JAC HFC4DA1-2C engine. Instruction — part 37

ABS

ABS

ABS

ABS Anti-lock

Anti-lock

Anti-lock

Anti-lock Brake

Brake

Brake

Brake System

System

System

System

100

Troubleshooting

Troubleshooting

Troubleshooting

Troubleshooting procedures

procedures

procedures

procedures

S/N

Operating Step

Operation

Detection
Result

Next Step

1

Checking fuse

(a) Check if the 10A, 25A and 40A fuses for power supply

ECU of ABS operate normally.

Normal: Continuity

Yes

Go to the next step.

No

Check fuse circuit.

2

Using multimeter to
check battery voltage

(a) Check battery voltage under various conditions.
① Idling: with headlamp turned on, A/C turned to the

coldest mode/blower turned to the maximum speed
mode

② Parking: With all electrical equipments turned off,

rotation speed increased to 3500rpm and hold on for 30s

③ During application of service brake

Normal value: 10～16.9V

Yes

Go to the next step.

No

Check

charging

system.

3

Using

diagnostic

instrument

to

read

battery voltage

(a) Connect the diagnostic instrument to read battery

voltage under various conditions.

① Idling: with headlamp turned on, A/C turned to the

coldest mode/blower turned to the maximum speed
mode

② Parking: With all electrical equipments turned off,

rotation speed increased to 3500rpm and hold on for 30s

③ During application of service brake

Normal value: 10～16.9V

Yes

Intermittent fault, go
to Step 5

No

Go to the next step.

4

Checking voltage of
ABS power line and
ground cable

(a) Turn off the ignition switch.

(b) Remove connectors from ABS hydraulic governor with

ECU.

(c) With ignition switch turned on, use multimeter to

measure if driving voltage of each solenoid valve, motor
or ECU is between 9.3V～16.9V.

Normal

Go to the next step.

Abnormal

Check

and

repair

circuit.

5

Fault reconfirmation

(a) Simulate fault for reconfirmation.

(b) Read DTC.

Normal state: No DTC memory

Normal

Go to the next step.

Abnormal

Replace

the

ABS

hydraulic

governor

with ECU.

6

Intermittent fault

(a) If it is intermittent fault, please return the vehicle to customer, for the fault cannot be located at that

moment.

(b) Ask the customer to record relevant data once the same fault occurs:

·

Vehicle speed

·

With/without brake pedal depressed

·

Weather

·

Road condition and etc.

7

Conduct

final

inspection to confirm
the fault is removed.

(a) Clear DTC

(b) With ignition switch turned on, ABS has no DTC memory.

ABS

ABS

ABS

ABS Anti-lock

Anti-lock

Anti-lock

Anti-lock Brake

Brake

Brake

Brake System

System

System

System

101

Removal/Installation

Removal/Installation

Removal/Installation

Removal/Installation

ABS

ABS

ABS

ABS system

system

system

system

1.

Remove the negative cable of battery.

2.

Drain the brake fluid in the hydraulic brake system
completely.

3.

Loosen the oil pipe of brake master cylinder.

4.

Remove the ABS connector.

5.

Remove the brake fluid pipe from ABS hydraulic
assembly. Wrap the pipe with plastic bag to avoid
dirt. Use clean water to wash the surface that
having brake fluid on it.

6.

Remove the mounting bolts from ABS hydraulic
assembly and then remove the assembly.

ABS

ABS

ABS

ABS Anti-lock

Anti-lock

Anti-lock

Anti-lock Brake

Brake

Brake

Brake System

System

System

System

102

Removal/Installation

Removal/Installation

Removal/Installation

Removal/Installation (Continued)

(Continued)

(Continued)

(Continued)

Installation
1.

Clean the surface of ABS hydraulic assembly and
fix the assembly onto bracket with bolts.

2.

Install the brake pipe onto the ABS hydraulic
assembly.

Attention:

Attention:

Attention:

Attention:

As for the installation of aluminum alloy parts, the
brake pipe should be fit in place smoothly by
correct alignment; otherwise, the original part
bodies may be damaged easily.

3.

Insert the ABS plug into relevant socket.

Attention:

Attention:

Attention:

Attention:

The ABS plug should be installed in carefully and

smoothly instead of violently.

4.

Install and fasten the oil pipe of brake master
cylinder.

5.

Fill the reservoir of master cylinder with brake
fluid.

6.

Two persons shall work together to bleed the air in
brake line until pure brake fluid is drained out. Air
bleeding order: left rear, right front, right rear and
left front wheels.

7.

Connect the negative cable of battery.

