replace with new.
3) Move alternator outwards, adjusting the belt tension to the specified
Fig. 1.4-1 value.
2) If the belt is too tight or loose, readjust the alternator mounting. 4) Tighten the alternator adjusting bolt and lower mounting bolts.
3) Loosen the alternator adjusting bolt and lower mounting bolt, and Note: The repairs described above must be done when the engine is
move the alternator, adjusting the belt tension to the specified value turned off and the radiator temperature is low.
(see Fig. 1.4-2).
2. Valve clearance
(1) Remove the valve cover. The specified torque for the exhaust manifold nuts is 18-23 N·.M (1.8-
(2) Check the valve clearance of intake and exhaust valves, and adjust 2.3kg.m).
if necessary. The specified torque for the air intake manifold nuts is 18-23 N·m (1.8-
Standard valve clearance: 0.13-0.18mm (cold engine), 0.23-0.28mm 2.3kg•m).
(hot engine).
(3) Reinstall the valve cover, and tighten the mounting bolts to the
specified torque (4-5 N·m).
.
3. Cylinder head bolts
(1) When checking the cylinder head bolts, the valve cover must be
removed. The specified torque for cylinder head bolts is 55-60 N·m
(5.5-6.0kg•••m).
(2) When retorquing the cylinder head, the cylinder head gasket
should be under even stress. The tightening sequence for the cylinder Fig. 1.4-4
head bolts is shown in Fig. 1.4-3. 4. Engine oil filter replacement
(1) Remove the engine oil filter with an oil filter wrench.
Note: Before installing the new oil filter, apply a thin film of clean
engine oil to the filter mounting gasket.
(2) On the engine, wipe the filter gasket contact surface clean with a
clean towel. Screw the new filter by hand onto the engine until the filter
gasket makes contact.
(3) Tighten the filter 3/4 of a turn with an oil filter wrench.
Fig. 1.4-3
(3) The specified torque for the valve cover bolts is 4-5 N·m
(0.4-0.5kg•m).
(4) Check the tightness of air intake and exhaust manifold nuts, and
tighten to the specified torque if necessary. See Fig. 1.4-4.
Note: Tighten the oil filter adequately to prevent leakage, but take (1) When the engine is COLD, remove the radiator cap.
care not to overtighten. (2) Remove the lower radiator drain plug to drain the old coolant, as
(4) After installing the oil filter, start the engine and check for leaks. shown in Fig. 1.4-6.
5. Replacement of engine oil
Before draining the engine oil, check for engine oil leaks. In the event
of any leaks, repair the leaks before proceeding with the oil change.
(1) With the engine slightly warm, remove the oil pan drain plug, and
drain the old oil.
(2) After the engine oil is completely drained, clean the drain plug and
oil pan plug mounting surface with a clean towel. Then reinstall the
drain plug, tightening it securely to a torque of 20-25 N·m(2.0-
Fig. 1.4-5 Fig. 1.4-6
2.5kg•m). 1.Reference line 2. “Low” level mark 3. “Full” level mark
(3) Remove the engine oil fill cap, located on the valve cover, to refill
the engine with FAW-specified oil (3.5 L). Start the engine, ensuring (3) Remove the overflow reservoir ①, and empty the coolant. See Fig.
the low oil pressure indicator turns off, and operate the engine for 2 1.4-7.
minutes, checking for leaks. Then turn the engine off, wait 2 minutes,
and check the engine oil level with the engine oil dipstick. The level
should be near or at the high mark on the dipstick.
Engine oil capacity table
Oil pan capacity 3.0L
Oil filter capacity 0.2L
Other 0.3L
Total engine oil capacity 3.5L
Oil type 10W-30 Fig. 1.4-7
6. Engine coolant replacement

Note: In order to avoid personal harm, when engine coolant
temperature is high, DO NOT remove the radiator cap, as extremely
hot coolant and steam will be released which can cause severe bodily
harm.
(4) Reinstall the lower radiator drain plug and the overflow reservoir. (II) Ignition system
Refill the radiator with coolant, and run engine at idle speed, until the 1. Ignition wires
thermostat opens at least one time, then turn off the engine. After the (1) Verify the ignition wires are securely attached to the spark plugs and
engine temperature drops, fill up the radiator again, and reinstall the distributor cap. Replace any wires with damaged end connections.
radiator cap. (2) Measure the resistance of the ignition wires.
(5) Refill the overflow reservoir with coolant, until the level reaches Ignition wire resistance specifications: Standard---16 kΩ/m
the “FULL” mark Operational limit---20 kΩ/m
Coolant capacity table (3) Replace worn out or damaged ignition wires.
Engine, radiator and heater 3.4L 2. Distributor cap and rotor
Overflow reservoir 0.6L (1) Check the distributor cap for cracks and damage. Replace if required.
Total coolant capacity 4.0L (2) Check the center electrode and contacts for wear and corrosion, as
7. Cooling system hoses and joints shown in Fig. 1.4-8. Replace if required.
Visually check for any leakage or abrasion and replace as required.
Verify that the hose clamps are properly tightened and replace if
necessary.
8. Exhaust piping and accessories
Note: In order to avoid personal harm, when the exhaust system
temperature is high, DO NOT touch the exhaust system components.
Any relevant service of the exhaust system should be done after the
system has cooled.
When the vehicle is on a car lift receiving service work, check the
exhaust system using the following steps: Fig. 1.4-8
(1) Check for damage, aging, and severe distortion of rubber parts.
(2) Check for leakage, loose connections, and exhaust system
damage. If any bolts or nuts are loose, torque them to specification.
Exhaust system torque specifications: exhaust pipe nuts: 35-45N·m
(3.5-4.5kg•m)
Exhaust pipe bolts: 35-50N·m (3.5-5.0kg•m)
(3) Check for any damage that could allow exhaust gases to infiltrate
the inside of the vehicle, and repair immediately.
(3) Check the distributor rotor contact for wear and corrosion. (3) Install the new spark plug to the specified torque, using a spark plug
Replace if required. socket, extension, and torque wrench.
Note: Clean any dust or dirt inside the distributor with a soft, clean The spark plug torque specification is 20-30N·m(2.0-3.0kg·m).
cloth. (4) Reconnect the ignition wire to the spark plug, holding the sleeve
3. Replacement of spark plugs (rather than the wire) to secure the connection.
(1) Disconnect the ignition wire from the spark plug, by holding the 4. Ignition timing check
spark plug sleeve on the ignition wire and pulling outwards, as Check the ignition timing to verify its correct setting. If the timing is not
shown in Fig. 1.4-9. correct, it must be adjusted.
For additional information including adjustment procedure, refer to the
engine manual.
5. Distributor vacuum advance unit
Check whether the vacuum advance unit is operating normally. For
relevant inspection procedures, please refer to the engine manual.
(III) Fuel system
1. Cleaning and replacement of the air filter element
(1) Remove the air filter housing cover.
(2) Remove the air filter element from the filter housing.
(3) Clean the air filter element or replace it with a new one. When
cleaning the air filter element, use only clean, low-pressure air to blow
out dust from the inside of the element, as shown in Fig. 1.4-10.
Fig. 1.4-9
(2) Loosen and remove the spark plug using a special spark plug
socket, extension, and ratchet.
Note: New spark plugs which conform to the specified heat range
and size must be used (refer to the engine manual).
Fig. 1.4-9
(4) Insert the air filter element into the air filter housing. (2) Visually check the fuel tank cap gasket. In the event of abrasion,
Note: If the vehicle is operated in dusty conditions, the air filter breakage, or distortion, replace the gasket.
should be checked more often and replaced as required. 4. Replacement of the gasoline filter
(5) Pre-cleaner The fuel filter must be replaced regularly. The replacement method is as
Remove the lower bowl from the pre-cleaner, and empty the bowl as follows:
shown in Fig. 1.4-11. (1) Disconnect the inlet and outlet filter hoses, and remove the filter
from the vehicle.
(2) Install a new filter, and reconnect the inlet and outlet hoses.
Note: For carbureted engines, the “outlet” is located on the top side of
the filter and the “inlet” is located at the lower side.
See Fig. 1.4-12
Pre-cleaner Loosen Bowl
Screw Dust
Fig. 1.4-11
Throttle cable, choke cable and throttle shaft

Lubricate the moving parts, and verify that the choke cable is
actuating the carburetor choke flap properly when the choke knob is
pulled out.
3. Fuel tank and piping Fig. 1.4-12
(1) Visually check the fuel line piping for leakage. Check the fuel 1. Inlet 2. Outlet
hoses for abrasion, dry rot, breakage, and replace as required. Make 5. Engine idle and idle mixture
sure all fuel hose clamps are properly tightened. Check idle and idle mixture, and adjust as required.
For idle and idle mixture adjustment procedures, refer to the engine 3. Fuel evaporation control system
manual. 1) Check for breaks, cracks, or excessive bends in the hose, and replace
(IV) Emissions control system as required.
Crankcase breather hose and connector 2) Check the hose mounting clips and replace if required.
Check for breaks or leaks in the crankcase breather hose, and repair or 3) Refer to the engine manual to check the vapor channel of activated
replace as required. Make sure the hose connector is securely charcoal container.
fastened. (V) Electrical equipment
2. PCV (positive crankcase ventilation) valve check 1. Lighting
(1) Disconnect the hose connecting tee joint from the PCV valve. Check all lamps for normal operation. Repair or replace as required.
(2) Start the engine and run at idle speed; block one end of the hose 2. Harness and connector
with your thumb to check for vacuum pressure in the hose. If a (1) Check the condition of the vehicle wiring and connections.
vacuum is evident, the PCV valve is good, as shown in Fig. 1.4-13. (2) All harness mounting clamps must hold the harness securely.
(3) Any wires in bad condition should be replaced.
(VI) Chassis and body
1. Clutch pedal free travel inspection
(1) Check clutch pedal free travel.
Free travel: 20-30mm.
(2) Apply a small amount of grease to the hook and connecting positions
of the clutch stay.
2. Brake rotor, brake pad, brake drum and brake shoe
(1) Brake rotor and brake pad
Disassemble the wheel and brake caliber, but do not disconnect the brake
Fig. 1.4-13 hose.
(2) Turn off the engine, and reconnect the hose to the tee joint. 2) Check for any abnormal brake pad or brake rotor wear. Repair as
required.
During reassembly, torque all bolts to specification.
(4) Brake drum and brake shoe
1) Disassemble the wheel, brake drum, and brake shoe.
2) During disassembly, check the wear level of the brake drum and (2) Pull up completely on the parking brake lever with one hand, to fully
brake shoes. Also, check the brake wheel cylinder for any leakage. actuate the parking brake. If when pulling up on the parking brake lever,
Repair if required. the number of teeth “clicks” exceeds 8, the parking brake must be
3. Brake line check adjusted.
Check whether brake hoses and lines are clamped correctly, and that Parking brake lever travel: within 3-8 “clicks” (when the brake lever is
there is no fluid leakage, cracked hoses or lines, or other damage. pulled up with 20 kg of force).
Repair as required. For parking brake specifications and adjustment, please refer to Section
Note: After replacing any brake hoses or lines, air must be bled from 7 of Chapter 3.
the brake system prior to vehicle operation. (3) Parking brake cable
4. Brake fluid inspection and replacement Check the parking brake cable for smooth operation. Replace if required.
(1) Check whether there is any brake fluid leakage around the brake 7. Tire check and rotation
master cylinder and brake fluid reservoir. If so, repair as required and (1) Check whether any tires are worn unevenly or have excess wear. If
refill with fluid. so, replace as required.
(2) Check the brake fluid level. If the brake fluid level is below the (2) Check the air pressure of each tire, and adjust to the specified
low fluid mark, refill to the high mark. pressure as required.
Note: The brake system of the vehicle has been filled with DOT 3 Note: Tire pressure must be checked when the tires are “cool”. The
type brake fluid at the factory. It is very important that other types of specified tire pressure can be found on the sidewall of the tire and within
brake fluid are not used. Do not use brake fluid from an unsealed this manual.
container, or used brake fluid. (3) Tire rotation
(3) Change the brake fluid every two years. The steps for changing For instructions on tire rotation, please refer to Section 8 of Chapter 3.
the brake fluid are as follows: completely drain the brake fluid in the 8. Rim and lug nut
brake system, then refill with new brake fluid, and bleed the system (1) Rims
properly. Check whether the rims are dented, distorted, or cracked. Damaged rims
For bleeding instructions, please refer to Section 7 of Chapter 3. should be replaced.
5.Brake pedal (2) Wheel bearing
Check brake pedal free travel.
For checking instructions, please refer to Section 7 of Chapter 3.
6. Parking brake lever and stay
(1) Check the teeth of the parking brake handle ratchet plate for wear
or damage. If there is any wear or damage, the parking brake handle
must be replaced.
1) Check the condition and preload of the front wheel bearings. (2) Part replacement is required based on the above-mentioned
2) Check the condition and preload of the rear wheel bearings. inspection.
(3) Lug nuts 10. Driveshaft
Check that all lug nuts are installed and torqued to specification (see (1) Check the u-joints and slip yoke for looseness. If you hear a
Fig. 1.4-14). “chattering” sound, the worn parts should be replaced. See Fig. 1.4-15
Lug nut torque specification: 50-80 N·m (5.0-8.0kg·m).
Fig. 1.4-15
(2) Check the tightness of the driveshaft mounting bolts, and retorque
them to specification as required.
Torque specification: 18-28 N·m (1.8-2.8 kg·m)
11. Gear oil inspection and replacement
(1) Check
1) Check the transmission and rear axle for oil leakage, and repair as
required.
Fig. 1.4-14 2) When checking the oil level, the vehicle must be on a level surface.
9. Shock absorber 3) Remove the filler plug. Insert one finger into the filler hole to
(1) Check the shock absorbers for oil leakage, dents or other damage, determine whether the oil level is at or near the full level, as shown in
breakage or aging of the upper front strut mounts, and rear shock Fig. 1.4-16.
absorber mounting bushings.
Fig. 1.4-17
1. Oil filler plug 2. Oil drain plug
2) Rear axle
Fig. 1.4-16 Oil capacity: 1.3L
Oil type: 80W-90(GB13985-92) or hypoid gear oil.
1. Transmission filler hole 2. Transmission oil
If gear oil is deficient, add FAW-specified gear oil until the oil level is
even with the fill hole.
4) Remove the rear axle filler plug. The oil level can be checked at the
oil fill hole, and oil added, using the same method as described above.
(2) Oil replacement
Note: Before oil replacement, first check for any oil leakage. If there
is oil leakage, it should be repaired first. Then drain (when warm) and
refill with the specified amount and type of new oil.
Oil capacity: 1.3L
Oil type: 80W-90(GB13985-92) GL-5 grade gear oil.
Fig. 1.4-18
1. Oil drain plug 2. Oil filler plug
12. Suspension Note: When doing the following road test, it is necessary to select a safe
(1) Check the springs for abrasion and breakage. If abrasion or area free of pedestrians and other vehicles, to avoid any possible
damage is found, the springs must be replaced. accident.
(2) Check the tightness of mounting bolts and nuts, and retorque them 1. Engine
to specification as required. Start the engine to prepare for the test.
13. Steering system 2. Clutch
(1) Check the steering wheel free travel. The vehicle must be on level Check the following items:
ground with the front wheels facing straight ahead.  When depressing the clutch pedal, the clutch should release
Steering wheel free travel: 0-30mm completely.
(2) Check the steering shaft joint for looseness or damage. Repair as  Release the pedal and depress the accelerator simultaneously
required. for a smooth engagement. Do not “slip” the clutch by releasing
(3) Check the tightness of bolts and nuts, and tighten as required. the pedal too slowly, but do not release the pedal too quickly.
(4) Check the steering rack for breakage and other damage (ie, torn  The clutch should not exhibit any abnormal sounds or function.
dust boot). Repair as required. 3. Shift lever
(5) Check the globular pin dust cap for damage. Replace if required. Make sure the gear shift lever moves freely, allows complete
(6) Check the front wheel alignment. Realign to factory specifications engagement of all gears, and does not “pop out” of gear during vehicle
as required. operation.
(7) During vehicle operation, abnormal steering wheel resistance and 4. Brakes
chattering is not acceptable. If present, repair as required. (1) Brakes
14. Door hinge lubrication When depressing the brake pedal during vehicle operation, check the
Wipe away any dirt and apply a thin layer of engine oil. Open and following items:
close the door several times to spread the oil through the hinge.  Braking action is good.
(VII) Test driving  There are no noises from the brakes.
After conducting a standard check of all repairs as listed above, a road  The braking force acted on all wheels is uniform.
test shall be done in safe area. (2) Parking brake
Check that the parking brake, when the parking brake lever is fully
actuated, does not allow vehicle movement when parked on a 20%
incline.
5. Steering gear
Rotate the steering wheel, and verify there is no binding, tightness, or
abnormal noises.
6. Engine
• Operate the engine and verify smooth operation at all rpm’s.
• Check the engine and ensure no abnormalities during operation
7. Body, wheel and drivetrain
Check the body, wheels, and drivetrain. There should be no
abnormal noises, vibrations, and other conditions.
8. Instruments
Check the function and accuracy of the speedometer, odometer, fuel
gauge, and water temperature gauge.
9. Warning indicator lamps (oil pressure, charge indicator, low brake
fluid level, and engine failure)
Verify the lamps turn off during engine operation. If any of the
lamps do not, this indicates the related system is faulty and requires
immediate service.
10. Seat belt
Seat belts should be worn securely in the event of emergency
braking.
When the ignition switch is in the ON position, the fuel pump is actuated
Chapter II. Engine and fuel is drawn from the fuel tank. After being filtered by the fuel
Note: The parts of the engine are mainly described in the service filter, the filtered fuel flows to the carburetor through the fuel pump and
manual. The following illustrates aspects not referred to in the intake pipe. In the event there is excessive fuel in the float chamber of
previous section. carburetor, the fuel is returned to the fuel pump via the fuel return pipe.
Section 1 Carbureted Engine Accessories 2. Fuel tank
(1) Fuel tank structure
I. Fuel system for carbureted engine The fuel tank is constructed from sheet steel stampings. A fuel sending
(I) Components of fuel supply system unit is attached to the upper center. A fuel fill spout is seamed on the
The fuel supply system consists of the fuel tank, fuel piping, fuel side, and a fuel drain plug is fixed on the bottom, which is used to drain
filter, fuel pump, intake system, and exhaust emission control devices. deposited water and particles from the fuel tank.
Please refer to Fig. 2.1-1. (2) Fuel tank mounting
1. Operating principle of the fuel supply system The fuel tank is connected to the fuel tank support bolts by means of four
holes in the tank body. After removing the bolts and draining the fuel
tank, the fuel fill hose should be removed first, then disconnect the fuel
tank sending unit harness, and last, remove the fuel supply hose and fuel
return hose mounting clamps.
3. Fuel filter
The fuel filter is plastic and barrel-shaped. A filter element is mounted
internally, a fuel inlet port is located on the barrel body, and a fuel outlet
port is located on the barrel cover. The fuel filter cannot be
disassembled, so a new filter should be installed at 40,000 km (if the fuel
quality is poor, the service interval should be appropriately shortened).
4. Fuel pump
The electric fuel pump is attached to the right frame rail. Please refer to
Fig. 2.1-1 Operating principle of the fuel supply system Fig. 2.1-2.
1. Fuel tank 2. Fuel filter 3. Fuel pump 4. Intake pipe 5. fuel return (1) Power stroke
pipe 6. Exhalant pipe 7. Carbon canister 8. Vacuum tube 9. When the ignition switch is turned on, electrical current flows to the coil
Carburetor 10. Desorption pipe 11. Air filter 12. Pre-cleaner 13. (3) through a contact switch and excites the wiring. The exciting coil (3)
Cool air pipe 14. Hot air pipe 15. Intake valve 16. Gas-oil separator attracts the plunger (4) and makes the pull rod (12) and diaphragm (7)
move up and down. Thus the lower volume is increased and fuel is
drawn to the fuel chamber (11) through the fuel valve (10). Meanwhile,
as the pull rod moves up and makes the upper caliper trigger the spring
seat, the position of springs (15) are
Chapter II. Engine Operation and Service Manual - FAW Jiabao Series Light Passenger Van
therefore changed resulting cutting off of contact switch (2) and the
electrical current, thus terminating the wiring magnetism. The
diaphragm and pull rod are pushed downward under the force of
gravity and elasticity, so fuel in the fuel chamber can push the fuel
valve and flow out of the fuel pipe, the upper contact can be again
connected. The process is reciprocated and results in continuous fuel
pumping.
(1) Internal fuel pump check
1) When the electric fuel pump fails, the fuel piping should be
checked for breakage or crimpage. The pump body should be checked
for leakage, and the diaphragm should be checked for cracks. Any
leakage should be repaired and cracked parts replaced.
2) The contact point should be checked for corrosion. If present, an oil
stone may be used to clean and restore good contact.
Fig. 2.1-3 Fuel pump flow check

1. Battery 2. Black/ white wire 3. Black wire 4. Fuel pump
5. Kerosene H=50cm
3) After reassembling the fuel pump, check the fuel pump flow
capacity according to the method referred to in Fig. 2.1-3. The flow
pressure should exceed 500ml/min.
Fuel Pump (mechanical)
(1) Introduction
The diaphragm type pump assembly pumps fuel into the carburetor
float chamber. The pump is driven via a rocker arm by an eccentric on
the engine camshaft. The rocker arm is tightly pressed on the eccentric,
Fig.2.1-2 Illustration of the fuel pump which causes the pump’s diaphragm to move up and down. Please refer
1. Contact switch 2. Contact point 3. Coil 4. Plunger 5. Pump to Fig. 2.1-4.
cover 6. Spring 7. Diaphragm 8. Fuel valve 9. Fuel valve spring
10. Fuel feed valve 11. Fuel chamber 12. Pull rod 13. Caliper 14.
Spring seat 15. Displacement spring
Operation and Service Manual - FAW Jiabao Series Light Passenger Van Chapter II. Engine
(2) Disassembly
Fuel Pump Specifications As indicated in Fig. 2.1-5, the upper and lower joints shall be marked ①,
Discharge pressure 24.5-24.3kPa to recognize the angle position of upper body ② and lower body. ③.
Pump capacity 1.3L/min (200r/min) Only if angle relation is ensured, the fuel circuit can be connected.
Pump diaphragm
Fig. 2.1-5
Rocker arm (3) Check for
1) Fuel pump leakage.
Fig 2.1-4 2) Fuel hose breakage or crimpage.
3) Tightness of all bolts.
4) Cracked or damaged diaphragm after disassembly of the fuel
pump.
Fig. 2.1-6 Fig. 2.1-7

(4) Assembly (II) Engine air intake system
1) Put the pump diaphragm on the rocker arm as indicated in Fig. 1. The intake system is composed of a fresh air intake pipe, hot air
2.1.-6, and then insert the pump stay into the rocker arm. Swivel it pipe, intake valve, pre-cleaner, and air filter housing assembly.
90º while also pushing the rocker arm, thereby attaching the 2. Operational principle of the air intake system
diaphragm to the rocker arm④. The system incorporates a dual air filtering system. As shown in Fig.2.1-
Note: When the diaphragm is swiveled 90º and attached to the 1, the lever on the intake valve (key #15) shall be turned to “summer” in
rocker arm, the diaphragm tongue piece shall be on the position of summer, causing the fresh air to flow into the pre-cleaner (12) through
pump rod ⑤. Please refer to 2.1-6. the air intake pipe (13) from the front of the vehicle, and after being pre-
2) Based on the relative positions of the upper body and lower body cleaned of large particles, the air flows into the air filter assembly (11).
which are marked before disassembly, reinstall the eight body When the lever on the intake valve is turned to the “winter” position in
screws loosely. winter, warmed air will flow into the pre-cleaner from the vehicle’s
3) Push the rocker arm ④ to the extreme position 4 or 5 times, and interior before going on to the air filter assembly.
make sure the diaphragm is moving freely within the pump body.
Please refer to 2.1-7
4) Finally, tighten the eight screws.
The third (1) Operational principle
chamber During engine operation, air is drawn into the first chamber of the dirt
collector, and then flows into the second chamber through a windmill air
vane shaped diaphragm orifice ①, which will exert a vortex effect on the
Outlet
The first air. The centrifugal force generated by rotating air current spreads the
chamber
dirt particles around, causing them to flow towards the internal wall of
the second chamber and fall into the cup ② surrounding the wall, while
Inlet
the pre-cleaned air is drawn toward the air filter assembly through the
third chamber. Please refer to 2.1-8.
The
second
chamber Dirt
Release
Tighten
Fig. 2.1-8
3. Pre-cleaner
The air pre-cleaner is mounted on the front of the air filter inlet, and
is designed to remove large dirt particles, thus extending the life and
efficiency of the air filter assembly.
Fig. 2.1-9 Cleaning of pre-cleaner
(2) Daily cleaning II. Exhaust System

Clean the dust bowl monthly. Remove the dust bowl from the pre-cleaner, empty The exhaust system is made up of exhaust piping, a muffler, and related
out the dirt, and reinstall the bowl to its previous position, as shown in Fig. 2.1-9. mounting hardware.
4. Exhaust emission control device (I) Muffler
In order to prevent the fuel vapors from flowing into the air and creating pollution 1. Muffler structure
problems, fuel vaporization is controlled in two ways: the first is to seal fuel The purpose of the exhaust muffler is to reduce the impulse of the
pump and increase the internal pressure to reduce the original vaporized volume; exhaust current and thus reduce the exhaust noise level.
the second is to store and absorb the vaporized volume after surpassing certain The welded muffler assembly applies dual rate muffling, the first rate
pressure, and send it to the intake pipe to burn during engine operation. adopts extending muffling and the second rate adopts expanding
Exhaust emission control device include carbon canister, fuel-vapor separator, muffling.
fuel tank cap with single directional valve, exhalant pipe, vacuum pipe, and
desorption pipe. Please refer to Fig. 2.1-1.
The operational principle of the system is that: absorb the fuel vapors from the
fuel tank by using the excellent absorption and desorption qualities of active
carbon. When the engine is operating normally, the fuel vapor stored in the active
carbon is dispersed by applying the vacuum of the engine’s intake system, thus
restoring the active carbon’s ability to store and absorb vapors.
The power stroke of the system is that: with changes in ambient temperature and
pressure, fuel vapor in the fuel tank exhausted from vapor escape port will be Fig. 2.1-10
condensed through fuel-vapor separator, the condensed liquefied fuel returns to 1. Sealing gasket 2. exhaust pipe 3. Bolt 4. Spring 5. Sealing coil 6.
the fuel tank and the vaporized fuel flows into the active carbon to be stored Muffler 7. mounting insulator
through the double directional valve of the carbon tank. When the engine runs
normally, vacuum is created in the engine carburetor; the fresh air is drawn
through the air port of carbon tank due to the carburetor’s vacuum. When fresh air
passes through the carbon tank, it takes the fuel vapor stored in the active carbon
to the carburetor and then flows into the combustion chamber together with
combustible intake mixture to burn. When vacuum is created as a result of falling
ambient temperatures and fuel consumption, fresh air will be drawn from the air
port of the carbon tank due to fuel tank vacuum and flow into the fuel tank
through carbon tank and the fuel-vapor separator will release the vacuum in the
fuel tank, thus protecting the fuel tank to ensure the normal operation of the
engine.
As the exhaust manifold of engine applies compound exhausting, the Section 2 Electro Engine Series of Accessories
exhaust system can be divided into two parts, the exhaust piping and I. UAES system (ally electronics)
the muffler assembly. The exhaust pipe works in conjunction with the (I) Fuel supply system
engine to make compound exhausting, and combines the two pipes
into one pipe.
2. Installation and function
The exhaust pipe is bolted to the engine’s exhaust manifold, utilizing
a sealing gasket. A ball-shaped sealing gasket seals the exhaust pipe
and muffler assembly, utilizing cone-shaped springs and bolts to
maintain tension. A rubber mounting insulator is used to connect the
muffler assembly to the vehicle’s frame rail.
After connecting the exhaust pipe and muffler assembly, raise them
toward the frame rail and then rotate them to a suitable angle so the
tailpipe will not interfere with other parts, and tighten all mounting
bolts securely. Refer to 2.1-10.
3. Maintenance and service
The exhaust system should be checked at 20,000 kilometers intervals. Fig. 2.1-1 Schematic Diagram of UAES Fuel Supply System
The check includes the following: whether any damage exists to the 1. Electronic controller 2. Water temperature sensor 3.Fuel injector
muffler sealing gasket, exhaust pipe, and muffler assembly. If so, the 4. Fuel guide 5. Carbon tank magneto valve 6. Fuel return valve
part should be replaced. If the exhaust pipe joints are leaking, they 7. Induction manifold 8. Carbon tank 9. Fuel filter 10. Fuel tank
should be tightened. 11. Fuel pump 12. Fuel-vapor separator 13. Fuel pressure regulator
14. Air intake temperature and pressure sensor 15. Step motor
16. Restrictor position sensor 17. Air filter 18. Pre-cleaner
19. Intake pipe 20. Restrictor valve body
1. Harness assembly 2. Wire clip 3.

