JAC HFC4DA1-2C engine. Service Manual — 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
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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
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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
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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
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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
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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
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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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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
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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
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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
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