JAC HFC4DA1-2C engine. Instruction — part 41

PS

PS

PS

PS PowerSteering

PowerSteering

PowerSteering

PowerSteering System

System

System

System

- 167 -

Removal

Removal

Removal

Removal and

and

and

and Installation

Installation

Installation

Installation of

of

of

of

Steering

Steering

Steering

Steering Wheel

Wheel

Wheel

Wheel

Removal:
1.

Remove the negative cable of the battery.

2.

Remove the upper and lower protective plates of
the steering column.

3.

Disconnect the plug of the ignition switch harness.

4.

Carry out steering wheel centering and lock it up.

5.

Remove the steering wheel central covering plate.

PS

PS

PS

PS PowerSteering

PowerSteering

PowerSteering

PowerSteering System

System

System

System

- 168 -

Removal

Removal

Removal

Removal and

and

and

and Installation

Installation

Installation

Installation of

of

of

of Steering

Steering

Steering

Steering Wheel

Wheel

Wheel

Wheel (Continued)

(Continued)

(Continued)

(Continued)

6.

Remove mounting nuts of the steering wheel and
remove the steering wheel.

Installation
Warning:

Warning:

Warning:

Warning:

Prior to the steering wheel installation, Keep the

ignition switch upright all the time.

1.

Return the steering wheel to ensure the ignition
switch set in place.

2.

Reinstall all parts in the reverse order of removal.

PS

PS

PS

PS PowerSteering

PowerSteering

PowerSteering

PowerSteering System

System

System

System

- 169 -

Removal

Removal

Removal

Removal and

and

and

and Installation

Installation

Installation

Installation of

of

of

of

Steering

Steering

Steering

Steering Column

Column

Column

Column

Removal
1.

Disconnect the negative cable of the battery

2.

Remove the upper and lower protective plates of
the steering column.

3.

Remove the multi-functional combination switch.

4.

Return the steering wheel to the intermediate
position and lock it up.

5.

Remove track bolts on the joint of the steering
column and steering knuckle.
Turn clamped plates and take them down.

PS

PS

PS

PS PowerSteering

PowerSteering

PowerSteering

PowerSteering System

System

System

System

- 170 -

Removal

Removal

Removal

Removal and

and

and

and Installation

Installation

Installation

Installation of

of

of

of Steering

Steering

Steering

Steering Column

Column

Column

Column (Continued)

(Continued)

(Continued)

(Continued)

6.

Remove four mounting nuts for fixing the lower
part of the steering column onto the partition panel.

7.

Disconnect the ignition switch plug.

8.

Remove the steering column.

Installation
9.

Install the steering column in place and ensure the
correct positioning of bolts on the lower part of the
steering column.

PS

PS

PS

PS PowerSteering

PowerSteering

PowerSteering

PowerSteering System

System

System

System

- 171 -

Removal

Removal

Removal

Removal and

and

and

and Installation

Installation

Installation

Installation of

of

of

of Steering

Steering

Steering

Steering Column

Column

Column

Column (Continued)

(Continued)

(Continued)

(Continued)

10. Fix the lower part of the steering column onto the

partition panel.

11. Reconnect the harness plug of the ignition switch.
12. Reinstall the combination switch.
13. Fix the wire with cable ties.

Caution:

Caution:

Caution:

Caution:

Ensure

that

the

steering

wheel

is

in

the

intermediate position.

14. Align the clamped plates of the cardan universal

joint to the shaft and install the clamped plates.

15. Install the upper and lower protective plates of the

steering column in place.

