JAC S2 (Chassis). Instruction — part 10

Wheel and Tire

Wheel and Tire

134

2). Remove the girdle clamp to disconnect vacuum hose
and vacuum power steel pipe

(II) Installation

1. Install the vacuum hose assembly

1). Install the girdle clamp to connect vacuum hose and
booster

2). Install the girdle clampto connect vacuum hose and
power steel pipe

2. Close the engine hood

XVII Liquid sensor of brake fluid

(I) Disassembly

1. Open the engine hood
2. Disconnect the battery’s negative cable
3. Remove the liquid sensor

1). Remove the clamp to disconnect sensor’s harness
connector

Wheel and Tire

Wheel and Tire

135

2). Take out the sensor from the side face of storage tank

△Notice No need to discharge the brake fluid

(II) Installation

1. Install the liquid sensor of brake fluid

1). Install the sensor into the correct position of the liquid
tank

2). Connect the harness connector of sensor

2. Connect the battery’s negative cable
3. Close the engine hood

XVIII Air-removal of brake system

(I) System’s air-exhaust

△Notice Air cannot be exhausted from hydraulic brake on
MT type. If the air is mixed in ABS hydraulic brake, or
unfilled ABS hydraulic brake is installed, it is necessary to
use fault diagnosis tester to exhaust air from the brake
system. The situation of ABS brake when the car goes off-
line is filled without air, and air will not enter the ABS
brake during normal service process. Under this situation,
please use instruction air-removal process.

1. Preparation

Wheel and Tire

Wheel and Tire

136

1). Keep the engine shut down, and stamp the brake pedal
for several times till no assist power exists.

2). Add brake fluid into fluid storage of master cylinder,
and ensure the liquid level more than half during air-
removal process

2. Exhaust air from master cylinder

△Notice If the master cylinder is re-installed, or the
liquid storage is empty, please exhaust the air from the
master cylinder

1). Stamp and hold the brake pedal till the end side

2). Loosen one brake oil pipe from the master cylinder,
and fasten the joint after the brake fluid runs off

3). Loosen the other brake oil pipe from the master
cylinder, and fasten the joint after the brake fluid runs off
△Notice Cover the painting side with rag to prevent fluid
adhesion

4). Repeat step 1) to 3) for 3~4 times

3. Exhaust air from brake pipe

1). Remove the dust cover of bleeder screw on the brake

2). Connect a transparent tube with the bleeder screw on
the left-rear brake, and soak
△Notice Exhaust air from brake pipe consecutively from
far to near ABS brake

3). Stamp the brake pedal slowly for several times till the
pedal is on the end side
△Notice Do not stamp the pedal quickly

4). Loosen the bleeder screw and exhaust air from brake
while holding the brake pedal

5). Tighten the bleeder screw and slowly loosen the brake
pedal when the brake fluid stops overflowing

6). Repeat step 3) to 5) till the air in the brake fluid is
completely exhausted

7). If no air bubble appears in the tank when loosen the
bleeder screw, it means the air is completely exhausted
△Notice ensure the liquid level is more than half during
air-removal process

8). Tighten the bleeder screw

Tightening torque 7~13N.m

9). Exhaust air in other brakes by following step 1) to 8)

10). Check whether the brake pedal is stamped softly or
not after exhausting air from all brakes. If yes, please

Wheel and Tire

Wheel and Tire

137

repeat the whole process till it works normally.

XIX Oil outlet tube of master cylinder

(I) Disassembly

1. Open the engine hood
2. Drain the brake fluid (please refer to “brake fluid”)
3. Remove the assembly of master cylinder’s fuel outlet pipe

1). Loosen the screw on fuel pipe to disconnect pipe
assembly and brake master cylinder

2). Remove the oil pipe screw to disconnect fuel outlet
pipe assembly and ABS/ESP controller

3). Loosen the two pipe clamps and 2 front pipe clamps
that fix the oil outlet pipe assembly

(II) Installation

1. Install the oil outlet pipe assembly

1). Install the assembly on the 2 pipe clamps and 2 front
pipe clamps

Wheel and Tire

Wheel and Tire

138

2). Install the oil pipe screw to connect the assembly and
ABS/ESP controller

Tightening torque: 16~18N.m

3). Install oil pipe screw to connect assemblyand master
cylinder

Tightening torque: 16~18N·

m

2. Add brake fluid (please refer to “brake fluid”)
3. Exhaust air from brake system (please refer to “air-
removal of brake system”)
4. Close the engine hood

XX Front brake pipe assembly

(I) Disassembly

1. Open the engine hood
2. Drain the break fluid (please refer to “brake fluid”)
3. Remove the left-front brake oil pipe assembly

1). Remove the screw that connects left-front brake pipe
assembly and brake hose

Wheel and Tire

Wheel and Tire

139

2). Loosen the screw to disconnect left-front brake oil
pipe assembly and ABS/ESP controller