Spring 4. Guide rod 5. Pressure hose 6.
Fuel pump 7. Fuel pump bracket 8. Fuel
reservoir 9. Flange 10. Caliper 11. Fluid
level sensor assembly 12. Spring ring 13.
Holding ring 14. Fuel filter
Fig.2.2-2 Fuel Pump and Support Assembly

Installation method
The electric fuel pump is a submersible pump which is installed in
the fuel tank. The fuel pump housing is sealed to the fuel tank flange
The engine control system immediately supplies power to the engine with rubber sealing gaskets and related parts.
electronic controller when the ignition switch is turned to the “ON” (1) Fuel circuit joint
position. The electronic controller then connects fuel pump relay and The joint of intake pipe and return fuel pipe outside the flange must
the power source is switched on. 300kPa pressure will be produced in be fixed and reliable to ensure the system has no leakage under the
the fuel pipe after being filtered by the fuel filter and then sent to the pressure of 300kPa.
fuel guide rail and fuel guide rail distributor on the intake manifold. (2) Technical specifications
After the ignition switch is turned on, the controller turns on the fuel Operational voltage 6-15V DC(according to the
pump relay and the fuel pump power supply is switched on, then the vehicle power supply system)
controller controls the fuel injector of each cylinder intake pipe to rated operational voltage:12V
inject fuel regularly based on the ignition signal. (As to the Systematic pressure 300kPa
operational principle, please refer to engine service manual). Operational temperature range -40℃——+80℃
The injection order of fuel supply system: four nozzles inject fuel one allowable operational agent high quality lead-free gasoline with a
by one according to the sequence of one, two, three, four. rating of 90 or higher
1. Fuel pump (type: D580CN1009) Durability more than 100,000 kilometers under normal
The fuel pump and its support assembly consist of the following operating conditions, satisfying the
parts: fuel pump, fuel level sensor, flange with electric and oil circuit operational agent, and without
joint etc. (Please refer to Fig. 2.2-2). modifications
Note: The operational principle of the carbon canister is as follows: The
• As EFI engines require very high fuel pressure, rubber fuel hoses vacuum generated by the engine’s intake system causes fresh air to be
and related clamps must be able to ensure pressure in excess of drawn from the carbon canister’s air port. When passing through the
300kPa. Therefore, rubber hoses and related clamps cannot be carbon canister, fuel vapors are drawn from the carbon canister to the
substituted by ordinary parts, otherwise leakage will occur. More intake system, and sent to the combustion chamber together with the
seriously, a fire hazard will also occur. intake mixture. In the event that vacuum is created as a result of falling
• The fuel pump requires ample fuel in the fuel tank for proper ambient temperature or fuel consumption, fresh air will be drawn from
operation. If there is insufficient fuel in the fuel tank, the fuel pump the air port of the carbon canister as a result of fuel tank vacuum, and
may burn up due to a lack of fuel. Fuel acts to cool the pump during flow into the fuel tank through the carbon canister, dual directional
operation. Therefore, the fuel tank must always have an adequate valve, fuel-vapor separator, and air port to release the vacuum existed in
amount of fuel to avoid costly damage. the fuel tank, thus protecting the fuel tank and ensuring the normal
• When removing the fuel pump and support assembly, the fuel operation of the engine.
pressure must first be released in order to avoid injury. (II) Intake system
2. Fuel filter For the operational principle, refer to Fig.2.2-1.
The barrel-shaped fuel filter cannot be disassembled. The filter The electronic controller module measures intake temperature, pressure,
element is installed internally. A new fuel filter should be installed at engine rpm, phase signal through the intake temperature and pressure
10,000 kilometers intervals. sensor installed in the intake system, coolant temperature sensor, and
Note: As the fuel pressure requirements of the EFI fuel filter are Hoor sensor located in the ignition coil. The system can also precisely
extremely high (in excess of 16kg), an EFI fuel filter cannot be calculate the actual intake volume of the engine based on the coolant
substituted with a carbureted engine fuel filter. fluid temperature input signal during engine operation. When idling, the
3. Emission control device controller governs the intake volume by controlling the section area of
For the operational principle, refer to Fig.2.2-1. idling step motor air adjusting valve.
With ambient temperature and pressure changes, the fuel vapor in the Note: If the controller’s power cable is disconnected or the battery is
fuel tank exhausted from the air port will be condensed through fuel- replaced, the controller must be reprogrammed before restarting the
vapor separator. The condensed liquefied fuel is returned to the fuel engine.
tank and the vaporized fuel is stored in the active carbon canister The procedure is as follows: turn the ignition switch to the “ON”
through carbon canister’s dual directional valve. During normal position (do not start the engine), and restart the engine “after” 10
engine operation, the controller controls the carbon canister control seconds.
valve and drive, and adjusts the volume of desorption air current. (III) Exhaust system
The exhaust system is composed of a 3 way welded catalytic converter
assembly, muffler welding assembly and joint components. Please refer
to Fig.2.2-3.
1. Catalytic converter
(1) The function of the catalytic converter is: convert harmful exhausts
(HC, CO, NOx) from the engine tailpipe into harmless exhausts (H2O,
CO2, N2) to reduce air pollution.
• If an engine fire occurs, the engine does not run properly after starting,
engine power significantly decreases or other abnormal phenomenons
indicate the existence of a fault in the ignition system, please contact the
FAW dealer immediately. If necessary, low speed and short distance
driving can be made at low engine rpm’s.
• Try to avoid frequent starts and excessive idling, because fuel is
injected into the cylinders during the start-up, and will be exhausted to
the catalytic converter without being burned, which will cause premature
wear to the converter.
Fig. 2.2-3 Illustration of the exhaust system • When the fuel tank is nearly empty, irregular fuel supply will result in
1. 3 way catalytic converter assembly 2. welded muffler assembly 3. damage to the catalytic converter.
Connecting joints • Do not pull or push the vehicle to start the engine, as unburned fuel
(2) Catalytic converter structure will flow into the catalytic converter and cause premature wear to the
Catalytic converter contains a piece of ceramic honeycomb wrapped converter).
with a backing strap and inserted into the tube shaped body. The Note For Maintenance and Service
ceramic honeycomb is covered with a special coating (Pt, PD, and • Regular maintenance should be performed to ensure normal operation
Rh). of the electronic control system. If any abnormal condition occurs, it
Note: should be repaired quickly to ensure low vehicle exhaust levels and long
• Fuel used must be high quality lead-free gasoline (over RON90 with life of the catalytic converter.
lead volume less than 0.005L etc), as leaded gasoline will damage the • The exhaust pipe sealing gasket must be replaced when changing a
catalytic converter and the components of electric control system, related exhaust component.
thus interfering with the normal operation of parts. • No foreign objects should fall into the catalytic converter during
• The catalytic converter should not be struck and subject to strong assembly or damage will result.
vibration, as the ceramic honeycomb interior may be break and block • Check for any gas leakage or other abnormal noises from the exhaust
the exhaust system. system joints. Check whether the electric system works normally after
normal running of the engine.
II. DELPHI EFI system
(1) Fuel supply system
When the ignition switch is turned on, the engine control system
immediately supplies power to the engine electronic control module. In
the event that the engine start switch is turned on, once the system
detects the first impulse signal of crankshaft rotation, the electric
controller connects fuel pump relay. The power source of the fuel pump
is then turned on and fuel is pumped by the electric fuel pump, then fuel
is sent to the fuel guide rail and guide rail distributor above the engine to
enable the fuel injectors installed on each cylinder to regularly inject
filtered from the fuel filter.
The injection order shall be grouped injection: cylinder 1 and 4 are (2) Technical specifications
grouped together, and cylinder 2 and 3 are grouped together. Operational voltage 6-15V DC(according to the vehicle power
1. Fuel pump (type: DELPHI25330569) supply system)
For fuel pump and support assembly components, please refer to Rated operational voltage:12V
UAES system. Systematic pressure 300kPa
(1) Installation method Operational temperature range -40℃——+80℃
The electric fuel pump is a submersible type pump installed in the Allowable operational agent high quality lead-free gasoline (over
fuel tank. The fuel pump flange is sealed to the fuel tank flange by RON90, and lead volume is less
rubber sealing rings. than 0.005g/L)
Durability more than 100,000 kilometers under normal
operating conditions, satisfying the
operational agent, and without
modifications
Please refer to UAES system to see the notes.
2. For the fuel filter, refer to UAES system.
(II) Intake system
For an illustration of the intake system, please refer to Fig. 2.2-4.
Fig.2.2-4 Schematic Diagram of Fuel Supply System The engine electronic controller precisely measures the engine rpm and
1. Electric controller 2. Fuel nozzle 3. Fuel pressure adjustor 4. various input signals through intake temperature sensor (MAT) installed
Crankshaft position sensor 5. Carbon canister magneto valve 6. on the intake system, coolant temperature sensor (MAP) and crankshaft
Return fuel pipe 7. Induction manifold 8. Carbon canister 9. Fuel position sensor (CPS) located on the transmission flywheel cover.
filter 10. Fuel tank 11. Fuel pump 12. Fuel-vapor separator 13. Oil Meanwhile, the system meters the actual intake volume of the engine
guide 14. Water temperature sensor 15. Intake pressure sensor 16. based on the input signals of the coolant temperature sensor when the
Step motor 17. Restrictor position sensor 18. Air filter engine is running. When idling, the controller controls the intake volume
19. Pre-cleaner 20. Intake pipe 21. Restrictor valve body by controlling the section area of idling step motor air adjusting valve.
22. Intake temperature sensor (III) Exhaust system
The exhaust system is composed of a 3 way welded catalytic converter
assembly, welded muffler assembly, and connecting joints. Please refer
to Fig.2.2-5.
Please refer to UAES system for additional notes.
Fig.2.2-5 Structure Chart of Exhaust System
1.3 way catalytic converter assembly

2. Muffler assembly 3. Connecting joints
When the clutch is released, the outer rings of the diaphragm springs are
tightly pressed against the pressure plate, which in turn presses the clutch
Chapter III. Chassis
friction disc against the flywheel.
Section 1 Clutch When the clutch pedal is depressed, the release fork causes the release
I. Introduction bearing to move forward and push the inner ring diaphragm spring
This vehicle’s clutch is a dry type single-disc diaphragm spring fingers. Diaphragm springs make the spring outer ring move inward as a
clutch. Diaphragm spring outer side is a whole body. Inner rings have result of the rivet and separate the pressure plate from the friction pad.
some center pointing release fingers. The clutch friction disc is Thus during clutch separation, the engine’s effective power is
installed on the transmission input shaft. Four torsion buffer springs disconnected from the transmission.
are built into the clutch disc. Diaphragm springs are fixed to the This simple clutch design provides for complete separation, excellent
clutch pressure plate with rivets which form the support point of the heat emission, compact size, and does not require adjustment.
diaphragm springs.
Clutch pressure plate
Transmission input shaft
Flywheel
Crankshaft
Clutch release
bearing
Clutch plate
Fig.3.1-1b Clutch
1. Clutch friction disc 2. Clutch pressure plate 3. Spring washer
Fig.3.1-1a 4. Clutch bolt 5. Clutch release bearing 6. Clutch release pin
7. Bushing 8. Clutch release shaft 9. Return spring 10. Sizing bolt 11.
Clutch release lever
Chapter III. Chassis Operation and Service Manual - FAW Jiabao Series Light Passenger Van
Operation and Service Manual - FAW Jiabao Series Light Passenger Van Chapter III. Chassis
II. Disassembly 3. Clutch pressure plate

The prerequisite for disassembling the clutch is that the transmission Check the friction spring rivet of the clutch pressure plate to find
be removed in the following order. whether there exists release. If the rivet releases or begins to release,
The removal procedure is as follows: indicated by the clutch pressure plate producing a “chattering” noise
① Unscrew the six clutch pressure plate mounting bolts, and remove when the clutch pedal is depressed during engine operation, a new clutch
the clutch pressure plate and clutch friction disc. pressure plate assembly should be installed.
② Remove the clutch release bearing from the transmission input Check the wear condition of the joint point between diaphragm spring
shaft. release finger and clutch release bearing. If the wear condition is serious,
③ Remove the flywheel. a new clutch pressure plate should be installed.
④ Remove the pilot bearing from the flywheel. 4. Release bearing
III. Examine the components Rotate the release bearing to make sure it turns freely. If there is any
1. Clutch friction disc wear roughness, “clatter” noise, or other abnormal noises, a new release
Measure the hollow depth of each rivet head, the distance between bearing should be installed
the rivet head and the friction lining surface, to check the wear 5. Transmission input shaft pilot bearing
condition of the friction lining. If the hollow depth of any hole has Rotate the release bearing to make sure it turns freely. If there is any
reached the wearing limit, a new clutch friction disc should be roughness, “clatter” noise, or other abnormal noises, a new release
installed. bearing should be installed
Hollow depth Standard Operating limit 6. Flywheel
of rivet head 1.2mm 0.5mm Check for any wear or damage (ie, heat cracks) on the contact surface
2. Fit clearance of clutch friction disc splines between flywheel and clutch friction disc.
Rotate the clutch friction disc installed on the transmission input shaft IV. Reassembly
to check spline clearance. If the clearance exceeds the operating limit, Reassemble the clutch in the reverse order of disassembly. The important
a new clutch friction disc should be installed. Clearance means the steps are as follows.
displacement number on the circumference measured by using ① The flywheel bolts should be torqued to 40-50N·m.
micrometer gauge. ② Install the clutch pressure plate on the flywheel. Note that the two
Fit clearance of Operating limit sizing bolts shall not be omitted. The clutch pressure plate bolts should
splines 0.8mm be torqued to18-28N·m.
③ Apply a thin film of grease on the shaft of the front bearing cover
before installing the release bearing.
④ Apply a thin film of grease to the splines of the clutch release arm
and the clutch release shaft.
⑤ The two stamped marks shall be aligned when mounting the clutch
release shaft to clutch release bearing.
V. Maintenance Clutch cable routing

Suspension framework
1. Clutch pedal free travel A directional view
① Depress the clutch pedal. Stop pressing when clutch resistance is

Framework
first felt, and measure the distance (namely free travel of clutch Radiator
pedal). The free travel of the clutch pedal should be 20-30mm. Drag rod bracket
② If the free travel of the clutch pedal is not within the specified
range, then adjust it with the clutch cable adjusting nut located on the
side of pedal and release arm.
③ After completing the clutch pedal adjustment, the clutch cable side
screw should exceed the adjust nut by 1-5mm. Clip B directional view
Clip
2. Lubricate the clutch cable
Apply a thin film of grease to the clutch cable yoke clevis pin ①. Clip
Clip
Clutch
cable
Choke
cable
15-25 N·m
D directional view E directional view
C directional view
Fig.3.1-2
1. Clutch pedal 2. Clutch cable yoke Fig.3.1-2
3. Clutch cable VI. Torque specifications
The following fasteners must be torqued to the specifications below.
Component tightening torque
N·m
Flywheel bolt 40-50
Clutch pressure plate bolt 18-28
Clutch release arm bolt and nut 10-16
Clutch cable lock nut 15-25
Section 2 Transmission II. Gear shift control
I. Introduction 1. The gear shift control system is mainly composed of the following
The transmission is a gear meshed type, with five (four) forward gears parts. (Please refer to Fig.3.2-1) Shift lever is connected to gear shifting
and one reverse gear, and is cable actuated. arm and speed selecting arm on the transmission by control cables (shift
cable and speed selecting cable).
2. Disassembly
Five speed transmission
Fig.3.2-1
1. Shift lever 2. Speed selecting arm 3. bracket base 4. Ball base 5. Lining 6. Speed select
return spring 7. Gear shift handle assembly 8. Gum cover 9. Cylindrical roller 10. The first
pressure spring of gear shifting handle shaft 11. Washer 12. Reverse gear lock spring 13. Four speed transmission
Reverse gear lock ball 14. Fork arm 15. Limit stop 16. The second pressure spring of gear
shifting handle shaft 17. Reverse gear shifting spacer 18. Gear shifting cover body
1) Shift lever Check each component for wear, damage or deformation, and replace if
① Disassemble the front shift lever assembly. required.
② Disassemble the shift cable from the gearlever. New oil seals should be used during reassembly.
③ Disassemble the speed selecting arm. 3) Spring
2) Shift cable and speed selecting cable Check each spring for weakness or damage and replace if required.
① Remove the cable and the speed selecting cable from the 4) Shifter fork shaft
transmission side gear shifting arm and gear selecting arm. Visually examine each mounting point between the shift rail (first gear,
② Remove the front shift lever assembly. second gear, third gear, fourth gear, and reverse gear) and shift fork for
③ Remove the shift cable and the speed selecting cable from the any wear, and replace as required.
gearlever and bracket. 5) Gear shift lever and bracket
3) Gear shifting cover body Check each bushing and washer for wear and replace as required. If any
① Remove the shift cable and speed selecting cable from the gear binding exists in gear lever action, apply a thin film of grease as
shifting arm and gear selecting arm after making sure the gearlever is required.
in the neutral position. 4. Reassembly
② Remove the gear shift cover from the transmission. Reassemble in the reverse order of disassembly. The important steps are
③ Remove the gear shifting arm and gear shifting arm shaft. as follows.
④ Remove the reverse gear lock screws, coil springs, reverse gear Note: All interior components must be coated with gear oil before being
lock ball. installed into the gear shift cover.
⑤ Remove the cylindrical roller from the shift cover. 1) Shift cover
⑥ Pull the gear shifting handle shaft from the shift cover and remove ① Install reverse gear limit stop.
the second spring, fork spring, washer and first spring. Note: This step only applies to five speed transmissions.
⑦ Disassemble the limit stop. Note: This step is not required for four ② Install the second spring, fork arm, washer and the first arm to the
speed transmissions. shift cover. The tightening torque for the reverse gear limit stop screw is
3. Examine the components 18-28N·m (Please refer to Fig.3.2-2).
1) Fork arm and gear shifting arm shaft Note: For four speed transmissions, a spacer is installed between the
Check each lever arm end for wear and replace if required. second spring and gearlever.
The limit stop should be examined (five speed transmission only).
2) Oil seal of gear shifting arm shaft and gear selecting arm shaft
Fig.3.2-3
1. Fork arm lever arm 2. Cylindrical roller
Fig.3.2-2 3. Gear shift handle shaft arm
1. The second spring 2. Reverse gear limit pawl 3. Gear lever ⑤ Install the poppet ball, springs and screws, and screw the screws to
4. Washer 5. The first spring the specified torque 8-14N·m.
⑥ Simulate the gear shifting and gear selecting action, and pull the gear
③ Insert the gear shifting handle shaft into the gear shift cover until selecting arm and gear shifting arm, to check the flexibility of their
groove “A” on the shaft aligns with pin hole “B” on the gear shifting action.
cover body. The lever arm of fork arm and the arm center line on the ⑦ The mounting surface must be cleaned before installing the gear shift
gear shifting handle axle must be on the same level. (Please refer to cover to the rear transmission case. Apply a thin coat of sealant to the
Fig.3.2-3) mounting surfaces.
④ Install the gear shift arm shaft and screw it to the specified torque ⑧ Torque the gear shift cover mounting bolts to specification. (18-
13-20N·m. 28N·m)
⑨ Connect the speed shift cable and the speed selecting cable to their
respective rocker arms. Pay particular attention that the speed selecting
cable is attached to the gear selecting rocker arm, and the speed shifting
cable is attached to the speed shifting rocker arm, and not vice versa.
⑩ After connecting the shift control cables, operate the gear shift lever
to check the effectiveness and flexibility of gear engagement. If any
problem exists, please refer to the service manual.
2) Speed operating cable and speed operating lever 4) Transmission shift levers
Reassemble according to the reverse order of disassembly. The installation position should not be reversed when installing the
3) Washer and lining speed shifting cable and speed selecting cable to the transmission control
The washer and lining must be installed on the correct position, and lever or speed
A directional viewoperating levers. Please refer to Fig.3.2-4 and Fig.3.2-5 to
lubrication grease should be applied at the positions indicated below. ensure correct mounting. Check whether the shift levers can smoothly
engage
Washer gears afterballreassembly
Shift cable joint of all components.
Speed shifting cable assembly
Cable grommet
Cable mounting clamp
22-35 N·m
2.2-3.5 Kg·m
Speed selecting cable

assembly
B directional view Washer
4-7 N·m Coated with water proof sealant

0.4-0.7 Kg·m
Shift cable ball Shift cable mounting clamp
8-12 N·m joint

0.8-0.7 Kg·m
Fig.3.2-4
1. Gear shift knob 2. shifter boot 3. Gear shift lever 4. Shifter base 5. Speed
shifting cable assembly 6. Dust proof and pressure resistant plate 7. Hose seal
lock 8. Speed selecting cable assembly 9. Gear selecting arm 10. Speed
selecting return spring Fig.3.2-5
←: lubrication grease A (99000-25010) should be applied here
5. Maintenance
Shifter cable adjustment
Note:
• Each lubricated part listed in Fig.3.2-4 must be checked before
adjustment for adequate lubrication and no excessive wear to the
lining and other components. If so, repair as required.
• The speed shifting cable cannot be adjusted. In the event of failure,
it can only be replaced.
If the gear shift lever can easily and effectively be moved from the
neutral position to third or fourth gear, it indicates the speed selecting
cable is in good condition.
If gear shift lever cannot be easily and effectively moved from the
neutral position to third or fourth gear, the following method can be
used to adjust the speed selecting cable:
1) Move the gear shift lever slightly toward the left, making the speed
selecting shaft turn from the neutral position to the second gear side
(gear selecting position). If the gear shift lever can be easily and
effectively be put in third and fourth gear at this point, release the
speed selecting cable adjusting bolt “A” indicated in Fig.3.2-6 and
tighten bolt “B” until the gear shift lever can easily and effectively be
put in third and fourth gear.
2) Move the gear shift lever slightly toward the right, making the
speed selecting shaft turn from the neutral position to the reverse gear Fig.3.2-6
side (gear selecting position). If the gear shift lever can easily and
effectively be put in third and fourth gear at this point, release the
speed selecting cable adjusting bolt “B” indicated in Fig.3.2-6 and
tighten bolt “A” until the gear shift lever can be easily and effectively
put in third and fourth gear.
6. Torque Specifications Unit: N·m
Fastener Tightening
torque
Reverse gear limit screw 18-28
Reverse gear lock ball screw 8-14
Reverse gear arm axle nut 13-20
Reverse gear cover bolt 18-28
III. Transmission (five speed) CA6350 series mini-vehicles are available with two different types of
1. Introduction manual transmissions: a five speed transmission is installed on vehicles
using the 456 series engine and a four speed transmission is used with
the 462 series engine. The four speed transmission has four synchronized
forward gears and one reverse gear, with fourth gear being direct. The
five speed transmission has five synchronized forward gears and one
reverse gear, with fifth gear being an overdrive gear.
The transmission housing is divided into an upper case and a lower case.
The upper transmission case contains the three piece gear shaft assembly
and the lower transmission case contains the countershaft. The
transmission includes a rear transmission extension housing which
contains the reverse gear.
The front of the transmission housing, with the upper and lower cases
mounted together, acts as the bellhousing. The transmission input shaft
extends out the front of the transmission, through the clutch, with the end
resting in the pilot bearing at the center of the flywheel. The transmission
output shaft extends from the rear of the transmission, to which the
transmission driveshaft yoke is mounted.
The synchronizer used in these transmissions is a sliding inertia type.
The synchronizer is designed to speed up or slow down the rotation
speed of the gear and shaft until they are both rotating at the same speed
so they can slide together without gear “clashing”, and thus increase the
life of the transmission.
For five speed transmissions, please refer to Fig.3.2-7a and Fig.3.2-7b.
1. Input shaft 2. Spigot bearing 3. Input shaft bearing 4. Snap ring 5. Collar ring 6. Input shaft seal 7. Mainshaft
8. Mainshaft poppet ball 9.Thrust washer 10. First gear 11. Bearing inner race 12. Needle bearing 13. Second gear
14. Third gear 15. Needle bearing 16. Fifth gear 17. Thrust washer 18. Needle bearing 19. Bearing 20. Snap ring
21. Bearing 22. Snap ring 23. Snap ring 24. Countershaft 25. Fifth speed driven gear 26. Front countershaft
bearing 27. Snap ring 28. Center countershaft bearing 29. Bearing 30-1. Low speed commutating gear cover 30-2
Fig.3.2 – 7a outer gear ring 31. Low speed synchronizer ring 32. Elastic ring 33. Spring clamp ring 34-1. High speed
commutating gear ring 34-2 outer gear ring 35. Fifth gear synchronizer ring 36. High speed synchronizer ring 37-1
Reverse gear and the fifth gear commutating gear 37-2. Outer ring 38. Slide block 39. Fifth gear slide block 40.
Reverse gear countershaft 41. Sizing pin 42. Reverse gear countershaft assembly 43. Shield ring 44. Reverse
driving gear 45. Reverse driven gear 46. Lining 47. Speedometer drive gear 48. Speedometer driven gear 49.
Lining 50. Rubber ring 51. Rubber cup assembly 52. Oil seal 53. Spring clamp ring
Reverse gear shifting fork
High gear shifting fork

：Low gear shifting fork
Third gear
Reverse driving gear
Deceleration drive gear
Second gear First gear
Fifth gear driving gear
Mainshaft
Countershaft
Fifth speed driven gear
Reverse speed driven gear
Reverse idler assembly
Fig.3.2-7b
2. Transmission gear ratios: 13) Remove the rear transmission mounting bracket from the
First gear 3.652 transmission housing.
Second gear 1.947 14) Disassemble the transmission.
Third gear 1.432 4. Breakdown
Fourth gear 1.000 1) Replace clutch release shaft bushing
Fifth gear 0.795 ① Remove the clutch release shaft.
Reverse gear 3.466 ② Remove the springs from the clutch release shaft.
3. Disassembly ③ Remove the clutch release lever from the shaft.
1) Disconnect the negative (-) and positive (+) battery terminals ④ Remove the clutch release shaft from the transmission housing.
from the battery posts. ⑤ When replacing the clutch release shaft bushings, apply a thin film of
2) Disconnect the reversing lamp switch wiring harness. grease to the exterior of the bushings, and carefully tap the bushing into
3) Disassemble solenoid wire and positive (+) wire from the starter the transmission housing until it is flush with the surface.
motor. 2) Disassembling the upper and lower transmission case
4) Disassemble the motor from the transmission housing and ① Remove the clutch release bearing from the transmission input shaft.
disconnect the ground wire from the transmission cover. ② Remove the front input shaft cover bolts, and remove the cover from
5) Remove the reverse lamp wire from the clip. the transmission housing by creating a puller by using 3 longer M6 bolts.
6) Disconnect the speedometer cable from the transmission. ③ Remove the gear shift cover and the speedometer driven gear
7) Remove the oil drain plug and drain the gear oil from the bushing.
transmission. ④ Remove the rear transmission extension housing mounting bolts, and
8) Disconnect the clutch cable from the clutch release lever. remove the rear transmission extension housing.
9) Remove the gear selecting cable from the rocking arm and ⑤ Remove the upper and lower transmission case mounting bolts, and
bracket. disassemble the upper case from the lower case.
10) Disconnect the driveshaft and disassemble the hot air hose clip 3) Remove the mainshaft from the input shaft.
from the transmission cover body. ①Remove first gear, taking care not to drop the high speed
11) Remove the lower clutch inspection plate from the front synchronizing ring.
transmission housing. ② Remove the necessary snap rings and the speedometer shaft, and slide
12) Remove the transmission housing to cylinder block mounting the high speed synchronizer ring, third gear, and the needle bearing off
bolts. the mainshaft.
Note: Check again to make sure that all relevant parts have been ③ Remove the speedometer drive gear retaining snap rings, and remove
disconnected prior to removing the transmission. the speedometer drive gear from the mainshaft. Remove the rear
mainshaft bearing retaining snap rings.
④ Remove the five thrust washers, mainshaft poppet balls, gears, gear
synchronizer rings, and five gear needle bearing from the mainshaft.
⑤ Remove the collar ring, reverse gear synchronizer, reverse gear, and
reverse gear needle bearing.
58
⑥ Remove the thrust washers and reverse gear bushing from the Check the gears for any wear, damage, or heat discoloration. Replace as
mainshaft. required.
Note: The mainshaft poppet balls may fall during disassembly. Do not 2) Synchronizer, synchronizer rings, outer ring, and slide block
misplace the poppet balls. Also, the ball bearing cannot be Examine whether any wear or damage exists, and replace as required.
disassembled simultaneously with the above-mentioned thrust 3) Shift fork and outer ring
washers and bushing. Examine whether any wear or damage exists on the contact surfaces.
⑦ Remove the poppet balls from the mainshaft. Measure the maximum clearance between the shift fork and outer ring.
⑧ Remove the first gear, needle bearing, and synchronizer ring from The maximum clearance should be 1mm.
the mainshaft. 4) The mainshaft
⑨ Remove the first gear bushing, low speed synchronizer and Check the body of the mainshaft for any wear, damage, or discoloration.
synchronizer ring, and the second gear and second gear bearing. Replace as required.
4) Removing the countershaft 5) Bearing and bushing
① Remove the countershaft assembly. Check for any wear, damage, or discoloration. The bearings must also be
② Remove the rear countershaft bearing. checked for smooth operation and excessive noise. Replace as required.
③ Remove fifth and reverse gear from the countershaft. 6) The input shaft
④ Remove the snap ring from the countershaft. Remove the rear Check for any wear on the bearing mounting surface ①, gear ring ②,
bearing. Press the countershaft out the rear transmission extension gear tooth ③ and splines ④ exists, according to Fig.3.2-8. If any serious
housing using a hydraulic press. Remove the countershaft. problem is present, the input shaft must be replaced.
5) Removing the gear shift forks and rails 7) Gear and synchronizing ring
All gear shift forks must be in the neutral position before disassembly. Install the ring on the corresponding gear cone. Measure the gear
① Pull the reverse gear shifting fork. The poppet balls and springs clearance between two circumferences. If the clearance is less than the
located in the hole may jump out during this operation. Do not lose maximum operational limit, it should be replaced based on the actual
them. need.
② Remove the spring pin of the low speed gear shifting fork, being Check for any abnormal wear on the (gear) outer cone and the (ring)
careful not to damage the shift cover housing, and remove the shift inner cone. Make sure the surface contact is even and complete, without
fork and rail. Be careful to collect the shift rail poppet balls and and any surface warpage. Any worn part must be replaced. If the clearance
springs during removal. between the ring and gear, and the condition of the cone surface, satisfy
③ Remove the spring pin of the high speed gear shifting fork the specified requirements, proper synchronizer action will occur during
according the above-mentioned steps, and remove the shift fork and transmission operation.
rail.
5. Inspect the components
1) Gear
8) Chamfered tooth edge of synchronizing ring (outer tooth) and outer

Clearance between gearing ring and tooth
ring (inner ring)
Standard Operation limit The synchronizer ring and commutating ring have three grooves
Low gear, direct gear 1.0-1.4mm 0.5mm respectively which locate the slide block, and are supported by
Fifth gear 1.21-1.6mm 0.5mm expanding springs. In this way, the two rings of the commutating ring
and end side can move together. As the outer ring connects with the
commutating ring by its inner teeth, the outer ring and the commutating
ring and ring can move together.
During the meshing process, the outer ring is pushed aside (by the gear
shift fork) and pushes the ring to the cone surface of the gear. The
Fig.3.2-8 pushing force is passed on by three slide blocks. The rings rotate through
the friction of the gear cone and the (inner) ring cone. However, as the
slide blocks are obstructed by the commutating ring, the rings are turned
while the outer ring continues moves the rings forward to the cone of the
gear. When the rings cannot move forward any more, the outer ring
releases the slide blocks and straddles on the rings. Meanwhile, the first
contact occurs between the chamfered edge of the ring tooth and the
outer ring inner tooth which makes the inner tooth of the outer ring align
with the groove of the ring tooth. When the outer ring continues to move
forward and slides into the ring, the rings will rotate at the almost same
speed with the gear. Therefore, the outer ring can easily slide in the
clutch tooth of the clutch.
The first contact mesh is determined by the slide block and groove width
or the clearance between slide block and the inner groove.
Fig.3.2-9 When the synchronizer is correctly installed on the mainshaft, push and
turn each synchronizer and observe whether the mesh is 3/1. Otherwise,
it indicates the total wear extent (sum of groove, slide block and
chamfered edge tooth) exceeds the limit. In this case, the whole
synchronizer assembly must be replaced.
Mesh between synchronizer ring and outer ring chamfered edge tooth:
Chamfered edge tooth contact length of relative top shall exceed 1/3 of
chamfered edge length.
9) Synchronizer ring
Measure the width of each groove. Examine whether any wear exists on
the slide block groove of each synchronizer ring. If the width exceeds
the limit, it must be replaced. (Please refer to Fig.3.2-11).
10) Sift rail poppet (detent) springs

Slide block groove width Standard Operation limit If the transmission develops a problem of popping (sliding) out of gear,
of synchronizer ring 10.1mm 10.4mm measure the unsprung length of spring. If the length is less than the
operational limit, the spring must be replaced.
Free length of spring Standard Operation limit
25.5mm 21.0mm
11) Transmission shift levers
Check the transmission shift levers for excessive wear. Replace if
required.
To check the rear case bushing, measure the radial clearance between the
bushing hole and the slide fork of the transmission shaft, and examine
whether any damage exists on the rear case cover. If the slide fork of the
transmission shaft can rock in the bushing because of excessive wear,
Fig.3.2-10 and thus rocks the transmission shaft, the rear case cover of the slide fork
of the transmission shaft must be replaced. Replacing only the bushing is
not satisfactory.
Allowed clearance between the Standard Operational limit
transmission shaft and bushing 10.1mm 10.4mm
6. Important steps for installation
Note:
• Each part must be cleaned and FAW-specified gear oil must be coated
on the sliding surface of the bearing and gear before installation.
• During reassembly, a new collar ring must be used instead of the old
Fig.3.2-11
one.
• Tighten each bolt and nut according to the torque chart in the next part
of this section.
1) The mainshaft and input shaft
Reassemble in the reverse order of disassembly. Pay attention to the
installation direction of each washer, gear, commutating ring and outer
ring. The cylindrical roller must be attached to the main shaft.
① Attach the second gear bearing, second gear, the synchronizer ring,
low speed commutating spring, and the outer ring to the mainshaft. Pay
attention to the installation order during operation. After being placed on
each synchronizer, the three splines of the commutating ring have to be
inserted into the grooves of each ring in order.
Then, use a hydraulic press to install the first gear bushing and install ③ Install the reverse drive gear and fifth gear onto the countershaft.
the two second gear bushings in the same way. Then tap the rear bearing of the countershaft onto the mainshaft.
② Install the first gear needle bearing, collar ring, synchronizer ring, ④ Install the reverse intermediate gear and washers onto the reverse
the first gear, cylindrical roller, and washer on the second gear. Insert idler shaft, and then install the pin. Install the completed assembly in the
the poppet ball into the hole of the mainshaft and install the thrust lower transmission case.
washer to make its groove locate above the poppet ball. To ensure the 3) Gear shifting fork, pin and fork pin
correct mounting of the thrust washer, the teeth of the thrust washer Note: The three gear shift rails have their own special poppet balls and
must face the middle bearing of the mainshaft. springs, while the transmission shift levers should each be installed with
③ Install the countershaft, paying attention to the installation order. 2 poppet balls and one roller.
Install the cylindrical roller and washer. The teeth of the thrust washer ① Insert the three shift rail springs into the three holes of the upper shift
must face the middle bearing of the mainshaft, and the groove must be cover, and install the shift rail poppet balls on top of the shift rail springs
located above the poppet ball during operation. within each hole.
④ Press on the reverse gear bushing. Prevent the poppet balls ② Install the third and fourth speed shift rail into the shift cover.
installed based on the step ③ from falling out during this operation. ③ Depress the third and fourth speed shift rail poppet ball. After the
⑤ Install the reverse gear bearing, reverse gear, and the reverse gear self-lock pin is inserted into the shift rail, install the 1st/2nd and 4th/5th
commutating ring/outer ring. To ensure the correct installation order, speed shift rails following steps ② and ③. Install the shift forks and tap
the lower diameter and longer cam side must face the rearward while the shift rail until the surface between the shift rail and the shift fork
installing the commutating ring. Insert the collar ring of the reverse become even.
gear into the groove of the second gear. 4) Transmission upper and lower case
⑥ Install fifth gear bearing, fifth gear synchronizer ring, and fifth ① After the countershaft assembly, reverse idler shaft, and reverse gear
gear. Then install the poppet ball and thrust washer. The teeth of the axle has been installed into the lower case, make sure the two locating
thrust washer must face fifth gear. dowel pins are in place on the lower transmission case.
⑦ Press on the second gear rear bearing. Install the snap ring onto the ② The contact surfaces of the upper and lower transmission cases must
groove of the mainshaft. be clean.
⑧ Install the third gear bearing, third gear, and the high speed ③ Verify the thrust washers has been installed in the grooves of the front
synchronizing commutating ring/outer ring. The cam side of higher bearing and middle bearing of the mainshaft.
outer diameter should face the three gears. Then, install the snap ring
onto the groove of the mainshaft.
⑨ Install the speedometer drive gear onto the rear of the mainshaft.
⑩ Install the synchronizer ring, the needle bearing, and the input
shaft.
2) Countershaft and reverse gear idler shaft
① Tap the front side of the countershaft into the cover body. Tap the
countershaft slightly into the front bearing by using a plastic hammer.
In the same way, tap the bearing onto the countershaft and the lower
cover body.
② Insert the front collar ring of the countershaft into the groove.
④ Install the input shaft and the mainshaft into the upper transmission Others
case. An appropriate amount of FAW-specified gear oil should be added to the
⑤ A thin coat of sealant should be evenly applied to the mounting transmission upon completion. Do not overfill.
surface of the lower transmission case. 7. Maintenance and service
⑥ Insert the three gear shifting forks into the three grooves of the Gear oil
synchronizer sleeves on the mainshaft, and install the upper Note: Apply a thin film of sealant on the threads of the oil fill and oil
transmission case to the lower transmission case. drain plugs and torque the plugs to specification (36-54N·m).
⑦ Torque the transmission case mounting bolts to specification (18- After initial operation, check for oil leakage. If leakage occurs, repair
28N·m). immediately.
5) Rear transmission extension housing Transmission oil capacity: 1.3L, type: 80W-90 (GB13985-1992) GL-5.
① Check whether the locating dowel pin has been correctly installed. Note: The vehicle should be regularly checked for transmission oil
② Apply a thin film of lubricating grease should be applied to the lip leakage during any type of maintenance service, whether or not the
of the output oil seal. service involves the transmission.
③ Clean the rear transmission case extension housing mounting 8) Torque specifications
surface and evenly apply a thin coat of sealant. Unit: N·m (refer to Fig.3.2-12)
④ The three gear shift rails must be in the neutral position. Fastener Tightening torque
⑤ Install the rear transmission extension housing to the main 1. Reverse gear cover bolt 18-28
transmission case and tighten the mounting bolts to the specified 2. Reverse gear lock bolt 8-14
torque (18-28N·m). 3. Reverse gear arm nut 13-20
⑥ Clean the gear shift cover mounting surface, and evenly apply a 4. Reverse gear limit bolt 18-28
thin coat of sealant. 5. Upper and lower case mounting bolts 18-28
⑦ Apply a thin film of lubricating grease to the speedometer driven 6. Shift cover mounting bolts 18-28
gear and bushing, and install. 7. Oil fill and drain plugs 36-64
6) Input shaft cover 8. Input shaft cover mounting bolts 18-28
① Apply a thin film of lubricating grease should be applied to the lip 9. Clutch release arm nut 10-16
of the input shaft oil seal.
10. Speedometer driven gear bushing bolt 4-7
② Clean the mounting surface and evenly apply a thin coat of sealant.
③ Torque the mounting bolts to specification (18-28N·m).
④ Rotate the input shaft of the transmission and check the
smoothness of rotation.
⑤ Check the operating condition of each gear shift fork and rail.
7) Clutch release bearing
Apply a thin film of lubricating grease to the inner surface of the
bearing.
Operation and Service Manual on FAW Jiabao Series Light Passenger Van Chapter III. Chassis
1. Input shaft assembly 2. Spigot bearing 3. Input shaft bearing 4. Snap ring
5. Snap ring 6. Input shaft seal 7. Mainshaft 8. Poppet ball 9. Thrust washer 10. First gear 11.
Bushing 12. Needle bearing 13. Second gear 14. Needle bearing 15. Third gear 16. Needle bearing
17. Bearing 18. Snap ring 19. Snap ring 20. Countershaft 21. Front countershaft bearing 22. Snap
ring 23. Rear countershaft bearing 24. Snap ring 25. Low speed synchronizer hub 26. Synchronizer
sleeve 27. Low speed synchronizer ring 28. Synchronizer insert spring 29. High speed synchronizer
hub 30. Synchronizer sleeve 31. High speed synchronizer ring 32. Synchronizer insert spring 33.
Low gear synchronizer hub 34. Synchronizer sleeve 35. Synchronizer insert 36. Reverse gear idler
shaft 37. Locating dowel pin 38. Reverse intermediate gear 39. Snap ring 40. Reverse driving gear
41. Reverse driven gear 42. Bushing 43. Needle bearing 44. Collar ring 45. Odometer worm shaft
46. Odometer driven gear 47. Lining 48. Oil seal assembly 49. O-ring 50. Elastic ring 51. Snap
ring
Fig.3.2-13a
First gear
Third gear Second gear

