JAC HFC4DA1-2C Maintenance Manual

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Chapter I Technical Characteristics of Engine .......................................................................................................... 11

Section I Technical Requirements for Fuel, Oils, and Auxiliary Materials ..................................................... 11

Section II Main Technical Specification of Engine ............................................................................................ 14

Section III Performance Curve of Engine .......................................................................................................... 15

Section IV Main Checking and Adjustment Parameters .................................................................................. 16

Section V Tightening Torque for Critical Bolts of Engine ................................................................................. 17

Section VI Main Fitting Clearances and Allowable Wear Limits of Engine ................................................... 21

Section VII Specification of Main Attachments and Accessories ...................................................................... 24

Chapter II Maintenance for Main Structures of Engine ........................................................................................... 25

Section I Disassembly of Engine Assembly ......................................................................................................... 25

Section II Assembly of Engine ............................................................................................................................. 43

Section III Crankshaft and Flywheel System ..................................................................................................... 68

Section IV Piston and Connecting Rod Group ................................................................................................... 69

Section V Valve Distribution Mechanism ........................................................................................................... 70

Section VI Lubrication System ............................................................................................................................ 71

Section VII Cooling System ................................................................................................................................. 72

Section VIII Turbocharger and Inter-Cooler System ........................................................................................ 73

Section IX EGR System ........................................................................................................................................ 75

Section X Exhaust System .................................................................................................................................... 76

Chapter III Working Principle of Engine Control and Actuator Units ................................................................... 77

Section I Overview of Diesel Common Rail System .......................................................................................... 77

Section II Working Principle of Low Pressure Fuel Line System .................................................................... 79

Section III Working Theory of High Pressure Fuel Line .................................................................................. 82

Section IV Electronic Control Unit of High Pressure Common Rail System .................................................. 84

Chapter IV Engine Diagnosis .................................................................................................................................... 109

Section I. Precautions ......................................................................................................................................... 109

Section II. Maintenance Procedures ................................................................................................................. 111

Section III. Fault Diagnosis ................................................................................................................................ 113

Section IV. DTC List ........................................................................................................................................... 115

Section V. Fault Diagnosis for Electronic-Controlled Common Rail Diesel Engines .................................... 133

