Page 1 2011 BENNI MINI SERVICE MANUAL This service manual consists of BENNI MINI repair information 2011 Changan Automotive Co., Ltd. Copyright © Information up to Nov 2011. Without written permission, any form of duplicate, storage or distribution (including, but not limited to, electronic copying, photocopying,...
Page 3 Maintenance Manual of BENNI-MINI...
Page 5 100-00-1 Overview 100-00-1 Section 100-00 Overview Contents Page Instruction and Operation About the Manual ............................100-00-3 Brief Introduction ............................100-00-4 Spare Parts Substitution ........................... 100-00-3 Special Tools ..............................100-00-3 Important safety instruction ..........................100-00-3 Warning, Caution and Prompting ........................100-00-4 How to Use the Manual ...........................
Page 6 100-00-2 Overview 100-00-2 100-00-11 Sealing on Vehicle Base........................... 100-00-11 Soldering ................................Warning Signs on Vehicle..........................100-00-12 Petroleum Solvent Oil ............................100-00-13 Standard Workshop Operating Manual ......................100-00-14 100-00-14 Vehicle in the Maintenance Workshop ......................100-00-14 Vehicle Traction............................... 100-00-14 Connect the Auxiliary Battery with the Jumper Wire ..................Component Cleaning............................
Page 7 100-00-3 Overview 100-00-3 Instruction and Operation DESCRIPTION AND OPERATION About the Manual Each chapter gives a brief description of a specific part of automobile. This manual is divided into five Brief Introduction chapters: Overview, Chassis, Power Steering System, Electricity, Vehicle Body and Coating. The compiling format of this manual aims to satisfy the requirements of the maintenance skill men, and Page numbers of all the chapters and sections are...
Page 8 100-00-4 Overview 100-00-3 Instruction and Operation Illustration Indication testing diagram shows required measurement or test in some certain testing procedure. The typical test diagram is suitable for the use of a voltage gauge and an ampere meter. When a signal diagram shows the multi-step test, the solid line draws the conducting wire until the multi-step measured conducting wire branch points, and the conducting wire of multi-step measuring...
Page 9 100-00-5 Overview 100-00-3 Instruction and Operation the gas generator is broken, the complete protective Precautions of Health and of Safety working clothes must be worn during the treatment. Brief Introduction After the air bag is normally extended, the Many operations in connection with the service and protective gloves and glasses must be worn on site maintenance of the vehicle will threaten and during the treatment.
Page 10 100-00-6 Overview 100-00-6 Description and Operation (Continued) For melting and sealing agents and adhesive agent, see Section Melting Agent Air-conditioning Cooling Agent Follow the instruction book of the manufacturer. See Section Chemical Substance. Inflammable substance—observance Water Soluble Sealing Agent and Adhesive non-smoking regulation Agent Frostbite can be caused when the cooling agent is...
Page 11 100-00-7 Overview 100-00-7 Description and Operation (Continued) or go to hospital. Forbid to touch the wound Electrolyte Please see Section Acid and Alkali Metal position by hands. Select the places of well simultaneously. ventilation because the steam will stimulate eyes and nose. When the battery cell is charged, the released gas will cause explosion.
Page 12 100-00-8 Overview 100-00-8 Description and Operation (Continued) smog, etc. and avoid the combustion and Corrosion Preventing Material explosion caused by such substance. Please see Sections Melting Agent and Fire – Clean hands immediately after touching the Prevention simultaneously. substance. Because the corrosion preventing material belongs –...
Page 13 100-00-9 Overview 100-00-9 Description and Operation (Continued) The electric wire of electric appliance shall be Fire Prevention ensured not to be intercepted or damaged when the See Welding, Foam and Legal Affairs. automobile is hoisted. Most of the substances related to the automobile Ensure that the electrician be trained in first aid.
Page 14 100-00-10 Overview 100-00-10 Description and Operation (Continued) with allergic history is not allowed to operate in the The gasoline shall be transported or used in the unvulcanized material place or nearby. places of air circulation. The damage to human respiratory system due to the gasoline leakage must Some components, steam or spray will have be strictly avoided.
Page 15 100-00-11 Overview 100-00-11 Description and Operation (Continued) Lubricating Oil and Lubricating Grease See Section High Pressure Cylinder. Avoid touching the mineral oil for a long time. All the lubricating oil and lubricating grease have irritability to eyes and skin. General Purpose Maintenance Tool / Device All tools and devices shall be kept in the intact state, Used oil and the appropriate safe device shall be used if...
Page 16 100-00-12 Overview 100-00-12 Description and Operation (Continued) recycling dealer in the designated site. Consult with not be generated during the welding process. The the local authority if have doubts. oxygen bearing acetylene flame can not be used because the leady smog will be generated due to the Directly dumping the depleted engine oil to the high temperature of the oxygen bearing acetylene ground, the sewer, the drainage ditch or the water...
Page 17 100-00-13 Overview 100-00-13 Description and Operation (Continued) When spraying the substances with the solvent, There will be metal splashing during the use of the such as oil paint, adhesive agent, ensure that the arc welding, so the correct protection measures for the eye and the skin should be taken.
Page 18 100-00-14 Overview 100-00-14 Description and Operation (Continued) 4. The mark shows that there are inflammable and 1. The above figure shows that the relevant parts of explosive fluids or steam nearby. It is prohibited the special instruction manual should be referred to use open fire.
Page 19 eneral Introduction 100-00-15 100-00-15 Instruction and Operation When the automatic speed-changing automobile is Standard Workshop Operating Manual dragged, the gear position must be at the N position. The pulling speed of the automatic speed-changing automobile can not exceed 50 km/h or the trailer Automobile in Maintenance Workshop car distance can not exceed 50 km.
Page 20 General Introduction 100-00-16 100-00-16 Instruction and Operation (Continued) Component Cleaning In order to avoid dirtying the entry, the dirt accumulation, grease, the decomposing component or the assembly shall be eliminated before disconnecting the jumper wire. During the reassembly, the components shall be cleaned carefully and then checked and assembled.
Page 21 General Introduction 100-00-17 100-00-17 Instruction and Operation (Continued) Melting Agent, Sealing agent, Sealing Agent, Adhesive Agent and Adhesive Agent Warnings: If the applicability of any Brief Introduction melting agent or sealing agent for the special purpose is with question, please contact with the Warnings: The operator shall be cautious manufacturer for the storage, processing and fairly when all the melting agents, the sealing...
Page 22 General Introduction 100-00-18 100-00-18 Instruction and Operation Road Test or Rolling Testing Platform Start the engine Test Notes: Within the time of the initial starting of the In many cases, the road test or rolling testing cold engine or the initial 1.5 km, before the platform test is required to for the automobile.
Page 23 General Introduction 100-00-19 100-00-19 Instruction and Operation If the running is steady during loosening the Warnings: The braking test including the clutch, the automobile will not skid or tremble. heavy-trodden braking shall performed brake shoe – The transmission shift is steady, thus the plate/brake disc or the friction disc/brake abnormal noise or the vibration does not occur drum, unless the components have been...
Page 24 General Introduction 100-00-20 100-00-20 Instruction and Operation Braking Test Warnings: During checking the brake, the smog released by hot braking can be avoided. See Safety and Health Precautions. Avoid the check of the brake on the road with many vehicles, as that may cause inconvenience or danger for others.
Page 25 100-01-1 Lifting 100-01-1 Chapter 100-01 Lifting Vehicle applied: Changan·Benni MINI Contents Page Description and operation Support ............................ 100-01-2 L ifting ............................ 100-01-3 Changan·Benni MINI...
Page 26 100-01-2 Lifting 100-01-2 Description and operation Support Warning: Be sure that the vehicle is When the jack is needed during the maintenance of vehicles, the comprehensive parked on the hard ground. If the vehicle is on understanding of the following guidelines is soft ground, things should be put under the essential.
Page 27 100-01-3 Lifting 100-01-3 Description and operation Lifting Note: When using the two-column lift to lift vehicle, pads must be used at the location Use the correct lifting and support position is very important Changan·Benni MINI...