16. Connect the negative cable of the battery.

WT

WT

WT

WT Wheels

Wheels

Wheels

Wheels and

and

and

and Tires

Tires

Tires

Tires

- 173 -

Wheels

Wheels

Wheels

Wheels and

and

and

and Tires

Tires

Tires

Tires

Applied models: SUNRAY products manufactured by JAC

Subject

Page

Instruction

Instruction

Instruction

Instruction and

and

and

and Operation

Operation

Operation

Operation

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

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

Diagnosis

Diagnosis

Diagnosis

Diagnosis and

and

and

and Testing

Testing

Testing

Testing

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

Removal/installation

Removal/installation

Removal/installation

Removal/installation

Removal/installation of wheel

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

WT

WT

WT

WT Wheels

Wheels

Wheels

Wheels and

and

and

and Tires

Tires

Tires

Tires

- 174 -

Instruction

Instruction

Instruction

Instruction and

and

and

and Operation

Operation

Operation

Operation

SUNRAY

SUNRAY

SUNRAY

SUNRAY vehicles

vehicles

vehicles

vehicles adopts

adopts

adopts

adopts tire

tire

tire

tire models

models

models

models of

of

of

of GITI

GITI

GITI

GITI 1

1

1

19

9

9

95

5

5

5/70

/70

/70

/70R15LT

R15LT

R15LT

R15LT and

and

and

and 185R15LT

185R15LT

185R15LT

185R15LT.

Tires of different sizes are applied for bearing the
vehicle weight, supplying driving force and brake force,

buffering the impact from road surface as well as
changing the running direction of vehicle..

WT

WT

WT

WT Wheels

Wheels

Wheels

Wheels and

and

and

and Tires

Tires

Tires

Tires

- 175 -

Notice

Notice

Notice

Notice for

for

for

for tire

tire

tire

tire usage

usage

usage

usage

Please use the genuine tires manufactured by the
original manufacturer.
During running-in period of new tires, please avoid fast
starting, sharp turning and emergent braking, and don’t
use tires under severe working conditions, in order to
protect the new tires from premature damage.
Wheel

balance

should

be

conducted

before

the

application of new tires.

Tires

Tires

Tires

Tires

Inspection:

Inspection:

Inspection:

Inspection:

1.

Inspection of tire pressure

�

Check the inflation pressure of tire. Make
adjustment if the pressure is not within the
standard range.

Standard value: 450±10KPa

Attention:

Attention:

Attention:

Attention:

Check the tire pressure by using tire pressure gauge
of good performance. Check tires for wear,
improper inflation, crack or other damage.
Please check the tire pressure if the ambient
temperature experiences violent change.

�

Improper tire pressure shall lead to the results
below:

a.

Under-pressure shall lead to quick wear of tire
shoulder, as well as increase of tire deflection
and rolling resistance.

b.

Over-pressure shall lead to quick wear of the
middle part of tire crown and decrease of
buffer capacity.

2.

Inspection of improper alignment
Too large/small front/rear wheel toe-in shall lead to
feathered wear of tire.

3.

Inspection of tire tread

�

Check the tread depth of tire.

Note:

Note:

Note:

Note: Tire size: 185R15LT

When the tread depth reaches to the limit

value or smaller, wear mark shall be shown on
the tread; at this time, please replace the tire.

�

Check tire tread for any foreign matter. If any,
please clear it.

4.

Check wheel for crack or other damages. If there is
deformation, please check the wheel runout.

�

Remove the tire from wheel and install it onto
the wheel balancer.

�

Set the dial indicator as shown in figure.
Please

refer

to

“Maintenance

Data

and

Specification” for wheel runout. If it exceeds the
limit, please replace it.
Tire rotation::::
Perform tire rotation after the vehicle running for
8000Km. tire rotation shall also be conducted when
changing with a new tire.

Replacement:

Replacement:

Replacement:

Replacement:

①

Please replace tire after normal running for
50000Km.

②

Replace tire in case one of the following conditions
occurs:

�

At least 3 wear marks exposed on tire tread.

�

Tire cord fabric or tire cord exposed on the
rubber.

�

Cracking of tire tread or shoulder with cord
fabric exposed.

�

Tire bulge, upheaval or layering.

�

Tire being punctured or scratched or other
damages that is hardly to recover.