Maintenance manual for sunray hfc4da1-2c china-IV diesel engines

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Page 1: Table Of Contents
Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Contents Chapter I Technical Characteristics of Engine ......................11 Section I Technical Requirements for Fuel, Oils, and Auxiliary Materials ............. 11 Section II Main Technical Specification of Engine .................... 14 Section III Performance Curve of Engine ......................15 ...
Page 2: Chapter I Technical Characteristics Of Engine
Section I Technical Requirements for Fuel, Oils, and Auxiliary Materials I. Diesel HFC4DA1-2C diesel engine adopts electronically controlled, high pressure common rail, fuel injection system and conforms to Euro-IV emission regulation and thus extends higher requirements over the fuel. To guarantee the reliability of the fuel supply system, make sure to use the qualified clean diesel produced by national well-established fuel company, in order to prevent the blockage or early wear of fuel injector due to poor fuel.
Page 3 II. Engine Oil HFC4DA1-2C diesel engine shall use the diesel engine oil with the quality grade at API CH-4 or above, of which the viscosity is related to the environment temperature. When the environment temperature is reduced, the viscosity of the engine oil is increased to increase the start resistance so that the diesel engine can’t reach the start speed and cause...
Page 4 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Never mix different trademarks of engine oils. Periodically replace the engine oil as per the maintenance regulations. III. Coolant Make sure to use clean automotive antifreeze coolant featuring antifreeze in winter, anti-boiling in summer, and anti-corrosion, anti-rusting, and anti-scaling.
Page 5: Section Ii Main Technical Specification Of Engine
Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Section II Main Technical Specification of Engine Model HFC4DA1-2C Inline 4-cylinder, longitudinal layout, water-cooled, 4-stroke, turbocharged Type inter-cooler, high pressure common rail, and direct injection engine Nominal power/speed 85/3600（kw/rpm） Top torque/speed 250/1800～2800(Nm/rpm) Minimum fuel consumption ≤...
Page 6: Section Iii Performance Curve Of Engine
Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Section III Performance Curve of Engine 扭矩 Torque Power 功率 Speed 转速（r p m ）油耗率 Fuel consumption 油耗量 Fuel consumption 转速（r pm ） Speed...
Page 7: Section Iv Main Checking And Adjustment Parameters
Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Section IV Main Checking and Adjustment Parameters 1、At rated power: (1) Exhaust temperature (master pipe) (ºC) ≤700 (2) Thermostat opening temperature (ºC) (3) Thermostat full open temperature (ºC) (4) Temperature of engine oil in main oil way (ºC) ≤130...
Page 8: Section V Tightening Torque For Critical Bolts Of Engine
Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Section V Tightening Torque for Critical Bolts of Engine ☆ Comparison Table of Tightening Torque for Critical Bolts Description N．m Fixing bolt of rockshaft Heater plug Nut and washer for fuel injector body...
Page 9 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Description N．m Belt pulley bolt Fan pulley 12.5 Crankshaft bearing cap bolt Connecting rod bearing cap bolt 25 for first step 85 for second step Camshaft timing gear Fuel injection pump nut...
Page 10 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Description N．m Tightening socket nut Bolt and nut of starter motor Fixing nut of starter cable Exhaust branch pipe bolt Bolt of heat shield Support bolt Front exhaust pipe nut Crankshaft belt pulley bolt...
Page 11 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines M22×1.5 256~422 370~555 433~649 M24×2.0 360~550 439~725 565~847...
Page 12: Section Vi Main Fitting Clearances And Allowable Wear Limits Of Engine
Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Section VI Main Fitting Clearances and Allowable Wear Limits of Engine Assembly Fitting Clearance for Wear Limit Name Standard Size (mm) nature New Engine (mm) (mm) Contact width between valve and seat ring...
Page 13 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Assembly Fitting Clearance for Wear Limit Name Standard Size (mm) nature New Engine (mm) (mm) Assembly Fitting Clearance for Wear Limit Name Standard Size (mm) nature New Engine (mm) (mm) Protrusion height 0～０.08...
Page 14 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Assembly Fitting Clearance for Wear Limit Name Standard Size (mm) nature New Engine (mm) (mm) Grouping of cylinder sleeve inside diameter (after pressed-in) Group A 93.021～93.032 Group B 93.032～93.043 Group C 93.043～93.054 Group D 93.054～93.065...
Page 15: Section Vii Specification Of Main Attachments And Accessories
Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Section VII Specification of Main Attachments and Accessories Engine oil pump type Externally engaged gear pump Flow rate of engine oil pump ≥ 23L/m (at 1,000r/m and 0.4MPa) ≥ 23L/m (at 1,800r/m and 0.44MPa)
Page 16: Chapter Ii Maintenance For Main Structures Of Engine
Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Chapter II Maintenance for Main Structures of Engine Section I Disassembly of Engine Assembly I. Special Notices: a) Before overhauling the engine, make sure to firstly disconnect the negative cable of the battery, or it will damage the harness and other electric units;...
Page 17 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines III. Illustration for Disassembly of Engine 1. Disassemble the flywheel. a. Block the flywheel with flywheel clamp, loosen the fixing bolts between damping pulley and flywheel, and disassemble the flywheel assembly. 2. Disassemble the belt, air conditioner compressor, and alternator and water pump pulleys.
Page 18 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines 3. Disassemble the exhaust system. a. Disassemble the fixing bolts of turbocharger lubricating oil pipe and disassemble the fixing clamp of return hose. b. Remove the exhaust pipe shield. c. Remove the EGR cooler.
Page 19 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Loosen the conical nut at fuel injector end and the conical nut on fuel injection pump side (one is to reversely tighten the fuel inlet of fuel injector and one is to loosen the nut of high pressure fuel pipe); Loosen the...
Page 20 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Remove the fixing bolts of fuel-gas separator housing and take out the fuel-gas separator filter element. Clean the fuel-gas separator housing, check the state of filter element, and when necessary replace the filter element.
Page 21 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Disassemble the fixing bolts of power steering pump and remove the power steering pump. Check the power steering pump for presence of oil leakage and check the belt pulley of power steering pump for presence of wear;...
Page 22 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Remove the fuel rail and rail pressure sensor assembly and the rail bracket and install the fuel pressure rail protective sleeve; Disassemble Disassemble the fixing bolts of oil dipstick fixing sleeve and disassemble the oil dipstick conduit.
Page 23 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Remove the fixing bolts of compressor bracket and remove the compressor bracket; Remove the bypass rubber pipe, remove the thermostat housing and water outlet assembly; Disassemble the fixing bolts of thermostat housing and remove the thermostat housing.
Page 24 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Remove the cylinder head bolts by several times as per the specified sequence (front circle drawing method). The failure to disassemble by several times as per specified sequence will damage the cylinder head and impair the deflection of lower surface of cylinder head*.
Page 25 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Disassemble the fixing bolts of engine oil filter and remove the engine oil filter. Use an open-end wrench to disassemble the engine oil pressure connector and remove the connector and lubricating oil pipe.
Page 26 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Remove the fixing bolts of idler gear pressure plate and remove the idler gear pressure plate, idler gear, and idler gear shaft. Remove the fixing bolts and fixing nuts of oil sump by one time as per the specified sequence and remove the oil sump.
Page 27 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines cc. Pull out the camshaft. dd. Remove the nuts of connecting rod large end as per specified sequence and use piston installation tool to push out the piston. Position the piston orderly.
Page 28 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines gg. Take out the crankshaft timing gear. hh. Rotate the bolts of master bearing cap as per specified sequence to pull out the bolts of master bearing cap and remove the main shaft bushes (Position the main shaft bushes orderly).
Page 29 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines cylinder head. If the measurement is between limit and standard value, re-grind the fitting surface between exhaust branch pipe and cylinder head. If the measurement is out of the specified limit, make sure to replace the branch pipe.
Page 30 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Measure the cam height of the camshaft. The standard value is 42.02±0.05mm and the limit is 41.65mm. If the measurement is out of the limit, make sure to replace the camshaft. Use a multimeter to measure the outside diameter of each camshaft journal.
Page 31 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Measure the free height of valve spring. If the measurement is out of specified limit, make sure to replace the spring. The standard value is 0.05mm or less and the limit is 0.20mm.
Page 32 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Install the oil ring bush ring. Use a piston ring expander to install the 2 compression ring and the 1 compression ring. While installing the compression rings, face upward the marking N (The lip of 2 compression ring shall face downward).
Page 33 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Measure the outside diameter of connecting rod journal and the inside diameter of bush bore of connecting rod fitted with bush. Calculate the clearance between main journal of crankshaft and the main bush bore of crankshaft: The difference...
Page 34: Section Ii Assembly Of Engine
Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Section II Assembly of Engine I. Basic Technical Requirements for Assembly The assembly of the engine is one important step for service of the engine. The service performance of the engine is closely related to the assembly accuracy, assembly technical requirements, and the assembly quality.
Page 35 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines II. Illustration for Assembly of Engine 1. Install the piston cooling fuel injector subassembly. Install the piston cooling fuel injector subassembly: Install the piston cooling fuel injector subassembly onto the engine block;...
Page 36 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Install the crankshaft thrust plates to the 3 main journal portion (The surface with oil groove faces to crankshaft thrust surface and the oil groove shall be sprayed with lubricating oil). Spray oil to the main journal portion and install the 1~4 main bearing caps of crankshaft as per the marked sequence.
Page 37 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Apply engine oil onto the threads of main bearing cap bolts, install into the main bearing caps, and tighten the bolts to 170 N.m torque as per the specified sequence. Tighten to 20 N·m for the 1 step, to 120 N·m for the 2...
Page 38 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Install the tappet anti-drop tool. 3. Install the piston connecting rod assembly. a. Spray one film of oil onto the cylinder bore. b. Spray oil onto the piston skirt, install the piston into the piston taper sleeve, insert into the cylinder bore, and use nylon bar and guide jig to install the piston.
Page 39 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines 4. Install the timing gear and related accessories. Insert the lubricated tappets in turn into the tappet holes. Install the water manifold (The water manifold is paralleling with the cylinder block)
Page 40 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Spray oil to the crankshaft gear and then install. Install the gasket of timing gear chamber. Install the timing gear chamber and idler gear lining plate and pre-tighten the fixing bolts.
Page 41 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Spray lubricating oil onto the camshaft bush, add lubricating oil to the head of tappet, and spray lubricating oil onto the camshaft subassembly. Install the camshaft (with the bottom facing upward and the left facing forward).
Page 42 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Install the idler gear shafts A and C onto the idler gear lining plate and use nylon bar for idler gear shaft to lightly knock into the idler gear lining plate. Apply oil onto the surface of idler gear C bush and lightly rotate into the idler gear shaft C.
Page 43 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines m. Apply oil onto the surface of idler gear B bush and lightly rotate into the idler gear shaft B. In event of difficult installation, slightly rotate the crankshaft to help installation.
Page 44 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Apply sealant to the lower end face of timing gear chamber and the lower rear end of engine block. Install the oil sump gasket. Apply the sealant for the second time to both sides of oil sump gasket.
Page 45 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines As per the specified sequence, tighten the fixing bolts *10 of oil sump and the fixing nuts * 12 of oil sump to 23.5±3.5N.m torque. Use a cotton cloth to wipe away excessive sealant.
Page 46 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines n. Install and tighten the bolts and nuts of water pump in diagonal manner to 25±5N.m. o. Install the timing gear chamber cover subassembly and attach and tighten the fixing bolts of gear chamber cover to 20±5 N.m.
Page 47 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines b. Install the cylinder head onto the cylinder block. c. Immerse the thread portion of cylinder head bolts into oil and then install into the cylinder head and pre-tighten. d. Tighten the cylinder head bolts by steps from the center to two sides as per the specified sequence: 65N.m→85N.m→105N.m...
Page 48 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines 7. Install the intake manifold and related accessories. a. Use hexagon flange bolts to fix the fuel rail bracket onto the cylinder block and tighten to 37.5±9.5N.m. b. Use hexagon flange bolts to install the fuel rail assembly with rail pressure sensor onto the fuel rail bracket and tighten to 25±5N.m.
Page 49 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines e. Install the intake manifold and install and tighten the fixing bolts, plain washers, and fixing nuts. Install the intake manifold harness bracket and intake pressure and temperature sensor. 8. Install the push rod rocker arm subassembly and adjust the valve clearance.
Page 50 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Rotate the crankshaft, till the top dead center (TDC) line of crankshaft damping pulley is aligned with the timing pointer. In such case, either 1 cylinder piston or cylinder piston is at top dead center (TDC) of compression stroke.
Page 51 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines 9. Install other peripheral accessories. a. In turn install the fuel injection assembly with sealing gasket onto the cylinder head. b. Install the fuel injector fixing pressure plate and install and tighten the fuel injector pressure plate bolts to 8±2N.m+40～45°.
Page 52 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines e. Install the engine oil filter and O-ring subassembly and tighten the fixing bolts of engine oil filter bracket to 25±5 N.m. Install the engine right bracket and shock absorber subassembly and install and pre-tighten the fixing bolts.
Page 53 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Check the cylinder head shield O-ring. Install the cylinder head shield and install and tighten the cylinder head shield bolts to 13±5N.m. k. Install the exhaust manifold gasket and install the exhaust manifold and turbocharger subassembly.
Page 54 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Tighten bolts as per sequence shown in figure. m. Install the EGR cooling steel pipe and tighten the fixing bolts. n. Install the EGR valve and tighten the fixing bolts. o. Apply sealant onto the thread of vacuum pump oil...
Page 55 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Adjust the tension of alternator belt and tighten the alternator adjustment bolts and clutch fixing nuts. Tighten the alternator fixing nuts. Install the vacuum pump oil inlet pipe fixing bolts I (M8×20) and tighten the fixing bolts to 18±2N.m and 25±5N.m respectively.
Page 56 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines w. Install the compressor bracket and tighten the bracket fixing bolts. x. Use perforated bolts II and copper washers II to install the turbocharger oil inlet pipe assembly onto the turbocharger oil inlet and use perforated bolts I and...
Page 57 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines aa. Install the VNT electromagnetic valve and connect various vacuum hoses. 10. Install the flywheel and related accessories. a. Apply oil to the outer ring and lip of the crankshaft rear oil seal and use installation jig I to push the rear oil seal into the oil seal groove.
Page 58 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines c. Install the flywheel. d. Install the flywheel fixing gasket and install and pre-tighten the fixing bolts of flywheel. e. As per the specified sequence, tighten the fixing bolts of flywheel to 25N.m→70N.m →140N.m by steps, in order to prevent the occurrence of false tightening torque.
Page 59: Section Iii Crankshaft And Flywheel System
Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Section III Crankshaft and Flywheel System It works along with the connecting rod to convert the gas pressure applied onto the piston into rotating power and transmit to the transmission mechanism of the chassis. At the same time, it drives the valve distribution mechanism and other accessories, such as fan, water pump, and alternator.
Page 60: Section Iv Piston And Connecting Rod Group
The HFC4DA1-2C piston rings include two compression rings and one oil control ring: The first ring adopts the trapezoid tubbish ring, which can effective reduce the consumption of engine oil.
Page 61: Section V Valve Distribution Mechanism
Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Section V Valve Distribution Mechanism It’s a device that opens and closes at fixed times the intake and exhaust valves of all cylinder to enable the ingress of fresh air into cylinders and the exhaust of exhaust gas from the cylinders.
Page 62: Section Vi Lubrication System
Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Section VI Lubrication System While the engine is working, all motion parts apply one specific force onto another part and generate relatively high speed motion. With the relative motion, the friction is necessarily generated on the part surfaces, which will accelerate the wear.
Page 63: Section Vii Cooling System
Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Section VII Cooling System The cooling system is functioned to maintain the engine within an appropriate temperature range under all working conditions. The cooling system can prevent the engine against overheating and prevent the engine from being too cold in winter.
Page 64: Section Viii Turbocharger And Inter-Cooler System
Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Section VIII Turbocharger and Inter-Cooler System The turbocharger technology utilizes the motion energy of engine exhaust gas to drive the rotation of turbine. At the same time, the coaxial air compressor compresses the air and provides more air to the cylinder so that more fuel can combust to generate higher power, promote the engine torque, and reduce the fuel consumption.
Page 65 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines section passage is greatly higher than that passing through the constant section passage. High speed Small passage Large passage running of engine Idling of section section engine Rotation direction of adjustment ring...
Page 66: Section Ix Egr System
Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Section IX EGR System The exhaust gas recirculation (EGR) introduces one small portion of exhaust gas from the exhaust pipe into the intake pipe that is mixed with the fresh intake air to artificially increase the exhaust amount in the fresh intake air and thus reduce the combustion temperature of engine and reduce the formation of NOx.
Page 67: Section X Exhaust System
Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Section X Exhaust System The exhaust pipe is composed of four exhaust manifolds leading to the exhaust master pipe and one manifold leading to the exhaust gas chamber of EGR valve. During the operation, the exhaust gas from the combustion chamber is introduced into the EGR valve by the manifold leading to the exhaust gas chamber of EGR valve through the EGR passage in the cylinder head.
Page 68: Chapter Iii Working Principle Of Engine Control And Actuator Units
Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Chapter III Working Principle of Engine Control and Actuator Units Section I Overview of Diesel Common Rail System Diesel common rail injection system Fuel pressure sensor Cut-off valve High pressure Distribution (optional)
Page 69 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines The high pressure common rail system is composed of fuel tank, diesel filter, high pressure fuel pump, common rail pipe, electronically controlled fuel injector, high pressure fuel pipe, and low pressure fuel return pipeline.
Page 70: Section Ii Working Principle Of Low Pressure Fuel Line System
Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Section II Working Principle of Low Pressure Fuel Line System I. Composition of low pressure fuel line: The low pressure fuel line is functioned to supply sufficient fuel to the high pressure fuel line and is composed of:...
Page 71 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines engine. After the fuel is used up. After the water drainage from the fuel-water separator. After the replacement of fuel filter Replacement of fuel filter 1. Replacement interval of fuel filter: Once every 7,000km;...
Page 72 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines VI. Common malfunctions and troubleshooting for low pressure fuel line Malfunction Troubleshooting Remarks Weak pumping of Retighten the connectors (temperature The tightening torque for connectors is fuel sensor, plug, and pile connector), in 30-35N.m.
Page 73: Section Iii Working Theory Of High Pressure Fuel Line
Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Section III Working Theory of High Pressure Fuel Line I. High pressure fuel line parts The high pressure fuel line generates and accumulates Drive shaft sufficient fuel pressure required for the fuel injectors.
Page 74 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines The space of the common rail is always filled with high pressure fuel. It utilizes the fuel compressed due to high pressure to achieve the accumulator effect. When the fuel is departed from the common rail for injection, the pressure in the high pressure accumulator is basically constant.
Page 75: Section Iv Electronic Control Unit Of High Pressure Common Rail System
Section IV Electronic Control Unit of High Pressure Common Rail System The EDC17 system of HFC4DA1-2C engine belongs to electronically controlled diesel injection system and incorporates the dynamic fuel injection timing system and air and fuel management system. It adopts the BOSCH...
Page 76 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Resistance: 860 Ohm; Clearance between sensor and top of signal gear: 0.5~1.2mm. 2) Working Principle The electromagnetic sensor simulates the AC signal generator, namely such sensor generates AC signal, and is generally composed of a magnet wound by coil and two wiring terminals. These two coil terminals are the output terminals of the sensor.
Page 77 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Use diagnosis instrument to check the trouble code and determine the malfunction position. Mainly check whether the sensor is installed in place and whether the clearance is normal, check the sensor circuit whether there is...
Page 78 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines 4) Malfunction Mode Short-circuit or open-circuit of sensor; Distorted, error, and suspicious signal; Unstable sensor signal; Sensor signal is out of range. 5) Troubleshooting Use diagnosis instrument to check the trouble code and determine the malfunction position. Mainly check whether the...
Page 79 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines 3) Test analysis Wiring terminals: 1 - +5V, 2 – Signal +, 3 – Grounding 5V power supply Pressure Pressure difference signal difference Earthing sensor 3. Turbocharger pressure sensor 1) Overview The turbocharger pressure sensor is connected to the intake pipe and is functioned to measure the absolute pressure of the intake pipe.
Page 80 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines resistor is mounted on the diaphragm surface, of which the resistance varies under the application of pressure. These resistors are connected to form a resistor bridge. Therefore, any movement of the diaphragm will change the balance of resistor bridge, namely the voltage of the resistor bridge is one measurement of turbocharger pressure.
Page 81 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines 2) Working Principle This sensor is composed of two sensors, namely airflow sensor and intake temperature sensor, and is installed on the intake hose after the air cleaner. This type of sensor requires that there shall be free of air leakage from the sensor to the engine combustion chamber, or it will lead to unstable idling of engine or even engine flameout.
Page 82 The light-up of the engine malfunction indicator lamp indicates the presence of malfunction in the engine system and it’s necessary to diagnose with diagnosis instrument. Use JAC special diagnosis instrument to communicate with ECU of electronic injection system and read out the malfunction data in the ECU.
Page 83 If the water temperature alarm indicator lamp lights up, stop for cooling immediately. If the water temperature alarm indicator lamp lights up frequently, drive to the authorized service station of JAC Multifunctional Commercial Vehicle Company for service. 7. Water level sensor 1) Overview The fuel-water separator position sensor is functioned to measure the water content in the fuel filter;...
Page 84 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines The fuel-water separator position sensor is installed on the bottom of the fuel filter; Wiring terminals: 1. Water level sensor; 2. Water level signal; 3. +12V power supply. 2) Working Principle The grain substances are high-accuracy filtered by means of the interception and absorption of the filter medium and...
Page 85 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines 2）Working Principle The accelerator pedal position sensor internally adopts the damping structure and internally incorporates two same potentiometer sensors. The signal pointers of the sensors are coaxial with the pedal. When the accelerator pedal is stepped down, the potentiometer pointer will rotate coaxially with the pedal and, following the sliding of the potentiometer pointer, the signal terminals output different voltage or resistance signal.
Page 86 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines 2）Working Principle The signal of vehicle speed sensor provides vehicle speed signal to the ECU, based on which the ECU calculates the vehicle speed. It’s internally composed of one Hall speed sensor. Please refer to the camshaft position sensor for the working principle.
Page 87 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines 11.Dual brake switch 1) Overview The dual brake switch is located on the upper portion of the brake pedal and internally incorporates two independent switches. 2) Working Principle The brake switch monitors the action of the brake pedal and transmits the signal measured to the engine ECU. The brake switch is equipped with two switching mechanisms, which are the main and secondary units of the brake switch.
Page 88 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines 5) Troubleshooting Use Sunray special diagnosis instrument to check the trouble code and determine the malfunction position. Mainly check the circuit of sensor and determine whether there is short-circuit or open-circuit between circuit and the...
Page 89 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines 3) Measurement analysis Outlet Interface A Outlet Interface K Definition for ECU pins of EDC17 control system: Terminal Terminal Description Description Interface A High fuel injector of 3 cylinder Low fuel injector of 2...
Page 90 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Terminal Terminal Description Description 5V power supply of camshaft position sensor Earthing of rail pressure sensor Signal of crankshaft position sensor Earthing of crankshaft position sensor High fuel injector of 1 cylinder...
Page 91 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Terminal Terminal Description Description Accelerator pedal sensor signal 2 Earthing signal of air flowmeter Vehicle speed signal input CAN communication Intake flow signal of air flowmeter Grounding of accelerator pedal sensor 1...
Page 92 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines board due to water ingress of ECU. 5) Troubleshooting Connect the plug and use engine data diagnosis cable to read the engine malfunction records; disconnect the plug and check whether the ECU connecting wire is intact. Mainly check whether ECU power supply and grounding circuit are normal, whether the external sensors are working normally, whether the output signal are reliable, and whether the circuit is intact.
Page 93 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines is opened by solenoid valve. After the fuel drainage hole is closed, the hydraulic force applied onto the valve controlled plunger (9) exceeds the pressure on the pressure shoulder of injector nozzle needle valve (11). Therefore, the needle valve is pushed into the needle valve seat to block the high pressure passage to the combustion chamber.
Page 94 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines closes the fuel drainage hole. The armature is of two-part design. Though the armature block is guided by the pressure shoulder during the downward movement, it can bounce back following the return spring and thus will not apply downward force onto the armature and the ball valve.
Page 95 3. Variable nozzle turbocharger (VNT) control 1) Overview HFC4DA1-2C adopts variable section turbocharger technology so that the turbocharger and the engine are well matched under all working conditions to realize best engine performance. The blades of the VNT are connected to the control tie rod and the displacement of the control tie rod is controlled by the vacuum pressure of the vacuum chamber on the VNT.
Page 96 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Fuel metering unit signal Fuel metering unit 4) Malfunction Mode Short-circuit or open-circuit of metering valve; damage of metering valve; contamination of metering valve. 5) Troubleshooting Use Sunray special diagnosis instrument to check the trouble code and determine the malfunction position. Mainly...
Page 97 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines helical metal wire embedded within the magnesium oxide powder (Figure). This helical metal wire is composed of two resistors in series connection and one heating oil and one control coil are installed on the tip of the heating tube.
Page 98 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines 6. Malfunction indicator lamp 1) Overview The malfunction indicator lamp is located on the instrument. In event of malfunction of engine control system units, the engine malfunction indicator lamp will light up to remind the driver for checking and service by the service station as soon as possible.
Page 99 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines instrument circuit and determine whether there is short-circuit or open-circuit between circuit and the grounding wire, whether there is short-circuit or open-circuit to power supply, and whether the circuit is consistent with the given pin definition.
Page 100: Chapter Iv Engine Diagnosis
Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Chapter IV Engine Diagnosis Precautions Section I. 1. Removal/Installation Requirements for Electronic Control Unit (ECU): Remove the controller before welding or baking finish; When removing the controller, turn off the ignition switch and disconnect the battery from the system at the same time, in order to avoid damaging the ECU.
Page 101 (phase) sensor. After inspection, all sensors should be well connected and system DTCs should be cleared by using the special diagnostic instrument for JAC commercial vehicles. It is not allowed to touch the engine gear train and rotating parts when the engine is at high speed;...
Page 102: Section Ii. Maintenance Procedures
Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Section II. Maintenance Procedures Fuel system of common rail engine consists of low-pressure delivery pipes and high-pressure oil pipes and maximum pressure of it is over 1800bar. Some components of fuel injector and HP pump are machined with accuracy of 0.1mm.
Page 103 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Remove battery negative cable. For safety reasons: Confirm whether system pressure is low prior to high-pressure system disassembly. Apply special tools and torque wrenches in calibration. In disassembly or replacement of fuel injector, it is necessary to apply new copper washers and tighten fixing bolts for fuel injector according to fixed torque at the same time.
Page 104: Section Iii. Fault Diagnosis
Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Section III. Fault Diagnosis 1. Fault Information Record Electronic control unit continually monitors sensors, actuators, relevant circuits, MILs, battery voltage and even its self and carries out reliability tests to sensor output signals, actuator drive signals and internal signals. Once there are faults in certain link or certain signal is unreliable, electronic control unit sets fault information record in RAM fault memory immediately.
Page 105 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines 7. Elimination of Fault Information Record Fault information records in memory should be cleared after fault elimination. DTC can be cleared with ways as follows:   W hen value of ECU frequency counter (Hz) becomes 0, fault information records in fault memory are all cleared automatically.
Page 106: Section Iv. Dtc List
Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Section IV. DTC List Meaning P0030 The linear oxygen sensor heater circuit is open. P0031 The linear oxygen sensor heater circuit is short to ground. P0032 The linear oxygen sensor heater circuit is short to battery.
Page 107 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Meaning P0128 Closed-loop control is actuated due to too low coolant temperature. P0131 Oxygen sensor IAIPUNVG point is short to ground. P0132 Oxygen sensor IAIPUNVG point is short to battery. P0168 The signal level of fuel temperature sensor is relatively high.
Page 108 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Meaning P022A EGR valve circuit is open. P022B EGR valve circuit is short to ground. P022C EGR valve circuit is short to power supply. The signal level at the output position of EGR cooling bypass valve position sensor P022E is below the lower limit.
Page 109 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Meaning P0340 No signal from camshaft P0341 The offset angle of camshaft is too large. P0380 The preheating indicator light output circuit is high. P0382 The preheating indicator light output circuit is low.
Page 110 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Meaning P0523 The signal level of oil pressure sensor is relatively high. P0524 The minimum oil pressure signal is unreliable. P0532 The signal level measured by A/C coolant pressure sensor is too low.
Page 111 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Meaning P0660 The positive deviation of throttle controller exceeds the upper limit for a long time. P0661 The Port 1 of EGR valve bridge-H chip is short to ground. P0662 The Port 1 of EGR valve bridge-H chip is short to power supply.
Page 112 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Meaning P1020 The heating drive circuit of fuel filter is open. P1021 The heating drive circuit of fuel filter is short to power supply. P1022 The heating drive circuit of fuel filter is short to ground.
Page 113 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Meaning P1061 OBD General fault 10 P1062 OBD General fault 11 P1063 OBD General fault 12 P1064 OBD General fault 13 P1065 OBD General fault 14 P1066 OBD General fault 15 P1067...
Page 114 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Meaning The signal level of intake air temperature sensor (integrated inside the air flow P1123 sensor) is relatively low. P1130 The signal level of fuel temperature sensor is relatively low. P1131 The signal of fuel temperature is unreliable.
Page 115 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Meaning P121C cylinder IQA error P121D cylinder IQA error P121E cylinder IQA error P121F cylinder IQA error P1220 The signal level of intercooler downstream temperature sensor is relatively high. P1221 The signal level of intercooler downstream temperature sensor is relatively low.
Page 116 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Meaning P1419 Overheating of indicator actuator for EGR bypass regulating valve P141A The indicator actuator circuit for EGR bypass regulating valve is short to battery. P141B The indicator actuator circuit for EGR bypass regulating valve is short to ground.