Page 28: Applicable Vehicle Models: Benni Mini
201-00-1 Suspension System - General Section 201-00 Suspension System - General Applicable Vehicle Model： Benni Mini Contents Pages Specification Specification 201-00-2 Instruction and Operation Suspension System 201-00-2 Inspection and Confirmation 201-00-4 Failure Table 201-00-6 Fixed Point Inspection 201-00-9 Common Procedures Toe-in Adjustment 201-00-21 Inspection of the Wheel Bearing...
Page 29 201-00-2 Suspension System - General Specification Front Wheel Alignment (Kerb Mass) - Kingpin Caster Angle and Camber Angle Kingpin Caster Kingpin Caster Camber Angle Camber Angle Model Angle Angle Vehicle Model Standard Value Tolerance Scope Standard Value Tolerance Scope 2.8° or 2°48’ 2.3°...
Page 30 201-00-3 201-00-3 Suspension System - General Diagnosis and Test (Continued) – Loosened or worn front wheel bearings. – Loosened or worn suspension or steering components. – Excessive run-out of the front brake disc. – Loosened engine or driving axle bracket. –...
Page 31 201-00-3 Suspension System Diagnosis and Test (Continued) Inspection and Confirmation into. If the situation is related to the engine rotating speed, the vibration cause has nothing to do with tyres. Vibration diagnosis procedures usually begin with road test. The road test and the interview with clients (if possible) can provide a great deal of information Ball Head of the Tie Rod...
Page 32 201-00-3 Suspension System Diagnosis and Test (Continued) 1. Oil leakage. A layer of oil film is allowed to be Automobile Inspection (exuded) attached on front and rear shock 1. Inspect air pressure of all tyres. absorbing devices, which normal. 2. Inspect tyres to confirm positioning of the ball penetration refers to a situation that a layer of head of the tie rod, dynamic balancing of the tyre thick oil film accumulates outside the shock...
Page 33 201-00-3 Suspension System Diagnosis and Test (Continued) Warning： When disassembling the dust shield / limit block, over pushdown of the pushing rod of the shock absorber should be avoided in the compression process, so as not to cause damage of internal components. The shock absorber should be vertically placed on a vice.
Page 34 201-00-15 Suspension System-General Information Diagnosis and Testing Failure Table Phenomena Possible Reasons Measures •Swing / Derivation / Excursion • Excessive difference of the kingpin • Perform tyre positioning. See the caster angle or camber angle of the section of Common Procedures for left and right wheels relevant information.
Page 35 201-00-16 Suspension System-General Information Diagnosis and Testing (Continued) •Loosening and abrasion of the •Check suspension device suspension device assembly assembly. See this section for relevant information. • Loosening of the bracket for the •Fasten according to the torque suspension device assembly requirements.
Page 36 201-00-16 Suspension System-General Information Diagnosis and Testing (Continued) • Swaying of the Vehicle Body • Abrasion of the connecting rod or • Replace the connecting rod or axle bearing of the front direction bushing of the front direction stabilizing rod (if equipped) stabilizing rod.
Page 37 201-00-16 Suspension System-General Information Diagnosis and Testing (Continued) • Loosening and abrasion of the rear • Check the rear suspension. See suspension, axle bushing or bolts. Section 201-02 relevant information. • Abrasion of the axle bushing or • Replace the axle bushing or connecting rod of the direction connecting rod of the direction stabilizing rod...
Page 38 201-00-16 Suspension System-General Information Diagnosis and Testing (Continued) • Loosening of the front or rear • Repair or replace the suspension suspension components components. See Section 201-01 for relevant information. • Loosening or abrasion of the axle • Repair or replace the axle bushing bushing of the lower cross arm of of the lower cross arm of the front the front suspension...
Page 39 201-00-16 Suspension System-General Information Diagnosis and Testing (Continued) Phenomena Concrete Procedures/Results/Measures • Is the steering wheel in central position and the wheel alignment data in regulated scope? 　 Y es Switch to A4 　 N o Perform the wheel alignment if necessary. Test and operate the system to determine whether it is in the normal condition.
Page 40 201-00-16 Suspension System-General Information Diagnosis and Testing (Continued) Phenomena Concrete Procedures/Results/Measures Switch to fixed point inspection C. 　 N o Perform the Wheel alignment if necessary. Test and operate the system to determine whether it is in the normal condition. Fixed Point Inspection C: Abnormal Running Trace Phenomena Concrete Procedures/Results/Measures...
Page 41 201-00-16 Suspension System-General Information Diagnosis and Testing (Continued) Phenomenon Concrete Procedures/Results/Measures Confirm the failures described by the customer. ixed Point Inspection E: Excessive Noises Phenomena Concrete Procedures/Results/Measures E1: Check the suspension 1 Hoist the automobile . See Section 100-01 for relevant information.
Page 42 201-00-16 Suspension System-General Information Diagnosis and Testing (Continued) • Does there have free movement? Replace the ball head. See Section 201-01 for relevant information. Test and run the system to determine if it works normally. Switch to E5 E5: Check the front wheel bearings 1 Check the front wheel bearings Hold the bottom and top of wheel and sway forcefully.
Page 43 201-00-16 Suspension System-General Information Diagnosis and Testing (Continued) Fixed Point Inspection F: Check Tyre Wire Phenomena Concrete Procedures/Results/Measures F1: Check tyres 1 Hoist the automobile. See Section 100-02 for relevant information. Check the unbalanced abrasion of inner edge and outer edge abrasion of the tyre or sawtooth abrasion.
Page 44 201-00-16 Suspension System-General Information Diagnosis and Testing (Continued) Fixed Point Inspection G: Vibration Phenomena Concrete Procedures/Results/Measures G1: Check the tyre 1 Hoist the automobile. See Section 100-02 for relevant information. Check the damage or excessive wear of the tyre. Is the tyre damaged or excessively worn? Replace tyre.
Page 45 201-00-16 Suspension System-General Information Diagnosis and Testing (Continued) Phenomena Concrete Procedures/Results/Measures See component test part in this Section. Check the ball head. Switch to G4 If necessary, replace the wheel hub and bearings assembly. Test and run the system to determine if it is normal. G4: Check the rear wheel bearing 1 Check the rear wheel bearing.
Page 46 201-00-16 Suspension System-General Information Diagnosis and Testing (Continued) G7: Measure the wheel/tyre run-out value under the automobile 1 Measure the wheel that the radial run-out or the transverse run-out exceeds 1.14 mm. The positions of the tyre bolts and the relevant bolt holes should be marked before the wheel is disassembled so that the wheel can be installed at the original position.
Page 47 201-00-16 Suspension System-General Information Diagnosis and Testing (Continued) Replace the tyre. Checke the run-out of the new wheel. If the new wheel is in the regulated scope, search and mark the lowest point of the wheel run-out. Install the wheels, to make the highest point of the wheel run-out coordinate with the lowest point of the wheel run-out.
Page 48 204-00-17 Suspension System-General Information GENERAL PROCEDURES GENERAL PROCEDURES Toe-in adjustment (14 117 0) 2. Loosen the locking nuts of the ball head of the tie rod. General Tool Wheel Alignment Ruler Inspection 1. Operate toe-in adjustment with a wheel alignment ruler on a flat ground according to the instruction.
Page 49 Inspection of the Wheel Bearing 5. Install an appropriate fixer of the dial gauge or similar devices on the wheel hub and then push and pull the wheel hub. Measure the Special Tool axial clearance between the wheel hub and the wheel bearing assembly.
Page 50 201-01-1 Front Suspension Item Ⅰ Section 201-01 Front Suspension Applicable Vehicle Model: Benni Mini Contents Pages Specification Specification 201-01-2 Instruction and Operation Front Suspension 201-01-2 Diagnosis and Test Front Suspension 201-01-3 Disassembly and Installation Front oscillating arm 201-01-4 Front supporting column 201-01-7 Front stabilizing rod 201-01-09...
