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Great Wall Pickup has a good reputation at home and abroad for the following advantages: good
comfortability, high practicability, complete function and reasonable performance/price ratio . In order to
meet the demand of market, Great Wall company offers second-generation product of Great Wall Pickup:
K2 series Pickup automobile. With novel design and elegant appearance, this automobile applies
turbocharging control direct injection diesel and has the following features: large torque, low fuel
consumption, long service life and perfect reliability etc. In order to meet the demand of most Great Wall
after-sale service technical personnel, we compile this service manual.
Service maintenance and repair information contained in this manual is provided for qualified profes-
sional technical personnel. Maintaining and repairing in the case of personnel without regular training or
not using correct tools and devices will injure the personnel himself/herself and others. Meanwhile, it is
possible to cause vehicle damage and unsafe state. Therefore, correct service and maintenance is
very important to customer safety and vehicle reliability.In order to help you make a wise decision,
corresponding safe information or other safe instructions are given in this manual, which is throughout
the manual. Despite all this, we still could not give corresponding warnings to all dangers in service and
repair. You must make use of your correct judgement. Some most important after-sale service safety
preventive measures are given in the following:
1.
Ensure that you have a clear understanding on the common sense of safety in all basic service
shops, wear corresponding protective clothing and use safe device. In taking any service, it is
especially necessary to note the following items:
(a) Before starting, read all the safe instructions, ensure that you have well prepared correct tools,
replacing or repairing parts and have required skills to finish the task safely and thoroughly.
(b) In pounding, drilling, grinding operation or working around pressure air, fluid, spring and other
energy accumulating parts, wear safety glasses, safety goggles or face shield to protect eyes.
In any other cases, as long as you are not sure, you must use eye protective device.
(c) Use other safety appliances such as gloves or safety boots if necessary.Moving hot or sharp
parts will cause severe burn or cut, so wear gloves before holding any object that seems to
cause injury.
(d) When lifting vehicles, you must protect yourself and others. Use crane or jack to lift vehicles
and use supporting rack to ensure the vehicles get reliable support.
2.
Unless otherwise specified, before starting any maintenance, ensure the engine has flamed out
which can prevent the following dangers:
(a) Engine exhaust gas will cause carbon monoxide intoxication. Ensure perfect ventilation when
starting the engine.
(b) Hot parts or refrigerant burn. Before working near engine and exhaust system area, let the
engine and exhaust system cool down .
(c) Injury caused by rotating parts. When rotating the engine as required, ensure your hands,
fingers and clothes are far away from the rotating parts.
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Summary of Contents for Great Wall Motor CC1031PS40

  • Page 1 Preface Great Wall Pickup has a good reputation at home and abroad for the following advantages: good comfortability, high practicability, complete function and reasonable performance/price ratio . In order to meet the demand of market, Great Wall company offers second-generation product of Great Wall Pickup: K2 series Pickup automobile.
  • Page 2 Great Wall company depending on this manual, and we shall not bear any liability for the loss caused by using this manual.Defects and mistakes are inevitable in this manual for limited level of compiler, we sincerely expect you to criticize and correct. Great Wall Motor Co., Ltd has the final explanation right to this manual. Compiler June 2006 PDF 文件使用...
  • Page 3 Chassis and vehicle body Service manual Overview Vehicle parameters Fuel supply system and exhaust system Clutch Transmission Transfer case Drive shaft Suspension system and axle Braking system Steering system Vehicle body electrical equipment system Air conditioning system Vehicle body PDF 文件使用 "pdfFactory" 试用版本创建 www.fineprint.com.cn...
  • Page 4 OV-1 Overview Page How to use this manual........... OV-2 Identification number position ........OV-3 Integrated repair instruction .......... OV-4 PDF 文件使用 "pdfFactory" 试用版本创建 ÿ www.fineprint.com.cn...
  • Page 5 Overview — How to use this manual OV-2 How to use this manual In order to help you find the contents of this manual more easily, chapter name and main title are given on the top of each page. In order to introduce maintenance items for you, index is given on the first page of each chap ter.
  • Page 6 Overview — Identification number position OV-3 This format can help experienced technical personnel quickly find out the source of trouble. Repair personnel can browse operation title and refer to the detailed instructions under it if necessary. Important specification and warning are written with boldface. Specification In the whole manual, the corresponding specification is given with boldface for each repair step, so you do not need to stop repair...
  • Page 7 Overview — Integrated repair instruction OV-4 Integrated repair instruction Protect all the paint coating and seats with clean cloth and ● polythene to prevent dust and scratches. Concentrate yourself and be careful in working. After lifting ● front and rear wheels, wedge the wheels not lifted reliably. If two or more persons work together, communicate with each other as much as possible.
  • Page 8 Overview — Integrated repair instruction OV-5 Parts no longer for use after service ● When reassembling parts, use new packing, gasket, O seal ring and cotter pin. Parts no longer for use after service are marked with “ ◆ ” symbol in part drawing. Do not continue using old parts needing replacement and it is ●...
  • Page 9 Overview — Integrated repair instruction OV-6 In order to facilitate reassembling the hose, add labels in disconnecting to help recognize. Inspect carefully after finishing the work to ensure the vacuum hose is connected correctly. When using vacuum gauge, do not connect the hose to oversized joint compulsively.
  • Page 10 Overview — Integrated repair instruction OV-7 Trouble shooting instruction on electrical equipment malfunction Before trouble shooting ● Check corresponding fuse/fuse in the relay box. Check charging status of the battery, whether the battery is damaged, and clean, and tighten the connector. Note: Do not perform quick charge to the battery if the battery ground cable is not cut, or the diode of...
  • Page 11 Overview — Integrated repair instruction OV-8 4. Dismounting of the harness Wrong Wrong When dismounting the harness, check the wiring and tightening of the harness before operating to reassemble the parts correctly. It is absolutely forbidden to distort, extend or loosen the harness.
  • Page 12 Overview — Integrated repair instruction OV-9 Assembling and disassembling of the clip ● The method to assemble and disassemble vehicle body parts is shown as the table below. Remark: if this clip is damaged during operating, replace new clip. Shape Disassembling/assembling Jaw vice Clip detacher...
  • Page 13 OV-10 Continued table: Shape Disassembling/assembling Disassembling assembling Screwdriver Pressing Clip detacher Push out the king pin and remove it, and prize off the king pin bush. Disassembling assembling Screwdriver Pressing Clip detacher Screw off the king pin and prize off the king pin bush. Disassembling assembling Pressing...
  • Page 14: Table Of Contents

    PA-1 Complete Vehicle parameters page Complete vehicle type ..............PA-2 Complete vehicle basic parameters ........... PA-3 Dimension and weight parameters ......... PA-3 Complete vehicle basic performance parameters ....PA-4 PA-6 Structure and performance parameters of main assembly Vehicle body dimension schematic diagram ......PA-7 PDF 文件使用...
  • Page 15: Complete Vehicle Type

    Complete vehicle type Two wheels drive Four wheels drive Two wheels drive Left rudder Right rudder Left rudder Right rudder Left rudder Right rudder CC1031PS40 CC1031PS50 CC1031PS60 CC1031PS70 CC1031PS41 CC1031PS51 Complete vehicle basic parameters Dimension and weight parameters Type code CC1031PS40...
  • Page 16: Complete Vehicle Basic Performance Parameters

    Complete vehicle parameters page — Complete vehicle basic parameters PA-3 Complete vehicle basic performance parameters Type code CC1031PS40 CC1031PS60 CC1031PS41 Engine model GW2.8TC-2 Delivery capacity(L) 2.771 Rated power / rotating speed(kw/rpm) 70/3600 Max. torque / rotating speed (Nm/rpm) 225/1800~2000 ≥140 Max.
  • Page 17 Complete vehicle parameters page — Complete vehicle basic parameters PA-4 Main assembly structure and parameters of chassis Type code CC1031PS40 CC1031PS60 CC1031PS41 Type Single dry diaphragm spring Outside diameter of Clutch friction disc ( mm ) Manipulate Hydraulic control Type...
  • Page 18 Complete vehicle parameters page — Complete vehicle basic parameters PA-5 Vehicle body structure type Assembly Structure parameters Vehicle body type Body-chassis frame construction, double seats White vehicle body All-metal closed structure Push, four doors open, panel door lock, hinge, central control door lock, Vehicle Door assembly electric window regulator...
  • Page 19 Complete vehicle parameters page — Complete vehicle basic parameters PA-6 Electrical system structure and parameters System Structure parameters Circuit Single wire, cathode earth, DC voltage 12V Generator 90A, with vacuum pump, built-in regulator Power supply, startup and Starter 12V,2.8KW charging system Air conditioning system 2-speed Battery...
  • Page 20: Vehicle Body Dimension Schematic Diagram

    Complete vehicle parameters page — Vehicle body dimension schematic diagram PA-7 Vehicle body dimension schematic diagram (Two-dimensional distance size) PDF 文件使用 "pdfFactory" 试用版本创建 www.fineprint.com.cn...
  • Page 21 Complete vehicle parameters page — Vehicle body dimension schematic diagram PA-8 (Two-dimensional distance size) PDF 文件使用 "pdfFactory" 试用版本创建 www.fineprint.com.cn...
  • Page 22 FE-1 Fuel supply system and exhaust system Page Fuel supply system: Trouble shooting ............FE-2 Fuel supply system ............. FE-3 Removal of fuel tank and supporting plate ....FE-4 Removal of oil filler assembly ........FE-5 Removal of fuel sensor assembly bracket ....FE-5 Exhaust of fuel supply system ........
  • Page 23: Trouble Shooting

    FE-2 Fuel supply system and exhaust system—Trouble shooting Trouble shooting Trouble Causes Countermeasures Engine does not start after Air in the system Loosen the air bleed bolt of the fuel filter and disassembling and assembling continuously press the hand fuel pump manually to of fuel supply system discharge air Engine does not start...
  • Page 24: Fuel Supply System

    Fuel supply system and exhaust system — Fuel supply system FE-3 Fuel supply system Part drawing Accelerator pedal bracket M6 bolt 9-12 M6 nut ★ Fuel pump gland Accelerator pedal Fuel sensor bracket as- Oil filler assembly sembly Fuel tank cap steel wire elastic hoop ★...
  • Page 25: Removal Of Fuel Tank And Supporting Plate

    Fuel supply system and exhaust system — Removal of fuel tank and supporting plate FE-4 Removal of fuel tank and supporting plate Note: When repairing the fuel supply system, remove the oil line and release the pressure of the fuel system to prevent the injection of high-pressure fuel.
  • Page 26: Removal Of Oil Filler Assembly

    Fuel supply system and exhaust system —Removal of oil filler assembly FE-5 Removal of oil filler assembly 1. Remove bolt Q2214216A fixed in the body with cross screwdriver. 2. Take down the fuel tank opening cable 3. Remove the left rear wheel fender shield 4.
  • Page 27: Exhaust Of Fuel Supply System

    Fuel supply system and exhaust system — Replacement of fuel filter element FE-6 Exhaust of fuel supply system Loosen the air bleed bolt of the fuel filter with No.10 wrench and press the hand fuel pump upwards and downwards until the fuel coming from the bolt has no air bubble.
  • Page 28: Exhaust System

    Fuel supply system and exhaust system — Exhaust system FE-7 Exhaust system Part drawing Exhaust elbow gasket joint Muffler gasket Exhaust elbow bolt Three-hole rubber block Front exhaust pipe Muffler assembly Three-hole rubber block Hexagon flange nut Muffler gasket Three-hole rubber block Hexagon flange bolt Middle exhaust pipe Three-hole rubber block...
  • Page 29: Removal Of Exhaust Pipe Assembly

    Fuel supply system and exhaust system — Removal of exhaust pipe assembly FE-8 Removal of exhaust pipe assembly Warning: the removal of all parts of exhaust system is required to be performed after parking for 30 minutes to prevent personnel injury caused by high-temperature parts. 1.
  • Page 30: Installation Of Exhaust Pipe Assembly

    Fuel supply system and exhaust system — Installation of exhaust pipe assembly FE-9 5. Take down the three-hole rubber block in front, middle and back of the muffler in order so as to take out the muffler, and in performing this operation, a person must prop the muffler specially to prevent its falling and injuring the operator.
  • Page 31 CL-1 Clutch Page Trouble shooting ............CL-2 Inspection and adjustment of clutch pedal ....CL-3 Air bleed of clutch ............CL-3 Clutch control mechanism .......... CL-4 Clutch set ..............CL-6 PDF 文件使用 "pdfFactory" 试用版本创建 ÿ www.fineprint.com.cn...
  • Page 32: Trouble Shooting

    Clutch — Trouble shooting CL-2 Trouble shooting Trouble Causes Countermeasures Hard to shift or Clutch pedal free travel too large Adjust free pedal travel will not shift Air in the clutch pipeline Discharge the air in clutch system Trouble of clutch wheel cylinder Replacement Trouble of clutch master cylinder Replacement...
  • Page 33: Inspection And Adjustment Of Clutch Pedal

    Clutch — Inspection and adjustment of clutch pedal,Air bleed of clutch CL-3 Inspection and adjustment of clutch pedal 1. Check the pedal height is correct The pedal height calculated from dash board: Adjust the pedal height if it is not correct. Pedal height 2.
  • Page 34: Clutch Control Mechanism

    Clutch — Clutch control mechanism CL-4 Clutch control mechanism Part drawing Clutch master cylinder fuel pipe Clutch master cylinder 25-30 Plastic clip 23 ± 3 Spring clip Clutch hose bracket set Clutch wheel cylinder Open retainer Clutch hose 30-40 Seal washer 30 ±...
  • Page 35 Clutch — Clutch control mechanism CL-5 Removal of clutch master pump and wheel pump 1. Drain off the clutch fluid Remove the hose connection hole bolt with specification of 16 open wrench, and cover the wheel pump oil outlet with cloth to prevent the brake oil spattering, and continuously depress the clutch pedal several times to drain off the clutch fluid.
  • Page 36: Clutch Set

