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JAC HFC1130KR1 2008 Workshop Manual

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WORKSHOP MANUAL
HFC1130KR1-G1560
JAC International
2008.05

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Summary of Contents for JAC HFC1130KR1 2008

  • Page 1 WORKSHOP MANUAL HFC1130KR1-G1560 JAC International 2008.05...
  • Page 2 This shop manual was prepared for 4 x 2 Truck. Configurations as follows: Suspension HFC1130KR1-G1610，CA4DF3， LC6T138 ，JAC G1610 rear axle(5.125). Brake Please inform Customer Service Department of JAC International if there is any mistake, and Body you will be highly appreciated. Tel：0086-0551-2296344 Fax：0086-0551-2296454 Email：hwfw@jac.com.cn...
  • Page 3 CA6DF3-18E3 排量(cc)Displacement 6740 发动机 最大输出功率（Hp/rpm）Max output Engine power 180/2300 680/1400 680/1400 变速箱 Transmission CA6T138-85 驱动桥 Real axle 型号 Model JAC(5.125) 外形尺寸（mm）Overall dimension 8980*2390*3105 主参数 Main parameter 轴距（mm）Wheelbase 5300 轮距（mm）Tread 2040/1860 总质量（Kg）Mess weight 19400 车架断面尺寸 Frame section sizes(mm) 265*75*8 轮胎 Tire 9.00-20...

  • Page 4: Main Specifications

    Main Specifications Code：25---represents the maximum gross weight is 25 tons. Product serial No.： 1---Product development serial No.（1 change，2 development） Code from company：K---Diesel R1---King cabin For example： HFC3251KR1 represents JAC vehicle with king cab, 25 tons maximum gross weight, the first change.
  • Page 5 General GE-3 1.3 VIN----Vehicle Identification Number VIN comprises of 17 digits. They separately represent: 黑色 中国安徽江淮汽车股份有限公司 制造 V Ⅰ N L J 1 1 K D F A 4 4 0 0 0 2 5 2 1 型 号 品 牌 ： 江 淮 额定功率...

  • Page 6: Standard Bolts And Nuts

    General GE-4 1.4 Tightening Torques of Bolts and Nuts for Hyundai Unless otherwise specified, the parts and equipment of vehicle must be tightened by the following standard bolts nuts. Tightening torques for these bolts and nuts are shown below. Note: Threads and seat surface must be in dry state.

  • Page 7: Table Of Contents

    Engine ENG-1 CA6DF3-18E3 ENGINE CONTENTS Appearance of CA4DF diesel engines Appearance of CA6DF diesel engines 1. Main specification & data for diesel engine… … … … … … … … … … … … … … … … … … ..(1) 1.1 Main technical specifications…...

  • Page 8: Appearance Of Ca4Df Diesel Engines Appearance Of Ca6Df Diesel Engines 1. Main Specification & Data For Diesel Engine

    Engine ENG-2 4.8 Cautions on operating in winter… … … … … … … … … … … … … … … … … … … … .(37) 5. Maintenance requirements of diesel engine… … … … … … … … … … … … … … … … … .(38) 5.1 Run-in of new diesel engine and technical maintenance…...
  • Page 9 Engine ENG-3 1.1 Main technical specifications 1.1.1 Main technical specifications for CA4DF2 diesel engine Model 4DF2-13 4DF2-14 4DF2-16 4DF2-17 Type In-line, 4stroke, water-cooled, direct injection combustion chamber Aspiration Exhaust-turbocharged、Air-air cooled Compression ratio 16.8: 1 Number of cylinders Cylinder bore (mm) Piston stroke (mm) Total displacement (L)

  • Page 10: Data For Adjustment And Operation

    Engine ENG-4 Rated power/ Rated speed (kW/r/min) 177/2300 192/2300 206/2300 Max. torque/Speed Max. torque (N· m/r/min) 890/1400 930/1400 960/1400 Crankshaft rotation direction (Viewing toward flywheel) Counter-clockwise Firing order 1-5-3-6-2-4(first cylinder near the fan) Lubrication method Forced splash Start mode Electric start Min.
  • Page 11 Engine ENG-5 1.2 Data for adjustment and operation Model 4DF2 6DF1 6DF2 Item Intake valve 0.30 Cold valve clearance (mm) Exhaust valve 0.35 Fuel supply advance angle (crankshaft 9±1 rotation angle (℃A) Deflection of fan belt (mm) 10～15(under a force of 39.2 applied) Outlet temperature of coolant (℃) ≤95...

  • Page 12: Tightening Torque Of Threaded Fasteners For Diesel Engine

    Engine ENG-6 5 Piston pin and connecting rod small end bush Clearance 0.12 φ42 0.027～0.057 6 Piston pin and piston pin seat hole Clearance 0.002～0.015 0.04 φ42 7 Piston skirt and cylinder liner Clearance 0.15～0.175 0.35 φ110 8 Piston ring end clearance compression ring Clearance 0.35～0.55...
  • Page 13 Engine ENG-7 φ64.5 Fifth rank Seventh rank Camshaft bush and camshaft journal Clearance φ60 0.08～0.16 0.25 Axial Camshaft and thrust washer 0.08～0.218 0.35 clearance Intermediate timing gear (1) and bush Interference 0.03～0.076 φ52 Intermediate timing gear (2) bush and gear shaft Clearance 0.04～0.10 φ48...

  • Page 14: Adjusting Parameters For Injection Pump

    Engine ENG-8 GB6170-1986 Air compressor gear fixing nut (M18) 147± 15 Spread oil 1006023/CK Timing gear fixing bolt-camshaft (M20×1.5) 200± 15 Spread oil Hexagon-headed bolt M10 (fixing cylinder head) Q150B1030 33±6 Hexagon-headed bolt M10 (fixing water pump belt wheel) All specifications of hexagon-headed bolt M8 (fixing intake 19±...
  • Page 15 Engine ENG-9 Clutch (≤φ350) Clutch (≤φ430) Specifications of bolts Note (N·m) (N·m) 28± 2 Tighten bolt on the cross when fix clutch 54± 9 70± 8 assy. 80± 9 3) Tightening torque of other threaded fasteners should be performed according to next table Grade 8.9(general plain steel) 10.9(hardened and tempered steel)
  • Page 16 Engine ENG-10 Table 1.5-1 Adjusting parameter for fuel injection pump matching with CA4DF2 diesel engine Model 4DF2-14 4DF2-16 4DF2-17 Injection Non- Injection Non- Injection Non- Operation Speed Speed Speed volume uniformity pressure volume uniformity pressure volume uniformity pressure condition (r/min) (r/min) (r/min) (ml/200times)
  • Page 17 Engine ENG-11 Table 1.5-2 Adjusting parameter for fuel injection pump matching with CA6F1 diesel engine Model 6DF1-24 6DF1-26 6DF1-28 Injection Non- Injection Non- Injection Non- Operation Speed Speed Speed volume uniformity pressure volume uniformity pressure volume uniformity pressure condition (r/min) (r/min) (r/min) (ml/200times)

  • Page 18: Technical Methods For Meeting The Emission Standard And Cautions On Operation

    Engine ENG-12 Table 1.5-4 Adjusting parameter for fuel injection pump matching with CA4DF2-13 diesel engine Operation condition 4DF2-13 Injection volume Rated Speed (r/min) Non-uniformity (％) Air pressure (Mpa) (ml/200times) Calibrated 1250 27.5± 0.9 ±5 Low speed 24± 0.8 ±3 Starting 20±...

  • Page 19: Cautions On Operation Of Engines

    Engine ENG-13 ③ Optimizing turbocharger In order to achieve the optimal capability matching, through optimizing and matching for different kinds of diesel engine, the high efficiency turbochargers with intake and exhaust valve are adopted. This ensures the emission standard, the light smoke and high/low speed capability. Different kinds of turbochargers are used for different kinds of diesel engines.
  • Page 20 Engine ENG-14 ③ Because the emission standard could be met by the combination of the technical methods introduced in 2.1. The parts such as fuel injection pump, turbocharger, and fuel injector must be chosen the same model type and producer as the original diesel engines used. Pay attention to types on the nameplates of these three parts (these are steel seal number on the shell of fuel injector).

  • Page 21: Constructions Of Diesel Engine

    Engine ENG-15 Chapter 3 Construction of diesel engine 3.1 Suspension system and peripheral accessories setting The appearance of CA4DF and CA6DF are included in the pictures at the pre-pages of the text. 3.1 CA4DF Diesel Engine 4-point elastic suspension is adopted for CA4DF series diesel engines. The front suspension cushions are installed on both sides of cylinder block front end, and the rear ones on both sides of the flywheel housing.

  • Page 22: Lubricating System

    Engine ENG-16 3.2 Lubricating system Lubricating system consists of oil sump, oil collector, oil pump, centrifugal oil fine filter (only for CA6DF), oil cooler, piston cooling nozzle, oil gallery regulating valve and oil channels, etc. The combination of forced lubrication and splash lubrication is adopted. Oil pump is located under the last main bearing of engine block, and it is driven by the gears of crankshaft.
  • Page 23 Engine ENG-17 The T-joint located in oil outlet pipe separately supplies oil to paper oil coarse filter and centrifugal fine filter. The oil passing through oil filter enters oil cooler first, then the oil gallery, main bearing and crankpin bearing. Through the oil gallery on the back baffle of cylinder block oil enters oil duct on 5 bearing (7 of CA6DF) of camshaft and the central oil duct in camshaft to...
  • Page 24 Engine ENG-18 图 3-2 离心式机油滤清器 1-进油限压阀； 2-底座； 3-转子罩； 4-转子； 5-转子轴； 6-橡胶密封权（2 处） Fig. 3-2 centrifugal oil filter 1.inlet pressure limiting valve 2.seat 3.cover of rotor 4.rotor 5.rotor shaft 6.o-ring (two) Oil filter is spin-oil filter (Fig.3-3). A filter restriction indicator is mounted on the seat of oil filter.