Page 51 201-01-2 Front Suspension Instruction and Operation (ⅰ) Torque Specification Description lb-ft lb-in Locking nuts between the ball head of the tie rod 30-55 Connecting bolts between the bracket of the front 89-95 stabilizing rod and the front oscillating arm Connecting nuts between the low bracket of the front longibeam and the low crossbeam of radiator 65-79 Connecting bolts and nuts between the low bracket...
Page 52 204-01-3 Front Suspension 204-01-3 Disassembly and Installation Front Suspension See Section 201-00. Front oscillating arm Disassembly Unscrew the tyre nuts. Hoist the automobile. See Section 100-01 for relevant information. 3. Disassemble the wheel. 4. Disassemble the connecting nuts and bolts between the low bracket of the front longibeam and the low plate of the front cabin.
Page 53 201-01-4 Front Suspension Disassembly and Installation (Continued) Disassemble the tie rod Disassemble front oscillating arm Installation Disassemble the connecting bolts between the ball head pin of the front oscillating arm and the Reverse the disassembly process for steering knuckle installation. Install the bolts of the front oscillating arm and the front oscillating arm mounting plate.
Page 54 201-01-5 Front Suspension Install the connecting nuts and bolts between the low bracket of the front longibeam and the low plate of the front cabin. Install the Connecting nuts between the low bracket of the front longibeam and the low crossbeam of radiator Install the locking nuts and locking pin of the tie Benni Mini...
Page 55 204-01-6 Front Suspension 204-01-6 Disassembly and Installation 节 1.02 DIAGNOSIS AND TESTING (b) Front supporting column assembly Disassembly 1. Loosen the tyre bolts. 2. Hoist the automobile. See Section 100-02 for relevant information. 3. Disassemble the wheel. 4. Remove the rotating speed sensors of the front wheels and brake fuel pipe from the front supporting column.
Page 56 201-01-7 Front Suspension Disassembly and Installation (Continued) Install the rotating speed sensors of the front wheels and brake fuel pipe to the front supporting column. Benni Mini...
Page 57 201-01-8 Front Suspension Disintegration and Assembly (d) Shock absorbing supporting column and absorbing supporting spring assembly (14 783 4) Disassemble the absorbing assembly Disintegration 1. Disassemble the suspension assembly. See this section for relevant information. Warning: Always be careful to avoid injury as the spiral spring is at the extreme strained state.
Page 58 201-02-1 Rear Suspension 201-02-1 Section 204-02 Rear Suspension Applicable Vehicle Model : Benni Mini Contents Pages Specification 201-02-2 Specification Instruction and Operation 201-02-3 Rear Suspension Diagnosis and Test 201-02-4 Rear Suspension Disassembly and Installation 201-02-5 The connecting rubber cushion of the tie rod The tie rod The upper seat of the spiral spring The collision mat...
Page 59 201-02-2 Rear Suspension 201-02-2 Specification Torque Specification Instructions lb-ft lb-in 80~95 Connecting bolts between rear shock absorber and the vehicle body 80~95 Connecting bolts between the rear shock absorber and the rear axle 80~95 Connecting bolts between the rear axle and the vehicle body Connector of the barking hose 16±2...
Page 60 201-02-3 Rear Suspension 201-02-3 Instruction and Operation DESCRIPTION AND OPERATION Rear Suspension Name Serial Parts Number Number The connecting rubber cushion of the tie rod 2916012-K01 the tie rod 2916010-K01 The upper seat of the spiral spring 2912002-C01 The collision mat 2912012-K01 The rear spiral spring 2912011-K01...
Page 61 201-02-4 Rear Suspension 201-02-4 Diagnosis and Test DIAGNOSIS AND TESTING Rear Suspension See this section for relevant information. Benni Mini...
Page 62 201-02-5 Rear Suspension 201-02-5 Disassembly and Installation The tie rod and the connecting rubber cushion Disassembly 2. Install the tie rod to the vehicle body. 3. Lower the vehicle. 1. Hoist the vehicle. See the section 100-01 for relevant information 4.
Page 63 201-02-6 Rear Suspension 201-02-6 Disassembly and Installation Rear shock absorber assembly 2. Remove the jack from the rear axle. Disassembly 3. Lower the vehicle. 4. Tighten the nuts and the lower bolts on the rear shock absorber assembly to the stated torque. 1.
Page 64 201-02-7 Rear Suspension 201-02-7 Disassembly and Installation The rear spiral spring and the upper and the lower seats of the rear spiral spring and shock absorber cushion Disassembly 1. Hoist the automobile. See this section for relevant information. Use a jack to support the rear axle. 3.
Page 65 201-02-8 Rear Suspension 201-02-8 Disassembly and Installation The longibeam oscillating arm The spareparts of the rear suspension Disassembly must be last fastening when the vehicle is lowered completely and unloaded. Hoist the automobile. See Section 100-01 for relevant information. Use a jack to support the rear axle. 3.
Page 66 201-02-9 Rear Suspension 201-02-9 Disassembly and Installation Rear Axle Base plate Disassembly 1. Loosen the parking braking dragline. hoist the automobile. See this section for relevant information. 2. Loosen the tyre nuts, remove the tyre. 3. Disassemble the nip of the wiring harness of the wheel speed sensor from the rear axle ,according to the process of disassembly the wheel speed sensor.
Page 67 201-02-10 Rear Suspension 201-02-10 Disassembly and Installation (Continued) 11. Disassemble the spiral spring . Note: 12. Disassemble the connecting nuts between the 1. when assembling the spiral spring, make the end longibeam oscillating arm and rear axle, but do not of the spiral spring fix to the spring retainer.
Page 68 201-02-11 Rear Suspension 201-02-11 Disassembly and Installation (Continued) 10. Connect the wheel speed sensor and braking hose nips (if equipped). 11. Full the brake fluid and exhaust the braking system. See Section 203-00 for relevant information 12. Install the wheel, tighten the tyre nuts to the stated torque.
Page 69 201-02-12 Rear Suspension 201-02-12...
Page 70 201-03-1 Wheel and Tyre Section 201-03 Wheel and Tyre Applicable Vehicle Model: Benni Mini Contents Pages Specification ............................Specification 201-03-2 Instruction and Operation ............................ Safety Warning 201-03-3 Diagnosis and Test Wheel and Tyre 201-03-4 Inspection and Verification 201-03-4 ........................Failure Phenomenon Table 201-03-5 Disassembling and Installation Wheel and Tyre...
Page 71 201-03-2 Wheel and Tyre Specification Torque Specifications Description lb-ft lb-in Wheel Bolt 85±10 Benni Mini...
Page 72 201-03-3 Wheel and Tyre Instruction and Operation DESCRIPTION AND OPERATION Safety Warning Warning: Tyres of various types, such as radial tyre, diagonal tyre or diagonal textile cord tyre, are prohibited to be mounted in one vehicle in a mixing way. Warning: Prohibit starting vehicle when tire replacement is performed.
Page 73 201-03-4 Wheel and Tyre Diagnosis and Test Wheel and Tyre – Engine torque – Vehicle speed – Engine rotating speed – Vibration type - sensitivity: torque sensitivity, Inspection and Verification vehicle speed sensitivity or sensitivity of the In order to play the maximum efficiency of the tyre, engine rotating speed.
Page 74 201-03-5 Wheel and Tyre Diagnosis and Test Failure Phenomena Phenomena Possible Failure Causes Measures • Insufficient tyre air pressure •The tyre air pressure is adjusted. Excessive Wear of the Edge of the Tyre •Overload of the automobile • Correction should be performed if necessary.
Page 75 201-03-6 Wheel and Tyre Diagnosis and Test（continued） Phenomena Possible Failure Causes Measures • Wheel run-out is influenced by • Wheel is disabled (especially • Inspect wheel rim. Parts shaking or abnormal vibration. external retaining ring of the front replacement should be performed if wheel bearing and the rolling necessary.
Page 76 201-03-7 Wheel and Tyre Diagnosis and Test（continued） Foreign matters exist between • •The installation surfaces should be installation surface of the wheel cleaned. and the installation surface of the hub. • The radial run-out of the wheel or •Radial run-out of the wheel and the the tyre is excessive.