    Clutch — Clutch set CL-6 Clutch set Part drawing Release rocker ball support Release bearing assembly Abnormal type spring Release rocker set 30-40 Clutch pressure plate assembly Clutch driven plate assembly N · m : Specified torque Removal of clutch set 1.
  • Page 37 Clutch — Clutch set CL-7 Inspection of clutch parts 1. Check the clutch plate is worn or damaged. Measure the rivet head depth with calipers. Min. rivet head depth: 0.3mm If the rivet head depth exceeds the limit, replace the clutch plate.
  • Page 38 Clutch — Clutch set CL-8 Install the guide bearing with special serrice tools. Remark: after encasing the guide bearing into the flywheel hub, ensure the bearing is in perfect operating status. 6. Check the diaphragm spring is worn. Check the depth and width of the diaphragm spring abrasion with calipers.
  • Page 39 Clutch — Clutch set CL-9 3. Check the height at the disengaging pawl of the diaphragm spring is consistent. Check the difference in height at the disengaging pawl of the diaphragm spring with special serrice tools. Allowable height change limit: 0.5mm If the difference in height exceeds the specified value, adjust with special serrice tools.
  • Page 40 MT-1 Transmission Page Structure drawing ............MT-2 Precautions ..............MT-2 Trouble shooting ............MT-3 Disassembling of the transmission ......MT-4 Input shaft assembly ........... MT-12 Part drawing ............MT-12 MT-12 ....Inspecting the synchronizing ring Replacing the bearing ..........MT-12 Output shaft assembly ..........
  • Page 41: Structure Drawing

    transmission - Structure drawing, Precautions MT-2 Structure drawing This product is manual mechanical triaxial transmission, and the control form is floor type direct control, and there are 5 forward gears with lock loop type full synchronization and 1 reverse gear with sliding type; this product applies separation structure with complete aluminium alloy housing, and the gear applies small module and slimness tooth;...
  • Page 42: Trouble Shooting

    transmission - Trouble shooting MT-3 Trouble shooting Trouble type Possible causes Eliminating methods Noise too loud or Bearing damaged Replacing the bearing abnormal Gear tooth face knocked or eroded Repairing or replacing the gear Gear axial position or clearance improper or inside Check, repair and adjustment parts scratched Lubricant level too low or lubricating insufficient...
  • Page 43: Disassembling Of The Transmission

    transmission - Disassembling of the transmission MT-4 Disassembling of the transmission 1. Remove the release fork and release bearing 2. Remove the backup lamp switch and odometer driven gear 3. Remove the clutch housing from the transmission case Remove the 9 bolts. 4.
  • Page 44 transmission - Disassembling of the transmission MT-5 8. Remove the front cover Remove the 8 bolts, and remove the front cover and the front cover oil seal. 9. Remove the bearing stop rings of input shaft and intermediate shaft. 10. Take apart the transmission case from the middle coupling plate Put the transmission straight as shown in the drawing.
  • Page 45 transmission - Disassembling of the transmission MT-6 Remove 1 and 2 and 4 and reverse gear fork shaft and 5 gear fork shaft set spring and lock ball. 13. Remove the gear-shifting forked axle retainer Gently turn and extract the gear-shifting forked axle retainer with 2 screwdrivers and 1 hammer.
  • Page 46 transmission - Disassembling of the transmission MT-7 15. Remove 5 reverse gear shift guide block and 5 reverse gear shift forked axle. Take out the interlock steel ball from the 5 reverse gear shift guide block. Remove 5 reverse gear shift guide block and 5 reverse gear shift fork.
  • Page 47 transmission - Disassembling of the transmission MT-8 18. Remove the 1 and 2 gear shift fork. Take out the 5 reverse gear shift fork and 1 and 2 gear shift fork interlock pin and interlock guide column with bar magnet. Remove the 1 and 2 gear shift fork location bolt.
  • Page 48 transmission - Disassembling of the transmission MT-9 20. Remove the 5 shift coupling gear, 5 gear synchronizer assembly, 5 shift gear set, 5 shift gear thrust washer and 5 gear needle bearing. Gently tap out the intermediate shaft rear shaft retainer with 2 screwdrivers and 1 hammer.
  • Page 49 transmission - Disassembling of the transmission MT-10 Remove the reverse gear idler and reverse gear idler shaft. 24. Remove the rear bearing baffle of the output shaft Remove 4 bolts with torque socket wrench. Remove the rear bearing baffle of the output shaft. 25.
  • Page 50 transmission - Disassembling of the transmission MT-11 27. Remove the output shaft Remove the rear bearing stop ring of the output shaft with split ring pliers. Pull out the output shaft with hands and gently knock the middle coupling plate with rubber mallet at the same time, and remove the output shaft from the middle coupling plate.
  • Page 51: Input Shaft Assembly

    transmission - Input shaft assembly MT-12 Input shaft assembly Part drawing Needle bearing Input shaft Bearing Bearing stop ring Retainer Synchronizing ring Inspecting the synchronizing ring 1. Turn the synchronizing ring and push it into to check its braking effect. 2.
  • Page 52 transmission - Input shaft assembly MT-13 2. Prize out the input shaft bearing with forcing machine 3. Install the new bearing with forcing machine and special serrice tools. 4. Select the retainer to achieve the min. axial clearance Remark: the clearance value should not be more than 0.1mm. 5.
  • Page 53: Output Shaft Assembly

    transmission - Output shaft assembly MT-14 output shaft assembly Part drawing and 4 gear synchronizer engagement sleeve and 4 shift gear needle bearing Synchronizer sliding block Synchronizer spring piston ring shift gear set Steel ball Synchronizer ring Steel ball Shaft retainer and 4 synchronizer hub Output shaft...
  • Page 54: Disassembling Of The Output Shaft Assembly

    transmission - Output shaft assembly MT-15 Disassembling of the output shaft assembly 1. Remove the odometer drive gear Prize out the retainers at both ends with split ring pliers. Remove the odometer drive gear Take out the lock ball with bar magnet. 2.
  • Page 55: Inspection Of The Output Shaft Assembly

    transmission - Output shaft assembly MT-16 7. Remove the 3 and 4 gear synchronizer assembly, 3 shift gear and needle bearing Remove the split ring with split ring pliers. Remove the 3 and 4 gear synchronizer assembly and shift gear with the forcing machine. Remove the needle bearing.
  • Page 56 transmission - Output shaft assembly MT-17 Measure the flange thickness of the 1 shift gear bush with calipers. Min. thickness: 3.99mm (c) Measure the outer diameter of the output shaft journal with micrometer. At 2 shift gear: 37.974mm At 3 shift gear: 34.974mm Measure the outer diameter of the 1 shift gear bush...
  • Page 57: Assembling Of The Output Shaft Assembly

    transmission - Output shaft assembly MT-18 5. Measure the clearance between the shift fork and engagement sleeve Measure the clearance between the gear sleeve and the shift fork with a clearance gauge. Max. clearance: 1.0mm Assembling of the output shaft assembly 1.
  • Page 58 transmission - Output shaft assembly MT-19 3. Install the shaft retainer Choose a shaft retainer that could make the min. axial clearance (clearance value not more than 0.1mm), and install it on the shaft. 4. Measure the axial clearance of 3 shift gear set Measure the axial clearance of 3 shift gear set with clearance...
  • Page 59 transmission - Output shaft assembly MT-20 7. Install the lock ball and 1 shift gear set Encase the lock ball into the shaft. Coat gear oil on the 1 shift gear needle bearing. Install the 1 shift gear set, synchronizing ring, needle bearing and 1 shift gear bush.
  • Page 60 transmission - Output shaft assembly MT-21 11. Measure the axial clearance of the 1 shift gear Measure the axial clearance of the 1 shift gear with clearance gauge. Standard clearance: (0.1-0.25) mm 12. Install the odometer drive gear Install the lock ball and the drive gear. Install the odometer drive gear retainer with shaft retainer pliers.
  • Page 61: Disassembling, Inspection And Assembling Of The Intermediate Shaft Assembly

    transmission - Intermediate shaft assembly and reverse gear idler assembly MT-22 Intermediate shaft assembly and reverse gear idler assembly Part drawing Intermediate shaft rear bearing Front bearing stop ring of the intermediate shaft Intermediate gear shaft Rear bearing stop ring of the intermediate shaft Steel ball Intermediate shaft front bearing Reverse gear idler shaft...
  • Page 62 transmission - Intermediate shaft assembly and reverse gear idler assembly MT-23 3. Check the journal diameter at the intermediate shaft 5 gear needle bearing installation position Measure the needle bearing diameter with micrometer. Allowable limit diameter: 25.975 mm 4. Inspect the synchronizing ring Turn the shaft retainer and push it into to check its braking action.
  • Page 63: The Assemblage Of Reverse Gear Assembly

    transmission - Intermediate shaft assembly and reverse gear idler assembly MT-24 Press in the bearing, side ring and inner race with socket wrench. Socket wrench Choose a split ring that could make the min. axial clearance, and install it on the shaft. 7.
  • Page 64: Rear Housing Assembly

    transmission - Rear housing assembly MT-25 Rear housing assembly Part drawing Rear housing set Rear housing dust cap Limit mechanism set Rear housing oil seal subassembly Guide oil groove Set spring screw plug and elastic straight pin Reservoir Replacing the oil seal 1.
  • Page 65: Inspection And Replacement Of Limit Mechanism Set

    transmission - Rear housing assembly MT-26 Inspection and replacement of limit mecha- nism set 1. Remove the limit mechanism set Remove the screw plug with torque socket wrench. Drift out the elastic straight pin with drift pin and hammer. Remove the limit mechanism set 2.
  • Page 66 transmission - Rear housing assembly MT-27 Coat sealant on the screw plug thread. Fasten the screw plug with torque socket wrench. PDF 文件使用 "pdfFactory" 试用版本创建 www.fineprint.com.cn...
  • Page 67: Bearing Front Cover

    transmission - Bearing front cover MT-28 Bearing front cover Part drawing ★ Front cover assembly Front cover oil seal assembly ★ Precoat parts Replacing the oil seal Replace the bearing front cover oil seal if necessary Prize out the oil seal with screwdriver. Press in the new oil seal with special service tool.
  • Page 68: The Assembling Of The Transmission

    transmission - The assembling of the transmission MT-29 The assembling of the transmission 1. Encase the output shaft into the middle coupling plate Pull out the output shaft and drive in the middle coupling plate at the same time, and encase the output shaft into the middle coupling plate.
  • Page 69 transmission - The assembling of the transmission MT-30 Encase the intermediate gear shaft into the middle coupling plate and hold the intermediate gear shaft at the same time, and install the intermediate shaft rear bearing with special service tool. 4. Install the output shaft rear bearing baffle Install and fasten the bolt with torque socket wrench.
  • Page 70 transmission - The assembling of the transmission MT-31 7. Install the steel ball and 5 shift gear thrust washer. Lock ball 8. Install the 5 shift gear set Coat gear oil on the needle bearing. Install the 5 shift gear set 9.
  • Page 71 transmission - The assembling of the transmission MT-32 10. Install the split ring Choose a shaft retainer that could make the min. axial clearance, and the clearance value should not be more than 0.1mm. Encase the shaft retainer with bar copper and hammer. 11.
  • Page 72 transmission - The assembling of the transmission MT-33 13. Install the 1 and 2 gear shift forked axle and 1 gear shift fork Coat the grease on the interlock guide column, and install it on the 1 and 2 gear shift forked axle. Encase the short interlock pin into the middle coupling plate with bar magnet.
  • Page 73 transmission - The assembling of the transmission MT-34 Encase the long interlock pin into the middle coupling plate with bar magnet. Encase the reverse gear shift forked axle into the reverse gear deflector rod and middle coupling plate. Encase the elastic straight pin with drift pin and hammer. 15.
  • Page 74 transmission - The assembling of the transmission MT-35 Encase the pin into the 5 gear shift fork with drift pin and hammer. Encase the 5 reverse gear shift forked axle into the 5 reverse gear shift guide block and middle coupling plate. Encase the elastic straight pin into the 5 reverse gear shift guide block with drift pin and hammer.
  • Page 75 transmission - The assembling of the transmission MT-36 17. Install the steel ball, set spring and set spring screw plug Install the steel ball and set spring. Remark: Encase the short spring into the bottom of the middle coupling plate. Coat sealant on the screw plug thread.
  • Page 76 transmission - The assembling of the transmission MT-37 20. Install the front bearing stop ring Install 2 stop rings on the input shaft bearing and intermediate shaft front bearing with snap ring pliers. Install the front cover set coated with sealant. Coat sealant on the bolt thread.
  • Page 77 transmission - The assembling of the transmission MT-38 Install and fasten the gear shift block set bolt. Tightening torque: (15-20)N·m 22. Install the steel ball, spring and screw plug Coat sealant on the screw plug thread. Install the steel ball, set spring and set spring screw plug Tightening torque: (17-22)N·m 23.
  • Page 78 TF-1 Transfer case Page Precautions ..............TF-2 Trouble shooting ............TF-3 Product instruction and simple maintenance ....TF-5 Disassembling and assembling of the transfer case ... TF-7 Disassembling of the transfer case ......TF-9 Cleaning, inspection, repair and replacement ....TF-14 Cleaning ..............
  • Page 79: Precautions

    Transfer case — Precautions TF-2 Precautions Precautions for disassembling and assembling of the transfer case During disassembling of the transfer case, pay attention to handle each part with care to avoid knock, especially the junction plane; put each part in order so as to prevent loss and wrong taking. When assembling, except the above precautions, the following should be noticed: 1.
  • Page 80: Trouble Shooting