Low gear shifting fork
Under drive gear
Mainshaft
Input
Shaft
Countershaft
Reverse driven gear
Reverse Intermediate gear

Note: For five speed transmissions, please refer to the table of ① Remove the countershaft assembly.
contents for any additional information. ② Remove the rear countershaft bearing.
1. For a basic introduction, please refer to Fig.3.2-13a and Fig.3.2- ③ Remove the countershaft reverse driven gear.
13b. 3) Remove the gear shift forks and rails
2. Transmission gear ratios: Please refer to the five speed transmission for disassembly instructions.
First gear 3.429 5. Inspect the components
Second gear 2.109 Please refer to the five speed transmission for inspection procedures.
Third gear 1.379 6. Important steps for installation
Fourth gear 1.000 Note:
Reverse gear 3.600 • Each part must be cleaned and the specified gear oil must be coated on
3. Disassembly (please refer to five speed transmissions) the sliding surface of the bearing and gear before installation.
4. Breakdown • During reassembly, a new collar ring must be used.
Please refer to five speed transmission instructions for any additional • Tighten each nut and bolt according to the torque chart in the next part
information. of this section.
1) Remove the mainshaft and input shaft. 1) The mainshaft and input shaft
① Remove the input shaft by hand. Do not drop the high speed Reassemble in the reverse order of disassembly. Pay attention to the
synchronizing ring. installation direction of each washer, gear, commutating ring and outer
② Remove the related snap rings and the speedometer driven gear, ring. The cylindrical roller must be attached to the main shaft.
and slide the high speed synchronizer ring, third speed driven gear ① Attach the second gear bearing, second gear, the synchronizer ring,
and needle bearing off of the mainshaft. low speed commutating spring, and the outer ring to the mainshaft. Pay
Remove the related snap rings, and slide off the speedometer drive attention to the installation order during operation. After being placed on
gear. each synchronizer, the three splines of the commutating ring have to be
③ Remove the mainshaft rear bearing retaining snap ring. inserted into the grooves of each ring in order.
④ Remove the reverse gear synchronizer ring, reverse gear, and ② Install the first gear needle bearing, spring collar ring, synchronizer
reverse gear needle bearing. ring, the first gear, poppet ball, and thrust washer on to the mainshaft.
⑤ Remove the bearing bushing and the reverse gear bushing from the Insert the poppet ball into the hole of the mainshaft and install the thrust
mainshaft by using a hydraulic press. washer to make its groove locate above the poppet ball. To ensure the
Note: The mainshaft poppet balls may fall during disassembly. Take correct order of the thrust washer, the teeth of the thrust washer must
care not to lose the poppet balls. Also, the ball bearing cannot be face the intermediate bearing of the mainshaft.
disassembled simultaneously together with the above-mentioned ③ Install the countershaft, paying attention to the installation order.
washers and bushings. ④ Install the poppet ball and thrust washer. The teeth of the thrust
⑥ Remove the poppet balls and intermediate bearing from the washer must face the intermediate bearing of the mainshaft, and the
mainshaft. groove must be located above the poppet ball during operation.
⑦ Remove the first gear, needle bearing, and synchronizer ring from
the mainshaft.
⑧ Remove the first gear bushing, the synchronizer ring, the second
gear, and the second gear bearing by using a hydraulic press.
2) Disassemble the countershaft
⑤ Press on the reverse gear bushing. Prevent the poppet balls ② The contact surfaces of the upper and lower transmission cases must
installed in step ④ from falling out during this operation. be clean.
⑥ Install the reverse gear bearing, the reverse gear, and the reverse ③ Check whether the thrust washer has been installed in the grooves of
gear synchronizer ring/outer ring. To ensure the correct installation the front bearing and middle bearing of the mainshaft.
order, the lower diameter and longer cam side must face rearward ④ Install the input shaft and mainshaft into the upper transmission case.
during installation of the synchronizer ring. ⑤ A thin coat of sealant should be evenly applied to the mounting
⑦ Insert the collar ring of the reverse gear into the groove of the surface of the lower transmission case.
second gear. ⑥ Insert the three gear shifting forks into the three grooves of the
⑧ Install the third gear bearing, the third gear, the third and fourth synchronizer sleeves on the mainshaft, and install the upper transmission
gear synchronizer ring and the commutating ring/outer ring. The cam case to the lower transmission case.
side of higher outer diameter shall face the third gear side. Insert the ⑦ Torque the transmission case mounting bolts to specification (18-
collar ring into the groove of the second axle. 28N·m).
⑨ Install the speedometer drive gear onto the mainshaft. 5) The rear transmission extension housing
⑩ Install the synchronizer ring, the spigot bearing, and the input Please refer to the five speed transmission for installation procedures.
shaft. 6) Input shaft cover
2) Countershaft and reverse gear idler shaft Please refer to the five speed transmission for installation procedures.
① Tap the front side of the countershaft into the cover body. Tap the 7) Clutch release bearing
countershaft slightly into the front bearing by using a plastic hammer. Please refer to the five speed transmission for installation procedures.
Using the plastic hammer, tap the bearing onto the countershaft and 7. Maintenance and service
into the lower transmission case. Gear oil
② Insert the front collar ring of the countershaft into the groove. Note: Apply a thin film of sealant on the threads of the oil fill and oil
③ Install the countershaft reverse gear and the fifth gear onto the drain plugs and tighten the plugs to the specified torque (36-54N·m).
countershaft. Then install the rear countershaft bearing onto the After initial operation, check for oil leakage. If leakage occurs, repair
countershaft. immediately.
④ Install the reverse intermediate gear and washers onto the reverse Transmission oil capacity: 1.0L, type: 80W-90 (GB13985-1992) GL-5
idler shaft, and then install the pin. (or GL-4) gear oil or NO.18 hyperbolic curve gear oil.
3) Gear shift forks, rails, and fork retaining pin Note: The vehicle should be regularly checked for transmission oil
Please refer to the five speed transmission for installation procedures. leakage during any type of maintenance service, whether or not the
4) Transmission upper and lower case service involves the transmission.
① After the countershaft assembly, reverse idler shaft, and reverse 8. Torque specification
gear axle has been installed to the lower cover body, make sure the Please refer to the five speed transmission.
two locating dowel pins are in place on the lower transmission case.
Chapter III. Chassis Operation and Service Manual on FAW Jiabao Series Light Passenger Van
Section 3 Rear Axle
I. Introduction
The vehicle’s rear axle is a single reduction, open differential type
driven by a conventional two u-joint driveshaft. The front end of the
driveshaft is connected to the transmission output shaft via a splined
slip yoke. The rear end of the driveshaft is connected to the real axle
pinion shaft via a flange yoke and splined companion flange.
The universal joints are of conventional spicer-type design. Rear axle pinion shaft
end
Transmission output
shaft end
Driveshaft
Driving axle splines yoke Universal joint
Fig.3.3-1 Driveshaft
II. Disassembly Section 4 Rear Axle

1. Raise the vehicle. I. Introduction
2. Remove the driveshaft retaining bolts and nuts. The vehicle’s rear axle is a hypoid gear, single reduction unit with
3. Remove the driveshaft. welded axle housing and semifloating axles.
If the vehicle is raised horizontally, because the transmission oil level
is higher than the output shaft opening, the transmission oil must first
be drained before pulling the driveshaft out of the transmission or oil
will pour out. If only the rear of the vehicle is raised, oil will not pour
out from the rear of the transmission. Take care to prevent any dirt
from entering the exposed opening of the transmission. Always check
the transmission fluid level after replacing the driveshaft.
C. Reassembly
Reassemble in the reverse order of disassembly.
Note:
• Torque the driveshaft retaining bolts and nuts to specification. (15-
25N·m)
• If any transmission oil leaks out of the transmission during
driveshaft removal, new FAW-specified oil must be added to the
transmission to reach the specified oil level after reinstalling the Fig.3.4-1
driveshaft. 1. Driving bevel pinion and driven bevel gear 2. Differential case 3.
D. Maintenance and service Cylindrical roller bearing 4. Bearing adjuster 5. Side gear, pinion gear
As normal wear will occur over time to the yoke splines and u-joints, 6. Side gear thrust washer 7. Pinion gear thrust washer 8. Planetary gear
these parts should be periodically checked for signs of wear, pad
especially if the u-joints produce a “chattering” noise. 9. Conical roller bearing (7306E) 10. Driving gear adjusting pad
Abnormal u-joint noises are most apparent in high speed/low engine 11. Crush sleeve 12. Differential housing 13. Conical roller bearing
rpm situation and can be easily recognized. The noise will be (7305E) 14. Pinion seal 15. Welded axle housing assembly
particularly distinct upon application and release of the accelerator
pedal (due to the braking effect of the engine).
As the driveshaft requires strict dynamic balancing for quiet
operation, the entire driveshaft assembly should be replaced if it
produces noise.
Replacement of the driveshaft u-joints can be accomplished with the
use of special tools. However, the disassembled driveshaft must be
dynamically balanced before being reinstalled into a vehicle.
II. Disassembly 4) Pull off the right side differential bearing from the differential case by
1) Release parking brake lever. using the appropriate factory tool.
2) Raise the vehicle and remove the real wheels. 5) Remove the mounting bolts from the driven bevel gear, and remove
3) Remove the oil drain plug and completely drain the gear oil from the driven bevel gear.
the rear axle. 6) Remove the pinion gears and the pinion gear shaft after removing the
4) Pull off the brake drums using an M8 bolt. elastic retaining pin.
5) Rotate and remove the brake shoe retainer pin from the brake shoe 7) Pull off the left side differential bearing from the differential case by
and backing plate. using the appropriate factory tool. Remove the differential side gears and
6) Remove the parking brake cross bracing wire from the parking side gear thrust washers.
brake draw arm and remove the brake shoes. IV. Maintenance and service
7) Remove the split washer and remove the parking brake cross 1. Differential side gear clearance
bracing line from the brake backing plate. Compare the measured clearance with the clearance indicated in the
8) Disconnect the brake line from the brake wheel cylinder. Prevent following table to obtain proper bearing preload. Increase or decrease the
excessive brake fluid from leaking from the brake line by plugging thrust washer height to adjust the clearance as required.
the line with a bleed screw. Differential side gear 0.1-0.2mm
9) Remove the brake backing plate from the axle housing flange. clearance
10) Remove the axle shaft with the brake backing plate using the Available thrust washer 0.9, 1.0, 1.1, 2mm
appropriate factory tool. thicknesses
11) Pull out the axle shaft. Note: If the differential side gear clearance can not be easily measured
12) Use a grinder as required to remove the axle bearing spacer, axle (by applying plastigage or lead), measure the axial clearance of the side
bearing, and axle bearing thrust washer from the axle shaft. gear. If the maximum value is 0.37, the clearance is within specification.
III. Disassembly 2. Determining the driving bevel pinion thrust washer thickness
1) Prevent the companion flange from rotating and remove the The quantity and thickness of thrust washers needed for proper bevel
companion flange retaining bolt. pinion bearing preload varies from vehicle to vehicle. The quantity and
2) Place a mark on the upper side of the two differential bearing caps thickness of thrust washers must be determined during reassembly in
(the bearing caps and differential housing are machined as a set) so order to achieve the proper tooth contact pattern (when the driving bevel
they may be reinstalled in the same position during reassembly. pinion and driven pinion gear achieve an acceptable tooth contact
3) Remove the mounting screws from the two differential bearing pattern, proper clearance has been obtained).
caps. Remove the two differential bearing caps. Remove the Calculating the thickness of the driving bevel pinion thrust washers
differential assembly from the differential housing. (refer to Fig.3.4-2).
The thrust washers between the driving bevel pinion and the pinion
bearing (30306/P06) can be calculated with the following formula.
computation expression: H=C-A-B A=85+ First, press the front and rear pinion bearing races firmly into the
In the formula: C means the actual assembly distance of differential differential housing. Then install the determined amount of thrust
housing washers onto the driving bevel pinion. Install the rear pinion bearing,
A means the actual assembly distance of driving bevel pinion coated with gear oil, into the differential housing together with the
B means the actual assembly distance of the pinion bearing driving bevel pinion. Install the driving bevel pinion crush sleeve onto
(30306/P06) the driving bevel pinion. Install the front pinion bearing, coated with
means the difference in value between the best actual assembly gear oil. Finally, install the companion flange onto the driving bevel
distance of the driving bevel pinion and the theoretical assembly pinion and torque the lock nut to 190N·m. Do not install the oil seal at
distance this time. The proper torque used to rotate the driving bevel pinion is
H should be rounded off to the next higher 0.05 increment. 0.3-0.7N·m (excluding the resistance of the oil seal). The bearings must
be lubricated when measuring the preload of the bearing, and the driving
bevel pinion must be rotated 5 times continuously in the same direction.
Note:
The crush sleeve will be compressed each time after tightening the
companion flange lock nut onto the driving bevel pinion. It can not be
reused. Therefore, a new crush sleeve must be used after each
installation.
4. Adjusting the differential case side bearing preload
Install a dial indicator on the mounting end of the differential housing,
and roll the housing so the left side is facing down. Loosen the right side
gear adjuster one full turn and then tighten it until the tip of the dial
indicator begins to make contact. Then tighten the adjuster one or two
grooves. The correct preload of the differential is 0.3-0.7 N·m.
5. Check and adjust the tooth contact pattern of the driving bevel pinion
Fig.3.4-2 and driven bevel gear
Five thicknesses of thrust washers are available. Select the suitable Examine the tooth contact pattern of the driving bevel pinion and the
size and combine them so their total thickness reaches the desired driven bevel gear by using the method indicated in Fig.3.4-3. Carefully
measurement. install the differential assembly, and torque the bearing cover nut to 10-
The available thrust washer thicknesses for the driving bevel pinion 20N·m. Align the dial indicator spindle to the “tooth side” of the driven
are: 0.05, 0.10, 0.30, 0.50, 1.00 (mm) bevel gear, install the driving bevel pinion and rotate the pinion back and
3. Adjusting the preload of the pinion bearing forth. The reading number of the dial indicator is the clearance value,
Adjust the pinion bearing preload using the following steps: and the clearance value range shall be 0.1-0.2mm.
Tooth contact patterns of the driving bevel pinion and driven bevel gear,
and clearance adjustment
Adjustment method
Convex side (positive driving)
Concave side (negative driving)
Move the driven bevel

gear toward the
driving bevel pinion,
move the driving
bevel pinion away if
the clearance is too
Fig.3.4-3 small
Rotate the left and right side adjuster and change the axial position of Move the driven bevel
the driven bevel gear, thus adjusting the flank clearance between the gear away from the
driving bevel pinion and driven bevel gear. All adjustments must be driving bevel pinion,
done equally between the left and right side adjusters so as not to alter and move the driving
the adjusted bearing preload. Measure the clearance at 3 locations on bevel pinion closer if
the driven bevel gear. The value should be in the range of 0.1-0.2mm the clearance is too
and clearance variation should not exceed 0.08mm. much
6. Check and adjust the tooth contact pattern of the driving bevel Move the driving
pinion and driven bevel gear bevel pinion toward
The driving bevel pinion and driven bevel gear mesh should have the driven bevel gear,
suitable clearance and a proper tooth contact pattern to avoid “gear move the driven bevel
noise”, and prevent the standard double side gear tooth flank from gear away if the
enduring excessive pressure during operation. The following method clearance is too small
should be used to examine the tooth contact condition between
driving bevel pinion and the driven bevel gear after obtaining the
specified clearance effect: apply gear-marking compound to the
positive driving tooth flank and negative driving tooth flank of the
gear, then hold the driving bevel pinion to make it “brake and stop” Move the driving
with one hand and rotate the driven bevel gear back and forth with the bevel pinion away
other hand. Examine the tooth flank contact by referring to the from the driven bevel
following illustrations after obtaining the contact pattern. (Fig.3.4-4) gear, and move the
driven bevel gear
closer if the clearance
is too much
Correct graph
About right oriented on the central position
Fig.3.4-4
7. Torque the differential bearing cap bolts to 50-60N·m after · Differential case bearings
adjusting the gear tooth contact pattern. Install the adjuster nut Press the bearings onto the differential case with the appropriate special
locking tab and remove the companion flange. Apply a thin coat of factory tool. Do not install the bearings by tapping.
grease to the lip of the pinion seal. Apply a thin film of sealant to the VI. Assembly
outer side of the pinion seal and install the seal into the differential Reassemble in the reverse order of disassembly.
housing. Reinstall the companion flange and torque the lock nut to 1. Reassemble the axle assembly
120-190N·m. 1) Install the left or right brakes, bearing spacer, the sealed bearing
V. Reassembly (6027-Z/P6) onto the axle shaft in that order. Then press the bearing on
Reassemble according to the reverse order of disassembly. Pay with a hydraulic press. Press the bearing spacer against the bearing on
attention to the following points. the axle shaft, making sure the bearing can spin freely.
Note: 2) The beveled inner hole of the bearing spacer must be installed facing
· The driving bevel pinion and the driven bevel gear are manufactured outwards towards the convex shoulder of the axle shaft.
as a set and therefore must be replaced as a set. 3) The bearing should be installed with the enclosed side of the bearing
· Torque specifications facing outwards, mounted evenly on the bearing thrust ring.
Items N·m 4) NO.2 lithium-based grease must be coated on the dust proof bearing
Differential bearing cap bolt 50-65 (6027-Z/P6), without allowing any foreign matter near the bearing.
Driven bevel gear and differential case bolt 65-80 5) Heat a new bearing thrust washer to 100-150℃, and install it on the
Driving bevel pinion nut 120-190 axle shaft after keeping 10-15 minutes. Lubricate the axle shaft with a
Oil drain plug 40-70 thin film of oil and press the thrust washer towards the bearing using a
· Driven bevel gear bolt hydraulic press.
The driven bevel gear to differential case mounting bolts will 6) The thrust washer must not have any axial or radial looseness after
experience severe force when torque is transmitted during vehicle installation.
operation. Therefore, these bolts are specially manufactured bolts and Note: Protect the outer surface of the thrust washer to avoid damage.
cannot be substituted by ordinary bolts. The bolt threads must be 7) Apply a thin coat of sealant to the mounting surface between the axle
coated with thread locking sealant (Loctite 262 or equivalent) when flange and the brake backing plate.
installing the driven bevel gear to the differential case and then 8) Insert the axle shaft into the rear axle housing and attach the backing
torqued to specification. plate to the axle housing. Torque the mounting nuts to 18-28N·m.
· Driving bevel pinion bearings 9) Remove the bleeder screw from the brake line and reconnect the brake
Install the two conical roller bearings on the driving bevel pinion by line to the brake wheel cylinder on the brake backing plate. Torque the
using a hydraulic press in conjunction with the appropriate factory brake line nut to 14-28N·m. Do not overtighten.
tools. Press the outer bearing race into the differential housing, while 10) Apply a thin coat of sealant on the mounting surface between brake
pressing the inner bearing onto the driving bevel pinion. backing plate and the parking brake cross cable, and insert the parking
brake cross cable into the brake backing plate and attach it using a split
washer.
11) Connect the parking brake cross cable to the parking brake lever 2. Assemble the rear axle housing assembly
and install the brake shoes. 1) The rear axle housing assembly must be cleaned and free of any
12) In order to maximize the clearance between the parking brake foreign matter before reassembly.
shoes and the parking brake drums, position a screwdriver against the 2) Install the wheel oil seal retainer into the axle flange with the open
self-adjuster and push the gear segment as indicated in the illustration side facing outwards.
below before installing the brake drum (Fig.3.4-5). 3) The spring side of the oil seal must face inward toward the differential
when installing the oil seal. Apply a thin coat of sealant to the outer side
of the oil seal and install the seal evenly into the oil seal retainer. After
installing the seal, apply a thin coat of grease to the lip of the seal.
3. Assemble the differential housing
1) Mount the differential housing into the axle housing.
2) Apply a thin coat of sealant on the mounting surfaces of the
1. Self adjusting shoe clearance push differential housing or axle housing, and mount the differential housing
pedal
2. Quadrant into the rear axle housing. Coat the mounting bolt (CQ1420825) threads
with thread locking sealant (Loctite 262 or equivalent), and torque to 15-
33N·m.
3) Rear axle assembly gear oil specifications
Type:80W-90W (GB13895)
Oil capacity: 1.3L
Fig.3.4-5
Assembly data of rear axle Tightening torque unit: N·m
Items Specification Standard value
Preload - Driving conical gear bearing (excludes oil seal resistance moment) 30305/P6 30306/P6 0.3-0.7
Preload - Differential bearing 6027-Z/P6 0.3-0.7
Flank tooth clearance of driving and driven conical gear 0.1-0.2mm
Gear oil capacity of rear axle 1.3L
Torque - Driving bevel pinion locking bolt M18×1.5 120-190
Torque - Driven bevel gear and differential case mounting bolts M10×1.25 65-80
Torque - Differential bearing cover bolt M10×1.25 50-65
Torque – Adjuster lock piece tighten bolt M8 15-20
Torque – Differential housing mounting bolts M8 15-23
Torque - Brake backing plate mounting bolts M8 18-28
Torque - Oil fill plug M20×1.5 35-50
Torque - Oil drain plug M12×1.25 40-70
Section 5 Suspension System
I. Introduction
Front suspension: MacPherson strut and coil spring, with anti-sway
bar. Please refer to Fig.3.5-1.
Rear suspension: Lengthwise semi-elliptical leaf springs with
hydraulic shock absorbers. Please refer to Fig.3.5-2.
Fig.3.5-1 Front suspension system Fig.3.5-2 Rear suspension system

Note:
· The proper condition and installation of all fasteners is essential for
safe operation and optimum performance of the vehicle. Fasteners of the
same or equal design code must be used during replacement. Torque all
fasteners to specification during replacement.
· The damaged suspension system components should be replaced.
Heating and straightening is not approved.
II. Front suspension system
1. Strut rod
Disassembly
(1) Raise the vehicle and disassemble the wheels.
(2) Remove the nut from the front of the strut rod.
(3) Remove the rear mounting bolts from the strut rod. (3) Remove the upper strut mount bushing retainer.
(4) Remove the strut rod. (4) Remove the adjustment and locking bolts that connect the strut to the
Inspection steering knuckle.
(1) Replace the strut rod if any damage or wear exists. Note: Place a jack stand under the
(2) Replace the front mounting insulators if any damage, wear, or control arm to prevent the control arm
deterioration exists. from falling and damaging the front
Reassembly: brake hose.
Reassemble in the reverse order of disassembly steps (1) thru (4). Be (5) Remove the 3 upper strut mounting
sure to install the front mounting insulators with the large side of each nuts. Do not allow the strut assembly to fall.
insulator facing each other. Install the rear mounting bolts and front (6) Disassemble the coil spring and
mounting nut and torque to specification, as indicated in Fig.3.5-3. shock absorber. If any difficulty is
encountered in removing the strut
housing from the steering knuckle, insert an
applicable size chisel from the bottom up
in the open slot at the inner side of the steering knuckle and gently tap
the chisel upward to increase ID clearance and allow removal.
Disassembly
70-90N·m (1) Using a McPherson strut spring compressor, compress the coil
spring.
(2) With the coil spring compressed (see Fig.3.5-4), remove the shock
30-50N·m
piston rod nut. Disassemble the strut assembly.
Reassembly: please refer to Fig.3.5-4
Fig.3.5-3
2. Strut assembly
Disassembly:: (1) Compress the coil spring with a McPherson strut spring compressor.
(1) Raise the vehicle and remove the front wheels.
1. Piston Rod Nut 2. Coil Spring Washer 3. Plain
(2) Remove the brake hose retaining clip from the lower strut housing Washer 4. Upper strut mount bushing 5. Upper
and pull the brake hose loose. Pull the brake hose out of the way of strut mount retainer 6. Upper strut mount 7.
Passive Pad 8. Rubber Pad 9. Active Pad 10.
the repair area. Do not disconnect the brake hose from the brake pipe. Upper spring seat 11. Dust boot 12. Bump stop
13. Coil spring 14. strut housing (shock absorber)
(2) Position the coil spring in the lower spring seat of the strut
housing, matching the shape of the bottom end of the coil spring with
the contour in the shape of the lower spring seat.
(25-35N·m
(3) Install the bump stop over the piston rod. Do not install the bump
stop upside down.
(4) Pull the piston rod as far out of the shock absorber as possible. 40-60N·m
(5) Install the boot and upper spring seat, matching the shape of the
top end of the coil spring with the contour of the boot and upper
spring seat.
(6) Clean the active pad and apply a thin film of lithium grease. Install Fig.3.5-5
it on the upper spring seat in the proper direction. (4) Tighten the nut to the specified torque (20-30N·m).
(7) Apply a thin film of lithium grease on all surfaces of the rubber (5) Tighten the steering knuckle adjustment bolt to the specified torque.
pad and mount it around the outside of the active pad. (refer to Fig.3.5-6)
(8) Clean the passive pad and install. (6) Reinstall the brake hose. Do not twist the hose. Install the brake hose
(9) Install the upper strut mount, upper strut mount retainer, and upper retaining clip.
strut mount bushing on top of the passive pad in the correct order and
direction. Install and tighten the piston rod nut to the specified torque,
and apply a coating of rust inhibitor to the nut and piston threads. 30-50N·m 40-70N·m
Note: Make sure the upper strut mount has been correctly installed
under the upper strut mount retainer.
(10) Carefully release the spring compressor, making sure the top and
bottom ends of the coil spring line up with the contour of the upper
and lower spring seats, as mentioned in steps (2) thru (5).
Reassembly: Please refer to Fig.3.5-5.
(1) Insert the strut housing into the steering knuckle.
(2) Align the hole of the strut housing retaining bolt tab with the bolt Length of bolt out part: 3-5mm 30-55N·m
hole of the steering knuckle, and install the retaining bolt.
(3) After aligning the concave hole of the lower strut housing with the Fig.3.5-6
bolt hole of the steering knuckle, install the steering knuckle bolt in
the direction of front to back of the vehicle. Then install the washer
and nut.
3. Control arm assembly Reassembly

Disassembly (1) Reattach the anti-
(1) Raise the vehicle and remove the front wheels. sway bar to the control Front
(2) Remove the anti-sway bar retaining locknut, bushing washers, arm using the locknut, Nut
rubber bushings, and bolt from the control arm. bushing washers, rubber Suspension
(3) Remove the 2 nuts, washers, and bolts from the rear of the strut bushings, and bolt. Hand 30-50N·m
arm
rod. tighten. (refer to Fig.3.5-
(4) Remove the cotter pin and hexagon slotted nut from the ball joint. 8)
(5) Remove the nut, washer, and bolt that connect the control arm to (2) Reattach the strut rod
the front crossmember. to the control arm with
(6) Separate the control arm ball joint from the steering knuckle by the 2 nuts, washers, and
Suspension arm
using a puller-type tool. Be careful not to damage the threads of the bolts. Hand tighten.
ball joint. (3) Insert the control arm Fig. 3.5-7
(7) Disassemble the control arm. ball joint into the steering knuckle.
(8) Remove the control arm bushing using a hydraulic press. (4) Tighten all the fasteners to the specified torque. (refer to Fig.3.5-6).
Inspection (5) Insert the cotter pin thru the castellated nut and apply a coat of rust
(1) Check for any cracks, deformation, and damage. inhibitor to the threads.
(2) Check the ball joint for any looseness, and replace if required. Body Center
Replace the ball joint boot if it is missing or damaged.
18-28N·m
The Part Of Painted Yellow
Length Of Bolt Out Part 3-5mm
Fig.3.5-8
1. Crossmember 2. Anti-sway bar 3. Bolt 4. Control arm 5. Strut rod 6. Upper rubber bushing 7.
Lower rubber bushing 8. Washer 9. Nylon locknut
4. Anti-sway bar (5) Remove the upper spring seat, and upper and lower rubber spring
Disassembly shims.
(1) Raise the vehicle, allowing the front suspension to hang down. (6) Remove the front spring pin and the rear spring shackle bolts.
(2) Remove the front wheels. (7) Remove the leaf spring assembly.
(3) Remove the anti-sway bar. Reassembly
Inspection: Check the anti-sway bar and rubber mounting bushings Install the leaf spring assembly in the reverse order of disassembly.
for any damage or deformation, and replace if required. Note:
Reassembly: Please refer to Fig.3.5-8 · Apply a thin coating of soap to the exterior of the spring bushing to
(1) The anti-sway bar should be mounted with the yellow marking on facilitate pressing the new bushing into the spring assembly.
the ends of the anti-sway bar facing upwards. · Reinstall the shackle bolts in the direction from the vehicle center
(2) Torque the nuts and bolts to specification. outward. Reinstall the front spring pin in the direction toward the
C. Rear suspension system vehicle center. Do not tighten at this time.
1. Shock absorber · Align the center bolt and nut of the leaf spring with the hole in the
Disassembly spring plate. Install the U-bolts and torque to specification.
(1) Remove the lower retaining nut at the spring plate. · Install the rear shackle bolt nuts and front spring nut and torque to
(2) Remove the upper retaining nut, and remove the shock absorber. specification.(30-55N·m).
Reassembly · Reattach the parking brake cross bracing wire using adhesive tape.
(1) Install the shock absorber in the reverse order of disassembly. · Reinstall the rear wheels and torque the lug nuts to specification.
(refer to Fig.3.5-9).
20-30N·m
(2) Tighten the nuts.
2. Leaf spring (refer to Fig.3.5-10)
Disassembly
(1) Raise the vehicle with the tires slightly off the ground. Support the
rear axle housing with 2 jack stands.
(2) Remove the rear wheels and detach the parking brake cross
bracing wire from the axle housing.
13-20N·m
(3) Remove the lower shock absorber mounting nut and remove the
shock absorber.
(4) Remove the U-bolt nuts, U-bolts, and upper spring plate.
Fig.3.5-9
1. Spring Washer 2. Nut 3. Plain Washer 4. Rubber insulator 5. Rear shock absorber
6. Plain Washer 7. Spring Washer 8. Nut
Front Upper spring seat

Rear
Spring plate
nut
Front end
Spring center bolt Rear end
25-35N·m Spring upper base
Bolt
40-70N·m Body center
Nut Leaf spring front bushing

Spring lower base
When pressing the front bushing into the leaf spring, position the narrow notch forward as illustrated below Tighten the 4 U-bolts to equal amounts
Notch (wide) Central bolt and nut