Page 77 201-03-8 Wheel and Tyre Diagnosis and Test（continued） • The wheel bolts are deadly blocked. • Eroded. • Cautious: Lubrication oil should not be coated on the tapered surface of the bolt hole or the tapered surface of the wheel bolt. If corrosion is not so severe, an iron brush should be used for removal.
Page 78 204-04-9 Wheels and Tires 204-04-9 Removal and Installation (Continued) Wheel and Tyre Disassembly Warning: The method of heating should not be used for loosing the locked wheel bolts. Wheels and wheel rims may be damaged by heating. 1. Loose the wheel bolts. 2.
Page 79 202-01-1 Driving Axle 202-01-1 Chapter 202-01 Driving Axle Applicable Vehicle Model: BENNI MINI Contents Page Specification ............................Specification 202-01-2 Instruction and Operation Driving Axle ............................202-01-3 The Working Principle of the Driving Axle ..................202-01-4 The Treatment Of the Driving Axle..................... 202-01-4 Front Wheel Balancing ........................
Page 80 202-01-2 Driving Axle 202-01-2 Specification Oil, fluid, sealant and adhesive Designation Model High performance grease (color:Brown), constant speed universal joint G.A.Cpalex GTE Other replaceable greases molybdenum disulfide Capacity High performance grease, external constant speed 70±10 g universal joint High performance grease, internal constant speed universal 65 ±10 g joint Torque specifications...
Page 81 202-01-3 Driving Axle 202-01-3 INSTRUCTION AND OPERATION DESCRIPTION AND OPERATION Driving axle Constant speed universal joints are arranged at both The internal constant speed universal joint is fixed on sides of the driving axle. the differential gear through a differential spring ring. The internal constant speed universal joint (constant The external constant speed universal joint is fixed on speed ball or three-pin universal joint, roller or steel...
Page 82 202-01-4 Driving Axle 202-01-4 INSTRUCTION AND OPERATION (Continued) The Working Principle of the Driving Axle Designation Serial Parts tion The torque is transmitted from the engine to the wheels Number Number through the driving axle. 2203110-K Fixed end ball cage In order to adapt to the upper and lower motion of the universal joint wheel and the engine, the driving axle is required to run...
Page 83 205-04-5 205-04-5 Driving Axle INSTRUCTION AND OPERATION (Continued) Automobile hoisting The protection and rust prevention of the vehicle Warning: It is forbidden to use the universal bottom joint or the driving axle as the jacking Note: When the protection and rust prevention of the position.
Page 84 205-04-6 Driving Axle 205-04-6 DIAGNOSIS AND TESTING (Continued) Phenomena Possible faults Measures •Three-ball-pin type universal joint is • The retaining ring of the driving • Replace the retaining ring parted from the sliding ball cage axle drops off or incorrectly joint mounted in the differential gear •...
Page 85 202-01-7 Driving Axle 202-01-7 DISASEMBING AND INSATLLATION REMOVAL AND INSTALLATION Driving axle (left) To use the special tool: puller（CA201-006） General tool Two-claw puller Dismounting arning: The hexagonal socket wrench Is used to prevent the piston rod from 4. The front oscillating arm ball joint are taken out rotating.
Page 86 202-01-8 Driving Axle 202-01-8 DISASSEMBLING AND INSTALLATION (Continued) Caution: The driving axle should be well protected for preventing the constant speed universal joint from being damaged. The working angle of the internal constant speed universal joint should not be more than 22.5 degrees.
Page 87 202-01-9 Driving Axle 202-01-9 DISASSEMBLING AND INSTALLATION (Continued) 5. The wheel and tyre are installed. See Section 201-03 for relevant information. 2. 2. The driving axle is installed on the wheel hub 6. The transmission oil level is checked. See Section bearing.
Page 88 202-01-10 Driving Axle 202-01-10 DISASSEMBLING AND INSTALLATION (Continued) arning: The hexagonal socket wrench Is used to prevent the piston rod from rotating. The fixing nuts on the front supporting column assembly are secured. BENNI MINI...
Page 89 202-01-11 Driving Axle 202-01-11 DISASSEMBLING AND INSTALLATION (Continued) Driving axle(right) arning: The wheel hub fixing nuts are loosened by using the socket. Use the special tool 1. The wheel hub nuts is loosened. puller（CA201-006） General tool Two-claw puller Dismounting 4. The front oscillating arm ball joint are taken out arning: The hexagonal socket wrench Is from the steering knuckle.
Page 90 202-01-12 Driving Axle 202-01-12 DISASSEMBLING AND INSTALLATION (Continued) Warning: The driving axle is well protected for fear hat the constant speed universal joint is damaged. The working angle of the internal constant speed universal joint should not be more than 22.5 degrees. The working angle of the external constant speed universal joint should not be more than 45 degrees.
Page 91 202-01-13 Driving Axle 202-01-13 DISASSEMBLING AND INSTALLATION (Continued) 2. The driving axle is installed on the wheel hub 5. Install the wheel and tyre. See Section 201-03 for bearing. relevant information. 6. Check the transmission oil. See Section 302-03 for the manual transmission gear. Warnings: use socket wrench to fix the wheel hub fixing nut to prevent damage.
Page 92 202-01-14 Driving Axle 202-01-14 DISASSEMBLING AND INSTALLATION Dust shield of the inner constant speed universal joint Using the special tool: installation tool (CA201-008) General Tool 2. Hoist the vehicle. Retaining ring caliper 3. Disassemble the front oscillating arm on the steering knuckle.
Page 93 202-01-15 202-01-15 Driving Axle (continue) DISASSEMBLING AND INSTALLATION 6. Disassemble the triangular frame/ball-cage frame and dust shield. • Use the retaining ring caliper to take out the retaining ring and pull out the three-ball-pin type universal joint. • Remove the dust shield. Installation 1.
Page 94 驱动轴 202-01-16 202-01-16 拆卸和安装 (续) Use the special tool to fix the nip. 3. Fill the grease in the three-ball-pin type universal joint (G.A.Cpalex GTE)。 The size C of the opening of the nip is not bigger than 1.5mm after the large and small nip are tightly hooped. 4.
Page 95 202-01-17 202-01-17 Driving Axle (continue) DISASSEMBLING AND INSTALLATION 6. Install the front oscillating arm in the steering knuckle. 7. Put down the automobile. arning: The hexagonal socket wrench Is used to prevent the piston rod from rotating. Fix the nuts of the front supporting columns of the suspension.
Page 96 202-01-18 202-01-18 Driving Axle DISASSEMBLING AND INSTALLATION Dust shield of the external constant speed universal joint (including the universal joint) General Tool Retaining ring caliper Name Model High G.A.Cpalex GTE 2. Disassemble the wheel and tyre. See Section performance 201-03 for relevant information. grease Tape Take out the locking pin, and use the socket wrench of...
Page 97 202-01-19 Driving Axle 202-01-19 DISASSEMBLING AND INSTALLATION (Continued) Disassemble the driving axle nut, and take out the locking pin and the washer. 5. Loosen the nips on the dust shield. 使用两爪拉出器从轮毂中压出左边驱动轴。 Slide the dust shield on the driving axle. Installation 1.
Page 98 202-01-20 202-01-20 Driving Axle DISASSEMBLING AND INSTALLATION (Continued) • Material: aluminum plate or steel plate 6．Install wheel hub fixing nuts and washers, and insert the locking pin. Fix the tyre nuts（The torque is 85±10Nm）and the hub faxing nuts （The torque is200±10 Nm）. 5.
Page 99 202-01-21 202-01-21 Driving Axle DISASSEMBLING AND INSTALLATION (Continued) Fix the nuts of the suspension supporting columns. 9．Put down the automobile 10. 1． arning: The hexagonal socket wrench Is used to prevent the piston rod from rotating. BENNI MINI...
Page 100 202-01-22 202-01-22 Driving Axle DISASSEMBLY AND ASSEMBLY DISASSEMBLY AND ASSEMBLY 3. Disassemble the three-ball-pin/ ball-cage and dust shield. The special tool for semi-axle (movable 1. Disassemble the retaining ring. joint): caliper (CA201-002) 2. Uncover the dust shield. 3. unlock three-ball-pin frame, and disassemble the rolling column.