    Transfer case — Trouble shooting TF-3 Trouble shooting Common trouble Causes Eliminating methods Electric shift trouble Electrical control element, electrical Refer to vehicle operation manual, and control module, speed sensor, diagnose the ineffective element and electrical motor, electrical clutch or replace it as required.
  • Page 81 Transfer case — Trouble shooting TF-4 Troubleshooting (continued) Common trouble Causes Eliminating methods No front wheel drive when Driving chain broken. Disassemble and check the damage condition putting into four wheel drive of the inner parts, and replace the chain. Noise with all gears, the Incorrect lubricant or lubricating Replace lubricant or refill the amount as...
  • Page 82: Product Instruction And Simple Maintenance

    - TF-5 Transfer case Product instruction and simple maintenance Product instruction and simple mainte- nance 1. Product instruction This company applies Borg Warner 45-55 transfer case. It is 2-speed part-time drive, and a set of planetary mechanism aims to realize decelerating, and the power is passed to the front drive wheel through 1 high precision chain.
  • Page 83 Transfer case - Product instruction and simple maintenance TF-6 2. Replacing the lubricant regularly When replacing the engine lubricant or after driving 8000 km, check the transfer case oil level and refill the lubricant according to need. Every year or every 48000km, replace with specified lubricant.
  • Page 84: Disassembling And Assembling Of The Transfer Case

    Transfer case - Disassembling and assembling of the transfer case TF-7 Disassembling and assembling of the transfer case 1.Input shaft 2. Transfer case front housing 3.Transfer case rear cover 4.Flange plate 5.Front output shaft flange plate 6.Breather valve 7.Shim 8.Transmission rear housing 9.
  • Page 85 Transfer case - Disassembling and assembling of the transfer case TF-8 transmission. Do not force the transfer case Fill correct brand lubricant. spline to press into the transmission. Otherwise, Note: in engine starting, not filling correct lubricant damage may be caused. Rotate the transfer rear and appropriate lubricant amount as required will output shaft if necessary to make it align with cause the damage of the transfer case.
  • Page 86: Disassembling Of The Transfer Case

    Transfer case - Disassembling of the transfer case TF-9 Disassembling of the transfer case 1. Simple instruction As to the transfer case, if only the damaged part is repaired, disassemble the transfer case to the extent that this damaged part could be taken out. The part disassembled from the transfer case could be either subassembly or full group, and it is not necessary to take it apart unless it contains damaged parts.
  • Page 87 Transfer case - Disassembling of the transfer case TF-10 1.Transfer case front housing 2.Rear output shaft 3.Clutch coil assembly 4.Snap ring 5.Bearing 6.Nut 7.Transfer case cover assembly 8.Sign panel 9.Bolt 10.Odometer drive gear 11.Oil seal 12.Oil seal 13. Bearing 14.Transfer case rear cover 15.Needle bearing 16.Shift guide shaft 17.
  • Page 88 Transfer case - Disassembling of the transfer case TF-11 Remove the shift lock hub from rear output shaft. Remove the shift engagement sleeve assembly and shift fork from rear output shaft and shift guide shaft. Disconnect all assemblies and remove the shift guide shaft.
  • Page 89 Transfer case - Disassembling of the transfer case TF-12 8. Front output assembly Remove the following parts from residual transfer case housing assembly. Fix the front flange plate, screw off the nut and remove the shim, and pluck out the front flange plate assembly and the seal ring.
  • Page 90 Transfer case - Disassembling of the transfer case TF-13 10. Disassemble the shift flange parts (for electric shift transfer case) Remove the electric shift cam set as a whole from the transfer case housing. Remove the electric shift cam from the shift guide shaft. Clamp the end of the shift guide shaft with soft mouth jaw vice, and knock with a bolt driver to disconnect the torsion spring and remove it.
  • Page 91: Cleaning, Inspection, Repair And Replacement

    Transfer case - Cleaning, inspection, repair and replacement TF-14 Cleaning, inspection, repair and replacement Cleaning 1. Cleaning Note: before cleaning, firstly check the metal chips condition, and big, small, granular or irregular granular metal chips indicate the crack or similar damage. Smaller and powdery chips indicate uneven or excessive abrasion.
  • Page 92: Inspection

    Transfer case - Cleaning, inspection, repair and replacement TF-15 Inspection 1. General inspection process Visually check all the parts (except the parts that should be replaced by new ones such as oil pump oil pipe, O ring and oil seal etc) are damaged or excessively and unevenly worn. Abandon the damaged or worn parts that will affect performance.
  • Page 93 Transfer case - Cleaning, inspection, repair and replacement TF-16 Check the tooth contact zone form of gear or sprocket tooth as the following way: Optimal tooth contact zone. It is allowable for contact zone deviating toward one side. It is not allowable for contact zone deviating toward one side, and replacement is necessary.
  • Page 94 Transfer case - Cleaning, inspection, repair and replacement TF-17 It is allowable for contact zone deviating toward addendum. It is not allowable for contact zone deviating toward addendum, and replacement is necessary. It is allowable for contact zone deviating toward dedendum.
  • Page 95: Repair Or Replacement Of Gear And Sprocket Tooth

    Transfer case - Cleaning, inspection, repair and replacement TF-18 Repair or replacement of gear and sprocket tooth 1. Repair principle Repair the partial small block flaking with appropriate manual high-speed grinding tool. When grinding matrix metal, try your best not to remove more metal.
  • Page 96: Attached List On Parts Inspection, Repair And Replacement Standard

    Transfer case - Cleaning, inspection, repair and replacement TF-19 It is maintainable for the inbreak of the middle part of the interface side. If the middle part of the contact zone is flaked, replace this gear. For inbreak of two sides of the addendum, replace this gear.
  • Page 97 Transfer case - Cleaning, inspection, repair and replacement TF-20 Attached list on parts inspection, repair and replacement standard Parts (items) Inspection Accept/reject Ball bearing Visually check there is flaking, pasting, Reject damaged bearing pitting corrosion or other damages with Reject damaged or loosened bearing the ball and ball race of the bearing.
  • Page 98 Transfer case - Cleaning, inspection, repair and replacement TF-21 Parts (items) Inspection Accept/reject Driving chain Check the step slipping, loosening or the Reject the drive sprocket with abrasion or damage of the pin or connecting parts damage Filter screen Check the filter screen is clean and there is Clean it if necessary;...
  • Page 99: The Assemblage Of The Transfer Case

    Transfer case - The assemblage of the transfer case TF-22 The assemblage of the transfer case 1. Overview During assembling, please refer to specified instruction in this chapter. In assembling, pay attention to the following problrms: When there is requirement for the torque of thread parts, screw down the thread parts with torque wrench.
  • Page 100 Transfer case - The assemblage of the transfer case TF-23 4. The assembling of mechanical shift flange parts ( electric shift transfer case) For electric shift parts assembly, the installing process is as follows: Insert the shim into the inner diameter of the torsion spring and make it run through the free end of the shift shaft.
  • Page 101 Transfer case - The assemblage of the transfer case TF-24 Try your best to push the torsion spring and shim backwards together. Install the electric shift cam on the shift shaft, and make the end with drive tongue on the cam enter first. Fix the drive tongue of the cam under the drive tongue of the shift shaft and make it between two torsion springs at the same time, and make it enter as interior as possible.
  • Page 102 Transfer case - The assemblage of the transfer case TF-25 If the parts are removed, place the needle bearing as 1.25-1.75mm shown in the drawing and press into the input shaft. At the same time, press into the new sliding bearing as shown in the drawing to finish the whole input shaft assembly.
  • Page 103 Transfer case - The assemblage of the transfer case TF-26 7. The assembling of the decelerating shift parts. The installing process of parts is as follows: If the disassembled parts are replaced, assemble the shift fork assembly with new pin contact roller assembly. Press the pin contact roller assembly into the decelerating fork hole until the pin is completely through and clipped at position.
  • Page 104 Transfer case - The assemblage of the transfer case TF-27 10. The assembling of the shift lock parts The assembling process of parts is as follows (for electric shift transfer case): Install the return spring, engagement sleeve on the lock sleeve and fix with snap ring to finish 2W-4W lock sleeve assembly.
  • Page 105 Transfer case - The assemblage of the transfer case TF-28 11. The assembling of rear cover Install the parts into the rear cover, and the process is as follows: Put the rear cover on appropriate press machine with the junction plane toward upward and parallel to the working surface of the press machine.
  • Page 106 Transfer case - The assemblage of the transfer case TF-29 After putting the sign panel, screw down 9 bolts. Tightening torque: (27-46)N·m Encase the odometer drive gear into the rear cover assembly through rear output shaft spline. Press new oil seal into the rear cover assembly. 1.Harness clip 2.Motor assembly 3.Bolt...
  • Page 107 Transfer case - The assemblage of the transfer case TF-30 13. The assembling of the flange plate parts The installing process of parts is as follows: Install two oil plugs on the rear cover. Encase the flange plate, seal ring, shim and tightening nut.
  • Page 108 PR-1 Drive shaft page Precautions ..............PR-2 Trouble shooting ............PR-2 Drive shaft ..............PR-3 PDF 文件使用 "pdfFactory" 试用版本创建 www.fineprint.com.cn...
  • Page 109 Drive shaft — Precautions ,Trouble shooting PR-2 Precautions Note: do not clip the drive shaft pipe casing too tightly with leg vice to prevent causing deformation. Trouble shooting Trouble Possible causes Eliminating methods The spline of universal joint fork worn Replacement Noise Intermediate bearing worn...
  • Page 110 Drive shaft — Drive shaft PR-3 Drive shaft Part drawing Drive shaft assembly (2WD) Sliding yoke assembly Front part of the rear axle drive shaft Center support assembly Spline yoke Circlip Rear part of the rear axle drive shaft Flange yoke 80 ±...
  • Page 111 Drive shaft — Drive shaft PR-4 Removal of the drive shaft Firstly remove the center support bolt of the drive shaft, then remove the connection bolt of the drive shaft and rear axle, and then Two wheel drive: Take out the drive shaft assembly from the transmission output spline shaft, and remove them as a whole.
  • Page 112 SA-1 Suspension system and vehicle axle Page Trouble shooting ............SA-2 Front wheel alignment ..........SA-3 (2WD) Front wheel hub and steering knuckle ......SA-6 Front wheel hub and steering knuckle(coil spring type) SA-13 Front suspension ............SA-19 Front suspension(coil spring type) ......SA-33 (4WD) Front wheel hub and steering knuckle ......
  • Page 113: Trouble Shooting

    SA-2 Suspension system and vehicle axle—Trouble shooting Trouble shooting Phenomena of Happened reason Contents of repair troubles Swim/drag Tyres have been worn or charged improperly Charge tyres to proper pressure or change them Wheel alignment is wrong Check the situation of wheel alignment Wheel bearing is tightened too much Adjust wheel bearing Parts on front/rear suspension have been loosened...
  • Page 114: Front Wheel Alignment

    Suspension system and vehicle axle — Front wheel alignment SA-3 Front wheel alignment 1. Make following inspections to remove all malfunctions Check whether abrasion and charge of tyres are proper Charged pressure of tyres: (refer to page PA-4) Check whether front wheel bearing has been loosened Check whether front suspension has been loosened.
  • Page 115 Suspension system and vehicle axle — Front wheel alignment SA-4 5. Adjust camber angle of front wheels and kingpin Kingpin caster angle caster angle Camber angle of front wheels camber angle of front wheels:(refer to page PA-2) kingpin caster angle: (refer to page PA-2) Front If obliquity is not at regulated value, adjust it by increasing or decreasing shim on upper arm.
  • Page 116 Suspension system and vehicle axle — Front wheel alignment SA-5 (d) Move vehicle ahead to make the mark on rear part of tyres move to the height on front part which could be measured by device. Move vehicle ahead Remark: if tyres roll too far, repeat step (b). Measure the distance between the marks on front parts of tyres.
  • Page 117: Front Wheel Hub And Steering Knuckle

    SA-6 Suspension system and vehicle axle(2WD)— Front wheel hub and steering knuckle Front wheel hub and steering knuckle Part drawing Stabilizer bar ◆ Spring washer ◆ 63 ± 5 140 ± 10 Upper swing arm Plate braking pliers Flat washer ◆...
  • Page 118 Suspension system and vehicle axle(2WD)— Front wheel hub and steering knuckle SA-7 Front wheel hub Disassembly of front wheel hub 1. Dismantle plate braking pliers Dismantle braking pliers and hang it with tightwire. Remark: do not dismantle braking soft pipe and braking pipe 2.
  • Page 119 SA-8 Suspension system and vehicle axle(2WD)— Front wheel hub and steering knuckle 4. Dismantle oil seal of front wheel hub and inner bearing Prize the oil seal with screwdriver. Dismantle inner ring on inner bearing from wheel hub. Inspection and repair of front wheel hub 1.
  • Page 120 Suspension system and vehicle axle(2WD)— Front wheel hub and steering knuckle SA-9 Brief chart of special 3. Install inner bearing and oil seal serrive tools Put inner bearing in wheel hub. Hit new oil seal in wheel hub with special serrive tool. Spread HP-R lubricating grease on lip of oil seal.
  • Page 121 SA-10 Suspension system and vehicle axle(2WD)— Front wheel hub and steering knuckle 7. Check pre-load again Check pre-load again with spring tensometer Pre-load (when starting): (28-56)N If pre-load does not accord with regulated value, it is necessary to dismantle stop shim and adjust with adjusting nut. 8.
  • Page 122 Suspension system and vehicle axle(2WD)— Front wheel hub and steering knuckle SA-11 4. Take off connecting rod of stabilizer bar from lower arm Fix the sphere pin with inner hexagon wrench, then dismantle self locking nut. 5. Dismantle steering knuckle Dismantle cotter pin and nuts on upper sphere pin.
  • Page 123 SA-12 Suspension system and vehicle axle(2WD)— Front wheel hub and steering knuckle (b) Press down upper arm to link upper sphere pin to steering knuckle, and install and screw nuts by regulated moment. Screwing moment: (145±15)N·m Install new cotter pin. Remark: when installing cotter pin, head the notch on nut to pin hole correctly, at this time, nut must be tight.
  • Page 124: Front Wheel Hub And Steering Knuckle(Coil Spring Type