Upside 23-35N·m
Bolt
45-70N·m
Front Body center Rear
Leaf spring front lining

Notch (narrow) Tighten the four u-bolts evenly to keep the b height of the four
bolts nuts sizes the same
The narrow notch shall be towards Leaf
the frontspring
when pressing the spring eye lining into the
leaf spring
Upper side Notch (wide)
Fig. 3.5-10
Rear end
Notch (narrow)
Leaf spring
Fig.3.5-10
Leaf spring
The side must be aligned for each leaf spring
Section 6 Steering System Front end
I. Introduction
The steering system consists of a rack and pinion gear and
Rack and pinion
corresponding linkage. The rack and pinion gear is composed of a
gear shaft and pinion within a common housing. The gear shaft is
supported on deep groove ball bearing without inner ring and needle
bearing in the housing. The end of the pinion rides in the housing end
bushing and the other end rides against the adjusting bolt with a
pressure spring. The gear shaft is installed on the pinion at an inclined
angle of 2º54″, and directly meshes with the pinion. When the
steering wheel is turned, the pinion shaft is therefore rotated, and the
rack slides along the bushings within the gear housing. The steering
gear input shaft is on the side of the gear housing, while the output
shaft pulls and pushes a longitudinal pull rod connected to the bell
crank, tie rods, and steering knuckles. Fig.3.6-1 Steering system
The major components in the steering system are illustrated in
Fig.3.6-1.
1. Rack and pinion steering gear assembly 2. Gear oil 3. Dust boot
4. Steering pull rod 5. Bell crank 6 7. Left and right tie rod assemblies
8. Left steering knuckle
9. Right steering knuckle
II. Disassembly
Please refer to Fig.3.6-2 to see the steering gear assembly. 1. Steering wheel
1) Disconnect the negative battery cable from the battery.
2) Remove the steering wheel horn cover.
3) Remove the steering shaft nut.
4) Mark the steering wheel and steering column to assist in reassembly.
5) Remove the steering wheel.
2. Combination switch assembly
1) Remove the upper cover of the combination switch after removing the
steering wheel.
2) Disconnect the wire and clip from the universal joint.
3) Remove the combination switch assembly form the steering column.
3. Steering column assembly
1) Remove the upper side bolt of the universal joint yoke after removing
Fig.3.6-2 Steering Gear Assembly the steering wheel and combination switch.
2) Remove the four mounting bolts on the steering column assembly.
3) Remove the steering column assembly with steering shaft assembly.
If damage exists to any components of the steering column assembly
(including the steering shaft), the components must be replaced. Apply a
thin coat of grease to the inner side of the rubber bearing before
installing the steering shaft into the steering column assembly. Install the
1. Rack and pinion gear assembly 2. Steering gear housing and bushing assembly 3. Pinion gear
upper and lower snap rings on the grooves of the steering shaft.
4. Snap ring 5. Clip ring 6. Pinion gear oil seal 7. Plunger assembly 8. Pressure spring 9. Lock
4. Steering shaft universal joint
nut 10. Adjusting nut 11. Dust cover 12. Rack 13. Dust boot 14. Dust boot (output) 15. Wire
1) Remove the protective cover of the steering column universal joint,
tie wrap 16. 17. Clamp 18. Yoke 19. Hexagon flange side nut 20. Shock dampener ring 21.
and the upper universal joint yoke retaining bolt.
Shock dampener ring 22. Snap ring 23. Hexagon bolt
2) Turn the steering wheel so that the front wheels are facing forward.
3) Remove the lower universal joint yoke retaining bolt, and remove the
universal joint and yoke assembly.
5. Tie rod 2) Remove the rack output yoke pin connecting the output yoke to the
1) Raise the vehicle and remove the front wheels. pull rod.
2) Remove the tie rod end cotter pin and castellated nut from the 3) Remove the steering gear mounting bolts, and remove the steering
steering knuckle. Remove the tie rod end from the steering knuckle gear.
using a puller-type tool. Disassembly
3) Place a reference mark noting the position of tie rod end to the tie 4) Remove the rack dust boot retaining wire tie wraps and clamps, and
rod tube, to obtain the same “before disassembly” adjustment after remove the rack dust boots.
reassembly. 5) Remove the rack snap ring and the shock dampener rings. Remove the
6. Steering gear plunger assembly.
Removal 6) Remove the pinion gear dust cover, oil seal, clip ring, and snap ring.
1) Raise the vehicle and remove the front wheels. Remove the cotter 7) Remove the pinion gear from the steering gear housing.
pin and castellated nut from the rack output yoke pin. 8) Remove the rack from the steering gear housing.
9) Remove the needle bearing from the steering gear housing using a
special puller-type tool.
Reassembly
1) All components must be cleaned prior to reassembly.
2) Apply a coating of grease to the needle bearing.
3) Carefully tap the needle bearing into the steering gear housing with a
special tool. Make sure the needle bearing is installed correctly.
4) Apply grease to the inner walls of the steering gear housing and the
teeth on the rack.
5) Slide the rack into the steering gear housing.
Fig.3.6-3 6) Apply a coating of grease to the pinion gear, pinion gear bearing, and
pinion gear oil seal.
1. Tie rod 2. Reference mark 3. Tie rod end jam nut 4. tie rod end 7) Install the pinion gear.
8) Install the pinion gear retaining snap ring and clip ring. The tab of the
clip ring should be installed above the opening of the snap ring, as
shown in Fig.3.6-4. Install a new oil seal.
9) Apply a light film of grease to the top of the plunger where it rides
against the pinion. Apply a thin coating of sealant to the threads of the
adjusting bolt. Then screw the locking nut to its maximum value and
rotate it 0-90º, examining the rotating torque of the pinion gear and
the smoothness of its action.
Rotating torque of pinion shaft 0.5-1.5N·m
10) Tighten the lock nut to the specified torque after adjustment.
Please refer to Fig.3.6-5. Fig.3.6-5
11) Install the rack snap ring and the shock dampener rings. 40-60N·m
12) Install the rack dust boots onto the steering gear housing. Locate
the ends of the boots over the mounting groves on the housing and
rack, and install the rack dust boot retaining wire tie wraps and
clamps securely. Make sure the boots are not twisted after mounting.
13) Install the rack output yoke with surface “A” of the steering gear
housing parallel to surface “B” of the yoke, and torque the nut to
specification. (refer to Fig.3.6-6)
Elastic shield ring for holes
Collar ring
40-60N·m
Fig.3.6-6
Fig.3.6-4
IV. Assembly
1. Steering gear assembly
1) Turn the front wheels to the facing forward position.
2) Rotate the pinion gear to adjust the length of the rack to reach the
indicated value in Fig.3.6-7. Set the pinion gear at the straight driving
position.
50-80N·m
Fig.3.6-9
153mm
Fig.3.6-7
40-60N·m
40-60N·m
40-60N·m
1.Steering gear assembly
2.Steering gear assembling Fig. 3.6-10
bolts
Fig.3.6-8
3) Insert the steering gear shaft into the splined groove of the steering
Fig.3.6-10
shaft lower universal joint yoke.
4) Install the steering gear assembly and torque the mounting bolts to
specification. Please refer to Fig.3.6-8.
5) Connect the pull rod to the bell crank and tighten the castellated nut 2) With the front wheels facing forward AND the steering wheel straight,
to specification and install the cotter pin. (refer to Fig.3.6-9) install the steering gear shaft (lower) onto the universal joint yoke.
6) Torque the lower yoke pinch bolt to specification. Please refer to
Fig.3.6-10.
7) Reinstall the front wheels and torque the lug nuts to specification
(50-80N·m).
8) Lower the vehicle.
9) Examine the front tire wear and replace as required.
2. Tie rod
1) Install the jam nut on the tie rod end, and screw the tie rod end into 30-55N·m
50-70N·m
the tie rod until the mark made on the tie rod end matches the mark on
the tie rod tube that was made prior to disassembly. Tighten the jam
nut against the tie rod tube. Fig.3.6-11
2) Connect the tie rod the steering knuckle. Torque the castellated nut
to specification. (refer to Fig. 3.6-11)
3) If the cotter pin hole in the tie rod end stud does not align with one
of the in the castellated nut, continue tightening nut until aligned.
Install a new cotter pin.
4) Examine the front tire wear. If necessary, set the vehicle toe-in and
then tighten the tie rod end ham nuts against the tie rod tube to
specification. Without angle
5) Reinstall the front wheels and torque the lug nuts to specification With torsion angle
(50-80N·m).
6) Lower the vehicle.
Note:
Make sure that both tie rod ends are installed on the same axis, as
shown in fig.3.6-12. They must not be “twisted”.
3. Steering column assembly Fig.3.6-12
1) Align the non splined part “A” on the steering gear shaft (upper)
with the bolt hole “B” on the universal joint yoke, and insert the
steering gear shaft (upper) into the universal joint yoke.
8) Install the steering wheel horn cover.

V Maintenance and service
1. Inspect the steering column assembly to avoid accidental damage.
14- 1) Check the smoothness of the steering shaft rotation and repair as
17N· required.
m 2) Check the steering column assembly and steering shaft for any
bending, cracks, or deformation. Repair as required.
2. Steering shaft assembly
1) Check for any wear or damage on the gear shaft spline surface.
2) Check the lower dust boot for damage, and replace as required.
Fig.3.6-14 3) Check the u-joints for excessive play, and replace as required.
Fig.3.6-13 1. Steady rest (I) for steering gear shaft frame
1.Steering gear shaft (lower) 2. Steering bearing frame assembly
(with gear shaft)
Replace the damaged components.
2. Universal joint boom
3. Seady rest (II) for steering gear shaft frame a, b
bolts
3. Steering pinion gear
Check the pinion gear for any excessive freeplay, and wear or damage to
the spline surface. If freeplay exceeds the specified value, replace the
3) Install the steering column assembly and torque the mounting bolts pinion gear. Note: DO NOT use a steel wire brush when cleaning the
to specification. (refer to Fig.3.6-14) pinion.
Note: The nut on the universal joint yoke must be tightened after
tightening the steering column mounting bolts. Maximum allowed pinion freeplay 0.15mm
4) Install the dust cover.
5) Install the combination switch. 4. Steering gear housing bushing
6) Connect the wire from the combination switch and ignition switch Check the steering gear housing rack bushings for any wear or damage,
on the universal joint. Reconnect the negative battery cable to the and repair as required.
battery. 5. Steering gear rack plunger
7) Reinstall the steering wheel. Torque the steering wheel mounting Check the plunger and plunger spring for any wear or damage, and
nut to specification (25-40N·m). replace as required.
6. Steering shaft and universal joint assembly
Check the steering shaft and universal joint assemblies for any cracks,
breakage, deformation, failure, or excessive clearance. Replace as
required.
7. Steering gear rack dust boot

Note: Front End Alignment Specifications
During both regular and unscheduled maintenance, always check the Toe-in 155 mm tires 4-7mm
steering gear dust boots for any damage or breakage. 165 mm tires 2-5mm
1) Raise the vehicle. Camber angle of front wheels 1o
2) Check the dust boots for any breakage that would allow water and Caster angle of king pin 5o
dirt to enter and thus cause premature wear and failure to the steering Toe in angle of king pin 11o30，
gear. The alignment of the front wheels is related with the angle relationship
3) If any breakage is found, replace the dust boot(s). between front wheels, front suspension, and the ground. In general, the
8. Tie rod ball joint dust boots only adjustment needed for the front wheels is the toe-in. The camber
Check the ball joints for any missing, cracked, or damaged dust boots angle of the front wheels and the caster angle of the king pins cannot be
and replace as required. adjusted. Therefore, when a vehicle is damaged in a collision, the vehicle
9. Steering wheel must be carefully checked for chassis damage in addition to body
Park the vehicle on level ground with the front wheels pointing damage. While damaged body parts may often be repaired, damaged
straight ahead. With tires at proper pressure, check the free play and chassis parts must be replaced.
smoothness of the steering system. 1. Toe-in
Toe-in is a measurement of how much the front and/or rear wheels are
Allowable steering freeplay (A) 0-30mm turned in or out from a straight-ahead position. The purpose of having a
small degree of toe-in is to offset small deflections in the steering system
If the freeplay is not within acceptable limits, check the steering and therefore ensure that all wheels run parallel when the vehicle is
system using the following steps and repair as required. moving. Excessive toe-in however, will cause premature tire wear and
1) Tie rod ball joint wear (apply the force of 0.2N·m, it can swing). steering instability. (refer to Fig.3.6-15)
2) Steering gear shaft connector cushion block wear. 2. Camber
3) Steering gear pinion gear and rack wear or damage. Camber is the tilting of the wheels from the vertical when viewed from
4) Steering components are not firmly mounted. the front of the vehicle. When the wheels tilt outward at the top, the
VI. Front Alignment camber is positive (+). When the wheel tilts inward at the top, the camber
is negative (-). The amount of tilt is measured in degrees from the
vertical. Camber settings influence the directional control and the tire
wear. (refer to Fig.3.6-16)
Front end 3. Checking the front end alignment

Checks shall be done before adjusting the front end alignment to ensure
the precision of the front wheel alignment:
1) Check that all tires have proper air pressure and even tread wear.
2) Check for any excessive play in the steering and suspension systems,
and repair as required.
3) Check the wheels and tires for abnormal vibrations and rebalance the
B - A= Toe-in
Fig.3.6-15
tires as required. If a wheel is excessively bent or tire distorted, replace
as required.
4) The frequent carrying of heavy loads will cause a vehicle to become
out of alignment more often. Vehicles must be empty during the front
end alignment process for proper results.
5) The front end alignment equipment must be in proper operating
condition. The technician must be familiar with the proper use of the
equipment.
6) The vehicle must be on a level surface during the alignment process.
7) Make sure the front wheels are kept in the straight ahead position.
4. Adjusting the toe-in
Toe-in can be adjusted by changing the length of the tie rods. Release the
tie rod end jam nuts on each end of the tie rods. Then equally rotate the
left and right tie rod tube, adjusting the toe-in to the specification. The
length of left and right cross pull rod should be the same after
Fig.3.6-16 adjustment.
5. Adjust the camber and caster
If the factory-set camber and caster settings are found out of alignment,
the cause must first be determined. If it is caused by damage, looseness,
bending, or wear of the steering and/or suspension components, the
components must be replaced. If it is caused by the body structure itself,
it must be repaired until the proper camber and caster specifications are
met.
6. Turning angle The items marked with an asterisk (*) should be examined regularly.
o o
Turning angle Inner side 34 ±3
Outer side 28o±3o
Check the toe-in and turning angle with a front end alignment
machine after replacing the tie rods, tie rod ball joints, and bell crank.
Make sure the front wheels are kept in the straight ahead position.
If the turning angle is not correct, check whether the adjusted length
of the two tie rods is the same.
Note:
If the length of the tie rods is changed in order to adjust the turning
angle, the toe-in must be readjusted.
G. Torque Specifications
Fasteners Torque (N·m)
* 1. Steering shaft u-joint bolt 20-30
* 2. Steering gear mounting bolt 40-60
* 3. Tie rod ball joint castellated mounting 30-55
nut
* 4. Tie rod ball joint adjustment jam nut 50-70
5. Steering gear rack plunger adjusting 80-110
plug
6. Rack output yoke mounting nut 50-70
* 7. Bell crank pivot shaft mounting nut 80-150
* 8. Steering wheel mounting nut 25-40
* 9. Lower steering shaft connector nut 15-25
* 10. Steering column assembly mounting 14-17
bolt
* 11. Steering pull rod castellated nut (rack 50-80
output yoke)
* 12 Steering pull rod castellated nut (bell 30-55
crank)
Section 7 Brake System
I. Introduction
The vehicle utilizes a dual-circuit hydraulic brake system with front
disc brakes and self-adjusting rear drum brakes. The brake system
includes a brake proportional valve and vacuum booster. The parking
Rear
brake applies function to the rear wheels via two parking brake Front
Front Rear
cables. In addition, front and rear manually-adjusted drum brakes are
an available option. Please refer to Fig.3.7-1 for a brake illustration.
Fig.3.7-1
1. Brake master cylinder 2. 5-way valve
3. Parking brake lever 4. Parking braking cable
5. Proportioning valve
II. Front Wheel Disc Type Brakes Note: Do not use sand paper to polish the brake pad lining as sand
(I) Disassembly particles may stick to the lining and subsequently damage the brake
1. Brake pad rotor. Visually examine the brake caliper for brake fluid leakage when
1) Slightly loosen the front wheel lug nuts. Raise the front of the disassembling the brake pads. Any leakage must be repaired.
vehicle and position jack stands under the vehicle. Pad height Standard Minimum
2) Remove the front wheels. Liner + pad edge 15.5mm 6.5mm
3) Remove the brake caliper retaining bolts. 2. Brake caliper slider pins
4) Remove the brake caliper. Make sure the slider pins are free and allowing the caliper to slide back
Note: and forth properly. Repair or replace as required. Apply a coating of
DO NOT damage the brake hose OR press down on the brake pedal silicone brake caliper dielectric grease to the slider pins before
during disassembly. reinstalling.
5) Remove the brake pads. 3. Brake caliper piston dust boot
2. Brake caliper assembly Check the brake caliper piston boot for any cracks or damage. Replace
Disassemble the brake caliper piston and piston seals using the as required.
following steps. 4. Brake caliper piston seal
1) Clean the brake caliper. Uneven wearing of the brake pads will prevent the brake caliper piston
2) Unscrew the brake hose from the brake caliper. from moving smoothly within the brake caliper, causing premature wear
3) Remove the brake caliper slider pins, and remove the brake caliper to the piston seal. In this case, the piston seal must be replaced.
assembly. 5. Brake rotor
4) Blow compressed air into the brake caliper through the brake hose Check the brake rotor for uneven wear, warpage, cracks, and thickness.
port, thus pushing the brake caliper piston out of the caliper by means If the rotor has deep grooves or scores, the rotor must be replaced. The
of air pressure. rotor also must be replaced if it has reached its minimum thickness.
Note: Apply compressed air at LOW pressure, or serious injury may Brake rotor Standard Minimum
result. Blow the piston out gradually, keeping fingers away from the thickness 10mm 8.0mm
piston. As indicated in Fig.3.2-2, check the rotor for warpage by measuring the
5) Remove the piston boot and seal. Do not damage the brake caliper two points on the circumference and center by using a dial indicator
walls. gauge while rotating the brake rotor edge.
3. For brake rotor removal, refer to section 8. Maximum brake rotor run-out 0.15mm
(II) Inspection
1. Brake pads
Check the amount of brake pad wear and replace the brake pads if pad
wear exceeds specified limits.
Surface B shall keep equal

Fig.3.7-2 distance to the oil cylinder A on
the whole circumference
(III) Notes for assembly

Reassemble the front brakes in the reverse order of disassembly. Fig.3.7-3
Please note the following:
· All components should be cleaned externally with brake cleaner. All
internal parts and areas should be cleaned with new DOT 3 brake 3) Install the dust boot into the dust boot groove on the piston.
fluid, as is used in the vehicle’s brake system. 4) Make sure the dust boot has been correctly inserted into the groove on
· Do not use or mix other brake fluid types. the brake caliper. Pull the piston out slightly from the brake caliper. DO
· The brake caliper piston and piston seal should be coated with brake NOT pull it fully out.
fluid when reassembling the brake caliper. 5) Finally, push the piston into the brake caliper.
· Bleed the air from the brake system after reassembly. 3. Slider pins
1. Piston seal Make sure the 2 slider pins have been coated with silicone brake caliper
The piston seal is used to seal the clearance between the piston and dielectric grease and move freely before installing the caliper to the
caliper housing. A new piston seal should always be installed caliper bracket.
(lubricated with clean brake fluid) when the caliper piston is removed. Note: If silicone brake caliber dielectric grease is not available, lithium
Do not twist the piston seal when inserting the piston into the brake based grease should be used especially in areas where winter
caliper housing. temperatures fall below -30℃.
2. Piston and piston dust boot
1) Install the dust boot onto the piston before inserting the piston into
the brake caliper.
2) Insert the piston into the brake caliper bore using your fingers.
(refer to Fig.3.7-3).
3) Remove the rear wheels.

Torque Specifications 3) Raise the vehicle and release the parking brake lever.
Fasteners N·m 4) Pull off the brake drums using an M8 bolt. (refer to Fig.3.7-4)
1. Brake rotor mounting bolt 60-70
2. Front backing plate to steering knuckle bolt 18-25
3. Front brake hose banjo bolt 20-30
4. Fastening brake tongs bolt 70-100
5. Slider pin bolt (caliper side) 30-38
6. Slider pin bolt (caliper mounting bracket side) 50-60
M8 bolt
7. Bleed screw 9-13
4. Front brake hose
Connect the hose to the brake caliper, and torque the banjo bolt to
specification (20-30N·m).
Note:
· Bleed the brake system after reassembly to remove all air from the
system. Test the brake system and check all brake components for
brake fluid leakage.
· Remount the front tires and verify the tire can rotate smoothly with
applied force less than 33N. Do not depress the brake pedal when Fig.3.7-4
checking tire rotation. 5) Rotate the brake shoe adjusting spring pin and remove.
If the tire cannot rotate smoothly, check the following items: 6) Remove the parking brake cross bracing wire down from the parking
· Wheel bearing is worn out or damaged. brake draw arm, and disassemble the brake shoe.
· When the brake rotor rotates, brake lining contact is uneven. 2. Brake wheel cylinder
III. Rear wheel drum type “self-adjusting” brakes 1) Follow the above steps 1 thru 6 to disassemble the brake drum and
(I) Disassembly brake shoes.
1. Brake drums and shoes 2) Unscrew the brake line from the brake wheel cylinder and plug the
1) Slightly loosen the front wheel lug nuts. line to prevent spillage.
2) Raise the front of the vehicle and position jack stands under the 3) Unscrew the brake wheel cylinder mounting bolt and remove the
vehicle. wheel cylinder.
(II) Inspection
1. Brake drum
Measure the inner diameter of the brake drum and examine the brake 2. Brake shoes
surface wear. If brake shoe lining wear exceeds the operational limit, the brake shoes
Item Standard Maximum limit should be replaced. (refer to Fig.3.7-5).
Inner diameter of brake drum 220mm 222mm Brake friction lining Standard Minimum Limit
Once the brake drum is disassembled, it shall be completely cleaned Height (liner + shoe edge) 7.0mm 3.0mm
and checked for cracks, scuffing, or deep grooves. Replace cracked Brake shoes should always be replaced in pairs. Therefore, all 4 rear axle
brake drums. Do not attempt to weld cracked brake drums. Serious brake shoes should be replaced at the same time when brake shoe lining
scuffing on the surface will result in excess brake lining wear, wear exceeds the operational limit.
requiring the brake drum to be resurfaced. Moderate wear to the brake 3. Brake wheel cylinder
drum wear surface may be removed using fine sand paper instead of When removing the brake drum, check the wheel cylinder for brake fluid
resurfacing. leakage and repair as required.
Note: When removing the brake shoes, check the wheel cylinder for Check the brake cylinder components for any damage or excessive wear,
brake fluid leakage and repair as required. and repair as required.
4. Brake shoe self-adjuster
Check the brake shoe self-adjuster for any excessive wear or damage,
and repair as required.
5. Various Springs
Make sure the brake springs are not stretched or distorted, and replace as
required.
(II) Notes for reassembly
1. Brake wheel cylinder
1) Mount the brake wheel cylinder to the brake backing plate and torque
to specification.
2) Reinstall the brake line to the wheel cylinder, and torque the brake
line flare nut to specification.
Fig.3.7-5 3) Reinstall the protective rubber cap on the wheel cylinder bleeder
screw after bleeding the system.
2. Brake shoes
1) Apply a coating of waterproof sealant at the brake backing plate
where the parking brake cross bracing wire passes through. Thread the
parking brake cross bracing wire through the backing plate and
reconnect the cable end.
8) Check whether brake drum can rotate freely without obstruction and
has normal brake function. Lower the vehicle and road test for brake
function.
Note: The brake system must be bled whenever brake fluid hoses or lines
are disconnected.
V. Front and rear drum type “manually-adjusted” brakes
(I) The steps for disassembly, inspection, and assembly are identical to
rear drum type “self-adjusting” brakes.
III) Front brake structure is as indicated in Fig.3.7-7, rear brake structure
is as indicated in Fig.3.7-8.
Brake backing plate
Adjusting screw Brake wheel cylinder
Fig.3.7-6 Brake shoe
2) Assemble each component in the reverse order of disassembly.

Note: Do not damage the brake wheel cylinder dust boots when Hold down spring
installing the brake shoes.
3) Press the brake shoe self-adjuster spring down to the installation
position and rotate the sizing spring to complete installation.
Release spring
4) Before installing the brake drum, insert a screwdriver and press
down the toothed quadrant (as indicated in Fig.3.7-6) in the self-
adjuster to obtain maximum clearance between brake drum and brake
shoes.
Fig.3.7-7
5) Install the brake drum after ensuring the brake drum and brake
shoes are free of dirt and oil.
6) Reinstall the rear wheels and torque the lug nuts to specification.
7) Depress the brake pedal five times by applying a force of 300N to
obtain suitable clearance between the brake drum and brake shoes.
Brake backing plate
Rear brake wheel cylinder

Brake shoe strut
Brake shoe
Parking brake lever
Hold-down spring
Release spring
Fig.3.7-9
Adjusting nut V. Brake Master Cylinder

(I) Disassembly
Fig.3.7-8 1) Disconnect the negative battery cable from the battery.
Clearance adjustment: Insert the screwdriver into the adjusting hole of 2) Clean the outside of the brake master cylinder fluid reservoir.
the brake drum, and rotate the adjusting screw until the clearance 3) Drain the brake fluid.
between the brake shoe and brake drum becomes zero. Then rotate the 4) Remove the steering shaft ball joint cover.
adjusting screw 3 to 6 teeth in the reverse direction. (refer to Fig.3.7- 5) Disconnect the combination switch wire connector from the main
9). wiring harness.
Note: To ensure optimum brake performance, the front and rear 6) Remove the lower pinch bolt from the steering shaft u-joint.
brakes should always be adjusted together. 7) Remove the steering column assembly mounting bolts and remove the
steering column assembly.
8) Remove board “A” from the pedal bracket and instrument. Turn the
bolt ① and remove the screw ② to remove board “A”.
9) Remove the instrument cluster bezel.
19) Remove the brake master cylinder from the vacuum booster.
(II) Disassembly
1) As indicated in Fig.3.7-11, remove the spring, and carefully remove
the first piston using compressed air.
Note: Apply compressed air at LOW pressure, or serious injury may
result.
Fig.3.7-10
10) Remove the instrument cluster assembly.

11) Disconnect the brake vacuum hose (I) from the vacuum pipe (I) at
the floor.
12) Disconnect the 2 rubber brake fluid hoses from the brake master Fig.3.7-11
cylinder. 2) Install the piston reducer fitting and remove the second piston by
13) Disconnect the two brake lines from the brake master cylinder. blowing compressed air through reducer fitting hole.
14) Disconnect the clutch cable assembly from the clutch pedal and
the clutch cable base.
15) Disconnect the connecting wire from the brake light switch.
16) Remove the fuse box assembly from the pedal support.
17) Check for any other connectors on the pedal supports and
disassemble.
18) As the vacuum booster and brake master cylinder are both
installed on the pedal support, they shall be removed together with
pedal support.
1. Reducer fitting
2. Compressed air
Fig.3.7-12
(III) Inspection 3) Install the primary piston into the master cylinder.
1. Examine the internal components of the brake master cylinder 4) Push the primary piston slightly inward, install the reducer fitting and
Check for any wear or corrosion on the disassembled components and torque to specification torque (1.5-3N·m).
replace as required. 5) Install the induction manifold connector using directional pressure
Check for any scores or corrosion on the inner walls of the brake plate “A” and “B” in the angle indicated in Fig.3.7-13, and torque to
master cylinder. Corroded master cylinders must be replaced. specification.
Clean brake fluid should be used to clean the inner walls of the brake
master cylinder. Remove all used brake fluid from the brake master
cylinder. Blow dry with compressed air. Do not use a wiping cloth.
Note:
· Brake fluid should be used to clean each component.
· Do not reuse the old piston cup or gasket.
· Hone the inner wall of the master cylinder using brake fluid to
lubricate the stones.
2. Brake master cylinder fluid reservoir
Fill with brake fluid up to the maximum (MAX) position.
Note:
Fig. 7.7-13
The brake system of the vehicle has been filled with DOT 3 type
brake fluid at the factory. It is very important that other types of brake (V) Notes for reassembly
fluid are NOT used. Do not use brake fluid from an unsealed Reassemble in the reverse order of disassembly, and note the following
container, or used brake fluid. Filling the brake system with a mineral points:
oil based hydraulic fluid instead of DOT 3 will cause severe failure 1) Install the brake master cylinder to the vacuum booster, and torque the
due to extreme swelling of the rubber seals. attaching nut to specification. (Fig.3.7-14)
(IV) Assembly 2) Mount the vacuum booster and brake master cylinder onto the pedal
Note: All components should be cleaned externally with brake support, and reinstall the assembly onto the vehicle. Install the pedal
cleaner. All internal parts and areas should be cleaned with new DOT support mounting bolts.
3 brake fluid, as is used in the vehicle’s brake system. 3) Reconnect the clutch cable assembly to the pedal support and adjust
1) Install the secondary piston assembly. the stroke of the clutch pedal.
2) Insert the secondary piston assembly into the master cylinder. 4) Reconnect the two brake hoses to the brake master cylinder and
torque to specification (14-18N·m).
5) Reconnect the two brake lines to the brake master cylinder and tighten
securely.
c. Mount the steering column assembly to the body and torque the
steering column assembly mounting bolts to specification. Torque the
steering shaft U-joint yoke pinch bolt to specification.
11) Reconnect the combination switch wire connector to the main
harness and clamp the wire securely using clips.
12) Make sure all disassembled components have been reassembled. If
any problem occurs, repair as required.
13) Fill the brake master cylinder to the specified level after
reassembling all the components.
14) Check the lights and switches for proper function.
15) Check the height and stroke of brake pedal. Check for brake fluid
Fig. 3.7-14
leakage.
6) Reconnect the vacuum brake hose (I) to the vacuum brake hose
(II), and clamp them tightly.
7) Make sure that all components connected to the vacuum booster
and master cylinder assembly are tightened securely.
8) All components removed to facilitate removal of the pedal support
must be reinstalled.
9) Reconnect the wiring harness connector and speedometer cable to
the instrument assembly. Then reinstall the instrument assembly.
10) Reinstall the steering column assembly according to the following
sequence.
a. Position the front wheels pointing straight ahead.
b. Insert the U-joint onto the lower steering shaft.
Fig. 3.7-15
VI. Vacuum Booster

(I) Disassembly
1) Remove the vacuum booster from the vehicle by applying the same
method of brake master cylinder removal.
2) Remove the brake master cylinder from vacuum booster.
3) Remove the vacuum hose (I) from the vacuum booster. (Fig.3.7-16)
4) Disconnect the adjusting fork from the brake pedal arm. (Fig.3.7-
17)
5) Remove the connecting nut, washer and vacuum booster.
Fig.3.7-17
1. Clevis pin 2. Adjusting fork 3. Brake pedal arm 4. Cotter pin
(II) Adjusting the clearance between the master cylinder push rod and
master cylinder piston
Adjust the length of the master cylinder push rod to make the clearance
between push rod end and master cylinder primary piston satisfy the
specification. (Fig.3.7-18)
Fig.3.7-16 · Push the piston rod several times to ensure the reaction disc is in its
1. Vacuum booster housing 2. Vacuum hose position before measuring the clearance.
· The vacuum booster shall be kept under the barometric pressure during
measurement.
(1) Install the special tool (I) and (II) to the brake master cylinder. Push
(I) until the piston end surface A parallel master cylinder surface A.
(Fig.3.7-19)
(2) Reverse the tool and put them on the vacuum booster. Ensure the
clearance between vacuum booster piston rod and the other end of
special tool (I) is between 1.0-1.5mm. If the clearance is out of the
range, adjust to specification. (Fig.3.7-20)
Special tool I
Special tool II
Clearance between special

tool and piston rod is 1.0-
1.5mm
1. Brake master cylinder 2. Piston

Fig.3.7-18
Special tool I Special tool II
1. Adjusting fork 2. Hexagon flange nut

Fig3.7-20
20-30N·m
1. vacuum booster 2. master cylinder push rod

Fig.3.7-19
106.5-107.5mm
1. adjusting fork 2. hexagon flange nut

Fig.3.7-21
(III) Note for assembly

(1) As is indicated in Fig.3.7-21, the distance between the fork pin
hole and vacuum booster front end should be between 106.5-
107.5mm. Torque the nut to specification.
(2) If the seal pad frame has been installed to the assistant chamber
10-16N·m
seal pad, install them to the rear housing. The installation direction is
indicated in Fig.3.7-22.
(3) Install the vacuum booster to the pedal support as indicated in Pedal support
Fig.3.7-23. And then install the vacuum booster adjusting fork to the Brake pedal arm
Cotter pin
brake pedal fork arm by using pin and cotter pin.