  • Page 25: Cooling System

    Engine ENG-19 4DF 机型用 6DF 机型用 图 3-3 机油滤清器 1-旋装滤芯 2-橡胶密封圈 3-滤座 4-堵塞报警器 Fig 3-3 oil filter For 4DF For 6DF 1.spin-on stage 2.rubber ring 3.seat 4.restriction alarm 3.3 cooling system Cooling system consists of water pump, thermostat, fan, water drain trap, water outlet pipe (thermostat house for 4DF), and water tank radiator in the car, etc.
  • Page 26 Engine ENG-20 You should choose thermostat with different opening temperature by different conditions (see the following table), the first two thermostat is fit for plain areas, while the last one is fit for altiplano with altitude over 3000m. Picture number of thermostat K-1306010 136020/CK-1 1306010G_K...

  • Page 27: Fuel System

    Engine ENG-21 图 3-5 水泵风扇总成 Fig 3-5 water pump fan assy. The diameter and blade numbers should be confirmed by engineis power and overall design requirement of different car cooling system. Since the cooling fan of automotive engine is of suction type, it should be fitted in the right direction.
  • Page 28 Engine ENG-22 Small amount of fuel leaking from injector and over fuel in the low pressure chamber of injection pump return through fuel return line to fuel tank (see fig 3-6). 图 3-6 燃油供给系统示意图 1-燃油箱 2-柴油粗滤器 3-喷油泵 4-低压油管 5-柴油滤清器 6-高压油管 7-喷油器...
  • Page 29 Engine ENG-23 图 3-7 P 型喷油器结构图 1-缝隙滤清器 2-喷油器体 3-调压垫片 4-调压弹簧 5-弹簧座 6-定位销 7-隔板部件 8-油嘴部件 9-油嘴紧帽 10-密封铜垫片 Fig 3-7 P-shaped injection structure 1-gap filter 2-injector body 3-pressure regulating gasket 4-pressure regulating spring 5-spring seat 6-oriernting pin 7-separator component 8-oil nozzle tighten cap 10-copper sealing ring 3.4.2 Injector To ensure the capability of the diesel engine, and achieve the exhausting standard, P shaped...
  • Page 30 Engine ENG-24 3.4.3 Fuel transfer pump Plunger type fuel transfer pump is mounted on side of injection pump (see fig 3-8), sucking fuel from fuel tank to supply fuel for injection pump. You can press the pump oil handle to let out the atmosphere in the fuel system for the new engine.

  • Page 31: Intake And Exhaust System

    Engine ENG-25 图 3-9 旋装式柴油滤清器 1-进油管接头螺钉 2-底座 3-旋装滤芯 4-放气螺塞 5-橡胶密封圈 6-出油管接螺钉 Fig 3-9 spin-on fuel filter 1-inlet oil pipe jointing bolt 2-seat 3-spin-on stage 4-air-exhaust screw plug 5-rubber ring 6-outlet oil pipe joint bolt 3.5 intake and exhaust system Intake and exhaust system consists of air filter, intake connection pipe, air heater or flame pre-heater, strainer, intake pipe, exhaust pipe, gasket, etc.

  • Page 32: Electrical System

    Engine ENG-26 图 3-10 涡轮增压器 1-涡轮壳 2-涡轮部件 3-涡轮密封环 4-浮动轴承 5-中间壳 6-止推轴承 7 压气机壳 8-压气机密封环 9-压气机叶轮 10-排气放气阀 Fig 3-10 turbine turbocharger 1-turbine shell 2-turbine component 3-turbine sealing ring 4-floating bearing 5-intermediate casing 6-thrust bearing 7-compressor casing 8-compressor sealing ring 9-impeller of compressor 10-exhaust valve The air-air iner-cooler which is located on front end of water tank radiator uses fan and wind produced by head-on vehicles to cool the inlet air and this can increase engine power and improve...
  • Page 33 Engine ENG-27 图 3-11 4DF、6DF 发电机电气原理图 Fig3-11 4DF & 6DF engine wiring diagram Water temperature sensor is worked together with the water temperature gauge, to show the cooling water temperature from outlet pipes. Oil pressure alarm is located in oil gallery of the engine: it works with alarm, when the pressure in oil gallery drops below 80kpa, the alarm lamp will light.
  • Page 34 Engine ENG-28 Before the engine start, insert the key and turn it to position 1, then the accumulator supply power for the controller. If the cooling water temperature is 0℃, then temperature sensor sends this signal to the controller, and the controller supply electricity for the flame plug with ratio of 100%. The flame plug is heated and the indicator lights up.
  • Page 35 Engine ENG-29 图 3-13 火焰预热器接线图 K1-点火开关NO 档 K2-点火开关ST档 P-预热塞 DL-预热指示灯 D-供油电磁阀 D+ -接发电机 D+端 K-预热继电器 Rt-预热用温度传感器 Fig3-13 flame pre-heater wiring picture K1-ignition switch NO position K2-ignition switch ST position P-preheat plug DL-preheat indicator D-electromagnetic valve D+-motor D+ port K-preheat relay RT-temperature sensor for preheating At the same time, the controller will start timing, if the driver don’...
  • Page 36 Engine ENG-30 damaged. If the rotate speed is too low, you should stop starting operation immediately, check if oil is too dense, and voltage of accumulator is natural, if still not ok, dismantle starter and check its rotate speed and joggle journey. 3.

  • Page 37: Cautions On Operation Diesel Engines

    Engine ENG-31 Chapter 4 Cautions on Operation of Diesel Engine 4.1 Choice of diesel oil Select the oil type for diesel engine according to ambient temperature of the atmosphere. In cold winter, diesel oil with low condensation point should be used, vice versa in summer. Users can choose the oil type recommended in table 4-1.

  • Page 38: Choice Of Cooling Water

    Engine ENG-32 Table 4-2 Type in grade L-ECF Ambient temperature -25～ -20～ -10～ -10～ -10～ -10～ -20～-5 5～30 >25 (℃) Lubricating oil must be kept clean, away from dirt and impurities. After filling, the level of lubricating oil in the oil sump should be checked in the following way: draw out the oil dipstick, wipe it with gauze and again insert it into the oil.

  • Page 39: Preparations Before Starting

    Engine ENG-33 When the ambient temperature is below 0℃, in case that the machine would be frozen, antifreeze fluid should be added to the cooling water. Generally the antifreeze fluid has three types: alcohol-water type, glycerin-water type, and glycol-water type. Different ratios of these chemical materials to water will lead to different freezing points.
  • Page 40 Engine ENG-34 repeatedly until there is no bubble in the fuel released from the outlet screw. Then screw it again while keeping pressing the handle. Finally, screw the handle (see fig4-2) Loosen the deaerating screw, press and pull the handle until no air bubbles escape from the diesel oil flowing off from the deaerating screw.

  • Page 41: Procedures Of Starting

    Engine ENG-35 Loose4n the hexagon-headed plug until no bubble escape from cooling water, then tighten the plug 图 4-3 排除冷却系统中空气 Fig 4-3 Deaerate cooling system 4.4.4 Inject lubricating oil to the turbocharger Before a new engine or the engine that has been shut down for a long period of time is started, firstly the oil inlet pipe of turbocharger should be removed, then inject clean lubricating oil to the oil inlet and the filter of turbocharger so as to ensure that the bearings of turbocharger be lubricated as early as the engine is started.

  • Page 42: Cautions On Running

    Engine ENG-36 After a newly assembled engine or the one changed lubricating oil is started, the lubricating oil level in the oil sump should be checked. If necessary, oil should be added or drained so as to keep the oil level between the upper and lower marks. Remove oil inlet pipe of turbocharger, fill lubricating oil into the inlet and filter of turbocharger respectively 图...

  • Page 43: Cautions On Stopping

    Engine ENG-37 The oil pressure at high or medium speed should be within 245~490kPa while the cooling water outlet temperature should be within 75~95℃. Check frequently after starting or before stopping whether there are any abnormal noises or faults. Stop immediately if abnormality should occur, and restart after the fault has been remedied. Pay frequent attention to the tightness of water pipes, oil pipes, gas pipes, etc.

  • Page 44: Cautions On Operating In Winter

    Engine ENG-38 4.8 Cautions on operation in winter The engine must be taken into special maintenance when the environment is lower than 5℃. Lubricating oil and diesel oil special for winter must be used (see table 4-1,4-2), and the diesel oil must not be contaminated with water in case the oil pipes may be blocked.

  • Page 45: Maintenance Requirements Of Diesel Engine

    Engine ENG-39 Chapter 5 Maintenance requirements of diesel engine Maintenance, which exerts a decisive influence on the nicer performance and the service life of the engine, is a necessity for a long-term reliability and economy of the engine. Therefore, users should strictly abide by the following regulations for maintenance.
  • Page 46 Engine ENG-40 Table 5-2 Items Of Technical Maintenance Interval Items of maintenance 1 Check oil level in the oil sump and amount of cooling water in the water tank 2 Check tightness of the connections of water-, oil- and gas ways Daily maintenance 3 Clean the engine 4 Remedy faults and abnormalities found...