Page 101 202-01-23 Driving Axle 202-01-23 DISASSEMBLY AND ASSEMBLY (continued) Assembly 1. Notes: replace all the retaining ring and nip of the dust shield. Configure a nip for the special tool 14-044. • Material: aluminum plate or steel plate. Warnings: do not damage the bearing seat of the rolling column.
Page 102 202-01-24 Driving Axle 202-01-24 DISASSEMBLY AND ASSEMBLY (continued) 4. Notes: use new retaining ring, and make sure the retaining ring is well installed. 5．Notes: do not damage the installing surface of the dust shield. Fill high performance grease in the constant speed universal joint housing and dust shield.
Page 103 202-01-25 Driving Axle 202-01-25 DISASSEMBLY AND ASSEMBLY (continued) BENNI MINI...
Page 104 202-01-26 Driving Axle 202-01-26 DISASSEMBLY AND ASSEMBLY Semi-axle (fixing joint) General Tool Retaining ring caliper Tape Name Model Take out the driving axle from the universal joint. High Performance Grease Take out the retaining ringfrom the universal joint. Take out the dust shield. 1.
Page 105 202-01-27 Driving Axle 202-01-27 DISASSEMBLY AND ASSEMBLY (continued) 3. Notes: make sure that the ball cage, housing, rolling 2. Install the ball cage and the ball-cage frame in the ball and frame are free from the grease and engine oil. housing.
Page 106 202-01-28 Driving Axle 202-01-28 DISASSEMBLY AND ASSEMBLY (continued) 4. Notes: make sure the retaining ring is well installed. • Nest the dust shield. Install the driving axle in the universal joint. • Use the special tool. Ensure that the special tool •...
Page 107 203-00-1 Steering System-General 203-00-1 Section 203-00: Steering System-General Applicable Vehicle Model: BENNI MINI Contents page Specifications ........................... Specification 203-00-2 Instruction And Operation ............................ 203-00-3 Braking System Diagnosis and Test ........................Braking System 203-00-4 ....................... Inspection and Confirmation 203-00-4 ..........................203-00-4 Road Test .......................
Page 108: Table Of Contents
203-00-2 Braking System-General 203-00-2 Specifications Grease, Oil Fluid, Sealant and Bonding Agent Name Model HZY4 Braking Fluid Specifications of Disc Type Brake Diameter of Brake Disc 12.5 Normal thickness of Brake Disc Disabled thickness of the brake disc Maximum Run-out Amount of Brake Disc (arranged) 0.015 Maximum Thickness Variation Value of Brake Disc Piston Diameter of Brake Caliper...
Page 109 203-00-3 Braking System-General 203-00-3 Instruction and Operation DESCRIPTION AND OPERATION Braking System This braking system adopts the double loops and The controlling rod of the parking braking is positioned diagonal arrangement, the front-disc-rear-drum or the between two front seats, and the rear brake is controlled front-disc-rear-disc braking system.
Page 110 203-00-4 Braking System-General 203-00-4 Diagnosis and Test makes the adhesive forces of the tyre and the road Braking System surface different. The arch road is also not suitable, because the weight of the vehicle body is mostly concentrated on the two lower wheels. Once the route The braking system transmits the force exerted on the is conformed and usually used, the road factor will not brake pedal by the driver to the bake of each wheel.
Page 111 203-00-5 Braking System-General Diagnosis and Test (continued) Contents/results/measures Phenomenon Possible Reasons • The wheel alignment is not correct • Perform the wheel alignment. See 201-00 • The load adjustment of the wheel • Adjust or replace the wheel bearing. bearing is not correct See 203-02.
Page 112 203-00-6 203-0 Braking System-General Diagnosis and Test (continued) Contents/results/measures Phenomenon Possible Reasons • The “aftershock” of the brake disc • Replace the brake disc. See 203-01 (The brake caliper piston is pushed backwards into the brake caliper by the friction plate due to the too large axial run-out of the braking disc or the loosened vehicle wheel bearing) •...
Page 113 203-00-7 Braking System-General Diagnosis and Test (continued) Contents/results/measures Phenomenon Possible Reasons • The pedal return is low or • The brake booster • Turn to the fixed point inspection L. incomplete • The master braking pump Fixed Point Inspection Fixed Point Inspection A: Brake Slip or Deviation Phenomenon Measures A1: Road Test...
Page 114 203-00-8 203-0 Braking System-General Diagnosis and Test (continued) Phenomenon Measures Replace the pressure controlling valve of the right rear wheel. The braking system exhausts. Refer to the Chapter 203-00. Test and operate the system to see if it is in the normal condition. A5: Inspect the Left and Right Pressure Controlling Valve 1Connect the pressure gauge on the right front or left rear air outlet.
Page 115 203-00-9 Braking System-General Diagnosis and Test (continued) Phenomenon Contents/results/measures 　 No Turn to B3 B3: Inspect the brake warning switch or circuit 1 Turn the ignition switch to the ON position. 2 Disassemble the filtering cap or the switch of the fluid can of the master braking pump.
Page 116 203-00-10 203-0 Braking System-General Diagnosis and Test (continued) Phenomenon Contents/results/measures Inspect whether the rear brake drum is over abraded or cracked. Replace the components if necessary. Test and operate the system to see if it is in the normal condition. 　...
Page 117 203-00-11 Braking System-General Diagnosis and Test (continued) Phenomenon Contents/results/measures D4: Inspect the leakage of the braking system １ Inspect the external leakage of the brake and clutch system. Please read “Master Braking Pump Component Test” in this section. • Is the leakage discovered? 　...
Page 118 203-00-12 203-0 Braking System-General Diagnosis and Test (continued) Fixed Point Inspection E: The Pedal is slowly Sunk Phenomenon Contents/results/measures E1: Inspect the running of the brake pedal 1 When the automobile runs, step down the brake pedal and inspect the failure. •...
Page 119 203-00-13 Braking System-General Diagnosis and Test (continued) Phenomena Contents/results/measures • Does the brake pedal feel soft? 　 Yes Turn to F2 　 No The automobile is normal. F2: Check the level of the braking fluid １Check the fluid level of the fluid can of the master braking pump.
Page 120 203-00-14 203-0 Braking System-General Diagnosis and Test (continued) Phenomena Contents/results/measures Replace the wheel hubs retaining nuts of the front wheels, note: the wheel hubs retaining nuts of the front wheels can not be used again. Test and operate the system to see if it is normal. 　...
Page 121 203-00-15 Braking System-General Diagnosis and Test (continued) Phenomena Contents/results/measures 　 Yes Test the brake booster. Turn to the Fixed Point Inspection I. 　 No Replace the right rear pressure control valve. See Section 203-00 for relevant information. Test and operate the system to see if it is normal. G5: Check the left and right pressure controlling valves 1 Connect the pressure gauge on the right front or left rear exhaust holes.
Page 122 203-00-16 203-0 Braking System-General Diagnosis and Test (continued) Phenomena Contents/results/measures Check the changing situation of the thickness of the braking disc. Replace the components if necessary. Test and operate the system to see if it is in the normal condition. F ixed Point Inspection 1: Towing of the Brake 现象...
Page 123 203-00-17 Braking System-General Diagnosis and Test (continued) Phenomena Contents / Results / Measures J2: Check the leakage of the brake booster 1Keep the idle running of the engine, release the acceleration pedal and shut down the engine. Step the brake after 90 seconds, the brake shall work through press twice or more times.
Page 124 203-00-18 203-0 Braking System-General Diagnosis and Test (continued) Contents / Results / Measures Phenomena 　 Yes Turn to J7 　 NO Repair or replace the bushing of the brake pedal. Test and operate whether the system is normal. J7: Check the control valve of the braking pressure 1 Check the pollution of the control valve of the braking pressure.
Page 125 203-00-19 Braking System-General Diagnosis and Test (continued) Phenomenon Contents/Results/Measures L1: Check the return of the brake pedal 1 Ensure the fast idle running of the engine, press the brake for several times. Pull the brake pedal backwards with the force of approximately 44.5 N (10 lbs).