ABS

ABS

ABS

ABS Anti-lock

Anti-lock

Anti-lock

Anti-lock Brake

Brake

Brake

Brake System

System

System

System

103

Removal/Installation

Removal/Installation

Removal/Installation

Removal/Installation (Continued)

(Continued)

(Continued)

(Continued)

Wheel

Wheel

Wheel

Wheel speed

speed

speed

speed sensor

sensor

sensor

sensor

1.

Disconnect the negative cable of battery.

2.

Lift the vehicle.

3.

Disconnect the plug of wheel speed sensor and
remove the harness fixture of sensor.

4.

Remove the mounting bolts from wheel speed
sensor and then remove the sensor.

Installation

1.

Insert the sensor into relevant hole and fix it with
bolt.

2.

Fix the sensor harness and install the harness onto
the plug.

3.

Lower the vehicle.

4.

Connect the negative cable of battery.

TR

TR

TR

TR Transmission

Transmission

Transmission

Transmission Shaft

Shaft

Shaft

Shaft

- 105 -

Transmission

Transmission

Transmission

Transmission Shaft

Shaft

Shaft

Shaft

Applied models: SUNRAY products manufactured by JAC

Subject

Page

Instruction

Instruction

Instruction

Instruction and

and

and

and Operation

Operation

Operation

Operation

Transmission Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 106

Explosive View of Transmission Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 106
Introduction of Transmission Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Diagnosis

Diagnosis

Diagnosis

Diagnosis and

and

and

and Testing

Testing

Testing

Testing

Transmission Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 107

Inspection and Confirmation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..107
Fault Symptom Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Removal/Installation

Removal/Installation

Removal/Installation

Removal/Installation

Removal

of Transmission shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Installation of Transmission shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

TR

TR

TR

TR Transmission

Transmission

Transmission

Transmission Shaft

Shaft

Shaft

Shaft

- 106 -

Introduction
Transmission shaft is a kind of device that is applied to joint transmission and rear axle together and to transmit power
from transmission to rear axle. Transmission shaft, made of hollow steel tube, is equipped with intermediate support to
reduce resonance during power transmission. Transmission shaft adopts constant velocity universal joints that are
maintainable. Balance weights are equipped for transmission shaft in order to ensure stable power transmission.

TR

TR

TR

TR Transmission

Transmission

Transmission

Transmission Shaft

Shaft

Shaft

Shaft

- 107 -

Inspection

Inspection

Inspection

Inspection and

and

and

and Confirmation:

Confirmation:

Confirmation:

Confirmation:

1.

Inspection of flange
Check flange between transmission and transmission shaft. Check flange screw hole for any deformation or
crack. Check flange internal spline for tooth looseness, missing or damage. If there are more than two teeth is
damaged, please replace the flange assembly.

2.

Maintenance and repair of universal joint
Maintenance of universal joint: Use grease nipple that is aligned to the oil filler of universal joint to add grease
until clean grease is extruded out.
Repair of universal joint: Remove universal joint and rotate it to check for any sticking, obvious clearance,
deformation or fracture. Replace the universal joint accordingly.

3.

Inspection of intermediate support
Inspection of intermediate support: Use crow bar to pry up the rubber part of intermediate support and check
rubber part for any wear, deformation or crack. Hold and shake the transmission shaft by hand to check for
excessive clearance of intermediate support. If any, please replace the support.

TR

TR

TR

TR Transmission

Transmission

Transmission

Transmission Shaft

Shaft

Shaft

Shaft

- 108 -

Fault

Fault

Fault

Fault Diagnosis

Diagnosis

Diagnosis

Diagnosis Procedures

Procedures

Procedures

Procedures for

for

for

for Transmission

Transmission

Transmission

Transmission Shaft

Shaft

Shaft

Shaft

Vibration

Check radial runout

of shaft

Normal

Abnormal

Check shaft balance

Replace

Normal

Unbalance

Adjust

Check rear housing bush of

transmission

Normal

Worn

Replace

Check universal joint sliding york

spline shaft

Normal

Stuck

Replace

TR

TR

TR

TR Transmission

Transmission

Transmission

Transmission Shaft

Shaft

Shaft

Shaft

- 109 -

Removal/Installation

Removal/Installation

Removal/Installation

Removal/Installation

Transmission

Transmission

Transmission

Transmission shaft

shaft

shaft

shaft

1.

Lift the vehicle.

Note:

Note:

Note:

Note:

Mark properly in pair on transmission shaft front
flange and transmission flange.

2.

Remove transmission shaft front flange from
transmission flange.

3.

Loosen transmission shaft intermediate bearing.

4.

Remove transmission shaft rear flange from rear
axle flange.

�

Mark properly in pair on transmission shaft
rear flange and rear axle flange.

�

Remove

four

mounting

bolts

from

transmission shaft.