(4) Torque the vacuum booster mounting nuts to specification.
Flat-head pin
Plain pin
Fig.3.7-23
(5) Reinstall the brake master cylinder to the vacuum booster as
indicated in Fig.3.7-24, and torque the mounting nuts to specification.
Fig.3.7-22 (6) Reconnect the vacuum hose to the vacuum booster as is indicated in
1. Assistant chamber seal pad 2. Seal pad framework Fig.3.7-25.
3. Rear housing The arrow on the hose should point to the intake manifold of the engine.
Secure the hose tightly.
(7) Reinstall the pedal support assembly and vacuum booster assembly
to the vehicle. Make sure the brake fluid hose connector is rotated at the
correct installation angle before reconnecting the hose.
Tightening torque N·m

Brake line flare nut 14-18
Brake hose connecting fitting 20-30
Fig.3.7-24
1. Vacuum booster 2. Vacuum hose connector
3. Vacuum hose 4. Clamp
VII. Brake Pipe
(A) Disassemble and assembly
1) Clean the dirt from the brake hose connector, and remove the brake
hose and line assembly.
2) Reinstall the brake hose and line assembly in the reverse order of Fig.3.7-25
disassembly. Make sure the hose is not twisted during installation or 1. Vacuum booster 2. Vacuum hose connector
rubbing against other components. Turn the front wheels fully to the 3. Vacuum hose 4. Clamp
left and right, and modify the hose routing if it contacts other
components. Fill the master cylinder to the specified level and bleed
the brake system, Check the brake fluid level after completion and
add as required.
VIII. Maintenance and service
1. Brake fluid leakage
Check the brake fluid level of the brake master cylinder. If the brake
fluid level in the brake master cylinder has only decreased slightly, it
indicates a normal condition due to brake pad/shoe wear. If the brake
fluid level has decreased significantly, it indicates that a brake fluid
leakage problem may exist in the brake system. In this case, check the
brake system for brake fluid leakage. Even if the brake fluid leakage
is slight, the cause should be determined and the component repaired
or replaced.
2. Checking the brake fluid level
DOT 3 brake fluid as specified in this manual must be used. No other
types of brake fluid or mineral oil may be used.
The operational brake fluid level should be between the minimum Fig.3.7-26
(MIN) line and the maximum (MAX) line. 1. Brake pedal 2. Contact bracket 3. Brake lamp switch 4. Mounting nut
If the low brake fluid lamp flashes during vehicle operation, it

indicates that brake fluid should be added to the brake master cylinder
until the fluid level reaches the MAX line position.
If the brake fluid level is decreasing rapidly, the brake system should
be checked for brake fluid leakage. Repair the failed part(s) which are
causing the leakage, and refill the brake master cylinder to the
maximum (MAX) level position.
3. Filling the brake master cylinder with brake fluid
DOT 3 brake fluid must be used. Do not use shock absorber fluid or
Fig.3.7-27
other mineral oils. Do not use containers which have been filled with
mineral oil or water. Filling the brake system with a mineral oil based
hydraulic fluid will cause severe failure due to extreme swelling of
the rubber seals. Water contamination will reduce the boiling point.
Fill the brake master cylinder with DOT 3 brake fluid to the
maximum (MAX) level position.
4. Adjusting the brake pedal free play
The brake pedal height should be equal to the clutch pedal height.
1) When installing the vacuum booster adjusting fork, the distance
between booster mounting surface and push rod pin hole must be
adjusted to the range of 106.5-107.5mm.
2) When the brake lamp switch is removed, please reinstall the switch 9. Inspecting the brake rotor
correctly according to instructions in “Adjusting the brake lamp The brake rotors should be checked regularly according to the
switch”. maintenance schedule.
5. Adjusting the brake lamp switch 10. Inspecting the brake shoe lining
When installing the switch, first pull the brake pedal upward. Adjust The brake shoe lining should be checked regularly according to the
the switch position to make the clearance between screw end and maintenance schedule, and also checked when the wheels are removed
brake pedal contact bracket within the range of 0.5-1.0mm. Torque as a result of other repairs.
the lock nut to specification. 11. Inspecting the brake drums
6. Troubleshooting excessive pedal stroke The brake drums should be checked regularly according to the
1) Turn off the engine. maintenance schedule.
2) Fully depress the brake pedal several times. 12. Inspecting and adjusting the parking brake
3) Depress the brake pedal with a force of about 30kg, and measure 1) Inspect the parking brake
the clearance between the brake pedal arm and the floor. The Holding the middle of the parking brake handle, gradually pull the
clearance should exceed 95mm. (Fig.3.7-27). handle upward with a force of 20kg until the parking brake is fully
4) If the clearance is less than 95mm, the most probable cause is the engaged. When pulling upward, listen to the “clicks” produced by the
rear brake shoe lining wear has exceeded operation limits or air is in ratchet wheel. One “click” is produced when pulling one tooth upward.
the brake system and must be bled out. If the brake shoes have been If the “clocks” exceed 8, the parking brake cable should be adjusted.
replaced or air in the system has been bled out, and the clearance “B” Check the ratchet teeth for wear or damage, and replace as required.
is still less than 95mm, the rear brakes may not be adjusted properly 2) Adjusting the parking brake
or the brake booster push rod length is adjusted incorrectly (for ① Check the parking brake handle to see whether it satisfies the
vehicles equipped with boosters). specifications in the following table.
7. Inspecting brake hoses and lines ② If it does not conform to the specifications in the table, the parking
1) Brake hoses brake cable should be adjusted.
Check for any risk of damage and leakage during operation, and for Parking brake handle stroke
breaks, scuffing, or deterioration. Repair as required. Pull the handle by applying a force of 20kg Within 3-8 teeth range
2) Brake lines The following conditions should be met before adjusting the parking
Check for any damage, cracks, or corrosion. Repair as required. brake cable:
8. Inspecting the brake pad lining a) The rear brake shoe linings are within operational limits, and the self-
The brake pad lining should be checked regularly according to the adjusters are working properly.
maintenance schedule, and also checked when the wheels are b) No air is in the brake system.
removed as a result of other repairs. c) Brake pedal stroke is normal.
d) The brake pedal has been depressed several times with a force of
about 30kg.
e) The parking brake handle has been pulled several times with a
force of 20kg.
③ The brake drum should not be “dragging” after loosening the
adjusting nut to adjust the stroke as is indicated in Figure 3.7-28.
1.Adjusting nut Free stroke of pedal 1-

8mm
Fig.3.7-29
14. Adjusting the brake clearance
Same as the above mentioned points.
15. Flushing the brake hydraulic system
Each time a new component is installed in the brake hydraulic system, it
is suggested that new brake fluid be flushed through the entire brake
hydraulic system.
It is recommended that the customer replace the brake fluid every two
Fig.3.7-28. year.
16. Bleeding the brake system
3) Inspecting the parking brake cable Air must be bled from the brake system whenever repairs or failures
Check the parking brake cable and housing for damage. Make sure allow air to enter the brake system.
the cable moves freely within the housing. Repair as required. ① If the brake hose of the front wheel brake line or hoses are
13. Inspect the brake pedal free play disconnected, the resulting air in the front brake system must be bled out.
The brake pedal free play should be within the range specified in ② If the rear wheel brake lines or hoses are disconnected, the resulting
Fig.3.7-29. If the stroke deviates from the specified range, check to air in the rear brake system must be bled out.
see if the stop lamp switch mounting adjustment is correct and adjust ③ If air is present in the brake master cylinder and 5-way valve, the
if required. Check the brake pedal bolt and pintle that connect the entire brake system must be bled. The bleed screws are represented by
vacuum booster adjusting fork and brake pedal arm for excessive “A”, “B” and “C” in Fig.3.7-30. Bleeding should begin at the wheel
wear or damage. Repair as required. cylinder farthest away from the brake master cylinder, until reaching the
wheel cylinder closest to the master cylinder. The steps are as follows,
system. Repeat the procedure until there are no more air bubbles coming
Right wheel brake wheel cylinder Right wheel brake wheel cylinder
from the hose in the container.
d) Reinstall the bleed screw protective cap.
Rear
e) Depress the brake pedal several times after bleeding and check for
Front
leaks.
f) Fill the brake fluid reservoir with brake fluid reaches the MAX level.
g) Check to see if the pedal is “soft”. If so, repeat the bleeding process.
17. Inspecting the vacuum booster
Two methods can be used to check the vacuum booster: with and without
a test watch. Usually, the operational condition can be roughly
determined without using a test watch. The following instructions
explain how to check the vacuum booster without a test watch. To obtain
accurate results, no air may be present in the brake system during the
vacuum booster test.
① Check airtightness
Fig.3.7-30 a) Start the engine.
b) Turn off the engine after 1 or 2 minutes.
a) While bleeding the brake system, the brake fluid reservoir should c) Pump the brake pedal several times. If the pedal goes down deep the 1st
be filled to the MAX position. Do not allow the level to fall below the time but gradually rises after the 2nd or 3rd times, it is in good condition. If
half. the first stroke can reach the floor, and the pedal stroke on the second
b) Remove the protective cap from the bleed screw. Connect an and third time gradually decreases, it shows that airtightness is normal.
ethylene rubber hose to the brake wheel cylinder bleed screw and d) If there is no change in pedal height when depressed the 2nd and
insert the other end in a clear container. successive times, airtightness is abnormal. Check the vacuum booster and
c) Press (pump) the brake pedal several times, and after the last time vacuum hose and repair as required. Then repeat the test.
keep the pedal depressed. While the pedal is depressed, briefly open ② Check operation
the bleed screw 1/3 to 1/2 a turn to remove the air, and immediately a) With the engine turned off, depress and release the brake pedal several
retighten the bleed screw. The pedal will fall to the floor when the times to remove any vacuum retained in the booster.
bleed screw is opened. This is normal. Do not release the brake pedal b) Hold down the brake pedal with medium effort, and start the engine.
until the bleed screw has been retightened or air will reenter the c) If the brake booster is functioning properly, the brake pedal will give
slightly underfoot as the booster takes effect.
③ Check air tightness under load Section 8 Wheel and Tire
a) Depress the brake pedal with the engine running. Turn off the
engine while keeping the brake pedal depressed. I. Tire replacement
b) Hold the pedal depressed for 30 second. If the pedal height does When it is necessary to replace a tire, an original equipment type tire
not change, the vacuum booster is functioning properly. If the pedal should be used. It must be the same size, load range, and design as the
rises, it is must be replaced. original factory-installed tires. If other size or type tires are used, it will
affect important factors such as ride comfort, reliability, speedometer
calibration, and ground clearance.
Note:
Except for emergencies, radial and bias ply tires cannot be used together
on one vehicle. Combining different types of tires on one vehicle will
seriously reduce the operational reliability of vehicle and vehicle control.
Matching tires should be used on the same vehicle axle. If only one tire
needs to be replaced, a tire with the most identical tread pattern should
be used to keep the traction force in balance during braking.
II. Wheel replacement
If a wheel is bent, cracked, warped, damaged stud holes, or seriously
corroded, it should be replaced.
If tire inflation exceeds the minimum limit indicated in Fig.3.8-1,
harmful vibrations and a loss of control will occur. Replacement wheels
should have the same load capacity, diameter, width, offset, and lug
pattern as the original wheels. If the size or type does not conform to
original specifications, it will affect vehicle life, wheel bearings, brake
and cooling system performance, speedometer calibration, and ground
clearance.
1. Bumping driving
2. Tire or wheel damage
3. Rapid tire wear in the center of the tire tread
The following conditions will occur if the tire is underinflated:
1. Excessive tire noise during steering
2. Heavy steering
3. Rapid and uneven wear at the edges of the tire tread
Limit value 4. Wheel may be damaged or broken
1.2mm 5. Tire cord is broken
6. Tire temperature is dangerously high
Limit value 7. Tire failure
Fig.3.8-1 1.2mm 8. Excessive fuel consumption
The following conditions will occur if the tire inflation pressures are
uneven:
1. Uneven braking performance
2. Steering pull
3. Increases tire temperature and the risk of tire failure
III. Tire inflation pressure 4. Wheel spin during acceleration
The recommended tire inflation pressure for each model has been IV. Tire rotation
carefully calculated to provide the best ride quality and comfort, The tires should be rotated regularly to obtain maximum tire wear.
reliability, handling, and maximum tire wear. Tire pressure should be Please refer to Fig.3.8-2.
checked when the tires are cool (after the vehicle has been parked
over 3 hours or driven less than 1 km). Inflate the tire to the specified
air pressure.
Radial tires: Front tire 200kpa
Rear tire, spare tire 230kpa
Bias ply tires: Front tire 210kpa
Rear tire, spare tire 260kpa Radial tires Bias ply tires
Air pressure in typical tires will increase 30-50kPa during operation Fig.3.8-2
as they become warm. For this reason, tire pressure should always be
checked and adjusted when the tire is cold.
The following conditions will occur if the tire is overinflated:
V. Wheel removal Static imbalance will cause uneven wearing to the tire.
1. Loosen the lug nuts about half a turn. Dynamic imbalance will cause the front wheels to vibrate.
2. Raise the vehicle. Note:
3. Remove the lug nuts. Remove the wheel. · Completely clean any dirt deposited on the inside and outside of the
Note: rim.
· Do not use heat (torch, ect.) during wheel removal, or tire, wheel · Any stones wedged in the tire tread must be removed to prevent bodily
seal, and wheel bearing damage will result. harm during the balance test, and to achieve better balance results.
· Install the lug nuts and screw them to the specified torque 60-80N·m VIII. Disassemble the wheel hub and bearing
in order. 1. Raise the vehicle and remove the wheels.
· Clean corrosion on the wheel installation surface and brake drum or 2. Remove the front hub grease cap. Do not damage (bend) the grease
brake disc installation surface by using a steel wire brush before cap.
assembly of wheels. 3. Remove the cotter pin from the castellated wheel bearing retaining
VI. Tire removal and installation nut.
A tire machine should be used to remove the tires from the rims, 4. Remove the castellated wheel bearing retaining nut.
carefully following the manufacturer’s instructions and established 5. Press the brake pedal and loosen the brake rotor mounting bolts.
procedures. Do not use hand tools (ie, crowbar, ect.) to remove the 6. Remove the brake caliper mounting bolts.
tires, as damage to the tire bead and rim will result. 7. Remove the brake caliper from the brake rotor, and hang it using a
A steel wire brush or steel wool should be used to clean any oil, old steel wire hook.
rubber, or corrosion from the rim. Tire lubricant should be applied to Note: DO NOT press the brake pedal before reinstalling the brake
the upper and lower tire bead prior to removal and installation. caliper.
After tire installation, inflate the tire to the manufacturer’s 8. Pull the wheel hub off by using special tools.
recommended operating pressure, making sure the tire beads have 9. Remove the snap ring and hub wheel bearing.
seated on the rim. IX. Reassemble the wheel hub and bearing
Note: Note:
· Do not overinflate the tires. · The hub wheel bearing can not be reused It must be replaced with new.
· If the tire beads do not seat on the rim at the tire’s recommended · Make sure the snap ring is installed properly in the ring groove of the
operating pressure, discharge the air pressure, deflate the tire and wheel hub.
reinflate. Overinflation will damage the tire beads and cause serious 1. Reinstall the brake rotor onto the wheel hub. Hand-tighten the brake
bodily harm. rotor mounting bolts.
VII. Tire balancing 2. Reinstall the wheel hub onto the steering knuckle. Gently tap the hub,
There are two methods for balancing tires: dynamic balancing and making sure it is not twisted on the steering knuckle spindle. After being
static balancing. sure that the hub is going on straight, tap it on completely using the
special tool.
3. Reinstall the brake caliper.
4. Torque the hub wheel bearing retaining nut to specification and

install the cotter pin.
5. Torque the brake caliper mounting bolts to specification.
6. While depressing the brake pedal, torque the brake rotor mounting
bolts to specification. (refer to Fig.3.8-3.)
7. Reinstall the front hub grease cap.
Note: When installing the grease cap, tap lightly on the flange at the
side of the grease cap using a rubber hammer, until the flange surface
is flush with the wheel hub. If the flange surface of grease cap has
been deformed, preventing an airtight fit or causing looseness, the
grease cap must be replaced.
8. Reinstall the wheels and torque the lug nuts to specification.
9. Lower the vehicle.
Cotter pin
Fig.3.8-3
Fig.3.8-4
1. Wheel and tire assembly 2. Front hub 3. Castellated retaining nut 4. Thrust washer 5. Grease cap
6. O-ring 7. T 3CC 025 8. Brake assembly 9. T 4CC 030 10. Steering knuckle 11. Oil seal seat 12.
oil seal
4. Operation And Maintenance

X. Front wheel hub and bearing assembly and adjustment (drum (1) Second class maintenance (6,000-8,000km): disassemble the front
brakes) hub, clean the hub cavity and wheel bearings, pack with new wheel
1. Disassembly bearing grease, and reassemble it. Adjust the wheel bearing retaining nut
(1) Raise the vehicle and remove the front wheels. to specification.
(2) Carefully remove the front hub grease caps and rubber o-rings. Do (2) Third class maintenance (35,000-45,000km): disassemble, clean and
not deform the grease caps. check the front axle, reassemble, and adjust it. Check the hub grease seal
(3) Remove the castellated wheel bearing retaining nut pin and nut. for wear and damage, and replace as required.
(4) Remove the thrust washer and outer bearing (T 3CC 025). 5. Bearing and oil seal specifications
(5) Remove the front hub and inner bearing (T 4CC 030) using the Bearing
special tool. Fig. No. Designation Number
(6) Clean the wheel bearings and blow dry WITHOUT spinning the T 3CC 025 Conical roller bearing 2
bearings. Check for wear and replace as required. Note: bearings and (ISO355 series code)
races must be replaced in sets. T 4CC 030 Conical roller bearing 2
(7) Clean the hub cavity with solvent and wipe dry. (ISO355 series code)
2. Reassembly Grease seal
Pack the inner bearing (T 4CC 030) with new high-temperature Fig. No. Designation Number
lithium NLGI#2 wheel bearing grease and insert into the hub. Fill 3103025-V70 Grease seal 2
about 60% of the inner chamber of the hub between the two wheel
bearings with new wheel bearing grease. Apply a thin film of new
wheel bearing grease to the rubber lip of the new grease seal and
install in into the hub. Push the hub onto the spindle, rotating it to
assure that all parts are seated. Pack the outer wheel bearing with new
wheel bearing grease and slide it on the spindle into the hub. Install
the castellated wheel bearing retaining nut.
3. Front wheel bearing adjustment (refer to Fig.3.8-4)
Torque the castellated wheel bearing retaining nut to 30-60N·m while
rotating the hub back and forth to make sure all parts are seated. Back
the nut off 1/6-1/3 turn, allowing the slots in the castellated nut to line
up with the cotter pin hole in the spindle. If necessary, back off the
adjustment to align with the hole. Insert a new cotter pin. The hub
should rotate freely with no obvious sway.
Chapter IV Vehicle body Operation and Service Manual on FAW Jiabao Series Light Passenger Van
Chapter IV Vehicle body

I. Front door glass and regulator
Section 1: Front door and rear sliding door (I) Disassembly
Disassemble front door glass and front door glass regulator using the
Front door assembly parts (refer to Fig. 4.1-1) following instructions:
1) Front door inner handle bezel.
2) Front door inner pull handle.
3) Window regulator handle. Insert a piece of cloth into the circlip, pull
down, and disassemble glass regulator handle. (refer to Fig. 4.1-2)
Fig. 4.1-1
1. Front door 2. Front door glass 3. Front door outer weather strip 4. Font door inner weather strip 5. Front door seal 6. Front door inner panel 7
front door inner handle bezel 8. Front door pull handle 9. Window regulator handle 10. Front door inner handle 11. Front door window regulator
12. Front door upper hinge 13. Front door lower hinge 14. Window regulator handle circlip 15. Front door glass lift channel
7) Mounting screw for front door glass lift channel. (refer to Fig. 4.1-4)
8) Pull up the rear side of the front door glass, and remove the front door
glass with the lift channel. (refer to Fig. 4.1-5)
9) Remove the door glass from the lift channel.
10) Font door window regulator mounting screws. Remove the 6
mounting screws and remove the window regulator from opening A.
(refer to Fig. 4.1-6)
Fig. 4.1-2
Fig. 4.1-3
4) Front door inner panel .

5) Front door seal.
6) Front door inner weather strip. Roll down the front door glass Fig. 4.1-4
completely, then use a screwdriver wrapped with tape to pry up the 1. Mounting screws
inner and outer weather strip. (refer to Fig. 4.1-3)
Operation and Service Manual on FAW Jiabao Series Light Passenger Van Chapter IV Vehicle body
Operation and Service Manual on FAW Jiabao Series Light Passenger Van Chapter IV Vehicle body
Chapter IV Vehicle body Operation and Service Manual on FAW Jiabao Series Light Passenger Van
(II) Inspection
1. Check the front door glass window regulator gear for excessive wear
or damage.
2. Check the front door glass window regulator spring for looseness.
(III) Reassemble front door glass and window regulator in the reverse
order.
Pay attention to the following during installation:
1) Apply multi-purpose grease to all sliding and moving parts of the
window regulator. (note the positions indicated by the arrows in Fig.
Fig. 4.1-5 4.1-7)
1. Front door glass
Fig. 4.1-6
1. Front door glass window regulator mounting screws Fig. 4.1-7
Apply grease at the positions indicated by arrowheads
Fig. 4.1-8
1. Glass bearer 2. Lift channel rubber gibs
Fig. 4.1-9
2) When installing the front window glass on lift channel rubber gibs,
apply some soapy water to the lift channel rubber gibs, and use a
rubber hammer to gently tap the glass. The glass should be positioned
on the lift channel as shown in Fig. 4.1-8.
3) If the front door glass is difficult to roll up and down, the reason
may be that the glass leans toward the doorcase. If so, adjust the fixed
slide rail of the window regulator, making size A equal to size B.
(refer to Fig. 4.1-9, Fig. 4.1-10)
Fig. 4.1-10 Adjusting fixed slide rail
1. Fixed slide rail mounting screw
Operation and Service Manual - FAW Jiabao Series Light Passenger Van Chapter IV Vehicle body
Chapter IV Vehicle body Operation and Service Manual - FAW Jiabao Series Light Passenger Van
4) Use adhesives to adhere the front door seal tightly to the inner door II. Door lock
panel. (refer to Fig. 4.1-11) (I) Front door lock
5) Reinstall the window regulator handle at a 45º ahead of the vertical For an illustration of the main front door lock parts, refer to Fig. 4.1-13.
plane when the glass fully closed, as shown in Fig. 4.1-12. (II) Side sliding door lock
For an illustration of the main side sliding door lock parts, refer to Fig.
4.1-14.
(III) Disassembly
1. Front door lock
Disassemble the front door lock in the following sequence:
1) Front door inner handle bezel.
2) Front door inner handle.
3) Front door window regulator handle.
Fig. 4.1-11 4) Front door trim panel.
1. Front door seal 2. Adhesive 5) Front door seal.
6) Mounting frame for front door glass guide rail.
7) Front door inner handle and lock body assembly.
After disconnecting the handle control rod end clips, remove the inner
handle and front door lock assembly.
2. Side sliding door lock
Disassemble the side sliding door lock in the following sequence:
1) Sliding door inner handle assembly.
Fig. 4.1-12 2) Sliding door trim board.
3) Sliding door seal.
4) Sliding door lock control rod mechanism assembly and lock body
assembly. After disconnecting the handle control rod end clips, remove
the lock connection rod mechanism assembly and lock body assembly.
(refer to Fig. 4.1-5)
Fig. 4.1-13
1. Front door outer handle assembly 2. Front door lock cylinder assembly 3. Front door inner handle assembly
4. Front door lock body assembly 5. Front door lock ring assembly 6. Mounting frame for front door glass guide rail.
Fig. 4.1-14
1. Outer handle assembly 2. Lock control rod mechanism assembly
3. Inner handle assembly 4. Lock body assembly
5. Lock ring assembly
Fig. 4.1-15
1. Screwdriver(disconnect door opening control rod)

(IV) Installation
Install the front door lock and side sliding door lock in the reverse
sequence of disassembling. Pay attention to the following during
installation.
1. Outer handle dragrod
When attaching the outer handle control rod (1) to the outer handle,
turn the regulating nut (3) to make distance A reach 0-2mm, as shown
in Fig. 4.1-16 and Fig. 4.1-17.
Note:
When installing and adjusting the outer handle control rod,
do not press downward (front door) or forward (rear door) on
the “opening” control rod (6).
Fig. 4.1—17 Rear side slide door lock
1. Outer handle control rod 2. Rear side slide door outer handle
3. Adjusting nut
4. Outer handle rod end clip
5. Lock control rod mechanism assembly
6. Opening control rod “A”: 0-2mm
2. Front door inner handle

When installing the front door inner handle, move the front inner handle
control rod in the direction indicated by the arrow, to regulate the
clearance between the inside opening lever “1” and outer opening lever
“3”, to make it 0-2mm. (refer to Fig. 4.1-18)
Fig. 4.1-16 Front door
1. Outer handle control rod 2.
Front outer handle
3. Adjusting nut 4. Outer handle
rod end clip
5. Front door lock body assembly
6. Opening control rod “A”: 0-
2mm
4. Side sliding door inner handle

Install the inner handle as shown in Fig. 4.1-20. With handle “2” fully
open, adjust so that it slightly touches the door lock toggling plate “3”,
and tighten the mounting bolt.
Fig. 4.1-19
1. Door lock control rod clip
Fig. 4.1-18
1. Inside opening lever 2. Front door inner handle lever
3. Outside opening lever
4. Front door lock ring assembly B: 0-2mm
3. Door lock control rod end clip

Use control rod end clip “1” to attach the door lock control rod
according to the illustration in Fig. 4.1-19. Fig. 4.1-20
1. Side door inner handle frame 2. Full opening inner handle
3. Door lock toggling plate 4. Screw
Fig. 4.1-22 Front door lock

1. Lock body assembly 2. Striker plate
Fig. 4.1-21 Striker plate adjustment

1. Striker plate 2. Door lock regulating plate 3. Door 4. Front 5.
Body (B-post) D: front door:12.7-14.7mm rear door:14.6-16.6mm
5. Striker plate adjustment
To adjust the position of the striker plate forwards and backwards, add
or reduce adjusting shims between the vehicle body and striker plate
to achieve proper positioning. Front door D size must be adjusted to
12.7-14.7mm, and rear D size to 14.6-16.6mm. (refer to Fig. 4.1-21) 1. Upper hinge 2. Lower hinge
Regulate the upper and lower positions of the striker plate, making its 3. Front door A: filler hole
axis aim at lock body C. (refer to Fig. 4.1-22)
Note:
The striker plate can be adjusted upward and downward horizontally. Fig. 4.1-23
Do not attempt to adjust the lock body.
III. Front door

The front door mounts to the main vehicle body with upper and lower
hinges. For smooth door operation, add lubricating oil to the upper
and lower hinge axes. (refer to Fig. 4.1-23)
Fig. 4.1-25
Fig. 4.1-24 (I) Disassembly
1. Front door hinge 2. Bolt 3. Front door seal Disassemble the front doors in the following sequence:
4. Front door hinge plug 1) Front door inner handle bezel. 2) Front door pull handle. 3) Front
door window regulator handle. 4) Front door trim panel. 5) Remove the
seal from the front door hinge bolt hole. 6) Remove the front door hinge
plug (see Fig. 4.1-24). 7) Remove the pivot pin from the door stop
assembly (see Fig. 4.1-25). 8) Using a floor jack, position a wood block
between the jack and bottom of the door. (see Fig. 4.1-26) 9) Remove the
hinge bolts to remove the front door assembly.
2) After installation, adjust the door striker so that it properly makes

contact with the door latch.
(III) Regulation of front door
1) Loosen the front door hinge bolts, properly adjust the front door in
every direction, and retighten the hinge bolts.
2) Adjusting the door striker (refer to the above description).
IV. Side sliding door
For an illustration of the main assembly parts included in the side sliding
door, refer to Fig. 4.1-27.
(I) Disassembly
Disassemble the side sliding doors in the following sequence:
1) Remove the slide rail rear end panel.
2) Remove lower roller arm assembly mounting bolt, pull the sliding
door backwards to allow the sliding hinge to separate from the guide rail.
Remove the side sliding door. (refer to Fig. 4.1-28)
(II) Reassembly
Install rear side slide door in the reverse sequence of disassembly. Pay
attention to the following when installing:
Fig. 4.1-26 1) If the door seal is worn or damaged, water leakage may occur.
Replace as required.
1. Cloth 2. Wood block 2) After installation, adjust the door and striker plate mounting using
the following method.
(II) Reassembly (III) Side sliding door mounting adjustment
Install front door in the reverse sequence of disassembling. Pay 1) Loosen the rear side sliding door guide block screw.
attention the following during installation. 2) Adjust the lower roller arm (4), so that the outer door surface (2) is
1) If the door seal is worn or damaged, water leakage may occur. flush with the outer body surface (3). (refer to Fig. 4.1-29)
Replace as required.
Front
C (Skid
surface)
Fig. 4.1-27
1. Side sliding door 2. Lower roller arm
3. Door slide hinge
4. Upper roller arm 5. Door slide rail
6. Slide rail rear panel 7. Door guide block positions A,B, C, and D
should all receive a light coating of grease.
Fig. 4.1-28
1. Rear end of skate 2. Screw
1. Lower roller arm assembly 2. Bolt
Front side Rear side
Front side
Fig. 4.1-30
1. Vehicle body(rear side ) 2. Vehicle body (front side)
Fig. 4.1-29 3. Door rear end 4. Door front end 5. Slide hinge
1. Guide block 2. Outer door surface 3. Outer body surface 3) Remove the sliding door inner handle, slide door inner trim panel,
4. Lower roller arm and slide hinge hole seal. Adjust slide hinge (5) so that the rear outer
door surface (3) is flush with the outer body surface (1). At the same
time, adjust clearance “B” between the rear of the door and the body
(1) so that the gap at the front and rear of the sliding door is the
same when the door is closed. (refer to Fig. 4.1-30).
4) Adjust the rear guide block and tighten the screw. (refer to Fig. 4.1- Section 2 Rear door
31)
5) Adjust the striker plate position as described above. Rear liftgate door main assembly parts (refer to Fig. 4.2-1).
Fig. 4.1-31 Fig. 4.2-1

1. Sliding door guide block 1. Rear liftgate door glass 2. Rear liftgate door glass weatherstrip 3.
Rear liftgate door 4. Rear liftgate door seal 5. Rear door inner trim panel
6. Rear door bumper 7. Rear door support bar assembly 8. Rear liftgate
door support cylinder 9. Rear liftgate door latch assembly 10 Rear
liftgate door striker plate 11. Rear liftgate door striker plate adjustment
shim 12. Rear door hinges
I. Rear door support cylinder

Note:
 The support cylinder is a gas-charged non-serviceable
assembly. Do not attempt to disassemble.
 If the support cylinder must be replaced, the old failed
cylinder must be destroyed by
wrapping it in a thick plastic bag
according to the illustration in Fig.
4.2-2. Then use a 2-3-mm drill bit
and drill into the cylinder thru the
bag, as shown in the figure, to allow the gas to escape.
Fig. 4.2-2 Fig. 4.2-3
 During packing, transport, and installation of the support 1. Latch assembly 2. Striker plate loop 3. Adjusting shim
cylinder, be careful not to score the piston rod. 2) In order to adjust the height of the door latch and striker plate,
 Do not rotate the piston shaft when the support cylinder is adjusting shims can be added or removed under the striker plate, as
fully extended. shown in Fig. 4.2-4. 8.9±2mm
II. Rear liftgate door lock
(I) Disassembly Adjusting shim
The rear liftgate door lock may be disassembled in the following
sequence:
1) Rear door inside panel.
2) Rear door seal.
3) Rear door latch and rear door support cylinder.
After the disconnecting the rear liftgate door lock control rod end clip, Fig. 4.2-4
the lock body assembly and lock cylinder can be removed.
(II) Reassembly
Install the rear door lock in the reverse sequence of disassembly.
(III) Striker plate adjustment
1) Adjust the striker plate so that the striker plate loop is aimed at the
center position of door latch opening. (refer to Fig. 4.2-3)
III. Disassembly Section 3 Seat

The rear liftgate door may be disassembled in the following sequence: CA6350 model passenger bus has 3 rows of seats to carry 6, 7 or 8
1) Rear liftgate door support cylinder assembly. persons. Seat color can be changed to match the interior trim color of the
2) Rear door hinges. vehicle. The first and second rows of seats are equipped with seat back
IV. Reassembly adjusters, which can adjust to any angle for increased occupant comfort.
Reinstall the rear liftgate door in the reverse sequence of disassembly. The first row of seat offer fore-and-aft adjustment, with an adjustable
V. Rear liftgate door adjustment range of 120mm.
1) Unscrew the rear liftgate door hinge bolts, and adjust the rear The second row of seats in Saloon models can be rotated up to 180º, so
liftgate door along the front, rear, left and right. second row occupants can turn around and talk face to face with third
2) Adjust the rear liftgate door up and down by adding and removing row occupants. The second row seat back can tilt backwards and become
shims from under the hinge pads. flat with the third row seat, thus creating a bed where occupants can
3) Unscrew the rear liftgate door bumper bolt. Adjust the bumper in sleep.
an up and down direction to obtain the proper position. Retighten the Disassembly: The first row seats are composed of seat assemblies, slide
mounting bolt. rail assemblies, and engine cover panel assemblies, all bolted on the
4) Use the above method to adjust the striker plate position. engine rear cross member. After removing the mounting bolts, the seats
can be removed as shown in Fig. 4.3-1. There are two nuts on engine
cover panel. Unscrew them and pull the engine cover panel forward or
backward for removal. Slide rail and seat are also mounted with bolts for
easy removal.
The front legs of the second row of seat are mounted to the vehicle floor
with combined bolts. Unscrew the combined bolts and the seats can be
quickly removed, as shown in Fig. 4.3-2. The second row seat backrest
can be tilted forward, to allow easier entry to the third row seat.
The front legs of the third row seat are also mounted to the vehicle floor
with combined bolts. Unscrew the combined bolts and the seat can be
quickly removed, as shown in Fig. 4.3-3. Both ends of the third row seat
are equipped with seat back latch. Pull up on the latches to allow the seat
back to fold forward and down for increased rear storage space when
carrying bulky items.
Note:
 Keep the seat surface clean, and avoid spilling chemicals on
the seat surface.
 Smokers should not discard cigarette butts on the seats.
Fig. 4.3-2
Fig. 4.3-1
Fig. 4.3-3
Section 4 Dashboard assembly
I. General
Dashboard assembly as shown in Fig. 4.4-1 (hard plastic panel
shown)
Fig. 4.4-1
1. Dash panel 2. Phillips head screw 3. Gasket 4.Glove box door 5.

