Great Wall - Hover - Workshop Manual - 2012 - 2012

Preface Since the Great Wall Hover is put into the market, it has won the favor from the customers for its elegant appearance, excellent performance&price ratio,concept of double area and eternal safety.The car is furnished with Mitsubishi 4G64 engine.It has both the type of five shifts manual transmission and the type of automatic transmission as an option. At the same time, there are also options of ABS and safety airbag, etc. Before of its complex structure, high technical intervention and difficulty of maintenance, its maintenance needs the reference of related documents. Upon the request of the after-sale maintenance technical personnel of Great Wall, we have prepared this Hover Maintenance Manual. The manual is oriented towards the aftersale maintenance technical personnel of the Great Wall, and mainly introduces the disassembly of the various systems of Hover (refer to the maintenance manual of motor for the introduction of the motor), the troubleshooting, matters needing attention for maintenance and the related technical parameters. During the preparation of this book, a lot of professional personnel have given support and help, here we would like to express our sincere thanks. Though we have made efforts to prepare this manual earnestly, we cannot guarantee that the content in the manual is totally accurate and without error. The user cannot raise improper request to the Great Wall Company with the manual as legal basis. We cannot bear any responsibility for the losses caused by using this manual. Confined to the knowledge of the editor, the fault and errors are inevitable, your advice and comment are appreciated. The final authority for the interpretation of this manual belongs to the Great Wall Motor Co., Ltd. Instroduction-1 Instrodution How to use this mannual................................................2 Identification mark........................................................ Instruction to comprehensive maintenance......................5 Instroduction-2 Maintenance procedure How to use this manual Most part of the maintenance operation can be started In order to help you to use this manual, the chapter name and main from referencing the illustration. These illustrations help topics are given at the upper side of each page. you recognize the parts and show the mutual coordination. To introduce to you the maintenance items, there is an index on the first page of each chapter. At the beginning of each chapter, there are also the matters needing attention of all the maintenance operations. Please read the following matters needing attention before starting the maintenance work. The failure diagnostic list of each system can help you to diagnose the failure of the system and find out the causes of failure. The maintenance method with regard to the possible causes is given in the column of maintenance method to facilitate you to acquire the method of solving the problem quickly. For example: washer upper arm shaft upper arm bush upper arm bush washer upper arm upper ball pin split pin Specified torque Used component which can not be used any more. .Pregummed components Instroduction-3 The maintenance procedure is explained in the form step by step: The illustration shows what to do and where to do. The topic of maintenance work tells you what to do. The detailed instruction tells you how to finish the maintenance work and introduce other related issues, such as specification and warning, etc. Work topics: what to do For example Detailed instruction: 3. Check the drive of ball pin How to do a. Remove the ball pin. b. As shown in the Figure, shake the ball pin back and forth for several times before mounting the cap nut, c. Turn the but with torque meter continuously, turn one cycle every 2 to 4 seconds, read the torque meter at the fifth cycle. Specification Tightening torque (for rotary): Upper ball pin Lower ball pin 0.1 This format can help the experienced technical personnel to locate the causes of failure quickly. The maintenance personnel can browse the work topics, and reference the detailed explanation below it only when necessary. The important specification and warnings are given in bold face letter. Specification In the whole manual, each maintenance step is given with corresponding specification in bold face letter, so there is no need to stop working to look at the specification. All the specification can be located quickly in Annex A. Warning, Attention, Remarks: The Warning is given in bold face letter, which means there is the possibility of harming both the person himself and others. The Attention is written in bold face letter, which means there is the possibility of damaging the parts under maintenance. The Remarks is written separately in the instruction, it is also in bold face letter. Its main function is to make some additional explaining to help you to finish the repair work more efficiently. Instroduction-4 Identification mark The identification code of the car is a unique code of 17 bits to identify nameplate the car. Besides appearing on the label plate of the entire car, it is also inscripted on the external right side of the right stringer (chassis number) nameplate and on the VIN nameplate at the upper left part of the panel. vehicle VIN NO. Motor serial number The manufacture number of motor is inscripted on the right side of the cylinder . Instroduction-5 Comprehensive maintenance instruction 1. Use the protection plate, seat and floor covering cloth to make the car clean and prevent it from being damaged. 2. During the disassembling, place the components in order for the convenience of assembly. Observe the following issues: a. Before conducting the electrical work, remove the negative pole of the cable from the accumulator terminal. b. When it is necessary to remove the accumulator for checking or maintenance, the cable shall be removed from the negative pole ( ) connected to the car body. c. In order to avoid the damage of accumulator terminal, when removing the cable, loosen the terminal nut, then pull the cable upwards vertically, do not twist or pry it. d. Please use cleaning cloth to clean the accumulator terminal. Do not use file or other similar tools, which may scuff them. e. Mount the cable terminal onto the binding post of the loosened nut, then tighten the nut. Does not use hammer to knock at the terminal onto the post. f. Do remember to check whether the positive pole ( ) terminal cap is in its position. 4. Check all the soft tubes and wire terminal, check to see whether they are connected correctly and firmly. 5. Used component which can not be used any more. a. The following spare parts needs always to be renewed: split pin, seal gasket, O ring and oil seal, etc. b. For the used component which can not be used any more, it is indicated by symbol “¦” in elements diagram. 