  • Page 47: Working Requirements Of Maintenance

    Engine ENG-41 5.2 Working requirements of maintenance 5.2.1 check the oil level in the oil sump Oil level should be checked with the engine shut down and kept horizontal. Draw out the oil dipstick, wipe it with clean cloth and insert it to the limit position. Draw it out again and he normal oil level should be between the upper and lower marks.
  • Page 48 Engine ENG-42 element from inner side with clean compressed air not higher than 600kPa. At the same time, check the safety filter element (the small one in the primary filter element), and maintain it similarly if it has dust. Generally, the primary filter element should be replaced after six maintenances. The safety filter element needn’...
  • Page 49 Engine ENG-43 It must be emphasized here that no matter the air filter of whatever type, the assembly of rubber seal washer and rubber pipes is of great importance for the filter element, otherwise, unfiltered dust may enter into the cylinder directly. Because the component of dust is SiO , its hardness is two times of cylinder liner, entry of dust into the cylinder may lead to abnormal wear of cylinder liner and piston ring.
  • Page 50 Engine ENG-44 5.2.3 check the tension of the belt Tension of the fan belt should be checked frequently. Excessive tension may cause early damage of water pump bearing and generator bearing, while inadequate tension may cause slipping and heating of the belt and therefore shorten the belt life. Check according to Fig.
  • Page 51 Engine ENG-45 crankshaft travel of 180∞ is achieved; model 6DF according to the firing order 1-5-3-6-2-4 each time a crankshaft travel of 120∞ is achieved. The valve clearance should be adjusted according to data in 1.2 (see Fig 5-5). After all the cylinders have been adjusted, check by observation or touch by hand in idling running whether there is any mistakes in adjustment.
  • Page 52 Engine ENG-46 (a) 供油前出油阀接头中油面 (b) 开始供油时出油阀接头中油面波动 图 5-6 检查喷油泵供油提前角 Fig. 5-6 Check fuel supply advance angle of the injection pump (a) Fuel level in the delivery vale fitting, before fuel supply (b) Fluctuation of fuel level in the delivery valve fitting, at the beginning of fuel supply 1.
  • Page 53 Engine ENG-47 图 5-7 检查喷油器喷雾质量 Poor spray Good spray Fig 5-7 Check the spray quality of injector In case of a poor spray quality of the injector, needle valve elements can be dismantled and cleaned and adjusted to the standard pressure value. While checking the injector, pay attention not to confuse injectors from different cylinders, so as to ensure that the intrusion of the injector tip from the cylinder head bottom plane is within a permissible range.
  • Page 54 Engine ENG-48 Before stopping, the engine should keep idle running for 3-5 minutes, so that the turbocharger can slow down and cool off and its sound may be monitored. If any abnormality is found, stop and check the engine immediately. If the turbocharger rotor is not free in rotating, with sound of sticking or friction, repairs should be done in well-equipped service station.

  • Page 55: Cautions On Starting A New Or Overhauled Engine

    Engine ENG-49 图 5-8 喷油泵手柄及限位螺钉 1-停油手柄 2-增压补偿器管接螺钉 3-油门手柄 4-高速限位螺钉 5-怠速限位螺钉 Fig 5-8 Limiting screw and injection pump throttle handle 1-stop oil handle 2-the screw of pipe connections of turbocharged compensator 3-injection pump throttle handle 4-high speed throttle limiting screw 5-idling throttle limiting screw The RQV-K actiyator is adopted for P7100 pump of 4DF &...

  • Page 56: Cautions On Assembly Of Diesel Engine

    Engine ENG-50 Chapter 6 Cautions on assembly of diesel engine The machine should be assembled correctly according to the technical regulations of this manual if we want credible operation of the diesel engine. So the user must pay more attention to the content of this chapter when disassembling and assembling the machine.

  • Page 57: Assembly Of Crankshaft

    Engine ENG-51 (3) After pressing cylinder liner, check whether the top surface of cylinder liner’ s should is 0.045-0.105mm higher than the top surface of cylinder block. The difference between the height of two neighboring cylinder liners above the top surface of cylinder block should not exceed 0.03mm. 6.3 Assembly of crankshaft (1) Fit the main bearing shells into the main bearing recess on cylinder block (the guide lugs on shell should be inserted into the recess on main bearing recess).

  • Page 58: Assembly Of Piston-Connecting Rod Assy

    Engine ENG-52 Each block protruding flat towards fan end Marks of block order Machine body of 4DF engine Each block protruding flat towards fan end Marks of block order Machine body of 6DF engine Fig 6-1 step figure of tightening main bearing cap bolts 6.4 Assembly of piston-Connecting rod assy.
  • Page 59 Engine ENG-53 图 6-2 活塞连杆的装配 Partnership and marks of cylinder order Assembly sign toward fan end Weight mark A direction Positioning face This face leaning against rod body Weight classification mark Piston pinhole classification mark Skirt classification mark Assembly sigh toward fan end Fig.

  • Page 60: Assembly Of Camshaft

    Engine ENG-54 图 6-3 活塞环的装配 Top sign upwards Inside gap downwards Second mouth of air ring Mouth of oil-ring bush spring First mouth of air ring Mouth of oil-ring Fig. 6-3 assembly of piston ring The shape of the upper head of connecting rod bolt is unsymmetrical. When being fitted, the location of the head relative to body of connecting rod should be in accordance with Fig.

  • Page 61: Assembly Of Gear Train

    Engine ENG-55 图 6-4 凸轮轴的装配 1-紧固螺栓 2-锁紧垫圈 3-延时齿轮 4-正推片 5-半圆键 6-凸轮轴 Fig. 6-4 assembly of camshaft 1-Force bolt 2-fix washer 3-delaying gear 4-thrust plate 5-half circular key 6-camshaft 6.6 Assembly of gear train Following the assembly of crankshaft and camshaft, assemble timing gears in order. Pay attention to the meshing signs on the end faces of gears.
  • Page 62 Engine ENG-56 Sign 1, the upper constringent stop point of a cylinder, should be aimed at the inspecting pointer of flywheel shell 图6-5 齿轮系的装配 1-曲轴主动齿轮 2-机油泵传动齿轮 3-曲轴机油泵齿轮 4-正时中间齿轮(一) 5-正是中间齿轮(二) 6-喷油泵齿轮 7-转向泵齿轮 8-凸轮轴齿轮 9-正时中间齿轮(三) 10-空压泵齿轮 11 空压泵中间齿轮 Fig. 6-5 assembly of gear train 1-Dynamic gear of crankshaft 2-oil pump transmitting gear 3-crankshaft oil pump gear...

  • Page 63: Assembly Of Flywheel

    Engine ENG-57 After aligning the pins on both cylinder head and cylinder block, tighten all cylinder head bolts sequentially from the center to both ends. In no way omit any bolts. (see Fig. 6-5). The metal gasket used in type of 6DF can be disassembled and reused again and again as long as no damage on it. (7) Adjust intake valve and exhaust valve clearances to the specified values after assembling valve pushing bar and pushing arm discreteness.

  • Page 64: Assembly Of Peripheral Accessory And Adjustment Of Whole Machine

    Engine ENG-58 The fix bolt of damper (or front pulley) should be tightened by required torque of this manual. 6.10 assembly of peripheral accessory and adjustment of whole machine Main peripheral accessories of diesel engine include fuel injection pump, fuel injection pump drive axis, exhaust water tube, water pump, intake and exhaust manifold, turbocharger, lubricating oil filter, diesel oil filter, air compressing pump, generator, starter, fan and all kinds of pipes.

  • Page 65: Trouble And Remedies

    Engine ENG-59 Chapter 7 Trouble and remedies Trouble of diesel is inevitable in using, it can bring about serious accident if we can’ t find out and eliminate it in time. In this part, the causes and remedies of the common faults are described as follows for reference.

  • Page 66: Failure Of The Engine To Develop Full Power

    Engine ENG-60 7.2 Failure of the engine to develop full power Causes Remedies Air filter blocked, insufficient air intake Clean or replace air filter element Clogging in fuel pipe or fuel filter, insufficient fuel Clean fuel line or replace fuel filter element injection Incorrect advance angle of fuel supply Readjust...

  • Page 67: Overspending Of The Engine

    Engine ENG-61 7.4 Overspending Of the engine Causes Remedies Governor invalid Check governor Governor spring broken Change the broken spring Check and repair injection pump Note: in this case, the engine must be shut down at once, Control rack and ring gear stick cut off fuel supply, stop the air inlet.

  • Page 68: Unstable Running

    Engine ENG-62 Knocking sound in idling operation camshaft to ensure the correct clearance Damage of water pump shaft resulting in Change shaft or assemblies of water pump or alternator continuous noise. Friction between turbine scroll and impeller of Check and replace turbocharger 7.6 Unstable Running Causes...

  • Page 69: Overheating Of The Engine

    Engine ENG-63 7.8 Overheating of the engine Causes Remedies Overload, hot weather Reduce the excessive load Too high oil Inefficient of by-pass valve due to Clean or replace oil cooler; check by-pass valve; clean temperature clogging of oil cooler core and oil oil channel gallery Dirty radiator element...

  • Page 70: Mixing Of Oil And Water

    Engine ENG-64 Incorrect oil and viscosity of oil is too low Use the correct oil Clogging in oil filter or oil cooler Clean or replace oil filter element or oil cooler Clogging in oil collector Clean Piston cooling injector damaged Check and replace 7.11 Mixing of oil and water Causes...

  • Page 71: Injector Faults

    Engine ENG-65 Rotation of starter inefficient Bushing of bearing worn Replace the new bushes Poor contact of bush Clean the contact surface of inverter Clean the contact surface of inverter, and polish it with Inverter dirty abrasive cloth Loose terminal connection Re-weld Slipping of frictional clutch Adjust the frictional torque of clutch...

  • Page 72: Failure Of Governor

    Engine ENG-66 7.16 Failure Of Governor Causes Remedies Idling unstable or too high Control arm not been put to the end Check and adjust Ring gear and regulating rack stick Check and adjust Hunting Permanent deformation of governing spring Replace spring Distance of weights flying out different from that of Check and adjust retracting back...