Page 117 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Meaning P1442 Conversion failure of oxygen sensor regulator P1450 The particulate filter upstream temperature is unreliable. P1451 The signal level of particulate filter upstream temperature is relatively high. P1452 The signal level of particulate filter upstream temperature is relatively low.
Page 118 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Meaning P1477 The calibration signal level of oxygen sensor is relatively low. P1478 The oxygen concentration of oxygen sensor exceeds the maximum threshold. P1479 The oxygen concentration of oxygen sensor exceeds the minimum threshold.
Page 119 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Meaning P1521 Under-voltage of turbocharger bridge-H P1522 Overcurrent of turbocharger bridge-H P1523 Overtemperature of turbocharger bridge-H P1524 Overcurrent of turbocharger bridge-H temperature sensor P1525 The valve is stuck in deviation learning process.
Page 120 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Meaning P1623 The drive circuit for fuel consumption display is open. P1624 Overtemperature of the drive circuit for fuel consumption display P1625 TTLAMP drive circuit is short to power supply. P1626 TTLAMP drive circuit is short to ground.
Page 121 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Meaning P1666 Several faults occur when testing the whole ROM zone. The number of responsive bytes obtained from CPU in monitoring mode is too small P1667 / Error of the set response time of monitoring mode...
Page 122 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Meaning P168C CJ945 Power level is short to battery. P168D CJ945 Power level is short to ground. P168E CJ945 Power level is short to ground. P1700 Unreliable clutch signal / Clutch signal error...
Page 123 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Meaning P2173 False positive deviation of throttle regulator P2175 False negative deviation of throttle regulator P2226 Fault of signal obtained from CAN by air pressure sensor P2228 The signal value of ambient pressure is below the lower limit.
Page 124: Section V. Fault Diagnosis For Electronic-Controlled Common Rail Diesel Engines
Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Section V. Fault Diagnosis for Electronic-Controlled Common Rail Diesel Engines Prior to disconnecting or reconnecting the power cord of engine control module (ECM), be sure to turn off the ignition switch, in order not to damage the ECM.
Page 125 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Fault Tree: Check the connection of brake valve. 检查制动阀连接 Repair or replace it. Connector fault 插接件问题检修或更换 Check the appearance of brake valve. 对制动阀外观检测 Fault of brake valve Replace the brake valve.
Page 126 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines P0069 The boost pressure sensor drift The boost pressure sensor output voltage is below the lower limit (the wiring P0237 is short to ground). The boost pressure sensor output voltage is above the upper limit (the wiring P0238 is open or short to high level).
Page 127 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Diagnosis Hint: The normal boost pressure sensor shall make quick response to the change of accelerator pedal position, so its slow action should not appear or it should not act slower than the change of accelerator pedal position.
Page 128 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Fault Tree: Check the component connector. Connector fault Repair or replace it. Detect the sensor. Sensor fault Replace the sensor. Repair or replace it. Fault of ECU connector Check continuity and insulating property.
Page 129 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines P0087 The fuel pressure is below the lower limit. P0088 The fuel pressure is above the upper limit. P0191 The forward drift of common rail pressure sensor is too large. The common rail pressure sensor output voltage is below the lower limit (the wiring P0192 is short to ground).
Page 130 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Terminal Power supply terminal of common rail pressure sensor Signal terminal of common rail pressure sensor Ground terminal of common rail pressure sensor...
Page 131 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Fault Tree: Read DTC. Repair accordingly. Fault of fuel metering unit Check the common rail pressure sensor. Fault of common rail pressure Repair accordingly. sensor Check the low pressure oil circuit by referring to fault tree of “Low Pressure Oil Circuit”.
Page 132 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Inspection for Low Pressure/Hig h Pressure Oil Circuit: Low pressure oil circuit Check fuel tank supply. Only checking the fuel tank level indicator is not enough, for its indication may be invalid.
Page 133: Coolant Temperature
Maintenance manual for sunray hfc4da1-2c china-IV diesel engines P0116 The dynamic characteristics of coolant temperature sensor are unreliable. The coolant temperature sensor output voltage is below the lower limit (the P0117 wiring is short to ground). The coolant temperature sensor output voltage is above the upper limit (the P0118 wiring is open or short to high level).
Page 134 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines − Poor contact between terminal and wire Check the harness for any damage. If the harness appears normal, observe the ECT indication on the diagnostic tool while moving relevant connector and harness of ECT sensor. If the ECT indication changes, there must be failure in that part.
Page 135 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Fault Tree: Check the sensor connection. Connector fault Repair accordingly. Detect the sensor resistance. (Is it consistent with the vehicle condition?) Fault of sensor resistance Replace the sensor. Fault of ECU connector Repair accordingly.
Page 136 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines P0122 The output voltage of accelerator pedal potentiometer 1 is below the lower limit. P0123 The output voltage of accelerator pedal potentiometer 1 is above the upper limit. P0222 The output voltage of accelerator pedal potentiometer 2 is below the lower limit.
Page 137 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Terminal Power supply terminal of APP sensor 1 Signal terminal of APP sensor 1 Ground terminal of APP sensor 1 Power supply terminal of APP sensor 2 Signal terminal of APP sensor 2...
Page 138 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Fault Tree: Check the component connector. Repair accordingly. Connector fault Visually check the component. Component fault Replace the component. Repair accordingly. ECU connector fault Check continuity and insulating property. Electrical fault Repair the harness.
Page 139 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines P0201 The 1 cylinder fuel injector circuit is open. P0263 Other errors of the 1 cylinder fuel injector P1200 The forward error correction of the 1 fuel injector is too large. P1201 The reverse error correction of the 1 fuel injector is too large.
Page 140 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Fault Tree: Turn off the ignition switch and check the fuel injector connector. Connector fault Repair accordingly. Disconnect the fuel injector and turn on the ignition switch. Refer to “Inspection of Fuel Injector Does the problem still exist? Wiring”...
Page 141 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines P0202 The 2 cylinder fuel injector circuit is open. P0264 The low end of the 2 fuel injector is short to the high end. P0265 The low end of the 2 fuel injector is short to the high level.
Page 142 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Fault Tree: Turn off the ignition switch and check the fuel injector connector. Connector fault Repair accordingly. Disconnect the fuel injector and turn on the ignition switch. Refer to “Inspection of Fuel Injector Does the problem still exist? Wiring”...
Page 143 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines P0203 The 3 cylinder fuel injector circuit is open. P0267 The low end of the 3 fuel injector is short to the high end. P0268 The low end of the 3 fuel injector is short to the high level.
Page 144 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Fault Tree: Turn off the ignition switch and check the fuel injector connector. Repair accordingly. Connector fault Disconnect the fuel injector and turn on the ignition switch. Refer to “Inspection of Fuel Injector Does the problem still exist? Wiring”...
Page 145 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines P0204 The 4 cylinder fuel injector circuit is open. P0270 The low end of the 4 fuel injector is short to the high end. P0271 The low end of the 4 fuel injector is short to the high level.
Page 146 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Fault Tree: Turn off the ignition switch and check the fuel injector connector. Repair accordingly. Connector fault Disconnect the fuel injector and turn on the ignition switch. Refer to “Inspection of Fuel Injector Does the problem still exist? Wiring”...
Page 147 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines P0251 The control line of fuel level control unit is open. P0252 The ECU internal driver module of fuel level control unit is overheating. P0253 The control line of fuel level control unit is short to ground.
Page 148 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Fault Tree: Check the connector of fuel metering unit. Connector fault Repair accordingly. Check the ECU connector. Repair accordingly. Connector fault Check continuity and insulating property. Electrical fault Repair the harness. Measure the resistance of fuel metering unit (it is about 5.3 Ohms at 20℃)
Page 149 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines P0335 No signal from crankshaft sensor P0336 False signal from crankshaft sensor Signal Wheel speed sensor Ground Shielded wire Diagnosis Hint: The signal of crankshaft position (CKP) sensor is used for indicating the rotary speed and position of crankshaft.
Page 150 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Check if the ground and connection of ECU and engine is reliable and clean. If the DTC is determined to be intermittent failure, please refer to the fault records to find out when the previous DTC is set.
Page 151 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Fault Tree: Check the sensor connection. Connector fault Repair accordingly. Check the ECU connector. Repair accordingly. Connector fault Check continuity and insulating property. Repair the harness. Electrical fault The new sensor is connected.
Page 152 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines P0340 No signal from phase sensor P0341 False signal from phase sensor 5V power supply Camshaft position CMP signal sensor Ground Fault Description: The camshaft position (CMP) sensor is a Hall Effect switch. The ECU shall supply 5V voltage to the 5V reference voltage circuit and also supply grounding for the low reference voltage circuit.
Page 153 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Fault Tree: Check the sensor connection. Connector fault Repair accordingly. Visually check the sensor. Replace the sensor. Sensor fault Check the ECU connector. Connector fault Repair accordingly. Check the signals of camshaft and crankshaft sensor with oscilloscope if possible.
Page 154 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines P0380 The glow plug works without the command from ECU. P0382 The glow plug doesn’t work with the command from ECU. P0383 ECU control line for glow plug is short to ground.
Page 155 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Fault Tree: Check the connector of glow plug. 检查预热塞接插件 Repair accordingly. 接插件问题做必要的修理 Connector fault Check the ECU connector. 检查ECU接插件接插件问题 Connector fault Repair accordingly. 做必要的修理 Check continuity and insulating property. 检查连续性和绝缘性...
Page 156 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines P0500 Error of vehicle speed sensor acquisition hardware P0501 The vehicle speed sensor signal is unreliable. Fault Description: Vehicle speed sensor (VSS) provides vehicle speed signals to ECU. It is a kind of Hall Effect sensor.
Page 157 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Fault Tree: Check the sensor connection. Connector fault Repair accordingly. Check the ECU connector. Repair accordingly. Connector fault Check continuity and insulating property. Electrical fault Repair the harness. Check the VVS. Replace the VVS.
Page 158 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines P0504 Unreliable comparison between main and auxiliary brake pedal signals Main brake switch Auxiliary brake switch Fault Description: The brake switch detects the brake pedal action and sends the signal to ECU. The brake switch is equipped with two switches, viz.
Page 159 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Fault Tree: Check the component connector. Connector fault Repair accordingly. Visually check the component. Replace the component. Component fault ECU connector fault Repair accordingly. Check continuity and insulating property. Electrical fault Repair the harness.
Page 160 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines P0562 Too low battery voltage P0563 Too high battery voltage P1617 The engine cannot be shut down with too high internal supply voltage. P1618 The engine cannot be shut down with too low internal supply voltage.
Page 161 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Fault Tree: Check the battery voltage at igniting. Charge the battery. Battery fault Check the battery connection. Fault of battery connectors Repair accordingly. Check the ECU connector. Connector fault Repair accordingly. Check the resistance between chassis and ECU ground.
Page 162 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines P060A Communication failure of ECU internal chip CJ940 Fault Description: It is mainly used for monitoring the internal microprocessor integrity failure in ECU to determine whether the ECU program is executed. With engine OFF and ignition switch ON, the ECU shall perform self-diagnosis.
Page 163 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines P0642 Sensor supply voltage 1 is too low. P0643 Sensor supply voltage 1 is too high. P0652 Sensor supply voltage 2 is too low. P0653 Sensor supply voltage 2 is too high.
Page 164 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Fault Tree: Read DTC. Provided that the signal lost is caused by a certain sensor, disconnect each sensor one by one until the fault Read DTCs of all sensors corresponding disappears and the failed sensor is to the power connector located.
Page 165 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines P0686 The main relay opens too early. P0687 The main relay opens too late. Ignition switch Power supply of main relay Main relay Control of main relay Power supply of ignition switch...
Page 166 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Fault Tree: Check the relay connector. Connector fault Repair accordingly. Check the ECU connector. Connector fault Repair accordingly. Check continuity and insulating property. Electrical fault Repair the harness. Replace relay (running circulation.) Get the Technical Support.
Page 167 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines P0704 Clutch signals are unreliable. Clutch switch Fault Description: Transmission control unit (TCU) is integrated with engine control unit (ECU) and calculates optimal time and speed for clutch engagement according to feedback information from sensors of accelerator pedal, transmission gear position, transmission input/output shaft speed, engine speed, throttle opening and etc.
Page 168 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Fault Tree: Check clutch switch. Clutch switch fault Replace the clutch switch. Check clutch switch harness. Harness fault Repair the harness. Check clutch switch power supply voltage. Power supply signals are distorted.
Page 169 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines There are faults (short circuit or open circuit) in ECU OBD malfunction P0650 indicator lamp (MIL) output connecting wire. Connection of ECU system MIL output connecting wire is short to high P1619 level.
Page 170 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Fault Tree: Check connection between instrument panel and ECU. 检查仪表板与ECU的连接 Repair accordingly. Connector fault 接插件问题做必要的修理 Check continuity and insulating property.. 检查连续性和绝缘性 Repair the harness. Electrical fault 电气问题修理线束 Replace corresponding components.
Page 171 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Mass air flow (MAF) signals measured by air flow meter without correction P0100 are too strong or too weak (Connection is in open circuit or short circuit). Mass air flow (MAF) signals measured by air flow meter with correction are P0101 too strong or too weak (Connection is in open circuit or short circuit).
Page 172 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines — Additional accessories after sale — Secondary ignition wires or coils — Solenoid valve — Relay — Motor In the case of idle running or deceleration, air flow goes through sensor may reach its minimum and this may lead to DTC occurrence.
Page 173 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Fault Tree: Check air flow meter connectors. 检查空气流量计接插件 Repair accordingly. Connector fault 接插件问题做必要的修理检查ECU接插件 Check ECU connectors. Connector fault 接插件问题做必要的修理 Repair accordingly. Check for continuity and insulating property. 检查连续性和绝缘性 Repair the harness.
Page 174 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Connection for additional air temperature sensor of air mass flowmeter is P0110 short or open. Temperature for additional air temperature sensor of air mass flowmeter is P0112 too low. Temperature for additional air temperature sensor of air mass flowmeter is P0113 too high.
Page 175 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Check harness damage. If the harness seems to be normal, move relevant connector and harness for intake air temperature (IAT) sensor and check display about IAT on diagnostic tool. If display of IAT changes, it is indicated that there is fault in the part.
Page 176 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines P0300 Multi-cylinder misfire P0301 The 1 cylinder misfire P0302 The 2 cylinder misfire P0303 The 3 cylinder misfire P0304 The 4 cylinder misfire Fault Description: ECU determines when engine misfire occurs with the help of information from ignition control (IC) module and camshaft position (CMP) sensors.
Page 177 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Fault Tree: Turn off ignition switch and check fuel injector connectors. 关闭点火开关并检查喷油器接插件 Connector fault Repair accordingly. 接插件问题做必要的修理检查曲轴位置传感器间隙 Check crankshaft position sensor clearance. Adjust clearance of crankshaft position sensor 调整曲轴位置传感器间隙曲轴位置传感器间隙问题？...
Page 178 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines P0401 Actual fresh air inflow is larger than target air inflow set by EGR system. P0402 Actual fresh air inflow is smaller than target air inflow set by EGR system. ECU internal drive module of EGR valve actuator control wire is P0403 overheated.
Page 179 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Terminal EGR position sensor 5V power supply EGR position sensor position signal EGR position sensor ground EGR actuator power supply EGR actuator ground...
Page 180 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Fault Tree: Check actuator connectors. Repair accordingly. Connector fault Check actuator resistance. Actuator resistance faults Replace the actuator. Check ECU for connector faults. Repair accordingly. Check for continuity and insulating property. Electrical fault Repair the harness.
Page 181 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines P0480 ECU Fan I control wire is open P0481 ECU Fan II control wire is open. P0483 ECU Fan I control wire internal drive module is overheated. P0484 ECU Fan II control wire internal drive module is overheated.
Page 182 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Fault Tree: Check relay connectors. Repair accordingly. Connector fault Check ECU connectors. Repair accordingly. Connector fault Check continuity and insulating property.. Repair the harness. Electrical fault Replace the relay (carry out ISO cycle).
Page 183 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines P0487 Throttle valve actuator control wire is open. P0488 ECU internal drive module of throttle valve actuator is overheated. P2141 Throttle valve actuator control wire is short to ground. Throttle valve actuator control wire is short to high level.
Page 184 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Fault Tree: Check throttle valve actuator connection. Connector fault Repair or replace. Check throttle valve appearance. Replace the throttle valve. Throttle valve faults Repair or replace. Check ECU connectors. Replace the ECU.
Page 185 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines P0615 ECU starting motor control wire is open or drive module is overheated. P0616 ECU starting motor control wire is short to ground. P0617 ECU starting motor control wire is short to high level.
Page 186 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Fault Tree: Check starting motor connectors. Connector fault Repair accordingly. Check ECU connectors. Repair accordingly. Connector fault Check for continuity and insulating property Electrical fault Repair the harness. Replace starting motor relay.
Page 187 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines ECU instrument panel engine speed output connecting wire is short to high P1605 level. ECU instrument panel engine speed output connecting wire is short to P1606 ground. P1607 ECU instrument panel engine speed output connecting wire is open.
Page 188 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Fault Tree: Check connection between instrument panel 检查仪表板与ECU的连接 and ECU. Connector fault 做必要的修理接插件问题 Repair accordingly. Check continuity and insulating property 检查连续性和绝缘性 Electrical fault 电气问题修理线束 Repair the harness. 更换相应的器件 Replace corresponding components.
Page 189 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines ECU instrument panel preheating indicator lamp output connecting wire is P1608 short to high level. ECU instrument panel preheating indicator lamp output connecting wire is P1609 short to ground. ECU instrument panel preheating indicator lamp output connecting wire is P160A open.
Page 190 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Fault Tree: Check connection between instrument panel and ECU. Connector fault Repair accordingly. Check for continuity and insulating property. Electrical fault Repair the harness. Replace corresponding components. Does the problem still exist?
Page 191 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines P2228 Atmosphere pressure sensor output voltage is too low. P2229 Atmosphere pressure sensor output voltage is too high. Fault Description: Atmosphere pressure indicates connection of ignition switch. When engine stops operation, control module calculates atmosphere pressure with signals sent by intake manifold absolute pressure sensor. Intake manifold absolute pressure sensor responses to internal pressure changes of intake manifold and the pressure changes according to different engine loads.
Page 192 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Fault Tree: Check sensor connection. Connector fault Repair accordingly. Check sensor resistance (for conformity with vehicle status). Sensor resistance faults Replace the sensor. Repair accordingly. Check ECU for connector faults. Check continuity and insulating property Repair the harness.
Page 193 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines P2264 There are faults in water level sensor of diesel filter oil-water separator. P2267 Water in diesel filter oil-water separator is overflowed. Water level signal Drain switch Fault Description: Main function of oil-water separator is to separate moisture from oil in fuel to ensure combustion quality of fuel.
Page 194 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Fault Tree: Drain filter. Eliminate the fault. Is there still water? Check water level sensor for electrical faults. Repair accordingly. Are there still electrical faults? Check water level sensor connectors. Are there still connector faults? Repair accordingly.
Page 195 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines P2299 Depress accelerator pedal and brake pedal at the same time. Fault Description: Accelerator pedal assembly consists of two accelerator pedal position (APP) sensors. Accelerator pedal position sensors are installed on pedal assembly and they are not maintainable. When driver depresses accelerator pedal, air inflow of cylinder is increased and ECU increases fuel injector pulse width in order to supply additional fuel during acceleration process for engine demand.
Page 196 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Fault Tree: Check brake system and acceleration system mechanical parts. Replace it accordingly. Mechanical part failures Check accelerator switch adjusting position. Adjust accelerator switch position Check switch position for improper (accelerator pedal electric adjustment.
Page 197 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines In the case of the maximum fault reading, there are EEPROM errors/ICM U0167 time-out communication failures. Fault Description: They are mainly taken as integrity failures for ECU internal microprocessor, being applied in determination of ECU programming procedure implementation.
Page 198 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Fault Tree: Check ECU connectors. Connector fault Repair accordingly. Check continuity and insulating property Control circuit failures Repair the harness. Check ECU. Replace the ECU or refresh ECU ECU faults data. Get the Technical Support.
Page 199 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines P0045 Supercharger actuator control wire is open. ECU internal drive module of supercharger actuator control wire is P0046 overheated. P0047 Supercharger actuator control wire is short to ground. P0048 Supercharger actuator control wire is short to high level.
Page 200 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Fault Tree: Check ECU connectors. 检查ECU的接插件 Connector fault Repair accordingly. 接插件问题做必要的修理 Check for continuity and insulating property. 检查连续性和绝缘性 Control circuit failures Repair the harness. 控制线路问题修理线束 Check ECU. 检查ECU ECU faults Replace the ECU or refresh ECU ECU问题...
Page 201 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines P1070 Catalytic converter is clogged. P2002 Catalytic converter is removed. P2454 Catalytic converter front and rear differential pressure is too low. P2455 Catalytic converter front and rear differential pressure is too high.
Page 202 Maintenance manual for sunray hfc4da1-2c china-IV diesel engines Fault Tree: Check the component connector. Connector fault Repair or replace. Check the sensor. Sensor faults Replace the sensor. Check ECU connectors. Repair or replace. Check continuity and insulating property Electrical fault Repair the harness.
Page 203 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.
Page 204 Body Body Body Body Electrical Electrical Electrical Electrical Volume Volume Volume Volume Content Content Content Contents s s s Body Body Electrical Electrical Volume Volume Content Content Contents s s s Body Body Electrical Electrical Volume Volume Content Battery Charging System Battery Battery...
Page 205 Body Body Body Body Electrical Electrical Electrical Electrical Volume Volume Volume Volume Content Content Content Contents s s s Installation of ETACS............................ET 53 ETACS..................................ET 54 Basic parameters..............................ET 54 Lighting System Lighting Lighting Lighting System System System Lighting..................................LT 56 Overview................................
Page 206 Body Body Body Body Electrical Electrical Electrical Electrical Volume Volume Volume Volume Content Content Content Contents s s s Audio/ Audio/ Audio/ Audio/Video Video Video Video System System System System Radio..................................AV 114 Mounting position.............................AV 114 Introduction functions............................AV 115 Precautions................................AV 119 Radio..................................AV 121 Troubleshooting..............................AV 121 Radio..................................AV 124...
Page 207 Body Body Body Body Electrical Electrical Electrical Electrical Volume Volume Volume Volume Content Content Content Contents s s s Air Conditioner Conditioner Conditioner Conditioner Air Conditioner..............................AT 158 Overview................................AT 158 Precautions................................AT 159 Functional operation............................AT 162 Air Conditioner..............................AT 165 Operating principle............................
Page 208 Body Body Body Body Electrical Electrical Electrical Electrical Volume Volume Volume Volume Content Content Content Contents s s s Turn signal lamp and hazard warning lamp......................EC 237 Small lamp................................EC 238 Central control..............................EC 239 Wiper and washer............................. EC 240 Power window..............................EC 241 Front A/C system..............................
Page 209: Battery Battery And And And Charging Charging Charging System System
Charging System System Battery Battery Charging Charging System System Battery Battery and and Charging Charging System System Applied models: SUNRAY products manufactured by JAC Subject Page Instruction Operation Instruction Instruction Instruction and and Operation Operation Operation Battery....................................2 Mounting Position............................... 2 Precautions..................................
Page 210: Battery
Battery Battery Charging Charging System System SC Battery Battery and and Charging Charging System System Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Battery Battery Battery Battery Maintenance-free battery is adopted by Sunray series with characteristics in low electrolyte consumption. In the service life of the battery, there is no need to replenish with distilled water.
Page 211: Precautions
Battery Battery Charging Charging System System SC Battery Battery and and Charging Charging System System Instruction Instruction Instruction Instruction and and Operatio Operatio Operatio Operation n n n Precautions Precautions Precautions of of of of Battery Battery Battery Precautions Battery tools or fault diagnosis with metal wires.
Page 212: Generator
Battery Battery Charging Charging System System SC Battery Battery and and Charging Charging System System Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Generator Generator Generator Generator Air-cooled generator is adopted by Sunray series vehicle, conducting cooling via the air blowing from the fan behind the pulley into the generator shell.
Page 213: Battery
Battery Battery Charging Charging System System SC Battery Battery and and Charging Charging System System Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing Maintenance Maintenance of of of of Battery Battery Maintenance Maintenance Battery Battery Battery status indicator (electric eye): As dual-purpose charger, one with constant Green: There is sufficient electric quantity in the voltage of 16.0V (maximum permitted voltage...
Page 214 Battery Battery Charging Charging System System SC Battery Battery and and Charging Charging System System charging current for battery can return to normal phenomenons like underpowered vehicle starting, gradually. dim lighting, abnormal honk etc., off-board boost In the process of charging, if there is a large charge for battery shall be carried out as well as quantity of acid spraying out from battery vent, normal maintenance.
Page 215 Battery Battery Charging Charging System System SC Battery Battery and and Charging Charging System System Diagnosis Diagnosis Test Test Diagnosis Diagnosis and and Test Test Fault diagnosis of Battery Fault Fault Fault Fault Fault Fault Fault Fault symptoms symptoms symptoms symptoms Cause Cause...
Page 216 Battery Battery Charging Charging System System SC Battery Battery and and Charging Charging System System Diagnosis Diagnosis Test Test Diagnosis Diagnosis and and Test Test Fault diagnosis of Battery Fault Fault Fault Fault Fault Fault Fault Fault symptoms symptoms symptoms symptoms Cause Cause...
Page 217 Battery Battery Charging Charging System System SC Battery Battery and and Charging Charging System System Diagnosis Diagnosis Test Test Diagnosis Diagnosis and and Test Test Fault diagnosis of Battery Fault Fault Fault Fault Fault Fault Fault Fault symptoms symptoms symptoms symptoms Cause Cause...
Page 218 Battery Battery Charging Charging System System SC Battery Battery and and Charging Charging System System Diagnosis Diagnosis Test Test Diagnosis Diagnosis and and Test Test Fault determination determination of of of of battery battery Fault Fault Fault determination determination battery battery Appearance inspection Items of Inspection...
Page 219: Fault Diagnosis
Battery Battery Charging Charging System System SC Battery Battery and and Charging Charging System System Diagnosis Diagnosis Test Test Diagnosis Diagnosis and and Test Test Fault determination determination of of of of Generator Generator Fault Fault Fault determination determination Generator Generator Fault diagnosis of charging system Fault symptoms...
Page 220 Battery Battery Charging Charging System System SC Battery Battery and and Charging Charging System System Diagnosis Diagnosis Test Test Diagnosis Diagnosis and and Test Test Operating principle principle of of of of generator generator Operating Operating Operating principle principle generator generator The operating principle of generator: divide three-phase alternating currents (AC) generated by the three-phase...
Page 221 Battery Battery Charging Charging System System SC Battery Battery and and Charging Charging System System Diagnosis Diagnosis Test Test Diagnosis Diagnosis and and Test Test Precautions Precautions of of of of generator generator maintenance Precautions Precautions generator generator maintenance maintenance maintenance For the output current of generator is generated by In the joint operation of generator and voltage...
Page 222: Removal Of Battery
Battery Battery Charging Charging System System SC Battery Battery and and Charging Charging System System Removal Removal Installation Installation Removal Removal and and Installation Installation Removal Removal of of of of Battery Battery Removal Removal Battery Battery Warning: Warning: Warning: In general, explosive gas may be Warning: generated by the battery.
Page 223 Battery Battery Charging Charging System System SC Battery Battery and and Charging Charging System System Removal Removal Removal Removal and and Installation Installation Installation Installation Removal Removal Removal Removal of of of of Battery Battery Battery Battery Open the engine hood. Unscrew mounting bolts of battery negative pole.
Page 224: Installation Of Battery
Battery Battery Charging Charging System System SC Battery Battery and and Charging Charging System System Removal Removal Installation Installation Removal Removal and and Installation Installation Installation Installation of of of of Battery Battery Installation Installation Battery Battery Warning: Warning: Warning: In general, explosive gas may be Warning: generated by the battery.
Page 225 Battery Battery Charging Charging System System SC Battery Battery and and Charging Charging System System Removal Removal Installation Installation Removal Removal and and Installation Installation Installation Installation of of of of Battery Battery Installation Installation Battery Battery Open the engine hood. Place the battery on its support plate steady.
Page 226: Generator
Battery Battery Charging Charging System System SC Battery Battery and and Charging Charging System System Removal Removal Removal Removal and and Installation Installation Installation Installation Removal Removal Removal of of of of Generator Generator Generator Removal Generator Disconnect the battery connection. Remove the front bumper.
Page 227 Battery Battery Charging Charging System System SC Battery Battery and and Charging Charging System System Removal Removal Removal Removal and and Installation Installation Installation Installation Removal Removal Removal of of of of Generator Generator Generator Removal Generator Unscrew tension bolts of generator. Remove the generator belt.
Page 228 Battery Battery Charging Charging System System SC Battery Battery and and Charging Charging System System Removal Removal Installation Installation Removal Removal and and Installation Installation Removal Removal of of of of Generator Generator Removal Removal Generator Generator Remove the generator. - 20 -...
Page 229: Installation Of Generator
Battery Battery Charging Charging System System SC Battery Battery and and Charging Charging System System Removal Removal Installation Installation Removal Removal and and Installation Installation Installation Installation of of of of Generator Generator Installation Installation Generator Generator Connect the generator harness connectors. Install mounting bolts of generator.
Page 230 Battery Battery Charging Charging System System SC Battery Battery and and Charging Charging System System - 22 -...
Page 231 Warning System System Instrument Warning System Instrument Instrument Instrument and and Warning Warning Warning System System System Applied models: SUNRAY products manufactured by JAC Subject Page Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Instrument..................................24 Mounting position..............................24 Performance characteristics............................
Page 232: Instrument Instrument And And And Warning Warning Warning System System
IP Instrument Instrument Instrument Warning Warning System System Instrument and and Warning Warning System System Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Combination Combination instrument instrument Combination Combination instrument instrument Sunray instruments are all-digital instruments which take stepping motors as the structural forms. Analog or digital signals of all sensors are converted into digital signals via processing of central processing units (CPU) to drive the stepping motors.