    Suspension system and vehicle axle(2WD)— Front wheel hub and steering knuckle SA-13 Front wheel hub and steering knuckle(coil spring type) Part drawing Upper swing arm ◆ Spring gasket Front braking pliers 140 ± 10 145 ± 15 Lower swing arm ◆...
  • Page 125 SA-14 Suspension system and vehicle axle(2WD)— Front wheel hub and steering knuckle 2. Dismantle the cover of front wheel hub Dismantle the cover of front wheel hub from the gap touched by cover and front wheel hub with slot type screwdriver. 3.
  • Page 126 Suspension system and vehicle axle(2WD)— Front wheel hub and steering knuckle SA-15 Connect front wheel hub with bolts on front braking plate and new spring washer, and screw to regulated moment with the moment diagonal wrench Screwing moment: (95±5)N·m 3. Change of exterior ring of bearing Hit new exterior ring of bearing in carefully with special serrive tools.
  • Page 127 SA-16 Suspension system and vehicle axle(2WD)— Front wheel hub and steering knuckle Turn wheel hub for 2-3 rings to left a nd right independently. (c) Loosen nut until it could be turned by hand. Tighten locknut again, and tighten bearing in advance. Screwing moment: (25±5)N·m Bring wheel hub to rotate at constant speed(45/4s)...
  • Page 128 Suspension system and vehicle axle(2WD)— Front wheel hub and steering knuckle SA-17 Steering knuckle Disassembly of steering knuckle 1. Dismantle braking pliers, front wheel hub and front braking plate. 2. Dismantle cover shell of front arrester. Dismantle the connecting bolt of steering knuckle and cover shell.
  • Page 129 SA-18 Suspension system and vehicle axle(2WD)— Front wheel hub and steering knuckle Press down upper arm, install steering knuckle on upper sphere pin and install nuts. Screw sphere pin nuts by regulated moment. Regulated moment: (145±15)N·m Screw lower sphere pin nuts by regulated moment. Regulated moment: (230±20)N·m Install new cotter pin on upper and lower sphere pin.
  • Page 130: Front Suspension

    Suspension system and vehicle axle(2WD)—Front suspension SA-19 Front suspension Part drawing Shim 210 ± 10 ★ Upper arm shaft Upper arm bushing Front stabilizer bar 210 ± 10 Upper arm bushing Upper swing arm Shim Rubber cover 63 ± 5 Clamp Upper sphere pin Flat shim...
  • Page 131 SA-20 Suspension system and vehicle axle(2WD)—Front suspension Sphere pin Inspection of sphere pin 1. Check whether sphere pin has been loosened Support front part of vehicle with jack, then hold it with shelf. Insure front wheels locate beeline advancing position, then step down braking pedal.
  • Page 132 Suspension system and vehicle axle(2WD)—Front suspension SA-21 Installation of sphere pin 1. Install upper sphere pin on upper arm Screwing moment: (78±5)N·m 2. Install lower sphere pin on lower arm Screwing moment: (140±10)N·m 3. Install assembly of steering knuckle and front wheel hub (refer to page SA-8) PDF 文件使用...
  • Page 133 SA-22 Suspension system and vehicle axle(2WD)—Front suspension Torsion rod spring Disassembly of torsion rod spring 1. Support vehicle frame with jack and hold it with bracket. 2. Make installing marks on torsion rod spring, torsion seat and adjusting arm. 3. Liking that shown in figure, measure the length of extended segment on bolts.
  • Page 134 Suspension system and vehicle axle(2WD)—Front suspension SA-23 Screw adjusting bolt to make its extended length equal to the value before disassembly. 2. For new torsion rod spring Dismantle wheels. Spread a folium of lithium lubricating grease on spline of torsion rod spring. Install torsion rod spring on torsion rod seat.
  • Page 135 SA-24 Suspension system and vehicle axle(2WD)—Front suspension Lower swing arm Disassembly of lower swing arm 1. Take off connecting rod of stabilizer bar from lower arm Support one side of lower swing arm with jack. Dismantle connecting nut, take off connecting rod of stabilizer bar from lower arm 2.
  • Page 136 Suspension system and vehicle axle(2WD)—Front suspension SA-25 Dismantle nuts and front axle of lower arm. 6. Dismantle rear axle of lower arm Unscrew nuts, dismantle rear axle of lower arm axle and dis- mantle lower swing arm. Change of lower swing arm bush 1.
  • Page 137 SA-26 Suspension system and vehicle axle(2WD)—Front suspension 4. Install lower arm long bush Install lower arm long bush with special serrice tools. Remark: do not spread lubricating grease on bush. Installation of lower swing arm 1. Installation of lower swing arm Install rear axle of lower arm, screw nuts by regulated moment.
  • Page 138 Suspension system and vehicle axle(2WD)—Front suspension SA-27 5. Install torsion rod spring (refer to page SA-22) 6. Screw nuts on lower arm front axle by regulated moment Install wheels, dismantle bracket and make vehicle bounce for several times to make suspension enter in stable statement.
  • Page 139 SA-28 Suspension system and vehicle axle(2WD)—Front suspension Upper swing arm Disassembly of upper swing arm 1. Take off upper sphere pin from steering knuckle Dismantle cotter pin and nut, and take off upper sphere pin from steering knuckle with special serrice tools. 2.
  • Page 140 Suspension system and vehicle axle(2WD) — Front suspension SA-29 Change of upper arm bush 1. Dismantle bush Dismantle bolts and washer. Pull out bush with special special tools. Dismantle upper arm axle, then dismantle the other bush with same method. 2.
  • Page 141 Suspension system and vehicle axle(2WD) — Front suspension SA-30 Screw nuts on upper arm axle by regulated moment. Screwing moment: (210±10)N·m Installation of upper swing arm 1. Install upper swing arm on vehicle frame Install upper hanging arm and extroversion adjusting shim.
  • Page 142 SA-31 Suspension system and vehicle axle(2WD)—Front suspension 5. Link braking soft pipe to braking pliers Install copper seal shim, and screw the bolts of braking soft pipe by regulated moment. Screwing moment: (50±5)N·m 6. Exhaust front braking system (refer to page BA-6) Remark: when dismantling right upper arm, it is necessary to exhaust rear braking system at the same time.
  • Page 143 Suspension system and vehicle axle(2WD)—Front suspension SA-32 Stabilizer bar Disassembly of stabilizer bar 1. Take off connecting rod which supports two sides of stabilizer bar from stabilizer bar . Fix sphere with inner hexagon wrench, then dismantle self tapping nuts. 2.
  • Page 144: Front Suspension(Coil Spring Type

    Suspension system and vehicle axle(2WD)—Front suspension(coil spring type) SA-33 Front suspension(coil spring type) Part drawing Upper swing arm 210 ± 15 Upper swing axle cover assembly Upper swing arm axle cover assembly ◆ Spring washer Upper sphere pin assembly 23 ± 3 ◆...
  • Page 145 SA-34 Suspension system and vehicle axle(2WD)—Front suspension(coil spring type) Sphere pin Inspection of sphere pin 1. Check whether lower sphere pin has been loosened Support front part of vehicle with jack, then hold it with bracket. Insure front wheels have been in beeline advancing position, and step down braking pedal.
  • Page 146 Suspension system and vehicle axle(2WD)—Front suspension(coil spring type) SA-35 Installation of sphere pin 1. Install upper sphere pin on upper arm Screwing moment: (23±3)N·m 2. Install lower sphere pin on lower arm Screwing moment: (145±10)N·m 3. Install assembly of steering knuckle and front wheel hub (refer to page SA-15) Lower swing arm Disassembly of lower swing arm...
  • Page 147 SA-36 Suspension system and vehicle axle(2WD)—Front suspension(coil spring type) 3. Dismantle front axle of lower arm Make installing mark on front and rear eccentricity washer Dismantle nuts and lower arm axle bolts. Separate lower sphere pin from steering knuckle, and dismantle lower swing arm.
  • Page 148 Suspension system and vehicle axle(2WD)—Front suspension(coil spring type) SA-37 2. Install absorber on lower swing arm Install absorber on bracket of lower swing arm. Screwing moment: (200±15)N·m 3. Link lower swing arm and steering knuckle Install lower sphere pin on steering knuckle, screw slot nuts and install new cotter pin.
  • Page 149 SA-38 Suspension system and vehicle axle(2WD)—Front suspension(coil spring type) Upper swing arm Disassembly of upper swing arm 1. Dismantle front braking oil pipe on upper arm Unscrew nuts used for fixing oil pipe bracket with open-end wrench, and dismantle front braking oil pipe from upper swing arm.
  • Page 150 Suspension system and vehicle axle(2WD)—Front suspension(coil spring type) SA-39 2. Press in new upper arm axle cover by correct direction with tools. Installation of upper swing arm 1. Install upper swing arm Install upper swing arm on vehicle frame, and install linking bolts and nuts of upper swing arm, at this time, it is not nec- essary to screw nuts by regulated moment.
  • Page 151 SA-40 Suspension system and vehicle axle(2WD)—Front suspension(coil spring type) Stabilizer bar Disassembly of stabilizer bar 1. Take off stabilizer bar from coupling position of lower swing arm Fix sphere pin with inner hexagon wrench, dismantle nuts, then take off stabilizer bar . 2.
  • Page 152: Front Wheel Hub And Steering Knuckle

    Suspension system and vehicle axle(4WD)— Front wheel hub and steering knuckle SA-41 Front wheel hub and steering knuckle(4WD) Part drawing Stabilizer rod ◆ Spring washer Plate arrester ◆ 63 ± 5 140 ± 10 Upper swing arm Flat washer ◆ Drive shaft Cotter pin Connecting rod...
  • Page 153 SA-42 Suspension system and vehicle axle(4WD)— Front wheel hub and steering knuckle Front wheel hub Disassembly of front wheel hub 1. Dismantle plate braking pliers Dismantle plate braking pliers and hang it with tightwire. Remark: do not dismantle braking soft pipe and braking pipe. 2.
  • Page 154 Suspension system and vehicle axle(4WD)— Front wheel hub and steering knuckle SA-43 4. Dismantle oil seal of front wheel hub and inner bearing. Prize out oil seal with screwdriver. Dismantle inner ring of inner bearing from wheel hub. Inspection and repair of front wheel hub 1.
  • Page 155 SA-44 Suspension system and vehicle axle(4WD)— Front wheel hub and steering knuckle 3. Install inner bearing and oil seal Brief chart of SST Put inner bearing in wheel hub. Hit new oil seal in wheel hub with special tools. Spread HP-R lubricating grease on lip of oil seal. 4.
  • Page 156 Suspension system and vehicle axle(4WD)— Front wheel hub and steering knuckle SA-45 7. Check pre-load again Check pre-load again with spring tensometer Pre-load (when starting): (28-56)N If pre-load does not accord with regulated value, it is necessary to dismantle stop shim and adjust with adjusting nut. 8.
  • Page 157 SA-46 Suspension system and vehicle axle(4WD)— Front wheel hub and steering knuckle 3. Take off steering transverse tie rod from steering knuckle Dismantle cotter pin and nut on sphere pin. Take off steering transverse tie rod from steering knuckle arm with special tools. 4.
  • Page 158 Suspension system and vehicle axle(4WD)— Front wheel hub and steering knuckle SA-47 Inspection and change of steering knuckle 1. Check steering knuckle Check whether there is any crack on steering knuckle with coloration penetrant If there is any crack, it is necessary to change steering knuckle.
  • Page 159 SA-48 Suspension system and vehicle axle(4WD)— Front wheel hub and steering knuckle 6. Installation of stop shim Reverse angle Spread HP-R lubricating grease on stop shim installed position of steering knuckle, and put in the side with reverse angle of stop shim towards steering knuckle.
  • Page 160 Suspension system and vehicle axle(4WD)— Front wheel hub and steering knuckle SA-49 Screw nuts of lower sphere pin by regulated moment. Screwing moment: (230±20)N·m Install new cotter pin. Remark: when screwing slot nuts, it is well to take the lower limited value210N·m ,and when installing cotter pin, it is necessary to head the notch on nut to pin hole correctly, at this time, nut must be tight.
  • Page 161: Front Suspension