Glove box latch 6. Glove box latch spring bolt 7. Phillips self-
tapping screw 8. Glove box door hinge 9. Plug 10. Climate control
panel 11. Front ash tray assembly 12. Phillips self-tapping screw 13.
Clip nut 14. Instrument bezel 15. Phillips self-tapping screw 16. Clip
nut 17. Center console storage box 18. Cover 19. Phillips screw 20.
Phillips self-tapping screw 21. Phillips self-tapping screw
II. Disassembly (as shown in Fig. 4.4-1) Section 5 Front windshield, rear windshield
1. The dashboard assembly (1) is installed with Phillips flat-round- and side windshield
head self-tapping screws (2). After removing the screws, the
dashboard assembly can be removed. I. Front windshield
2. The instrument bezel (14) is mounted on the dashboard assembly 1. Front windshield structure (refer to Fig. 4.5-1)
(1) with Phillips countersunk-head self-tapping screws (15).
3. The front ash tray assembly (11) can be removed from the
dashboard assembly for emptying.
Note:
 Do not place corrosive substances on the dashboard
assembly.
Fig. 4.5-1
1. Front windshield
2. Front windshield outer trim moulding
3. Front windshield inner trim moulding
2. Installation Note:
 ● The adhesive must be applied evenly on the glass. The glass
must be carefully positioned to avoid misplacement.
II. Rear windshield
1. Rear windshield structure (refer to Fig. 4.5-3)
Fig. 4.5-2 Windshield installation

1. Windshield glass 2. Windshield outer trim moulding
3. Windshield inner trim moulding 4. Adhesive Fig. 4.5-3
1. Rear liftgate door glass 2. Inner trim moulding
As shown in Fig. 4.5-2, first install the inner trim moulding on the 3. Outer trim moulding
windshield. Then install the windshield with the outer trim moulding
after applying a coating of adhesive around the perimeter of the glass.
2. Installation 2. Installation
As shown in Fig. 4.5-2, first install the inner trim moulding onto As shown in Fig. 4.5-2, install the inner trim moulding onto the rear side
the new rear liftgate window glass. Then install the outer trim window glass. Then install the outer trim moulding onto the glass and
moulding onto the glass and apply a coating of adhesive around apply a coating of adhesive around the perimeter of the glass.
the perimeter of the glass. Note:
Note: ●Apply the adhesive evenly on glass. Carefully position the glass to
● Apply the adhesive evenly on glass. Carefully position the avoid misplacement.
glass to avoid misplacement.
III. Side windows
1. Side window structure (refer to Fig. 4.5-4)
Fig. 4.5-4
1. Rear side window glass
2. Outer trim moulding
3. Inner trim moulding
Section 6 Bumper Two front fog lights are installed in the right and left side of the lower
bumper.
I. Front bumper
The front bumper assembly is composed of front bumper bracket (A),
front bumper bracket (B), and the front bumper, as shown in Fig. 4.6-
1.
Fig. 4.6-1
1. Front bumper 2. Front bumper mounting bracket (A) 3. Front bumper mounting bracket (B)
4. Nylon lock nut 5. Phillips flat round-head screw 6. Gasket
The front bumper assembly mounting is shown in Fig. 4.6-1. Remove II. Rear bumper
the mounting bolts and nuts on mounting bracket “A”, and remove the When removing the rear bumper, as shown in Fig. 4.6-2, remove the
front bumper. Reinstall the bumper in the reverse sequence of mounting screws. Reinstall the bumper in the reverse sequence of
disassembly. disassembly.
Fig. 4.6-2
1. Rear bumper assembly 2. Phillips flat round-head screw 3. Nylon lock nut
ChapterⅤ Air-conditioner system Operation and Service Manual - FAW Jiabao Series Light Passenger Van
Chapter V Air conditioning system

The function of the vehicle air conditioner system is to blow cooled
air into the vehicle at controlled speeds and temperatures to regulate
vehicle interior humidity and temperature for maximum comfort. To
meet this requirement, the CA6350’s air conditioner utilizes an
independent heating system and cooling system. The two systems
share common air ducts, blower fan assembly, and a multi-function
A/C-fan speed combination switch. The system allows for the use of
fresh outside air or recirculated interior air for greater air
conditioning efficiency.
Section 1 Heating system
I. General
The CA6350’s heating system utilizes recirculating engine coolant to
provide heat, as shown in Fig. 5.1-1. As warm coolant passes thru the
heater core, the blower fan assembly pushes air through the heater
core and on via air ducts to various outlet vents in the vehicle
including the defroster.
II. Blower motor
The blower motor is a direct current permanent magnetism motor.
The motor is controlled by the ignition switch and fan switch.
Utilizing a speed control resistor, the fan switch has 3 speed settings
for varying conditions.
Fig. 5.1-1 Heater structure

1. Climate control assembly 2. Right and left shell of heater 3. Heater core
4. Speed control resistor 5. Blower motor assembly 6. Fan wheel
III. Disassembly (2) Disconnect the wiring harness connector. (refer to Fig. 5.1-3)
1. Speed control resistor
The speed control resistor is installed on the driver side of heater
shell.
(1) Remove the defroster duct from the driver’s side of the heater
assembly. (refer to Fig. 5.1-2)
Fig. 5.1-3
1. Wiring harness connector 2. Resistor 3. Screw 4. Motor
(3) Remove the screw.

(4) Remove the speed control resistor.
2. Heater motor ( refer to Fig. 5.1-4)
(1) Remove the defroster duct from the driver’s side of the heater
assembly.
(2) Disconnect the wiring harness connector.
Fig.
5.1-2
Operation and Service Manual - FAW Jiabao Series Light Passenger Van ChapterⅤ Air-conditioner system
(3) Remove the 3 blower motor mounting screws. Check the heater hose connections, and replace the heater hoses and
(4) Remove the blower motor and fan wheel assembly. clamps as required. (refer to Fig. 5.1-6)
Fig. 5.1-5
Fig. 5.1-4
1. Wiring harness connector 2. Screw 3. Blower motor
IV. Inspection and repair

1. Speed control resistor
The resistor is mounted on the driver’s side of the heater assembly. Fig. 5.1-6
Check the resistor for cracks and damage, and replace as required. If
the blower motor does not rotate after changing the existing resistor,
the resistor must be checked for ohms resistance. (refer to Fig. 5.1-
5)
2. Heater water pipe
Section 2 Air conditioning system The customer should identify the applicable system when using this
I. Air conditioning system configuration manual. In order to help the customer better understand their new
The air conditioning system installed on both CA6350 saloon and vehicle, we will describe the air conditioning system used in vehicles
standard mini-cars with electronic fuel injection and carbureted with carbureted engines. (refer to Fig. 5.2-10)
engines is different in both composition and control.
Fig. 5.2-1 Air conditioning system configuration

1. Compressor 2. Condenser 3. Receiver dryer 4. Evaporator 5. Refrigeration pipe
The air conditioning system is composed of a compressor, condenser,

receiver dryer, evaporator, freon piping, and electric controls. The Table 5.2-1 Air conditioning compressor
CA6350’s air conditioning system utilizes environmentally friendly
R-134a refrigerant. Name Technical specifications
1. Compressor assembly: Refrigerant R-134a
The belt-driven A/C compressor is installed on the right front side of Rotation direction Clockwise
engine. The suction side of the compressor draws low pressure Allowable incline angel ±35º
refrigerant vapor through the low-side line coming from the system Discharge 96cc/r
evaporator. The compressor then compresses the refrigerant vapor and Max. continuous rotation speed 7800rpm(8400rpm)
discharges it at increased temperature and pressure through the high- Lubricant RG20
side line which connects the compressor to the condenser. The Weight 3.2kg
compressor assembly consists of three parts, the compressor body, (not including magnetic clutch)
magnetic clutch, and belt. CA6350 mini-cars utilize the Japanese SS-
96 type rotary compressor. (refer to Fig. 5.2-2 and Table 5.2-1) The A/C compressor is engine-driven, via a fan belt and electromagnetic
clutch. The electromagnetic clutch, installed on the main shaft of
compressor, includes a pulley, magnetic coil, magnetic plate and bearing
as shown in Fig. 5.2-3. When the magnet coil is electrified, a magnetic
field is produced which locks the magnetic plate and pulley together as a
single unit, thus driving the A/C compressor. When power is cut off, the
magnetic field disappears causing the magnetic plate and pulley to
separate, thus halting compressor operation. The magnetic clutch is
electrified within 0.6-1 seconds during compressor engagement. When
the compressor overloads, magnetic clutch is designed to drag as a
protective measure. The technical specifications of the magnetic clutch
are listed in Table 5.2-2.
Fig. 5.2-2 Compressor
2. Condenser assembly
The condenser is installed on the left lower side of the body. The
condenser consists of a series of coils, with inlet and outlet fittings,
surrounded by thin cooling fins. High pressure/high temperature
refrigerant vapor from the compressor enters at the top of the condenser,
circulates down through the coils, and exits at the bottom of the
condenser as high pressure/high temperature refrigerant liquid. As the
vapor condenses (changes state), heat is released to the outside air which
passes over the fin external surfaces to carry the heat away. The CA6350
mini-car utilizes a parallel flow type condenser, incorporating a DC-
motor driven fan. The heat dissipation capacity is in excess of
7000Kcal/h. (refer to Fig. 5.2-4)
Fig. 5.2-3 Electromagnetic clutch
Table 5.2-2 Electromagnetic clutch

Name Technical specifications
Rated work voltage 12V
Min. engaging voltage 7.5V
Rated power 42W Fig. 5.2-4 Condenser
Transmission torque 19.6N·m
Max. continuous rotation speed 7800r/min
Pulley O type, outer diameter 118mm
Weight 1.4kg Table 5.2-3 Condenser technical specifications
Air side capacity 7000±500Kcal/h
Air side pressure drop ≤70.0Pa
Test conditions Overheating temperature 2.5℃
Freezing temperature 5℃
Inlet pressure 1.47Mpa
Dried ball temperature 35℃
Wind speed 4.5m/s
Operation and Service Manual on FAW Jiabao Series Light Passenger Van ChapterⅤ Air-conditioner system
ChapterⅤ Air-conditioner system Operation and Service Manual on FAW Jiabao Series Light Passenger Van
3. The receiver dryer is installed under the right front seat. The plus an auxiliary evaporator on the front ceiling (refer to Fig. 5.2-7). The
receiver dryer has three functions: filter particles from the liquid evaporator is a cooling coil assembly made of fin and tube construction.
refrigerant, remove moisture from the liquid refrigerant, and store a It functions exactly in reverse of the condenser. Low pressure/low
portion of the liquid refrigerant until needed in the system evaporator temperature liquid refrigerant from the expansion valve enters the
to meet high cooling demand. For an illustration, refer to Fig. 5.2-5. evaporator as a spray. Upon entry into the evaporator the pressure is
In order to check the refrigerant level and system working condition, immediately reduced. This permits the liquid refrigerant to boil or
a sight glass is provided on the receiver dryer outlet pipe. For receiver evaporate, thereby changing its state from a liquid to a low pressure/low
dryer technical specifications, refer to Table 5.2-4. temperature vapor. Cooling and dehumidifying of the cab's interior takes
Drying agent place as the refrigerant vapor passes through the evaporator's finned
tubes and absorbs heat from the cab air forced across the evaporator by
the blowers. The refrigerant exits the evaporator outlet as a low
Refrigerant saving mode
pressure/low temperature vapor and is drawn into the suction side of the
compressor. Through the metering (controlling) action of the expansion
valve, greater or lesser amounts of refrigerant are provided in the
Fig. 5.2-5 Receiver dryer evaporator to adequately cool the vehicle. The main and auxiliary
evaporators are parallel connected with separate expansion valves. The
main evaporator utilizes the main blower while the auxiliary evaporator
has an independent blower. For evaporator technical specifications, refer
Table 5.2-4 Receiver dryer technical specifications to Table 5.2-5 and 5.2-6.
Description Capacity 445cc
Net capacity 370cc Table 5.2-5 Main evaporator technical specifications
Moisture absorption capacity MIN4kg(60℃, 90%) Refrigeration capacity 2760Kcal/h
Filtering agent Polyester Air output 240m3/h
Protection gas N2GAS Air tightness 15kg/cm2G
Intensity Air tightness 3.5Mpa(gage) Pressure resistance 22.5kg/cm2G
Pressure resistance 503Mpa(gage)
Table 5.2-6 Auxiliary evaporator technical specifications
4. Evaporator assembly Refrigeration capacity 135Kcal/h
The CA6350 series of mini-cars utilize 2 types of evaporators. Air output 225m3/h
Standard cars use a single evaporator located at the right lower Noise 60dB(A)
instrument cluster (refer to Fig. 5.2-6). Saloon car utilize a dual Power consumption 30W
evaporator system, incorporating the above “main” evaporator
5. Freon piping
All air conditioning system components are connected with refrigerant
hoses and piping. The compressor suction pipe and outlet elbow and the
induction pipe and outlet elbow of the CA6350 mini-car all use hose
connections. All other connections are hard molded piping. All possible
piping and hose contact areas utilize buffer heat shields. All piping
connectors are all o-ring sealed. The system piping is divided into high
pressure and low pressure pipes. High pressure pipes includes all pipes
from the compressor outlet to the evaporator expansion valve inlet. Low
pressure pipe includes all pipes from the evaporator outlet to the
compressor inlet. For high and low pressure piping technical
specifications, refer to Table 5.2-7 and Table 5.2-8.
Table 5.2-7 High pressure piping technical specifications
Using refrigerant R-134a
Pressure resistance 5.30Mpa(54kgf/cm2G)×5min.
Air tightness 3.53Mpa(36kgf/cm2G)×5min.
Table 5.2-8 Low pressure piping technical specifications

Using refrigerant R-134a
Pressure resistance 2.55Mpa(26kgf/cm2G)×5min.
Fig. 5.2-6 Main evaporator
Air tightness 1.67Mpa(17kgf/cm2G)×5min.
II. Air conditioning system operating principles
The CA6350 mini-car adopts a vapor compression refrigeration system.
The compressor sucks in low temperature and low pressure refrigerant
gas, which becomes high temperature and high pressure refrigerant
Fig. 5.2-7 Auxiliary evaporator vapor, then through the high pressure pipe into condenser to dissipate
heat. After condensing, it becomes high pressure liquid, entering into the
receiver dryer to store, dry, and filter. Then through the expansion valve
to change into a gas and liquid mixture.
After this vapor mixture enters the evaporator and absorbs heat, it
becomes low temperature and low pressure gas, which is sucked into
compressor to carry out another circulation. Thus, the evaporator
continually absorbs inside heat, the condenser continually dissipates
inside heat to the outer air, so as to lower the vehicle’s interior
temperature.
III. Air conditioning system adjustment and control
The air conditioning system operation can be adjusted and controlled
manually and automatically. The climate control panel is located at
the center of the instrument panel (refer to Fig. 5.2-8). The fan switch
for the overhead evaporator is located on the left side of the Fig. 5.2-9 Overhead evaporator fan switch
evaporator (refer to Fig. 5.2-9). The air conditioner switch is push button switch with a center green
lamp that illuminates when pushed in to indicate air conditioning
operation. The integral fan switch and overhead fan switch both
incorporate 3 fan speeds. When operating the air conditioner, in addition
to the aforementioned switches, you should adjust the mode selection
lever ⑤, inside / outside air lever ③, and the temperature control lever
④. The above levers should be slid to the far left side when operating
the air conditioner. The temperature control lever ④ allows for infinite
adjustment of the air temperature.
Since mini-car engines are smaller by nature, the computer and air
Fig. 5.2-8 Climate control panel conditioner amplifier control the air conditioner operation in different
operating conditions in order to improve the starting performance,
control stability, acceleration performance and idle stability. The air
conditioning system of the CA6350 mini-car with a carbureted engine is
used as an example for the following.
The carbureted CA6350 mini-car uses an air conditioner amplifier to 2. Air conditioner /fan switch control
carry out center control, while the automatic control of air conditioner Air conditioner/fan switch signal closes, automatically open vacuum
of CA6350 mini-cars with EFI engine is computer actuated. The magnetic valve, attracts and engages the magnetic clutch 0.8 second
amplifier has 7 total links of signal input, 1 piece of operating mode later, under the condition that air outlet temperature is higher than preset
selection wire and 2 pieces of switch output. Fig. 5.2-10 is the temperature, starting signal and vehicle acceleration switch signal both
electrical circuit diagram of the air conditioner. are OFF, and there is no overheating water temperature signal.
The 7 signal links are: 3. Water temperature control
a. Power supply switch control signal Water temperature gauge output low frequency pulsating voltage signal,
b. Air conditioner/fan switch signal when water temperature reaches 105℃±1.5℃(sensor impedance reaches
c. Water temperature signal 24.2 ±1.0Ω), the input water temperature control signal is overhot water
d. Air outlet temperature adjustment signal (preset temperature temperature signal. The amplifier must respond to the signal
signal) immediately, cut off the compressor magnetic clutch, keep or open
e. Evaporator air outlet temperature signal vacuum magnetic valve.
f. Engine starting signal 4. Air outlet temperature adjustment signal control
g. Vehicle acceleration switch signal There are two ports for this signal input, an adjustable potentiometer
The 2 output links are: the switch output of amplifier inner relay and with a resistance of 0-5KΩ is connected outside. When the potentiometer
the switch output of triode collector. The relay controls the on-off of is dialed on 5KΩ(max.), corresponding to temperature presetting on
the compressor magnetic clutch, and the triode controls the on-off of 15±2 ℃. When the potentiometer is dialed to 0KΩ(min.), corresponding
the vacuum magnetic valve. to temperature presetting on 3 ±0.5 ℃.
The short and open circuits of the operating mode selection wire 5. Evaporator air-out temperature signal control
express two different operating modes. CA6350 mini-car selects the Evaporator air-out temperature signal is provided by an evaporator
short circuit mode.(When the air conditioner is turned on, the vacuum negative temperature coefficient thermistor. The amplifier can logically
magnetic valve opens.) judge air outlet temperature adjustment signal and evaporator air-out
The control of 7 signal links is described as below: temperature signal. When air outlet temperature is higher than the preset
1. Power supply control temperature, the vacuum magnetic valve is opened which engages the
The power supply switch closes, switches on amplifier power, selects compressor’s magnetic clutch, vice versa, close or cut off.
the short and open circuit according to operating mode, enters two 6. Engine starting signal
different operating states, to provide the conditions for the signals This signal is a direct current signal. When the amplifier receives a
from item b to g controlling two links output action. If the power starting signal, and water temperature is not overheating, in order to
supply switch is cut off, the amplifier compressor magnetic clutch and reduce engine load, the compressor magnetic clutch is turned off (if it
vacuum magnetic valve are turned off, to stop air conditioner has been attracted and engaged) immediately, and open vacuum
operation. magnetic valve.
7. Acceleration switch signal

Acceleration switch signal is a negative logical signal, low level O 1
shows having acceleration signal. When the amplifier receives an
acceleration switch signal, it will close vacuum magnetic valve and
cut off magnetic clutch automatically, and open the vacuum magnetic 2
valve 9.2 seconds later, then engaging compressor magnetic clutch
after delaying 0.8 second. 3 6
Besides the above description, the air conditioner has relatively
independent high and low pressure protection control, for protection
of the whole system. Action is: when system low pressure is lower 4
than 0.20Mpa or higher than 3.14Mpa, the high and low pressure 7
switches cut off the system power supply automatically, thus realizing
protection. Fig. 5.2-11 is the action pressure set point for high and low
pressure switches.
Unit:
Fig. 5.2-11 Action pressure set point for high and low pressure switches
1. Refrigerant 2. Low pressure side 3. Set point
4. High pressure side 5. unit: 6. Low pressure side 7. High pressure side
Fig. 5.2-10 Air conditioner electric unit circuit diagram
1. Bimetal adjuster 2. Water thermometer 3. Water temperature gauge 4. Evaporator thermistor
5. Air conditioner control switch 6. Heater fan resistance 7. Switch 8. Acceleration stop switch
9. Acceleration stop switch 10. Timer 11. Switch 12. Starter 13. Min. 14. 15. Impendence
value of water temperature gauge 16. Delay time 17. Compression 18. Vacuum switch valve 19.
20. Adjustment
IV. Maintenance and inspection of the air conditioning system 3. Correct operation of the air conditioning system
1. Preventive maintenance of the air conditioning system In order to have maximum benefit and long life, the air conditioner must
Preventive maintenance is routine checking. If any problems are be operated properly in addition to receiving proper maintenance. Any
found, have them corrected within a reasonable amount of time. fault occurring in the air conditioning system must be corrected by a
Preventive maintenance items are as follows: trained technician. Do not remove, regulate, or replace parts by yourself
Outage check to avoid influencing the normal operation of air conditioner or system
a. Check the condenser and evaporator cooling fins for sludge and failure. When the air conditioner is not operated for extended periods,
dirt, and clean as required. such as in winter, the system should be operated once a month for 5-10
b. Make sure the air conditioner piping is not rubbing against other minutes, to circulate oil around the internal parts in the compressor.
components and check for leakage. Repair if required. 4. Qualitative detection of refrigeration performance
c. Check whether the air conditioning piping connectors and circuits Start engine, turn the fan switch on high, adjust the temperature lever to
are tight. Repair if required. MAX COOL, and press the A/C switch. After 2-3 min, carry out the
d. Check the air conditioning compressor driving belt tension. Adjust qualitative detection according to the following methods:
as required. (1) Handling detection: suction tube of compressor makes your hand feel
Start-up check cool, while the discharge tube makes hand feel hot. There should be an
a. Check whether compressor starts operation normally. If necessary, obvious temperature difference between the two tubes.
check the circuit voltage or inspect the compressor. (2) Look into the sight glass of the receiver dryer (refer to Fig. 5.2-12).
b. Check whether the amount of refrigerant in the system is correct. If The temperature of the suction tube and discharge tube should feel equal
necessary, add refrigerant. to the touch.
c. Check whether the temperature difference of the compressor inlet (3) Hand touch to compare the temperature of inflow and outflow tubes
and outlet pipes is normal (inlet pipe should be cold and outlet pipe of the condenser: the inflow tube temperature should be higher than the
should be hot). Repair as required. outflow tube. Cool air outlet has cool feel. Expansion valve front and
d. Check whether the condenser fan motor operates normally. Repair back should have an obvious temperature difference, hot in front and
as required. cold in back.
e. Check whether the air conditioning system is functioning normally. (4) Handling detection: The temperature from the condenser outflow
Repair as required. tube to the high pressure pipe and parts in front of the expansion valve
2. Regular maintenance of air conditioning system should be uniform. The pipe from the expansion outlet to the compressor
The regular maintenance of air conditioning system is generally suction inlet should be very cold but without frost.
carried out once each year. The regular maintenance should be 5. Quantitative detection of refrigeration performance
performed by factory-trained personnel. If necessary, replace faulty With an ambient temperature of 20-35℃, start the engine, press A/C
parts and refill with refrigerant. switch,
“Clear sight glass” “Bubbles in the sight glass” “Discolored streaks in the sight
glass”
There is adequate refrigerant A constant stream of bubbles Indicates dessicant breakdown in
in system, and system indicates that refrigerant is low the receiver dryer or
functioning properly. A few and needs replenishment. Also, contaminated compressor oil in
intermittent bubbles is normal there might be air in the system. the system.
when the compressor clutch “Clouded sight glass”
cycles, or during A/C Indicates dessicant breakdown in
operation at low ambient the receiver dryer that has
temperature. infiltrated the remainder of the
system.
Fig. 5.2-12 Observing refrigerant amount through the sight glass of the receiver dryer
place the fan switch max., move the temperature lever to MAX 10) When disassembling the refrigerant pipe or adding refrigerant,
COOL, open the door and operate the engine operate at 2000r/min for always keep your face away from the connections to avoid unexpected
15-20min. Then, check the pressure of the high and low pressure sides eye damage.
with high and low pressure gage. The low pressure side should be 1.7- 11) Discharge refrigerant slowly, to prevent discharging refrigerant oil.
2.1kgf/cm2 , and the high pressure side 15-21kgf/cm2 , with the 12) When adding refrigerant oil to compressor, be sure to use FAW-
pressure value varying with air temperature. Whenever the approved oil.
temperature drops 3℃ from 35℃, the pressure decrease magnitude of 13) When replacing air conditioning system parts, and it is necessary to
high pressure is 0.7-0.8kgf/cm2. supplement refrigerant oil, see Table 5.2-9 for system requirements.
6. Inspection of air conditioning system
(1) Air conditioner inspection items Table 5.2-9 System refrigerant oil requirements
1) When adding refrigerant for the second time after a new air
conditioner had been installed, first vacuumed for 5 min from the high Replaced parts Supplemented freezing Oil to be used
pressure side, then vacuumed from both the high and low pressure engine oil amount(ml)
sides. Condenser 25-30 RG20
2)When adding refrigerant, liquid refrigerant should be filled from Evaporator 15-30
high pressure end, strictly prohibit starting engine from low pressure Receiver dryer 10-20
end to fill liquid refrigerant; allow starting engine to fill gaseous Refrigerant pipe (1 piece) 5-10
refrigerant from low pressure end, but strictly prohibit opening the 14) When connecting the refrigerant piping, apply some refrigerant oil to
high pressure valve of pressure gage group. the o-ring seals.
3) In the process of filling refrigerant, never shake the refrigerant 15) When connecting the compressor suction and discharge tubes,
bottle. remove the cap slowly to prevent excessive loss of refrigerant oil.
4) DO NOT heat the refrigerant bottle in hot water of above 40℃ . 16) Be sure to install the receiver dryer, paying attention to the inlet and
5) When filling refrigerant in dry and aeration environments, avoid outlet directions.
high temperatures and fire sources. 17) When installing and removing the refrigerant pipe adaptor, two
6) DO NOT allow water, air, and other impurities to enter the
refrigerant pipes. DO NOT apply mouth blown air or compressed air open-end wrenches must be used. Tighten the adaptor fittings based on
to the refrigerant pipes. the torque specifications in Table 5.2-10.
7) When connecting the pressure manifold gauge hose, pay attention
to the correct corresponding connection of pressure manifold gauge
hose and pressure gauge group manifold valve, as well as the correct
connection of the high and low pressure gauge connectors
corresponding to the compressor inlet and outlet valves.
8) When connecting pressure manifold gauge hose or refrigerant
bottle valve, tighten the connecting nut by hand. Never use hand
tools.
9) Instrument hose must be disconnected from the compressor inlet
and outlet hose quickly and skillfully; the high pressure hose must be
disassembled after the compressor stops running (about several
minutes), and the high pressure drops.
Table 5.2-10 Adaptor torque specifications (2) Check items and check points
Joint Aluminum pipe size and Locking torque For general routine check items and check points, see Table 5.2-11.
nut size N•m(kg•cm)
Nut ф 8 tubing 12-15(120-150)
1/2″tubing 20-25(200-250)
5/8″tubing 30-35(300-350)
Strap M6 screw 4.0-7.0(40-70)
(receiver dryer, etc)
Table 5.2-11 Check items and check points
Check points
Number Check items
Check positions Check methods
Check
whether the 1. Pipe surface and all adaptor of pipe line
1. Observe after applying dense soap solution
1 refrigerant 2. Compressor oil seal, gasket and parts surface
2. Using R-134a gas leakage checking gage
has leaked 3. refrigerating system components damage positions
out
Check
Check the pipes and hoses for wear, abrasion, and
2 refrigerant Visually inspect
kinks
piping
Check
Check whether condenser fins are bent, or clogged with 1. Align bent fins with nipper
3 condenser
foreign matter 2. Carefully brush off sludge and dirt with a hairbrush
cleanness
Check steps are as follows: viewing the sight glass:
1. Verify that clear refrigerant is flowing continuously. Small bubbles appear when
Check the engine accelerates and decelerates, which indicates normal operation of the air
condition of conditioning system. Refrigerant is appropriate.
4 Observe the sight glass on the receiver dryer
the 2. If the air conditioner is turned on and off periodically, foam appearing continuously,
refrigerant indicates the refrigerant level is deficient.
3. See engine oil streaking precedence, which shows the presence of refrigerant
leakage. Refrigerant is severely deficient.
5 Check the 1.Check the temperature of inlet and outlet pipes of Visually inspect, hand touch
receiver receiver dryer, to determine whether the receiver dryer
dryer is blocked
2. Check whether expansion relief valve is damaged
3. Check whether the sight glass is cracked
4. Check the adaptors for leaks, which is indicated by
an oily appearance
Table 5.2-11 Check items and check points of air conditioning system
No. Check items Check points

Check positions Check methods
1. The temperature of the compressor high pressure side outlet, condenser, receiver dryer,
expansion valve inlet is very high, if the temperature of some sections is high and that of
other sections is low, which indicates those sections may be blocked.
Check the
2. The temperature of the expansion valve low pressure side outlet, evaporator, compressor
temperature on high
6 inlet should be from cold to cool, there should not appear frosting phenomenon on Hand touch
pressure and low
expansion valve.
pressure sides
3. There should be an obvious temperature difference between high pressure side and low
pressure side of compressor. Otherwise, this indicates refrigerant leakage and insufficient
refrigerant.
Check the
Cut the circuit on and off to check. If
electromagnetic 1. Check the presence and absence of fault in clutch coil circuit section.
7 necessary, check after the short circuit of
clutch for normal 2. Power on and power off, check whether magnetic clutch operates.
high and low pressure switches
operation
Check the 1. When compressor is running, the presence and absence of abnormal knocking.
8 compressor for 2. The temperature difference between compressor inlet and outlet is normal or abnormal. Start compressor to check
normal operation 3. Compressor vibrate severely or not.
Check the
1. Check the belt tension
9 compressor belt Hand press to check, eyes measure
2. Check the belt for abrasions and cracks.
condition
10 Check the idle lifting 1. Check the air passage connection of the idle lifting unit. Eye measure. If necessary, adjust the
unit of air conditioner 2. When checking engine’s idle operation state, turn on air conditioner and check if the adjusting screw of vacuum actuator for
engine rpm’s increase automatically. proper engine rpm at idle, after turning on
air conditioner adjust automatically to
required rpm.
Check the adherence
state of the
Check whether temperature sensing pack and evaporator outlet are adherence and thermal
11 temperature sensing Visually inspect, hands touch
insulation, protective layer is bound up firmly.
pack of expansion
valve
Check the presence
Check the presence and absence of slit on core and shell connection, whether air pipe
12 and absence of slit on Visually inspect
connection is good, has break phenomenon.
air conditioner shell
Check the connection
Check whether the connection of air conditioner circuit connector is safe. Check whether air
13 state of air Visually inspect, hand touch
conditioner circuit wire is over hot , and rotation parts and burr parts bump each other.
conditioner circuit
Check the connection
Check the condition of the air conditioner hose and discharge piping. They should be safely
14 state of air Visually inspect, hand touch
and properly routed to as to be free of damage, abrasion, and kinks.
conditioner hose
Check the blower
15 motor assy. for Check the blower motor for abnormal noises and the fan wheel for obstruction Visually inspect, listen
normal operation
(3) Inspection with compound pressure gage
Air conditioning system operation evaluation using a compound pressure gage(manifold pressure gage) (refer to Table 5.2-12)
Table 5.2-12
Measured value of compound pressure gage Fault Reasons

The pressure on high and low pressure sides is lower Refrigerant is deficient Refrigerant leakage
than specific value
The pressure on high and low pressure sides is much Refrigerant is severely deficient Serious refrigerant leakage
lower than specific value
The pressure of low pressure side is close to zero, that of Faulty expansion valve. Expansion valve jams or temperature
high pressure side is higher than specific value. sensing pack is faulty.
The pressure of high and low pressure sides is higher The air conditioning system is not cooling Refrigerant level is overfull, expansion
than specific value. adequately. valve adjustment is not proper, having air.
The pressure of high and low pressure sides is much The air conditioning system is not There is air in the air conditioning system.
higher than specific value. cooling. Bubbles infrequently appear in
the receiver fryer sight glass
The pressure of high pressure side is lower than specific The air conditioning system is not cooling The expansion valve or compressor is
value, the pressure of low pressure side is higher than damaged.
specific value,
The pressure of low pressure side is close to zero or The gas discharged from the air There is water in the refrigerant, expansion
negative value, the pressure of high pressure side is conditioning system is not cold. valve is blocked with ice.
specific value or slightly higher than that.
The pressure of low pressure side is much higher than The air conditioning system is not Condenser fan motor is damaged.
specific value, the pressure of high pressure side is cooling, low pressure pipe is hot.
slightly higher than specific value.
The pressure of low pressure side is lower than specific The air conditioning system is not cooling Receiver dryer or high pressure pipe is
value, the pressure of high pressure side is much higher adequately. High pressure pipe has frost. blocked.
than specific value.
Note: 1. the pressure of high pressure side of air conditioning system is generally (15-21kgf/cm2)
2. the pressure of low pressure side of air conditioning system is generally (1.7-2.1kgf/cm2)
Climatic conditions Density (g/cm2) at 15℃

Chapter VI Vehicle electrical system fully charged
Winter Summer
In areas where temperatures are lower 1.310 1.250
NOTE: For the ignition system, please refer to the engine manual than -40℃ in winter.
In areas where temperatures are 1.290 1.250
Section 1 Power Supply System higher than -40℃ in winter.
In areas where temperatures are 1.280 1.250
For the CA6350 series, the nominal voltage of the electrical system is higher than -30℃ in winter.
12 volts. A single wire system with negative ground is used. The In areas where temperatures are 1.270 1.240
electrical system consists of the battery, alternator, regulator and fuse higher than -20℃ in winter.
block. In areas where temperatures are 1.240 1.240
I. Battery higher than 0℃ in winter.
The battery capacity is 45Ah. When changing the battery, one of
equal capacity must be used. 3. Engine Terminal Voltage Control
(I) Normal Maintenance Engine terminal voltage should be controlled between 13.5V and 14.5V,
1. Fluid Level Adjustment and the battery should always be kept fully charged.
The battery fluid level (electrolyte) should always be 10 to 15 mm 4. Proper Starter Operation
higher than the top edge of the battery plates. Fluid level below the The starter should not be operated in excess of 5 seconds each time, and
top of the plates is not permissible. When the fluid level is low, time interval between uses should exceed 15 seconds.
distilled water should be added to return the level to normal. 5. Keeping the Battery Terminals Clean
2. Electrolyte Density Selection Battery terminals and connections should be cleaned periodically to
Appropriate electrolyte density should be selected according to ensure good connection.
changes in seasons and climatic conditions. See the following table: 6. The battery should be stored in a suitable environment. If stored for
more than one month, the battery should be recharged every month.
7. During use, air should flow smoothly across the ventilation hole in the
battery fill cap.
Operation and Service Manual - FAW Jiabao Series Light Passenger Van Chapter VI Vehicle electrical system
Chapter VI Vehicle electrical system Operation and Service Manual - FAW Jiabao Series Light Passenger Van
(II) Trouble Shooting 2. Self-discharge