Page 126 制动系统 –概述 203-00-20 203-00-20 诊断和测试 (续) process that the engine rotating speed reduces to Normal Situations the idle speed. The following statuses are normal, which does not indicate the master braking pump needs repairing. Check the status of the brake booster –...
Page 127 203-00-21 Braking System – General 203-00-21 Instructions and Operations (Continued) is adjusted improperly, or the control valve of the Put the transmission in the neutral gear, and hoist the braking pressure is damaged or polluted. automobile. Section 100-01 relevant information. –...
Page 128 206-00-22 Braking System – General 206-00-22 General Procedures GENERAL PROCEDURES Exhausting of the Braking System (12 141 0) 8. Continuously press the brake pedal until the braking not containing air flows into the Exhausting exhausting tank. 9. Press the brake pedal and fasten the exhaust Configure Anti-lock Automobile hole.
Page 129 206-00-23 Braking System – General 206-00-23 General Procedures Pressure Exhausting of the Braking System (12 141 0) Cautions: Please strictly comply with manufacturer’s instruments Exhausting appropriate pressure exhausting Warnings: The braking fluid contains machine is needed for pressurizing and polyglycol ether and polyethylene glycol. exhausting the system.
Page 130 206-00-24 Braking System – General 206-00-24 General Procedures Run-out Measurement of the Brake Disc (12 221 0) 7. Notes: If the run-out amount exceeds the specified value, measure the run-out of the wheel hub surface. Special Tool Fixing Supporting Seat of the Use the appropriate dial gauge to measure the Dial Gauge 205-070 (15-022A) internal and external surfaces of the brake disc.
Page 131 206-00-25 Brake System - General Information 206-00-25 GENERAL PROCEDURES (Continued) 9. Disassemble the brake disc. See Section 203-01for relevant information. 10. 10. Notes: Ensure the wheel hub is clean and without dust and sundries. Use the special tool to measure the run-out of the wheel hub surface.
Page 132 203-01-1 Disc Type Brake of the Front Wheel 203-01-1 Section 203-01 Disc Type Brake of the Front Wheel BENNI MINI Applicable Vehicle Model Contents Pages Specifications .......................... 203-01-2 Specifications Instruction and Operation ..................... 203-01-3 Disc Type Brake of the Front Wheel Diagnosis and Test .....................
Page 133: Specifications
203-01-2 Disc Type Brake of the Front Wheel 203-01-2 Specifications Grease, Oil Fluid, Sealant and Bonding Agent Name Model Braking fluid HZY 4 Specifications of the Disc Brake of the Front Wheel Diameter of the brake disc 12.5 Thickness of the brake disc Disabled thickness of the brake disc...
Page 134 203-01-3 Disc Type Brake of the Front Wheel 203-01-3 Instruction and Operation DESCRIPTION AND OPERATION Disc Type Brake of the Front Wheel Serial Parts NAME Number Number Brake disc Brake caliper Brake disc BENNI MINI...
Page 135 203-01-4 Disc Type Brake of the Front Wheel 203-01-4 Diagnosis and Test DIAGNOSIS AND TESTING Disc Type Brake of the Front Wheel See Section 203-01for relevant information. BENNI MINI...
Page 136 203-01-5 203-01-5 Disc Type Brake of the Front Wheel Disassembly and Installation REMOVAL AND INSTALLATION Brake Disc (12 234 0) 5. Disassemble the brake disc. Special Tool 206-005 (12-014) Piston tractor of the brake distributing pump 206-005 (12-014) Name Model HZY4 Brake fluid Installation...
Page 137 203-01-6 Disc Type Brake of the Front Wheel 203-01-6 Disassembly and Installation (Continued) 2. Install the brake disc. 3. Install the lower bolt of the brake caliper. 4. Install the wheel. Tread the brake pedal twice. • 6. Inspect the level of the braking fluid. BENNI MINI...
Page 138 203-01-7 203-01-6Disc Type Brake of the Front Wheel 203-01-7 Disassembly and Installation Brake Caliper (12 243 0) 4. Remove the brake caliper. General Tool of the barking hose Disassembly Caution: If braking fluid is spattered on the painted surface, immediately use cold water to rinse the region.
Page 139 203-01-8 Disc Type Brake of the Front Wheel 203-01-8 Disassembly and Installation (Continued) Installation 1. Reverse the disassembly sequence for installation. 2. Exhausting of the braking system. See Section 203-00 for relevant information. BENNI MINI...
Page 140 203-01-9 203-01-9 Disc Type Brake of the Front Wheel Disassembly and Installation Brake Disc (12 223 0) Disassembly Caution: hang up the brake caliper, to prevent the braking hose from being 1. 1. Disassemble the brake disc. See the Part of stretched.
Page 141 203-01-10 Disc Type Brake of the Front Wheel 203-01-10 Disassembly and Installation Installation 1. Reverse the disassembly sequence for installation. BENNI MINI...
Page 142 203-01-11 Disc Type Brake of the Front Wheel 203-01-11 Disassembly and Installation DISASSEMBLY AND ASSEMBLY Brake Caliper (12 001 0) 3. Disassemble and throw away the piston oil seal. Name Model Brake fluid HZY4 Disintegration Warning: If braking fluid is spattered on the painted surface, immediately use cold water to rinse the region.
Page 143 203-01-12 Front Disc Brake 203-01-12 Disassembly and Installation 3. Install a new dust-proof oil seal onto the piston of the brake distributing pump. Caution: Do not scratch the piston while assembling the piston into the piston hole. Assemble the piston of the brake distributing pump into the piston hole.
Page 144: Contents Page
203-02-1 Drum Type Brake 203-02-1 Section 203-02 Drum Type Brake Applicable Vehicle Model:BENNI MINI Contents Page Specifications .......................... Specifications 203-02-2 Instruction and Operation ........................203-02-3 Drum Type Brake Diagnosis and Test ........................Drum Type Brake 203-02-4 Disassembly and Installation ...................... (12 275 0) 203-02-05 Brake Drum...
Page 145: Specifications Of Drum Type Brake
203-02-2 Drum Type Brake 203-02-2 Specification Grease, Oil Fluid, Sealant and Bonding Agent Name Name Model HZY 4 Braking Fluid Specifications of Drum Type Brake Diameter of the new brake drum Disabled diameter of the brake drum Width of the brake shoe 17.46 （ABS）...
Page 146 203-02-3 Drum Type Brake 203-02-3 Instruction and Operation DESCRIPTION AND OPERATION Drum Type Brake DUDU DAGNOSIS AND TESTING DESCRIPTION AND OPERATION PARTS NAME Serial Base Plate Brake Distributing Pump Brake Shoe Brake Drum BENNI MINI...
Page 147 203-02-4 Drum Type Brake 203-02-4 Diagnosis and Test DIAGNOSIS AND TESTING Drum Type Brake See Section 203-00 for relevant information. BENNI MINI...
Page 148 203-02-5 Drum Type Brake 203-02-5 Disassembly and Installation REMOVAL AND INSTALLATION Brake Drum (12 275 0) Disassembly 1. Disassemble the decorative plate of the controlling rod of the parking brake See Section 501-05 for relevant information. 2. Dismount the controlling rod of the parking brake and loosen the adjusting nut. 3.
Page 149 203-02-8 203-02-8 Drum Type Brake Disassembly and Installation (continued) 7. Loosen the fixing nuts of the brake drum Disassemble the brake drum. 1. Disassemble the nuts. 2. Disassemble the brake drum. Installation Caution: If the wheel hub fixing nut is screwed, do not loosen it any longer. If the torque adjustment is required, the wheel hub fixing nut must be screwed after being loosened for two circles.
Page 150 203-02-7 203-02-7 Drum Type Brake Disassembly and Installation (continued) Adjust the parking braking dragline. See Section 203-03 for relevant information. Brake shoe (12 285 0) NAME Model Grease SAM1C-9107-A Disassembly 1. Disassemble the brake drum, wheel axle and wheel hub assembly. See Brake Drum in this Section for relevant information.