  • Page 73: Failure Of The Fire Pre-Heating Device

    Engine ENG-67 7.19 Increase Of Oil Consumption Causes Remedies Check leaks outside of engine, crankshaft oil seal, and Serious external leakage of oil replace the broken parts Clogging in air filter Clean or replace air filter element Block in crankcase ventilation inlet Clean crankcase breather Worn valve guide, valve stem sealing damaged Replace valve guide or valve stem seal...

  • Page 74: Appcnd1: Listofsale Departments

    Engine ENG-68...
  • Page 75 Engine ENG-69...
  • Page 76 Engine ENG-70 1.Main Parameter specifications of diesel engine 1.1 Parameter of diesel engine Data CA6DF3-18E3 CA6DF3-20E3 CA6DF3-22E3 CA6DF3-24E3 Cylinder bore (mm) Piston stroke(mm) Displacement (L) Compression ratio 17:1 Rated power/rated speed (kW/r/min) 132/2300 147/2300 162/2300 177/2300 (Ps/r/min) 180/2300 200/2300 220/2300 240/2300 Maximum torque/speed ( N·m/r/min)
  • Page 77 Engine ENG-71 1.2 Temperature and pressure Parameter of diesel engine Exhaust temperature before turbo ℃ ≤650 Diesel oil temperature ℃ 40±5 Lubricating oil temperature ℃ ≤95 (rated speed) Outlet temperature of coolant ℃ 85±5 Pressure of lubricating oil ≥150 (Idling speed kPa) Rated speed kPa 343~441 (Allowed lowest pressure)
  • Page 78 Engine ENG-72 Screw tighten Description Note quantity×specification torque(N.m) Fuel injection pump fixed bolt 4× M10 25± 2 Arm shaft bracket fixed bolt 6× M10 43+7 Plate of gear chamber cover 7× M10 34+7 fixed bolt Exhaust manifold fixed bolt 4× M10 32±...
  • Page 79 Engine ENG-73 Table 1-3 Relationship between the brand number of diesel oil and applicable lowest air temperature Brand number of diesel oil -10# -20# -35# Cetane value Freezing point (℃) Applicable lowest air temperature (working ambient temperature of diesel engine) (℃) Don’t use any milky diesel oil and other diesel oil.
  • Page 80 Engine ENG-74 2.service instruction of National Ⅲ diesel engine 2.1 Siginification of diesel engine code name Exhaust emission meet with Euro Ⅲ 1/10of rated power (horse power) Series number F series Diesel engine Cylinder number FAW code 2.2 Notice for new diesel engine The new diesel engine for the automobile shall restrain its rotation speed no more than 80% of the rated speed within the initial 2000km (about 40h);...
  • Page 81 Engine ENG-75 3. Notice for maintenance of National Ⅲ diesel engine The content of maintenance of National Ⅲ diesel engines , see table 3-1. If the diesel engines often work in the condition of the environmental temperature is lower than - 18℃ or higher than 3 8℃, the maintenance interval shall be shortened.
  • Page 82 Engine ENG-76 Table 3-1 Interval Maintenance Same as the content of first class maintenance Clean oil sump and oil collector filter web, replace new lubricating oil Two class maintenance Replace diesel oil filter, lubricating filter core and supercharge (10000km or 200 hours) lubricating oil filter core Clean diesel oil tank, fuel delivery pump filter web and diesel oil piping...
  • Page 83 Engine ENG-77 4. Introduction and adjustment for electronic control high pressure common rail fuel injection system This chapter only Introduced work principle, structure adjustment and maintenance diagnosis of electronic control high pressure common rail fuel injection system for National Ⅲ diesel engines.

  • Page 84: Oil Pump

    Engine ENG-78 of diesel engine by electrified time of control air intake heater. 6) Function of fault diagnosis: ECU has the function of fault diagnosis, When fault signal be tested by ECU, first fault light is lit, meanwhile fault signal be saved as type of code, repair men will eliminate this fault.
  • Page 85 Engine ENG-79 Parts of high pressure oil pump and function: 1) Oil transfer pump: CPN2.2 choose gear oil transfer pump, located on the rear end of high pressure oil pump and together with high pressure oil pump integration. Main task of oil transfer pump is supply fuel to high pressure oil pump.
  • Page 86 Engine ENG-80 2) Forbid knock ,hit oil pump and adjust with any ways. 3) High pressure oil pump is high precision parts, has strict requirement to cleanliness, All protection covers of high, low pressure oil pipe connector must be well when transport, convey and storage, only dismantle and seal before assembly.

  • Page 87: Fuel Injector

    Engine ENG-81 4) High pressure oil rail is high precision parts, has strict requirement to cleanliness, All protection covers of high pressure oil pipe connector must be well when transport, convey and storage, only dismantle and seal before assembly. forbidden high pressure oil rail parts cleaning or blushing with any liquid or gas.
  • Page 88 Engine ENG-82 4.2.2 Low pressure oil piping parts ● Oil tank Must using oil tank without plumbum. Oil outlet pipe inner diameter should ensure ≥12mm, Oil turning pipe inner diameter should ensure ≥12mm, Notice: When oil volume reach position of alertness line, must add oil. ●...
  • Page 89 Engine ENG-83 4.3 Electronic control system parts ● Electronic control Unit (ECU) Electronic control Unit (ECU) is core of Electronic control common rail system. ECU through each kinds of sensors and switches to collect current work information of engine, to analyze and calculate the best work parameter table which rated under this condition, to control fuel injection volume of engine, time of fuel injection and fuel injection pressure, so that to adjust work state of engine, to achieve aim of save oil, high efficiency, low emission.
  • Page 90 Engine ENG-84 ● Intake temperature pressure sensor Intake temperature pressure sensor is installed on intake manifold, to measure intake absolute pressure of intake manifold and intake temperature. Notice: 1) Intake temperature pressure sensor should be placed very carefully, don’ t allow to fall from altitude to prevent internal parts of intake temperature pressure sensor mangling.
  • Page 91 Engine ENG-85 5) In the engine bunch, patch connectors of assistant speed signal on oil pump are same as patch connectors of oil volume measurement unit. So when assistant speed signal is end, please distinguish with yellow label. 6) Patch connector of engine bunch should without water or oil. 7) Should be very carefully when installing and pulling out patch connector of engine bunch, prevent the patch connector destroying.
  • Page 92 Engine ENG-86 Fault code U3003 Display content System supply power voltage is too low Fault test of ECU ECU sensor voltage 1 is too high Fault code P0643 Display content Fault code P0642 Display content ECU sensor voltage 1 is too low Fault code P0653 Display content...
  • Page 93 Engine ENG-87 Fault code P0238 Display content Signal of air intake pressure sensor is too high Fault code P0237 Display content Signal of air intake pressure sensor is too low Signal value of air intake pressure sensor is error when CAN Fault code P0235 Display content...
  • Page 94 Engine ENG-88 Fault code P0016 Display content Signal deviation between crankshaft and camshaft sensor Fault inspect for accelerator pedal sensor (1) Fault code P0122 Display content Signal of accelerator pedal sensor (1) is too low Fault code P0123 Display content Signal of accelerator pedal sensor (1) is too high Fault code P0121...
  • Page 95 Clutch CL-1 Clutch Replacement of Brake Fluid 1. Fit vinyl pipe to the air bleeder of the clutch booster and put the other end of the vinyl pipe in an empty container. Loosen the air bleeder of the clutch booster and depress the clutch pedal until no more brake fluid flows out.