1. Sulfation of Pole Plate Self-discharge refers to the automatic capacity loss of a fully charged
Sulfation is the formation or deposit of lead sulfate on the surface and battery when not in service. Batteries with a self-discharge function
in the pores of the active material of the batteries' lead plates. If the should be replaced on time.
sulfation becomes excessive and forms large crystals on the plates, the
battery will not operate efficiently and may not work at all. Common 3. Short Circuit of Pole Plate
causes of battery sulfation are standing a long time in a discharged When the pole plate is short-circuited, active material of pole plate will
condition, operating at excessive temperatures, and prolonged under fall off in large amount, which is featured by turbid electrolyte, brown
or over charging. If serious, the battery cannot be used any more. material floating up from bottom, and low battery. In this situation, the
Charging with a quick charger can effectively remove sulfation. battery may continue to be used after the sediment assuming the
sediment amount is minimal. Otherwise, the pole plate should be
replaced.
NOTE:
Note the following when disassembling or replacing the battery:
● Protect the battery from fire.
● Prevent the battery electrolyte from spilling.
● When removing the battery, first disconnect the negative wire, and
then the positive wire.
● After reinstalling the battery, the battery cable connection should be
tightly fastened.
I. Alternator
(I) Structure
Alternators can be classified into two types, those with built-in
regulators and those with external regulators. Both types of alternators
function in the same manner. Figure 6.1-1 represents an alternator with a
Figure 6.1-1 Alternator built-in regulator, and normally this alternator is maintenance free.
1. Rotor 2. Stator 3. IC regulator 4. Rectifier (II) For principles of operation, see Figure 6.1-2.
5. Electrical brush 6. Pulley
(III) Parameters
Model JF132 JF158 JFZ162-2 JFZ162-1

JF138
Normal working voltage 12 volt
Max current output 35 amps 50 amps
Polarity Negative ground
Built of regulator external external
Effective diameter of pulley φ65mm φ58mm φ58.5mm
Idle rotation speed 1200r/min
Adjustable voltage 13.8—14.8V 14.5±0.3V
Rotation direction Clockwise viewed from pulley side
Max allowable rotation speed 13000r/min 15000r/min
Commutation mode Full wave commutation
1. Alternator (built-in regulator) 2. IC regulator 3. Stator coil 4. Diode
5 Three groups of diode 6. Magnetic field coil (rotor coil)
7. Indicator lamp for charge 8. Main switch 9. Battery
Figure 6.1-2 Alternator Working Principle
(IV) Trouble Shooting

NOTE:
● Never mix up the polarity of Terminal IG and Terminal L.
● Prevent short-circuits from being formed between Terminal IG and
Terminal L.
● Never connect Terminal I to Terminal E with any lead.
1. Alternator-related engine noises Voltmeter connected between motor (B) terminal
Loose drive belt, loose mounting bolts, worn or dirty bearings, or bad and ground
diode or stator will all create abnormal engine noises.
2. Charge indicator lamp malfunction
Trouble Possible cause Therapy Figure 6.1-3
Charge indicator Fuse is blown. Check fuse and bulb 1. Alternator 2. Ammeter 3. Voltmeter 4. Battery 5. Load 6. Switch
lamp does not give Bulb is blown. – replace as

turn on when the Connection wire is required. (2) Turn off all the power-consuming accessories (ie, wipers, radio/tape
ignition switch is loose. Tighten the loose player), increase the engine speed from idle to 2000rpm, and read the
turned ON and the IC regulator or connection wire. value indicated on the meter. In this case, the standard current is 10A
engine is not magnetic field coil is Repair or replace. max, and the standard voltage is 14.4—15V (at 20℃).
running. bad. (3) If the voltage exceeds the standard value, check the grounding of the
Charge indicator Drive belt is loose or Adjust or replace the brushes. If the brush is properly grounded, the IC regulator should be
lamp will not turn worn. drive belt. replaced.
off when the engine The IC regulator or Check the power (4) If the voltage is equal to the standard value when the engine is
is running (Battery alternator is faulty. supply system. running at 2000rpm, turn on the high beam headlamp and check the
requires frequent There is a faulty current. If it is lower than 20A, the alternator should be repaired.
charging.) wire connection. Check the wire. 4. When the battery is over-charged.
If the alternator needs checking when battery is over-charged, run the
3. Insufficient charging. engine at 2000rpm and check the voltage. If the measured value varies
When battery cannot be sufficiently charged, check the alternator as from the standard value, checking the grounding of the brush or the IC
follows: regulator.
(1) Connect a voltmeter and ammeter as per Figure 6.1-3. The battery (V) Disassembly, Inspection, and Reassembly
used here should be sufficiently charged.
1. Disassembly (3) Remove the alternator drive belt adjusting bolt, and alternator
(1) Disconnect the negative battery cable from the battery. mounting bolts.
(2) Disconnect the connection wire to the alternator. (4) Disassembling the alternator.
2. Disassembly (refer to Figure 6.1-4)
(1) For reassembly convenience, make matching marks as shown in
Figure 6.1-5 before separating the front and rear cases.
Figure 6.1-4
1. Pulley 2. Front case 3. Bearing 4. Guard 5. Rotor 6. Stator 7. IC regulator 8. Rectifier 9. Rear case 10. Brush
(2) Remove the case mounting bolts from the alternator. See Figure
6.1-6.
Marks
Figure 6.1-5
1. Front case 2. Rear case
Figure 6.1-6
(3) Insert a stick in between stator core and front case, to separate the Figure 6.1-7
front and rear cases. See Figure 6.1-7. 1. Rear casing 2. Stator 3. Front casing 4. Stick
(4) Loosen the pulley nuts with a vice and remove the pulley. See Figure
6.1-8.
Using a vice, put a piece of clean cloth between the rotor and chop in
order not to damage the rotor.
Figure 6.1-9
1. Front case 2. Guard screw
(7) When disassembling the rear case, please use a hydraulic press. See
Figure 6.1-10.
Figure 6.1-8
1. Pulley nut 2. Rotor 3. Cloth 4. Vice
Figure 6.1-10
(5) Remove the rotor from the front case and separation ring. 1. Rear bearing 2. Hydraulic press 3. General push-brace 4. General tool
(6) When removing the front bearing, the bearing guard screw and the
guard should be removed. See Fig. 6.1-9. (8) Move the stator slightly away from the rear case, loosen the three
screws and battery terminal screws, and then remove the rotor, regulator,
and rectifier assembly. See Figure 6.1-11.
Figure 6.1-11
1. Screw 2. Battery terminal screw
(9) Use a commercial soldering iron (over 180W) to separate the weld
between the regulator and rectifier assembly. Disconnect the stator
lead. See Figure 6.1-12.
Figure 6.1-13
Figure 6.1-12
(10) To remove the brush, first disassemble the brush support cover as Figure 6.1-14
shown in Figure 6.1-13. Then separate the weld with a soldering iron. 1. Searing iron 2. Brush support
Remove the brush support cover and pull out the brush. See Figure
6.1-14 and Figure 6.1-15.
Figure 6.1-15
1. Brush Figure 6.1-16
1. Rectifier 2. Diode lead 3. Three groups of diode
3. Inspection
(1) Check the fan belt’s tension and condition. (4) Check the brush and brush support.
(2) Check the rotor. The standard brush length is 16 mm with a minimum length of 2 mm. If
Use an ohmmeter to check each slip ring of the rotor for conductivity. it has been worn to the minimum service length, the brush should be
If the rotor lacks conductivity, replace the rotor. replaced.
Use an ohmmeter to check the conductivity between the slip ring and (5) Check the rectifier.
the rotor. If the rotor has conductivity, replace the rotor. As shown in Figure 6.1-16, use an ohmmeter to check the conductivity
Check the slip ring surface for roughness and scratches. If it is rough between all rectification diodes and each diode lead. Connect the
or scratched, replace the rotor. ohmmeter test pins in reserve to check two directions. Under either
(3) Check the stator. circumstance, conductivity should only exist in one direction. Otherwise,
Use an ohmmeter to check the conductivity of all leads. If the stator is the rectifier should be replaced.
not conducting, replace the stator.
Use an ohmmeter to check the conductivity between core lead and
stator core. If the stator is conducting, replace the stator.
Use the same method and steps as above to check the conductivity NOTE:
between each lead of three groups of diode. Conductivity should only ● The position of wire connection must be correct.
exist in one direction. ● Make sure that the regulator ground pole conforms to that vehicle.
(6) Check the capacitor. ● To avoid damaging the triode during use, never cut off the loading
Measure the capacitance with a capacitance meter. The standard current suddenly while the rated power is being produced.
capacitance value is 0.5 MF. Replace the capacitor if the test result is ● When soldering the transistor, perform quick and accurate
incorrect. workmanship. The power of the soldering gun can not exceed 25W.
4. Reassembly ● Alternator voltage should not be adjusted to an excessively high level.
The order for assembly is the reverse of sequence of disassembly. ● When a transistor type regulator is connected to the alternator, be
Note the following requirements: careful not to ground and therefore short circuit the wires.
(1) Check the installation direction of the brush for correctness. IV. Protective Fuse
(2) Tighten the alternator pulley nut to the specified torque (60—75 The battery cable assembly which attaches to the positive battery
N•m). terminal includes a lead type fuse 80 mm in length, 30A in rated current,
(3) Insert the brush into the brush support. Temporarily insert a metal and 0.85 mm2 in cross sectional area. This fuse protects the power supply
wire through the hole in the rear case to hold the brush. After heating circuit and other high current circuits. If a short circuit occurs in the
the bearing pedestal of the rear casing to 50—60 ℃, insert the rotor power supply or other high current circuits, the fusible wire will quickly
into the rear case. After installation of the rotor, remove the metal blow to protect the system. Whenever the fusible cable blows, the cause
wire and the alignment marks on the front and rear cases. must be identified and corrected. The blown cable must then be replaced
After reassembling the alternator, check the rotor for smooth rotation. with one of the specification. Do not substitute.
III. Regulator For CA6350 series vehicles and CA6350E EFI series vehicles, a 14-
If the vehicle is equipped with a transistor type regulator (external route protective fuse box is utilized. On the protective fuse box cover,
regulator), please pay attention to the regulator function. the main circuit and power-consuming equipment protected by the fuses
(I) If the regulator has adjusted the voltage to an excessively high are indicated. When a fuse is blown, the melted fusible wire can be
level: easily seen. When replacing a fuse, the related switch must be turned off.
(1) Electrical equipment will be damaged. Then, install a new fuse of the same specification.
(2) The service life of the battery and distributor contacts will be
severely shortened.
(3) Battery electrolyte will be consumed excessively.
(ii) If the regulator has adjusted the voltage to an excessively low
level:
(1) Battery will often be charged insufficiently, leading to sulfation of
plates.
(2) The vehicle will be difficult to start.
Whenever trouble occurs to the regulator, or adjustment and
maintenance is required, have it check and serviced by a factory-
trained technician.
For fuse box cover of CA6350 series carbureted vehicles, see Fig. V. Relay Socket
6.1-17.
For fuse box cover of CA6350E series EFI vehicles, see Fig. 6.1-18.
Headlamp Headlamp Brake Interior Instrument Left Right Headlamp Headlamp Brake Interior Instrument Left Right
(high (low lamp lighting combination combination (high (low lamp lighting combination combination
beam) beam) Fog lamp lamp beam) beam) Fog lamp lamp
lamp lamp
Instrument Heater Wiper Turn signal Warning Radio and Instrument Heater Wiper Turn signal Warning Radio and
Ignition Washer lamp lamp tape player Ignition Washer lamp lamp tape player
system Reverse Horn system Positions of relays in the relayReverse
socket are Hornshown in Figure 6.1-19.
lamp lamp
Headlamp Warning Interior Electronic ECM Electronic Fuel
Figure 6.1-17 Fuse box cover of carburetor vehicle lamp lamp Figure 6.1-19
injector Relay socket
Computer injector and pump
Horn Fog Main AC relay Oil
Brake lamp relay nozzle
Instrument Heater Turn Wiper Instrument License Radio
Ignition AC signal Washer lighting plate lamp and
Figure 6.1-18 Fuse box cover of electronic injection vehicle system lamp Front Rear tape
Reverse combination combination player
lamp lamp lamp
Section 2 Starting System

I. Starting System Circuit II. Starting Motor
The starting system consists of the battery, starting motor, ignition
switch, and related electrical wires. See Figure 6.2-1 for circuit
diagram.
9
3 4
2
1 10
11
7 8
Figure 6.2-1
1. Core 2. Detention coil 3. Traction coil 4. Electromagnetic switch 5. Electromagnetic switch contact 6. Pinion driving lever
7. Pinion and overspeed clutch 8. Starting motor 9. To distributor 10. Main switch 11. Battery
(I) See Figure 6.2-2 for structure.
Figure 6.2-2
1. Driving mechanism cover 2. Driving mechanism bushing 3. Driving mechanism case 4. Armature ring 5. Armature stopping ring 6. Overspeed clutch
7. Pinion driving lever 8. Switch cover 9. Brush switch 10. Rectifier end casing 11. Brush spring 12. Brush support 13. End cover seal 14. Armature braking spring
15 Armature panel 16. Rectifier end cover 17. Rectifier end lining 18. Brush 19. Starting motor yoke 20. Armature
(II) Parameters 6. Remove the armature.

Model QD1226 QD121A 7. Remove the overspeed clutch.
Output power 12V 0.8KW 8. Remove the brush from the brush support.
Rotation direction Counterclockwise viewed from (V) Inspection
pinion side 1. Inspect the armature.
Brush length 19≥L≥12mm (1) Check the armature for contamination or burning out. A piece of
Number of teeth of pinion 8 sandpaper or lathe can be used as shown in Figure 6.2-3.
Features of idling When U=11V, I＜50A, n＞5000r/min
Features of loading When U=9.5V and M=6.86N·m, I ＜
270A and n＞1200r/min
Operation voltage of Initial intake voltage≤8V, discharge
electromagnetic switch voltage≤4.5V
(III) Removal and Installation

Disassembly procedure:
1. Disconnect the negative battery cable from the battery.
2. Disconnect all connection wires from the starter terminal posts.
3. Remove the two starter mounting bolts.
4. Remove the starter.
Reinstall the starter in the reverse sequence if removal.
Figure 6.2-3
(IV) Disassembly
1. Disconnect the wire from the electromagnetic switch.
2. Remove the electromagnetic switch assembly. Lift up on one side Grade 300—400 sandpaper
of the terminal post to make the core carrying hook come out of
driving lever. If the electromagnetic switch is faulty, replace the whole (2) Check the armature for uneven friction. If the armature shaft is bent,
assembly. it must be replaced. If the shaft is not bent, check the non-roundness of
3. Disassemble the rectifier end cover casing, armature panel and the armature as shown in Figure 6.2-4. If the deflection indicated by the
spring. dial indicator gauge exceeds the limit, repair or replace it.
4. Loosen the two bolts and remove the rectifier end casing.
5. Remove the brush together with the motor yoke.
Inspection of armature Standard Minimum Mica insulator

non-roundness Under 0.05 mm 0.4 mm 0.5—0.8 mm
(0.0196—0.0314 inch)
Correct
Figure 6.2-4
(3) Check the outer surface of armature for wear. If the outer diameter Incorrect
is under the minimum dimension, replace the armature. Figure 6.2-5
Outer diameter of Standard Minimum Check the conductivity between the brush and case surface. As shown in
collector 28 mm 27 mm Figure 6.2-6, if it is not conducting, (i.e. there is an open circuit in the
magnetic field coil), the magnetic field coil must be replaced.
(4) Inspect the depth of mica on the armature. As shown in Figure 6.2-
5, if the depth is under the minimum dimension, replace it.
(5) Ground test: Check the conductivity between the armature and
armature coil core. The armature must be replace if the test is positive.
(6) Open circuit test: Check the conductivity between the armature
chips. If any tested point is not conducting (i.e. there is an open circuit
phenomenon), the armature must be replaced.
2. Inspect the magnetic field coil.
Figure 6.2-6
3. Check the brush. 5. Inspect the driving lever.

Measure the length of every brush to check whether the brush is worn. Check the driving lever and spring for wear. Replace as required.
If the measured length is under the limit value, the brush must be 6. Inspect the pinion.
replaced. (1) Check the pinion for wear, damage or any other abnormalities. Make
sure the clutch is able to lock while rotating in the driving direction, and
Brush length Standard Limit rotate flexibly in the reverse direction. Replace as required.
16 mm 10.5 mm (2) Push the core inwardly and release it. The core should quickly return
to the initial position. If the reaction is delayed, replace it.
4. Check the brush support and spring. (3) Traction coil open circuit test: Check the conductivity between
(1) Check the brush for looseness within the brush support. If the electromagnetic switch terminals S and M. Replace if it not conducting.
brush is not flexible, check the brush support for deformation or (4) Detention coil open circuit test: Check the conductivity between
surface contamination, and repair or replace as required. electromagnetic switch terminal S coil casings. Replace if it is not
(2) Check the conductivity between the brush support positive conducting.
terminal (insulation end) and negative terminal (grounded end). If it is (VI) Performance test
conducting, the brush support must be replaced. NOTE: These performance tests must be completed within 3 to 5
(3) Check the brush spring for wearing or damage. As shown in seconds, otherwise the coil will burn out.
Figure 6.2-7, replace it if it is faulty. 1. Traction test: Connect the battery and electromagnetic switch as
shown in Figure 6.2-8. At this time, the insertion stick type core should
Brush spring tension Standard Limit be pushed outward. Replace the electromagnetic switch if the core
1.6 kg 1.0 kg remains unmoved.
2. Detention test: Under the status that the core is stretched outward,
connect the lead as shown in Figure 6.2-9, and then disassemble the
negative lead from binding post M. At this time, check if the core is
detained outside. If the core is pushed inward, replace the
electromagnetic switch.
Figure 6.2-7
3. Coil return: Disconnect the negative lead from the electromagnetic

switch, and check if core has retracted. If the core does not retract, the
electromagnetic switch should be replaced.
4. Performance test: As shown in Figure 9.2-9, connect the magnetic
field coil wire to terminal M, and connect a battery and ammeter to the
starter. Check the starter for smooth rotation and the pinion for even
movement. At this time, check if the ammeter displays the specified
current. The specified current value is under 50 A at 11V.
Battery Disconnect the Section III. Electronic Injector Code Anti-theft System
magnetic field coil lead from
terminal M before inspection. The electronic injector code anti-theft system introduced in this section
Figure 6.2-8 is available on vehicles equipped with EFI engines. If your EFI vehicle
is equipped with this system, please pay attention to the details in this
section.
I. Electronic Injector Code Anti-theft System
1. This system consists of three parts: anti-theft controller, reading and
writing coil, and code key.
(1) Anti-theft controller
The anti-theft controller, an electronic control module controlled by a
micro-computer, reads the code in the code transponder when the vehicle
is being started, checks the code for correctness, and then according to
this code controls the working status of engine electronic injection
controller, so as to perform the function of anti-theft.
Figure 6.2-9
(3) Code key

A code key is an ignition key whose handle is equipped with a code
transponder inside. Each code anti-theft unit is equipped with two code
keys, one of which is red and the other black. The red key is the main
key which should be the first one to act during antitheft unit imitating the
key operation. The code transponder inside the code key is a precision
electronic product; a tiny microprocessor chip and a mini magnetic core
antenna are sealed inside a glass tube. Its operation is driven by a weak
wireless magnetic field to perform code exchanging with the anti-theft
controller. Its code combinations can be up to 2x10 28 kinds (96 digit
binary number), which assures that every key is different.
Figure 6.3-1 Anti-theft controller 2. Interface of anti-theft controller. (See Figure 6.3-4.)
(2) Reading and writing coil

The reading and writing coil is a hollow ring mounted on the ignition
key cylinder. It is connected by wire to the socket of the anti-theft
controller. Controlled by the anti-theft controller, this coil can Battery
generate a high-frequency electromagnetic field around the ignition
key cylinder, and receive a weak signal sent by code transponder, the
signal then being being processed by the anti-theft controller.
Figure 6.3-4
Figure 6.3-2 Reading and writing coil Figure 6.3-2 Code transponder
3. Definition of anti-theft controller socket and terminal (See Figure When the ignition switch is turned off, the anti-theft unit will engage
6.3-5.) automatically. The LED indicator will flash once every 2.5 seconds to as
a warning.
2. Disengaging the anti-theft system
With the anti-theft system engaged, insert and turn the ignition key to the
B A ON position. The anti-theft controller will begin to read the transponder
code in the code key. On receipt of the request from the electronic
B1…B8
A1…A3 injector controller, it will send the transponder code to the electronic
injector controller. If the code is correct, the anti-theft unit will
disengage and allow the engine to start. When it cannot read the
transponder code or when the code is incorrect, it will send a special
error code to the electronic injector controller, in which case the engine
will not start.
B1 LED indicator lamp A1 Positive pole of reading and writing
coil
B2 Ground A2 vacant
B3 Ignition switch input A3 Reading and writing coil ground
B4 Positive pole of battery
B5 Diagnosis interface
B6 Communication request line
B7 Vacant
B8 Code data line
Figure 6.3-5
II. Working Principle
The main component of the electronic injector code anti-theft system
is the anti-theft controller. The controller reads and check the code in
the code transponder through a reading and writing coil magnetic
field, and also performs code communication with the engine
electronic injector controller, controlling the working status of the Figure 6.3-6
electronic injector controller after inspection of the code transponder,
thus allowing or prohibiting engine starting as a anti-theft device.
1. Engaging the anti-theft system
III. Key Imitating Process NOTE: The ability of the anti-theft system to program a replacement key
An anti-theft controller has two possible conditions—non- (black) depends on the vehicle owner’s retaining the “red key.” With the
programmed and programmed. It is not programmed at delivery, “red key”, the dealer can program a new “black key” to match the
having not matched the code key with the electronic injector vehicle. However,, if the red key is lost, a replacement “black key” can
controller, so in this case any code key can start the engine. After key not be prepared.
has been programmed to the vehicle assembly line, the anti-theft unit For key duplication procedures, see Figure 6.3—7.
enters the program, checks the key code, and allows the vehicle to
start if the information is correct.
Ignition switch on, ton＜2 sec., use the “red key.”
LED on, toff=ton; the engine starting is allowed.
Ignition switch off, toff＜10 sec. LED off; the anti-theft ECU enters sleep mode.
I Ignition switch on, ton＜2 sec.,
use the “black key ” or the “red key.” LED off, toff=ton; the engine starting is prohibited.
Is it the “red key?”
Ignition switch off, toff＜10 sec. LED flashes. tflash=toff, fflash=10Hz
Finish LED on, ton=2 sec.
Figure 6.3-7 “Red key” key duplication procedure chart
1. Insert the red key, turn on the ignition switch, and turn it off within When the two controllers are connected for the first time, both will use a
2 seconds. special request and answer code to verify their non-programmed status,
2. Remove the red key and insert the black one. Turn on the ignition and allow engine starting. After programming, the anti-theft unit can
switch within 10 seconds and turn it off again within 2 seconds. program a new key. The “red key” is programmed first, as its code
3. Now it flashes at 10 Hz to indicate that the antitheft controller is in contains the code by which the anti-theft controller contacts the
the programming mode. electronic injector controller. After key programming, all key codes will
4. Insert the red key again, turn on the ignition switch within 10 be stored inside the anti-theft controller.
seconds, and turn it off again within 2 seconds. 2. New anti-theft controller+old electronic injector controller
The programming operation is now complete. The LED indicator When a new anti-theft controller is connected with an old electronic
lamp will turn on for 2 seconds, indicating that both keys are recorded injector controller, the existing “red key” should be used to put the new
into the anti-theft unit. anti-theft controller into key programming status, and complete the key
Remark: The programming process will be terminated under the any programming procedure. Afterward, the new anti-theft controller will be
of the following conditions: the programming interval of the two keys able to communicate with the old electronic injector controller correctly.
is over 10 seconds; the same key is inserted twice; the red key is not The engine can be started with the existing keys.
used to finish the programming process; the ignition key is on for 3. Old anti-theft controller+new electronic injector controller
more than 2 seconds; when the ignition switch is turned on, the code When an old anti-theft controller is connected with a new electronic
key is not used. In this case, the anti-theft controller will default to the injector controller, the new electronic injector controller will store the
previous system status (programmed or non-programmed). first “legal” anti-theft code received into the read-only unit, and allow
IV. Advantages of the Electronic Injector Code Antitheft System engine starting. The “legal” anti-theft code refers to the existing code in
The Electronic Injector Code Antitheft Unit engages when the vehicle the “red key” stored in the old anti-theft controller. Only when a legal
electrical system is off. It prohibits the vehicle from being started. key is used, will the old anti-theft controller send this code. Otherwise
This “passive” antitheft system is the most effective antitheft strategy. the old anti-theft controller will send improper key information, and the
The system minimizes false alarms. new electronic injector controller will prohibit engine starting.
V. Replacement of Electronic Parts 4. Old anti-theft controller+old electronic injector controller
If the key is lost or the antitheft controller or electronic injector An old electronic injector controller cannot imitate the code of an old
controller has been replaced, the owner should prepare have another anti-theft controller. When these two controllers are connected, the
key prepared at the dealer. The details are as follows: engine can not start.
1. New anti-theft controller+new electronic injector controller 5. Ignition switch and mechanical key replacement
When replacing the ignition switch key cylinder, the code transponder in
the original key must be taken out and put into the new red key (for
future programming). Only the transponder of the original red key can
make the anti-theft controller enter programming status.
VI. Anti-theft Unit Diagnosis
A anti-theft system LED indicator lamp indicates the condition of the
system. The LED indicator lamp is located in the instrument cluster.
When a fault is detected by the anti-theft controller, the indicator lamp
will flash after ignition.
Trouble Code Section IV. Electrical and Accessories

LED always on The anti-theft controller and I. Parameter of Power-consuming Equipments
electronic injector controller Circuit system: 12V, single line system, negative ground
do not match. Spark plug F6TC
LED on for 2 seconds Common status: The code Headlamp LQ12-60/50
key is recognized by the anti- Turn signal lamp 21W
theft unit, and the engine can Side turn signal lamp 5W
be started. Brake lamp 21W
LED flashing for 30 seconds at 0.5Hz Faulty electronic injector Tail lamp 5W
controller License plat lamp 5W
LED flashing for 30 seconds at 2Hz Faulty anti-theft system Reverse lamp 21W
which may have been caused Interior lamp QT12-5SV
by wrong code of code key, Front small lamp 5W
defective reading and writing Instrument lamp 3W、4W
coil, or defective anti-theft Front fog lamp LQ12-55
controller Rear fog lamp QT-12-21
LED always off Ignition has been completed, Wire section area is 0.85mm2
and the vehicle can be Fusible wire
started. Rated current is 30A.
LED flashing once every 2.5 seconds The anti-theft unit has Fuse 14-route fuse box
entered alertness status. Speed meter Mechanical cable-driven

Odometer Mechanical
Programming process Coolant sensor Electromagnetic

Fuel sender Electromagnetic
LED flashing at 10Hz for at most 10 The programming process
Alternator Max current output; 35A, 50A, 65A
seconds has been started by the red
key.
LED on for 2 seconds The programming process
has been successfully
completed by the red key.
LED off for at most 2 seconds The programming process:
The code key is detected, but
the programming process has
not been completed, and the
next key is expected.
LED flashing for 5 seconds at 2Hz The programming process
has been terminated because
too much time was spent or
the same key was repeated.
Regulator Transistor type (internal type) III. Wiper Intermittent Relay

Starter Output capacity: 0.8KW For wiring position and internal principle of wiper intermittent relay, see
Flasher relay 140W Figure 6.4-2.
Headlamp relay Rated current: 25A For CA6350E series EFI vehicles, the wiper intermittent relay is located
Horn Rated current: 4A inside the combination switch. Its principle is the same as that in Figure
Radio and tape player AM/FM stereo, auto reverse 6.4-2.
AM/FM stereo, manual reverse
AM/FM, manual reverse
AM, manual reverse
Speaker 5W, 4Ω
Antenna Hidden-type telescopic antenna
II. Flasher Relay
For flasher relay wiring, see Figure 6.4-1.
Figure 6.4-2
Figure 6.4-1
IV. Headlamp Relay V. Windshield Wiper and Washer

For wiring position and internal principle, see Figure 6.4-3.
(I) Windshield wiper
1. Structure
The wiper consists of motor (1), pivot linkage (2), and arm/blade assy.
(3). See Figure 6.4-4.
Figure 6.4-3 Figure 6.4-4 Power Wiper
1. Motor 2. Pivot linkage 3. Arm/blade 4. Motor mtg. bracket
2. Wiper operation (1) Whether the knob of driving mechanism is apart, or the nut of wiper
arm and blade shaft is loose
(2) When there is abnormality at wiper stopping or starting, check the
crankshaft linkage for alignment. Adjust it if not aligned.
(3) Whether the blade or rubber strip is partly damaged or come off.
(II) Windshield Washer
Windshield washer
1. Structure
The windshield washer mainly consists of washer reservoir (1), motor
Figure 6.4-5 pump (2), nozzle (3), and hose (4). See Figure 6.4-6. The washer
reservoir capacity is 1.5L.
The rotary-type wiper switch located on the right handle of the
combination switch has four positions (See Figure 6.4-5). In the OFF
position, the wiper is turned off. In the intermittent position, the wiper
motor operates intermittently at 4-second cycles for light rain
conditions. In the LO position, the wiper motor operates at low speed.
In the HI position, the wiper motor operates at high speed. During
operation, a driver should not try to go directly from OFF to HI, but
rather go from OFF to LO, pausing momentarily, and then to HI, so as
to decrease the impact on electrical parts and linkage. Likewise, the
driver should go from HI to LO, pausing momentarily, before going to
OFF.
NOTE: The vehicle is negative ground. Pay attention to the
connection plug direction while disassembling and reassembling. No
special maintenance is required for the motor. If necessary, the
internal parts may be cleaned and the grease can be changed (high-
temperature lithium NLGI#2 grease).
3. Troubleshooting Figure 6.4-6 Windshield washer
1. Washer reservoir 2. Pump 3. Nozzle 4. Hose
2. Windshield washer fluid

During the summer, add an adequate quantity of rust inhibitor and
detergent into 205ppm water. During winter, a proper quantity of
methanol or glycol should also be added.
Ingredient of mixture Proportion Application
Glycol 50% Temperature Volumetric thickness
Rust preventive and 2% Over 0℃ 5%
detergent ～-8 ℃ 20%
Rust preventive 48% ～-20℃ 35%
～under-20℃ 50%
3. Windshield washer operation

Figure 6.4-7
The windshield washer switch is located within the right handle of the
1. Motor 2. Wiper arm 3. Blade 4. Motor mtg. bracket
combination switch. Lifting up the handle will activate the washer
pump, causing fluid to spray from the nozzle. After releasing the
lever, the pump will stop.
VI. Rear Window Wiper and Washer
NOTE: One spray should not exceed 5 seconds, and the interval
(I) Rear Window Wiper
between sprays should exceed 25 seconds. Connect the wiring
(1) For illustration, see Figure 6.4-7.
connection properly during installation.
(2) Rear window wiper operation
The rear wiper and washer switch is located on the instrument panel, as
shown in Figure 6.4-8. When wiper switch is depressed, the rear wiper
will be engage. After pressing the switch again, the wiper will disengage
and park the wiper arm.
(2) Rear window washer operation
Wiper switch label (white)
Press the washer knob on the rear wiper and washer switch to engage the
pump and spray washer fluid from the nozzle. When released, the pump
will stop.
NOTE: One spray should not exceed 5 seconds, and interval between
two sprays should not exceed 25 seconds.
Washer switch label (white) VII. Rear Window Defroster
(I) Working principle of the rear window defroster
A defroster is equipped on the rear window glass to help remove frost
and fog that may accumulate during the winter. A rear defroster is an
electric grill embedded into the glass. It is composed of a pair of parallel
Figure 6.4-8 argentiferous ceramic wires with a connector on both sides of the glass
(II) Rear Window Washer Connecting ignition switch
that have welded-on insertion chips. One chip is for the power supply
(1) For illustration, see Figure 6.4-9. and the other for grounding. See Figure 6.4-10.
Defroster switch mark (white)
Connecting battery
Indicator lamp
Figure 6.4-10
1. Rear defroster switch 2. Defroster relay 3. Rear window glass
4. Indicator lamp 5. Fuse 6. Fuse 7. Defroster heating wire
(II) Rear Window Defroster Operation
The rear window defroster switch is located on the instrument panel, as
Figure 6.4-9 shown in Fig. 6.4-10. When the defroster switch is pressed, the indicator
1. Washer reservoir 2. Rear washer pump 3. Nozzle 4. Water pipe lamp is turns on to indicate the defroster is on. The defroster wire
connector 5. Front washer pump consumes substantial electricity during operation, so the defroster should
NOTE: The rear washer and the front washer share a common tank be turned off after 10 minutes of operation. After melting the frost
but utilize separate pumps. completely, use the defroster at 5 minute intervals for routine defogging.
(III) Defroster Testing and Service

The rear window defroster wire is very thin and small, so use a soft
cloth when cleaning the rear window glass. If the defroster is not
functioning properly, examine and repair according to the following
possible reasons:
(1) The defroster fuse is blown.