TR

TR

TR

TR Transmission

Transmission

Transmission

Transmission Shaft

Shaft

Shaft

Shaft

- 110 -

Removal/Installation

Removal/Installation

Removal/Installation

Removal/Installation

Transmission

Transmission

Transmission

Transmission shaft

shaft

shaft

shaft

Installation
Note:

Note:

Note:

Note:

Have marks properly aligned.

1.

Install the transmission shaft front flange onto
transmission.

2.

Install transmission shaft intermediate support onto the
intermediate support seat located on body bottom plate.

Note:

Note:

Note:

Note:

Don’t tighten bolt for the moment to facilitate
adjustment.

3.

Install transmission shaft rear flange with rear axle
flange.

�

Have two marks on flanges properly aligned.

�

Use new mounting bolts for transmission shaft.

4.

Tighten

mounting

bolts

for

transmission

shaft

intermediate bearing after alignment of transmission
shaft.

FAX

FAX

FAX

FAX Front

Front

Front

Front Suspension

Suspension

Suspension

Suspension

---- 111

111

111

111 ----

Front

Front

Front

Front Suspension

Suspension

Suspension

Suspension

Applied models: SUNRAY products manufactured by JAC

Subject

Page

Instruction

Instruction

Instruction

Instruction and

and

and

and Operation

Operation

Operation

Operation

Front Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..112

Front Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112

Diagnosis

Diagnosis

Diagnosis

Diagnosis and

and

and

and Testing

Testing

Testing

Testing

Front Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..114

Inspection and Confirmation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...114
Fault symptom Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...115

Removal

Removal

Removal

Removal and

and

and

and Installation

Installation

Installation

Installation

Removal and Installation of Subframe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Specification

Specification

Specification

Specification

Specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131

Tightening Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

FAX

FAX

FAX

FAX Front

Front

Front

Front Suspension

Suspension

Suspension

Suspension

---- 112

112

112

112 ----

Instruction

Instruction

Instruction

Instruction and

and

and

and Operation

Operation

Operation

Operation

Front

Front

Front

Front Suspension

Suspension

Suspension

Suspension

This front axle is a steering axle at front of the vehicle,
mainly consisting of the front overhang subframe
assembly, lower swing arm assembly, front anti-roll bar
link assembly, steering knuckle with brake assembly,

helical spring assembly and mounting cushion for
helical spring, etc., realizing vehicle steering via vehicle
steering gear by pushing steering knuckle that may
make wheels to deflect with certain angle.

FAX

FAX

FAX

FAX Front

Front

Front

Front Suspension

Suspension

Suspension

Suspension

-113

113

113

113 -

SN

Name

Quantity

Remarks

1

Front helical spring assembly

2

2

Mounting cushion for front helical spring

2

3

Left lower swing arm weld assembly

1

4

Right lower swing arm weld assembly

1

5

Lower swing arm bushing assembly

2

6

Lower swing arm ball pin assembly

2

7

Taper washer(16X61X3)

2

8

Front shock absorber assembly

2

9

Brake hose mounting flat spring nut

2

10

Front anti-roll bar assembly

1

11

Front anti-roll bar mounting bushing

2

12

Front anti-roll bar mounting bracket

2

13

Front anti-roll bar link assembly

2

14

Type 1 all-metal hexagon lock nut (thickness

15.5)

2

15

Hexagon headed bolt

6

16

All-metal hexagon flange face lock nut

12

17

Hexagon flange face lock nut (length of screw

thread is 57)

2

18

Type 1 all-metal hexagon lock nut

2

19

Hexagon headed bolt (length of screw thread is

78)

2

Grade 10.9

20

All-metal hexagon flange face lock nut

2

21

Hexagon headed bolt and flat washer assembly

8

22

Hexagon lobular socket pan head screw

2

FAX

FAX

FAX

FAX Front

Front

Front

Front Suspension

Suspension

Suspension

Suspension

---- 114

114

114

114 ----

Use

Use

Use

Use and

and

and

and Maintenance

Maintenance

Maintenance

Maintenance

1.

Inspect the wear condition of brake pad. After the
first 40000km or 24-month driving of the vehicle,
inspect the wear condition of friction linings and
measure the thickness of the most worn part of
brake caliper friction linings with the standard
value of 18mm and limit value of 17mm.When the
thickness of brake lining is lower than the limit
value, the brake lining should be replaced.

2.

In Level III maintenance, the front suspension may
be removed for cleaning of interiors of the steering
knuckle with bushing and wheel hub as well as
bearings. Please tighten bolts and nuts of each
component with specified torques.

3.

Precautions:
The vehicle loading should not exceed the max.

loading weight.