Wheel

Wheel

Wheel

Wheel &

&

&

& tire

tire

tire

tire assembly

assembly

assembly

assembly

Removal/installation:

Removal/installation:

Removal/installation:

Removal/installation:

1.

Removal

�

Remove wheel nut.
Tightening torque: 220～280N.m

�

Remove wheel & tire assembly.

2.

Installation
Install wheel & tire assembly and tire nut.
Attention:

Attention:

Attention:

Attention:
As for instruction installation, tighten it according to
the diagonal order after nuts are pre-tightened in
sequence.
As for auto tightening, adjust the tightening torque
and tighten it at one time.
Please tighten all wheel nuts in the order indicated
in the figure.

Wheel

Wheel

Wheel

Wheel balance:

balance:

balance:

balance:

1.

Removal

�

Remove the wheel and tire in need of
adjustment.

�

Remove the used balance weight on both sides
of wheel and clear any foreign matter on the
tire tread.

Attention:

Attention:

Attention:

Attention:

Don’t make the tire scratched during removal. In
case of new tire, rubber belt on tire should be
removed.

2.

Wheel balance adjustment

�

Install the wheel onto the balancer by
centering the center hole and start the wheel
balancer.

�

When both inner and outer balance values are
displayed on the balancer, the actual balance
weight can be obtained by multiplying the
outer balance value by 5/3. Choose the outer
balance weight approaching to the calculated
value and install it onto the specified position
outside or diagonal position.

Attention:

Attention:

Attention:

Attention:

Install

the

inner

balance

weight

after

the

installation

of

outer

balance

weight.

Before

installation, please make the mating surface clean.
a.

Install the balance weight to the position as

WT

WT

WT

WT Wheels

Wheels

Wheels

Wheels and

and

and

and Tires

Tires

Tires

Tires

- 176 -

shown in the figure.

b.

When installing balance weight onto wheel,
the balance weight shall be placed onto inner
wall with grooves as shown in the right figure,
with the center of balance weight aligned with
the position (or angle) indicated by the wheel
balancer.

c.

If the calculated balance weight exceeds by
50g, please install two balance weights in the
same straight line.

Attention:

Attention:

Attention:

Attention:

�

For balance weight cannot be reused, please
apply new one every time.

�

No more than two pieces of balance weight
can be installed.

�

Please always use genuine balance weight.

�

Please don’t place one balance weight onto
another one.

③

Restart the wheel balancer.

④

Knock in the balance weight from the inside of
wheel as per position (or angle) indicated by wheel
balancer.

⑤

Start the balancer to verify if the residual
inside/outside unbalance value is below 10g. If the
residual unbalance value of any side is over 10g,
dynamic balance test should be conducted.

