JAC HFC4DA1-2C engine. Instruction — part 30

EC

EC

EC

EC Circuit

Circuit

Circuit

Circuit Diagram

Diagram

Diagram

Diagram

- 254 -

Engine compartment harness specification

Identification code

Name

E01

Connected to generator control

E02

Connected to generator positive pole

E03

Connected to starter control

E04

Connected to starter positive pole

E05

Connected to oil pressure switch

E06

Connected to reversing lamp switch

E07

Connected to water temperature sensor

E08

Connected to preheating harness

E12

Connected to battery positive pole

E13

Connected to battery negative pole

E14

Engine ground

E15

Vehicle body ground

EM01

Connected domain harness

EC

EC

EC

EC Circuit

Circuit

Circuit

Circuit Diagram

Diagram

Diagram

Diagram

- 255 -

Left front door harness specification

Identification code

Name

D01

Left window regulator motor

D02

Left electric rear view mirror

D03

Window regulator main switch

D04

Left door loud speaker

D06

Left door lock actuator

D08

Electric rear view mirror switch

MD01

Connected to left main harness

MD02

Connected to left main harness

EC

EC

EC

EC Circuit

Circuit

Circuit

Circuit Diagram

Diagram

Diagram

Diagram

- 256 -

Right front door harness specification

Identification code

Name

D11

Right power window motor

D12

Right electric rear view mirror

D13

Power window auxiliary switch

D14

Right door loud speaker

D16

Right door lock actuator

MD03

Connected to right main harness

MD04

Connected to right main harness

EC

EC

EC

EC Circuit

Circuit

Circuit

Circuit Diagram

Diagram

Diagram

Diagram

- 257 -

Left tail lamp harness specification

Identification code

Name

L01

Front ceiling lamp

L02

Left rear combination lamp

L03

High-mounted brake lamp

L04

Reversing radar ECU

L05

Antenna amplifier

L06

Rear blower

LR01

Connected to reversing radar harness

LT01

Connected to left back door harness

LM01

Connected to main harness 1

LM02

Connected to main harness 2

Ground

G

EC

EC

EC

EC Circuit

Circuit

Circuit

Circuit Diagram

Diagram

Diagram

Diagram

- 258 -

Right tail lamp harness specification

Identification code

Name

N01

Intermediate ceiling lamp

N02

Rear ceiling lamp

N03

Right rear combination lamp

N04

Right rear fog lamp

NM01

Connected to right main harness

Ground

G

EC

EC

EC

EC Circuit

Circuit

Circuit

Circuit Diagram

Diagram

Diagram

Diagram

- 259 -

Left back door harness specification

Identification code

Name

T03

Left license plate lamp

T04

Right license plate lamp

LT01

Connected to left roof harness

Ground

G

EC

EC

EC

EC Circuit

Circuit

Circuit

Circuit Diagram

Diagram

Diagram

Diagram

- 260 -

Rear loud speaker harness specification

Identification code

Name

S01

Left rear loud speaker

S02

Right rear loud speaker

SM01

Connected to main harness

EC

EC

EC

EC Circuit

Circuit

Circuit

Circuit Diagram

Diagram

Diagram

Diagram

- 261 -

ABS harness specification

Identification code

Name

B01

ABS system control module

B02

Left front wheel speed sensor

B03

Right front wheel speed sensor

B04

Right front wheel speed sensor

B05

Right rear wheel speed sensor

BM01

Connected to fuse box

BM02

Connected to main harness 1

Ground

G01

EC

EC

EC

EC Circuit

Circuit

Circuit

Circuit Diagram

Diagram

Diagram

Diagram

- 262 -

Fuel tank harness specification

Identification code

Name

G01

Fuel sensor

G02

Condenser fan motor

GM01

Connected to main harness 1

EC

EC

EC

EC Circuit

Circuit

Circuit

Circuit Diagram

Diagram

Diagram

Diagram

- 263 -

Reversing radar harness specification

Identification code

Name

R01

Left rear fog lamp

R02

Left external probe

R03

Left intermediate probe

R04

Right intermediate probe

R05

Right external probe

RL01

Connected to left tail lamp harness

Preface

Preface

Preface

Preface

This SUNRAY Service Instruction is hereby compiled by the Customer Service

Department of JAC to help the technical service personnel correctly understand and

get familiar with SUNRAY products of JAC INTERNATIONAL better and to provide

them with the ability of quick repair and proper maintenance. This instruction comprises

five volumes: Engine Control, Engine Mechanical, Chassis, Body Electrical, and

Body Accessories.

The Chassis Volume details the technical standards on removal/installation, testing,

debugging and diagnosis for systems and components of SUNRAY long-wheelbase

vehicle chassis.

When replacement is necessary, only genuine spare parts recommended by JAC can

be adopted. During maintenance, please conduct tightening in strict accordance with

tightening torque specified in the Instruction. If locking device is damaged during

removal, please replace it with new one.

No part of this instruction can be reproduced or used in any form or by any mean without

written permission. All Rights Reserved.