  • Page 96: Installation

    Clutch CL-2 5. Check for the level of fluid in the clutch reservoir tank and add fluid as necessary up to the “ MAX”level. Adjustment of Clutch Pedal Adjust the end play by the stopper bolt or the length of push rod. 1.
  • Page 97 Clutch CL-3 Disassembly sequence 1. Clutch disc 2. Lock bolt 3. Lock washer 4. Support nut 5. Strap bolt 6. Strap support washer 7. Strap washer 8. Clutch cover 9. Strap plate 10. Pressure spring 11. Spring seat 12. Adjusting washer 13. Release lever pin 14. Release lever pin 15. Lever support 16. Return spring 17.
  • Page 98 Clutch CL-4 Disassembly procedure 1. Clutch switch 2. Return spring 3. Bracket(RH) 4. Clevis pin 5. Master cylinder 6. Bushing 7. Clutch pedal 8. Pedal pad 9. Bushing 10. Shift 11. Bracket（LH） 1. Before removing, drain the clutch fluid. 2. Remove the return spring of the clutch pedal. 3.
  • Page 99 Clutch CL-5 Disassembly 1. Disassemble the push rod and the boot 2. Remove the snap ring 3. Remove the stop-pin 4. Remove the piston Reassembly Reassembly is the reverse of the disassembly.
  • Page 100 Clutch CL-6 Master Cylinder Disassembly 1. Disassemble the push rod and the boot 2. Remove the snap ring 3. Remove the stop-pin 4. Remove the piston Reassembly Reassembly is the reverse of the disassembly.
  • Page 101 Clutch CL-7 Booster Removal 1. Remove brake fluid from the clutch system, then remove air pipes and oil pipes from the clutch booster. Note Plug the open clutch booster ports and pipes removed to prevent entry of dust and dirt. 2.
  • Page 102 Clutch CL-8 6. Disassemble the retaining ring, pin and piston assembly. 7. Disassemble the body assembly and O-ring. 8. Remove the power piston assembly. 9. Disassemble the power piston assembly. 10. Remove the ring and disassemble the washer, retainer, cup packing, washer and oil seal.
  • Page 103 Clutch CL-9 Disassembly 1. Remove the push rod 2. Remove the connector, gasket, poppet spring and proper valve. 3. Disassemble the valve fitting and gasket. 4. Disassemble the ring and cup packing. 5. Disassemble the hydraulic cylinder.
  • Page 104 Clutch CL-10 Removal sequence 1. Return spring 2. Clutch shifter 3. Elbow 4. Clutch release bearing 5. Set screw 6. Clutch release fork 7. Release fork shaft 8. Needle roller bearing 9. Clutch housing...
  • Page 105 Transmission TR-1 CA6T138 Transmission FAW Eaton Transmission Co., Ltd...
  • Page 106 Transmission TR-2 Ⅰ. Product Introduction CA6T138 transmission has 6 forward speeds and 1 reverse speed among which the to 6 speed have synchronizer with neat, quick and non-shock shifting. During machining, the advanced manufacturing technology is applied and many digital equipments are utilized to assure product quality, especially for gear manufacturing, the new technologies like grinding, shot peening, phosphating etc.
  • Page 107 Transmission TR-3 new gear oil(free service in nearby FAW Service Station). Clear up the metal powder on oil plug magnet and meanwhile check if all the fasteners are loose or not, and fasten if necessary. Check oil leaking of all contact faces and oil seals. 2.
  • Page 108 Transmission TR-4 Ⅴ. Maintenance Data Ⅴ-1 Main Specifications： Transmission Model CA6T138 Serial No. 1700945BJH-3 6 forward and 1 reverse with synchronizers Structure on 2 to 6 speed Control Type Manual remote control Center Distance Rated Input Torque(Kg.f.m) Max. Input Rev. (r/min) 3000 Weight Dimension (L*W*H)
  • Page 109 Transmission TR-5 Ⅴ-2. Maintenance Criteria Item Standard Dimension(mm) Wear Limit (mm) Flank Clearance forAll Gears Rev. 0.08 ~ 0.16 0.08 ~ 0.18 0.50 0.08 ~ 0.16 0.08 ~ 0.16 0.04 ~ 0.12 0.40 Axial Clearance for Main Shaft Gears Rev. Gear 0.20 ~ 0.35 1.00 Idle Gear...
  • Page 110 Transmission TR-6 Ⅴ-3. Fastening Torque Position Tightening Torque Main shaft lock nut 588~784 Clutch housing bolt 245~323.4 Drainage plug 100~120 Counter shaft rear cover bolt 70~80 Input shaft cover bolt 70~80 Rear cover bolt 70~80 Shift bar housing bolt 37~49 Control tower bolt 37~49 Releasing fork screw...
  • Page 111 Transmission TR-7 Ⅵ. Failure Diagnosis & Reason Analysis Ⅵ-1. Failure Diagnosis Ⅵ-1-1. Initial Check 1.Visual check: look for the damage evidence, especially key components, eg. installation points. 2.Ask the drivers or owners to get related information, eg. working condition and failures history 3.Build the records, including maintenance and lubricating cycles;...
  • Page 112 Transmission TR-8 Ⅵ-2. Transmission Common Failures and Troubleshooting Failures Cause Troubleshooting Lack of lubricant oil Refill the oil High noise Viscosity of the lubricant is low Replace the lubricant Wear of bearings or gears Replace the worn parts Bearing burnt or damage Replace .
  • Page 113 Transmission TR-9 Air plug jammed or damage Replace Fastener loose Re-fasten Oil Leakage Shim damage or sealing glue not evenly applied Replace or re-apply the glue Oil seal wear or damage Replace Too much lubricant oil Reduce oil quantity Ⅵ-3. Attention Points for Disassembling In this manual, the directions is defined in this way: the output end of the transmission as “...
  • Page 114 Transmission TR-10 Ⅵ-4. Disassembling Transmission 1. Screw off the drainage plug located at the bottom of the transmission, and drain the lubricant in the transmission completely (Draining should be done when the oil is warm.) 2. Remove PTO connecting shaft, and then remove the drive shaft assembly and middle support.
  • Page 115 Transmission TR-11 Ⅶ. CA6T138 Transmission Disassembling and Assembling （Ⅰ）Transmission Disassembling 1. Remove release bearing oil fill pipe 2. Remove release bearing 3. Untie release fork wire 4. Screw down release fork screw...
  • Page 116 Transmission TR-12 5. Remove release fork positioning spline 6. Remove release fork and release fork thrust arm assy 7. Take the clutch housing screw apart 8. Remove clutch housing...
  • Page 117 Transmission TR-13 9. Remove control tower screw 10. Remove control tower assy 11. Remove shift bar housing screw 12. Prize up shift bar housing ass’ y...
  • Page 118 Transmission TR-14 3. Remove shift bar housing ass’ y 14. Remove PTO 15. Unlock the riveting point of main shaft lock nut to make it flat 16 Remove main shaft lock nut...
  • Page 119 Transmission TR-15 17. Remove flange ass’ y 18. Loosen rear cover screw 19. Knock it down by bronze stick and remove rear cover ass’ y 20. Remove speedometer worm...
  • Page 120 Transmission TR-16 21. Loosen input shaft cover screw 22. Knock down input shaft cover ass’ y 23. Remove input shaft ass’ y 24. Install input shaft puller on input shaft ass’ y...
  • Page 121 Transmission TR-17 25. Pull input shaft ass’ y out 26. Remove main shaft rear bearing circlip 27. Install main shaft rear bearing puller on bearing circlip 28. Pull out main shaft rear bearing by rotating puller screw...
  • Page 122 Transmission TR-18 29. Screw main shaft screw cap onto main shaft 30. Lift main shaft out 31. Remove counter shaft rear cover screw 32. Knock down counter shaft rear cover...
  • Page 123 Transmission TR-19 33. Remove counter shaft rear cover 34. Remove counter shaft rear bearing outer ring 35. Remove idle gear shaft lock pin screw and lock pin 36. Remove idle gear shaft...
  • Page 124 Transmission TR-20 37. Remove idle gear 38. Lift out counter shaft ass’ y...
  • Page 125 Transmission TR-21 （Ⅱ） Disassembling Main shaft 1. Remove M/S screw cap 2. Remove reverse speed thrust pad 3. Remove reverse gear 4. Remove reverse needle bearing...
  • Page 126 Transmission TR-22 5. Pull out reverse gear bush by using puller 6. Remove reverse hub 7. Remove reverse sliding sleeve 8. Remover 1st gear...
  • Page 127 Transmission TR-23 9. Remove 1st gear needle bearing 10. Pull out 1st gear bush by using puller 11. Remove 1st gear bush 12. Remove 2nd synchro hub...
  • Page 128 Transmission TR-24 13. Remove 2nd gear 14. Remove 2nd gear needle bearing 15. Turn the rest parts with the angle of 180° 16. Remove 5/6 synchro hub circlip...
  • Page 129 Transmission TR-25 17. Remove 5/6 synchro hub 18. Remove 6th gear 19. Remove 6th gear needle bearing 20. Remove 4th gear bush circlip...
  • Page 130 Transmission TR-26 21. Remove 4th gear bush retainer 22. Remove 4th gear 23. Remove 4th gear needle bearing 24. Remove 4th gear bush...
  • Page 131 Transmission TR-27 25. Remove 3/4 synchro hub 26. Remove 3rd synchro ring 27. Remove 3rd synchro cone 28. Remove 3rd gear...
  • Page 132 Transmission TR-28 29. Remove 3rd needle bearing 30. Complete M/S disassembling...
  • Page 133 Transmission TR-29 （Ⅲ）Transmission Assembling 1. Assemble idle gear, idle gear shaft and idle gear needle bearing 2. Assemble idle gear shaft lock pin and screw The torque for lock sheet bolt is 18.6-25.5N.m. 3. Install counter shaft ass’ y 4. Put counter shaft rear bearing outer ring flatly onto rear bearing hole...
  • Page 134 Transmission TR-30 5. Install bearing outer ring into case using core shaft Assure that the inner race and outer race of bearing shall balance out to eliminate axial clearance between elastic block ring and outer race of bearing. Apply QM-3 sealant evenly on 6.
  • Page 135 Transmission TR-31 9. Choose adjusting shim between C/S rear cover plate and bearing outer ring Apply QM-3 sealant evenly 10. Install counter shaft rear bearing cover on the gasket. shim Screw the opposite bolts according to 11. Install adjusting shim and counter shaft stipulated order.
  • Page 136 Transmission TR-32 13. Put main shaft rear bearing on main shaft Put the detent ring inside with larger angle side toward reverse gear. 14. Press rear bearing by bearing press machine 15. Install shift bar housing positioning ring Apply QM-3 sealant 16.
  • Page 137 Transmission TR-33 17. Install rear bearing cover and screw to the 2-3 thread 18. Tighten rear cover screw Common bolts shall be applied with Loctite 516. Spanner torque for rear cover Screw the opposite bolt bolts according to 70-80N.m. stipulated order. 19.
  • Page 138 Transmission TR-34 Apply QM-3 sealant evenly on the gasket. 21. Install input shaft shim and put glue on the surface Keep bolt hole and back oil hole in the same level 22. Install input shaft cover plate and screw to 2-3 thread In order to protect oil seal from damage, shall turn input shaft while press it and there should be a bush...
  • Page 139 Transmission TR-35 25. Screw main shaft lock nut to 2-3 thread 26. Tighten main shaft lock nut spanner torque locknut 588-784N.m. speeds when screw, lest mainshaft moves 27. Tighten main shaft lock nut by riveting Rivet the locknuts along rivet groove after the locknut been tightly screwed.
  • Page 140 Transmission TR-36 29. Install Double head bolt –for PTO 30. Install PTO and Nut, Fasten Nut 31. Pre-fill lubricant for main shaft needle bearing 32. Check gear clearance and bearing clearance for main shaft...
  • Page 141 Transmission TR-37 33. Put glue on the connecting surface between case and shift bar housing Assure that squeezed sealant take the shape of Φ2-Φ4mm bar without stop, in the middle of the surface, inside of the hole position, do not drop in the case. 34.
  • Page 142 Transmission TR-38 37. Assemble control tower ass’ y 38. Fasten control tower screw The spanner torque for top tower bolt is 37-49N.m 39. Assemble clutch housing 40. Install clutch housing screw，Fasten the screw The spanner torque for PTO case bolt is 245-323N.m.
  • Page 143 Transmission TR-39 41. Assemble release fork and thrust arm ass’ y Assemble lockable bolt and steel wire The spanner torque for bolt is 24-37N.m. 42. Assemble release bearing ass’ y Assure that bearing assembly, release fork and neck of input shaft cover can fit well.
  • Page 144 Transmission TR-40 （Ⅳ）Main Shaft Assembling 1. Fix the front end on fixture 2. Assemble 3rd gear needle bearing 3. Coat lubricant 4. Install 3rd gear ass’ y Assure gear moves freely.
  • Page 145 Transmission TR-41 5. Install 3rd synchro ring 6. Install 3/4 synchro ass’ y 7. Install 4th synchro ring 8. Install 4th gear bush...
  • Page 146 Transmission TR-42 9. Install 4th gear needle bearing 10. Coat lubricant 11. Install 4th gear ass’ y Assure gear moves freely. 12. Install 4th gear bush retainer...
  • Page 147 Transmission TR-43 13. Choose circlip 14. Install the circlip into the slot 15. Install 6th gear needle bearing 16. Install 6th gear ass’ y...
  • Page 148 Transmission TR-44 17. Install 6th synchro ring 18. Install 5/6 synchro ass’ y 19. Choose circlip 20. Install the circlip into slot...
  • Page 149 Transmission TR-45 21. Install 5th synchro ring 22. Install 5th synchro cone 23. Turn the semi-finished M/S to the angle of 180° 24. Install 2nd gear needle bearing...
  • Page 150 Transmission TR-46 25. Coat lubricant 26. Install 2nd gear ass’ y 27. Install 1/2 synchro ass’ y 28. Install 1st gear bush...
  • Page 151 Transmission TR-47 29. Install 1st gear needle bearing 30. Install 1st gear ass’ y 31. Install rev. hub and sleeve 32. Install reverse bush...
  • Page 152 Transmission TR-48 33. Install reverse needle bearing 34. Install reverse gear 35. Install reverse gear thrust shim 36. Fasten nut...
  • Page 153 Transmission TR-49 （Ⅴ）SBH Assembling 1. Mark assembly identificaion 2. Install guiding plate and pin bar 3. Coat glue on guiding plat pin bar thread 4. Install guiding plate pin bar screw cap...
  • Page 154 Transmission TR-50 5. Fasten the screw cap 6. Install guiding plate pin bar screw pin 7. Install self lock spring 8. Install interlock pad...
  • Page 155 Transmission TR-51 9. Install interlock steel ball 10. Install wedge-shaped guiding pin 11. Install reverse shift bar 12. Install reverse fork...
  • Page 156 Transmission TR-52 13. Install reverse block 14. Install 1/2 shift bar and 1/2 fork 15. Install 1/2 shift block 16. Install 1/2 shift bar and 1/2 fork...
  • Page 157 Transmission TR-53 17. Install 3/4 shift bar and 3/4 fork 18. Install 5/6 guiding shift bar, block and guiding block 19. Install 5/6 shift bar and 5/6 fork 20. Install flexible pin and swelling pin The hatch of two dowels is 180°...
  • Page 158 Transmission TR-54 21. Flat the flexible pin and swelling pin 22. Install interlock stopper 23. Press interlock stopper 24. Install shift bar stopper and press it...
  • Page 159 Transmission TR-55 25. Coat glue on all stoppers Apply glue along the circle of filler. 26. Install reverse light switch Use hand to screw 2-3 rounds, then use spanner torque 26.5-31.4N.m...