(2) The defroster relay is faulty.
(3) The defroster switch is faulty.
(4) The defroster wire is damaged.
(5) The defrosting device circuit or ground is faulty.
VIII. Power Window Regulator and Central Door Lock System Figure 6.4-11 Power window regulator
(Luxury model) 1. Glass installation channel panel 2. Driven arm 3. Driving arm 4.
(I) Power Window Regulator Bracket 5. Balance spring 6. Motor 7. Segment gear
1. For illustration, see Figures 6.4-11 and 6.4-12.
2. Operation of the power window regulator
There are two buttons on the left front inner door panel to raise and
lower the left and right front windows. There is a button on the front
right inner door panel for regulation of the front right window only.
Figure 6.4-12 Motor transmission
1. Permanent magnet 2. Worm wheel 3. Segment gear 4. Pinion 5.
Worm 6. Rubber coupling 7. Motor rotor
3. Power window regulator failure
Failure Cause Remedy
Window glass can only Check for an open circuit in the control Repair
move in one direction. wire between the sub-switch and main
switch.
Window glass will not (1) Motor failure. Repair or change
move in either (2) Check the wire between the sub-switch Repair
direction. and motor.
(II) Central Control Door Lock System (Luxury model)

1. Functions of central door control system
1). When the front left door is locked by the driver, the other doors are
automatically locked at the same time rather than having to lock each
one of them individually.
2). Unlocking the front left door has the exact opposite effect.
3). For convenience, each door can still be manually locked and
unlocked.
2. For illustration, see Figure 6.4-13.
Figure 6.4-13 Central door lock linkage control mechanism
1. Outer door lock handle to door lock linkage 2. Key cylinder to door
lock linkage 3. Door lock assembly 4. Door lock motor 5. Motor to
door lock linkage 6. Key cylinder positioning bracket 7. Washer 8.
Key cylinder 9. Outer door lock handle
Troubleshooting
Appendix
Fault Reasons Remedy
Difficult starting Starter will not activate
1. Fuse is loose or blown. Replace
2. Contact in ignition switch is faulty. Repair or replace
3. Battery is low. Recharge or replace
4. Starter magnetic switch is faulty. Replace
5. Battery cable terminal clamps are loose. Clean and tighten
6. Starter brush is worn out. Replace
7. Body ground wire is loose. Tighten
8. Starter magnetic field or armature circuit is opened. Repair or replace
9. Repair according to fault code (vehicle with Adjust or replace
electronic fuel injection engine)
No spark
1. Fuse is loose or blown. Repair or replace
2. Contact in ignition switch is faulty. Repair or replace
3. Spark plugs are faulty. Adjust gap or replace
4. Spark plug wire(s) is shorted. Replace
5. Distributor rotor or cap is faulty. Replace
6. Ignition timing is incorrect. Adjust
7. Ignition coil is faulty. Replace
Intake and exhaust system failure
1. Fuel in fuel tank is insufficient. Add
2. Carburetor is misadjusted. Adjust
3. Gasoline pump oil supply is deficient. Replace
4. Gasoline filter is clogged. Replace
5. Choke mechanism is damaged. Repair or replace
6. Intake manifold is loose. Repair
7.Carburetor is dirty or fouled. Clean
8. Float level is misadjusted. Adjust
9. Fuel piping is clogged. Clean or replace
10. Fuel cut-off magnetic valve is faulty. Repair or replace
Appendix
Trouble shooting
Continued
Difficult starting Internal engine fault
1. Cylinder rings Replace
2. Improper valve clearance Adjust
3. Valve spring are worn or broken Replace
4. Intake manifold is loose. Tighten and replace gasket as required
5. Piston, piston rings, or cylinder is worn. Replace worn piston and piston rings; bore cylinder as
required
6. Timing belt fractures. Replace
7. One or more intake or exhaust valves is not seating Replace
properly.
8. Engine oil is incorrect. Replace with FAW-specified engine oil
9. Valve is burned. Replace
10. Valve stem is seized Repair or replace valve and valve guide
Low compression
Adjust
1. Improper valve clearance.
Repair
2. One or more valves is not seating properly.
Repair or replace valve or conduit
3. Valve stem is seized.
Replace
4. Valve spring has not deficient elasticity or fractures.
Replace
5. Piston ring is seized in groove, or damaged.
Replace worn piston and piston ring, and bore cylinder
6. Piston, piston ring or cylinder is abraded.
again
Replace
7. Cylinder ring is broken.
Adjust or replace
8. Inspect according to fault code (vehicle with electronic
fuel injection engine)
Low power
Ignition timing is incorrect

Adjust
1. Improper ignition timing.
Adjust gap or replace
2. Spark plugs are faulty.
Repair or replace
3. Ignition wire(s) is arcing, loosely or disconnected.
Repair or replace
4. Distributor vacuum advance unit is faulty.
Adjust or replace
5. Inspect according to fault code (vehicle with electronic fuel
injection engine)
Fuel system fault

Clean
1. Carburetor jet is clogged.
Trouble shooting
Appendix
Continued
2. Gasoline pump is damaged. Repair or replace
3. Gasoline filter is clogged. Replace
4. Choke mechanism is damaged. Repair or replace
6. Fuel pipe is clogged. Clean or replace
7. Fuel tank outlet is clogged. Clean
8. Fuel system connections are loose. Screw down
9. Inspect according to fault code (vehicle with electronic fuel injection engine) Adjust or replace
Low power
Air intake system fault

1. Air filter element dirty or clogged. Replace
2. Choke return is not good. Repair, adjust or replace
Others
1. Brakes are dragging Repair or replace
2. Clutch is slipping Repair or replace
Electric system fault
1.Spark plugs are faulty.
Replace
2. Distributor rotor or cap is broken.
Replace
3. Ignition coil is faulty.
Replace
4. Ignition wire(s) is arcing.
Adjust
Replace
6. Capacitor is damaged.
Engine breathing problems(when Adjust or replace
7. Inspect according to fault code (vehicle with electronic fuel injection engine)
accelerating from any speed, the
Fuel system fault
vehicle temporarily loses power, Adjust
1.Float level is misadjusted.
and is most noticeable from a Clean
2.Carburetor jet is clogged.
complete stop) Repair or replace as required
3.Gasoline pump is faulty.
Add
1.Fuel in fuel tank is insufficient.
Adjust or replace
2.Inspect according to fault code(vehicle with electronic fuel injection engine)
Inside engine fault
Replace
1. Excessive piston ring wear has caused low compression.
Replace or bore cylinder as required
2. Piston, piston ring, and cylinder are worn, or valve burning causes low compression.
Appendix
Trouble shooting
Continued
Fuel system fault
Replace
1. Gasoline filter is clogged.
Check and replace as required
2. Gasoline pipe is kinked.
Replace
3. Gasoline pump is faulty.
Repair or replace
4. Air intake manifold or carburetor gasket has leakage.
Adjust
5. Float level is misadjusted.
Adjust or replace
Ignition system fault
Engine rpm’s are not steady. 1. Improper ignition timing.
Adjust
2. Distributor vacuum advance unit is faulty.
Repair or replace
3. Ignition wire(s) is arcing or the connection is loose.
Repair or replace
4. Spark plugs are faulty (excessive carbon deposits, improper gap, and electrode is
Clean, adjust or replace
burned.)
5. Distributor rotor or cap is broken.
Replace
6. Capacitor is damaged.
Replace
Adjust or replace
1. The carburetor’s electromagnetic fuel cut-off valve is faulty. Check the electromagnetic fuel cut-off valve for
Engine will not stop
normal function, and replace if required
(ignition switch is turned off
Adjust or replace
but engine continues to run)
2. Inspect according to fault code(vehicle with electronic fuel injection engine)
Idle is not steady Ignition system fault
1. Spark plugs are faulty.
Repair or replace
2. Ignition wire(s) is arcing or disconnected. Replace
3. Distributor electrode is worn out. Adjust
4. Improper ignition timing. Replace
5. Distributor cap is faulty, arcing current internally. Adjust or replace
Fuel system fault Clean
1. Carburetor jet is clogged. Adjust
2. Improper idle adjustment. Replace
3. Air cleaner element is dirty or clogged.
Trouble shooting
Appendix
Continued
4. Air intake manifold, carburetor or cylinder gasket leak. Repair or replace
6. Choke mechanism is damaged. Adjust or replace
7. Fuel cut off magnetic valve to occur fault. Replace
Idle is not steady Others
1. Vacuum hose connection is loose or disconnected. Connect and screw down
2. PCV valve is faulty. Repair
3. Low compression. Refer to the above description
4. Carburetor and air intake manifold fasteners are loose. Tighten
5. Carburetor and air intake manifold gaskets are leaking Replace
Abnormal spark knock Ignition system fault
Replace with proper specification spark plugs
1. The heat range of the spark plugs is improper.
Adjust
Repair
3. Loose connection within the high voltage or low voltage circuit.
Replace
4. Distributor assembly has internal wear.
Adjust or replace
Fuel system fault
Clean or replace
1. Gasoline filter or fuel pipe is clogged.
Clean
2. Carburetor jet is clogged.
Adjust
3. Float level is misadjusted.
Replace
4. Gasoline pump is faulty.
Replace
5. Intake manifold and/or carburetor gasket are faulty (leaking air).
Adjust or replace
Inside engine fault Clean
1. Piston and cylinder head have excessive carbon accumulation. Replace
2. Cylinder gasket is faulty, causing low compression. Adjust
3. Improper valve adjustment. Replace
4. Valve Replace
5. Valve spring have excessive wear.
Appendix
Trouble shooting
Continued
Engine is overheating Ignition system fault
Adjust
Replace with proper specification spark
2. The heat range of the spark plugs is improper.
plugs
Adjust or replace
Fuel system fault
Adjust
1. Float level is set too low.
Clean
2. Carburetor jet is clogged
Tighten
3. Air intake manifold is loose.
Adjust or replace
Cooling system fault
Add
1. Coolant is insufficient.
Adjust or replace
2. Water pump belt is loose or broken.
Replace
3. Engine thermostat is faulty.
Replace
4. Water pump is faulty.
Repair or replace
5. Radiator core leaks.
Lubricating system fault
Replace filter and engine oil
1. Engine oil filter is clogged.
Clean or replace screen, and replace oil
2. Oil pump pick-up tube screen is clogged.
and filter
Replace
3. Engine oil pump is faulty.
Repair or replace
4. Engine oil pan or oil pump is leaking.
Replace with FAW-specified engine oil
5. Engine oil specification is wrong.
Add
6. Engine oil level is low.
Others Repair or replace
1. Brakes are dragging. Adjust or replace
2. Clutch is slipping. Replace
3. Cylinder gasket is burned.
Trouble shooting
Appendix
Continued
Abnormal engine noises Abnormal crank shaft noises
Replace
1. Main bearing(s) has excessive wear.
Replace
Note: Before checking the noise, check the 2. Connecting rod bearing(s) had excessive wear.
Replace
following: 3. Connecting rod is bent.
Repair or replace
 Ignition timing has been adjusted 4. Crankshaft journal is damaged.
Repair or replace
well. 5. Connecting rod journal is damaged.
 Spark plug conforms to the
specification Abnormal piston, piston rings, piston wrist pin, or cylinder noise
Bore cylinder
 Fuel conforms to specification 1. Cylinder walls have excessive wear.
Replace
2. Piston, piston rings, or piston wrist pin have excessive wear.
Replace
3. Piston(s) is damaged (ie, scored).
Replace
4. Piston ring(s) is damaged.
Others
Replace
1. Camshaft journals have excessive wear (axial clearance is excessive).
Replace
2. Camshaft journal and cylinder camshaft hole have excessive wear.
Repair
3. Crankshaft main bearing clearance excessive.
Adjust
4. Improper valve clearance.
Add
5. Engine oil level is low.
Excessive fuel consumption Ignition system fault

Adjust
Repair or replace
2. Ignition wire(s) is arcing or loosely connected.
Clean, adjust or replace
3. Spark plugs are faulty (excessive carbon deposits, improper gap, and
electrode is burned.) Replace
4. Distributor rotor or cap is broken. Repair or replace
5. Distributor vacuum advance unit is faulty. Adjust or replace
Fuel system fault Adjust
1. Float level is improper. Repair or replace
2. Fuel tank, oil pipe or carburetor leak fuel. Repair or replace
3. Choke mechanism is damaged.
Appendix
Trouble shooting
Continued
4. Carburetor jet is clogged. Clean
5. Air cleaner element is dirty or clogged. Replace
Internal engine fault

1. Low compression. Refer to the above description
Excessive fuel consumption
2. One or more intake or exhaust valves is not seating properly. Repair or replace
3. Improper valve clearance Adjust
Others
1. Brakes are dragging. Repair or replace
2. Clutch is slipping. Adjust or replace
3. Improper tire pressure. Adjust
Excessive engine oil consumption Oil leak
Tighten
1. Engine oil drain plug is loose.
Tighten
2. Oil pan mounting bolts are loose.
Replace
3. Oil pan gasket is damaged.
Replace
4. Oil seal leaks.
Replace
5. Cylinder gasket is burned.
Tighten
6. Engine oil filter is loose.
Tighten
7. Engine oil pressure switch is loose.
Cleanup accumulated carbon and replace

Pump oil (engine oil suck in combustor )
piston ring
1. Piston ring is sticking.
2. Piston ring groove or piston ring has excessive wear. Replace piston and piston ring
3. Piston ring opening clearance position is improper. Adjust
4. Piston or cylinder has excessive wear. Replace piston and bore cylinder if
necessary
Engine oil leak along valve rod
1. Valve seal is damaged. Replace
2. Valve or valve guide is damaged. Replace
Trouble shooting
Appendix Table
Continued
II. Carburetor
Gasoline is 1. Float valve is dirty or has excessive wear. Clean or replace
overflowing from the 2. Float level set is too high. Adjust
carburetor 3. Float is broken (full of fuel). Replace
4. Broken gasket. Replace
5. Float chamber fastening bolt is loose. Tighten
III. Exhaust pipe and silencer
Muffling 1. Exhaust pipe connection is loose. Tighten
performance is poor. 2. Silencer gasket is broken. Replace
3. Exhaust manifold or silencer is broken. Replace
4. Exhaust manifold is loose. Tighten
5. Body and silencer interference. Repair
IV. Clutch
Clutch is slipping 1. There is no gap on separate shifting fork top. Adjust
2. Friction disc with smear. Replace
3. Friction disc has excessive wear. Replace
4. Diaphragm spring has insufficient elasticity. Replace
5. Clutch plate or flywheel are warped. Replace
6. Improper clutch pedal free travel. Adjust
Clutch is sticking 1. Friction disc is dipped by oil. Replace
2. Friction disc has excessive wear. Replace
3. Rivet on friction disc bulged. Replace
4. Torsion spring had deficient elasticity. Replace
Appendix
Fault inspection
Continued
1. Improper clutch pedal free travel. Adjust
2. Diaphragm spring has insufficient elasticity or diaphragm spring end is Replace
worn.
Clutch action is retarded. 3. Transmission input shaft spline is abraded or damaged. Replace
4. Transmission input shaft bearing is abraded or damaged. Replace
5. Friction disc excessively pendulates. Replace
6. Friction disc is abraded or with smear. Replace
1. Friction disc surface is glazed. Repair or replace
2. Friction disc has discoloration and/or burnt smell. Replace
3. Friction disc is warped or friction surface contact is bad. Replace
Abnormal clutch vibration
4. Torsion spring elasticity is deficient. Replace
5. Friction disc rivet is loose. Replace
6. Clutch plate or flywheel surface is warped. Replace
7. Engine frame buffer block is loose or broken. Tighten or replace
1. Throwout bearing is worn or broken. Replace
2. Transmission input shaft bearing has excessive wear. Replace
Abnormal noises 3. Friction disc combination spline gap is excessive. Replace
4. Friction disc is broken. Replace
5. Clutch plate or diaphragm spring is loose. Replace
V. Transmission
One or more gears can not be 1. Gearshift shifting fork shaft is worn Replace
2. Position friction ball is worn. Replace
3. Position ball spring has insufficient elasticity. Replace
4. Gearshift shifting fork is worn. Replace
engaged.
5. Gear axial gap is excessive. Replace
6. Synchronizer ring and hub are worn. Replace
7. Input shaft, output shaft and middle shaft bearings are worn. Replace
Trouble shooting
Appendix
Continued
1. Synchronizer spring has insufficient elasticity or is damaged. Replace
2. Inner ring groove of synchronizer ring is worn. Replace
Gear will not disengage.
3. Synchronizer ring is seized on the friction conical surface. Replace synchronizer lock ring
4. Gearshift shifting fork shaft or gearshift shifting fork are bent. Replace
1. Transmission gear oil is low. Supplement
2. Synchronizer is damaged. Replace
Gear noise is over loud. 3. Gear axial direction gap is excessive. Replace
4. Bearing is worn or broken. Replace
5. Gear is worn or damaged. Replace
1. Clutch pedal free travel is excessive. Adjust
2. Friction disc is worn. Replace
3. Friction disc has discoloration and/or burnt smell. Replace
4. Gearshift shifting fork shaft is bent or is worn unevenly. Replace
Gear shifting is difficult. 5. Position ball is worn. Replace
6. Synchronizer slider or synchronizer ring are worn. Replace
7. Synchronizer hub is worn. Replace
8. Gear selection arm or gearshift lining are worn. Replace
9. Improper shift cable adjustment. Adjust
VI. Rear axle
Abnormal differential noises 1. Improper gap between the driving bevel pinion and the driven bevel gear. Adjust
2. The mesh between driving bevel pinion and driven bevel gear is incorrect or has tooth Adjust or replace
damage.
3. The contact of mesh tooth face between the driving bevel pinion and driven bevel gear is Adjust
incorrect.
4. Gear oil is insufficient or incorrect specification. Supplement or replace with FAW-
approved oil.
5. Driven bevel gear oscillates or its fastening bolt is loose. Replace or tighten
6. The cogs of axle shaft gear or planetary gear are damaged. Replace
1. (Certain noise) Gear oil is deficient or the brand is wrong. Supplement or replace
2. (Certain noise) Bearing is abraded or damaged, or parts are damaged. Replace
Bearing noises
3. (Emitting noise when inertia coasting) The bearing of drive bevel gear is damaged. Replace
4. (Emitting noise in running) Halfshaft gear is damaged. Replace
Appendix
Fault inspection
Continued
VII. Driveshaft
1. The pinion gears are worn or broken. Replace
2. Driveshaft is bent. Replace
Vibration or abnormal noise
3. Driveshaft imbalance exceeds specifications. Adjust or replace
4. Driveshaft bolt is loose. Screw down
1. Universal joint is worn or damaged. Replace
Noise when vehicle starts or coasts 2. Driveshaft spline is worn. Replace
3. Driveshaft is loose. Screw down
VIII. Braking system
1. Brake lines and/or hoses are leaking fluid. Repair
2. Brakes are overheated. Repair
3. The brake shoes are out of adjustment. Adjust
4. The brake shoe linings are soaked with oil or water. Clean or replace
Braking force is deficient.
5. The brake shoe lining is excessively worn. Replace
6. Brake wheel cylinder(s) is faulty. Repair or replace
7. Brake rotors and/or brake calipers are soaked with oil or have excessive wear. Clean or replace
8. Brake caliper assemblies do not operate smoothly. Repair or replace
The braking force of the right and 1. The brake shoe linings are soaked with oil or water. Clean or replace
left wheels is different. 2. The brake shoes are out of adjustment. (brake shoe self-adjusters are faulty.) Repair
3. One or more of the brake hubs is warped. Replace
4. Tire pressure is not equal. Adjust
5. One or more of the brake wheel cylinders is faulty. Repair or replace
6. Front wheel position is misadjusted. Adjust
7. The tire size and type on one axle is not the same. Use the same size and type of tires
8. The brake fluid within the brake lines does not flow smoothly. Repair or replace
9. Suspension parts are loose. Tighten
10. Brake caliper assembly does not work smoothly. Repair or replace
11. Brake calipers are loose. Tighten
Trouble shooting
Appendix
Continued
Brake pedal free travel is excessive. 1. Braking fluid level in the reservoir is low. Add
2. There is air in the brake lines. Discharge
3. The rear brakes are out of adjustment (brake shoe self-adjusters are faulty.) Repair
4. Brake shoe is bent. Replace
5. Brake shoe lining is excessively worn. Replace
Brake shoe or brake calibers do not 1. Brake master cylinder piston does not return. Repair
return. 2. The oil return hole within brake master cylinder is clogged. Clean
3. The brake fluid within the brake lines does not flow smoothly. Repair or replace
4. Parking brake is misadjusted. Adjust
5. The brake return spring has deficient elasticity or is broken. Replace
6. Parking brake stay or rod is seized. Repair or replace
7. Brake wheel cylinder or brake caliper pistons are seized. Repair or replace
Pedal chatters when braking 1. Wheel bearing is loose or damaged. Tighten or replace
2. Rear brake hub is warped. Replace
3. Horizontal oscillation of brake rotor is excessive. Replace
4. Brake rotor is excessively warped. Replace
Noise when braking 1. Brake shoe lining is glazed, or has foreign matter on it. Repair or replace
2. Brake shoe lining is excessively abraded or distort. Replace
3. Front wheel bearing is broken. Replace
4. Braking floor distort or bolt is loose. Replace or screw down
IX. Suspension, steering system, and tires
Difficult steering 1. Tire inflation pressure is low. Adjust
2. The tie rod end ball joints and/or control arm ball joints are excessively worn. Replace
3. Steering linkage is binding. Repair or replace
4. Steering gear is misadjusted. Adjust
5. Steering shaft bearings are worn. Replace
6. Front end alignment is incorrect. Adjust
Continued
Appendix
Fault inspection
1. Tire inflation pressure is incorrect. Adjust
2. Front wheel is bent. Repair of replace
3. The left and right tires are not the same size. Use the same tires.
4. Wheel lug nut is loose. Screw down
5. Wheel bearing is worn or damaged. Replace
Steering wheel shakes
6. The tie rod end ball joints are excessively worn or damaged. Replace
8. Steering gear mounting bolts are loose. Screw down
9. Tires are out of balance. Spin balance the tires
1. Tire wear is uneven. Replace
2. One side of the wheel braking system does not return. Repair
3. Tire inflation pressure is not equal. Adjust
Steering wheel is misaligned
4. Steering pull rod or tie rods are worn or damaged. Replace
6. Suspension parts are loose, bent, worn, or damaged. Screw down or replace
Steering wheel moves abruptly. 1. Tire inflation pressure is too high. Adjust
2. Shock absorber performance is poor. Replace
3. The tire diameters among the 4 tires are different. Use the same tires
4. Steering system connections are excessively worn. Replace
5. Front wheel bearings are worn or damaged. Replace
6. Front wheel is loose. Tighten
7. Steering wheel is loose. Tighten
8. Tire has blisters or bulges. Replace
1. Tire inflation pressure is incorrect. Adjust
2. The tire diameters among the 4 tires are different. Use the same tires
3. Wheel bearings are worn or loose. Replace
Tire is wearing fast or unevenly.
4. Tire vibration Replace
5. Tire is out of balance. Spin balance the tires
Trouble shooting
Appendix
Abnormal noises while steering 1. Steering gear mounting bolts are loose. Screw down
2. Wheel bearings are worn or damaged. Replace
4. Steering shaft connection is excessively worn. Replace
5. The steering ball joints are excessively worn. Replace
Steering wheel “return to center” 1. The tie rod ball joint ends are excessively tight. Replace
function is poor. 2. Steering wheel is caught. Repair or replace
3. Steering gear is lack of grease. Lubricate or replace
4. Front wheel position is maladjusted. Adjust
5. Steering gear is maladjusted. Adjust
6. Tire charge pressure is improper. Adjust
Abnormal front end noises 1. Ball pin is abraded or caught. Replace
2. Absorber or upward pivot rubber lining block is damaged. Repair or replace
3. The anti-sway bar is loose. Screw down
4. Wheel nut is loose. Screw down
5. Suspension bolt or nut is loose. Screw down
6. Wheel bearing is abraded or damaged. Replace
7. suspension spring is damaged. Replace
Sagging suspension 1. Vehicle is overloaded. Check load
2. Shock absorber is damaged. Replace
3. Spring(s) is worn or broken.. Replace
Body leans or swings 1. Vehicle is overloaded. Check load
2. The anti-sway bar is loose. Screw down
3. Shock absorber or upper strut mount bushing is damaged. Repair or replace
4. Spring(s) is worn or broken. Replace
Appendix
Fault inspection
X. Starter
1. The starter drive gear is excessively worn. Replace
Starter motor has function, but the
2. Spline is damaged. Replace
starter drive (bendix) will not
3. Bushing is excessively worn. Replace
engage the flywheel ring gear
4. Flywheel ring gear teeth are excessively worn. Replace
Battery fault
1. Battery has no charge. Charge or replace
2. The battery cable connection is poor. Clean and screw down
3. Ground wire connection is loose. Screw down
4. Battery voltage is deficient. Charge or replace
Ignition switch fault

1. Contact is not good. Repair or replace
2. Wire connections are loose. Repair
Starter motor has no function, or 3. Circuit between ignition switch and the electromagnetic switch is broken. Repair
the rotation speed is too slow to start Electromagnetic switch fault

engine. 1. Lead wire is loose. Repair
2. Touch panel is burned or has loose connection. Replace or repair
3. Circuit within drawing coil is open. Replace
4. Circuit within retention soil is open. Replace
Starter fault
1. Brush joint is worn or broken. Repair or replace
2. Rectifier is burned. Repair or replace
3. Circuit within armature coil is open. Replace
4. Starter is damaged. Replace

1. Ignition switch return action is poor. Repair or replace
Starter will not stop running. 2. The contact of electromagnetic switch touch panel is blown. Repair or replace
3. Circuit within the electromagnetic switch coil is open. Replace
Trouble shooting
Appendix
1. Water pump belt is loose or broken. Adjust or replace
2. Battery cable connection is loose or corroded. Clean and screw down
3. Battery electrolyte concentration is excessive, or electrolyte level is too low. Replace or supplement electrolyte
Battery is discharging excessively.
4. Battery plates are damaged. Replace battery
5. Electrical load is excessive. Reduce load
6. IC adjuster or motor is faulty. Replace
When ignition switch has been 1. Fuse is blown. Replace
turned on(ON), but engine has not 2. Lamp is burned out. Replace
been started, charge indicator lamp 3. Connection is loose. Repair
is not on. 4. IC adjuster is faulty. Replace
Abnormal starter motor noise. 1. Starter motor bearing is excessively worn. Replace
XII. Electric wipers

1. Fuse is loose or blown. Repair or replace
2. Connector is loose. Repair
3. Brush is suspended or worn. Repair or replace
4. Rectifier is dirty or worn. Repair or replace
Wiper motor does not function.
5. Magnetic field coil is short or blown. Replace
6. Wiper switch connector is loose. Repair
7. Intermittent relay is loose or damaged. Repair or replace
1. Wiper switch is damaged. Repair or replace

Wiper motor will not turn off.
Wiper arm will not park at normal 1. Wiper arm adjustment is improper. Adjust
position. 2. Return mechanism is damaged. Repair or replace
1. Windshield glass is excessively dirty. Clean
2. Wiper arm spring is excessively worn. Replace
Wiper blade function is poor.
3. Wiper blade is excessively worn. Replace
4. Wiper blades are improperly installed. Repair or replace
Appendix
Fault inspection
XIII. Fuel gauge
1. Connector contact is poor. Repair
2. Sensor contactor is burned or bimetal components distorted. Replace
Faulty indication
3. Float movement is irregular. Replace
4. Sensor fuel gage ground is poor. Repair
1. Instrument circuit is opened. Repair
2. Contactor is burned. Replace
No indication
3. Bimetal components are distort. Replace
4. Resistor circuit is opened Replace
XIV Speedometer
1. The driving or driven speedometer gear is damaged. Replace
2. Speedometer cable is faulty. Replace
Wrong indication
3. Speedometer cable connection is bad. Repair
4. Speedometer is faulty. Repair or replace
1. Soft lubricating oil is worn out or insufficient. Lubricate or add
Speedometer is noisy
2. Transmission gear oil is low Add
XV. Water temperature gauge
Faulty indication 2. Water temperature sensor is faulty. Replace
3. Water temperature gauge is faulty. Replace
No indication 1. Water temperature gauge circuit is opened. Repair
2. Water temperature sensor is faulty. Replace
3. Water temperature gauge is faulty. Replace
Trouble shooting
Appendix
XVI. Engine oil pressure warning lamp
Lamp is not on when the ignition 1. Fuse is blown. Replace
switch is turned to the ON position 2. Lamp is damaged. Replace
prior to stating the engine. 3. Circuit is cut off. Repair
4. Engine oil pressure sensor is damaged. Replace
After the engine is started, the lamp 1. Engine oil level is low. Add
does not turn off. 2. Engine oil pressure is too low Repair
3. Sensor is damaged. Replace
XVII. Charge indicator lamp
Lamp is not on when the ignition 1. Fuse is blown. Replace
switch is turned to the ON position 2. Lamp is damaged. Replace
prior to starting the engine. 3. Circuit is cut off. Repair
4. Regulator is faulty. Repair
After the engine is started, the 1. Engine belt is loose. Repair
warning lamp does not turn off. 2. Regulator is faulty. Repair
3. Motor is faulty. Repair
XVIII. Horn
Horn has no function. 1. Fuse is blown. Replace
3. Pull button ground is poor. Repair
4. Horn is damaged. Replace
5. Relay is loose or damaged. Repair or replace
Sound quality is poor. 1. Horn pull button is not making good contact, resistance increases. Repair
2. Horn inside contactor gap is incorrect, or contactor is damaged. Adjust or replace
3. Membrane has crack. Replace
Trouble shooting
Appendix
XIX. Turn signal indicator
Left and right turn signal indicator 1. Fuse is blown. Replace
lamps do not turn on, or do not flash. 2. Connector is loose. Repair
3. Flasher is faulty. Repair or replace
4. The rated power of used lamp is lower than specific value. Replace
Flash frequency is abnormally fast, or 1. Lamp ground is poor. Repair
lamps only flash on one side of the 2. Bulb on high flash frequency side of the vehicle is faulty. Replace
vehicle. 3. Flasher relay frequency is excessive. Repair or replace
4. Turn signal switch contact is poor. Repair or replace
Flash frequency is abnormally low. 1. The rated power of lamps in use is lower than the specific value. Replace
2. Lamp ground is poor. Repair
3. Power voltage is too low. Charge
5. Flasher relay frequency is too low. Repair or replace
XX. Lighting lamp
When the lighting switch on the 1. The license plate lamp ground connection is shorted. Repair
combination switch is turned to 2. Circuit connecting switch has a short circuit. Repair or replace
position 1, the fuse is blown.
When the lighting switch on the 1. Fuse is blown. Replace
combination switch is turned to 2. Connector is loose. Repair
position 1, the related lighting does nut 3. Lead wire is open and making contact. Repair
turn on. 4. Faulty light bulbs. Replace
5. Relay is loose or damaged. Repair or replace
When the lighting switch on the 1. Circuit connecting switch has a short. Repair or replace
combination switch is turned to 2. The electric equipment or wire in the headlamp circuit is shorted. Repair
position 2, the fuse is blown.
Headlamp beam is not changed. 1. Faulty light bulbs. Replace
2. Headlamp dimming switch is faulty. Replace
Tool set
Appendix
Tool set
No. Content
1 Tool bag
2 Open-end wrench 8 ×10
3 Open-end wrench 12×14
4 Open-end wrench 13 ×16
5 Dual-point screwdriver
6 Screwdriver handle
7 Slip-joint pliers
8 Socket (spark plug)
9 Extension (spark plug socket)
10 Square-head wrench
11 Wheel lug nut wrench
12 Jack
13 Jack handle

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Operation and Service Manual

FAW Jiabao Series Light Passenger Van

China First Automobile Group Corporation - Jilin Light Vehicle Plant

FAW Jiabao Series Light Passenger Van

China First Automobile Group Corporation Jilin Light Vehicle Plant

Manufacturer’s Product Number

Jilin Light Vehicle Plant

Mini-Passenger Car Series

Front Tread 1,205

Overall Length 3,902 mm

Chapter I. Complete vehicle………………………………………………………………………………………………………………………1

Section 1. General introduction………………………………………………………………………………………………………………………1

Chapter II. Engine ……………………………………………………………………………………………………………………………….36

Section 1. Engine accessories (carbureted engines)…………………………………………………………………………………………………36

Chapter III. Chassis……………………………………………………………………………………………………………………………48

Chapter IV. Vehicle body…………………………………………………………………………………………………………………………116

Section 1. Front doors and rear sliding doors…………………………………………………………………………………………………116

Chapter V. Climate control system…………………………………………………………………………………………………………140

Section 1. Heating system…………………………………………………………………………………………………………………………140

Chapter VI. Vehicle electrical system………………………………………………………………………………………………………157

Section 1. Power supply system…………………………………………………………………………………………………………157

Chapter I. Complete Vehicle

Fig. 1-1 VIN location Fig. 1-2 Engine number location

Engine model LJ465QE1 DA465Q-1A/D DA465Q-1A/D1 DA462-1A/D DA462-1A/D DA465Q-1A/D1

LJ465Q-1AE1 LJ462Q-1AE1 LJ465Q-1AE1

Rated passenger capacity 6-8 persons 2 persons 6-8 persons 6 persons

Curb weight 895kg 865kg 895kg

Rated load capacity —————— 545kg ——————

Gross weight 1410kg

Rear axle 415kg 390kg 415kg

Full load Front axle 642kg

Rear axle 768kg

Dimensions Overall Length 3496mm

height 1841mm 2041mm

Track Front wheel 1215mm

Rear wheel 1210mm

Front suspension 844mm

Rear suspension 712mm

Min. ground clearance 156mm

Angle of approach 26.1°

Angle of departure 31.7 °

Max. steering angle 37 °

Kingpin caster angle 5°

Front wheel camber angle 1°

Max. Speed.+ 110km/h 100km/h 110km/h

Max. gradeability ≥29%

Fuel consumption ≤6L/100km

Engine model DA462-1A/D DQ465Q-1A/D1

Rated passenger capacity 6 persons 2 persons 6 persons 2 persons

Curb weight 895kg 870kg

Gross weight 1410kg

Weight No Front axle 480kg 470kg

load Rear axle 415kg 400kg

Full Front axle 642kg

Dimensions Overall Length 3496mm

Height 1841mm 2041mm 1841mm 2041mm

Track Front wheel 1215mm

Rear wheel 1210mm

Front suspension 844mm