Page 233: Instrument
IP Instrument Instrument Instrument Warning Warning System System Instrument and and Warning Warning System System Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Performance Performance Performance Performance characteristics characteristics characteristics characteristics of of of of the the combination combination combination combination instrument:...
Page 234 IP Instrument Instrument Instrument Warning Warning System System Instrument and and Warning Warning System System Diagnosis Diagnosis Test Test Diagnosis Diagnosis and and Test Test Function Function description description description of of of of the combination combination instrument instrument Function Function description the combination combination instrument...
Page 235 IP Instrument Instrument Instrument Warning Warning System System Instrument and and Warning Warning System System Diagnosis Diagnosis Test Test Diagnosis Diagnosis and and Test Test Function Function description description description of of of of the combination combination instrument instrument Function Function description the combination combination instrument...
Page 236 IP Instrument Instrument Instrument Warning Warning System System Instrument and and Warning Warning System System Diagnosis Diagnosis Test Test Diagnosis Diagnosis and and Test Test Function Function description description description of of of of the combination combination instrument instrument Function Function description the combination combination instrument...
Page 237 IP Instrument Instrument Instrument Warning Warning System System Instrument and and Warning Warning System System Diagnosis Diagnosis Test Test Diagnosis Diagnosis and and Test Test Function Function description description description of of of of the combination combination instrument instrument Function Function description the combination combination instrument...
Page 238 IP Instrument Instrument Instrument Warning Warning System System Instrument and and Warning Warning System System Diagnosis Diagnosis Test Test Diagnosis Diagnosis and and Test Test Function Function description description description of of of of the combination combination instrument instrument Function Function description the combination combination instrument...
Page 239 IP Instrument Instrument Instrument Warning Warning System System Instrument and and Warning Warning System System Diagnosis Diagnosis Test Test Diagnosis Diagnosis and and Test Test Function Function description description description of of of of the combination combination instrument instrument Function Function description the combination combination instrument...
Page 240 IP Instrument Instrument Instrument Warning Warning System System Instrument and and Warning Warning System System Diagnosis Diagnosis Test Test Diagnosis Diagnosis and and Test Test Definitions Definitions Definitions of of of of instrument instrument instrument pins pins Definitions instrument pins pins Terminal NO.
Page 241 IP Instrument Instrument Instrument Warning Warning System System Instrument and and Warning Warning System System Removal Removal Installation Installation Removal Removal and and Installation Installation Removal Removal Removal of of of of the instrument instrument Removal the instrument instrument Disconnect the connecting wire of battery. Remove the steering wheel.
Page 242 IP Instrument Instrument Instrument Warning Warning System System Instrument and and Warning Warning System System Removal Removal Installation Installation Removal Removal and and Installation Installation Removal Removal Removal of of of of the instrument instrument Removal the instrument instrument Disconnect the connector plug of the instrument. Take out the instrument.
Page 243 IP Instrument Instrument Instrument Warning Warning System System Instrument and and Warning Warning System System Specification Specification Specification Specification Technical Technical Technical Technical parameter parameter parameter parameter of of of of the the instrument instrument instrument instrument Item Technical parameter Remark Operating temperature range of the -30℃～65℃...
Page 244 IP Instrument Instrument Instrument Warning Warning System System Instrument and and Warning Warning System System - 36 -...
Page 245 ETACS Body Body Computer Computer ETACS ETACS Body Body Computer Computer ETACS ETACS Body Body Computer Computer Applied models: SUNRAY products manufactured by JAC Subject Page Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation ETACS................................... 38 Mounting position..............................38 Information functions...............................
Page 246 ETACS ETACS Body Body Computer Computer ET ETACS ETACS Body Body Computer Computer Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation ETACS body computer ETACS ETACS ETACS body body body computer computer computer SUNRAY ETACS is for controlling a majority of electrical systems and equipments on vehicle, such as front water sprayer, front wiper, key hole lamp, interior ceiling lamp, anti-theft alarm bell, seat belt alarm, power window, rear fog lamp, rear defroster, front fog lamp, step lamp, small lamp, headlamp, hazard warning lamp, and locking device.
Page 247 ETACS ETACS Body Body Computer Computer ET ETACS ETACS Body Body Computer Computer Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Introduction Introduction to to to to ETACS ETACS functions Introduction Introduction ETACS ETACS functions functions functions SUNRAY ETACS defines 17 kinds of function listed below: Washer &...
Page 248 ETACS ETACS Body Body Computer Computer ET ETACS ETACS Body Body Computer Computer Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing System structure System System System structure structure structure System structure chart: Remote control receiving Sensor input Interior electrical equipments Switch...
Page 249 ETACS ETACS Body Body Computer Computer ET ETACS ETACS Body Body Computer Computer Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing Introduction Introduction to to to to ETACS ETACS functions Introduction Introduction ETACS ETACS functions functions functions Washer & Wiper Control Turn the ignition switch to “ON”...
Page 250 ETACS ETACS Body Body Computer Computer ET ETACS ETACS Body Body Computer Computer Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing Introduction Introduction to to to to ETACS ETACS functions Introduction Introduction ETACS ETACS functions functions functions Front Ceiling Lamp Illumination Control (Decayed Room Lamp) With the front ceiling lamp set to “DOOR”...
Page 251 ETACS ETACS Body Body Computer Computer ET ETACS ETACS Body Body Computer Computer Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing Introduction Introduction to to to to ETACS ETACS functions Introduction Introduction ETACS ETACS functions functions functions Power Window Timer When the ignition switch is turned to “ON”...
Page 252 ETACS ETACS Body Body Computer Computer ET ETACS ETACS Body Body Computer Computer Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing Introduction Introduction to to to to ETACS ETACS functions Introduction Introduction ETACS ETACS functions functions functions 11. Power Door Latch Control Four door locks can be controlled through doors at Pull up Driver side door...
Page 253 ETACS ETACS Body Body Computer Computer ET ETACS ETACS Body Body Computer Computer Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing Introduction Introduction to to to to ETACS ETACS functions Introduction Introduction ETACS ETACS functions functions functions 14. Auto Locking. With the ignition switch turned to “ON”...
Page 254 ETACS ETACS Body Body Computer Computer ET ETACS ETACS Body Body Computer Computer Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing Introduction Introduction to to to to ETACS ETACS functions Introduction Introduction ETACS ETACS functions functions functions With the middle door open, if you press �...
Page 255 ETACS ETACS Body Body Computer Computer ET ETACS ETACS Body Body Computer Computer Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing Control strategy Control Control Control strategy strategy strategy Item Function Turn the ignition switch to “ON” position. 1. If the washer is switched on over 0.6 sec, the wiper Washer &...
Page 256 ETACS ETACS Body Body Computer Computer ET ETACS ETACS Body Body Computer Computer Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing Control strategy Control Control Control strategy strategy strategy Item Function With the key in and driver side door open, if you push down the latch switch, doors cannot be locked after a door lock signal output by locking device.
Page 257 ETACS ETACS Body Body Computer Computer ET ETACS ETACS Body Body Computer Computer Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing Diagnosis Service Diagnosis Diagnosis Diagnosis and and Service Service Service Function Service Methods and Phenomena a．Press “Learning” key on decoder and the fault lamp lightens. b．If you press the “Warning-off”...
Page 258 ETACS ETACS Body Body Computer Computer ET ETACS ETACS Body Body Computer Computer Diagnosis Diagnosis Diagnosis Diagnosis and and Testing Testing Testing Testing ETACS ETACS Definition Definition ETACS ETACS Pin Pin Definition Definition (Gray) (White) Port No. Port Name Input/Output Initial Status Operating Status Remark...
Page 259 ETACS ETACS Body Body Computer Computer ET ETACS ETACS Body Body Computer Computer Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing ETACS Definition (Continued) ETACS ETACS ETACS Pin Pin Definition Definition Definition (Continued) (Continued) (Continued) Port No. Port Name Input/Output Initial Status Operating Status...
Page 260 ETACS ETACS Body Body Computer Computer ET ETACS ETACS Body Body Computer Computer Removal/Installation Removal/Installation Removal/Installation Removal/Installation Removal Removal of of of of ETACS ETACS Removal Removal ETACS ETACS Disconnect the negative cable of battery. Remove the glove box. Remove the mounting bolts from body computer. Disconnect the harness connector of controller and remove the body computer.
Page 261 ETACS ETACS Body Body Computer Computer ET ETACS ETACS Body Body Computer Computer Removal/Installation Removal/Installation Removal/Installation Removal/Installation Installation Installation of of of of ETACS ETACS Installation Installation ETACS ETACS Connect the harness connector of controller. Tighten the mounting bolts of body computer. Install the glove box.
Page 262 ETACS ETACS Body Body Computer Computer ET ETACS ETACS Body Body Computer Computer Specification Specification Specification Specification Parameters Parameters Parameters Parameters Electrical Parameter Requirement Operating voltage DC12V Operating voltage range DC9V～DC16V ＜10mA Quiescent current Insulating resistance 100MΩ (DC500V megger) Remote control transmitting frequency 315MHz±0.075MHz Receiving frequency of body controller 315MHz±100KHz...
Page 263 System System LT Lighting Lighting System System Lighting Lighting System System Lighting Lighting System System Applied models: SUNRAY products manufactured by JAC Subject Page Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Overview.................................. 56 Lighting configuration table............................. 58 Introduction to functions............................59...
Page 264 Lighting Lighting System System LT Lighting Lighting System System Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Lighting system Lighting Lighting Lighting system system system SUNRAY front lamps (headlamps) are installed on both sides of vehicle head, for lighting when driving at night. Fog lamps are installed on head positions lower than headlamps, for roadway lighting when driving in rainy or foggy days.
Page 265 Lighting Lighting System System LT Lighting Lighting System System Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Tail lamps Tail Tail Tail lamps lamps lamps - 57 -...
Page 266 Lighting Lighting System System LT Lighting Lighting System System Instruction Instruction Instruction Instruction and and Operation Operation Operation Operation Lighting Lighting configuration configuration table table Lighting Lighting configuration configuration table table Name Qty. (For single vehicle) Rear ceiling lamp assembly Front ceiling lamp assembly Left front courtesy lamp Right front courtesy lamp...
Page 267 Lighting Lighting System System LT Lighting Lighting System System Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Introduction Introduction to to to to functions functions Introduction Introduction functions functions Position switch. Rotate the cylinder at the end of multifunctional switch lever to the first position to turn on small lamps, tail lamps, license plate lamps and instrument panel lamp.
Page 268 Lighting Lighting System System LT Lighting Lighting System System Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Introduction Introduction to to to to functions functions Introduction Introduction functions functions Front fog lamp switch. Turn the headlamp switch knob to position lamp, press the front fog lamp switch knob, and the front fog lamp lightens.
Page 269 Lighting Lighting System System LT Lighting Lighting System System Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Introduction Introduction to to to to functions functions Introduction Introduction functions functions Hazard warning lamp switch. If you press the hazard warning lamp switch, turn signal lamps on both sides and instrument indicator shall lighten.
Page 270 Lighting Lighting System System LT Lighting Lighting System System Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing Fault diagnosis Fault Fault Fault diagnosis diagnosis diagnosis Front fog lamp diagnosis Step Operation ①Turn on the ignition switch and set the headlamp to “position lamp” position. Go to Step 2.
Page 271 Lighting Lighting System System LT Lighting Lighting System System Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing Fault diagnosis Fault Fault Fault diagnosis diagnosis diagnosis Turn signal indicator diagnosis Step Operation Turn on the ignition switch and press the hazard warning lamp switch. Go to Step 2.
Page 272 Lighting Lighting System System LT Lighting Lighting System System Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing Fault diagnosis Fault Fault Fault diagnosis diagnosis diagnosis High-mounted brake lamp failed Step Operation Is the fuse blown out? Go to Step 4. Go to Step 2.
Page 273 Lighting Lighting System System LT Lighting Lighting System System Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing Fault diagnosis Fault Fault Fault diagnosis diagnosis diagnosis Ceiling lamp failed Step Operation Check if the bulb filament of ceiling lamp is burnt out. Is the filament burnt out? Go to Step 4.
Page 274 Lighting Lighting System System LT Lighting Lighting System System Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing Fault diagnosis Fault Fault Fault diagnosis diagnosis diagnosis Glove box lamp failed Step Operation Is the fuse blown out? Go to Step 3. Go to Step 2.
Page 275 Lighting Lighting System System LT Lighting Lighting System System Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing Fault diagnosis Fault Fault Fault diagnosis diagnosis diagnosis Both high and low beams failed Step Operation Set the switch to position and the high/low beam switch to high beam Go to Step 2.
Page 276 Lighting Lighting System System LT Lighting Lighting System System Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing Fault diagnosis Fault Fault Fault diagnosis diagnosis diagnosis Only high beam failed Step Operation Check if the high beam signaling device operates normally (only for high Go to Step 2.
Page 277 Lighting Lighting System System LT Lighting Lighting System System Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing Fault diagnosis Fault Fault Fault diagnosis diagnosis diagnosis Low beam failed Step Operation Check lamps and wiring harness connectors. Are they intact? Go to Step 2.
Page 278 Lighting Lighting System System LT Lighting Lighting System System Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing Fault diagnosis Fault Fault Fault diagnosis diagnosis diagnosis Diagnostic program for front rear fog lamp Step Operation Go to Step 7. Go to Step 2.
Page 279 Lighting Lighting System System LT Lighting Lighting System System Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing Fault diagnosis Fault Fault Fault diagnosis diagnosis diagnosis 10. Rear fog lamp failed with front fog lamp and rear fog lamp turned on simultaneously Step Operation Turn on low beam and front fog lamp and then turn on rear fog lamp switch.
Page 280 Lighting Lighting System System LT Lighting Lighting System System Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing Fault diagnosis Fault Fault Fault diagnosis diagnosis diagnosis 11. Diagnostic program for reversing lamps Step Operation Is the fuse intact? Go to Step 3. Go to Step 2.
Page 281 Lighting Lighting System System LT Lighting Lighting System System Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing Fault diagnosis Fault Fault Fault diagnosis diagnosis diagnosis 12. Diagnostic program for brake lamps Step Operation Turn on the ignition switch to check fuse. Is the fuse intact? Go to Step 3.
Page 282 Lighting Lighting System System LT Lighting Lighting System System Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing Fault diagnosis Fault Fault Fault diagnosis diagnosis diagnosis 13. Hazard warning lamp failed but with normal operation of turn signal lamps Step Operation Is the fuse intact?
Page 283 Lighting Lighting System System LT Lighting Lighting System System Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing Fault diagnosis Fault Fault Fault diagnosis diagnosis diagnosis 14. Turn signal lamp failed but with normal operation of hazard warning lamp Step Operation Is the fuse intact?
Page 284 Lighting Lighting System System LT Lighting Lighting System System Removal/Installation Removal/Installation Removal/Installation Removal/Installation Removal Removal of of of of headlamp headlamp Removal Removal headlamp headlamp Disconnect the negative cable of battery. Remove the front grille, front compartment panel, and front bumper. Remove mounting bolts from headlamps.
Page 285 Lighting Lighting System System LT Lighting Lighting System System Removal/Installation Removal/Installation Removal/Installation Removal/Installation Removal Removal of of of of clearance clearance lamps Removal Removal clearance clearance lamps lamps lamps Disconnect the negative cable of battery. Hold the side turn signal lamp with hands and push it forwards, and then pull the lamp outwards with force.
Page 286 Lighting Lighting System System LT Lighting Lighting System System Removal/Installation Removal/Installation Removal/Installation Removal/Installation Removal Removal Removal of of of of front front front lamps lamps Removal front fog fog lamps lamps Disconnect the negative cable of battery. Remove the front bumper. Disconnect the connecting wire of fog lamp.
Page 287 Lighting Lighting System System LT Lighting Lighting System System Removal/Installation Removal/Installation Removal/Installation Removal/Installation Removal Removal of of of of ceiling ceiling lamps Removal Removal ceiling ceiling lamps lamps lamps Disconnect the negative cable of battery. Remove the casing of ceiling lamp. Remove the mounting bolts from ceiling lamp.
Page 288 Lighting Lighting System System LT Lighting Lighting System System Removal/Installation Removal/Installation Removal/Installation Removal/Installation Removal Removal of of of of rear rear tail lamps Removal Removal rear rear tail tail tail lamps lamps lamps Disconnect the negative cable of battery. Remove the mounting bolts from tail lamp. Disconnect the connecting wire of tail lamp.
Page 289 Lighting Lighting System System LT Lighting Lighting System System Removal/Installation Removal/Installation Removal/Installation Removal/Installation Removal Removal of of of of high-mounted high-mounted brake lamp Removal Removal high-mounted high-mounted brake brake brake lamp lamp lamp Disconnect the negative cable of battery. Open the back door. Remove the mounting bolts and disconnect the connecting wire of high-mounted brake lamp.
Page 290 Lighting Lighting System System LT Lighting Lighting System System Removal/Installation Removal/Installation Removal/Installation Removal/Installation Removal Removal of of of of rear rear lamp Removal Removal rear rear fog fog lamp lamp lamp Disconnect the negative cable of battery. Remove the rear bumper. Disconnect the connecting wire of rear fog lamp.
Page 291 Lighting Lighting System System LT Lighting Lighting System System Specification Specification Specification Specification Basic parameters Basic Basic Basic parameters parameters parameters Name Bulb Type Power H4 12V 60/55W 60/55W High/low beam Front H4 12V 60/55W 60/55W combination Position lamp 12V 16W lamp Turn signal lamp 12V 21W...
Page 292 Lighting Lighting System System LT Lighting Lighting System System - 84 -...
Page 293 Washer System System Wiper Wiper Washer Washer System System Wiper Wiper and and Washer Washer System System Applied models: SUNRAY products manufactured by JAC Subject Page Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Wiper....................................86 Mounting position..............................87 Information functions............................... 89...
Page 294 WW Wiper Wiper Wiper Washer Washer System System Wiper and and Washer Washer System System Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Wiper Wiper system system Wiper Wiper system system Wiper system is the system used for cleaning raindrops on windshield and rear window in order to maintain clear vision.
Page 295 Wiper Wiper Washer Washer System System WW Wiper Wiper and and Washer Washer System System Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Mounting Mounting position position position of of of of wiper wiper wiper system system components components Mounting Mounting position...
Page 296 WW Wiper Wiper Wiper Washer Washer System System Wiper and and Washer Washer System System Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Mounting Mounting position position position of of of of wiper wiper wiper system system components components Mounting Mounting position...
Page 297 Wiper Wiper Washer Washer System System WW Wiper Wiper and and Washer Washer System System Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Operation Operation Operation of of of of wiper wiper wiper system system function function Operation wiper system system function function...
Page 298 WW Wiper Wiper Wiper Washer Washer System System Wiper and and Washer Washer System System Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Operation Operation Operation of of of of wiper wiper wiper system system function function Operation wiper system system function function...
Page 299 Wiper Wiper Washer Washer System System WW Wiper Wiper and and Washer Washer System System Diagnostic Diagnostic Test Test Diagnostic Diagnostic Test Test Definitions Definitions Definitions Definitions of of of of pins pins pins pins Color Green Blue Yellow Black Positive High Negative...
Page 300 WW Wiper Wiper Wiper Washer Washer System System Wiper and and Washer Washer System System Diagnostic Diagnostic Diagnostic Diagnostic Test Test Test Test Troubleshooting Troubleshooting Troubleshooting Troubleshooting Fault mode： No matter what gear is the wiper switch at, there are no operations of the wiper and washer. Step Operation Inspect the wiper fuse for the existence of damage.
Page 301 Wiper Wiper Washer Washer System System WW Wiper Wiper and and Washer Washer System System Diagnostic Diagnostic Test Test Diagnostic Diagnostic Test Test Troubleshooting Troubleshooting Troubleshooting Troubleshooting Fault mode: No operation at INT gear only Step Operation Remove the wiper relay and shift the ignition switch to ON and shift the wiper Go to Step 4 Go to Step 2 switch to internal gear.
Page 302 WW Wiper Wiper Wiper Washer Washer System System Wiper and and Washer Washer System System Diagnostic Diagnostic Test Test Diagnostic Diagnostic Test Test Troubleshooting Troubleshooting Troubleshooting Troubleshooting Fault mode: Deviation of the wiper blade form its original position Step Operation Remove the wiper switch and inspect the internal structure of it.
Page 303 Wiper Wiper Washer Washer System System WW Wiper Wiper and and Washer Washer System System Removal Removal Installation Installation Removal Removal and and Installation Installation Removal Removal Removal of of of of the wiper wiper Removal the wiper wiper Disconnect the connecting wire of battery. Remove mounting bolts of the wiper.
Page 304 WW Wiper Wiper Wiper Washer Washer System System Wiper and and Washer Washer System System Removal Removal Installation Installation Removal Removal and and Installation Installation Removal Removal Removal of of of of the wiper wiper Removal the wiper wiper Take down the wiper blade and wiper decorative panel.
Page 305 Wiper Wiper Washer Washer System System WW Wiper Wiper and and Washer Washer System System Removal Removal Installation Installation Removal Removal and and Installation Installation Removal Removal Removal of of of of the windshield windshield washing washing fluid fluid reservoir reservoir Removal the windshield...
Page 306 WW Wiper Wiper Wiper Washer Washer System System Wiper and and Washer Washer System System Removal Removal Installation Installation Removal Removal and and Installation Installation Removal Removal Removal of of of of the Wiper Wiper washing washing nozzle nozzle Removal the Wiper Wiper washing washing nozzle...
Page 307 Wiper Wiper Washer Washer System System WW Wiper Wiper and and Washer Washer System System Specification Specification Specification Specification Technical Technical parameter parameter Technical Technical parameter parameter No load Loaded 4.4N.m Low speed High speed Low speed High speed Speed r/min Current A Speed r/min Current A...
Page 308 WW Wiper Wiper Wiper Washer Washer System System Wiper and and Washer Washer System System - 100 -...
Page 309 PT Reversing Reversing parking parking assistance assistance system system Reversing Reversing Radar Radar Reversing Reversing Radar Radar Applied models: SUNRAY products manufactured by JAC Subject Page Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Reversing Radar................................102 Mounting position sensor............................102 Operating principle..............................
Page 310 Reversing Reversing parking parking assistance assistance system system PT Reversing Reversing parking parking assistance assistance system system Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Reversing radar sensor Reversing Reversing Reversing radar radar radar sensor sensor sensor There are 4 sensor probes for Sunray reversing radar. With the application of ultrasonic sensor, the distance measurement of the obstacle and the vehicle can be carried out.
Page 311 Reversing Reversing parking parking assistance assistance system system PT Reversing Reversing parking parking assistance assistance system system Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Operating principle principle of of of of the reversing radar Operating Operating Operating principle principle the reversing reversing...
Page 312 Reversing Reversing parking parking assistance assistance system system PT Reversing Reversing parking parking assistance assistance system system Diagnosis Diagnosis Test Test Diagnosis Diagnosis and and Test Test Definitions Definitions of of of of reversing reversing radar computer pins Definitions Definitions reversing reversing radar radar...
Page 313 Reversing Reversing parking parking assistance assistance system system PT Reversing Reversing parking parking assistance assistance system system Diagnosis Diagnosis Test Test Diagnosis Diagnosis and and Test Test Definitions Definitions Definitions Definitions of of of of reversing reversing reversing reversing radar radar radar radar computer...
Page 314 Reversing Reversing parking parking assistance assistance system system PT Reversing Reversing parking parking assistance assistance system system Diagnosis Diagnosis Test Test Diagnosis Diagnosis and and Test Test Possible conditions out of of of of operation operation reversing radar Possible Possible Possible conditions conditions conditions for...
Page 315 Reversing Reversing parking parking assistance assistance system system PT Reversing Reversing parking parking assistance assistance system system Diagnosis Diagnosis Test Test Diagnosis Diagnosis and and Test Test Possible conditions reversing radar false alarms Possible Possible Possible conditions conditions conditions for for the the reversing reversing...
Page 316 Reversing Reversing parking parking assistance assistance system system PT Reversing Reversing parking parking assistance assistance system system Removal Removal Installation Installation Removal Removal and and Installation Installation Removal Removal of of of of the reversing radar computer Removal Removal the reversing reversing reversing radar radar...
Page 317 Reversing Reversing parking parking assistance assistance system system PT Reversing Reversing parking parking assistance assistance system system Removal Removal Installation Installation (continued) (continued) Removal Removal and and Installation Installation (continued) (continued) Removal Removal of of of of the reversing radar Removal Removal the reversing...
Page 318 Reversing Reversing parking parking assistance assistance system system PT Reversing Reversing parking parking assistance assistance system system Removal Removal Installation Installation Removal Removal and and Installation Installation Removal Removal of of of of the reversing radar sensor Removal Removal the reversing reversing reversing radar radar...
Page 319 Reversing Reversing parking parking assistance assistance system system PT Reversing Reversing parking parking assistance assistance system system Specification Specification Specification Specification Basic parameter parameter of of of of the reversing radar: Basic Basic Basic parameter parameter the reversing reversing reversing radar: radar: radar: Technical...
Page 320 Reversing Reversing parking parking assistance assistance system system PT Reversing Reversing parking parking assistance assistance system system - 112 -...
Page 321 Audio/Video Video System System Audio/ Audio/ Video Video System System Audio/ Audio/Video Video System System Applied models: SUNRAY products manufactured by JAC Subject Page Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Radio.................................... 114 Mounting position..............................114 Introduction functions.............................115 Precautions................................119...
Page 322 Audio/ Audio/ Video Video System System AV Audio/ Audio/Video Video System System Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Audio system Audio Audio Audio system system system SUNRAY audio control system, powered by 12V DC power supply, is composed of CD module, radio module and MP3 module, which features with 10 seconds electronic anti-vibration reliability, USB data reading function and FM/AM radio, and can supports play formats of CD, MP3 and WMA.
Page 323 Audio/ Audio/ Video Video System System AV Audio/ Audio/Video Video System System Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Introduction Introduction to to to to CD player function Introduction Introduction CD player player player function function function Press it shortly.
Page 324 Audio/ Audio/ Video Video System System AV Audio/ Audio/Video Video System System Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Introduction Introduction to to to to CD player function Introduction Introduction CD player player player function function function Press it shortly.
Page 325 Audio/ Audio/ Video Video System System AV Audio/ Audio/Video Video System System Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Introduction Introduction to to to to CD player function Introduction Introduction CD player player player function function function Press it shortly.
Page 326 Audio/ Audio/ Video Video System System AV Audio/ Audio/Video Video System System Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Introduction Introduction to to to to CD player function Introduction Introduction CD player player player function function function 13.
Page 327 Audio/ Audio/ Video Video System System AV Audio/ Audio/Video Video System System Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Precautions Precautions Precautions Precautions Don’t place CD player under hot environment. Don’t remove the CD player violently. Don’t use the CD player when driving on bumpy road surface.
Page 328 Audio/ Audio/ Video Video System System AV Audio/ Audio/Video Video System System Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Precautions Precautions Precautions Precautions Handle the CD properly. The CD is not allowed to be exposed under strong sunlight.
Page 329 Audio/ Audio/ Video Video System System AV Audio/ Audio/Video Video System System Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing Troubleshooting Troubleshooting Troubleshooting Troubleshooting 1. 1. 1. 1. Poor reception reception of of of of antenna. antenna. Poor Poor Poor reception reception...
Page 330 Audio/ Audio/ Video Video System System AV Audio/ Audio/Video Video System System Diagnosis Diagnosis Diagnosis Diagnosis and and Testing Testing Testing Testing Troubleshooting Troubleshooting Troubleshooting Troubleshooting No radio display with the parking lamp on. Step Operation ①Turn the ignition key to ACC position. ②Turn on the radio.
Page 331 Audio/ Audio/ Video Video System System AV Audio/ Audio/Video Video System System Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing Troubleshooting Troubleshooting Troubleshooting Troubleshooting Loudspeaker failed to operate. Step Operation Does every loudspeaker fail to operate? Go to Step 6. Go to Step 2.
Page 332 Audio/ Audio/ Video Video System System AV Audio/ Audio/Video Video System System Removal/Installation Removal/Installation Removal/Installation Removal/Installation Removal Removal of of of of CD player Removal Removal CD player player player Disconnect the negative cable of battery. Remove the outer cover plate of CD player. Unscrew the mounting bolts from CD player.
Page 333 Audio/ Audio/ Video Video System System AV Audio/ Audio/Video Video System System Removal/Installation Removal/Installation Removal/Installation Removal/Installation Removal Removal of of of of loudspeakers loudspeakers Removal Removal loudspeakers loudspeakers Disconnect the negative cable of battery. Remove the third and fourth rows of seat. Remove the inner trims.
Page 334 Audio/ Audio/ Video Video System System AV Audio/ Audio/Video Video System System Removal/Installation Removal/Installation Removal/Installation Removal/Installation Removal Removal of of of of loudspeakers loudspeakers Removal Removal loudspeakers loudspeakers Disconnect the connecting harness and remove the loudspeaker. -126-...
Page 335 Audio/ Audio/ Video Video System System AV Audio/ Audio/Video Video System System Specification Specification Specification Specification Basic parameters parameters of of of of audio audio system Basic Basic Basic parameters parameters audio audio system system system Operating condition and performance parameter: Item Range Typical Value...
Page 336 Audio/ Audio/ Video Video System System AV Audio/ Audio/Video Video System System Technical data for USB-MP3 play: Item Unit Performance Parameter Frequency response 100Hz/100KHz ±3dB Standard distortion ≤3% S/N ratio ≥50 Channel separation ≥45 Maximum output power ≥10 Technical data for CD play: Item Unit Test Condition...
Page 337 Seat Belt Belt SB Seat Seat Belt Belt Seat Seat Belt Belt Seat Seat Belt Belt Applied models: SUNRAY products manufactured by JAC Subject Page Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Seat Belt..................................130 Overview................................130...
Page 338 Seat Seat Belt Belt SB Seat Seat Belt Belt Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Seat Belt Seat Seat Seat Belt Belt Belt The seat belts are assembled on each seats for Sunray. The seat belt is designed to limit the movement of passengers and protect the passengers when a collision occurs to the vehicle.
Page 339 Seat Seat Belt Belt SB Seat Seat Belt Belt Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing T T T T roubleshooting roubleshooting roubleshooting roubleshooting Fault of driver’s seat belt indicator lamp circuit Step Operation ①Turn the ignition switch on and the engine switch is off. Important precautions: When the driver’s seat belt is not fastened, the seat belt indicator lamp should illuminate.
Page 340 Seat Seat Belt Belt SB Seat Seat Belt Belt Removal/Installation Removal/Installation Removal/Installation Removal/Installation Removal Removal of of of of seat seat belt Removal Removal seat seat belt belt belt Disconnect the connecting wire of battery. Remove the left front door stepping shield. Remove the bottom mounting bolts of seat belts.
Page 341 Seat Seat Belt Belt SB Seat Seat Belt Belt Remove the B pillar inner trim panel. - 133 -...
Page 342 Seat Seat Belt Belt SB Seat Seat Belt Belt Removal/Installation Removal/Installation Removal/Installation Removal/Installation Removal Removal of of of of seat seat belt Removal Removal seat seat belt belt belt Remove the covers of top mounting bolts. Remove the top mounting bolts. Remove the bottom mounting bolts.
Page 343 Seat Seat Belt Belt SB Seat Seat Belt Belt Removal/Installation Removal/Installation Removal/Installation Removal/Installation Removal Removal of of of of seat seat belt buckle lock Removal Removal seat seat belt belt belt buckle buckle buckle lock lock lock Disconnect the connecting wire of battery. Remove the front seat inner lateral panel assembly.