    SA-50 Suspension system and vehicle axle(4WD)—Front suspension Front suspension Part drawing Shim 210 ± 10 Upper arm bushing ★ Upper arm shaft Shim Front stabilizer bar Upper arm bushing 210 ± 10 Upper swing arm Rubber cover 63 ± 5 Upper sphere pin Clamp Flat shim...
  • Page 162 Suspension system and vehicle axle(4WD)—Front suspension SA-51 Sphere pin Inspection of sphere pin 1. Check whether lower sphere pin has been loosened Support front part of vehicle with jack, then hold it with bracket. Insure front wheels have been in beeline advancing position, and step down braking pedal.
  • Page 163 SA-52 Suspension system and vehicle axle(4WD)—Front suspension Installation of sphere pin 1. Install upper sphere pin on upper arm Screwing moment: (78 ± 5)N·m 2. Install lower sphere pin on lower arm Screwing moment: (140 ± 10)N·m 3. Install assembly of steering knuckle and front wheel hub (refer to page SA-43) PDF 文件使用...
  • Page 164 Suspension system and vehicle axle(4WD)—Front suspension SA-53 Torsion rod spring Disassembly of torsion rod spring 1. Make installing marks on torsion rod spring, torsion rod seat and adjusting arm. 2. A Liking that shown in figure, measure the length of extended segment on bolts.
  • Page 165 SA-54 Suspension system and vehicle axle(4WD)—Front suspension Screw adjusting bolt to make its extended length equal to the value before disassembly. 2. For new torsion rod spring Dismantle wheels. Spread a folium of lithium lubricating grease on spline of torsion rod spring. Install torsion rod spring on torsion rod seat.
  • Page 166 Suspension system and vehicle axle(4WD)—Front suspension SA-55 Lower swing arm Disassembly of lower swing arm 1. Disassembly of the assembly of front wheel hub and steering knuckle Including disassembly of absorber, stabilizer rod and steering tie rod. (refer to page SA-42) 2.
  • Page 167 SA-56 Suspension system and vehicle axle(4WD)—Front suspension Change of lower swing arm bush 1. Dismantle lower arm short bush Press out short bush from lower swing arm with special tools. 2. Install lower arm short bush Press short bush in lower swing arm with special tools. Remark: do not spread lubricating grease on bush.
  • Page 168 Suspension system and vehicle axle(4WD)—Front suspension SA-57 2. Install assembly of front wheel hub and steering knuckle (refer to page SA-43) 3. Install absorber on lower swing arm Install absorber on bracket of lower swing arm. Screwing moment: (90 ± 10)N·m 4.
  • Page 169 SA-58 Suspension system and vehicle axle(4WD)—Front suspension 7. Screw nuts on lower arm front axle by regulated moment Install wheels, dismantle bracket and make vehicle bounce for several times to make suspension enter in stable statement. Screw nuts by regulated moment after heading installing marks rightly.
  • Page 170 Suspension system and vehicle axle(4WD)—Front suspension SA-59 Upper swing arm Disassembly of upper swing arm 1. Take off upper sphere pin from steering knuckle Dismantle cotter pin and nut, and t ake off upper sphere pin from steering knuckle with special tools. 2.
  • Page 171 SA-60 Suspension system and vehicle axle(4WD)—Front suspension Change of upper arm bush 1. Dismantle bush Dismantle bolts and washer. Pull out bush with special tools. Dismantle upper arm axle, then dismantle the other bush with same method. 2. Install bush Press in bush with special tools.
  • Page 172 Suspension system and vehicle axle(4WD)—Front suspension SA-61 Screw nuts on upper arm axle by regulated moment. Screwing moment: (210 ± 10)N·m Installation of upper swing arm 1. Install upper swing arm on vehicle frame Install upper hanging arm and extroversion adjusting shim.
  • Page 173 SA-62 Suspension system and vehicle axle(4WD)—Front suspension 5. Link braking soft pipe to braking pliers Install copper seal shim, and screw the bolts of braking soft pipe by regulated moment. Screwing moment: (50 ± 5)N·m 6. Exhaust front braking system (refer to page BA-6) Remark: when dismantling right upper arm, it is necessary to exhaust rear braking system at the same time.
  • Page 174 Suspension system and vehicle axle(4WD)—Front suspension SA-63 Stabilizer bar Disassembly of stabilizer bar 1. Take off connecting rod which supports two sides of stabilizer bar from stabilizer bar . Fix sphere with inner hexagon wrench, then dismantle self tapping nuts. 2.
  • Page 175: Front Drive Shaft

    Suspension system and vehicle axle —Front drive shaft SA-64 Front drive shaft Installation resolving chart of front drive shaft assembly on front drive axle Front drive shaft assembly Hanger plate-right 90-110 ★ Oil seal-front retarder Snap spring Bearing-front retarder Snap spring Assembly of front retarder and electric-control separator Power tie-in of electric clutch 23-26...
  • Page 176 Suspension system and vehicle axle —Front drive shaft SA-65 Front drive shaft resolving chart Inner trumpet tie-in Three-pin joint assembly Snap spring Inner sheath big clip Inner sheath Inner sheath small clip Exterior sheath small clip Exterior sheath Exterior sheath big clip outer trumpet tie-in dustproof cover Disassembly of front drive shaft assembly...
  • Page 177 Suspension system and vehicle axle —Front drive shaft SA-66 N · m :Specified torque 9. Hold fro nt drive axle with jack, then unscrew lift bolts of ★ 90-110 hanger plate and vehicle frame. 10. Dismantle whole drive axle. Held part 11.
  • Page 178 Suspension system and vehicle axle —Front drive shaft SA-67 2. Dismantle inner sheath big clip Note: do not break inner and exterior sheath. Pliers 3. Disassembly of inner trumpet tie-in part Make installing marks on inner trumpet tie-in and three- Installing mark pin joint assembly.
  • Page 179 Suspension system and vehicle axle —Front drive shaft SA-68 6. Dismantle exterior sheath big clip and small clip with gad screwdriver. 7. Dismantle exterior sheath Clean sheath and remove lubricating grease on exterior trumpet tie-in, and do not disconnect exterior trumpet tie-in. 8.
  • Page 180 Suspension system and vehicle axle —Front drive shaft SA-69 3. Harness inner sheath small clip, inner sheath and inner sheath big clip If inner sheath has been damaged or its aging is heavy, change with new one. 4. Install three-pin joint assembly on front drive shaft Head one end with transverse angle of three-pin joint End with assembly to inner shaft direction.
  • Page 181 Suspension system and vehicle axle —Front drive shaft SA-70 5. Install exterior sheath on exterior trumpet tie-in CAPLEX or KY1 Use lubricating grease that is provided as a set of sheath to fill sheath before installing sheath. Lubricating greases recommended: Lubricating grease dosage: about 110 grams 6.
  • Page 182 Suspension system and vehicle axle —Front drive shaft SA-71 Use nutcracker to lock inner sheath small clip. Make big and small connecting part of sheath locate at corresponding flute of trumpet tie-in and shaft. nutcracker Use special pneumatic power pliers to lock big and small clip of exterior sheath.
  • Page 183 Suspension system and vehicle axle —Front drive shaft SA-72 Installation of front drive shaft assembly on front drive axle 1. Harness hanger plate in drive shaft, harness oil seal Snap spring pliers and install inner snap spring with snap spring pliers. If oil seal has been damaged, change it with new one.
  • Page 184 Suspension system and vehicle axle —Front drive shaft SA-73 8. Install ventilation pipe connecter assembly, and link each Installing mark interface between it and front drive axle. (refer to page SA-103) 9. Firstly, hold up whole drive axle with jack, and use hanger plate to hang drive axle and screw hanging bolts to regulated moment, secondly install steering knuckle on both sides and upper and lower sphere pin, lastly, link...
  • Page 185: Front Reducer