WT

WT

WT

WT Wheels

Wheels

Wheels

Wheels and

and

and

and Tires

Tires

Tires

Tires

- 177 -

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

Solution

Steering wheel circular vibration

Excessive deflection of wheel and rim

Looseness of wheel nut

Wheel unbalance

Uneven wear of tire

Under-pressure of tire

Damage or wear of front wheel bearing

Steering system fault

Suspension system fault

Replace

Tighten

Adjust

Adjust or replace

Adjust

Adjust or replace

Adjust or replace

Adjust or replace

Premature wear of tire

Improper tire pressure

Adjust

Tire noise

Improper tire pressure

Tire deterioration

Adjust

Replace

Road noise or body vibration

Under-pressure of tire

Wheel unbalance

Deformation of rim and tire

Uneven wear of tire

Adjust

Adjust

Repair or replace

Adjust or replace

Up and down vibration of steering wheel

Excessive deflection of wheel and rim

Looseness of wheel nut

Wheel unbalance

Fracture or wear of engine mounting rubber

Fracture or wear of transmission mounting
rubber

Replace

Tighten

Adjust

Replace

Replace

Steering wheel drifted to one side

Improper tire pressure

Excessive or uneven wear of tire

Steering system fault

Brake system fault

Suspension system fault

Adjust

Adjust or replace

Adjust or replace

Adjust or replace

Adjust or replace

Wobbling

Both side tire pressure unbalance

Deformation of rim and tire

Looseness of wheel nut

Steering system fault

Suspension system fault

Adjust

Repair or replace

Tighten

Adjust or replace

Adjust or replace

Brake pulled to one side

Both side tire pressure unbalance

Brake system fault

Adjust

Adjust or replace

Heavy steering wheel felt

Under-pressure of tire

Steering system fault

Suspension system fault

Adjust

Adjust or replace

Adjust or replace

Poor steering wheel return

Under-pressure of tire

Steering system fault

Suspension system fault

Adjust

Adjust or replace

Adjust or replace

WT

WT

WT

WT Wheels

Wheels

Wheels

Wheels and

and

and

and Tires

Tires

Tires

Tires

- 180 -

Removal/installation

Removal/installation

Removal/installation

Removal/installation of

of

of

of front

front

front

front wheel

wheel

wheel

wheel assembly

assembly

assembly

assembly

Removal/installation

Removal/installation

Removal/installation

Removal/installation

Removal

1.

Loosen tire nut, and have the vehicle jacked to
remove the tire.

2.

Remove brake hose from shock absorber.

Note:

Note:

Note:

Note:

Loosen the brake caliper top bolt properly for
removal of brake caliper.

3.

Remove the brake caliper.

�

Hang the brake caliper beside the shock
absorber in order to avoid damage of brake
hose.

Caution:

Caution:

Caution:

Caution:

The left hand side bearing adjusting nut is of left
hand thread.

4.

Remove flange assembly.

�

Remove dust cover.

�

Remove split pin and nut lock piece.

�

Remove wheel bearing adjusting nut.

�

Remove washer and flange assembly together.

WT

WT

WT

WT Wheels

Wheels

Wheels

Wheels and

and

and

and Tires

Tires

Tires

Tires

- 181 -

Removal/installation

Removal/installation

Removal/installation

Removal/installation

Installation
Caution:

Caution:

Caution:

Caution:

The left hand side bearing adjusting nut is of left
hand thread.

1.

Install flange assembly.

�

Install washer and hub assembly together
with outer bearing.

Install wheel bearing adjusting nut.

2.

Install brake caliper.

3.

Install brake hose onto shock absorber.

4.

Install wheel plane bearing.

5.

Determine wheel bearing end play.

�

Tighten wheel bearing adjusting nut and rotate
the wheel at the same time to make bearing
installed in place.

�

Unscrew nut by 180° and shake wheel mount.

�

Push and pull wheel until bearing end play
can be felt.

�

If necessary, loosen the adjusting nut again by
90° until clearance can be felt.

�

Measure end play (required to be 0.002 ～
0.05mm）.

�

If

necessary,

rotate

the

adjusting

nut

clockwise or counterclockwise

to obtain

required end play.

6.

Use new split pin and dust cover and reinstall the

nut lock piece.

7.

Lower the vehicle.

WT

WT

WT

WT Wheels

Wheels

Wheels

Wheels and

and

and

and Tires

Tires

Tires

Tires

- 182 -

Replacement

Replacement

Replacement

Replacement of

of

of

of front

front

front

front flange

flange

flange

flange assembly

assembly

assembly

assembly (with

(with

(with

(with flange

flange

flange

flange assembly

assembly

assembly

assembly already

already

already

already removed)

removed)

removed)

removed)

Removal
1.

Mark properly on flange and brake disc to facilitate
positioning during reinstallation.

2.

Remove flange from brake disc.

3.

Remove oil seal.

4.

Remove inner and outer races of conical bearing.

Caution:

Caution:

Caution:

Caution:

Don’t make burr on flange to ensure bearing race
can be fitted in place.