Page 344 Power Window Window GW Power Power Window Window Power Power Window Window Power Power Window Window Applied models: SUNRAY products manufactured by JAC Subject Page Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Power Window................................136 Installation position..............................136 Operation Instructions............................
Page 345 Power Power Window Window GW Power Power Window Window Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Power Window Power Power Power Window Window Window Both front door windows for Sunray adopt electric up/down operation. Power window system can lift or lower windows electrically by turning on the switches on each door trims.
Page 346 JAC Multifunctional Commercial Vehicle Company Sunray series Power Window Instruction Instruction operation operation Instruction Instruction and and operation operation Instructions power window function Instructions Instructions Instructions for for power power power window window window function function function Power window switch.
Page 347 Power Power Window Window GW Power Power Window Window Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing Troubleshooting Troubleshooting Troubleshooting Troubleshooting All the door power windows cannot operate. Step Operation Method Check if F31 50A fuse of engine compartment fuse block, F29 15A fuse, F7 Go to Step 8 Go to Step 2 10A fuse, F12 10A fuse of meter fuse block are disconnected.
Page 348 JAC Multifunctional Commercial Vehicle Company Sunray series Power Window Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing Troubleshooting Troubleshooting Troubleshooting Troubleshooting The left front door power window cannot operate. Step Operation Method Check if the output signal from power window main switch is normal...
Page 349 Power Power Window Window GW Power Power Window Window Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing Troubleshooting Troubleshooting Troubleshooting Troubleshooting The right front door power window cannot operate. Step Operation Method Check if the output signal from power window main switch is normal Disconnect the right front door power window motor connector and turn the ignition switch on.
Page 350 JAC Multifunctional Commercial Vehicle Company Sunray series Power Window Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing Troubleshooting Troubleshooting Troubleshooting Troubleshooting The auto down function for left front door power window fails. Step Operation Method The normal replacement and check operation for left front door power Go to Step 2 window switch.
Page 351 Power Power Window Window GW Power Power Window Window Removal/Installation Removal/Installation Removal/Installation Removal/Installation Removal Removal of of of of window window regulator motor Removal Removal window window regulator regulator regulator motor motor motor Disconnect the connecting wire of battery. Remove the left front door inner trim. Disconnect the harness connection and remove the mounting bolts of motor.
Page 352 JAC Multifunctional Commercial Vehicle Company Sunray series Power Window Removal/Installation Removal/Installation Removal/Installation Removal/Installation Removal Removal of of of of window window regulator switch Removal Removal window window regulator regulator regulator switch switch switch Disconnect the connecting wire of battery. Remove the left front door inner trim.
Page 353 Power Power Window Window GW Power Power Window Window Removal/Installation Removal/Installation Removal/Installation Removal/Installation Installation Installation of of of of window window regulator motor Installation Installation window window regulator regulator regulator motor motor motor Install the motor. Connect the harness and install the mounting bolts of motor.
Page 354 JAC Multifunctional Commercial Vehicle Company Sunray series Power Window Removal/Installation Removal/Installation Removal/Installation Removal/Installation Installation Installation of of of of window window regulator switch Installation Installation window window regulator regulator regulator switch switch switch Install the window switch. Connect the harness and install the mounting bolts of switch.
Page 355 Power Power Window Window GW Power Power Window Window -- 146 --...
Page 356 Electric Electric rear-view rear-view mirro mirro Electric Electric rear-view rear-view mirro mirro Applied models: SUNRAY products manufactured by JAC Subject Page Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Electric rear-view mirro............................... 148 Overview................................148...
Page 357 Electric Electric rear-view rear-view mirro mirro EM Electric Electric rear-view rear-view mirro mirro Instruction Instruction Instruction Instruction and and Operation Operation Operation Operation Rear Rear view view mirror mirror Rear Rear view view mirror mirror Sunray rear view mirrors is devided into interior rear view mirror and exterior interior rear view mirror. The exterior rear view mirrors are fixed on the top of front windshield and at left and right outboard sides of vehicle body for observation of conditions inside and behind the vehicle.
Page 358 Electric Electric rear-view rear-view mirro mirro EM Electric Electric rear-view rear-view mirro mirro Removal Removal Installation Installation Removal Removal and and Installation Installation Removal Removal of of of of rear rear view mirror Removal Removal rear rear view view view mirror mirror mirror Disconnect the connecting wire of battery.
Page 359 Electric Electric rear-view rear-view mirro mirro EM Electric Electric rear-view rear-view mirro mirro Removal Removal Removal Removal and and Installation Installation Installation Installation Removal Removal Removal of of of of rear rear rear view view mirror mirror switch switch Removal rear view view mirror mirror switch...
Page 360 HORN HORN HO HORN HORN H H H H orn Applied models: SUNRAY products manufactured by JAC Subject Page Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation H H H H orn orn.................................... 152 Mounting position..............................152 Diagnosis Diagnosis...
Page 361 HORN HORN HO HORN HORN Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Mounting position position of of of of horn horn Mounting Mounting Mounting position position horn horn - 152 -...
Page 362 HORN HORN HO HORN HORN Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing Troubleshooting Troubleshooting Troubleshooting Troubleshooting Horn always on. Step Operation Is the vehicle equipped with any anti-theft system? Go to Step 2. Go to Step 3. Check vehicle Is the vehicle diagnostic system check performed? Go to Step 4.
Page 363 HORN HORN HO HORN HORN Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing Troubleshooting Troubleshooting Troubleshooting Troubleshooting Horn failed to work. Step Operation Is the vehicle equipped with any anti-theft system? Go to Step 2. Go to Step 3. Check vehicle Is the vehicle diagnostic system check performed? Go to Step 4.
Page 364 HORN HORN HO HORN HORN Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing Troubleshooting Troubleshooting Troubleshooting Troubleshooting Inferior tone quality of horn. Step Operation Is the vehicle equipped with any anti-theft system? Go to Step 2. Go to Step 3. Check vehicle Is the vehicle diagnostic system check performed? Go to Step 4.
Page 365 HORN HORN HO HORN HORN Removal/Installation Removal/Installation Removal/Installation Removal/Installation Removal Removal of of of of horn horn Removal Removal horn horn Disconnect the negative cable of battery. Remove the front bumper. Remove the mounting bolt of horn and disconnect the horn plug. Remove the horn.
Page 366 Conditioner Conditioner AT Air Air Conditioner Conditioner Conditioner Conditioner (A/C) (A/C) Air Conditioner Conditioner (A/C) (A/C) Applied models: SUNRAY products manufactured by JAC Subject Page Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Air Conditioner................................158 Overview................................158 Precautions................................159...
Page 367 Conditioner Conditioner AT Air Air Conditioner Conditioner Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation system A/C system system system SUNRAY adopts dual A/C system, with the front and rear A/C controlled independently. In this system, the front and rear A/C use independent condenser and evaporator but share the same compressor.
Page 368 Conditioner Conditioner AT Air Air Conditioner Conditioner Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Precautions Precautions Precautions Precautions Refrigerant is of low freezing point and strong volatility, so please wear gloves and goggles in order to avoid frostbite, blindness and other phenomena caused by its contact with skin.
Page 369 Conditioner Conditioner AT Air Air Conditioner Conditioner Instruction Instruction Instruction Instruction and and Operation Operation Operation Operation Precautions Precautions Precautions Precautions R-134a shall be adopted as refrigerant. Use of other kinds of refrigerant may bring negative effect to system components. R-134a refrigerant and R-12 refrigerant are incompatible, so even little amount of R-12 refrigerant is not allowed to be mixed into R-134a...
Page 370 Conditioner Conditioner AT Air Air Conditioner Conditioner Instruction and Operation Precautions Generally, dust covers are adopted for A/C components, in order to avoid access of sewage, dust and moisture. Dust covers should be removed before operation and sealed after operation. Moisture Dust 10.
Page 371 Conditioner Conditioner AT Air Air Conditioner Conditioner Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Functional operation Functional Functional Functional operation operation operation “TO-FACE” mode Air is adjusted when passing through system and vented out through upper air vent. This mode is applied to most of places using A/C.
Page 372 Conditioner Conditioner AT Air Air Conditioner Conditioner Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Functional operation Functional Functional Functional operation operation operation Defroster Air is adjusted and vented out through defroster air vent and a little air is vented out through side window defroster.
Page 373 Conditioner Conditioner AT Air Air Conditioner Conditioner Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Functional operation Functional Functional Functional operation operation operation Front control panel temperature control knob Rotate the knob within the range shown in the right figure, and the interior temperature can be controlled within the indicated range.
Page 374 Conditioner Conditioner AT Air Air Conditioner Conditioner Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing Operating principle Operating Operating Operating principle principle principle During operation, low pressure gaseous refrigerant from evaporator transforms into high pressure and high temperature gas after passing through compressor, which transforms into high pressure and low temperature liquid after being cooled by condenser radiating pipe;...
Page 375 Conditioner Conditioner AT Air Air Conditioner Conditioner Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing Operating principle Operating Operating Operating principle principle principle Condensation process. Throttling and expansion process. Evaporation process. - 166 -...
Page 376 Conditioner Conditioner AT Air Air Conditioner Conditioner Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing distribution system introduction Air distribution distribution distribution system system system introduction introduction introduction Mixing flow. The outside air is mixed through: Instrument panel air vent �...
Page 377 Conditioner Conditioner AT Air Air Conditioner Conditioner Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing Leak test Leak Leak Leak test test test Required tools. R-134a A/C system dye tracer (24 pcs.). General purpose 12V leak detector lamp. Fluorescent dye scavenger.
Page 378 Conditioner Conditioner AT Air Air Conditioner Conditioner Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing system performance testing A/C system system system performance performance performance testing testing testing Test the vehicle under direct sunlight. Don’t test the vehicle under airflow obstruction of condenser, such as the vehicle is parked closely against wall.
Page 379 Conditioner Conditioner AT Air Air Conditioner Conditioner Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing system performance testing A/C system system system performance performance performance testing testing testing Set the cooling temperature to the coldest status. Open the instrument panel air vent facing right ahead.
Page 380 Conditioner Conditioner AT Air Air Conditioner Conditioner Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing system performance testing A/C system system system performance performance performance testing testing testing The engine hood is closed. 10. Connect the precision pressure gauge to A/C system.
Page 381 Conditioner Conditioner AT Air Air Conditioner Conditioner Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing R R R R efrigerant efrigerant recovery efrigerant efrigerant recovery recovery recovery Park the vehicle in well-ventilated areas. Connect to the refrigerant recovery machine. Turn on the refrigerant recovery machine and select the refrigerant reclaimer on the control panel.
Page 382 Conditioner Conditioner AT Air Air Conditioner Conditioner Diagnosis and Testing Refrigerant recovery The refrigerant recovery machine shall start to recover refrigerant and lubricating oil from A/C system, which respectively flows into a fluid reservoir and a removable oil reservoir. Refrigerant recovery machine shall drain all refrigerant out of A/C system, achieving partial vacuum of A/C system with pressure at about 34 kPa (10 Hg).
Page 383 Conditioner Conditioner AT Air Air Conditioner Conditioner Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing System Performance Table A/C System System System Performance Performance Performance Table Table Table Ambient air Temperature of central Pressure at low-pressure Pressure at high-pressure Engine Relative temperature...
Page 384 Conditioner Conditioner AT Air Air Conditioner Conditioner Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing System Performance Table A/C System System System Performance Performance Performance Table Table Table ℃ ℉ ℃ ℉ Definition: This table lists the pressure of refrigerant 134a under different temperature. For example, under room temperature of 26.6 ℃...
Page 385 Conditioner Conditioner AT Air Air Conditioner Conditioner Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing system performance diagnosis A/C system system system performance performance performance diagnosis diagnosis diagnosis Air heater performance diagnosis. Step Operation Whether or not to conduct this diagnosis based on “ symptoms ” or Go to Step 2.
Page 386 Conditioner Conditioner AT Air Air Conditioner Conditioner Run the system to check the maintenance result. System is normal. Go to Step 2. Is the fault detected and eliminated? - 177 -...
Page 387 Conditioner Conditioner AT Air Air Conditioner Conditioner Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing system performance diagnosis A/C system system system performance performance performance diagnosis diagnosis diagnosis Insufficient defrosting. Step Operation Whether or not to conduct this diagnosis based on “symptoms” or Go to Step 2.
Page 388 Conditioner Conditioner AT Air Air Conditioner Conditioner Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing system performance diagnosis A/C system system system performance performance performance diagnosis diagnosis diagnosis Blower motor noise diagnosis. Step Operation Whether or not to conduct this diagnosis based on “symptoms” or Go to Step 2.
Page 389 Conditioner Conditioner AT Air Air Conditioner Conditioner Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing system performance diagnosis A/C system system system performance performance performance diagnosis diagnosis diagnosis Refrigerating system noise diagnosis. Step Operation Whether or not to conduct this diagnosis based on “A/C system Go to Step 2.
Page 390 Conditioner Conditioner AT Air Air Conditioner Conditioner Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing system performance diagnosis A/C system system system performance performance performance diagnosis diagnosis diagnosis A/C system actuator noise diagnosis. Step Operation Whether or not to conduct this diagnosis based on “symptoms” or Go to Step 2.
Page 391 Conditioner Conditioner AT Air Air Conditioner Conditioner Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing system performance diagnosis A/C system system system performance performance performance diagnosis diagnosis diagnosis Odour diagnosis. Step Operation Whether or not to conduct this diagnosis based on “symptoms” or Go to Step 2.
Page 392 Conditioner Conditioner AT Air Air Conditioner Conditioner Is the fault detected and eliminated? Diagnosis Diagnosis Diagnosis Diagnosis and and Testing Testing Testing Testing system performance diagnosis A/C system system system performance performance performance diagnosis diagnosis diagnosis Diagnosis of failed blower motor operation. Step Operation ①Turn the ignition switch to ON position with the engine off.
Page 393 Conditioner Conditioner AT Air Air Conditioner Conditioner Is the fault eliminated? - 184 -...
Page 394 Conditioner Conditioner AT Air Air Conditioner Conditioner Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing system performance diagnosis A/C system system system performance performance performance diagnosis diagnosis diagnosis Fault diagnosis of blower motor. Step Operation ①Turn the ignition switch to ON position with the engine off. ②Turn the blower motor switch to each speed position.
Page 395 Conditioner Conditioner AT Air Air Conditioner Conditioner Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing system performance diagnosis A/C system system system performance performance performance diagnosis diagnosis diagnosis Diagnosis of poor A/C system refrigeration. Step Operation Check the operation of air mixing damper to confirm no blockage or rupture.
Page 396 Conditioner Conditioner AT Air Air Conditioner Conditioner Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing system performance diagnosis A/C system system system performance performance performance diagnosis diagnosis diagnosis 10. Diagnosis for insufficient warm air. Step Operation Check the operation of air mixing damper to confirm no blockage or rupture.
Page 397 Conditioner Conditioner AT Air Air Conditioner Conditioner Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing system performance diagnosis A/C system system system performance performance performance diagnosis diagnosis diagnosis 11. Inadequate air out. Step Operation ①Start the engine. ②Set the mode switch to “OFF” position. Go to Step 2.
Page 398 Conditioner Conditioner AT Air Air Conditioner Conditioner Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing system performance diagnosis A/C system system system performance performance performance diagnosis diagnosis diagnosis 12. Fault diagnosis of internal/external circulation. Step Operation ①Turn the ignition switch to ON position with the engine off. ②Set the blower motor switch to maximum speed position.
Page 399 Conditioner Conditioner AT Air Air Conditioner Conditioner Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing system performance diagnosis A/C system system system performance performance performance diagnosis diagnosis diagnosis 13. Fault diagnosis of internal/external circulation. Step Operation Check internal circulation damper and internal circulation actuator for: Dislocation of circulation actuator.
Page 400 Conditioner Conditioner AT Air Air Conditioner Conditioner Removal/Installation Removal/Installation Removal/Installation Removal/Installation Removal Removal of of of of front front assembly Removal Removal front front A/C A/C assembly assembly assembly Recover refrigerant. Disconnect negative cable of battery. Remove instrument panel. Remove mounting bolts from expansion valve. - 191 -...
Page 401 Conditioner Conditioner AT Air Air Conditioner Conditioner Removal/Installation Removal/Installation Removal/Installation Removal/Installation Removal Removal of of of of front front assembly Removal Removal front front A/C A/C assembly assembly assembly Remove mounting bolts from front A/C. Disconnect the connector and remove the front A/C assembly.
Page 402 Conditioner Conditioner AT Air Air Conditioner Conditioner Removal/Installation Removal/Installation Removal/Installation Removal/Installation Removal Removal of of of of top evaporator tank Removal Removal top evaporator evaporator evaporator tank tank tank Recover refrigerant. Disconnect negative cable of battery. Remove luggage rack. Remove ceiling and interior trim. - 193 -...
Page 403 Conditioner Conditioner AT Air Air Conditioner Conditioner Removal/Installation Removal/Installation Removal/Installation Removal/Installation Removal Removal of of of of top evaporator tank Removal Removal top evaporator evaporator evaporator tank tank tank Disconnect the A/C drain pipe. Remove mounting bolts from expansion valve. Remove mounting bolts.
Page 404 Conditioner Conditioner AT Air Air Conditioner Conditioner Removal/Installation Removal/Installation Removal/Installation Removal/Installation Removal Removal Removal of of of of front front front condenser condenser Removal front condenser condenser Recover refrigerant. Disconnect negative cable of battery. Remove front bumper. Remove mounting bolts. - 195 -...
Page 405 Conditioner Conditioner AT Air Air Conditioner Conditioner Removal/Installation Removal/Installation Removal/Installation Removal/Installation Removal Removal of of of of front front condenser Removal Removal front front condenser condenser condenser Disconnect pipeline. Remove condenser. - 196 -...
Page 406 Conditioner Conditioner AT Air Air Conditioner Conditioner Removal/Installation Removal/Installation Removal/Installation Removal/Installation Removal Removal of of of of bottom bottom condenser Removal Removal bottom bottom condenser condenser condenser Recover refrigerant. Disconnect negative cable of battery. Remove mounting bolts and disconnect pipeline. Remove bottom condenser assembly.
Page 407 Conditioner Conditioner AT Air Air Conditioner Conditioner Removal/Installation Removal/Installation Removal/Installation Removal/Installation Removal Removal of of of of heater heater water tank Removal Removal heater heater water water water tank tank tank Recover refrigerant. Disconnect negative cable of battery. Remove connecting pipe of heater water tank. Disconnect the plug.
Page 408 Conditioner Conditioner AT Air Air Conditioner Conditioner Removal/Installation Removal/Installation Removal/Installation Removal/Installation Removal Removal of of of of heater heater water tank Removal Removal heater heater water water water tank tank tank Remove mounting bolts from heater water tank. Remove heater water tank assembly. - 199 -...
Page 409 Conditioner Conditioner AT Air Air Conditioner Conditioner Removal/Installation Removal/Installation Removal/Installation Removal/Installation Removal/installation Removal/installation of of of of temperature temperature control motor Removal/installation Removal/installation temperature temperature control control control motor motor motor Disconnect negative cable of battery. Remove instrument panel. Disconnect harness connector remove...
Page 410 Conditioner Conditioner AT Air Air Conditioner Conditioner Removal/Installation Removal/Installation Removal/Installation Removal/Installation Removal/ Removal/i i i i nstallation nstallation nstallation of of of of mode mode damper motor Removal/ Removal/ nstallation mode mode damper damper damper motor motor motor Disconnect negative cable of battery. Remove instrument panel.
Page 411 Conditioner Conditioner AT Air Air Conditioner Conditioner Removal/Installation Removal/Installation Removal/Installation Removal/Installation Removal/ Removal/i i i i nstallation nstallation nstallation of of of of speed speed governing module Removal/ Removal/ nstallation speed speed governing governing governing module module module Disconnect negative cable of battery. Remove instrument panel.
Page 412 Conditioner Conditioner AT Air Air Conditioner Conditioner Removal/Installation Removal/Installation Removal/Installation Removal/Installation Removal/ Removal/i i i i nstallation nstallation nstallation of of of of internal/external internal/external damper motor Removal/ Removal/ nstallation internal/external internal/external air air damper damper damper motor motor motor Disconnect negative cable of battery.
Page 413 Conditioner Conditioner AT Air Air Conditioner Conditioner Removal/Installation Removal/Installation Removal/Installation Removal/Installation Removal/ Removal/i i i i nstallation nstallation nstallation of of of of compressor compressor assembly Removal/ Removal/ nstallation compressor compressor assembly assembly assembly Recover refrigerant. Disconnect negative cable of battery. Disconnect A/C clutch switch harness.
Page 414 Conditioner Conditioner AT Air Air Conditioner Conditioner Removal/Installation Removal/Installation Removal/Installation Removal/Installation Removal/ Removal/i i i i nstallation nstallation nstallation of of of of compressor compressor assembly Removal/ Removal/ nstallation compressor compressor assembly assembly assembly Loosen mounting nuts from tension pulley, unscrew adjusting bolt for tension pulley and remove the compressor drive belt.
Page 415 Conditioner Conditioner AT Air Air Conditioner Conditioner Removal/Installation Removal/Installation Removal/Installation Removal/Installation Installation Installation of of of of compressor compressor assembly Installation Installation compressor compressor assembly assembly assembly Refill compressor with compressor oil and tighten the oil filler bolt. Install the compressor onto vehicle in reverse order of removal.
Page 416 Conditioner Conditioner AT Air Air Conditioner Conditioner Removal/Installation Removal/Installation Removal/Installation Removal/Installation Removal Removal of of of of front front control panel Removal Removal front front A/C A/C control control control panel panel panel Disconnect negative cable of battery. Remove outer cover plate of A/C control panel. Remove mounting bolts from A/C control panel and disconnect harness.
Page 417 Conditioner Conditioner AT Air Air Conditioner Conditioner Removal/Installation Removal/Installation Removal/Installation Removal/Installation Removal Removal of of of of front front control panel Removal Removal front front A/C A/C control control control panel panel panel Disconnect negative cable of battery. Remove outer cover plate of A/C control panel. Remove mounting bolts from A/C control panel and disconnect harness.
Page 418 Conditioner Conditioner AT Air Air Conditioner Conditioner Specification Specification Specification Specification Basic parameters Basic Basic Basic parameters parameters parameters Name Item Parameter Type: 10-cyliner swash-plate compressor Air displacement: ml/r 210ml/r A/C compressor Lubricating oil grade: Lubricating oil volume: g 400±15g Electromagnetic clutch: Four-groove disc clutch of 110mm diameter.
Page 419 Conditioner Conditioner AT Air Air Conditioner Conditioner - 210 -...
Page 420 Circuit Diagram Diagram Circuit Circuit Diagram Diagram Circuit Circuit Diagram Diagram Applied models: SUNRAY products manufactured by JAC Subject Page Diagram specification..............................210 Circuit Diagram................................218 Interior fuse box..............................218 Exterior fuse box..............................219 Start charging system..............................220 Engine ECU electronic control unit........................222 Horn..................................
Page 421 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram Instruction This chapter consists of two parts as circuit diagram and harness layout drawing. Circuit Diagram Start to understand every system form understanding its circuit diagram for circuit diagram indicates all operating paths of every component.
Page 422 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram Harness layout drawing Mounting and fixed position of main harness and wire connector and route of main harness are indicated in this part. With the help of these harness layout drawings, circuit repair would become easier. - 211 -...
Page 423 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram Notation The following electrical notations, electrical symbols and abbreviations are adopted in this manual. Notation of circuit diagram - 212 -...
Page 424 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram - 213 -...
Page 425 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram - 214 -...
Page 426 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram Wire color description Wire color Code Wire color Code Black Orange Blue Pink Brown Green Violet Gray Yellow Light green White Identification of wire connector codes Wire connector identification code consists of harness position identification code and wire connector identification code.
Page 427 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram Electrical symbols of circuit diagram - 216 -...
Page 428 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram - 217 -...
Page 429 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram - 218 -...
Page 430 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram - 219 -...
Page 431 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram - 220 -...
Page 432 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram - 221 -...
Page 433 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram - 222 -...
Page 434 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram - 223 -...
Page 435 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram - 224 -...
Page 436 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram - 225 -...
Page 437 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram - 226 -...
Page 438 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram - 227 -...
Page 439 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram - 228 -...
Page 440 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram - 229 -...
Page 441 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram - 230 -...
Page 442 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram - 231 -...
Page 443 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram - 232 -...
Page 444 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram - 233 -...
Page 445 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram - 234 -...
Page 446 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram - 235 -...
Page 447 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram - 236 -...
Page 448 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram - 237 -...
Page 449 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram - 238 -...
Page 450 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram - 239 -...
Page 451 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram - 240 -...
Page 452 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram - 241 -...
Page 453 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram - 242 -...
Page 454 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram - 243 -...
Page 455 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram - 244 -...
Page 456 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram - 245 -...
Page 457 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram - 246 -...
Page 458 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram - 247 -...
Page 459 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram - 248 -...
Page 460 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram - 249 -...
Page 461 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram - 250 -...
Page 462 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram Main harness specification Identification code Name Identification code Name Relay box Key and faulted door switch Left front fog lamp Buzzer Left headlamp Rear air heater Left electric horn BCM controller interface 1 Oil-water separator sensor BCM controller interface 2 Oil temperature sensor...
Page 463 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram Main harness 1 - 252 -...
Page 464 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram Main harness 2 - 253 -...
Page 465 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram Engine compartment harness specification Identification code Name Connected to generator control Connected to generator positive pole Connected to starter control Connected to starter positive pole Connected to oil pressure switch Connected to reversing lamp switch Connected to water temperature sensor Connected to preheating harness Connected to battery positive pole...
Page 466 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram Left front door harness specification Identification code Name Left window regulator motor Left electric rear view mirror Window regulator main switch Left door loud speaker Left door lock actuator Electric rear view mirror switch MD01 Connected to left main harness MD02...
Page 467 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram Right front door harness specification Identification code Name Right power window motor Right electric rear view mirror Power window auxiliary switch Right door loud speaker Right door lock actuator MD03 Connected to right main harness MD04 Connected to right main harness - 256 -...
Page 468 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram Left tail lamp harness specification Identification code Name Front ceiling lamp Left rear combination lamp High-mounted brake lamp Reversing radar ECU Antenna amplifier Rear blower LR01 Connected to reversing radar harness LT01 Connected to left back door harness LM01...
Page 469 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram Right tail lamp harness specification Identification code Name Intermediate ceiling lamp Rear ceiling lamp Right rear combination lamp Right rear fog lamp NM01 Connected to right main harness Ground - 258 -...
Page 470 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram Left back door harness specification Identification code Name Left license plate lamp Right license plate lamp LT01 Connected to left roof harness Ground - 259 -...
Page 471 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram Rear loud speaker harness specification Identification code Name Left rear loud speaker Right rear loud speaker SM01 Connected to main harness - 260 -...
Page 472 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram ABS harness specification Identification code Name ABS system control module Left front wheel speed sensor Right front wheel speed sensor Right front wheel speed sensor Right rear wheel speed sensor BM01 Connected to fuse box BM02 Connected to main harness 1...
Page 473 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram Fuel tank harness specification Identification code Name Fuel sensor Condenser fan motor GM01 Connected to main harness 1 - 262 -...
Page 474 Circuit Circuit Diagram Diagram EC Circuit Circuit Diagram Diagram Reversing radar harness specification Identification code Name Left rear fog lamp Left external probe Left intermediate probe Right intermediate probe Right external probe RL01 Connected to left tail lamp harness - 263 -...
Page 475 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.
Page 476 Chassis Chassis Volume Volume Contents Contents Chassis Chassis Volume Volume Contents Contents Chassis Chassis Volume Volume Content Content Contents s s s Chassis Chassis Volume Volume Content Clutch Clutch Clutch Clutch Clutch....................................1 Explosive View of Clutch............................1 Introduction of Clutch..............................1 Clutch....................................2 Operating Principle..............................2 Inspection and Maintenance............................
Page 477 Chassis Chassis Volume Volume Contents Contents Chassis Chassis Volume Volume Contents Contents 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...
Page 478 Chassis Chassis Volume Volume Contents Contents Chassis Chassis Volume Volume Contents Contents 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......................
Page 479 Clutch Clutch CL Clutch Clutch Clutch Clutch Clutch Clutch Applied models: SUNRAY products manufactured by JAC Subject Page Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Clutch....................................1 Explosive View of Clutch............................1 Introduction of Clutch..............................1 Diagnosis Diagnosis...
Page 480 Clutch Clutch CL Clutch Clutch Instruction Instruction Operation Operation Instruction Instruction and and 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...
Page 481 Clutch Clutch CL Clutch Clutch driven disc. Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Operating Operating Operating Operating Principle Principle Principle Principle The clutch control is realized via remote hydraulic control of clutch engagement and release for the power transmission and cutting-off.
Page 482 For all parts to be replaced, only authorized Step on the pedal completely, maintain the status parts of JAC shall be applied. For damaged clutch and tighten the bleed bolts. pressure plates or driven discs, they are not repairable Refill with hydraulic fluid for the clutch hydraulic and it is necessary to replace corresponding assemblies.
Page 483 Clutch Clutch CL Clutch Clutch Common Common Common Common f f f f ault ault ault ault diagnosis diagnosis diagnosis diagnosis table table table table Fault Symptom Possible Cause of Fault Troubleshooting Incapable release of the clutch means unable functioning of the clutch and the power transmitted from the engine can not be cut off.
Page 484 Clutch Clutch CL Clutch Clutch Fault Symptom Possible Cause of Fault Troubleshooting Replace deformed, worn and fractured Inspect for following conditions: parts. 1. Improper clutch friction lining. Install specified clutch friction lining. 2. Poor balance Noise In the case of poor balance in some parts, replace clutch assembly.
Page 485 Clutch Clutch CL Clutch Clutch Removal Removal Removal Removal and and Installation Installation Installation Installation Clutch Clutch Clutch Clutch Disconnect the negative cable of battery. Lift the vehicle. Remove the clutch slave cylinder. Remove bleed bolts of clutch slave cylinder �...