  • Page 160: Propeller Shaft

    Propeller Shaft SHA-1 Propeller Shaft General Disassembly and Assembly of the Propeller Shaft Disassembly and Reassembly of Universal Joint Disassembly and Assembly of Center Bearing...
  • Page 161 Propeller Shaft SHA-2 General The propeller shaft, installed between the transmission and rear axle, transmits the engine power( rotation) changed by the transmission to the final gear of the rear axle. The propeller shaft consists of two sections: the front and rear propeller shafts. Two or more sections are coupled together depending on the wheelbase.
  • Page 162 Propeller Shaft SHA-3 Tightening Torques Standard...

  • Page 163: Troubleshooting

    Propeller Shaft SHA-4 Troubleshooting Symptom Probable cause Remedy Yoke installed in wrong Realign the match marks direction Worn universal joint Replace as a spider kit needle roller bearing Bent propeller shaft Replace propeller shaft At high speed Propeller shaft out of Adjust dynamic dynamic balance...
  • Page 164 Propeller Shaft SHA-5 Disassembly and Assembly of the Propeller Shaft Disassembly procedure： Assembly procedure: 1. Bolt, nut and spring washer( near 6. Middle propeller shaft differential) 4. Nut and spring washer( near transmission) 2. Bolt, nut and spring washer 5. Bolt, nut and spring washer 3.
  • Page 165 Propeller Shaft SHA-6 Reassembly Reassembly procedure as described above Tightening torque for nut( near transmission) Torque 199-243Nm Tightening torque for nut( near the center bearing ) Torque 199-243Nm Tightening torque for centre support Torque 127-176 Nm Tightening torque for nut( near the differential) Torque 199-243Nm...
  • Page 166 Propeller Shaft SHA-7 Disassembly and Reassembly of the Universal Joint Disassembly procedure of the universal joint: 1. Grease nipple 2. Snap ring 3. Needle roller bearing 4. Spider 5. Flange yoke The reassembly procedure is the reverse of disassembly. Preparation work： Align matching marks put at time of disassembly.
  • Page 167 Propeller Shaft SHA-8 The concentricity of the propeller shaft： Measure the concentricity at the center of the propeller shaft. （mm） Standard Limit ≤0.5 The clearance when the spline rotates in normally direction: Check the clearance between the spline and sleeve in normal direction with clearance gauge. （mm）...
  • Page 168 Propeller Shaft SHA-9 Clearance of the spider end: 1. Measure the width of the flange yoke” A” . 2. Measure the width of the spider with needle roller bearings”B” . Clearance of the spider end=A－B A－B（mm） 0.02~0.08 Choose the snap ring with appropriate width( Note: Use the rings with same width, never reuse the snap spring, it must be replaced)
  • Page 169 Propeller Shaft SHA-10 Assembly procedure: As described above. Use flange to press the center bearing to protect the bearing. Grease quantity： Grease quantity（g） 20~25 Assembly of flange nut： Fix the flange with special tool, Tighten the flange nut to specification with spanner, rivet the flange nut to the V groove with riveting tool.

  • Page 170: Front Axle

    Front Axle FAX-1 Front Axle General Specifications Service Standards Troubleshooting Service Procedure...

  • Page 171: Specifications

    Front Axle FAX-2 General The front axle supports and transmits the weight of the front portion of vehicle to the tires and also services as part of the steering system and brake system. The front axle also has proper wheel alignment for stabilizing the vehicle as it is driven.

  • Page 172: Service Standards

    Front Axle FAX-3 Service Standards Service Standard Table Nominal value Limit Remedy and remarks Maintenance item (Basic diameter in[ ]) Front axle Kingpin angle 7° 7° 30’ Correct or replace Bend Vertical 3 or less Replace Horizontal 3 or less Knuckle to front axle clearance 0.2 or less Adjust with thrust washer...
  • Page 173 Front Axle FAX-4 Troubleshooting Symptom Probable cause Remedy Steering wheel vibrates Worn kingpin Replace with a kingpin kit Clearance between kingpin and bushing to large Seized worn or poorly turning wheel hub Replace bearing Wheel misalignment Adjust Excessively worn tie rod end ball stud Replace tie rod end assembly Uneven tire inflation pressure Adjust...
  • Page 174 Front Axle FAX-5 Inspection items of front axle in using: Front axle (not drive steering axle) is made up of beam axle、 steering knuckle、 kingpin、 bracket、 wheel hub and so on. The beam axle is a I type forged beam, connected with steering knuckle by kingpin in the two ends.

  • Page 175: Service Procedure

    Front Axle FAX-6 Service Procedure Removal and Installation Note 1. Remove the brake hose from the frame end first and install to the wheel brake end first. During the procedure, make sure that the hose is not twisted. 2. Plug the end of the brake hose removed to prevent entry of dust and dirt.

  • Page 176: Wheel Hub

    Front Axle FAX-7 Wheel Hub Disassembly and Inspection Disassembly sequence: 1.Front wheel hub cover 2.Hub cover gasket 3.Lock bolt 4.Lock plate 5.Lock nut 6.Lock washer 7.Outer bearing 8.Oil seal 9.Hub bolt 10.Front wheel hub 11.Front brake drum 12.Front brake assembly 13.Inner bearing 14.Knuckle retainer Note The connection between slack adjuster and brake chamber should be disconnected at the front brake assembly.