Note:

Note:

Note:

Note:

Tap the bearing race alternately and diagonally and
don’t make the sleeve tilted.

5.

Remove inner and outer races of bearing.

6.

Clean mating face between wheel hub and brake
disc.

WT

WT

WT

WT Wheels

Wheels

Wheels

Wheels and

and

and

and Tires

Tires

Tires

Tires

- 183 -

Removal/installation

Removal/installation

Removal/installation

Removal/installation

Installation
1.

Install the flange onto the brake disc.

Caution:

Caution:

Caution:

Caution:

The adopted bearing races and rollers should be
from the same manufacturer.

2.

Reinstall the inner and outer races of bearing.

3.

Apply grease onto race and roller bearing.

4.

Reinstall it onto the bearing race.

5.

Clean the periphery of oil seal seat and apply
sealant onto it.

6.

Install oil seal and remove redundant sealant.

7.

Fill sealing shaft with grease and apply grease onto
lip surface.

FT

FT

FT

FT Four-Wheel

Four-Wheel

Four-Wheel

Four-Wheel Alignment

Alignment

Alignment

Alignment

- 183 -

Four-Wheel

Four-Wheel

Four-Wheel

Four-Wheel Alignment

Alignment

Alignment

Alignment

Applied models: SUNRAY products manufactured by JAC

Subject

Page

Instruction

Instruction

Instruction

Instruction and

and

and

and Operation

Operation

Operation

Operation

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

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

Diagnosis

Diagnosis

Diagnosis

Diagnosis and

and

and

and Testing

Testing

Testing

Testing

Four-Wheel Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185

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

Adjustment

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

FT

FT

FT

FT Four-Wheel

Four-Wheel

Four-Wheel

Four-Wheel Alignment

Alignment

Alignment

Alignment

- 184 -

Instruction

Instruction

Instruction

Instruction and

and

and

and Operation

Operation

Operation

Operation

Objectives

Objectives

Objectives

Objectives for

for

for

for four-wheel

four-wheel

four-wheel

four-wheel alignment:

alignment:

alignment:

alignment:

�

Elimination of deflection

�

Decrease of chassis wear

�

Straightness of linear steering wheel

�

Decrease of tire wear

�

Straightness of steering wheel after turning

�

Decrease of tire wear

�

Straightness of linear steering wheel

�

Recovery of new car driving feeling

Principle

Principle

Principle

Principle and

and

and

and five

five

five

five factors

factors

factors

factors of

of

of

of four-wheel

four-wheel

four-wheel

four-wheel alignment

alignment

alignment

alignment

Principle:

Principle:

Principle:

Principle:

Rear wheels aligned first and then front wheels
Five

Five

Five

Five factors

factors

factors

factors:

1.

Camber

2.

Inclination angle

3.

Caster

4.

Toe-in

5.

Adjustment of thrust axis and angle

Function of four-wheel alignment
Four-wheel alignment functions for measurement of
alignment angle of chassis. In case of a little change in
chassis parameters, it is only needed to adjust the
alignment angle; in case of large difference, the

deformed or damaged parts should be detected for
complete removal of fault.
Note: It is a must to check the chassis condition before
conducting four-wheel alignment.
Preparation

Preparation

Preparation

Preparation before

before

before

before four-wheel

four-wheel

four-wheel

four-wheel alignment

alignment

alignment

alignment

1.

Check tire pressure and adjust it as required.

2.

Check body height.

�

Front part measurement

�

Rear part measurement

3.

Check wheel bearing clearance and replace front
wheel bearing when necessary.

4.

Check rim and tire condition.

5.

Check steering linkage and ball joint for looseness.

6.

Park the vehicle on flat ground with no luggage or
person inside.

7.

Check

wheels;

check

front

suspension

for

looseness.

8.

Check shock absorber for normal operation.

Note:
Make sure half level in oil tank, as well as the required
level of cooling water in water tank and proper engine
oil. The tire jack and accessories should be placed at the
specified position.