Diagnosis

Diagnosis

Diagnosis

Diagnosis and

and

and

and Testing

Testing

Testing

Testing

Inspection

Inspection

Inspection

Inspection and

and

and

and Maintenance

Maintenance

Maintenance

Maintenance of

of

of

of Front

Front

Front

Front Suspension

Suspension

Suspension

Suspension

1.

Special measuring apparatuses and tools should be
applied in part inspection. For damaged parts, carry
out maintenance or replacement according to
relevant requirements. In the case of one of the
matching parts is worn and its clearance exceeds the
specified one, please replace this worn part together
with its matching part according to relevant
requirements. Measure the starting torque of the
front wheel hub at wheel bolts, it should be 17 ～
25N.m.

2.

From the point of view of preventive maintenance,
some parts which are still in maintenance or within
wear limit should be replaced before exceeding the
limit.

3.

Carry out appearance inspections of all parts with
specified visual method or red pigment penetration
method. In the case of following abnormalities in
part outside surfaces, carry out maintenance or
replacement

for

relevant

parts

according

to

corresponding

requirements:

Abnormalities

�

Failure or fatigue (in helical spring)

�

Bending deformation (generally in steering

knuckle)

�

Abnormal noise（for bearings）

�

Looseness （in bolts of anti-roll bar and lower
swing arm）

�

Discoloration or seizure（for steering knuckle
ball joint etc.）

�

Rusting

�

Deterioration（for brake lining）

4.

For all rubber parts like oil seals, gaskets,
bushings,etc., they should be replaced with new
ones

after

removal.

For

standard

parts

like

pre-riveted nuts and bolts with rubber, they are not
reusable.

5.

Abnormal sound is a kind of noise, mainly
appearing as abnormal sounds like clash or harsh
screaming,etc. under different service conditions
(like vehicle speed or road

conditions). Some of

these sounds may fade out with running-in while
some may increase gradually due to improper
adjustment in assembling. On condition that the part
is qualified, adjustment of part assembly clearance
may be taken as solution.

FAX

FAX

FAX

FAX Front

Front

Front

Front Suspension

Suspension

Suspension

Suspension

-115

115

115

115 -

Fault

Fault

Fault

Fault Diagnosis

Diagnosis

Diagnosis

Diagnosis

Common

Common

Common

Common Fault

Fault

Fault

Fault Diagnosis

Diagnosis

Diagnosis

Diagnosis Table

Table

Table

Table

Fault Symptom

Possible Cause of fault

Troubleshooting

Arduous steering

No power steering

Repair or replace

Improper front wheel alignment

Adjust

Excessively low tire pressure

Carry out tire inflation

Steering exceeding the lower swing arm ball joint

Replace

Poor return

Improper front wheel alignment

Adjust

Fault in the shock absorber

Repair or replace

Wear or damage in the front anti-roll bar

Replace

Wear or damage in the helical spring

Replace

Wear in the lower swing arm bushing

Replace

Abnormal tire wear

Improper front wheel alignment

Adjust

Excessively low or high tire pressure

Adjust the tire pressure

Fault in the shock absorber

Repair or replace

Vehicle deviation

Improper front wheel alignment

Adjust

Insufficient steering resistance of the lower swing arm

ball joint connection

Replace

Looseness or wear in the lower swing arm bushing

Replace

Unilateral vehicle deviation

Improper front wheel alignment

Adjust

Insufficient steering resistance of the lower swing arm

ball joint connection

Replace

Bending of the lower swing arm

Replace

Wear or damage in the helical spring

Replace

Steering wheel fight

Fault in the shock absorber

Repair or replace

Insufficient steering resistance of the lower swing arm

ball joint connection

Replace

Looseness or wear in the lower swing arm bushing

Replace

Wear or damage in the helical spring

Replace

Wear or damage in the front anti-roll bar

Replace

Looseness in mounting screws of the steering gear

Repair

Improper front wheel alignment

Adjust

Vehicle sinkage

Vehicle body welding failure

Repair

Wear or damage in the helical spring

Replace

Fault in the shock absorber

Repair or replace

FAX

FAX

FAX

FAX Front

Front

Front

Front Suspension

Suspension

Suspension

Suspension

---- 116

116

116

116 ----

Removal

Removal

Removal

Removal and

and

and

and Installation

Installation

Installation

Installation of

of

of

of Subframe

Subframe

Subframe

Subframe

Removal
1.

Disconnect the negative cable of battery.

2.

Place the steering wheel in the center and lock it up
in the position of straight-ahead.

3.

Remove track bolts for fixing the steering column
onto the cross shaft. Rotate clamped plates to make
them separated.

4.

Loosen front wheel nuts and lift the vehicle.

5.

Remove the front wheel.

6.

Remove the brake hose from the shock absorber.