    Suspension system and vehicle axle — Front reducer SA-74 Front reducer Change of main gear oil seal of front reducer assembly Front reducer assembly Washer Bearing ◆ Oil seal Spacer bush- Driving bevel gear ◆ 140-160 N · m :Specified torque ◆...
  • Page 186 Suspension system and vehicle axle — Front reducer SA-75 Knock down assembly of main gear flange and dustproof cover with copper stick. 6. Dismantle main gear oil seal Rotate wrench clockwisely Dismantle oil seal with special tools, and note do not damage inner wall of decreased shell.
  • Page 187 Suspension system and vehicle axle — Front reducer SA-76 9. Adjust pre-load of Driving bevel gear bearing Measure the pre-load in clearance of driving bevel gear and driven bevel gear with torquemeter. Pre-load: (1.2-1.7)N·m If pre-load exceeds regulated value, change it with thicker washer.
  • Page 188 Suspension system and vehicle axle — Front reducer SA-77 Disassembly of front reducer assembly Front drive shaft assembly 90-110 ★ Hanger plate-right Oil seal- front retarder Snap spring Bearing-front retarder Snap spring Assembly of front retarder and electric-control separator Power tie-in of electric-control separator 23-26 Front drive axle ventilation pipe assembly Snap spring...
  • Page 189 Suspension system and vehicle axle — Front reducer SA-78 1. Support front part of vehicle, then dismantle left and Installing mark right front wheel and beam under retarder. 2. Discharge lubricating grease in front retarder assembly. 3. Separate f ront retarder assem b ly f lang e from transmission shaft.
  • Page 190 Suspension system and vehicle axle — Front reducer SA-79 Tie-in of electric separator 7. Hold front drive axle with jack. 8. Dismantle lift bolts of front drive axle hanger plate and vehicle frame. 9. Dismantle front drive axle assembly Note: do not damage drive shaft or break front drive shaft sheath.
  • Page 191 Suspension system and vehicle axle — Front reducer SA-80 Change of front retarder assembly side oil seal and long half-axle oil seal Change of front retarder assembly side oil seal 1. Dismantle front drive axle assembly (refer to page SA-77) 2.
  • Page 192 Suspension system and vehicle axle — Front reducer SA-81 Change of long half-shaft oil seal 1. After making electric clutch stay in four-drive statement, stop vehicle and dismantle front drive shaft assembly. (refer to page SA-7) 2. Unscrew the bolts on ventilation pipe bracket that are used for fixing connecter assembly of front drive axle Wrench ventilation pipe with wrench.
  • Page 193 Suspension system and vehicle axle — Front reducer SA-82 6. Disconnect snap spring used for locking long half-shaft bearing exterior ring with snap spring pliers. Shim plate Bolt pins (two) Ejection bolts (three) 7. Dismantle long half-shaft and bearing, snap spring as- sembly with special service tools 8.
  • Page 194 Suspension system and vehicle axle — Front reducer SA-83 10. Hit new oil seal in oil seal position in flange with special service tools. Note: it is necessary to spread some lithium base lubricating grease evenly when installing new oil seal in front lip, and hit oil seal rightly.
  • Page 195 Suspension system and vehicle axle — Front reducer SA-84 15. Spread a sheet of 1596 silicon rubber flat sealant evenly on connecting surface of flange, and scrape it flat with flat plate. Note: insure sealant is a continue bed, and it is necessary to keep away from thread to avoid sealant enters in thread hold when spreading.
  • Page 196 Suspension system and vehicle axle — Front reducer SA-85 Disassembly and installation of front reducer assembly and electric clutch part Part drawing of front reducer assembly Bearing gland Adjusting male tab 90-115 Bearing 80-95 ★ Differential shell Stop shim of half-shaft gear Half-shaft gear Planetary gear shaft Driven bevel gear...
  • Page 197 Suspension system and vehicle axle — Front reducer SA-86 Disassembly of front retarder assembly Disconnect this position 1. Dismantle front drive axle, left and right front drive shaft Disconnect this assembly. position (refer to page SA-64 and SA-77) 2. Dismantle those three connecting position of front drive axle ventilation pipe connecter assembly.
  • Page 198 Suspension system and vehicle axle — Front reducer SA-87 7. Dismantle the snap spring used for fixing long half-shaft bearing exterior ring with snap spring pliers. 8. Pull out long half-shaft, long half-shaft bearing and inner ring snap spring of long half-shaft with special service tools.
  • Page 199 Suspension system and vehicle axle — Front reducer SA-88 15. Knock front retarder shell to separate it from front drive axle shell with copper stick or hand hammer. 16. Check swing difference of driven bevel gear Turn the flange, then measure swing difference of driven bevel gear with percent meter Maximal swing difference: 0.07mm If swing difference exceeds 0.07mm, it is necessary to change...
  • Page 200 Suspension system and vehicle axle — Front reducer SA-89 21. Dismantle the assembly of main gear flange and dustproof cover Loosen riveted part of main gear nut with hand hammer and chisel. Lock main gear flange to dismantle main gear nuts with special service tools.
  • Page 201 Suspension system and vehicle axle — Front reducer SA-90 24. Dismantle two bearing pressed covers with wrench Remark: distinguish left and right to avoid confusion when dismantling bearing pressed cover. 25. Shake differential assembly upwards with copper stick, then take out differential assembly. 26.
  • Page 202 Suspension system and vehicle axle — Front reducer SA-91 Install washer on driving bevel gear, and install new big bearing with special service tools. 2. Change big bearing exterior ring of driving bevel gear Knock down big bearing exterior ring with copper stick and hand hammer.
  • Page 203 Suspension system and vehicle axle — Front reducer SA-92 4. Dismantle two side bearing inner rings from differential shell Dismantle side bearing inner ring on the side with bolts from differential assembly with special service tools. When dismantling bearing inner ring on the other side , note do not damage driven bevel gear which is nipped by vice.
  • Page 204 Suspension system and vehicle axle — Front reducer SA-93 Turn half-shaft gear, rotate to install it in planetary gear and put through planetary gear shaft. Check the clearance of stop sheet of half-shaft gear and differential shell. If turning half-shaft gear and planetary gear flexibly, pull planetary gear to inside, then measure the clearance of stop sheet of half-shaft gear and differential shell with percent meter.
  • Page 205 Suspension system and vehicle axle — Front reducer SA-94 (h) Press two inner rings of side bearing in bearing position on both sides of differential shell on press with special service tools. Put a adjusting male tab in side bearing position of Bearing front retarder shell and place it near exterior side.
  • Page 206 Suspension system and vehicle axle — Front reducer SA-95 4. Install driving bevel gear oil seal with special service tools. Note: before instating oil seal, it is necessary to spread lithium base lubricating grease on lip, and rear plane of oil seal should equal to top surface of front retarder shell after hitting in oil seal.
  • Page 207 Suspension system and vehicle axle — Front reducer SA-96 10. Measure the clearance value of gear side between driving and driven bevel gear with percent meter, and choose the adjusting male tab on the side whose clearance is 0.15mm. 11. Measure the thickness of this adjusting male tab. 12.
  • Page 208 Suspension system and vehicle axle — Front reducer SA-97 17. Adjust pre-load on axial direction of side bearing Take off two adjusting male tab, and re-measure the thickness of two adjusting mal tabs. Re-install new adjusting male tab whose thickness is 0. 06-0.09 mm more than dismantled adjusting male tab, and re-install them together with differential assembly in retarded shell.
  • Page 209 Suspension system and vehicle axle — Front reducer SA-98 Check the contacting situation of gear. If mesh moulage of driving and driven bevel gear could not accord with that shown in figure, choose proper adjusting washer to amend by the concrete methods of mesh moulage. Driven bevel gear convexity Driven bevel gear concave Unit: mm...
  • Page 210 Suspension system and vehicle axle — Front reducer SA-99 21. Measure the axial and radial flopping quantity of driving bevel gear flange with percentage meter. Maximal axial flopping quantity: 0.1mm Unit: mm Maximal radial flopping quantity: 0.1mm If flopping quantity exceeds 0.1 mm, it is necessary to check big and small bearing of driving bevel gear.
  • Page 211 Suspension system and vehicle axle — Front reducer SA-100 25. Install front retarded assembly on front drive axle shell, and screw hexagon bolts and spring washer combination part, then draw spring washer on dual-head bolts and screw nuts to regulated moment. (Threads of all bolts have been pre-spread thread locker) Screwing moment: (18-25)N·m Remark: tighten bolts evenly by relative bolts, and check...
  • Page 212 Suspension system and vehicle axle — Front reducer SA-101 33. Install snap spring to lock exterior ring of long half-shaft bearing with snap spring pliers. 34. Pull mechanical wheel of separator in roller pin bearing inner ring of long half-shaft until it could not be pulled. 35.
  • Page 213 Suspension system and vehicle axle — Front reducer SA-102 36. Harness fork cover on the spline of long half-shaft. 37. Install electric control separator shell on the flange of front axle pipe, and screw it to regulated moment with bolts. Pre-spread a sheet of thread locker evenly on bolts, and its dosage is that could cover all threads exactly.
  • Page 214 Suspension system and vehicle axle — Front reducer SA-103 44. Unscrew oil filler plug of front drive axle shell and fill hypoid gear oil in axle shell, then screw oil filler plug to regulated moment. Gear oil trademark: GL-5 Filled quantity: oil surface should equal to lower edge of oil filler hole.
  • Page 215 Suspension system and vehicle axle — Front reducer SA-104 3. Link front drive axle flange and transmission shaft with Installing mark bolts by the marks made before disassembly, then screw them to regulated moment. Regulated moment: (73-83)N·m 4. Install the beam under front drive axle, and screw the licking bolts of this beam to regulated moment.
  • Page 216 Suspension system and vehicle axle(Rear) — Rear axle shaft SA-105 Rear axle shaft Part drawing Half-shaft assembly ◆ Spring washer Rear braking drum ◆ Inner oil seal 100 ± 10 Rear axle shell Bearing seat Double row tapered Half shaft roller bearings ◆...
  • Page 217 Suspension system and vehicle axle(Rear) — Rear axle shaft SA-106 5. Dismantle half shaft assembly from rear axle shell Link half shaft flange surface with special tools by bolts. Hold swimming hammer of special tools to impact it again and again Note: do not damage oil seal.
  • Page 218 Suspension system and vehicle axle(Rear) — Rear axle shaft SA-107 2. Check exterior oil seal Dismantle exterior oil seal with special tools, check whether lip has been worn or damaged, and change it if necessary. Note oil seal lip especially. Note: do not damage oil seal when dismantling.
  • Page 219 Suspension system and vehicle axle(Rear) — Rear axle shaft SA-108 8 Install oil seal seat of rear axle Install heated oil seal seat of rear axle on half shaft. Requirement of heating installation: heat oil seal pressed seat in 22# motor oil to 100, after heating all parts completely, take out them to install immediately.
  • Page 220 Suspension system and vehicle axle(Rear) — Rear retarder SA-109 Rear retarder Part drawing Adjusting loop Adjusting washer Differential assembly Driving bevel gear 78-115 Rear bearing ◆ Bearing spacer bush Dual-ear stop washer Oil baffle disc Dustproof cover Flat washer 18-25 Bearing cover Front bearing ◆...
  • Page 221 Suspension system and vehicle axle(Rear) — Rear retarder SA-110 5. Install new oil seal. Spread HP-R lubricating grease on lip of oil seal. Hit in new oil seal with special service tools. depth of oil seal: 1.0mm 6. Install the assembly of flange and dustproof cover 7.
  • Page 222 Suspension system and vehicle axle(Rear) — Rear retarder SA-111 1. Check the internal clearance of driven bevel gear If internal clearance is not in that regulated range, adjust or repair the pre-load of side bearing. (refer to page SA-96) Standard clearance: (0.15-0.25)mm 2.
  • Page 223 Suspension system and vehicle axle(Rear) — Rear retarder SA-112 7. Dismantle the assembly of flange and dustproof cover Loosen the riveted part of nuts with hammer and chisel. Lock flange with special service tools, and dismantle nuts. Note: do not use the nuts again after this using. Dismantle the assembly of flange and dustproof cover 8.
  • Page 224 Suspension system and vehicle axle(Rear) — Rear retarder SA-113 12. Change of front and rear bearing exterior ring of driving bevel gear Hit out front and rear bearing with hammer and copper stick. Press in new bearing exterior ring with press and special service tools.
  • Page 225 Suspension system and vehicle axle(Rear) — Rear retarder SA-114 3. Install spacer bush Spacer bush Choose the adjusting washer between rear bearing and spacer bush by experience. Install spacer bush. 4. Install front bearing inner ring, oil baffle disco and oil seal of driving bevel gear Put front bearing inner ring in retarder shell, and put on oil raffle disco.
  • Page 226 Suspension system and vehicle axle(Rear) — Rear retarder SA-115 7. Measure turning initial tension of bearing New bearing: (1.2-1.7)N·m Re-used bearing: (0.4-0.6)N·m If it does not meet the requirement, change the adjusting washer under spacer bush until it meets the requirement. Specification for torque wrench: (0-3.5)N·m If measured value is less than standard value, decrease the thickness of adjusting washer;...
  • Page 227 Suspension system and vehicle axle(Rear) — Rear retarder SA-116 10. Install different assembly Dismantle bearing cover and distinguish left and right. Install differential assembly in retarder shell. 11. Install adjusting loop Press bearing exterior ring rightly with adjusting loop, then screw it properly.
  • Page 228 Suspension system and vehicle axle(Rear) — Rear retarder SA-117 If mesh clearance do not meet requirement, adjust left and right adjusting loop with special service tools until mesh clearance of main and auxiliary gear has met requirement. Check mesh clearance of main and auxiliary gear again. Mesh clearance: (0.13-0.18)mm 14.
  • Page 229 Suspension system and vehicle axle(Rear) — Rear retarder SA-118 f the contacting situation between gears is bad, choose proper washer to amend by following table. Fair difference Rear bearing Washer of washer thickness is ±0.01mm. Washer thickness (unit: mm) Group number Washer thickness Group number Washer thickness 1.65 1.95 1.75...
  • Page 230 Suspension system and vehicle axle(Rear) — Rear retarder SA-119 18. Rivet the nuts of driving bevel gear Installation of the assembly of rear retarder and differential 1. Install the assembly of retarder and differential on rear axle assembly. Clean the contacting end surface on axle shell for installing the assembly, then spread silicon rubber flat selant evenly.
  • Page 231 Suspension system and vehicle axle(Rear) — Rear differential SA-120 Rear differential (common type) Part drawing Planetary gear shaft ◆ Locking sheet 65-95 Tapered roller bearing Straight pin Half-shaft gear Planetary gear Differential shell Half-shaft gear stop shim Driven bevel gear Planetary gear stop shim N ·...
  • Page 232 Suspension system and vehicle axle(Rear) — Rear differential SA-121 2. Installation of differential Harness stop shim of half-shaft gear in half-shaft gear, then install them in differential shell. Unit: mm Group number Thickness Install stop shim of planetary gear, then roll planetary gear in differential and put it through planetary gear shaft.
  • Page 233 悬架系统和车桥—后悬架 SA-122 后悬架 元件图 钢板弹簧前销轴 180 ± 15 后吊耳挡板 180 ± 15 后钢板弹簧总成 后吊耳总成 U 形螺栓 后吊耳衬套 后缓冲块 U 形螺栓护板 后减振器固定垫片二 托瓦 180 ± 15 后减振器固定垫片一 后减振器 80 ± 10 牛 顿 · 米 : 规 定 扭 矩 钢板弹簧和减振器的拆卸与安装 1.
  • Page 234 悬架系统和车桥—后悬架 SA-123 3. 拆下 U 形螺栓 (a) 拆下 U 形螺栓的安装螺母。 (b) 拆下 托瓦(弹 簧下 座) (c) 拆下 U 形螺栓。 (d) 拆下 U 形螺栓护板。 4. 拆下钢板弹簧 (a) 拆下钢板弹簧前销轴固定螺母。 (b) 拆下钢板弹簧前销轴。 (c) 从支架上将钢板弹簧脱开。 (d) 拆下后吊耳总成和后吊耳挡板,拆下钢板弹簧。 钢板弹簧的更换 1. 将弹簧夹箍扳开 用凿子撬开弹簧夹箍。 2. 拆下中心螺栓 用虎钳夹住弹簧上靠近中心螺栓的地方,拆下中心螺 栓...
  • Page 235 悬架系统和车桥—后悬架 SA-124 4. 安装弹簧中心螺栓 (a) 对准钢板弹簧的中心孔,用虎钳夹住钢板弹簧。 (b) 装上和拧紧弹簧中心螺栓。 拧紧力矩: ( 5 0 ± 5 ) N ·m 5. 将弹簧夹箍弯好 用榔头将弹簧夹箍弯到正确位置。 钢板弹簧的安装 1. 安装钢板弹簧 (a) 将钢板弹簧的前卷耳装入前支架内。 (b) 装上前卷耳销轴固定螺栓。 (c) 用手装垫片 Q401 14,并拧紧前卷耳销轴螺母。 (d) 将钢板弹簧的后吊耳装入后支架内,装上后吊耳总 成。 (e) 装上后吊耳挡板,用手指拧上螺母。 2. 安装 U 形螺栓 (a) 将上护板摆正放到桥壳上。...
  • Page 236 悬架系统和车桥—后悬架 SA-125 备注:交叉拧紧 U 形螺栓螺母,使所有 U 形螺栓伸出托 瓦下面的长度基本相同。 所有螺栓伸出长度基本相同 3. 安装减振器 (a) 先将减振器上端连接环装入车架的销轴上,并拧紧 螺 母 。 拧紧力矩: ( 8 0 ± 1 0 ) N ·m (b) 再将减振器下端连接环装入托瓦的销轴上,并拧紧 螺 母 。 拧紧力矩: (8 0 ± 1 0 ) N ·m 备注:安装减振器固定垫片一、二时,注意其方向,...
  • Page 237 BR-1 Braking system Page Precautions ..............BR-2 Troubleshooting ............BR-2 Overhaul of braking system ........BR-6 Brake pedal ..............BR-9 Parking brake control lever assembly ......BR-11 Vacuum booster with brake cylinder assembly .... BR-13 Front brake ..............BR-15 Rear brake ..............BR-22 Loading sensing pressure proportioning valve .....
  • Page 238: Precautions

    Braking system — Precautions,Troubleshooting BR-2 Precautions 1. Always be careful when replacing each part, since any error shall affect the performance of the braking system and lead to accidents and dangers during running. The parts to be replaced must be those of the same part No. or type.
  • Page 239 Braking system — Troubleshooting BR-3 Troubleshooting (continued) Trouble Causes Countermeasures Cracking or clatter (Drum brake) sound is heard when Brake shoe stuck on flange of brake bottom plate Fill up lubricant using brakes Wear of flange of brake bottom plate Replace the lubricant flange Brake shoe compression spring loose or lost Replacement...
  • Page 240 Braking system — Troubleshooting BR-4 Troubleshooting (continued) Trouble Causes Countermeasures Continuous Adjustment error of brake pedal or booster push rod Check and adjustment squealing and squeak Poor return of brake booster or master cylinder or Check, repair or replacement wheel cylinder sound is heard when (Disc brake) brake is not working...
  • Page 241 Braking system — Troubleshooting BR-5 Troubleshooting (continued) Trouble Causes Countermeasures Serious leakage of master Oil leakage of master cylinder, wheel Eliminate leaking places cylinder oil storage cylinder or hydraulic pipeline Insufficient vacuum boost, no Vacuum leak of vacuum booster not in Check and replace the damaged boost after engine flame out that operation...
  • Page 242: Overhaul Of Braking System

    Braking system — Overhaul of braking system BR-6 Overhaul of braking system Brake lamp switch Inspection and adjustment of brake pedal Pedal push rod 1. Check that the pedal height is correct Distance from pedal to lower front wall plate: 152mm Distance from pedal to lower front wall plate: 152mm 2.
  • Page 243 Braking system — Overhaul of braking system BR-7 hydraulic system; Inspection and renewal of brake fluid 5. Yardstick for completion of rinse: brake fluid that Brake fluid affects directly brake performance and flows out of discharge valve is clear without dirt. operating condition and service life of braking system Emptying of hydraulic system elements.
  • Page 244 Braking system — Overhaul of braking system BR-8 Slowly press down the pedal and do not release Fluid level needs to be checked frequently in it, observe whether brake fluid that flows out order to keep the volume of fluid reservoir above of the joints contains bubbles;...
  • Page 245: Brake Pedal

    Braking system — Brake pedal BR-9 Brake pedal Part drawing Brake pedal return spring Brake pedal shaft Welding assembly of brake pedal bracket Brake pedal bush Spring washer Brake lamp limit block Braking lamp switch Welding assembly of brake pedal arm Pedal cover Disassembly of brake pedal assembly 1.
  • Page 246 Braking system — Brake pedal BR-10 2. Mount pedal cover, brake lamp limit block and return spring of brake pedal on welding assembly of brake pedal arm. 3. Assemble welding assembly of brake pedal bracket and the assembled brake pedal arm assembly with brake pedal shaft, nuts and spring washer, and tighten them with a 30N·m wrench.
  • Page 247 Braking system — Parking lever assembly BR-11 Parking lever assembly Part drawing Handle Self-locking nut Control lever assembly Switch M4 screw Cable assembly Disassembly of parking lever assembly Remark: parking lever is connected to rear parking brake cable assembly through cable balancing plate, and mounted to vehicle body floor through 3 connecting bolts, thus other operations can only be made after the two connections are loosened.
  • Page 248: Parking Brake Control Lever Assembly

    Braking system — Parking lever assembly BR-12 3. Dismount switch Screw off M4 screws that connect switch and foundation with a philips driver, then pull out the switch. Assembly of parking brake control lever as- sembly 1. Assemble switch Dismount parking brake switch and premount it in location hole on foundation, then screw tight M4 screws that connect switch and foundation with a philips driver.
  • Page 249: Vacuum Booster With Brake Cylinder Assembly