Page 486 Clutch Clutch CL Clutch Clutch Removal Removal Installation Installation (continued) (continued) Removal Removal and and Installation Installation (continued) (continued) Clutch Clutch Clutch Clutch Remove the rear support pad of the transmission. Jack up the transmission with a jack. Remove bolts at the side of connection between the transmission rear flange plate and the propeller shaft.
Page 487 Clutch Clutch CL Clutch Clutch Removal Removal Removal Removal and and Installation Installation Installation Installation (continued) (continued) (continued) (continued) Clutch Clutch Clutch Clutch 11. Remove the release bearing. Attention: Do not make the lubricating grease to contact with the clutch assembly. 12.
Page 488 Clutch Clutch CL Clutch Clutch Removal Installation (continued) Removal Removal Removal and and Installation Installation Installation (continued) (continued) (continued) Installation Installation Installation of of of of Clutch Clutch Clutch Installation Clutch Installation: Install the flywheel onto the crankshaft and pay attention to the fixed pin there.
Page 489 Clutch Clutch CL Clutch Clutch Removal Removal Installation Installation (continued) (continued) Removal Removal and and Installation Installation (continued) (continued) Installation Installation of of of of Clutch Clutch Installation Installation Clutch Clutch Install the transmission in the clamping jaw to corresponding position and install a bolt there without tightening.
Page 490 Clutch Clutch CL Clutch Clutch Removal Removal Installation Installation (continued) (continued) Removal Removal and and Installation Installation (continued) (continued) Clutch master cylinder Clutch Clutch Clutch master master master cylinder cylinder cylinder Disconnect the negative cable of battery. Remove the lower protective plate of driver’s instrument panel.
Page 491 Clutch Clutch CL Clutch Clutch Removal Removal Removal Removal and and Installation Installation Installation Installation ( ( ( ( ) ) ) ) continued continued continued continued Clutch Clutch master master cylinder cylinder Clutch Clutch master master cylinder cylinder Installation Clean the clutch master cylinder completely.
Page 492 Clutch Clutch CL Clutch Clutch Specification Specification Specification Specification Tightening Tightening Torque Torque Tightening Tightening Torque Torque Part name Tightening torque Nm Quantity 23～29 Clutch master cylinder bolt and nut cap 23～29 Nut for installing the master cylinder to the vehicle body 120～140 Clutch slave cylinder bolt 23～29...
Page 493 Transmission Transmission MT Manual Manual Transmission Transmission Manual Manual Transmission Transmission Manual Manual Transmission Transmission Applied models: SUNRAY products manufactured by JAC Subject Page Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Manual Transmission..............................16 Explosive View of Manual Transmission......................... 16 Introduction of Manual Transmission........................16...
Page 494 Manual Manual Transmission Transmission MT Manual Manual Transmission Transmission Instruction Instruction Instruction Instruction and and Operation Operation Operation Operation SUNRAY vehicles adopt synchronizer manual-shift mechanical transmissions of good shifting flexibility, good hand feel, low noise, compact structure, large carrying capacity as well as good sealing performance, which consist of five forward gears and one reverse gear.
Page 495 Manual Manual Transmission Transmission MT Manual Manual Transmission Transmission Instruction Instruction Instruction Instruction and and Operation Operation Operation Operation bearing. Control Control Control Control Note: Note: Note: Note: Gear selector lever and gear shift lever can be controlled Please check the stop ring on bearing during through controlling the control handle inside cab to replacement of bearing.
Page 496 Manual Manual Transmission Transmission MT Manual Manual Transmission Transmission Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Fault diagnosis Fault Fault Fault diagnosis diagnosis diagnosis Common fault diagnosis table Common Common Common fault fault fault diagnosis diagnosis diagnosis table table table Fault Symptom...
Page 497 Manual Manual Transmission Transmission MT Manual Manual Transmission Transmission Removal/Installation Removal/Installation Removal/Installation Removal/Installation Manual Manual Manual Manual transmission transmission transmission transmission Remove manual transmission. Oil drainage ● Attention: Remove oil drain plug with wrench and drain oil through this plug instead of other parts.
Page 498 Manual Manual Transmission Transmission MT Manual Manual Transmission Transmission Removal/Installation Removal/Installation Removal/Installation Removal/Installation (Continued) (Continued) (Continued) (Continued) Manual Manual transmission transmission Manual Manual transmission transmission Remove clutch housing. Place upside down cardboard � horizontally. Remove input shaft oil seal from transmission. Remove top cover from transmission.
Page 499 Manual Manual Transmission Transmission MT Manual Manual Transmission Transmission Removal/Installation Removal/Installation Removal/Installation Removal/Installation (Continued) (Continued) (Continued) (Continued) Manual Manual transmission transmission Manual Manual transmission transmission Use pneumatic gun or wrench to remove output shaft bolt of transmission and knock out flange nut. 10.
Page 500 Manual Manual Transmission Transmission MT Manual Manual Transmission Transmission Removal/Installation Removal/Installation Removal/Installation Removal/Installation (Continued) (Continued) (Continued) (Continued) Manual Manual transmission transmission Manual Manual transmission transmission 13. Remove side cover from transmission. Turn over the transmission. � Remove bolts from side cover. �...
Page 501 Manual Manual Transmission Transmission MT Manual Manual Transmission Transmission Removal/Installation Removal/Installation Removal/Installation Removal/Installation (Continued) (Continued) (Continued) (Continued) Manual Manual transmission transmission Manual Manual transmission transmission 17. Remove gear selector fork from transmission. Attention: Attention: Attention: Attention: Please notice the position of steel balls. This transmission has 7 steel balls and 1 steel locking piece, among which, 3 steel balls are self-locking devices and the others are interlocking devices.
Page 502 Manual Manual Transmission Transmission MT Manual Manual Transmission Transmission Removal/Installation Removal/Installation Removal/Installation Removal/Installation (Continued) (Continued) (Continued) (Continued) Manual Manual transmission transmission Manual Manual transmission transmission 21. Remove output (input) shaft of transmission and place it on cardboard horizontally. 22. Remove output shaft of transmission. 23.
Page 503 Manual Manual Transmission Transmission MT Manual Manual Transmission Transmission Removal/Installation Removal/Installation Removal/Installation Removal/Installation (Continued) (Continued) (Continued) (Continued) Manual Manual transmission transmission Manual Manual transmission transmission 25. Use a rubber hammer or copper rod to knock on the reverse gear shaft gently. 26.
Page 504 Manual Manual Transmission Transmission MT Manual Manual Transmission Transmission Removal/Installation Removal/Installation (Continued) (Continued) Removal/Installation Removal/Installation (Continued) (Continued) Manual transmission Manual Manual Manual transmission transmission transmission 29. Loosen the 5 gear circlip with circlip pliers and remove the fixed circlip from the 5 driving gear.
Page 505 Manual Manual Transmission Transmission MT Manual Manual Transmission Transmission Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Exploded View View of of of of Reverse Reverse Gear Shaft Exploded Exploded Exploded View View Reverse Reverse Gear Gear Gear Shaft Shaft Shaft Reverse Gear Shaft Parts List...
Page 506 Manual Manual Transmission Transmission MT Manual Manual Transmission Transmission Instruction Instruction Instruction Instruction and and Operation Operation Operation Operation Exploded Exploded View View View of of of of Output Output Output Shaft Shaft Assembly Assembly Exploded Exploded View Output Shaft Shaft Assembly Assembly -28-...
Page 507 Manual Manual Transmission Transmission MT Manual Manual Transmission Transmission Output Shaft Parts List Output Output Output Shaft Shaft Shaft Parts Parts Parts List List List Name Qty. Name Qty. Output shaft head needle Thrust washer of 5 gear roller bearing Circlip Ball bearing 3rd/4th gear synchronizer...
Page 508 Manual Manual Transmission Transmission MT Manual Manual Transmission Transmission Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Exploded View View of of of of Top Cover Assembly Exploded Exploded Exploded View View Top Cover Cover Cover Assembly Assembly Assembly -30-...
Page 509 Manual Manual Transmission Transmission MT Manual Manual Transmission Transmission Cover Assembly Parts List Top Cover Cover Cover Assembly Assembly Assembly Parts Parts Parts List List List Name Qty. Name Qty. Transmission cover Hexagon bolt Outer gear selector rocker arm assembly Large washer Flat washer Spring washer...
Page 510 Manual Manual Transmission Transmission MT Manual Manual Transmission Transmission Instruction Instruction Instruction Instruction and and Operation Operation Operation Operation Exploded Exploded Exploded Exploded View View View View of of of of Input Input Input Input Shaft Shaft Shaft Shaft Assembly Assembly Assembly Assembly...
Page 511 Manual Manual Transmission Transmission MT Manual Manual Transmission Transmission Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Exploded View View of of of of Transmission Transmission Rear Cover Exploded Exploded Exploded View View Transmission Transmission Rear Rear Rear Cover Cover Cover Name...
Page 512 Manual Manual Transmission Transmission MT Manual Manual Transmission Transmission Exploded View View of of of of Countershaft Countershaft Assembly Exploded Exploded Exploded View View Countershaft Countershaft Assembly Assembly Assembly Name Qty. Name Qty. Circlip Circlip Cylinder roller bearing 5th gear of countershaft Main gear of countershaft Cylinder roller bearing 3rd gear of countershaft...
Page 513 Manual Manual Transmission Transmission MT Manual Manual Transmission Transmission Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Exploded View View of of of of Housing Housing Assembly Exploded Exploded Exploded View View Housing Housing Assembly Assembly Assembly Name Qty.
Page 514 Manual Manual Transmission Transmission MT Manual Manual Transmission Transmission Instruction Instruction Instruction Instruction and and Operation Operation Operation Operation Exploded Exploded View View View of of of of Shift Shift Shift Fork Fork Assembly Assembly Exploded Exploded View Shift Fork Fork Assembly Assembly Name...
Page 515 Manual Manual Transmission Transmission MT Manual Manual Transmission Transmission Instruction Instruction Instruction Instruction and and Operation Operation Operation Operation Exploded Exploded View View View of of of of Transmission Transmission Transmission Front Front Cover Cover Assembly Assembly Exploded Exploded View Transmission Front Front Cover Cover Assembly...
Page 516 Manual Manual Transmission Transmission MT Manual Manual Transmission Transmission Instruction Instruction Instruction Instruction and and Operation Operation Operation Operation Transmission Transmission Assembly Assembly Diagram Diagram Transmission Transmission Assembly Assembly Diagram Diagram -38-...
Page 517 Manual Manual Transmission Transmission MT Manual Manual Transmission Transmission Removal/Installation Removal/Installation Removal/Installation Removal/Installation (Continued) (Continued) (Continued) (Continued) Transmission Transmission Transmission Transmission Installation Place transmission housing onto a clean cardboard. Install reverse gear and reverse gear shaft onto transmission housing. Install side cover and reverse gear shaft pin of transmission in place and tighten to the specified torque.
Page 518 Manual Manual Transmission Transmission MT Manual Manual Transmission Transmission Removal/Installation Removal/Installation Removal/Installation Removal/Installation (Continued) (Continued) (Continued) (Continued) Transmission Transmission Transmission Transmission Install the fixed circlip of 5 driving gear of transmission countershaft in place. Install output shaft transmission into transmission housing. Install guide bearing of input shaft of transmission in place.
Page 519 Manual Manual Transmission Transmission MT Manual Manual Transmission Transmission Removal/Installation Removal/Installation Removal/Installation Removal/Installation (Continued) (Continued) (Continued) (Continued) Transmission Transmission Transmission Transmission Install gear shift control mechanism assembly. Install the self-locking device of gear shift � control mechanism in place. 10. Knock the input shaft gently into transmission. Attention: During the installation of input shaft, use rubber hammer to knock gently on symmetric...
Page 520 Manual Manual Transmission Transmission MT Manual Manual Transmission Transmission Removal/Installation Removal/Installation Removal/Installation Removal/Installation (Continued) (Continued) (Continued) (Continued) Transmission Transmission Transmission Transmission 13. Install top cover of transmission. Maintain gear shift control mechanism and gear shift shaft at reverse gear position. 14.
Page 521 Manual Manual Transmission Transmission MT Manual Manual Transmission Transmission Maintenance Maintenance Maintenance Maintenance Parameters Parameters Parameters Parameters Tightening Tightening torque torque Tightening Tightening torque torque Position Technical Requirement (N.m) Connection between clutch housing and transmission housing 68.6～93.2 Reversing lamp switch 29.4～39.2 Rear cover, transmission cover bolts 25～35...
Page 522 Manual Manual Transmission Transmission MT Manual Manual Transmission Transmission Care Care Care Care and and maintenance maintenance maintenance maintenance Transmission Transmission maintenance maintenance Transmission Transmission maintenance maintenance Transmission operation and maintenance should be conducted in accordance with application and maintenance requirements for commercial vehicles, which are generally divided into three technical maintenance stages.
Page 523: Fault Symptom Table
System System BR Brake Brake System System Brake Brake System System Brake Brake System System Applied models: SUNRAY products manufactured by JAC Subject Page Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Brake System................................. 46 Explosive View................................. 46 Introduction of Brake..............................47...
Page 524 Brake Brake System System BR Brake Brake System System Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation SUNRAY vehicles’ brake system adopts cross type brake line and the front disc/rear drum brake type. 1．Brake master cylinder 2. Hydraulic distribution valve - 46 -...
Page 525 Brake Brake System System BR Brake Brake System System Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Operating principle Operating Operating Operating principle principle principle Good Poor Brake Brake Brake Brake fluid fluid fluid fluid Inspection Inspection Inspection Inspection of of of of brake brake brake...
Page 526 Brake Brake System System BR Brake Brake System System Standard thickness: 24.3mm Wear limit: 22.3mm ② Check the runout with dial indicator. (It is preferable to conduct measurement at points 10mm distant from the disc edge) Runout limit: 0.05mm ③ If the disc runout exceeds the specified value, please replace or reprocess it accordingly.
Page 527 Brake Brake System System BR Brake Brake System System Fault Fault Diagnosis Diagnosis Fault Fault Diagnosis Diagnosis Common fault diagnosis table Common Common Common fault fault fault diagnosis diagnosis diagnosis table table table Fault Symptom Possible Cause Solution Insufficient left/right tire pressure Adjust Improper front wheel alignment Adjust...
Page 528 Brake Brake System System BR Brake Brake System System Removal/Installation Removal/Installation Removal/Installation Removal/Installation Front Front Front Front brake brake brake brake disc disc disc disc Removal Have the vehicle lifted and remove the front wheel. Remove the brake hose from the shock absorber. Note: Note: Note:...
Page 529 Brake Brake System System BR Brake Brake System System Removal/Installation Removal/Installation Removal/Installation Removal/Installation Installation Install the wheel hub onto the brake disc. Bend the lock lug on the set bolt up. Caution: Caution: Caution: Caution: The left hand side bearing adjusting nut is of left hand thread.
Page 530 Brake Brake System System BR Brake Brake System System Replacement Replacement Replacement Replacement of of of of front front front front brake brake brake brake disc disc disc disc Removal Have the vehicle lifted to remove the front wheel. Remove the plastic cap of brake caliper sliding pin. Make the brake disc exposed: Remove the guide pin bolt of brake caliper.
Page 531 Brake Brake System System BR Brake Brake System System Removal/Installation Removal/Installation Removal/Installation Removal/Installation During the installation of new brake lining, please remove the snap ring of brake lining from the brake caliper. Clear any dirt within the mounting areas. Installation Install new snap ring onto new brake lining.
Page 532 Brake Brake System System BR Brake Brake System System Removal/Installation Removal/Installation Removal/Installation Removal/Installation Brake caliper assembly Brake Brake Brake caliper caliper caliper assembly assembly assembly Removal Have the vehicle lifted and remove the front wheel. Note: Note: Note: Note: Clamp the brake hose with SST in order to avoid damage of brake hose.
Page 533 Brake Brake System System BR Brake Brake System System Removal/Installation Removal/Installation Removal/Installation Removal/Installation Installation Reinstall the brake caliper. Connect the brake hose to the brake caliper. Fix the brake hose onto the shock absorber. Bleed air out of brake line in accordance with specification.
Page 534 Brake Brake System System BR Brake Brake System System Removal/installation Removal/installation Removal/installation of of of of rear rear rear wheel wheel brake brake shoe shoe Removal/installation rear wheel wheel brake brake shoe shoe Removal Release the parking brake lever, have the vehicle lifted and remove the rear wheel.
Page 535 Brake Brake System System BR Brake Brake System System Removal/Installation Removal/Installation Removal/Installation Removal/Installation Remove the leading shoe: Remove the lock pin and its spring cap. � Remove the brake shoe lower end from the � support. Loosen the lower return spring. �...
Page 536 Brake Brake System System BR Brake Brake System System Removal/Installation Removal/Installation Removal/Installation Removal/Installation Installation Clean the support plate and apply ABS fluid onto the bonding point between brake bottom plate and brake shoe. Assemble the trailing shoe. Apply grease onto parking brake lever and brake shoe.
Page 537 Brake Brake System System BR Brake Brake System System Parking Parking brake brake adjustment adjustment Parking Parking brake brake adjustment adjustment Release the parking brake and have the vehicle lifted. Release the parking brake regulator. Loosen the lock nut. � Rotate the regulator.
Page 538 Brake Brake System System BR Brake Brake System System Removal/installation Removal/installation Removal/installation of of of of parking parking parking brake brake lever lever Removal/installation parking brake brake lever lever Removal Loosen the parking brake lever. Remove the wavy dust shield of parking brake. Remove the parking brake lever assembly: Remove the spring clip and the clevis pin for �...
Page 539 Brake Brake System System BR Brake Brake System System Removal/installation Removal/installation Removal/installation of of of of parking parking parking brake brake cable cable Removal/installation parking brake brake cable cable Removal Loosen the parking brake lever. Remove the spring clip and the clevis pin from the main cable and remove the cable from the parking brake lever.
Page 540 Brake Brake System System BR Brake Brake System System Replacement Replacement Replacement of of of of parking parking parking brake brake cable cable Replacement parking brake brake cable cable Removal: Loosen the parking brake lever. Remove the main cable from the equalizer: Remove the spring clip and the clevis pin.
Page 541 Brake Brake System System BR Brake Brake System System Removal/installation Removal/installation Removal/installation of of of of brake brake brake pedal pedal Removal/installation brake pedal pedal Removal Disconnect the negative cable of battery. Remove the clevis pin and spring clip from the vacuum booster control rod of brake pedal.
Page 542 Brake Brake System System BR Brake Brake System System Removal/Installation Removal/Installation Removal/Installation Removal/Installation Remove the brake pedal: Push the spider to the direction of clutch � pedal. Remove the brake pedal. � Remove the pedal bushing and spring: Remove the pedal bushing. �...
Page 543 Brake Brake System System BR Brake Brake System System Removal/installation Removal/installation Removal/installation of of of of brake brake brake master master cylinder cylinder Removal/installation brake master master cylinder cylinder Caution: Caution: Caution: Caution: Don’t the make the brake fluid splashing onto the paint surface.
Page 544 Brake Brake System System BR Brake Brake System System Removal/installation Removal/installation Removal/installation of of of of vacuum vacuum vacuum pump pump Removal/installation vacuum pump pump Caution: Caution: Caution: Caution: Don’t the make the brake fluid splashing onto the paint surface. In case of any, please wash the surface with clean water immediately.
Page 545 Brake Brake System System BR Brake Brake System System Removal/Installation Removal/Installation Removal/Installation Removal/Installation Remove the seal ring between generator and vacuum pump. Installation Reinstall the seal ring between generator and vacuum pump. Reinstall the vacuum booster. Reinstall the oil inlet pipe and the oil return pipe onto the pump.
Page 546 Brake Brake System System BR Brake Brake System System Removal/installation Removal/installation Removal/installation of of of of vacuum vacuum vacuum booster booster Removal/installation vacuum booster booster Caution: Caution: Caution: Caution: Don’t the make the brake fluid splashing onto the paint surface. In case of any, please wash the surface with clean water immediately.
Page 547 Brake Brake System System BR Brake Brake System System Removal/Installation Removal/Installation Removal/Installation Removal/Installation Remove the brake switch. Remove the harness connector. � Remove the booster and master cylinder assembly. Separate the booster from the master cylinder. Installation Install the vacuum booster. Install the booster control rod onto the brake pedal.
Page 548 Brake Brake System System BR Brake Brake System System Removal/Installation Removal/Installation Removal/Installation Removal/Installation Reinstall and debug the brake switch. Reinstall the master cylinder onto the booster. Ensure proper position and clean joint surface for sealing washer of vacuum pump. Reconnect the brake line. Reconnect the brake line with the master cylinder.
Page 549 Brake Brake System System BR Brake Brake System System bleeding bleeding brake brake system system Air bleeding bleeding for for brake brake system system Caution: Caution: Caution: Caution: Don’t the make the brake fluid splashing onto the paint surface. In case of any, please wash the surface with clean water immediately.
Page 550 Anti-lock Anti-lock Brake Brake System System ABS Anti-lock Anti-lock Brake Brake System System Anti-lock Brake System (ABS) Applied models: SUNRAY products manufactured by JAC Subject Page Instruction Instruction Instruction Instruction and and Operation Operation Operation Operation ABS system..................................74 Diagnosis Diagnosis...
Page 551 Instruction Instruction and and Operation Operation Operation Operation Anti-lock Anti-lock brake brake system system (ABS) (ABS) Anti-lock Anti-lock brake brake system system (ABS) (ABS) BOCSH 8 ABS is adopted for JAC multifunctional commercial vehicles. ABS Hydraulic Assembly - 74 -...
Page 552 Anti-lock Anti-lock Brake Brake System System ABS Anti-lock Anti-lock Brake Brake System System Instruction Instruction Instruction Instruction and and Operation Operation Operation Operation Operating Operating principle principle Operating Operating principle principle Connection Connection Diagram Diagram Diagram of of of of ABS Brake Brake Line...
Page 553 Anti-lock Anti-lock Brake Brake System System ABS Anti-lock Anti-lock Brake Brake System System Instruction Instruction Instruction Instruction and and Operation Operation Operation Operation Precautions Precautions system system diagnosis diagnosis Precautions Precautions for for ABS ABS system system diagnosis diagnosis As ABS is a safety related component, the following removed for overhaul or partly/separately precautions should be observed in addition to general replaced.
Page 554 Anti-lock Anti-lock Brake Brake System System ABS Anti-lock Anti-lock Brake Brake System System Instruction Instruction Instruction Instruction and and Operation Operation Operation Operation Fault Fault diagnosis diagnosis procedures procedures with with Fault Fault diagnosis diagnosis procedures procedures for for ABS ABS with with EBD Operation...
Page 555 Anti-lock Anti-lock Brake Brake System System ABS Anti-lock Anti-lock Brake Brake System System Diagnosis Diagnosis Diagnosis Diagnosis and and Testing Testing Testing Testing Diagnosis Diagnosis Diagnosis Diagnosis Preliminary inspection installed. Inspect those easily accessible components that may (g) ABS is a kind of active safety system, which lead to ABS system fault.
Page 556 Anti-lock Anti-lock Brake Brake System System ABS Anti-lock Anti-lock Brake Brake System System Operating principle principle: : : : ABS Operating Operating Operating principle principle and avoid boosting or reducing of hydraulic pressure. ABS shall enter antilock brake mode once wheel Pressure reducing skidding is detected during braking.
Page 557 Anti-lock Anti-lock Brake Brake System System ABS Anti-lock Anti-lock Brake Brake System System Diagnosis Diagnosis Diagnosis Diagnosis and and Testing Testing Testing Testing Diagnosis Diagnosis Diagnosis Diagnosis Checking instrument warning lamp warning lamp shall be lit (details based on actual conditions). (a) Release the parking brake lever.
Page 558 Anti-lock Anti-lock Brake Brake System System ABS Anti-lock Anti-lock Brake Brake System System Diagnosis Diagnosis Diagnosis Diagnosis and and Testing Testing Testing Testing Detection Detection by by by diagnostic diagnostic diagnostic instrument instrument Detection Detection by diagnostic instrument instrument Remarks: ABS and conventional brake system.
Page 559 Anti-lock Anti-lock Brake Brake System System ABS Anti-lock Anti-lock Brake Brake System System Diagnosis Diagnosis Diagnosis Diagnosis and and Testing Testing Testing Testing Brake Brake bleeding bleeding Brake Brake bleeding bleeding Note: Manual brake bleeding procedures Brake bleeding can be performed in the first and second Step Operation circuits.
Page 560 Anti-lock Anti-lock Brake Brake System System ABS Anti-lock Anti-lock Brake Brake System System Diagnosis Diagnosis Diagnosis Diagnosis and and Testing Testing Testing Testing Component activation test Component activation test for reflux pump: cannot rotate the left front wheel by hand. (1) Turn off the ignition switch.
Page 561 Anti-lock Anti-lock Brake Brake System System ABS Anti-lock Anti-lock Brake Brake System System DTC List List List List Attention: Attention: Attention: Attention: Please turn off the ignition switch before removal of parts. Note: Note: Note: Note: Please use the diagnostic instrument to read DTC. If no fault is detected during the detection of components, ABS hydraulic governor with ECU and its ground point/power line should be inspected.
Page 562 Anti-lock Anti-lock Brake Brake System System ABS Anti-lock Anti-lock Brake Brake System System Diagnosis Diagnosis Diagnosis Diagnosis and and Testing Testing Testing Testing Fault symptom table If fault occurs without fault memory during DTC reading, please check relevant circuits of each fault symptom in order listed below and by referring to relevant fault diagnosis content.
Page 563 Anti-lock Anti-lock Brake Brake System System ABS Anti-lock Anti-lock Brake Brake System System Diagnosis Diagnosis Diagnosis Diagnosis and and Testing Testing Testing Testing Intermittent fault diagnosis table Note: In case one of the following conditions occurs, there is intermittent fault. Fault does not always occur;...
Page 564 Anti-lock Anti-lock Brake Brake System System ABS Anti-lock Anti-lock Brake Brake System System Diagnosis Diagnosis Diagnosis Diagnosis and and Testing Testing Testing Testing Wheel speed sensor fault (C0035, C0040, C0045, C0050, and C0245): Wheel speed sensors are applied to detect the wheel speed and transmit relevant signals to ABS ECU.
Page 565 Anti-lock Anti-lock Brake Brake System System ABS Anti-lock Anti-lock Brake Brake System System Detection Condition Set Condition Possible Faulty Areas C0035 With ignition 1) Monitor if the power voltage of sensor is too low; 1. Wheel speed sensor bodies switch turned on C0040 2) Monitor if the power wire and signal wire of sensor is 2.
Page 566 Anti-lock Anti-lock Brake Brake System System ABS Anti-lock Anti-lock Brake Brake System System Occurrence of fault shall give rise to the following operation: Braking Strategy Failure Protection � Relevant wheels cannot be controlled any more because correct The system shall be converted to EBD wheel speed sensor signals cannot be obtained.
Page 567 Anti-lock Anti-lock Brake Brake System System ABS Anti-lock Anti-lock Brake Brake System System Operating Step Operation Detection Next Step Result Using diagnostic (a) Connect the diagnostic instrument to read data stream. Normal Go to Step 8 instrument to read (b) One repair main conduct test run uniformly in a straight Abnormal Check wheel speed sensors.
Page 568 Anti-lock Anti-lock Brake Brake System System ABS Anti-lock Anti-lock Brake Brake System System Diagnosis Diagnosis Diagnosis Diagnosis and and Testing Testing Testing Testing Hydraulic governor solenoid valve fault: C0060, C0065, C0070, C0075, C0080, C0085, C0090, C0095 Circuit Circuit description description description: : : : Circuit Circuit description...
Page 569 Anti-lock Anti-lock Brake Brake System System ABS Anti-lock Anti-lock Brake Brake System System Troubleshooting procedures Troubleshooting Troubleshooting Troubleshooting procedures procedures procedures Operating Step Operation Detection Next Step Result Checking (a) Turn off the ignition switch; Normal Go to the next step. hydraulic governor (b) Turn on the ignition switch without brake pedal depressed;...
Page 570 Anti-lock Anti-lock Brake Brake System System ABS Anti-lock Anti-lock Brake Brake System System Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing Reflux pump motor fault: C0110 Circuit description: ABS hydraulic unit with ECU integrates reflux pump with motor. Reflux pump relay shall stop operation and the reflux pump shall be under stationary state if no regulation is performed by ABS.
Page 571 Anti-lock Anti-lock Brake Brake System System ABS Anti-lock Anti-lock Brake Brake System System Operating Step Operation Detection Next Step Result Using diagnostic (a) Turn off the ignition switch; Normal Go to the next step. instrument to perform (b) Connect the diagnostic instrument to OBD port; Abnormal Replace ABS control component testing for...
Page 572 Anti-lock Anti-lock Brake Brake System System ABS Anti-lock Anti-lock Brake Brake System System Diagnosis Diagnosis Diagnosis Diagnosis and and Testing Testing Testing Testing Solenoid valve relay circuit fault: C0121 Circuit description: With the ignition switch turned on and ABS solenoid valve relay powered on, battery voltage can be provided to one terminal of solenoid valve of hydraulic governor.
Page 573 Anti-lock Anti-lock Brake Brake System System ABS Anti-lock Anti-lock Brake Brake System System Operating Step Operation Detection Next Step Result Using diagnostic Remarks: Normal Go to the next step. instrument to perform ① Before testing solenoid valve, please test he reflux pump Abnormal Replace ABS control component testing for...
Page 574 Anti-lock Anti-lock Brake Brake System System ABS Anti-lock Anti-lock Brake Brake System System Diagnosis Diagnosis Diagnosis Diagnosis and and Testing Testing Testing Testing ABS brake lamp switch circuit fault: C0161 Circuit description: Brake lamp switch is a kind of normally open switch. This switch shall be on with the brake pedal depressed, providing +12V signal voltage to brake lamp signal circuit (+BLS).
Page 575 Anti-lock Anti-lock Brake Brake System System ABS Anti-lock Anti-lock Brake Brake System System Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing ABS ECU fault: C0550 Circuit description: ABS ECU, installed in ABS hydraulic governor with ECU, is the control center of ABS system. Programmable and calibration data required by ABS operation are stored in ROM of ABS ECU.
Page 576 Anti-lock Anti-lock Brake Brake System System ABS Anti-lock Anti-lock Brake Brake System System Diagnosis Diagnosis Diagnosis Diagnosis and and Testing Testing Testing Testing Voltage out of range: C0800 Circuit description: ABS ECU monitors the battery power supply voltage supplied to ABS ECU through Uz. If the voltage is out of the specified range, the following faults shall occur: Too low voltage supplied to ABS ECU may lead to abnormal operation of ABS system.
Page 577 Anti-lock Anti-lock Brake Brake System System ABS Anti-lock Anti-lock Brake Brake System System Troubleshooting Troubleshooting procedures procedures Troubleshooting Troubleshooting procedures procedures Operating Step Operation Detection Next Step Result Checking fuse (a) Check if the 10A, 25A and 40A fuses for power supply Go to the next step.
Page 578: Removal/Installation Abs System
Anti-lock Anti-lock Brake Brake System System ABS Anti-lock Anti-lock Brake Brake System System Removal/Installation Removal/Installation Removal/Installation Removal/Installation system system ABS system system Remove the negative cable of battery. Drain the brake fluid in the hydraulic brake system completely. Loosen the oil pipe of brake master cylinder. Remove the ABS connector.
Page 579 Anti-lock Anti-lock Brake Brake System System ABS Anti-lock Anti-lock Brake Brake System System Removal/Installation Removal/Installation Removal/Installation Removal/Installation (Continued) (Continued) (Continued) (Continued) Installation Clean the surface of ABS hydraulic assembly and fix the assembly onto bracket with bolts. Install the brake pipe onto the ABS hydraulic assembly.
Page 580 Anti-lock Anti-lock Brake Brake System System ABS Anti-lock Anti-lock Brake Brake System System Removal/Installation Removal/Installation Removal/Installation Removal/Installation (Continued) (Continued) (Continued) (Continued) Wheel Wheel speed speed sensor sensor Wheel Wheel speed speed sensor sensor Disconnect the negative cable of battery. Lift the vehicle. Disconnect the plug of wheel speed sensor and remove the harness fixture of sensor.
Page 581 Shaft Shaft TR Transmission Transmission Shaft Shaft Transmission Transmission Shaft Shaft Transmission Transmission Shaft Shaft Applied models: SUNRAY products manufactured by JAC Subject Page Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Transmission Shaft..............................106 Explosive View of Transmission Shaft........................106 Introduction of Transmission Shaft........................106...
Page 582 Transmission Transmission Shaft Shaft TR Transmission Transmission Shaft Shaft Introduction Transmission shaft is a kind of device that is applied to joint transmission and rear axle together and to transmit power from transmission to rear axle. Transmission shaft, made of hollow steel tube, is equipped with intermediate support to reduce resonance during power transmission.
Page 583 Transmission Transmission Shaft Shaft TR Transmission Transmission Shaft Shaft Inspection Confirmation: Inspection Inspection Inspection and and Confirmation: Confirmation: Confirmation: Inspection of flange Check flange between transmission and transmission shaft. Check flange screw hole for any deformation or crack. Check flange internal spline for tooth looseness, missing or damage. If there are more than two teeth is damaged, please replace the flange assembly.
Page 584 Transmission Transmission Shaft Shaft TR Transmission Transmission Shaft Shaft Fault Fault Fault Fault Diagnosis Diagnosis Diagnosis Diagnosis Procedures Procedures Procedures Procedures for for Transmission Transmission Transmission Transmission Shaft Shaft Shaft Shaft Vibration Check radial runout of shaft Normal Abnormal Check shaft balance Replace Normal Unbalance...
Page 585: Transmission Transmission Shaft Shaft
Transmission Transmission Shaft Shaft TR Transmission Transmission Shaft Shaft Removal/Installation Removal/Installation Removal/Installation Removal/Installation Transmission shaft Transmission Transmission Transmission shaft shaft shaft Lift the vehicle. Note: Note: Note: Note: Mark properly in pair on transmission shaft front flange and transmission flange. Remove transmission shaft front flange from transmission flange.
Page 586 Transmission Transmission Shaft Shaft TR Transmission Transmission Shaft Shaft Removal/Installation Removal/Installation Removal/Installation Removal/Installation Transmission Transmission shaft shaft Transmission Transmission shaft shaft Installation Note: Note: Note: Note: Have marks properly aligned. Install the transmission shaft front flange onto transmission. Install transmission shaft intermediate support onto the intermediate support seat located on body bottom plate.