JAC INTERNATIONAL

March 2011

Chassis

Chassis

Chassis

Chassis Volume

Volume

Volume

Volume Contents

Contents

Contents

Contents

- 1 -

Chassis

Chassis

Chassis

Chassis Volume

Volume

Volume

Volume Content

Content

Content

Contentssss

Clutch

Clutch

Clutch

Clutch

Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...1

Explosive View of Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 1
Introduction of Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...2

Operating Principle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Inspection and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 3
Fault Symptom Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..4

Removal and Installation
Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7
Specification
Specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 14

Tightening Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Instruction

Instruction

Instruction

Instruction Transmission

Transmission

Transmission

Transmission

Instruction Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Explosive View of Instruction Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Introduction of Instruction Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...16

Instruction transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 17

Inspection and confirmation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fault Symptom Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Removal/Installation
Instruction Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Tightening Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Care and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 44

Brake

Brake

Brake

Brake System

System

System

System

Brake System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Explosive View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Introduction of Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Diagnosis and Testing
Brake System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Inspection and confirmation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Fault Symptom Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Removal/Installation

Removal/installation of brake disc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 50
Removal/installation of brake caliper assembly. . . . . . . . . . . . . . . . . . . . . . . . . ...54
Removal/installation of rear wheel brake shoe. . . . . . . . . . . . . . . . . . . . . . . . . . 56
Parking brake adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Removal/installation of parking brake lever. . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Removal/installation of parking brake cable. . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Replacement of parking brake cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Removal/installation of brake pedal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Removal/installation of brake master cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . .65
Removal/installation of vacuum pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Removal/installation of vacuum booster. . . . . . . . . . . . . . . . . . . . . . . . . . . . ..68
Air bleeding for hydraulic pressure brake system. . . . . . . . . . . . . . . . . . . . . . . . . 71

Chassis

Chassis

Chassis

Chassis Volume

Volume

Volume

Volume Contents

Contents

Contents

Contents

-2-

Anti-lock

Anti-lock

Anti-lock

Anti-lock Brake

Brake

Brake

Brake System

System

System

System (ABS)

(ABS)

(ABS)

(ABS)

ABS system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Diagnosis and Testing
ABS system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Operating principle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 79
Inspection and confirmation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Fault Symptom Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Removal/Installation
ABS system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..101

Wheel speed sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103

Transmission

Transmission

Transmission

Transmission Shaft

Shaft

Shaft

Shaft

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

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

Diagnosis and Testing
Transmission Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 107

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

Removal/Installation

Removal

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

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

Front

Front

Front

Front Suspension

Suspension

Suspension

Suspension

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

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

Diagnosis and Testing
Front Suspension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..114

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

Removal and Installation
Removal and Installation of Subframe. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131

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

Rear

Rear

Rear

Rear Axle

Axle

Axle

Axle

Rear axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 134

Explosive View of Rear Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..134
Introduction of Rear Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 135

Diagnosis and Testing
Rear axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 136

Operating principle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Inspection and Confirmation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 137
Fault symptom Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 140

Removal/Installation
Rear axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 141

Differential. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..141

Specification
Specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148

Tightening torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

Chassis

Chassis

Chassis

Chassis Volume

Volume

Volume

Volume Contents

Contents

Contents

Contents

- 3 -

Steering

Steering

Steering

Steering System

System

System

System

Steering System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

Explosive View of Steering System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Introduction of Steering System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Diagnosis and Testing
Steering System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

Operating Principle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Inspection and confirmation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 156
Fault Symptom Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..159

Removal and Installation

Removal and Installation of Steering System. . . . . . . . . . . . . . . . . . . . . . . . . . 164
Removal and Installation of steering wheel. . . . . . . . . . . . . . . . . . . . . . . . . . ... 167

Wheels

Wheels

Wheels

Wheels and

and

and

and Tires

Tires

Tires

Tires

Wheels and Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..174

Explosive View of Wheels and Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 175
Precaution for Tire Usage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 175

Diagnosis and Testing

Removal/Installation Instruction of Tire Assembly. . . . . . . . . . . . . . . . . . . . . . . . 176
Fault Symptom Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..177

Removal/installation

Removal/installation of wheel

and Tires. . . . . . . . . . . . . . . . . . . . . . . . . . 178

Four-Wheel

Four-Wheel

Four-Wheel

Four-Wheel Alignment

Alignment

Alignment

Alignment

Four-Wheel Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184

Preparation before four-wheel alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . ... 184

Diagnosis and Testing
Four-Wheel Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185

Function of each angle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Common fault symptom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

Adjustment
Four/wheel alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 187

Attached

Attached

Attached

Attached List

List

List

List—

—

—

—SUNRAY

SUNRAY

SUNRAY

SUNRAY Special

Special

Special

Special Service

Service

Service

Service Tools

Tools

Tools

Tools

CL

CL

CL

CL Clutch

Clutch

Clutch

Clutch

- 1-

Clutch

Clutch

Clutch

Clutch

Applied models: SUNRAY products manufactured by JAC

Subject

Page

Instruction

Instruction

Instruction

Instruction and

and

and

and Operation

Operation

Operation

Operation

Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...1

Explosive View of Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 1
Introduction of Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Diagnosis

Diagnosis

Diagnosis

Diagnosis and

and

and

and Testing

Testing

Testing

Testing

Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...2

Operating Principle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Inspection and Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 3
Fault Symptom Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..4

Removal

Removal

Removal

Removal and

and

and

and Installation

Installation

Installation

Installation

Clutch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7

Specification

Specification

Specification

Specification

Specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 14

Tightening Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

CL

CL

CL

CL Clutch

Clutch

Clutch

Clutch

- 2-

Instruction

Instruction

Instruction

Instruction and

and

and

and Operation

Operation

Operation

Operation

Clutch

Clutch

Clutch

Clutch

System diagram:

Diagram of Clutch Control System

1.Clutch

2.Clutch release cylinder

3.Release fork

4.Release bearing

5.Clutch line

6.Clutch master cylinder 7.Clutch pedal

8.Fluid reservoir

Schematic Diagram of Clutch Control Principle

1.Clutch pedal

2.Clutch master cylinder

3.Clutch hydraulic line

4.Clutch release cylinder

5.Release fork

6.Pressure plate

7.Driven disc

8.Flywheel