    Braking system — Vacuum booster with brake cylinder assembly BR-13 Vacuum booster with brake cylinder assembly Part drawing Hitch yoke Lock pin Spacer (riser block) Pin shaft Hitch yoke lock nut Cup cap Absorbing pad (shim) Hexagon flange nut Booster assembly Vacuum alarm switch assembly Hexagon socket cross recessed screw Master cylinder connecting nut...
  • Page 250 Braking system — Vacuum booster with brake cylinder assembly BR-14 2. Disassembly of oil cup assembly and master cylinder Oil cup assembly assembly Screw off cross recessed hexagon head screws with a philips driver, then pull out slots on the same side of oil cup from Slot dummy club of master cylinder directly with hands (here do not overexert), and tilt oil cup in pull-out direction to...
  • Page 251: Front Brake

    Braking system — Front brake BR-15 7. Disassembly of hitch yoke Hitch yoke lock nut When disassembling hitch yoke, please note first measure the Hitch yoke distance between center of hitch yoke and rear housing plane, and perform assembly according to this distance. To screw off hitch yoke from control valve rod, first put a shaft whose diameter is a little smaller than that of hitch yoke hole through the hole, then grip it and loosen lock nuts of hitch yoke with a...
  • Page 252 Braking system — Front brake BR-16 2. Check the thickness of brake stop friction material Check the thickness of brake stop friction material through sightglass on caliper body, and if it does not fall within stipulated range, replace the friction material. Minimum thickness: 2.0mm 3.
  • Page 253 Braking system — Front brake BR-17 7. Install brake stop circlip sheet 8. Install new brake stop Mount alarm piece for wear limit of brake stop on inboard brake stop. Mount one silencer sheet and one silencer sheet compound piece on inboard brake stop. Mount only one silencer sheet compound piece on outboard brake stop.
  • Page 254 Braking system — Front brake BR-18 Dismount of brake wheel cylinder 1. Dismount front brake hose Dismount front brake hose, and hold the brake fluid with a container. 2. Dismount brake wheel cylinder from caliper bracket Dismount hexagon flange bolt, anchor pin and guide pin. Dismount brake wheel cylinder 3.
  • Page 255 Braking system — Front brake BR-19 Inspection of front brake parts 1. Measure the thickness of brake stop friction wafer Standard thickness: 9.0mm Minimum thickness: 2.0mm If the thickness is smaller than minimum thickness or trace of uneven wear is found, replace the brake stop. 2.
  • Page 256 Braking system — Front brake BR-20 2. Install piston seal in caliper body (a) Screw air bleed screw into air bleed hole of caliper body. Tightening torque: (7-10)N·m (b) Put rectangular seal ring into two – cylinder seal groove of caliper body after coating its working surface with rubber lubricant of appropriate amount.
  • Page 257 Braking system — Front brake BR-21 3. Connect front brake hose Connect front brake hose with caliper body. Tightening torque: (50±5)N·m 4. Fill liquid reservoir of brake with brake fluid and discharge air in braking system. 5. Check there is no leakage of brake fluid Attention: discharge air after replacement.
  • Page 258: Rear Brake

    Braking system — Rear brake BR-22 Rear brake Part drawing Wheel cylinder assembly ◆ Drawing arm grip ring Self – regulating dial piece Elastic washer Dial piece anchor pin ◆ Elastic shield ring Return Clearance Rubber blanking spring adjusting cover mechanism assembly Compression...
  • Page 259 BR-23 Braking system — Rear brake 4. Dismount brake shoe strap drawing arm assembly and brake shoe strap dial piece assembly Dismount compression spring on brake shoe strap drawing arm assembly and brake shoe strap dial piece assembly respectively, press down compression spring and rotate it, release when square hole of compression spring turns parallel with head of compression spring nutted rod, then dismount compression spring.
  • Page 260 Braking system — Rear brake BR-24 6. Dismount brake drawing arm assembly (a) Dismount grip ring of drawing arm with pliers. (b) Dismount washer. (c) Dismount drawing arm pin. (d) Dismount brake drawing arm assembly 7. Dismount self – regulating dial piece Dismount elastic shield ring with pliers.
  • Page 261 Braking system — Rear brake BR-25 3. Measure the thickness of brake shoe lining Standard thickness: 5.5mm Minimum thickness: 1.5mm Brake shoe shall be replaced if its thickness is smaller than minimum thickness or uneven wear is found. Remark: if one of brake shoes needs replacing, all rear brake shoes shall be replaced in order to maintain consistent brake performance.
  • Page 262 Braking system — Rear brake BR-26 Assembly of rear brake Note: assemble parts according to direction indicated in the figure Front Front Left wheel right wheel 1. Assemble brake wheel cylinder Coat two piston cups with lithium soap based glycol grease of appropriate amount.
  • Page 263 Braking system — Rear brake BR-27 (c) Put return spring through clearance adjusting screw lever, and coat thread and screw lever of clearance adjusting wheel, head of clearance adjusting shaft and clearance adjusting screw lever (see locations indicated by arrows in the figure) with lithium soap based grease of appropriate amount.
  • Page 264 Braking system — Rear brake BR-28 7. Install brake shoe strap dial piece assembly Mount brake shoe tension spring between brake shoe strap drawing arm assembly and brake shoe strap dial piece assembly. Install brake shoe strap dial piece assembly and insert shoe end into wheel cylinder assembly.
  • Page 265 Braking system — Rear brake BR-29 12. Check clearance between brake shoe and brake drum Dismount brake drum. Measure inner diameter of brake drum and outer diameter of brake shoe, and confirm whether the difference between them falls within standard range. Clearance of shoe: 0.6mm If the clearance is not correct, check parking brake system.
  • Page 266: Loading Sensing Pressure Proportioning Valve

    Braking system — Loading sensing pressure proportioning valve BR-30 Loading sensing pressure proportioning valve Assembly relationship drawing Lower bracket of loading sensing pressure proportioning valve Loading sensing pressure proportioning valve assembly Upper bracket of loading sensing Hexagon flange bolt pressure proportioning valve Tube bank fixing bracket Disassembly and assembly of loading sensing pressure proportioning valve...
  • Page 267 Braking system — Loading sensing pressure proportioning valve BR-31 4. Dismount holddown bolts (2) and take off loading sensing pressure proportioning valve assembly 5. Perform repair or other overhauls 6. Mount loading sensing pressure proportioning valve on bracket with holddown bolts 7.
  • Page 268 SR-1 Steering system Page Precautions ..............SR-2 Troubleshooting ............SR-2 On-vehicle inspection..........SR-3 Steering driving device ..........SR-4 Hydraulic power steering system ........ SR-6 PDF 文件使用 "pdfFactory" 试用版本创建 ÿ www.fineprint.com.cn...
  • Page 269: Precautions

    Steering system — Precautions,Troubleshooting SR-2 Precautions Always be careful when replacing each part, since any error shall affect the performance of the steering system and lead to accidents and dangers during running. Troubleshooting Trouble Causes Remedy 1. Insufficient tire pressure 1.
  • Page 270: On-Vehicle Inspection

    Steering system — On-vehicle inspection SR-3 On-vehicle inspection Steering wheel inspection 1. Check steering wheel for clearance or clattering sound. Steering wheel play “a”: (0-30) mm 2. Check to see if bolts and nuts are tightened. Then tighten them if necessary. If damaged parts are found, repair or replace them.
  • Page 271: Steering Driving Device

    SR-4 Steering system — Steering driving device Steering driving device Part drawing Steering wheel body assembly Rubber joint Steering column assembly Coupling Steering wheel cover sheet assembly Middle drive shaft Fixed bolt of cover sheet Lower drive shaft 55 ± 5 Steering drive pair Hexagon hole bolt 55 ±...
  • Page 272 Steering system — Steering driving device SR-5 Technical requirement 1. Tightening torque of holddown bolts of power steering gear assembly is (90 ± 10)N.m 2. Tightening torque of connecting bolts between steering drive pair assembly and power steering gear assembly is (25 ±...
  • Page 273: Hydraulic Power Steering System

    Steering system — Hydraulic power steering system SR-6 Hydraulic power steering system Control valve Fuel pipe Power steering oil pump Power steering gear assembly assembly Fluid reservoir Steering system and power steering principle Power steering system consists of steering oil pump, fluid r e s e r v o i r , p o w e r s t e e r i n g g e a r a n d o i l p i p e .
  • Page 274 Steering system — Hydraulic power steering system SR-7 piston is equivalent. In the presence of front wheel alignment parameters, vehicles shall return to straight driving automatically. During the process of returning to straight driving, the piston moves and oil at one side of the piston flows to the other side through control valve channel.
  • Page 275 BE-1 Vehicle body electrical system Page Instruction for electrical system ........BE-2 Wire harness .............. BE-3 Exploded view of vehicle circuit ........BE-9 Central door lock ............BE-19 Audio system .............. BE-22 PDF 文件使用 "pdfFactory" 试用版本创建 www.fineprint.com.cn...
  • Page 276: Instruction For Electrical System

    Vehicle body electrical system — Instruction for electrical system BE-2 Instruction for electrical system Vehicle body electrical system is basically the same as that of “Hover”. Front headlights are converted to 2 high beam lights, and air bag is also an option. In order to facilitate understanding of details of this section, apart from schematic diagram of operating principles of electrical equipment provided, schematic diagram of connection of wire harnesses and relevant plug-in units and terminal box are also introduced.
  • Page 277: Wire Harness

    Vehicle body electrical system — Wire harness BE-3 分两页布置 Wire harness PDF 文件使用 "pdfFactory" 试用版本创建 www.fineprint.com.cn...
  • Page 278 Vehicle body electrical system — Wire harness BE-4 Wire harness middle wire connection serial number function diagram 1 Connected to engine Connected to engine room wire harness A wire harness A Connected to engine Connected to engine room wire harness B wire harness B Connected to engine Connected to engine...
  • Page 279 Vehicle body electrical system — Wire harness BE-5 middle wire connection serial number function diagram 2 Connected to instru- Connected to engine ment wire harness A room wire harness A Connected to instru- Connected to engine ment wire harness B room wire harness B Connected to instru- Connected to engine...
  • Page 280 Vehicle body electrical system — Wire harness BE-6 middle wire connection serial number function diagram 3 Connected to dome Connected to instru- wire harness ment wire harness Connected to engine Connected to instru- room wire harness ment wire harness Connected to transmis- Connected to instru- sion wire harness ment wire harness...
  • Page 281 Vehicle body electrical system — Wire harness BE-7 middle wire connection serial number function diagram 4 Connected to instrument Connected to right left door wire harness assembly A wire harness assembly A Connected to instrument Connected to right left door wire harness assembly B wire harness assembly B Connected to instrument...
  • Page 282 Vehicle body electrical system — Wire harness BE-8 middle wire connection serial number function diagram 5 Connected to Chassis wire Connected to floor wire harness assembly harnessassembly Connected to Connected to left rear floor wire harness door wire harness assembly Connected to Connected to right rear floor wire harness...
  • Page 283: Exploded View Of Vehicle Circuit

    Vehicle body electrical system — Exploded view of vehicle circuit BE-9 Exploded view of vehicle circuit Power generation and starting system PDF 文件使用 "pdfFactory" 试用版本创建 www.fineprint.com.cn...
  • Page 284 Vehicle body electrical system — Exploded view of vehicle circuit BE-10 Engine electronic control system PDF 文件使用 "pdfFactory" 试用版本创建 www.fineprint.com.cn...
  • Page 285 Vehicle body electrical system — Exploded view of vehicle circuit BE-11 PDF 文件使用 "pdfFactory" 试用版本创建 www.fineprint.com.cn...
  • Page 286 Vehicle body electrical system — Exploded view of vehicle circuit BE-12 PDF 文件使用 "pdfFactory" 试用版本创建 www.fineprint.com.cn...
  • Page 287 Vehicle body electrical system — Exploded view of vehicle circuit BE-13 4WD electric controlled transmission and electric clutch system PDF 文件使用 "pdfFactory" 试用版本创建 www.fineprint.com.cn...
  • Page 288 Vehicle body electrical system — Exploded view of vehicle circuit BE-14 Entertainment and air conditioner system PDF 文件使用 "pdfFactory" 试用版本创建 www.fineprint.com.cn...
  • Page 289 Vehicle body electrical system — Exploded view of vehicle circuit BE-15 Cigarette lighter, power plug, wiper and power mirror system PDF 文件使用 "pdfFactory" 试用版本创建 www.fineprint.com.cn...
  • Page 290 Vehicle body electrical system — Exploded view of vehicle circuit BE-16 ABS system PDF 文件使用 "pdfFactory" 试用版本创建 www.fineprint.com.cn...
  • Page 291 Vehicle body electrical system — Exploded view of vehicle circuit BE-17 Air bag PDF 文件使用 "pdfFactory" 试用版本创建 www.fineprint.com.cn...
  • Page 292 Vehicle body electrical system — Exploded view of vehicle circuit BE-18 Central controller and riser system PDF 文件使用 "pdfFactory" 试用版本创建 www.fineprint.com.cn...
  • Page 293: Central Door Lock

    Vehicle body electrical system — Central door lock BE-19 Central door lock Definition of wire harness of central door lock controller 1. Headlight detection It is connected to anode wire of high beam light which produces an output voltage of 12V during operation. 2.
  • Page 294 Vehicle body electrical system — Central door lock BE-20 This wire is connected to unlock signal of air bag. 19. Manual lock signal It is connected to lock control wire of central door lock of left front door, and is to be connected to cathode of power source (earth) during operation.
  • Page 295 Vehicle body electrical system — Central door lock BE-21 By opening the door then closing it, the light shall be on for 10 seconds. If the door is locked within the 10 seconds, reading lamp shall go out immediately. By pulling out the key from ignition switch, the light shall be on for 1 minute. If the key is inserted into ignition switch again, reading lamp shall go out immediately.
  • Page 296: Audio System

