Content .. 117 118 119 120 ..

Engine JAC HFC4DA1-2C. Manual - part 119

EC Circuit

Circuit

Circuit Diagram

Diagram

- 263 -

Reversing radar harness specification

Identification code

Name

R01

Left rear fog lamp

R02

Left external probe

R03

Left intermediate probe

R04

Right intermediate probe

R05

Right external probe

RL01

Connected to left tail lamp harness

Preface

This SUNRAY Service Manual is hereby compiled by the Customer Service

Department of JAC to help the technical service personnel correctly understand and

get familiar with SUNRAY products of JAC INTERNATIONAL better and to provide

them with the ability of quick repair and proper maintenance. This manual comprises

five volumes: Engine Control, Engine Mechanical, Chassis, Body Electrical, and

Body Accessories.

The Chassis Volume details the technical standards on removal/installation, testing,

debugging and diagnosis for systems and components of SUNRAY long-wheelbase

vehicle chassis.

When replacement is necessary, only genuine spare parts recommended by JAC can

be adopted. During maintenance, please conduct tightening in strict accordance with

tightening torque specified in the Manual. If locking device is damaged during

removal, please replace it with new one.

No part of this manual can be reproduced or used in any form or by any mean without

JAC INTERNATIONAL

March 2011

Chassis

Chassis Volume

Volume

Volume Contents

Contents

- 1 -

Chassis

Chassis Volume

Volume

Volume Content

Content

Contentssss

Clutch

Clutch...............................................................................................................................................................................1

Explosive View of Clutch........................................................................................................................................... 1
Introduction of Clutch................................................................................................................................................ 1

Clutch...............................................................................................................................................................................2

Operating Principle.....................................................................................................................................................2
Inspection and Maintenance....................................................................................................................................... 3
Fault Symptom Table..................................................................................................................................................4

Removal and Installation
Clutch...............................................................................................................................................................................7
Specification
Specification.................................................................................................................................................................. 14

Tightening Torque.....................................................................................................................................................14

Manual

Manual Transmission

Transmission

Manual Transmission..................................................................................................................................................... 16

Explosive View of Manual Transmission................................................................................................................. 16
Introduction of Manual Transmission.......................................................................................................................16

Manual transmission...................................................................................................................................................... 17

Inspection and confirmation..................................................................................................................................... 17
Fault Symptom Table................................................................................................................................................18

Removal/Installation
Manual Transmission..................................................................................................................................................... 19
Specifications................................................................................................................................................................. 43

Tightening Torque.....................................................................................................................................................43
Care and Maintenance.............................................................................................................................................. 44

Brake

Brake System

System

Brake System................................................................................................................................................................. 46

Explosive View......................................................................................................................................................... 46
Introduction of Brake................................................................................................................................................47

Diagnosis and Testing
Brake System................................................................................................................................................................. 49

Inspection and confirmation..................................................................................................................................... 52
Fault Symptom Table................................................................................................................................................53

Removal/Installation

Removal/installation of brake disc........................................................................................................................... 50
Removal/installation of brake caliper assembly.......................................................................................................54
Removal/installation of rear wheel brake shoe........................................................................................................ 56
Parking brake adjustment......................................................................................................................................... 59
Removal/installation of parking brake lever............................................................................................................ 60
Removal/installation of parking brake cable............................................................................................................61
Replacement of parking brake cable........................................................................................................................ 62
Removal/installation of brake pedal.........................................................................................................................63
Removal/installation of brake master cylinder.........................................................................................................65
Removal/installation of vacuum pump.................................................................................................................... 66
Removal/installation of vacuum booster..................................................................................................................68
Air bleeding for hydraulic pressure brake system....................................................................................................71

Chassis

Chassis Volume

Volume

Volume Contents

Contents

-2-

Anti-lock

Anti-lock Brake

Brake

Brake System

System

System (ABS)

(ABS)

ABS system....................................................................................................................................................................74

Diagnosis and Testing
ABS system....................................................................................................................................................................79

Operating principle................................................................................................................................................... 79
Inspection and confirmation..................................................................................................................................... 81
Fault Symptom Table................................................................................................................................................85

Removal/Installation
ABS system..................................................................................................................................................................101

Wheel speed sensor.................................................................................................................................................103

Transmission

Transmission Shaft

Shaft

Transmission Shaft...................................................................................................................................................... 106

Explosive View of Transmission Shaft.................................................................................................................. 106
Introduction of Transmission Shaft........................................................................................................................ 106

Diagnosis and Testing
Transmission Shaft...................................................................................................................................................... 107

Inspection and Confirmation..................................................................................................................................107
Fault Symptom Table............................................................................................................................................. 108

Removal/Installation

Removal

of Transmission shaft................................................................................................................................. 109

Installation of Transmission shaft................................................................................................................................ 110

Front

Front Suspension

Suspension

Front Suspension..........................................................................................................................................................112

Front Suspension.....................................................................................................................................................112

Diagnosis and Testing
Front Suspension..........................................................................................................................................................114

Inspection and Confirmation...................................................................................................................................114
Fault symptom Table...............................................................................................................................................115

Removal and Installation
Removal and Installation of Subframe......................................................................................................................... 116
Specification.................................................................................................................................................................131

Tightening Torques................................................................................................................................................. 131

Rear

Rear Axle

Axle

Rear axle...................................................................................................................................................................... 134

Explosive View of Rear Axle..................................................................................................................................134
Introduction of Rear Axle....................................................................................................................................... 135

Diagnosis and Testing
Rear axle...................................................................................................................................................................... 136

Operating principle................................................................................................................................................. 136
Inspection and Confirmation.................................................................................................................................. 137
Fault symptom Table.............................................................................................................................................. 140

Removal/Installation
Rear axle...................................................................................................................................................................... 141

Differential..............................................................................................................................................................141

Specification
Specification.................................................................................................................................................................148

Tightening torque....................................................................................................................................................148

Content .. 117 118 119 120 ..