3). Unfix the two pipe clamps and two white three-hole
clamps that tighten the left-front brake oil pipe

4). Detach the left-front brake oil pipe assembly

4. Remove the left-rear and right-rear brake pipe assembly

1). Remove the oil pipe screw that connects left-rear brake
pipe assembly and pipe itself

2). Remove the oil pipe screw that connects right-rear
brake pipe assembly and pipe itself

3). Remove the oil pipe screw that connects left-rear brake
pipe assembly and pipe itself

4). Remove the oil pipe screw that connects right-rear
brake pipe assembly and pipe itself

Wheel and Tire

Wheel and Tire

140

5). Unfix the two pipe clamps and teo white three-hole cla

mps that tighten the left-rear and right-rear brake pipe
assembly

6). Detach the left-rear and right-rear brake pipe assembly

(II) Installation

1. Install the left-front brake oil pipe assembly

1). Install the screw that connects left-front brake oil pipe
and brake hose

Tightening torque:

16~18N·m

2). Install the screw that connects left-front brake oil pipe
and ABS/ESP controller

Tightening torque:

16~18N·m

3). Install the left-front brake oil pipe to the two pipe
clamps and two front clamps that fix the left-front brake
oil pipe assembly

Wheel and Tire

Wheel and Tire

141

2. Install the left-rear and right-rear brake pipe assembly

1). Tighten the screw that fixes the left-rear brake pipe
assembly and ABS/ESP controller

Tightening torque:

16~18N·m

2). Tighten the screw that fixes the right-rear brake pipe
assembly and ABS/ESP controller

Tightening torque:

16~18N·m

3). Install the screw that connects the left-rear brake pipe
assembly and the final part of left-rear brake pipe

Tightening torque 16~18N.m

4). Install the screw that connects the right-rear brake
pipe assembly and the final part of right-rear brake pipe

Tightening torque 16~18N.m

5). Install the left-rear and right-rear brake pipe assembly
on the two pipe clamps and two white triple clamps

3. Add brake fluid, please refer to “brake fluid”
4. Exhaust air from brake system, please refer to “Air-
removal of brake system”
5. Close the engine hood

XXI Rear brake pipe assembly

(I) Disassembly

1. Open the engine hood
2. Drain the brake fluid, please refer to “brake fluid”
3. Remove the rear wheel, please refer to “wheel”
4. Disassemble the final parts of left-rear and right-rear
brake pipe assembly

1). Remove the cover-sheet assembly of rear brake pipe
assembly

Wheel and Tire

Wheel and Tire

142

2). Loosen the screw that connects left-rear brake pipe and
the final part of left-rear brake pipe

3). Loosen the screw that connects right-rear brake pipe
and the final part of right-rear brake pipe

4). Loosen the screw that connects final part of left-rear
brake pipe assembly and left-rear brake hose

5). Loosen the screw that connects final part of right-rear
brake pipe assembly and right-rear brake hose

6). Dismantle the five pipe clamps and the single pipe
clamp that connects final-part of left-rear assembly and
car body

7). Dismantle the five pipe clamps and three single pipe
clamp that connects final-part of right-rear assembly and
car body

8). Take off the final part of left-rear and right-rear brake
pipe assembly

5. Dismantle the assembly of left-rear and right-rear brake pipe

1). Loosen the screw that connects left-rear brake pipe
assembly and left-rear brake hose II

2). Loosen the screw that connects right-rear brake pipe
assembly and right-rear brake hose II

Wheel and Tire

Wheel and Tire

143

3). Loosen the screw that connects left-rear brake pipe
assembly and left-rear brake hose

4). Loosen the screw that connects right-rear brake pipe
assembly and right-rear brake hose

5). Take off the left-rear and right-rear brake pipe
assembly

6. Remove the rear brake oil pipe support

1). Loosen the fixed bolt that connects rear brake oil
pipe and car body

2). Take off the rear brake oil pipe support

(II) Installation

1. Install the final part of left-rear and right-rear brake pipe assembly

1). Tighten the screw that connects left-rear brake pipe
assembly and the final part of left-rear brake pipe

Tightening torque 16~18N.m

2). Tighten the screw that connects right-rear brake pipe
assembly and the final part of right-rear brake pipe

Tightening torque 16~18N.m

3). Install the screw that connects the final part of left-
rear brake pipe assembly and left-rear brake hose

Tightening torque 16~18N.m

4). Install the screw that connects the final part of right-
rear brake pipe assembly and right-rear brake hose

Tightening torque 16~18N.m

Wheel and Tire

Wheel and Tire

144

5). Install the five pipe clamps and the single pipe clamp
that connect the final part of left-rear brake pipe
assembly and car body

6). Install the five pipe clamps and three single pipe
clamps that connect the final part of left-rear pipe
assembly and car body

7). Install the cover sheet of the final part of rear brake
pipe

2. Install the assembly of left-rear and right-rear brake
pipe

1). Install the screw that connects left-rear brake pipe
assembly and left-rear brake hose II