    Vehicle body electrical system — Audio system BE-22 Audio system Precautions: 1. When radio player is in CD mode, in order to avoid abnormal damage of instrument due to too high temperature, it shall start thermal protection function automatically and turn down the sound volume. 2.
  • Page 297 Vehicle body electrical system — Audio system BE-23 Composition and function of CC1031PS40/60 audio system Audio system of this model is equipped with either CD player or cassette player. Standard equipment: cassette player + 2 front door loudspeakers + 2 back door loudspeakers + telescopic antenna.
  • Page 298 Vehicle body electrical system — Audio system BE-24 技术参数 System Item Technical parameter Cassette player Mains voltage Current consumption 2.5A Rated power 4×6W(load 4Ω) <±1.5% Tape speed error 50dB Frequency response (100~8000)Hz FM : (87.5 ~ 108.0)MHz AM : (531 ~ 1629)KHz Frequency range FM:55dB AM:50dB CD player...
  • Page 299 AC-1 Air conditioning system page Troubleshooting ............AC-2 Air conditioning system ..........AC-5 Daily maintenance of air conditioning system ....AC-6 Vacuum pumping and filling of refrigerant ....AC-7 Maintenance and replacement of pipeline ....AC-8 Amount of refrigeration oil to be filled and method for filling ..........
  • Page 300: Troubleshooting

    AC-2 Air conditioning system—Troubleshooting Troubleshooting Location Trouble Causes Compressor does Fuse blown, compressor relay damaged conditioning not suck Contact of pressure switch disconnected, short circuit or open circuit system out Electromagnetic clutch coil of compressor open circuit of function Burn-out of switch Burn-out of main relay Clutch skidding Fracture or loose of compressor belt...
  • Page 301 Air conditioning system—Troubleshooting AC-3 Troubleshooting (continued) Location Trouble Causes Insufficient Appropria Compressor in normal condition refrigeration (3) Pressure at high tension side too low outlet (a) Damage of low pressure pipeline (b) Low pressure pipeline clogged (4) Pressure at low tension side too low (a) Frosting of evaporator (b) Expansion valve clogged (c) Low pressure pipeline clogged...
  • Page 302 AC-4 Air conditioning system—Troubleshooting Troubleshooting (continued) Location Trouble Causes Heating No heating or Blower of air conditioner out of function system insufficient heating Blower relay damaged Hot water pipe clogged Cooling water pipe clogged Cool and warm air door cable damaged Insufficient coolant Blower out of Fuse blown or poor contact of switch...
  • Page 303: Air Conditioning System

    Condenser Basic component of CC1031PS40/60 air conditioning system The air conditioning system of CC1031PS40/60C model is a manually controlled system featuring an integration of ventilation, heating and refrigeration. Cool and warm air is separated with silent air outlet. Air cleaning equipment is also equipped.
  • Page 304: Daily Maintenance Of Air Conditioning System

    Air conditioning system — Daily maintenance of air conditioning syste AC-6 2. Definition of each terminal of air conditioning system. Blower air outlet switch Control panel input 1 1 Gear position 1 Defrosting signal input 7 Null 2 Common port 8 Request signal output terminal 2 Backlight 3 Signal terminal...
  • Page 305: Vacuum Pumping And Filling Of Refrigerant

    Air conditioning system—Vacuum pumping and filling of refrigerant AC-7 Vacuum pumping and filling of refrigerant Low pressure High pressure Manifold gauge Blue Connect air conditioner (Compressor) pipeline and multi- Low pressure pipe purpose joint of vacuum pump with pressure manifold gauge, and then start vacuum pumping.
  • Page 306: Maintenance And Replacement Of Pipeline

    Air conditioning system — Maintenance and replacement of pipeline AC-8 Perform open and close operation accord- Low pressure High pressure Open ing to the following procedures Blue Open Turn up speed adjustment switch of blower to its limit, turn temperature control switch to coldest position, Y ellow press A/C switch, and select internal circulation mode for internal/external circulation,...
  • Page 307: Amount Of Refrigeration Oil To Be Filled And Method For Filling

    30-35 Amount of refrigeration oil to be filled and method for filling 1. CC1031PS40/60 air conditioning system is equipped with JSS-D14 compressor manufactured by Chongqin Construction. The stipulated refrigeration oil type is RS-20, and use of other types of refrigeration oil shall damage parts of the compressor. Refrigeration oil must be replenished when some of parts need replacing during repair: evaporator, condenser: 30mll;...
  • Page 308 B0-1 Vehicle body Page General ............... BO-2 Engine hood ..............BO-3 Front door ..............BO-4 Back door ..............BO-10 Vehicle body chafing strip ..........BO-15 Wheel trim ..............BO-17 Front windshield glass ..........BO-18 Rear windshield glass ..........BO-20 Trunk rear panel assembly .......... BO-22 Instrument panel ............
  • Page 309: General

    Vehicle body — General B0-2 General In the case of damage of vehicle body and parts, first take measures to protect vehicles from damage before repair. For example: 1. During disassembly and installation, protective tape shall be affixed to relevant parts of the body. 2.
  • Page 310: Engine Hood

    Vehicle body — Engine hood B0-3 Engine hood Adjustment of engine hood 1. Adjustment of engine hood in front/rear and left/right directions Unscrew bolts of engine hood hinge and adjust engine hood. 2. Adjustment of leading edge of engine hood in vertical direction Rotate buffer slab to adjust engine hood.
  • Page 311: Front Door

    B0-4 Vehicle body—Front door Front door Part drawing Right front door glass mud chute Right front door glass assembly Right front door external water bar Right outside rearview mirror assembly Right front door glass guide rail assembly Right front door glass rear guide rail Right side door lock Front door internal buckle assembly...
  • Page 312 Vehicle body—Front door B0-5 Adjustment of front door 1. Adjustment of door in front/rear and vertical directions Adjust the door after holding down bolts of door side hinge are unscrewed. 2. Adjustment of door in left/right and vertical directions djust the door after holding down bolts of door side hinge are unscrewed.
  • Page 313 B0-6 Vehicle body—Front door Inner manual door trim 5. Dismount of inner door trim Inner manual door trim: Remove internal buckle bolts and internal buckle. Remove bolts of door arm rest. Insert screwdriver between fixed clip and inner door trim and pry it loose.
  • Page 314 Vehicle body—Front door B0-7 10. Dismount of window regulator Remove 4 fixed bolt of regulator and 2 fixing nuts of regulator. Remove regulator through auxiliary hole. 11. Dismount of locking button inside vehicles Relieve control lever and dismount locking button inside vehicles.
  • Page 315 B0-8 Vehicle body—Front door 4. Installation of rear assembly of front door glass guide rail 5. Installation of window regulator Install regulator through auxiliary hole. Install 4 fixed bolt of regulator and 2 fixing nuts of regulator. 6. Installation of front door glass mud chute 7.
  • Page 316 Vehicle body—Front door B0-9 11. Installation of inside door handle Push door handle into panel board of the door and slide it backward. Tighten screws. 12.Installation of regulator handle In case doors and windows are all closed, install panel board and regulator handle with spring clip according to the drawing.
  • Page 317: Back Door

    Vehicle body — Back door B0-10 Back door Part drawing Right back door external water bar Right back door glass assembly Right back door glass mud chute Right front door glass front guide rail Rear check Right side door lock internal buckle assembly Right front door glass rear guide rail Right back side door...
  • Page 318 Vehicle body — Back door B0-11 Adjustment of back door The same as adjustment of front door Disassembly of back door 1. Dismount of regulator handle Open spring clip with a slotted screwdriver and remove regulator handle and diaphragm. 2. Dismount of inside door handle Remove screws and slide the handle forward.
  • Page 319 Vehicle body — Back door B0-12 4. Dismount of back door external water bar Lower the glass to appropriate position, grip external water bar by hand and pull it up with force to remove it. 5. Dismount of back door glass assembly Adjust glass to align fixed bolts of glass bracket with installation holes of inner panel, and remove 2 fixed bolts of glass bracket.
  • Page 320 Vehicle body — Back door B0-13 Assembly of back door 1. Before installation of parts, coat them with MP grease. Coat sliding plane and gear of glass regulator with MP grease. Attention: do not coat spring of window regulator with MP grease.
  • Page 321 Vehicle body — Back door B0-14 7. Installation of back door glass assembly Install glass into door chamber, and mount glass on window regulator with 2 bolts. 8. Installation of back door external water bar Lower glass to appropriate position and mount external water bar on rabbet of outer panel of the door.
  • Page 322: Vehicle Body Chafing Strip

    Vehicle body — Vehicle body chafing strip B0-15 Vehicle body chafing strip Precautions for storage of vehicle body chafing strip: 1. It shall be stored at a cool place to avoid direct sunshine, high temperature and dust. 2. As vehicle body chafing strip is PP+EPDM-T30 product, do not let it contact paint thinner, other solvents or boiling water.
  • Page 323 Vehicle body — Vehicle body chafing strip B0-16 Dismount of vehicle body chafing strip 1. Remove the end of chafing strip Pry loose a 30mm-long part of the end of chafing strip with a scraper. Attention: before scraper is used, its head must be wrapped with tape.
  • Page 324: Wheel Trim

    Vehicle body — Wheel trim B0-17 Wheel trim Installation site of parts Front part of front fender trim bar Front fender trim bar Rear fender trim bar Replacement of front fender trim bar and front part of front fender trim bar 1.
  • Page 325: Front Windshield Glass

    B0-18 Vehicle body—Front windshield glass Front windshield glass Installation site of parts Upper trim bar of front windshield Right clip bar of front windshield Front windshield glass assy. Wiper Left clip bar of front windshield Cover sheet of wiper Dismount of front windshield glass assem- 1.
  • Page 326 Vehicle body—Front windshield glass B0-19 Installation of front windshield glass assem- 1. Clean vehicle body and glass Remove the glass cement on surface of vehicle body and glass, then clean contact surface between vehicle body and glass with cleaning tools. 2.
  • Page 327: Rear Windshield Glass

    Vehicle body — Rear windshield glass B0-20 Rear windshield glass Installation site of parts Rear windshield glass Dismount of rear windshield glass assembly Prick a small hole in sealant between glass and vehicle body with a tool and insert a steel wire into it, then two people cooperate to pull the wire to separate glass from vehicle body completely by sawing off the sealant, finally pull glass outward and dismount it.
  • Page 328 Vehicle body — Rear windshield glass B0-21 2. Install rear windshield glass assembly Place two suction cups on surface of rear windshield glass, and put glass upside down on work bench. Coat cleaning activators along inner edge (glass black edge) of rear windshield glass and dry it (usually 5 to 15 minutes), then paint primer coat on cleaning activators and dry it (usually 15 to 20 minutes).
  • Page 329: Trunk Rear Panel Assembly

    Vehicle body — Trunk rear panel assembly B0-22 Trunk rear panel assembly Installation site of parts Right connecting rod Outside handle assembly Left connecting rod Lock body assembly Right hinge assembly of trunk back door Fixing bracket assembly of trunk Center hinge fixed check leaf assembly of...
  • Page 330: Instrument Panel

    Vehicle body — Instrument panel B0-23 Instrument panel Part drawing Central mask left and right Air bag cover plate ventilation port assembly Central mask assembly Instrument panel right ventilation port assembly Upper cover plate of instrument panel Instrument embellisher Instrument panel right side cover plate Upper cover plate of instrument panel Upper cover plate of instrument panel...
  • Page 331 Vehicle body — Instrument panel B0-24 Dismount of instrument panel 1. Disconnect battery cable from the cathode (-) 2. Dismount steering wheel 3. Dismount engine hood lock switch Remove 2 screws and engine hood lock cable. 4. Dismount combination switch mask component Remove the 3 screws.
  • Page 332 Vehicle body — Instrument panel B0-25 11. Dismount central mask assembly Pry out central mask with a screwdriver according to the drawing and dismount it. Attention: before screwdriver is used, its head must be wrapped with tape. Disconnect connectors. 12. Dismount air conditioner panel Remove 2 screws and pull out air conditioner panel.
  • Page 333: Seat Belt

    Vehicle body — seat belt B0-26 seat belt Part drawing Front seat belt 50 ± 5 50 ± 5 50 ± 5 50 ± 5 Rear seat belt 50 ± 5 50 ± 5 50 ± 5 N ·m : Specified torque PDF 文件使用...
  • Page 334 Vehicle body — seat belt B0-27 Inspection of seat belt Attention: seat b elt system must b e insp ected systematically after each accident, and if the following parts are found damaged, users must be informed to replace seat belts. In case users refuse to replace damaged seat belts, details must be recorded.
  • Page 335: Seat

    Vehicle body — Seat B0-28 Seat Part drawing Front row seat 85 ± 5 85 ± 5 85 ± 5 85 ± 5 85 ± 5 85 ± 5 Rear row seat 85 ± 5 85 ± 5 85 ± 5 85 ±...
  • Page 336: Body Dimension

    Vehicle body — Vehicle body dimension B0-29 Vehicle body dimension Head light bed plate (3D distance point dimension) 1051 1045 Unit:mm Symbol Description Diam eter (m m) Symbol Description Diameter (mm ) Installation hole of head light ¢ 7 Installation hole of horn ¢...
  • Page 337 Vehicle body — Vehicle body dimension B0-30 Windshield opening (3D distance point dimension) Unit:mm Symbol Description Diameter (mm) Symbol Description Diameter (mm) —— Technological cut of tonneau Installation hole of wiper cover plate ¢ 8 Connecting part of tonneau/side Connecting part of front wall upper ——...
  • Page 338 Vehicle body — Vehicle body dimension B0-31 Engine room (3D distance point dimension) Unit:mm Symbol Description Diameter (mm) Symbol Description Diameter (mm) Location hole of tonneau glass ¢ 6 Corresponding point on rear panel —— —— Location hole of tonneau glass 6×8 slotted hole Outer edge of rear panel PDF 文件使用...

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