  • Page 177: Disassembly Procedure

    Front Axle FAX-8 Disassembly Procedure 1. Removal of lock nut. 2. Removal of wheel hub and brake drum. 3. Removal of inner bearing inner race and knuckle retainer. Use the special tool( lever) to pry the knuckle retainer to obtain clearance.
  • Page 178 Front Axle FAX-9 Reassembly Reassembly Procedure 1. Installation of inner bearing outer race. 2. Installation of outer bearing outer race. 3. Installation of inner bearing inner race. Note Be sure to install the knuckle retainer. 4. Lubrication of bearing. Using a grease pump or equivalent, pack grease amply, making sure that space between bearing rollers is filled with grease.
  • Page 179 Front Axle FAX-10 （C）Install the lock plate and make sure that the lock nuts are all( three) aligned with the bolt holes of the lock plate. Then tighten the lock bolts to 6.9 to 11 Nm( 0.7 to 1.1 kgf.m). If the lock nut and lock plate bolt holes are not aligned, proceed as follows: 1.
  • Page 180 Front Axle FAX-11 Front Axle, Knuckle and Kingpin Disassembly and Inspection Disassembly sequence: 1. Tie rod assembly 2. Tie rod arm 3. Knuckle arm 4. St bolt 5. Chamber bracket 7. Kingpin lower cover 9. Kingpin 10 Knuckle 11. Upper bushing 12. Oil seal 13. Lower bushing 14. Stopper bolt 15.
  • Page 181 Front Axle FAX-12 Disassembly Procedure 1. Removal of set bolt 2. Removal of kingpin 3. Removal of kingpin bushing Note Do not reuse removed bushings( upper and lower) 4. Measurement of front axle bend Alignment ( bend) Item Nominal Limit value Vertical 3 or less...
  • Page 182 Front Axle FAX-13 5. Measurement of kingpin inclination Nominal value 7° Limit 7° 30'...
  • Page 183 Front Axle FAX-14 Reassembly Note： Before inserting the kingpin, apply wheel bearing grease to front axle kingpin hole and all through holes.
  • Page 184 Front Axle FAX-15 Reassembly 1. Press fit the kingpin bushing into the knuckle using the special tool, Kingpin Bushing Remover. At this time, one end of each bushing should be flush with the surface A and the nipple holes in the knuckle should be aligned with the oil holes in the bearing.
  • Page 185 Front Axle FAX-16...
  • Page 186 Front Axle FAX-17 1. Measurement and adjustment of toe-in. a) Place the front wheels in straight ahead position. b) Make a mark on the front side of each front tire, at the center of the tire width and height. c) Adjust the heights of the needle ends of the toe-in gauge to the same height as the marks made on the right and left front tires, and measure the distance between the marks.
  • Page 187 Front Axle FAX-18...
  • Page 188 Front Axle FAX-19 h) Slowly turn the steering wheel in the reverse direction until the scale of the turning radius gauge leaves the position adjusted to 0° and changes its direction 20° in the right direction for the left front wheel.

  • Page 189: Workshop Manual

    Rear axle RAX-1. JAC G1510 rear axle Workshop manual -Page 1 of 23...
  • Page 190 Rear axle RAX-2. ITEM Chapter Ⅰ Instruction of axle’ s construct Construct brief introduction Driving axle’ s exploding chart and list Sealant and adhesive for driving axle The list of tightening force List of wearing parts Chapter Ⅱ Inspection & maintenance Examine and repair parameter Check and maintenance Chapter Ⅲ...
  • Page 191 Rear axle RAX-3. Chapter Ⅰ instruction of axle’ s construct A、BRIEF DRIVING AXLE’ S STYLE（N0. 1） ITEM CONTENT The style of axle housing stamping and wholly welding Shaft holding’ s style Full holding gears’ type of final Cone gear reduction spider gears’...
  • Page 192 Rear axle RAX-4. B、the driving axle exploding and list： flange dust defender oil seal bearing bolt spring washer separator O seal Cushion Cushion cushion bearing drive geaar spring sprag assembly of sprag spring washer bearing adjusting nut bearing Diff. carrier cushion shaft gear cushion...
  • Page 193 Rear axle RAX-5. C、Sealant and adhesive for driving axle（No. 2） ITEM SEALANT AND ADHESIVE the surface of drive axle housing‘ s 515 adhesive assembly and final reduction assembly bolt for driven gear GY-340 adhesive bolts for differential GY-340 adhesive bolts for reducer mechanism Sealant 605 hub’...
  • Page 194 Rear axle RAX-6. E、tightening force list（4） ITEM G1510(N.m) nut for drive gear 550-600 bolt for separator of drive gear 178 ～ 235 bolt-driven gear 475 ～ 598 bolt for differential 178 ～ 235 bolt for reducer 178 ～ 235 bolt for bearing cap 450 ～...
  • Page 195 Rear axle RAX-8. inspection & maintenance Chapter Ⅱ A、 list of inspection date item G1510 B/L of pinion & ring gear 0.3～0.4 B/L of planet & shaft gear 0-0.15 mm 15-25 preload of pinion gear Kgf· cm gear oil of rear axle B、inspection &...
  • Page 196 Rear axle RAX-9. the main reason is adjustment N/G, we can solve them through adjusting the assembly B/L if all parts are good. 6、sometimes the plate cannot return after brake, we can solve it by adjusting brake B/L. item (maintenance standard) (abrasion utmost) (memo)
  • Page 197 Rear axle RAX-10. disassembly A、 disassembly rear axle 1． Wedge the wheel’ s front & rear position of wheel with triangle templet 2．Loose the outside wheel nuts 3． Rise rear axle disassembly shaft 1． Loose shaft nuts 2．Disassembly shaft. if difficult, strike the shaft slightly with copper hammer until it loose disassembly hub 1．...
  • Page 198 Rear axle RAX-11. 3． Disassembly shaft oil seal from axle spindle. note: the outer loop must apply lubrication then press into hub. 4． Disassembly oil seal bush and inner B/R loop. note: oil seal bush must be press into spindle with special tool after heat.
  • Page 199 Rear axle RAX-12. Pull the axle housing Disassembly differential carrier assy’ 1 ） 、 check and record the B/L of pinion & ring gear before disassembly Note: check the mesh condition of gears after adjust 2） 、Disassembly lock plate 3） 、Mark matching sign on the B/R cover & carrier 4）...
  • Page 200 Rear axle RAX-13. 6） 、disassembly the differential case assy’ 7） 、 disassembly the pinion gear assy’with special disassembly implement, and disassembly the shim disassembly differential case assy’ 1） 、disassembly right case 2） 、disassembly shaft gear & shim -Page 13 of 23...
  • Page 201 Rear axle RAX-14. 3） 、Inspection and record the backlash of planet gear Note: locking the cross shaft when check backlash 4） 、disassembly the cross shaft & planet gear assy’ , then take out the planet gear and washer 5） 、take out shaft gear and shim 6）...
  • Page 202 Rear axle RAX-15. disassembly of pinion gear 1） 、Disassembly the nut of pinion gear flange 3） 、Disassembly spring loop and take out the roller B/R 4） 、push out the pinion gear 5） 、disassembly adjust shim and distance washer -Page 15 of 23...
  • Page 203 Rear axle RAX-16. 6） 、disassembly B/R from pinion gear 7） 、take out oil seal from B/R housing 8） 、disassembly inner loop & outer loop of the B/R key point in disassembly 1. Check whether the pinion flange worn or broke 2.
  • Page 204 Rear axle RAX-17. movement in transmission. But the preload can not press too much, or the B/R will be worn rapidly. 1.2 Adjustment of pinion gear preload: after tight pinion nut, assembly pinion oil seal and adjust the preload(without ring gear)(according to table 2) through remove or add shim between inner and outer B/R.
  • Page 205 Rear axle RAX-18. plate tighten, then turn the teeth by direction, make the brake drum rotate freely. Air brake: rotate worm shaft of adjusting pole by wrench, make the brake drum connect with brake plate tighten, as to can’ t rotate the brake drum, then rotate worm shaft by different direction one second to one third turn, as to brake drum can rotate freely and no noise.
  • Page 206 Rear axle RAX-19. -Page 19 of 23...
  • Page 207 Rear axle RAX-20. Chapter Ⅳ Use and maintenance 1、As for the hypoid gear, the stated gear oil should be used other than common oil. 2、The taper gear of differential carrier mustn’ t be disassembled and adjusted randomly. 3、The dust on the axle housing should be cleaned periodically and make sure the ventilation inside and the lubrication should be checked as well.

  • Page 208: Ⅴ Trouble Shooting

    Rear axle RAX-21. Ⅴ Trouble Shooting 1 Hub bearing dragging Hub bearing dragging Excessive hub Bearing lack of Bearing is preloading force lubrication or use wrong contaminated with type of lubricating dust grease Adjust preload replace Clean lubricating grease lubricating grease 2 Unsmooth wheel Unsmooth wheel...
  • Page 209 Rear axle RAX-22. Abnormal transmission sound Abnormal transmission sound Improper Excessive Drive gear Wear or damage of Too low oil differential clearance bearing axle shaft gear, surface gear between drive preload planetary gear, cross clearance and driven gears small shaft thrust washer etc.
  • Page 210 Rear axle RAX-23. Insufficient brake force Insufficient brake force Unsmooth Improper Brake Improper Water camshaft adjustment of the lining contact brake contact surface rotation brake air chamber overheat or brake lining of brake lining or push rod stroke degrade brake drum Check the Adjust the stroke Replace...
  • Page 211 Rear axle RAX-24. Chapter Ⅵ Mark introducing According to the regulation of mark of final product and spare parts’ and requirement of Jianghuai Group, we need to provide mark of final product ,including bar code and mark on the axle housing. 1、...