Tightening torque 16~18N.m

2). Install the screw that connects right-rear brake pipe
assembly and right-rear brake hose II

Tightening torque 16~18N.m

3). Install the screw that connects left-rear brake pipe
assembly and left-rear brake hose

Tightening torque 16~18N.m

4). Install the screw that connects right-rear brake pipe
assembly and right-rear brake hose

Tightening torque 16~18N.m

3. Install the rear brake oil pipe support

1). Install the two fixed bolts that connect rear brake oil
tube support and car body

Tightening torque 20~25N.m

4. Add brake fluid, please refer to “brake fluid”
5. Exhaust air from brake system, please refer to
“Air-removal of brake system”
6. Install the rear wheels
7. Close the engine hood

Wheel and Tire

Wheel and Tire

145

XXII Rear brake hose assembly

(I) Disassembly

1. Lift the car
2. Drain the brake fluid, please refer to “brake fluid”
3. Dismantle the rear brake hose assembly

1). Remove the screw that connects rear brake hose
assembly and the final part of rear brake pipe

2). Remove the screw that connects left-rear brake hose
assembly and the left-rear brake pipe assembly

3). Take off the rear brake hose assembly

(II) Installation

1. Install the rear brake hose assembly

1). Install the screw that connects left-rear brake hose
assembly and the final part of left-rear brake pipe

Tightening torque 16~18N.m

2). Install the screw that connects left-rear brake hose
assembly and the left-rear brake pipe assembly

Tightening torque 16~18N.m

Wheel and Tire

Wheel and Tire

146

2. Add brake fluid, please refer to “brake fluid”
3. Exhaust air from brake system, please refer to “Air-
removal of brake system”
4. Lift down the car

XXIII Right-front brake oil pipe assembly

(I) Disassembly

1. Open the engine hood
2. Drain the brake fluid, please refer to “brake fluid”
3. Dismantle the right-front oil pipe assembly

1). Loosen the screw that connects right-front brake oil
pipe assembly and right-front brake hose

2). Loosen the screw that connects right-front brake oil
pipe assembly and ABS/ESP controller

3). Take off the right-front brake oil pipe assembly

(II) Installation

1. Install right-front brake oil pipe assembly

1). Tighten the screw that connects right-front brake oil
pipe and right-front brake hose

Tightening torque 16~18N.m

Wheel and Tire

Wheel and Tire

147

2). Tighten the screw that connects right-front brake oil
pipe and ABS/ESP controller

Tightening torque 16~18N.m

2. Add brake fluid, please refer to “brake fluid”
3. Exhaust air from brake system, please refer to “Air-removal of brake system”
4. Close the engine hood

Parking Brake System

Parking brake system

148

Parking Brake System

I General introduction

(I) Brief introduction of structure

Structure diagram of parking brake system

1. Parking brake handle assembly 3. Fibre-drawing assembly of right-parking brake
2. Fibre-drawing assembly of left-parking brake

(II) Maintenance parameter

Project

Specification

Rear parking
brake

Type

Drum

Diameter of wheel cylinder

17.46mm

Diameter of brake drum

204mm

Thickness of frictional pad

4mm

Type

Floating caliper/Ventilated disc

Disc diameter

275mm

Disc thickness

9mm

Thickness of frictional pad

8mm

Cylinder diameter

34mm

Parking Brake System

Parking brake system

149

(III) Torque parameter

No.

Project

Torque (N.m) Remark

1

Fixed bolt of parking brake handle 20~25

2

Fixing screw of parking brake
switch

6~8

3

Nut and bolt of fixing support for
parking brake

7~11

II Failure diagnosis

(I) Chart of failure and diagnosis

No.

Failure

Diagnosis

Solution

Remark

1

Indicator lamp
keeps lighting or
doesn’t work

Check whether the indicator lamp on
dashboard is broken

Change the indicator lamp
on dashboard

Check whether the bolt between the
switch and tooth plate is fixed

Adjustment

2

Brake delay

The parking is not released totally

Release the parking brake

Improper adjustment on parking brake

Adjustment

3

Insufficient
parking brake
force

Rear brake shoes are broke

Adjustment

Lubriacating grease or oil exists on the
surface of rear brake shoes

Change the brake shoes

The fibre-drawing of parking brake is
stuck

Adjustment

Malfunction appears in self-adjustment
mechanism

Adjustment

Excessive distance for parking brake
handle

Adjustment

4

Parking brake
fails

Fibre-drawing or sleeve corrodes

Stiff spring is broken, brake off or loses
elasticity

Check whether the fibre-
drawing or spare parts for
braking system are broken;
Check whether the handle
works smoothly without
delay; Check the connector
and fixed part of fibre-
drawing is loosen or
broken, and repair&change
these parts if necessary

III Check and adjustment on the assembly of parking brake system