Page 151 203-02-8 203-02-8 Drum Type Brake Disassembly and Installation (continued) 5. Dismount the brake shoe from the connection supporting frame 6. Dismount the parking braking dragline. 1. Push the trailing shoe backwards. 2. Dismount the dragline from the trailing shoe. Cautions: Do not damage the dust shield of Installation the brake distributing pump.
Page 152 203-02-9 203-02-9 Drum Type Brake Disassembly and Installation (continued) 4. Install the brake shoe to the special bottom supporting pin of the base. 5. Install the spring of the brake shoe. nstallation of the brake drum, the wheel axle and the wheel hub assembly. 7.
Page 153 203-03-1 Parking Brake 203-03-1 Section 203-03 Parking Brake Applicable Vehicle Model: BENNI MINI Contents Page Specifications .......................... Specifications 203-03-2 Instruction and Operation .......................... 203-03-3 Parking Brake Diagnosis and Test .......................... Parking Brake 203-03-4 ....................... Inspection and Confirmation 203-03-4 ......................203-03-4 Failure Inspecting Table Common Procedures ...............
Page 154 203-03-2 Parking Brake 203-03-2 Specifications Torque Specifications Description Adjusting Nut of the Parking Brake Dragline 23±2 Controlling Nut of the Parking Brake Dragline BENNI MINI...
Page 155 203-03-3 Parking Brake 203-03-3 Instruction and Operation DESCRIPTION AND OPERATION Parking Brake NO NAME Parking Braking Rod Assembly Parking Brake Dragline Assembly (Left) Parking Brake Dragline Assembly (Right) BENNI MINI...
Page 156 203-03-4 203-03-4 Parking Brake Diagnosis and Test DIAGNOSIS AND TESTING 驻车制动器 The Parking Brake Inspection and Confirmation Machinery Electric Appliance 1. Confirm the failure described by the customer through the operation of the parking braking system. – The Controlling Rod –...
Page 157 驻车制动器 203-03-5 203-03-5 诊断和测试 (续) Contents/Results/Measures Phenomenon A3: Check the damage of the parking brake dragline. 1 Check the damage and rustiness of the parking brake dragline. • Is the brake dragline intact? 　 Yes Check the reason of loosing of the control rod of the parking brake or components of related braking system.
Page 158 206-05-6 Parking Brake and Actuation 206-05-6 DIAGNOSIS AND TESTING (Continued) Contents/Results/Measures Phenomenon B3: Check the front dragline of the parking brake. 1 At the position of balancer, take off the front dragline of the parking brake from the rear dragline of the parking brake.
Page 159 203-03-7 Parking Brake 203-03-7 Common Procedures GENERAL PROCEDURES The adjustment of the parking brake dragline 4. Step on the brake pedal for six times. 5. Adjust the parking braking dragline. Adjustment 1. Lift the control rod of the parking brake until 1.
Page 160 203-03-8 203-03-8 Parking Brake Disassembly and Installation REMOVAL AND INSTALLATION The control rod of the parking brake Disassembly Installation 1. Disassemble the cover plate of the control rod of the parking brake. 1. The installation procedures are opposite to the disassembly sequence.
Page 161 203-03-9 203-03-9 Parking Brake Disassembly and Installation The parking brake dragline (12 675 0) Disassembly 6. Take off the rear dragline of the parking brake from the vehicle body (both sides) 1. Disassemble the cover plate of the control rod of the parking bake.
Page 162 203-03-10 203-03-10 Parking Brake Disassembly and Installation The warning lamp switch of the parking braking (33 546 0) Disassembly 1. Disassemble the control rod of the parking brake. For relevant information, please see the section of the control rod of the parking brake. 2.
Page 163 203-04-1 Hydraulic braking system operating mechanism 203-04-1 Chapter 203-04 Hydraulic Braking System Operating Mechanism Applicable vehicle model： BENNI MINI Contents Pages Specifications .......................... Specifications 203-04-2 Instruction and Operation ......................203-04-2 Hydraulic braking system Disassembling and Installation ................... (12 343 0) 203-04-错误！...
Page 164 203-04-2 203-0 Hydraulic braking system operating mechanism Specifications lubricating oil, grease, sealing component and binder Items HZY 4 braking fluid Torque Specifications Description Joining of the master braking pump and the oil pipe 16±2 20~30 Fixing nut of the master braking pump 20~30 Fixing nuts of the joining axle of the brake pedal DESCRIPTION AND OPERATION...
Page 165 203-04-3 Hydraulic braking system operating mechanism Disassembling and Installation DIAGNOSIS AND TESTING 拆卸与安装 Master braking pump Disassembling 2. 注意: Notes: this procedure should be performed on both sides to completely discharge all Notes: If braking fluid is carelessly splashed the braking fluid in the fluid storage can.。 onto the painting surface, clean with clean Discharge the braking fluid of the fluid storage water immediately。...
Page 166 203-04-4 203-04-4 Hydraulic braking system operating mechanism （） Disassembling and Installation Continued 4. Disassemble the master braking pump and the Installation brake fluid storage can assembly. Warning: please confirm the pulling rod of 1. Disassemble the fixing nut. the brake booster is placed at the right 2 Take off the master braking pump.
Page 167 203-04-3 Hydraulic braking system operating mechanism Disassembling and Installation Braking fluid storage can (12 341 0) Dissembling Warning: if the braking fluid is carelessly splashed onto the vehicle paint surface, clean it with clean water immediately. Warning: ensure the cover of the oil filler of the fluid storage not to be polluted 1.
Page 168 203-04-5 203-04-5 Hydraulic braking system operating mechanism Disassembling and Installation 长安·奔奔 MINI...
Page 169 203-05-1 203-05-1 Booster Braking System Section 203-05 Booster Braking System Applicable Vehicle Model: benni-mini contents page Specifications Specifications ........................203-05-2 Instruction and Operation .......................... Brake booster 203-05-3 Diagnosis and Test ......................203-05-4 Booster braking system Disassembly and Installation ....................(12 451 0 203-05-5 Brake booster CHANA·BENNI MINI...
Page 170 203-05-2 203-05-2 Booster Braking System specification Torque Specifications Description 20~30 Brake booster fixing bolt 20~30 Fixing bolt of the master braking pump CHANA·BENNI MINI...
Page 171 203-05-3 203-05-3 Booster Braking System Instruction and Operation DESCRIPTION AND OPERATION Brake Booster Name Seri Parts Number Brake Booster CHANA·BENNI MINI...
Page 172 203-05-4 203-05-4 Booster Braking System Diagnosis and test DIAGNOSIS AND TESTING Brake Booster Refer to Section 203-00 CHANA·BENNI MINI...
Page 173 203-05-5 203-05-5 Booster Braking System Disassembly and Installation REMOVAL AND INSTALLATION Brake Booster (12 451 0) Disassembly Warnings: If the braking fluid is splashed on the lacquer finish of the vehicle body carelessly, the braking fluid should be flushed with the clean water. 1.
Page 174 203-06-1 Anti-lock Braking System 203-06-1 Section 203-06 Anti-lock Braking System Applicable Vehicle Models: BENNI MINI Contents Page 1 Anti-lock braking system………………………………………………………………………………… 203-06-2 Specification specification ........................203-06-2 Instruction and Operation Anti-lock brake control ....................... 203-06-3 General ..........................203-06-3 Function ..........................203-06-3 Anti-lock brake control .......................
Page 175 203-06-2 Anti-lock Braking System 203-06-2 Specification 一、 Anti-lock braking system Lubricating oil, lubricating fat, sealing parts and binder Model Name HZY 4 Brake fluid Torque specifications Description Fixing bolts of the hydraulic controlling module 8~10 M10:16±2 Braking oil pipe leading to the hydraulic control module M12:18±2 Front：22~25 Fixing bolts of the wheel speed sensor...
Page 176: Anti-Lock Braking System
203-06-3 Anti-lock Braking System 203-06-3 Instruction and operation DESCRIPTION AND OPERATION Anti-lock Braking Control General .Function seri Parts Description As the closed loop controlling system in the braking number system, ABS aims to prevent the failure of non-serviceable steering and driving performance when the wheel braking is locked.