Page 587: Front Front Suspension Suspension
Front Suspension Suspension FAX Front Front Suspension Suspension Front Front Suspension Suspension Front Front Suspension Suspension Applied models: SUNRAY products manufactured by JAC Subject Page Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Front Suspension................................112 Front Suspension..............................112 Diagnosis...
Page 588 Front Front Suspension Suspension FAX Front Front Suspension Suspension Instruction Instruction Instruction Instruction and and Operation Operation Operation Operation Front Front Suspension Suspension Front Front Suspension Suspension This front axle is a steering axle at front of the vehicle, helical spring assembly and mounting cushion for mainly consisting of the front overhang subframe helical spring, etc., realizing vehicle steering via vehicle assembly, lower swing arm assembly, front anti-roll bar...
Page 589 Front Front Suspension Suspension FAX Front Front Suspension Suspension Name Quantity Remarks Front helical spring assembly Mounting cushion for front helical spring Left lower swing arm weld assembly Right lower swing arm weld assembly Lower swing arm bushing assembly Lower swing arm ball pin assembly Taper washer(16X61X3) Front shock absorber assembly Brake hose mounting flat spring nut...
Page 590 Front Front Suspension Suspension FAX Front Front Suspension Suspension Maintenance Maintenance Use and and Maintenance Maintenance Inspect the wear condition of brake pad. After the In Level III maintenance, the front suspension may first 40000km or 24-month driving of the vehicle, be removed for cleaning of interiors of the steering inspect the wear condition of friction linings and knuckle with bushing and wheel hub as well as...
Page 591 Front Front Suspension Suspension FAX Front Front Suspension Suspension Fault Fault Diagnosis Diagnosis Fault Fault Diagnosis Diagnosis Common Fault Diagnosis Table Common Common Common Fault Fault Fault Diagnosis Diagnosis Diagnosis Table Table Table Fault Symptom Possible Cause of fault Troubleshooting No power steering Repair or replace Improper front wheel alignment...
Page 592 Front Front Suspension Suspension FAX Front Front Suspension Suspension Removal Removal Removal Removal and and Installation Installation Installation Installation of of of of Subframe Subframe Subframe Subframe Removal Disconnect the negative cable of battery. Place the steering wheel in the center and lock it up in the position of straight-ahead.
Page 593 Front Front Suspension Suspension FAX Front Front Suspension Suspension Removal Removal Removal Removal and and Installation Installation Installation Installation of of of of Subframe Subframe Subframe Subframe (Continued) (Continued) (Continued) (Continued) Note: Note: Note: Note: Mounting bolts on the top of the brake caliper can not be loosened completely until the complete removal of the brake caliper has been done.
Page 594 Front Front Suspension Suspension FAX Front Front Suspension Suspension Removal Removal Removal Removal and and Installation Installation Installation Installation of of of of Subframe Subframe Subframe Subframe (Continued) (Continued) (Continued) (Continued) 12. Remove mounting nuts of the shock absorber from the cab.
Page 595 Front Front Suspension Suspension FAX Front Front Suspension Suspension Removal Removal Removal Removal and and Installation Installation Installation Installation of of of of Subframe Subframe Subframe Subframe (Continued) (Continued) (Continued) (Continued) Reinstall the helical spring. Ensure following operations: Correctly prevent the shock insulator from �...
Page 596 Front Front Suspension Suspension FAX Front Front Suspension Suspension Disassembly Disassembly Disassembly Disassembly and and Assembly Assembly Assembly Assembly of of of of Subframe Subframe Subframe Subframe Disassembly Remove the two mounting bolts at the mounting position of the front anti-roll bar. Remove the steering gear box.
Page 597: Front Suspension
Front Front Suspension Suspension FAX Front Front Suspension Suspension Removal Removal Removal Removal and and Installation Installation Installation Installation of of of of Subframe Subframe Subframe Subframe (Continued) (Continued) (Continued) (Continued) Assembly Install the compression travel stop block. Reinstall the lower swing arm assembly. Install feedthrough bolts and nuts between the lower swing arm and the cross rail from the rear side.
Page 598 Front Front Suspension Suspension FAX Front Front Suspension Suspension Removal Removal Removal Removal and and Installation Installation Installation Installation (Continued) (Continued) (Continued) (Continued) Reinstall the steering gear box. Make sure to install mounting bolts in the direction of underside of the cross rail. Caution: Caution: Caution:...
Page 599 Front Front Suspension Suspension FAX Front Front Suspension Suspension Removal Removal Removal Removal and and Installation Installation Installation Installation of of of of Lower Lower Lower Lower Swing Swing Swing Swing Arm Removal Loosen wheel nuts, lift the vehicle and remove wheels.
Page 600 Front Front Suspension Suspension FAX Front Front Suspension Suspension Removal Removal Removal Removal and and Installation Installation Installation Installation of of of of Lower Lower Lower Lower Swing Swing Swing Swing Arm Arm (Continued) (Continued) (Continued) (Continued) Remove the ball joint from the lower swing arm. Lower the lower swing arm and remove the helical spring.
Page 601: Front Suspension
Front Front Suspension Suspension FAX Front Front Suspension Suspension Removal Removal Removal Removal and and Installation Installation Installation Installation of of of of Lower Lower Lower Lower Swing Swing Swing Swing Arm Arm (Continued) (Continued) (Continued) (Continued) Caution: Caution: Caution: Caution: When install the ball joint into the lower swing arm, the mounting of the front axle is not allowed...
Page 602 Front Front Suspension Suspension FAX Front Front Suspension Suspension Removal Removal Removal Removal and and Installation Installation Installation Installation of of of of Helical Helical Helical Helical Spring Spring Spring Spring Removal Loosen wheel nuts, lift the vehicle and remove wheels.
Page 603 Front Front Suspension Suspension FAX Front Front Suspension Suspension Removal Removal Removal Removal and and Installation Installation Installation Installation of of of of Helical Helical Helical Helical Spring Spring Spring Spring Caution: Caution: Caution: Caution: To avoid lower swing arm ball joint damage, tie the top of the lower swing arm together with the cross swing arm.
Page 604 Front Front Suspension Suspension FAX Front Front Suspension Suspension Removal Removal Removal Removal and and Installation Installation Installation Installation of of of of Helical Helical Helical Helical Spring Spring Spring Spring Connect the steering tie rod link with the lower swing arm.
Page 605 Front Front Suspension Suspension FAX Front Front Suspension Suspension Removal Removal Removal Removal and and Installation Installation Installation Installation of of of of Front Front Front Front Shock Shock Shock Shock Absorber Absorber Absorber Absorber Removal Loosen wheel nuts, lift the vehicle and remove wheels.
Page 606 Front Front Suspension Suspension FAX Front Front Suspension Suspension Removal Removal Removal Removal and and Installation Installation Installation Installation of of of of Front Front Front Front Shock Shock Shock Shock Absorber Absorber Absorber Absorber 10. Fix the shock absorber firmly from the cab. Reinstall the disc washer.
Page 607 Front Front Suspension Suspension FAX Front Front Suspension Suspension Specification Specification Specification Specification List of Main Tightening Torques Name of Bolt（Nut） Tightening Torque (N.m) Tightening torque for ball pin nut 220～250 Connecting rod nut 20～30 Ball pin mounting bolt 35～75 Front anti-roll bar clamping bolt 16～26 Front nut of the lower swing arm...
Page 608: Inspection And Confirmation
Axle Axle RAX Rear Rear Axle Axle Rear Rear Axle Axle Rear Rear Axle Axle Applied models: SUNRAY products manufactured by JAC Subject Page Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Rear axle..................................134 Explosive View of Rear Axle..........................134 Introduction of Rear Axle............................
Page 609 Rear Rear Axle Axle RAX Rear Rear Axle Axle Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Rear axle Rear Rear Rear axle axle axle Rear axles for two-wheel drive vehicles with dependant cylinder roller bearing for bearing radial force only. The rear suspensions are adopted, mainly composed of final driven gear is fixed on the differential left housing by drive, differential and axle housing, which are the final...
Page 610: Rear Axle
Rear Rear Axle Axle RAX Rear Rear Axle Axle Driving gear flange nut Driving gear flange flat Driving gear flange Flange dust cover gasket Driving gear oil seal Tapered roller bearing Resilient spacer Driving gear Driving gear adjusting Tapered roller bearing Final drive housing I-type hexagon nut washer...
Page 611: Rear Axle
Rear Rear Axle Axle RAX Rear Rear Axle Axle Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Application Application maintenance maintenance Application Application and and maintenance maintenance Hyperbolic gear is of strict lubrication requirement drained completely. No ordinary gear oil can be and only the specified hyperbolic gear oil can be adopted.
Page 612: Rear Axle
Rear Rear Axle Axle RAX Rear Rear Axle Axle Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing Inspection maintenance Inspection Inspection Inspection and and maintenance maintenance maintenance Inspection and maintenance for rear axle the flange clockwise to the end and mark in pair Check parts by using special measuring apparatus properly on the flange dust cover and final drive or tools.
Page 613 Rear Rear Axle Axle RAX Rear Rear Axle Axle Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing Installation adjustment adjustment of of of of rear rear axle assembly Installation Installation Installation and and adjustment adjustment rear rear axle axle axle assembly assembly...
Page 614 Rear Rear Axle Axle RAX Rear Rear Axle Axle Adjustment of meshing marks: Contact status of driven gear Causes Adjusting method A-Tooth surface contact area working flank adjustment B-Backlash adjustment High driving gear, driven gear too 1. Driven gear away from driving gear 2.
Page 615 Rear Rear Axle Axle RAX Rear Rear Axle Axle Diagnosis Diagnosis Testing Testing Diagnosis Diagnosis and and Testing Testing Troubleshooting Troubleshooting Troubleshooting Troubleshooting Fault Causes Solutions/Preventive Measures Excessive preload for hub bearing Adjust the preload. Bearing lack of lubricant or adoption of improper Hub bearing sluggish Add or change grease.
Page 616 Rear Rear Axle Axle RAX Rear Rear Axle Axle Removal/Installation Removal/Installation Removal/Installation Removal/Installation Rear Rear Rear Rear axle axle axle axle Removal of rear axle Block the wheel front and back with anchor blocks. Loosen outside wheel nut. Jack up the rear axle. Removal of axle shaft Loosen axle shaft nut.
Page 617 Rear Rear Axle Axle RAX Rear Rear Axle Axle Removal/Installation Removal/Installation (Continued) (Continued) Removal/Installation Removal/Installation (Continued) (Continued) Rear axle Rear Rear Rear axle axle axle Remove axle shaft oil seal from the end of axle shaft sleeve. Note: Note: Note: Note: During assembly, apply lithium base grease onto the outer ring of axle shaft oil seal and then press it...
Page 618 Rear Rear Axle Axle RAX Rear Rear Axle Axle Removal/Installation Removal/Installation (Continued) (Continued) Removal/Installation Removal/Installation (Continued) (Continued) Rear axle Rear Rear Rear axle axle axle Disassembly of axle housing and final drive Drain gear oil from final drive. Disconnect the connection between propeller shaft and final drive.
Page 619 Rear Rear Axle Axle RAX Rear Rear Axle Axle Removal/Installation Removal/Installation (Continued) (Continued) Removal/Installation Removal/Installation (Continued) (Continued) Rear axle Rear Rear Rear axle axle axle Remove differential assembly. Remove driving gear assembly by using puller and remove adjusting washer at the same time. Disassembly of differential assembly Remove differential right housing.
Page 620 Rear Rear Axle Axle RAX Rear Rear Axle Axle Removal/Installation Removal/Installation (Continued) (Continued) Removal/Installation Removal/Installation (Continued) (Continued) Rear axle Rear Rear Rear axle axle axle Measure and record planetary gear backlash. Attention: Attention: Attention: Attention: Please hold the planetary gear spider during backlash measurement.
Page 621 Rear Rear Axle Axle RAX Rear Rear Axle Axle Removal/Installation Removal/Installation (Continued) (Continued) Removal/Installation Removal/Installation (Continued) (Continued) Rear axle Rear Rear Rear axle axle axle Removal of driving gear Remove driving gear flange nut. Remove retaining ring for shaft and remove driving gear guide bearing.
Page 622 Rear Rear Axle Axle RAX Rear Rear Axle Axle Removal/Installation Removal/Installation (Continued) (Continued) Removal/Installation Removal/Installation (Continued) (Continued) Rear axle Rear Rear Rear axle axle axle Remove bearing from driving gear. Remove oil seal from bearing support. Remove inner and outer rings of bearing. Inspection during removal Check driving gear flange for wear or damage.
Page 623: Specification
Rear Rear Axle Axle RAX Rear Rear Axle Axle Specification Specification Specification Specification Structure type of rear axle Item Specification Axle housing type Integral press-welding axle housing Axle shaft support type Full-floating type Reduction gear type Single-stage hyperboloid spiral bevel gear Planetary gear type 2/4 planetary gear Sealant and adhesive for rear axle...
Page 624 Rear Rear Axle Axle RAX Rear Rear Axle Axle Specification Specification Specification Specification Item Wear limit Wear of rear axle leaf spring retainer location hole Outer bearing journal radial runout of left/right axle shaft sleeve 0.1mm Middle unprocessed surface of axle shaft Radial runout 1.5mm End face runout of joint surface between hub and axle shaft flange...
Page 625 System System PS PowerSteering PowerSteering System System Steering Steering System System Steering Steering System System Applied models: SUNRAY products manufactured by JAC Subject Page Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Steering System................................152 Explosive View of Steering System........................152 Introduction of Steering System..........................
Page 626 PowerSteering PowerSteering System System PS PowerSteering PowerSteering System System Instruction Instruction Instruction Instruction and and Operation Operation Operation Operation Steering Steering System System Steering Steering System System Summary of Power Steering System With the purpose of reducing the working intensity of drivers, the power steering system is firstly installed on heavy-duty vehicles.
Page 627 PowerSteering PowerSteering System System PS PowerSteering PowerSteering System System Intermediate Position: Instruction Instruction Instruction Instruction and and Operation Operation Operation Operation In the case of vehicle straight running (without any Structural Structural Structural Structural Brief Brief Brief Brief Introduction Introduction Introduction Introduction of of of of Rack-and-pinion Rack-and-pinion...
Page 628: Tightening Torque
PowerSteering PowerSteering System System PS PowerSteering PowerSteering System System Power Steering Power Power Power Steering Steering Steering Oil performance or durability. Turn off the engine and make full lock turns of the steering wheel to the left and right for several times.
Page 629 PowerSteering PowerSteering System System PS PowerSteering PowerSteering System System keep the fluid level between MIN and MAX to Standard Value: <15mm ⑤ If the free play exceeds the standard value, remove avoid dry friction of the power steering pump. Excessively lone engine operation...
Page 630 PowerSteering PowerSteering System System PS PowerSteering PowerSteering System System returnability between the left and right side. It is necessary to carry out this step on safe ground and under safe traffic condition and pay attention to your safety. ① Turn the steering wheel for 90°, drive with the speed of 35Km/h, maintain the state for several seconds and then release the steering wheel, the returnability should be 70% at least.
Page 631 PowerSteering PowerSteering System System PS PowerSteering PowerSteering System System Inspection and Replacement of Steering Mechanism Schematic Diagram of Steering Column Assembly Parts: Horn hood with airbag Inspection of Rack Piston Assembly: Steering wheel Inspect the straightness accuracy for the intermediate Steering column assembly rack of the rack piston assembly and the maximum Connecting shaft with universal joint...
Page 632 PowerSteering PowerSteering System System PS PowerSteering PowerSteering System System is necessary to replace the tie rod. ③ On-car On-car Inspection Inspection Inspection of of of of Power-assisted Power-assisted Power-assisted Steering Steering Pump: Pump: On-car On-car Inspection Power-assisted Steering Steering Pump: Pump: Tie Rod Dust Boot Inspection of Release Oil Pressure...
Page 633 PowerSteering PowerSteering System System PS PowerSteering PowerSteering System System Common Common Common Common Fault Fault Fault Fault Diagnosis Diagnosis Diagnosis Diagnosis Table Table Table Table Fault Fault Symptom Fault Cause Troubleshooting Oil leakage from the Damage in oil seal of the power steering Replace the power steering pump oil power steering pump pump...
Page 634 PowerSteering PowerSteering System System PS PowerSteering PowerSteering System System Fault Fault Symptom Fault Cause Troubleshooting Too low oil level in the power steering oil Refill with oil reservoir Air entrainment Carry out air bleeding Seize in the steering column or steering Adjust the link.
Page 635 PowerSteering PowerSteering System System PS PowerSteering PowerSteering System System Troubleshooting Common Faults: Troubleshooting Troubleshooting Troubleshooting for for Common Common Common Faults: Faults: Faults: steering pump. Oil leakage: Dirty interior of the steering system may lead to Verify whether there is oil leakage in oil pipe of the excessive wears in the stator, rotor, oil distributor, steering system, joints of the power steering oil end cover and input shaft.
Page 636 PowerSteering PowerSteering System System PS PowerSteering PowerSteering System System Improper matching of system components before and steering oil, clean the whole power steering leaving factory may lead to unable vibration system (it is preferable to clean with kerosene and absorbing of pipeline as well as faults like it is not allowed to disassemble the pump body.
Page 637 PowerSteering PowerSteering System System PS PowerSteering PowerSteering System System Removal Removal Removal Removal and and Installation Installation Installation Installation Power-assisted Power-assisted Steering Steering System System Power-assisted Power-assisted Steering Steering System System Disconnect the negative cable of the battery. Remove the cardan universal joint on the steering gear box.
Page 638 PowerSteering PowerSteering System System PS PowerSteering PowerSteering System System Removal Removal Removal Removal and and Installation Installation Installation Installation (Continued) (Continued) (Continued) (Continued) Power-assisted Power-assisted Power-assisted Power-assisted Steering Steering Steering Steering System System System System Take down the cotter pin and remove castle nuts on the joint of the tie rod ball joint and steering knuckle.
Page 639 PowerSteering PowerSteering System System PS PowerSteering PowerSteering System System Removal Installation (Continued) Removal Removal Removal and and Installation Installation Installation (Continued) (Continued) (Continued) Power-assisted Steering System Power-assisted Power-assisted Power-assisted Steering Steering Steering System System System 9. Disconnect the booster oil pipe from the steering gear box.
Page 640 PowerSteering PowerSteering System System PS PowerSteering PowerSteering System System Removal Installation (Continued) Removal Removal Removal and and Installation Installation Installation (Continued) (Continued) (Continued) Power-assisted Steering System Power-assisted Power-assisted Power-assisted Steering Steering Steering System System System Note: Note: Note: Note: In the ball joint installation, make sure that the number of turns of the installation is the same with that of the removal.
Page 641 PowerSteering PowerSteering System System PS PowerSteering PowerSteering System System Removal Removal Removal Removal 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. Remove the upper and lower protective plates of the steering column.
Page 642 PowerSteering PowerSteering System System PS PowerSteering PowerSteering System System Removal Installation Installation of of of of Steering Steering Wheel (Continued) Removal Removal Removal and and Installation Installation Steering Steering Wheel Wheel Wheel (Continued) (Continued) (Continued) Remove mounting nuts of the steering wheel and remove the steering wheel.
Page 643 PowerSteering PowerSteering System System PS PowerSteering PowerSteering System System Removal Removal Installation Installation Installation of of of of Removal Removal and and Installation Steering Steering Steering Steering Column Column Column Column Removal Disconnect the negative cable of the battery Remove the upper and lower protective plates of the steering column.
Page 644 PowerSteering PowerSteering System System PS PowerSteering PowerSteering System System Removal Removal Removal Removal and and Installation Installation Installation Installation of of of of Steering Steering Steering Steering Column Column Column Column (Continued) (Continued) (Continued) (Continued) Remove four mounting nuts for fixing the lower part of the steering column onto the partition panel.
Page 645 PowerSteering PowerSteering System System PS PowerSteering PowerSteering System System Removal Removal Removal Removal 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.
Page 646 WT Wheels Wheels and and Tires Tires Wheels Wheels Tires Tires Wheels Wheels and and Tires Tires Applied models: SUNRAY products manufactured by JAC Subject Page Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Wheels and Tires................................174 Explosive View of Wheels and Tires........................175 Precaution for Tire Usage............................
Page 647 Wheels Wheels Tires Tires WT Wheels Wheels and and Tires Tires Instruction Instruction Instruction Instruction and and Operation Operation Operation Operation SUNRAY SUNRAY vehicles vehicles adopts adopts tire tire models models models of of of of GITI GITI GITI GITI 1 1 1 1 9 9 9 9 5 5 5 5 /70 R15LT R15LT 185R15LT...
Page 648 Wheels Wheels Tires Tires WT Wheels Wheels and and Tires Tires Notice tire usage Replacement: Notice Notice Notice for for tire tire tire usage usage usage Replacement: Replacement: Replacement: ① Please replace tire after normal running for Please use the genuine tires manufactured by the original manufacturer.
Page 649 Wheels Wheels Tires Tires WT Wheels Wheels and and Tires Tires shown in the figure. No more than two pieces of balance weight � When installing balance weight onto wheel, can be installed. the balance weight shall be placed onto inner Please always use genuine balance weight.
Page 650 Wheels Wheels Tires Tires WT Wheels Wheels and and Tires Tires Fault Fault Diagnosis Diagnosis Fault Fault Diagnosis Diagnosis Common fault diagnosis table Common Common Common fault fault fault diagnosis diagnosis diagnosis table table table Fault Symptom Possible Cause Solution Excessive deflection of wheel and rim Replace Looseness of wheel nut...
Page 651 Wheels Wheels Tires Tires WT Wheels Wheels and and Tires Tires Removal/installation Removal/installation Removal/installation of of of of front front front wheel wheel assembly assembly Removal/installation front wheel wheel assembly assembly Removal/installation Removal/installation Removal/installation Removal/installation Removal Loosen tire nut, and have the vehicle jacked to remove the tire.
Page 652 Wheels Wheels Tires Tires WT Wheels Wheels and and Tires Tires 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. Install flange assembly. Install washer and hub assembly together �...
Page 653 Wheels Wheels Tires Tires WT Wheels Wheels and and Tires Tires 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...
Page 654 Wheels Wheels Tires Tires WT Wheels Wheels and and Tires Tires Removal/installation Removal/installation Removal/installation Removal/installation Installation Install the flange onto the brake disc. Caution: Caution: Caution: Caution: The adopted bearing races and rollers should be from the same manufacturer. Reinstall the inner and outer races of bearing. Apply grease onto race and roller bearing.
Page 655 Alignment Alignment FT Four-Wheel Four-Wheel Alignment Alignment Four-Wheel Four-Wheel Alignment Alignment Four-Wheel Four-Wheel Alignment Alignment Applied models: SUNRAY products manufactured by JAC Subject Page Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Four-Wheel Alignment..............................184 Preparation before four-wheel alignment....................... 184...
Page 656 Four-Wheel Four-Wheel Alignment Alignment FT Four-Wheel Four-Wheel Alignment Alignment Instruction Instruction Instruction Instruction and and Operation Operation Operation Operation Objectives four-wheel alignment: Objectives Objectives Objectives for for four-wheel four-wheel four-wheel alignment: alignment: alignment: deformed or damaged parts should be detected for Elimination of deflection complete removal of fault.
Page 657 Four-Wheel Four-Wheel Alignment Alignment FT Four-Wheel Four-Wheel Alignment Alignment Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Four-wheel alignment parameters Four-wheel Four-wheel Four-wheel alignment alignment alignment parameters parameters parameters Front wheel camber 0.75±1° 1.25° Kingpin caster 1.5±1.5° 1° Kingpin inclination angle 12.75°±1°...
Page 658 Four-Wheel Four-Wheel Alignment Alignment FT Four-Wheel Four-Wheel Alignment Alignment from the front of vehicle. Kingpin inclination angle mainly functions for the realization of auto return after steering and the increase of adhesion force of vehicle. Kingpin inclination angle is unadjustable and its standard value can be achieved by the replacement of defect parts.
Page 659 Four-Wheel Four-Wheel Alignment Alignment FT Four-Wheel Four-Wheel Alignment Alignment Data Data adjustment adjustment adjustment of of of of four-wheel four-wheel four-wheel alignment alignment Data Data adjustment four-wheel alignment alignment 1. Check basic data of vehicle such as tire pressure, fuel level, vibration reduction effect, tire wear degree, accessories and tools.
Page 660 Special Special Special Tools Tools Tools Tools for for Sunray Sunray Sunray Sunray Attached List-Special Tools for Sunray Applicable model: SUNRAY products manufactured by JAC (4DA1 Series) Tool Tool Tool Tool number number number number Tool Tool Tool Tool name...
Page 661 Tool name name name Outline Outline Outline drawing drawing drawing Purpose/application Purpose/application Purpose/application JAC-T8F013 Cylinder liner puller Removing cylinder liners (engine) JAC-T8F014 Piston installer Installing pistons (engine) Crankshaft front oil seal JAC-T8F015 Installing crankshaft front oil seal (engine) installer Camshaft bushing...
Page 662 Tool number number Tool Tool name name Outline Outline drawing drawing Purpose/application Purpose/application JAC-T8B003 Clutch guide Centering clutch discs (transmission) Input shaft bearing JAC-T8B004 Installing input shaft bearings (transmission) installer Output shaft bearing JAC-T8B005 Installing output shaft bearings (transmission) installer...
Page 663 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.
Page 664 Body Body Accessor Accessor Volume Volume Content Content Contents s s s Body Body Accessor Accessories ies Volume Volume Content Body Body Accessor Accessor Volume Volume Content Content Contents s s s Body Body Accessor Accessories ies Volume Volume Content Body Glass Body...
Page 665 Body Body Accessor Accessor Volume Volume Content Content Contents s s s Body Body Accessor Accessories ies Volume Volume Content Interior rear-view mirror............................BP 91 Sun visor...................................BP 92 Curtains..................................BP 93 Luggage rack................................BP 94 Step plate assembly..............................BP 96 Front bumper................................BP 97 Rear bumper................................
Page 666 Glass Glass BG Body Body Glass Glass Body Body Glass Glass Body Body Glass Glass Applied models: SUNRAY products manufactured by JAC Subject Page Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation SST for Glass................................... 2 Front windshield................................3...
Page 667 Body Body Glass Glass BG Body Body Glass Glass Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Glass SST for for Glass Glass Glass Tool Illustration Function Tool Tool Tool Illustration Illustration Illustration Function Function Function For adjustment, removal or Door hinge adjusting wrench installation of door hinge Ceiling remover...
Page 668 BG 车身玻璃 Instruction Instruction Instruction Instruction and and Operation Operation Operation Operation Front Front windshield windshield Front Front windshield windshield Front windshield is mainly composed of laminated functioning for blocking wind and rain and providing glass and relevant accessories (interior rear-view safe and comfortable environment for driver and mirror base, antenna and antenna terminal, pad), passengers.
Page 669 Body Body Glass Glass BG Body Body Glass Glass Removal/Installation Removal/Installation Removal/Installation Removal/Installation Front windshield Front Front Front windshield windshield windshield Removal Remove glass molding Prepare repair kit, with the following articles included: Sea lant (carbamic acid Cleaner ethyl ester adhesive) Primer Cloth Wool brush...
Page 670 Body Body Glass Glass BG Body Body Glass Glass Removal/Installation Removal/Installation (Continued) (Continued) Removal/Installation Removal/Installation (Continued) (Continued) Front windshield Front Front Front windshield windshield windshield Install the precise cutting blade (24mm hook type blade) onto the cutter. Warning: Warning: Warning: Warning: When using tools for cutting glasses, please wear gloves and goggles to avoid possible injury caused by...
Page 671 Body Body Glass Glass BG Body Body Glass Glass Removal/Installation Removal/Installation (Continued) (Continued) Removal/Installation Removal/Installation (Continued) (Continued) Front windshield Front Front Front windshield windshield windshield Installation Note: Note: Note: Note: Don’t contact the already trimmed surface, otherwise, bonding effect of new sealant may be influenced. Trim the side grooves.
Page 672 Body Body Glass Glass BG Body Body Glass Glass Removal/Installation Removal/Installation Removal/Installation Removal/Installation Front triangle glass Front Front Front triangle triangle triangle glass glass glass Removal Remove the rear-view mirror from the window. Remove the glass. Compress the glass continuously and forcibly from the inside upper corner.
Page 673 Body Body Glass Glass BG Body Body Glass Glass Removal/Installation Removal/Installation (Continued) (Continued) Removal/Installation Removal/Installation (Continued) (Continued) Front triangle glass Front Front Front triangle triangle triangle glass glass glass Reinstall the window. Pass the cable through the window groove � and stick the lower edge of seal along the edge of window groove.
Page 674 Body Body Glass Glass BG Body Body Glass Glass Removal/Installation Removal/Installation Removal/Installation Removal/Installation Front door glass Front Front Front door door door glass glass glass Disconnect the negative cable of battery. Remove the interior trim panel of door. Disconnect the harness connector of interior trim panel of door.
Page 675 Body Body Glass Glass BG Body Body Glass Glass Removal/Installation Removal/Installation (Continued) (Continued) Removal/Installation Removal/Installation (Continued) (Continued) Front door window Front Front Front door door door window window window Pull out the glass seal from top to bottom. Remove the loudspeaker. Remove the glass regulator motor.
Page 676 Body Body Glass Glass BG Body Body Glass Glass Removal/Installation Removal/Installation Removal/Installation Removal/Installation Front door glass seal Front Front Front door door door glass glass glass seal seal seal Removal Disconnect the negative cable of battery. Peel off the window glass seal. Note: Note: Note:...
Page 677 Body Body Glass Glass BG Body Body Glass Glass Removal/Installation Removal/Installation Removal/Installation Removal/Installation Front door glass regulator Front Front Front door door door glass glass glass regulator regulator regulator Removal Disconnect the negative cable of battery. Peel off the window glass seal. Note: Note: Note:...
Page 678 Body Body Glass Glass BG Body Body Glass Glass Removal/Installation Removal/Installation (Continued) (Continued) Removal/Installation Removal/Installation (Continued) (Continued) Front door glass regulator Front Front Front door door door glass glass glass regulator regulator regulator Remove the mounting screws for regulator motor. Take down the regulator motor.
Page 679 Body Body Glass Glass BG Body Body Glass Glass Removal/Installation Removal/Installation Removal/Installation Removal/Installation Left side wall glass Left Left Left side side side wall wall wall glass glass glass Removal Prepare necessary tools. Peel off the window glass seal. Note: Note: Note: Note:...
Page 680 Body Body Glass Glass BG Body Body Glass Glass Removal/Installation Removal/Installation (Continued) (Continued) Removal/Installation Removal/Installation (Continued) (Continued) Left side wall glass Left Left Left side side side wall wall wall glass glass glass Install the precise cutting blade (24mm hook type blade) onto the cutter.
Page 681 Body Body Glass Glass BG Body Body Glass Glass Removal/Installation Removal/Installation Removal/Installation Removal/Installation Left side wall glass Left Left Left side side side wall wall wall glass glass glass Installation Prepare repair kit, with the following articles included: Sea lant (carbamic acid Cleaner ethyl ester adhesive) Primer...
Page 682 Body Body Glass Glass BG Body Body Glass Glass Removal/Installation Removal/Installation Removal/Installation Removal/Installation Right side wall glass Right Right Right side side side wall wall wall glass glass glass Removal Side wall glass. Remove the curtain. Remove the side pillar trim panel. Remove two mounting bolts for glass.
Page 683 Body Body Glass Glass BG Body Body Glass Glass Removal/Installation Removal/Installation (Continued) (Continued) Removal/Installation Removal/Installation (Continued) (Continued) Right side wall glass Right Right Right side side side wall wall wall glass glass glass Remove the mounting bolts for glass and take the glass down.
Page 684 Body Body Glass Glass BG Body Body Glass Glass Removal/Installation Removal/Installation Removal/Installation Removal/Installation Rear side wall glass Rear Rear Rear side side side wall wall wall glass glass glass Removal Rear side wall glass. Remove the curtain. Remove upper and lower trim panels and guard plates of pillar-D.
Page 685 Body Body Glass Glass BG Body Body Glass Glass Removal/Installation Removal/Installation Removal/Installation Removal/Installation Rear side wall glass Rear Rear Rear side side side wall wall wall glass glass glass Remove the mounting bolts for glass and take the glass down carefully. Installation Install it in reverse order of removal.
Page 686 Body Body Glass Glass BG Body Body Glass Glass Removal/Installation Removal/Installation Removal/Installation Removal/Installation Double-open back door glass Double-open Double-open Double-open back back back door door door glass glass glass Prepare repair kit, with the following articles included: Sea lant (carbamic acid Cleaner ethyl ester adhesive)
Page 687 Body Body Glass Glass BG Body Body Glass Glass Removal/Installation Removal/Installation Removal/Installation Removal/Installation Double-open back door glass Double-open Double-open Double-open back back back door door door glass glass glass Note: Note: Note: Note: Don’t contact the already trimmed surface; otherwise, bonding effect of new sealant may be influenced.
Page 688 Front Compartment Compartment Cover Cover Front/Rear Front/Rear Doors Doors and and Front Front Compartment Compartment Cover Cover Applied models: SUNRAY products manufactured by JAC Subject Page Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Front compartment cover............................... 24...
Page 689 Front/Rear Front/Rear Doors Doors Front Front Compartment Compartment Cover Cover BD Front/Rear Front/Rear Doors Doors and and Front Front Compartment Compartment Cover Cover Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Front compartment cover Front Front Front compartment compartment compartment cover cover...
Page 690 Front/Rear Front/Rear Doors Doors Front Front Compartment Compartment Cover Cover BD Front/Rear Front/Rear Doors Doors and and Front Front Compartment Compartment Cover Cover Removal/Installation Removal/Installation Removal/Installation Removal/Installation Front compartment cover Front Front Front compartment compartment compartment cover cover cover Open the front compartment cover. Mark below the mounting bolts of front fender.
Page 691 Front/Rear Front/Rear Doors Doors Front Front Compartment Compartment Cover Cover BD Front/Rear Front/Rear Doors Doors and and Front Front Compartment Compartment Cover Cover Removal/Installation Removal/Installation (Continued) (Continued) Removal/Installation Removal/Installation (Continued) (Continued) Front compartment cover Front Front Front compartment compartment compartment cover cover cover Install the cover with mounting marks properly...