  • Page 212: Front Suspension

    Suspension SU-1 Suspension Front suspension Overview Technical parameter Disassembly Reassembly Front shock absorber assembly Failure diagnosis of front suspension Rear suspension Failure diagnosis of rear suspension...
  • Page 213 Suspension SU-2 General The leaf springs and shock absorbers, installed between the frame and the front axle, support the weight of the vehicle body. They also absorb vibration and shock from the road surface, thereby preventing their direct transmission to the body for effective protection of the body, passengers, and cargo.
  • Page 214 Suspension SU-3 Troubleshooting Note Inspect the front and rear suspension at the same time. Symptom Probable cause Remedy Spongy feel Defective shock absorber Replace Tire unevenly worn Replace Cyclic bounce Wheels and tires out of balance Correct balance Tire inflation pressure too high Adjust Bumps directly received Cracked or broken leaf spring...
  • Page 215 Suspension SU-4 Leaf Spring and Shock Absorber Disassembly and Inspection Disassembly sequence 1. Lock bolt 2. Shackle pin 3. Side washer 4. Shackle link 5. Clip 6. Leaf spring 7. Bushing Note To reassemble, reverse the order of disassembly.

  • Page 216: Removal Procedure

    Suspension SU-5 Removal Procedure 1. Removal of U-bolt 2. Removal of shackle pin lock bolt. 3. Removal of shackle pin Remove the grease nipple from the shackle pin, then remove the shackle pin.
  • Page 217 Suspension SU-6 Failure diagnosis of front suspension Car body bouncing Road test car Noise produced with specified intervals Noise produced without specified Change tyre Check the tyre for balance Normal Abnormal Adjust Check the tyre for balance Normal Abnormal Adjust or change Check the liner of suspension Normal Damage...
  • Page 218 Suspension SU-7 Harsh noises of the tyre Check tyre for alignment Norm Abnormal Adjust Check steering joint shaft and steering transmission rod Normal Deformation Change Check the fixing bolt of the suspension Norm Loose Tighten Check pressure of the tyre Norm Abnormal Adjust...
  • Page 219 Suspension SU-8 Tyres are over-worn or partly worn Check tyre pressure Normal Abnormal Adjust Check wheel for alignment Normal Abnormal Adjust Check the bearing of wheel Normal Failures Change Check the brake regulator Normal Abnormal Adjust Check rotating conditions of the tyre Normal Dead Rotate the tyre with recommended intervals...
  • Page 220 Suspension SU-9 Breakage of springs Loads Check lug and guide pin Normal If the nut is loose Worn or damaged Normal Change Check the U bolt Normal Check bolt and nut Damaged Normal Change Check shock absorber Normal Oil leakage Liner Bracket Worn...
  • Page 221 Suspension SU-10 Car body inclination Check spring Rust Weakening or breaking of spring Normal Clean Change Check lug pin and liner Normal Inadequate lubricating Worn or broken Apply grease Check steel plate gasket and U bolt Normal Bolt loosen Breakage Tighten Check shock absorber Wearing or breaking of liner...
  • Page 222 Suspension SU-11 Failure diagnosis of rear suspension Car body inclination Check spring Weakening or breaking of spring Normal Rust Clean Change Check lug pin and liner Normal Inadequate Worn or broken Apply grease Check steel plate gasket and U bolt Norm Bolt loosen Breakage...
  • Page 223 Suspension SU-12 Shortened clearance with the earth Check loading condition Leaf spring Check leaf spring Normal Breakage Change Check the Clip Normal Loose Worn or damaged Screw tight Change Check the liner Normal Deterioration or breakage Change Lubricating conditions Normal Inadequate lubricating Over lubricating Add grease...
  • Page 224 Suspension SU-13 Car body bouncing Road test car Noise produced with specified intervals Noise produced without specified intervals Change tyre Check the tyre for balance Normal Abnormal Adjust Check the tyre for balance Normal Abnormal Adjust or change Check the liner of suspension Normal Damage Change...

  • Page 225: Air Brake

    Air brake BRA-1 Air Brake General Wheel Brake Valves...
  • Page 226 Air brake BRA-2 General 表— 参数...
  • Page 227 Air brake BRA-3 Working Principle...
  • Page 228 Air brake BRA-4 Inspection Principle...
  • Page 229 Air brake BRA-5 Wheel Brake Disassembly，Inspection...
  • Page 230 Air brake BRA-6 Disassembly Procedure...
  • Page 231 Air brake BRA-7 Reassembly Reassembly Sequence...
  • Page 232 Air brake BRA-8...
  • Page 233 Air brake BRA-9...
  • Page 234 Air brake BRA-10...
  • Page 235 Air brake BRA-11 Brake Chamber for Vehicle with Spring Brake...
  • Page 236 Air brake BRA-12 Troubleshooting...
  • Page 237 Air brake BRA-13...
  • Page 238 Air brake BRA-14 Valves Dual Brake Valve...
  • Page 239 Air brake BRA-15...
  • Page 240 Air brake BRA-16...
  • Page 241 Air brake BRA-17 Using the special tool, Needle, remove the O-rings. In relay piston: At bushing: At piston: In cover: Removal of retaining rings Using the special tool, Pliers, remove the retaining rings. At inlet valve: At exhaust cover assembly:...
  • Page 242 Air brake BRA-18 Reassembly...
  • Page 243 Air brake BRA-19 Relay Valve Disassembly, Inspection and Correction Reassembly...
  • Page 244 Air brake BRA-20 Inspection after Installation...
  • Page 245 Air brake BRA-21 Quick Release Valve Disassembly sequence 1. Body 2. O-rings 3. Spring 4. Retainer 5. Ring 6. Diaphragm and ring assembly 7. Housing...
  • Page 246 Air brake BRA-22 4-way Protection Valve...
  • Page 247 Air brake BRA-23 Disassembly and Reassembly...
  • Page 248 Air brake BRA-24 Double Check Valve...
  • Page 249 Air brake BRA-25 Reducing Valve...
  • Page 250 Air brake BRA-26 Cab Control Valve Disassembly and Inspection...
  • Page 251 Air brake BRA-27 Reassembly...
  • Page 252 Air brake BRA-28 Dual Relay Valve Disassembly and Inspection Inspection after Reassembly In the test setup, the operating pressure difference between the control port and delivery port should be 25kpa( 0.25kgf/ ) or less when air pressure is applied to the air delivery port and control port.
  • Page 253 Air brake BRA-29 Synchro Valve Disassembly and Inspection...
  • Page 254 Air brake BRA-30 Reassembly...
  • Page 255 BODY BO-1 Body General Bumper Front End Trim Instrument Panel and Floor Consol Headlining and Interior Trim Door Windshield Glass and Windows Seat and Seat Belt...
  • Page 256 BODY BO-2 General Specifications Items Remarks Upper hinged, lower opening Front Panel type Door Construction Front hinged, full door construction Regulator system X-arm type Locking system Pin-fork type Glass thickness mm(in.) Windshield glass 6.76（0.266） Door glass 3.2（0.126） Rear window 4.0（0.157） Side window 3.5（0.138）...

  • Page 257: Installation

    BODY BO-3 Bumper Removal 1. Disconnect the fog lamp connector 2. Loosen the bolts and remove the front bumper. Installation Installation is the reverse of removal procedure.
  • Page 258 BODY BO-4 Front End Trim Removal 1. Remove screw( 5EA) 2. Loosen bolts and remove the front panel. Tightening torque Gas spring to body 0.7-1.1kgf.m Front panel to gas spring 0.7-1.1kgf.m Front panel to hinge 0.7-1.1kgf.m Installation Installation is the reverse of removal procedure...
  • Page 259 BODY BO-5 Instrument Panel and Floor Console Removal 1. Removal the digital clock by using (-) screwdriver 2. Loosen the screws and remove the cigarette lighter. 3. Loosen the screws and remove the switch panel and audio 4. Remove the air temperature control lever. 5.
  • Page 260 BODY BO-6 6. Remove the shift knob and the floor console. 7. Remove the ash tray, lower trim. 8. Remove the instrument panel. Installation Installation is the reverse of removal procedure.
  • Page 261 BODY BO-7 Headlining and Interior Trim Removal Headlining 1. Loosen the screw and remove the curtain rails. 2. Remove the rear head lining. 3. Remove the grip, sun visor, room mirror, map lamp, overhead console lamp and overhead console. Interior Trim 1.
  • Page 262 BODY BO-8 3. Remove the seat belt upper anchor mounting bolt. 4. Rmove the side trim and front pillar trim. Installation Installation is the reverse of removal procedure.
  • Page 263 BODY BO-9 Door Removal 1. Remove the door pull handle and power window switch. 2. Remove the door inside handle.
  • Page 264 BODY BO-10 3. Remove the door trim panel. 4. Remove speaker and door trim seal and weatherstrip. 5. Remove the door center sash( Upper: 2EA, Lower: 1EA). 6. Remove the window glass and lower sash. 7. Remove the fixed glass and glass regulator. Installation Installation is the reverse of removal procedure.
  • Page 265 BODY BO-11 Adjustment 1. If the clearance between the door and the vehicle body is uneven, affix protective tape around the hinge and to the edge of the door. Then use the special tool to loosen the door hinge mounting bolts on the body and adjust the clearance around the door so that it becomes even.
  • Page 266 BODY BO-12 Windshield glass and windows Removal 1. Use screwdriver or the like to pry up the lip of weatherstrip and remove the windshield glass or rear window glass.
  • Page 267 BODY BO-13 Installation 1. Set around strings in the weatherstrip groove. Note Make certain that the strings overlap each other at both ends. 2. Apply soap solution to the entire surface of the body flange. 3. With the aid of an assistant to push the windshield from outside, slowly pull one end of the string at right angles to the windshield as the order of illustration and fit the...
  • Page 268 BODY BO-14 Seat and Seat Belt Seat...
  • Page 269 BODY BO-15 Seatbelt...

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Hfc1130kr1-g1560 2008

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