Page 177 203-06-4 Anti-lock Braking System 203-06-4 Instruction and Operation When the ignition switch is turned on, the ABS control module shall turn on the warning lamp inside the instrument panel. The warning lamp shall not extinguish until the ABS finishes the system Valve Assembly The valve assembly contains four oil filling valves and four oiling discharging valves.
Page 178 203-06-5 Anti-lock Braking System 203-06-5 Instruction and Operation(continued) Anti-lock Braking Control MK70-M Anti-lock Braking System(ABS) Seri Parts NO. Name pump valve ABS control model The MK70 ABS is specially designed for medium- and small-scale vehicles. Compared with the MK20 ABS system, the MK70 ABS greatly decreases the size of electric controlling...
Page 179 203-06-6 Anti-lock Braking System 203-06-6 Instruction and Operation（continued） Wheel Speed Sensor Front Wheel Speed Sensor Rear Wheel Speed Sensor integrated with the driving axle. The gear rings of the rear wheels are fixed on the core shafts of the rear Seri Parts Name...
Page 180: Anti-Lock Brake Control
206-09-7 Anti-lock control 206-09-7 DESCRIPTION AND OPERATION (Continued) sends the signal to the power controlling module (PCM). The failure of the ABS control module can be diagnosed through the data interface (DLC). The hydraulic unit shall be refilled after repair. 嘉年...
Page 181: Diagnosis And Test
203-06-8 Anti-lock Braking System 203-06-8 Diagnosis and Test DIAGNOSIS AND TESTING Anti-lock braking control Refer to the relevant wiring diagram in Section 203-06A for relevant structure and connection. Inspection and Confirmation Confirm the problems described by customers. 2. Visually measure the obvious mechanical or electric failure.
Page 182: Disassembly And Installation
203-06-9 Anti-lock Braking System 203-06-9 Disassemble and Installation 拆卸与安装 Hydraulic Control Mechanism (HCU) 3. Notes: thoroughly discharging the braking fluid in the fluid storage can is extremely necessary for the operation at both sides. Model Name Discharge the braking fluid in the fluid storage Brake fluid HZY4 can.
Page 183 206-09-10 Anti-lock Braking System 206-09-10 Disassemble and installation (continued) Remove the fixing bolts at the lower part of the hydraulic control module. Warning: cover the braking oil pipe to prevent the braking fluid from flowing out or the dirt from entering. Note: please mark down the position of the braking oil pipe for installation.
Page 184 203-06-11 Anti-lock Braking System 203-06-11 Disassemble and installation (continued) Gear ring of the Rear Wheel Speed sensor (12 788 0) Common Devices Oil Hydraulic Press Disassembly 1. Remove the brake drum. Refer to Section 203-02. 2. Remove and abandon the gear ring of the rear wheel speed sensor Installation Warning: make sure that the gear ring will...
Page 185: Proportioning Valve
203-06-12 Anti-lock Braking Control 203-06-12 Malfunction Inspection 一、Proportioning Valve Lubricating Oil, Lubricating Grease, Sealing Parts 3 、 Remove the installing bolts of the and Binder proportioning valve. Model Name HZY 4 Brake fluid Torque Specifications TorqueN.m Description 20±2 Installing Bolts of the Proportioning Valve 16±2 16±2...
Page 186 206-09-13 Anti-lock Braking Control 206-09-13 Disassembly and installation(Continued) CHANA·BENNI MINI...
Page 187 203-06-14 Anti-lock Braking Control 203-06-14 Malfunction Inspection Malfunction Inspection and Malfunction Diagnose A、 Malfunction Inspection The malfunction inspection methods just as the same with the air bag inspection section 405-00 b、Malfunction diagnose Through the diagnotic instrument, the current malfunction record and the history malfunction record of the ABS can be output directly.
Page 188 206-09-15 Anti-lock Braking Control 206-09-15 Disassembly and installation(Continued) CHANA·BENNI MINI...
Page 189 204-00-1 204-00-1 Steering System-General Section 204-00: Steering System-General Applicable Vehicle Model: BENNI MINI Contents Page Specification specification .......................... 204-00-2 Instruction and operation steering system ........................204-00-3 steering column ........................204-00-3 ........................Steering Mechanism 204-00-3 Diagnosis and Test .......................... 204-00-4 Steering System .......................
Page 190: Specifications
204-00-2 204-00-2 Steering System-General Specification General Parameters Specifications 10.0 Minimum turning diameter column electronic power assistant steering 200W、35A、12V(DC) CHANA·BENNI MINI...
Page 191: Instruction And Operation
204-00-3 204-00-3 Steering System-General Instruction and operation DESCRIPTION AND OPERATION Steering System Steering Column The steering column is equipped with a multi-direction steering wheel lock (or anti-theft lock) accepted the strict test, and the steering wheel lock is equipped with the lock core of the insurance degree.
Page 192: Diagnosis And Test
204-00-4 204-00-4 Steering System-General Diagnose and test DIAGNOSIS AND TESTING Steering System Failure Phenomenon Table Working Principles Check and Confirmation The rotating motion of the steering wheel is transmitted to the steering mechanism through the steering column. 1. Check the problems of the customer The steering mechanism can convert the rotating 2.
Page 193 204-00-5 204-00-5 Steering System-General Diagnose and test（continued） malfunction phenomenon Possible Reasons Measures •steering mechanism fixed bolt •check it and replace the fixed bolt loose if necessary, refer to the204-02 •steering column fixed bolt loose • replace a new fixed bolt if necessary •...
Page 194: Element Test
204-00-6 204-00-6 Steering System-General Diagnose and test Element Test Steering Linkage Device Check whether the dust shield of the steering mechanism is damaged, corroded or warped. The dust shield shall be ensured to be safe and reliable, and if necessary, replace the dust shield or the nip. 1.
Page 195: Specifications
Electric Power Assistant Steering Column 204-01- 204-01- Chapter 204-01 Electric Power Assistant Steering Column Applicable vehicle model: BENNI MINI content page specifications specifications ........................204-01-4 Instruction and operation Electric Power Assistant Steering Column ..........204-01-3 disassembly and installation Electric Power Assistant Steering Column ................
Page 196 Electric Power Assistant Steering Column 204-01-2 204-01-2 Regulation Torque Specifications Description lb-ft lb-in 25-40 Fixing nut of the steering wheel 24±3 Fixing bolts of the steering column 20-30 Clamping bolt between the steering universal joint and he steering column DESCRIPTION AND OPERATION Basic technical parameters description parameters...
Page 197: Instruction And Operation
Electric Power Assistant Steering Column 204-01-3 204-01-3 Instruction and Operation Electric Power Assistant Steering Column Steering motor Up steering shaft Connection joint Down steering shaft Controller BENNI·MINI...
Page 198: Disassembly And Installation
Electric Power Assistant Steering Column 204-04-4 204-04-4 Disassembly and installation REMOVAL AND INSTALLATI 1.Notice before the disassembly 1. Do not fall off during carrying. (If the component falls off, the component shall be abandoned) 2. Check whether the injection mold is loosened. 3.
Page 199: Controller Instruction And Inspection
Electric Power Assistant Steering Column 204-01-5 204-01-5 Controller instruction and inspection 1. Controller Maintenance Attention Issues 1. Remove the controller harness and make sure the controller in a open status, please shut down the vehicle Controller installation bolts and the power when removing the connector 2.
Page 200 Electric Power Assistant Steering Column 204-01-6 204-01-6 Controller instruction and inspection 1、 Circuit Figure *1 right rudder vehicle *2 left rudder vehicle 1 EPS controller 2 diagnosis connector 3 torque sensor 4 shield harness 5 noise reducer 6 speed odometer 7 battery 8 ignition switch 9 motor assy...

Changan BENNI MINI 2011 Service Manual

Specifications

Section 203-06 Anti-Lock Braking System

Quick Links

Chapters

Need help?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Changan BENNI MINI 2011

Summary of Contents for Changan BENNI MINI 2011

Table of Contents