Page 692 Front/Rear Front/Rear Doors Doors Front Front Compartment Compartment Cover Cover BD Front/Rear Front/Rear Doors Doors and and Front Front Compartment Compartment Cover Cover Inspection/Adjustment Inspection/Adjustment Inspection/Adjustment Inspection/Adjustment Front compartment cover Front Front Front compartment compartment compartment cover cover cover The adjustment direction of front compartment cover is shown in the figure.
Page 693 Front/Rear Front/Rear Doors Doors Front Front Compartment Compartment Cover Cover BD Front/Rear Front/Rear Doors Doors and and Front Front Compartment Compartment Cover Cover Removal/Installation Removal/Installation Removal/Installation Removal/Installation Radiator core bracket Radiator Radiator Radiator core core core bracket bracket bracket Remove the lock body of front compartment cover. Remove mounting bolts for radiator core bracket.
Page 694 Front/Rear Front/Rear Doors Doors Front Front Compartment Compartment Cover Cover BD Front/Rear Front/Rear Doors Doors and and Front Front Compartment Compartment Cover Cover Removal/Installation Removal/Installation Removal/Installation Removal/Installation Compartment cover release cable Compartment Compartment Compartment cover cover cover release release release cable cable cable Open the front compartment cover.
Page 695 Front/Rear Front/Rear Doors Doors Front Front Compartment Compartment Cover Cover BD Front/Rear Front/Rear Doors Doors and and Front Front Compartment Compartment Cover Cover Removal/Installation Removal/Installation (Continued) (Continued) Removal/Installation Removal/Installation (Continued) (Continued) Compartment cover release cable Compartment Compartment Compartment cover cover cover release release release cable...
Page 696 Front/Rear Front/Rear Doors Doors Front Front Compartment Compartment Cover Cover BD Front/Rear Front/Rear Doors Doors and and Front Front Compartment Compartment Cover Cover Removal/Installation Removal/Installation Removal/Installation Removal/Installation Right front door Right Right Right front front front door door door Disconnect the negative cable of battery. Remove the front bumper.
Page 697 Front/Rear Front/Rear Doors Doors Front Front Compartment Compartment Cover Cover BD Front/Rear Front/Rear Doors Doors and and Front Front Compartment Compartment Cover Cover Removal/Installation Removal/Installation (Continued) (Continued) Removal/Installation Removal/Installation (Continued) (Continued) Right front door Right Right Right front front front door door door Remove mounting screws for right front door...
Page 698 Front/Rear Front/Rear Doors Doors Front Front Compartment Compartment Cover Cover BD Front/Rear Front/Rear Doors Doors and and Front Front Compartment Compartment Cover Cover Inspection/Adjustment Inspection/Adjustment Inspection/Adjustment Inspection/Adjustment Right front door Right Right Right front front front door door door Adjust door hinges. Adjust door latches in four directions shown in the figure.
Page 699 Front/Rear Front/Rear Doors Doors Front Front Compartment Compartment Cover Cover BD Front/Rear Front/Rear Doors Doors and and Front Front Compartment Compartment Cover Cover Removal/Installation Removal/Installation Removal/Installation Removal/Installation Left front door Left Left Left front front front door door door Disconnect the negative cable of battery. Remove the front bumper.
Page 700 Front/Rear Front/Rear Doors Doors Front Front Compartment Compartment Cover Cover BD Front/Rear Front/Rear Doors Doors and and Front Front Compartment Compartment Cover Cover Removal/Installation Removal/Installation Removal/Installation Removal/Installation Left front door Left Left Left front front front door door door Remove mounting screws for left front door check. Remove mounting screws for hinges.
Page 701 Front/Rear Front/Rear Doors Doors Front Front Compartment Compartment Cover Cover BD Front/Rear Front/Rear Doors Doors and and Front Front Compartment Compartment Cover Cover Inspection/Adjustment Inspection/Adjustment Inspection/Adjustment Inspection/Adjustment Left front door Left Left Left front front front door door door Adjust door hinges in four directions shown in the figure.
Page 702 Front/Rear Front/Rear Doors Doors Front Front Compartment Compartment Cover Cover BD Front/Rear Front/Rear Doors Doors and and Front Front Compartment Compartment Cover Cover Removal/Installation Removal/Installation Removal/Installation Removal/Installation Left front door outer handle Left Left Left front front front door door door outer outer outer handle...
Page 703 Front/Rear Front/Rear Doors Doors Front Front Compartment Compartment Cover Cover BD Front/Rear Front/Rear Doors Doors and and Front Front Compartment Compartment Cover Cover Removal/Installation Removal/Installation (Continued) (Continued) Removal/Installation Removal/Installation (Continued) (Continued) Left front door outer handle Left Left Left front front front door door...
Page 704 Front/Rear Front/Rear Doors Doors Front Front Compartment Compartment Cover Cover BD Front/Rear Front/Rear Doors Doors and and Front Front Compartment Compartment Cover Cover Removal/Installation Removal/Installation Removal/Installation Removal/Installation Left front door lock cylinder Left Left Left front front front door door door lock lock lock cylinder...
Page 705 Front/Rear Front/Rear Doors Doors Front Front Compartment Compartment Cover Cover BD Front/Rear Front/Rear Doors Doors and and Front Front Compartment Compartment Cover Cover Removal/Installation Removal/Installation (Continued) (Continued) Removal/Installation Removal/Installation (Continued) (Continued) Left front door lock cylinder Left Left Left front front front door door...
Page 706 Front/Rear Front/Rear Doors Doors Front Front Compartment Compartment Cover Cover BD Front/Rear Front/Rear Doors Doors and and Front Front Compartment Compartment Cover Cover Removal/Installation Removal/Installation Removal/Installation Removal/Installation Left front door lock body Left Left Left front front front door door door lock lock lock body...
Page 707 Front/Rear Front/Rear Doors Doors Front Front Compartment Compartment Cover Cover BD Front/Rear Front/Rear Doors Doors and and Front Front Compartment Compartment Cover Cover Removal/Installation Removal/Installation (Continued) (Continued) Removal/Installation Removal/Installation (Continued) (Continued) Left front door lock body Left Left Left front front front door door...
Page 708 Front/Rear Front/Rear Doors Doors Front Front Compartment Compartment Cover Cover BD Front/Rear Front/Rear Doors Doors and and Front Front Compartment Compartment Cover Cover Removal/Installation Removal/Installation (Continued) (Continued) Removal/Installation Removal/Installation (Continued) (Continued) Left front door lock body Left Left Left front front front door door...
Page 709 Front/Rear Front/Rear Doors Doors Front Front Compartment Compartment Cover Cover BD Front/Rear Front/Rear Doors Doors and and Front Front Compartment Compartment Cover Cover Removal/Installation Removal/Installation Removal/Installation Removal/Installation R R R R ight ight front door lock body ight ight front front front door door...
Page 710 Front/Rear Front/Rear Doors Doors Front Front Compartment Compartment Cover Cover BD Front/Rear Front/Rear Doors Doors and and Front Front Compartment Compartment Cover Cover Removal/Installation Removal/Installation (Continued) (Continued) Removal/Installation Removal/Installation (Continued) (Continued) R R R R ight ight front door lock body ight ight front...
Page 711 Front/Rear Front/Rear Doors Doors Front Front Compartment Compartment Cover Cover BD Front/Rear Front/Rear Doors Doors and and Front Front Compartment Compartment Cover Cover Removal/Installation Removal/Installation Removal/Installation Removal/Installation Door seal Door Door Door seal seal seal Remove the step plate. Peel off door seal from top to bottom. Attention: Attention: Attention:...
Page 712 Front/Rear Front/Rear Doors Doors Front Front Compartment Compartment Cover Cover BD Front/Rear Front/Rear Doors Doors and and Front Front Compartment Compartment Cover Cover Removal/Installation Removal/Installation Removal/Installation Removal/Installation Double-open back door Double-open Double-open Double-open back back back door door door Removal Disconnect the negative cable of battery.
Page 713 Front/Rear Front/Rear Doors Doors Front Front Compartment Compartment Cover Cover BD Front/Rear Front/Rear Doors Doors and and Front Front Compartment Compartment Cover Cover Removal/Installation Removal/Installation (Continued) (Continued) Removal/Installation Removal/Installation (Continued) (Continued) Double-open back door Double-open Double-open Double-open back back back door door door Remove bolts for right door hinge.
Page 714 Front/Rear Front/Rear Doors Doors Front Front Compartment Compartment Cover Cover BD Front/Rear Front/Rear Doors Doors and and Front Front Compartment Compartment Cover Cover Removal/Installation Removal/Installation Removal/Installation Removal/Installation Double-open back door Double-open Double-open Double-open back back back door door door Installation After the installation of back door, lower/upper clearance should be adjusted properly.
Page 715 Front/Rear Front/Rear Doors Doors Front Front Compartment Compartment Cover Cover BD Front/Rear Front/Rear Doors Doors and and Front Front Compartment Compartment Cover Cover Removal/Installation Removal/Installation Removal/Installation Removal/Installation Back door outer handle Back Back Back door door door outer outer outer handle handle handle Removal...
Page 716 Front/Rear Front/Rear Doors Doors Front Front Compartment Compartment Cover Cover BD Front/Rear Front/Rear Doors Doors and and Front Front Compartment Compartment Cover Cover Removal/Installation Removal/Installation (Continued) (Continued) Removal/Installation Removal/Installation (Continued) (Continued) Back door outer handle Back Back Back door door door outer outer outer handle...
Page 717 Front/Rear Front/Rear Doors Doors Front Front Compartment Compartment Cover Cover BD Front/Rear Front/Rear Doors Doors and and Front Front Compartment Compartment Cover Cover Removal/Installation Removal/Installation Removal/Installation Removal/Installation Back door latch Back Back Back door door door latch latch latch Remove mounting screws for back door latch. Remove the back door latch.
Page 718 Front/Rear Front/Rear Doors Doors Front Front Compartment Compartment Cover Cover BD Front/Rear Front/Rear Doors Doors and and Front Front Compartment Compartment Cover Cover Removal/Installation Removal/Installation Removal/Installation Removal/Installation Outer lock lock of of of of back back door Outer Outer Outer lock lock back back door...
Page 719 Front/Rear Front/Rear Doors Doors Front Front Compartment Compartment Cover Cover BD Front/Rear Front/Rear Doors Doors and and Front Front Compartment Compartment Cover Cover Removal/Installation Removal/Installation (Continued) (Continued) Removal/Installation Removal/Installation (Continued) (Continued) Outer lock lock of of of of back back door Outer Outer...
Page 720 Front/Rear Front/Rear Doors Doors Front Front Compartment Compartment Cover Cover BD Front/Rear Front/Rear Doors Doors and and Front Front Compartment Compartment Cover Cover Removal/Installation Removal/Installation Removal/Installation Removal/Installation Inner lock lock of of of of back back door Inner Inner Inner lock lock back back door...
Page 721 Front/Rear Front/Rear Doors Doors Front Front Compartment Compartment Cover Cover BD Front/Rear Front/Rear Doors Doors and and Front Front Compartment Compartment Cover Cover Removal/Installation Removal/Installation (Continued) (Continued) Removal/Installation Removal/Installation (Continued) (Continued) Inner lock lock of of of of back back door Inner Inner...
Page 722 Front/Rear Front/Rear Doors Doors Front Front Compartment Compartment Cover Cover BD Front/Rear Front/Rear Doors Doors and and Front Front Compartment Compartment Cover Cover Removal/Installation Removal/Installation Removal/Installation Removal/Installation Back door seal Back Back Back door door door seal seal seal Removal Peel off the seal forcibly from top to bottom.
Page 723 Front/Rear Front/Rear Doors Doors Front Front Compartment Compartment Cover Cover BD Front/Rear Front/Rear Doors Doors and and Front Front Compartment Compartment Cover Cover - 58 -...
Page 724 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Interior/Exterior Interior/Exterior Trims Trims Interior/Exterior Interior/Exterior Trims Trims Applied models: SUNRAY products manufactured by JAC Subject Page Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Instrument panel................................60 Removal/Installation Removal/Installation...
Page 725 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Instruction Instruction Instruction Instruction and and Operation Operation Operation Operation Instrument Instrument panel panel Instrument Instrument panel panel - 60 -...
Page 726 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation Removal/Installation Removal/Installation Instrument panel Instrument Instrument Instrument panel panel panel Remove the negative cable of battery. Remove the upper cover of steering wheel. There are two mounting screws on the left and right sides of upper cover of steering wheel.
Page 727 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation (Continued) (Continued) Removal/Installation Removal/Installation (Continued) (Continued) Instrument panel Instrument Instrument Instrument panel panel panel Remove the instrument cover. Remove four mounting screws of instrument. Remove the harness connectors of instruments. Remove three mounting screws on the lower cover of steering wheel and take down the lower cover.
Page 728 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation (Continued) (Continued) Removal/Installation Removal/Installation (Continued) (Continued) Instrument panel Instrument Instrument Instrument panel panel panel Remove four mounting screws of the clock spring and take down the clock spring. 10. Remove three mounting screws of combined switch and take down the switch.
Page 729 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation (Continued) (Continued) Removal/Installation Removal/Installation (Continued) (Continued) Instrument panel Instrument Instrument Instrument panel panel panel 13. Remove two mounting screws of A/C control panel. 14. Disconnect the harness of A/C control panel. 15.
Page 730 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation (Continued) (Continued) Removal/Installation Removal/Installation (Continued) (Continued) Instrument panel Instrument Instrument Instrument panel panel panel 17. Remove four mounting screws of audio. 18. Disconnect the harness connector of audio. 19. Remove the lower cover of instrument panel. 20.
Page 731 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation (Continued) (Continued) Removal/Installation Removal/Installation (Continued) (Continued) Instrument panel Instrument Instrument Instrument panel panel panel 21. Loosen two mounting screws of instrument panel. 22. Remove the mounting bolt on the left side of instrument panel.
Page 732 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation (Continued) (Continued) Removal/Installation Removal/Installation (Continued) (Continued) Instrument panel Instrument Instrument Instrument panel panel panel 25. Remove two mounting bolt on the right side of instrument panel. 26. Remove the shift lever. 27.
Page 733 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation Removal/Installation Removal/Installation Instrument panel Instrument Instrument Instrument panel panel panel Installation During the installation of instrument panel, the clock spring should be installed under the premise that the wheels face forward and it should be rotated clockwise until rotation disabled (rotating with proper force instead of using too much force), and then rotated counterclockwise by three circles...
Page 734 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Roof lining Roof Roof Roof lining lining lining - 69 -...
Page 735 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation Removal/Installation Removal/Installation Roof lining Roof Roof Roof lining lining lining Removal Remove the negative cable of battery. Remove curtains. Remove upper and lower trim panels of B-pillar. Remove luggage racks on bolt left and right sides. - 70 -...
Page 736 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation Removal/Installation Removal/Installation Roof lining Roof Roof Roof lining lining lining Remove interior ceiling lamp 1. Remove interior ceiling lamp 2. Remove right sun visor. Remove left sun visor. - 71 -...
Page 737 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation Removal/Installation Removal/Installation Roof lining Roof Roof Roof lining lining lining Remove front interior ceiling lamp. 10. Remove clips of rear roof lining and take down the rear roof lining. 11.
Page 738 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation Removal/Installation Removal/Installation Roof lining Roof Roof Roof lining lining lining Installation Two service persons are necessary for installation of roof lining, to avoid fracture of roof interior trim. - 73 -...
Page 739 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation Removal/Installation Removal/Installation Right/Left upper trim panel panel of of of of A-pillar A-pillar Right/Left Right/Left Right/Left upper upper upper trim trim trim panel panel A-pillar A-pillar Removal Remove left upper trim panel of A-pillar with tool. Remove right upper trim panel of A-pillar with tool.
Page 740 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation Removal/Installation Removal/Installation Right upper/lower trim panel panel of of of of B-pillar B-pillar Right Right Right upper/lower upper/lower upper/lower trim trim trim panel panel B-pillar B-pillar Removal Remove curtains. Remove two mounting screws for right lower trim panel of B-pillar and then remove the lower trim panel.
Page 741 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation B-pillar B-pillar Trim Trim Panel Panel Removal/Installation Removal/Installation for for B-pillar B-pillar Trim Trim Panel Panel Left upper/lower trim panel panel of of of of B-pillar B-pillar Left Left Left upper/lower upper/lower upper/lower trim...
Page 742 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation Removal/Installation Removal/Installation Left upper/lower trim panel panel of of of of B-pillar B-pillar Left Left Left upper/lower upper/lower upper/lower trim trim trim panel panel B-pillar B-pillar Installation Install it in reverse order of removal. - 77 -...
Page 743 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation C-pillar C-pillar Trim Trim Panel Panel Removal/Installation Removal/Installation for for C-pillar C-pillar Trim Trim Panel Panel Left/Right trim panel panel of of of of C-pillar C-pillar Left/Right Left/Right Left/Right trim trim trim panel panel...
Page 744 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation (Continued) (Continued) Removal/Installation Removal/Installation (Continued) (Continued) Left/Right trim panel panel of of of of C-pillar C-pillar Left/Right Left/Right Left/Right trim trim trim panel panel C-pillar C-pillar Remove left trim panel of C-pillar. Installation Install it in reverse order of removal.
Page 745 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation Removal/Installation Removal/Installation Right side wall window trim panel Right Right Right side side side wall wall wall window window window trim trim trim panel panel panel Removal Remove curtains. Remove upper trim panel 1 and lower trim panel 1 of right side wall window pillar.
Page 746 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation (Continued) (Continued) Removal/Installation Removal/Installation (Continued) (Continued) Right side wall window trim panel Right Right Right side side side wall wall wall window window window trim trim trim panel panel panel Installation Install it in reverse order of removal.
Page 747 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation Removal/Installation Removal/Installation Left side wall window trim panel Left Left Left side side side wall wall wall window window window trim trim trim panel panel panel Removal Remove curtains. Remove upper trim panel 1 and lower trim panel 1 of left side wall window pillar.
Page 748 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation (Continued) (Continued) Removal/Installation Removal/Installation (Continued) (Continued) Left side wall window trim panel Left Left Left side side side wall wall wall window window window trim trim trim panel panel panel Installation Install it in reverse order of removal.
Page 749 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation Removal/Installation Removal/Installation Upper/lower trim panel panel of of of of right right D-pillar Upper/lower Upper/lower Upper/lower trim trim trim panel panel right right D-pillar D-pillar D-pillar Removal Remove curtains. Remove mounting screws for upper trim panel of right D-pillar and take down the upper trim panel.
Page 750 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation Removal/Installation Removal/Installation Upper/lower trim panel panel of of of of left left D-pillar Upper/lower Upper/lower Upper/lower trim trim trim panel panel left left D-pillar D-pillar D-pillar Removal Remove curtains. Remove mounting screws for upper trim panel of left D-pillar and take down the upper trim panel.
Page 751 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation Removal/Installation Removal/Installation Left trim panels panels 1, 1, 1, 1, 2, 2, 2, 2, 3 3 3 3 and and 4 4 4 4 and right trim panels panels 1, 1, 1, 1, 2 2 2 2 and and 3 3 3 3 Left Left...
Page 752 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation (Continued) (Continued) Removal/Installation Removal/Installation (Continued) (Continued) Left trim panels panels 1, 1, 1, 1, 2, 2, 2, 2, 3 3 3 3 and and 4 4 4 4 and right trim panels...
Page 753 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation Removal/Installation Removal/Installation Left trim panel panel of of of of front front door trim panel Left Left Left trim trim trim panel panel front front door door door trim trim trim panel panel...
Page 754 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation Removal/Installation Removal/Installation Left door Left Left Left door door door Removal Pry up the left door lower trim panel with tool carefully. Pry up the left door upper trim panel with tool carefully.
Page 755 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation Removal/Installation Removal/Installation Right door Right Right Right door door door Removal Remove inner handle cover of door. Remove the right door lower trim panel with tool. Remove right door upper trim panel with tool. Installation Install it in reverse order of removal.
Page 756 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation Removal/Installation Removal/Installation Interior rear-view mirror Interior Interior Interior rear-view rear-view rear-view mirror mirror mirror Removal Pull the interior rear-view mirror downwards carefully in the direction shown in the figure. Take out the interior rear-view mirror assembly.
Page 757 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation Removal/Installation Removal/Installation visor visor Sun visor visor Removal Remove mounting screws of right sun visor. Take down the sun visor. Remove mounting screws of left sun visor and take down the sun visor.
Page 758 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation Removal/Installation Removal/Installation Curtains Curtains Curtains Curtains Removal Pry out the curtain slide rail with screwdriver and make it separated from the clips mounted on the trim panel. Clips are positioned at the middle of each pillar and at the middle of each side window glass.
Page 759 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation Removal/Installation Removal/Installation Luggage rack Luggage Luggage Luggage rack rack rack Removal Two service persons are necessary for removal of luggage rack, in order to avoid personal injury and damage to luggage rack. Remove mounting nuts for luggage rack.
Page 760 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation (Continued) (Continued) Removal/Installation Removal/Installation (Continued) (Continued) Luggage rack Luggage Luggage Luggage rack rack rack Installation Install it in reverse order of removal. - 95 -...
Page 761 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation Removal/Installation Removal/Installation Step plate assembly Step Step Step plate plate plate assembly assembly assembly Removal Remove mounting screws of step plate. Take down the step plate assembly. Installation Install it in reverse order of removal. - 96 -...
Page 762 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation Removal/Installation Removal/Installation Front bumper Front Front Front bumper bumper bumper Removal Remove the negative cable of battery. Remove screws of front grille and take down the front grille. Remove the front trim panel. Disconnect the harness connector of fog lamp.
Page 763 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation Removal/Installation Removal/Installation Front bumper Front Front Front bumper bumper bumper Remove mounting screws of bumper. Remove four mounting screws of bumper. Take down front bumper. Installation Install it in reverse order of removal. - 98 -...
Page 764 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation Removal/Installation Removal/Installation Rear bumper Rear Rear Rear bumper bumper bumper Remove the negative cable of battery. Remove mounting screws below rear bumper. Remove mounting screws from rear bumper. Remove side mounting screws from rear bumper. - 99 -...
Page 765 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation Removal/Installation Removal/Installation (Continued) (Continued) (Continued) (Continued) Rear Rear bumper bumper Rear Rear bumper bumper Disconnect the harness connector of rear bumper and take down the rear bumper. Installation Install it in reverse order of removal. - 100 -...
Page 766 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation Removal/Installation Removal/Installation Front grille Front Front Front grille grille grille Removal Remove mounting screws for front grille. Take down the front grille. Installation Install it in reverse order of removal. - 101 -...
Page 767 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation Removal/Installation Removal/Installation Fender Fender Fender Fender Removal Remove the negative cable of battery. Remove the front grille. Remove front trim panel and headlamps. Disconnect harness connector of fog lamp. - 102 -...
Page 768 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation (Continued) (Continued) Removal/Installation Removal/Installation (Continued) (Continued) Fender Fender Fender Fender Remove front bumper. Remove clearance lamps. Remove pads for front bumper. Remove mounting bolts for fender. - 103 -...
Page 769 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation (Continued) (Continued) Removal/Installation Removal/Installation (Continued) (Continued) Fender Fender Fender Fender Remove mounting bolts for fender. 10. Remove rear-view mirror trim panel. 11. Remove mounting bolts for fender. 12. Remove front wheel trim panel. - 104 -...
Page 770 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation (Continued) (Continued) Removal/Installation Removal/Installation (Continued) (Continued) Fender Fender Fender Fender 13. Remove mounting screws for fender. 14. Remove mounting screws for fender and take down the fender. Installation Install it in reverse order of removal. - 105 -...
Page 771 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation Removal/Installation Removal/Installation Front door skirt trim panel Front Front Front door door door skirt skirt skirt trim trim trim panel panel panel Removal Remove front door skirt trim panel with tool. Clip position of front door skirt trim panel.
Page 772 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation Removal/Installation Removal/Installation Front side wall skirt trim panel Front Front Front side side side wall wall wall skirt skirt skirt trim trim trim panel panel panel Removal Remove front side wall skirt trim panel with tool. Clip position of front side wall skirt trim panel.
Page 773 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation Removal/Installation Removal/Installation Middle side wall skirt trim panel Middle Middle Middle side side side wall wall wall skirt skirt skirt trim trim trim panel panel panel Removal Remove mounting screws for middle side wall skirt trim panel.
Page 774 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation Removal/Installation Removal/Installation Rear wheel skirt trim panel Rear Rear Rear wheel wheel wheel skirt skirt skirt trim trim trim panel panel panel Removal Remove mounting screws. Remove rear wheel skirt trim panel with tool. Clip position of rear wheel skirt trim panel.
Page 775 Interior/Exterior Interior/Exterior Trims Trims BP Interior/Exterior Interior/Exterior Trims Trims Removal/Installation Removal/Installation Removal/Installation Removal/Installation Rear tire guard Rear Rear Rear tire tire tire mud mud guard guard guard Removal Remove mounting screws for rear tire mud guard and take down the mud guard. Installation Install it in reverse order of removal.
Page 776 Seats Seats SE Seats Seats Seats Seats Seats Seats Applied models: SUNRAY products manufactured by JAC Subject Page Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Driver’s seat................................. 112 Front row twin bench-type seat............................ 114 Front row individual seat..............................115...
Page 777 Seats Seats SE Seats Seats Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Components Components of of of of driver driver driver’ ’ ’ ’ s s s s seat seat Components Components driver seat seat 1. Vertical adjustable headrest 2.
Page 778 Seats Seats SE Seats Seats Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Driver Driver’ ’ ’ ’ s s s s seat seat Driver Driver seat seat 1. Armrest 2. Backrest cushion 3. Headrest assembly 4. Headrest latch 5.
Page 779 Seats Seats SE Seats Seats Instruction Instruction Instruction Instruction and and Operation Operation Operation Operation Front Front twin twin bench-type bench-type seat seat Front Front row row twin twin bench-type bench-type seat seat 1. Armrest 2. Backrest cushion 3. Headrest assembly 4.
Page 780 Seats Seats SE Seats Seats Instruction Instruction Operation Operation Instruction Instruction and and Operation Operation Front individual seat Front Front Front row row individual individual individual seat seat seat 1. Backrest cushion 2. Headrest assembly 3. Headrest latch 4. Armrest 5.
Page 781 Seats Seats SE Seats Seats Removal/Installation Removal/Installation Removal/Installation Removal/Installation Driver Driver’ ’ ’ ’ s s s s seat seat Driver Driver seat seat Disconnect the negative cable of battery. Remove two mounting nuts on the left side of seat. Remove two nuts on the right side of seat and disconnect the harness.
Page 782 Seats Seats SE Seats Seats Removal/Installation Removal/Installation Removal/Installation Removal/Installation Sliding rail seat Sliding Sliding Sliding rail rail rail and and seat seat seat Push the sliding rail rearwards and remove four mounting bolts. Pull the sliding rail forwards and remove three mounting bolts on the rear part.
Page 783 Seats Seats SE Seats Seats Removal/Installation Removal/Installation (continued) (continued) Removal/Installation Removal/Installation (continued) (continued) Sliding rail seat Sliding Sliding Sliding rail rail rail and and seat seat seat Install the sliding rail onto the vehicle and install seven mounting bolts in reverse order of removal. Install the seat onto sliding rail and tighten two mounting nuts on the left side.
Page 784 Seats Seats SE Seats Seats Removal/Installation Removal/Installation Removal/Installation Removal/Installation Front twin bench-type seat Front Front Front row row twin twin twin bench-type bench-type bench-type seat seat seat Removal Remove four mounting bolts below front row seat. Remove the front row twin bench-type seat from vehicle.
Page 785 Seats Seats SE Seats Seats Removal/Installation Removal/Installation Removal/Installation Removal/Installation Front individual seat Front Front Front row row individual individual individual seat seat seat Removal Remove four mounting bolts below front row seat. Remove the front row individual seat from vehicle. Installation Install the front row individual seat in reverse order of removal.
Page 786 Seats Seats SE Seats Seats Removal/Installation Removal/Installation Removal/Installation Removal/Installation Back Back Back Back row row seats seats seats seats Removal Remove four mounting bolts below back row seats. Remove the back row twin bench-type seat from vehicle. Installation Install the back row twin bench-type seat in reverse order of removal.
Page 787 Sealing Elements Elements Sealing Sealing Elements Elements Sealing Sealing Elements Elements Applied models: SUNRAY products manufactured by JAC Subject Page Removal/Installation Removal/Installation Removal/Installation Removal/Installation Inner acoustic baffle of front wall..........................124 Outer heat shield of front wall............................. 125 Front door seal................................125 Rear door seal................................126...
Page 788 SP Sealing Sealing Sealing Sealing Elements Elements Elements Elements Removal/Installation Removal/Installation Removal/Installation Removal/Installation Inner Inner Inner Inner acoustic acoustic acoustic acoustic baffle baffle baffle baffle of of of of front front front front wall wall wall wall Disconnect the negative cable of battery. Remove upper acoustic baffle of front wall.
Page 789 Sealing Sealing Elements Elements SP Sealing Sealing Elements Elements Removal/Installation Removal/Installation Removal/Installation Removal/Installation Outer Outer heat heat shield shield shield of of of of front front front wall wall Outer Outer heat heat shield front wall wall Disconnect the negative cable of battery. Remove clips.
Page 790 SP Sealing Sealing Sealing Sealing Elements Elements Elements Elements Removal/Installation Removal/Installation Removal/Installation Removal/Installation Rear Rear Rear Rear door door door door seal seal seal seal Remove middle seal of rear door frame. Remove seal of rear door frame. Removal/Installation Removal/Installation Removal/Installation Removal/Installation Fender...
Page 791 Sealing Sealing Elements Elements SP Sealing Sealing Elements Elements Removal/Installation Removal/Installation Removal/Installation Removal/Installation Front Front compartment compartment seal seal Front Front compartment compartment seal seal Remove the rear end seal of front compartment. Remove the front section seal assembly of front compartment.
Page 792 Repair Repair Parameters Parameters Body Body Repair Repair Parameters Parameters Applied models: SUNRAY products manufactured by JAC Subject Page Engine Compartment Repair Parameters........................130 Windshield Repair Parameters............................. 131 Front Door Repair Parameters............................. 132 Rear Double-Door Repair Parameters..........................133 Girder Repair Parameters.............................134...
Page 793 Body Body Repair Repair Parameters Parameters XE Body Body Repair Repair Parameters Parameters Engine Engine Compartment Compartment Repair Repair Parameters Parameters Engine Engine Compartment Compartment Repair Repair Parameters Parameters - 130 -...
Page 794 Body Body Repair Repair Parameters Parameters XE Body Body Repair Repair Parameters Parameters Windshield Windshield Repair Repair Parameters Parameters Windshield Windshield Repair Repair Parameters Parameters - 131 -...
Page 795 Body Body Repair Repair Parameters Parameters XE Body Body Repair Repair Parameters Parameters Front Front Front Front Door Door Door Door Repair Repair Repair Repair Parameters Parameters Parameters Parameters - 132 -...
Page 796 Body Body Repair Repair Parameters Parameters XE Body Body Repair Repair Parameters Parameters Rear Rear Double-Door Double-Door Repair Repair Parameters Parameters Rear Rear Double-Door Double-Door Repair Repair Parameters Parameters - 133 -...
Page 797 Body Body Repair Repair Parameters Parameters XE Body Body Repair Repair Parameters Parameters Girder Girder Repair Repair Parameters Parameters Girder Girder Repair Repair Parameters Parameters Side member repair parameters: Diagonal L1=5068mm Side member length L2=4998mm Side member ledge L3=840mm - 134 -...
Page 798 SUNRAY SUNRAY Special Special Service Service Tools Tools Attached Attached List SUNRAY Special Special Service Service Tools Tools Applied models: SUNRAY products manufactured by JAC Tool Tool Tool Tool Number Number Number Number Tool Tool Tool Tool Name Name Name...
Page 799 Number Tool Tool Name Name Illustration Illustration Function/Applied Function/Applied Part Part JAC-T8F013 Cylinder liner puller For removing cylinder liner (engine) JAC-T8F014 Piston installer For installing piston (engine) Crankshaft front oil JAC-T8F015 For installing crankshaft front oil seal (engine) seal installer...
Page 800 Illustration Illustration Illustration Function/Applied Function/Applied Function/Applied Function/Applied Part Part Part Part JAC-T8B002 Oil seal puller For removing oil seal (transmission) For center alignment of clutch disc JAC-T8B003 Clutch guider (transmission) Input shaft bearing JAC-T8B004 For installing input shaft bearing (transmission)
Page 801 SUNRAY SUNRAY SUNRAY SUNRAY Special Special Special Special Service Service Service Service Tools Tools Tools Tools...

JAC HFC4DA1-2C Maintenance Manual

Table of Contents

Table of Contents

Battery Battery and and and Charging Charging Charging System System

Instrument Instrument and and and Warning Warning Warning System System

Anti-Lockanti-Lock Brakeanti-Lockbrakebrake Systemsystemsystemsystem (Abs)(Abs)

Transmission Transmission Shaft Shaft

Front Front Suspension Suspension

Rear Rear Axle Axle

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