Engine JAC HFC4DA1-2C. Service manual — part 119
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 Manual 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 manual 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 Manual. If locking device is damaged during
removal, please replace it with new one.
No part of this manual 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
Manual
Manual
Manual
Manual Transmission
Transmission
Transmission
Transmission
Manual Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Explosive View of Manual Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Introduction of Manual Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...16
Manual transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 17
Inspection and confirmation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fault Symptom Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Removal/Installation
Manual 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
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