6. Precoated component The precoated component includes the bolt and nut which is precoated with the locking sealant in factory. a. If the precoated component is tightened, loosed or moved by any reason, it must be recoated with the specified sealant. b. Coating procedure of precoated component Remove the old sealant from the screw of component by washing. Dry it by compressed air. Coat the screw of components with the specified locking sealant. c. The precoated component is indicated by symbol “?” in elements diagram. 7. It can use the sealant or seal ring to prevent the leakage if necessary. 8. Abide by all specifications for bolt torque strictly. It should use the torque wrench. Instroduction-6 9. Determine the necessity of using special maintenance tools and special maintenance material according to the practical situation of maintenance. Use them on the necessary position, and go on with the maintenance according to proper procedures. 10. To replace the fuse, check to see whether the rated current of new fuse is correct. Do not exceed the rated current of the fuse, or do not use the fuse with low rated current. 11. When jacking up or supporting the car, lift or support the car on proper position with care. a. If only jacking up the car in the front part or rear part, choke up the wheel to ensure the safety. b. After the car is jacked up, use frame to support it. It is dangerous to conduct maintenance on the car that is only jacked up with one screw jack, even for the minor maintenance that can be finished error correct quickly. 12. Paying attention to the following matters to avoid the damage of components: a. If it is not absolutely necessary, do not open the housing of the ECU and the computers (if the IC terminals are touched, the IC may have electrostatic damage). b. When removing the vacuum tube, pull the end of the tube instead of the central part of the tube. c. When pulling the wire terminal, pull the terminal itself instead of the wire. d. Take care to not make the electrical components fallen, such as the sensor or relay. If they fall to the hard ground, they must be replaced. e. Never use the striking wrench to remove or install the electric thermostat or thermostat sensor. f. When checking the conducting state of the wire connector, insert the multimeter with care, do not bend the terminal. g. When using the vacuum meter, do not insert the soft tube onto large connector. Use the stepped terminal. Once the soft tube is swelled and tightened, there may be leakage. Preface Table of Contents Instruction How to use the manual Chapter 1 Overview of the entire car (parameters) Chapter 2 Fuel supply system and exhaust air system Chapter 3 Clutch Chapter 4 Transmission Chapter 5 Automatic transmission Chapter 6 Driving shaft Chapter 7 Suspension and vehicle axle Chapter 8 Brake (ABS) Chapter 9 Steering Chapter 10 Car body electric appliance Chapter 11 CD player and air-conditioning system Chapter 12 Safety airbag Annex: Important components guarantee and requirement List of non-metal material consumption Special tools D Important working components and tightening torque E Electric wiring diagram Overview of the entire car-1 Chapter 1 Overview of the entire car Basic parameter ....................................................... 2 Engine ..................................................................... 4 Air inlet system ........................................................ 5 Exhaust air system ................................................... 5 Fuel supply system ................................................... 5 Cooling system ........................................................ 5 Clutch ..................................................................... 5 Transmission ............................................................ 6 Drive shaft ............................................................... 6 Front shaft/axle ........................................................ 6 Rear axle ................................................................. 6 Wheel tyre ............................................................... 6 Suspension .............................................................. 7 Frame ..................................................................... 7 Steering system ........................................................ 7 Brake system ........................................................... 8 Car body ................................................................. 9 Electrical system .................................................... 10 Air-conditioning system …………………..............12 Basic parameter The basic parameters of the complete vehicle of CC6460K and CC6460KY estate car should be in accordance with the regulation in Table 1. Basic parameters of the complete vehicle of CC6460K and CC6460KY Item CC6460K CC6460KY Dimension parameter(no-load)(mm) L 4620 W 1800 H 1710(car body)/1755(with tail fin and luggage carrier) 1700(car body)/1765(with tail fin and luggage carrier) Axle tread 2700 Wheel tread: front/rear 1515/1520 Front suspension 850 Rear suspension 1070 weight parameter: Loading weight(kg) Complete weight(kg) Max. total weight(kg) 5 person × 65kg/person ＋ 150kg 1720 1830 2195 2305 No-load axial load distribution: front/rear(kg) 890/830 980/850 full-load axial load distribution: front/rear(kg) 980/1215 1070/1235 Traffic ability parameter ≤13 Min. turning diameter(m) Min. ground clearance (mm) ≥180 ≥175 Approach angle(°) ≥28(no-load) departure angle(°) ≥27.5(no-load) Dynamic parameter: Min. stable speed of direct step(km/h) ≤25 30km/h～100km/h acceleration time of direct step(s) ≤32 acceleration time from 1 step starting to 100km/h(s) ≤20 Max. speed(km/h) ≥160 Max. Climbing capability(%) ≥35 Economical character: Slipping distance in initial speed of 50km/h(m) ≥500 Traveling fuel consumption in 90km/h constant speed (L/100km) ≤10.19 Traveling fuel consumption in 120km/h constant speed (L/100km) ≤13.24 Under simulated urban and suburb comprehensive operating condition(L/100km) ≤11.9 ≤12.5 Braking characteristics: Traveling braking distance in 50km/h braking initial speed (m) ≤19(no-load), ≤20(full-load) Emergency braking distance in 50km/h braking initial speed(m) ≤38 Slope stop braking(%) ≥20(no-load), ≥18(full-load) Overview of the entire car-3 Stability: ≥35 Max. side rotary stable angle in no-load and static(°) Nan≥60 and NZ≥60 Operating stability(miniture0 Smooth characteristic: Weighted mean square value of acceleration σw(m/s2) Equivalent mean value Leq(dB) ≤0.6883 Decreased comfortable limitation TCD(h) ≥1.2 ≤116.5 Basic parameters of the complete vehicle of CC6460K and CC6460KY (continued) Item CC6460K CC6460KY Tightness: Dust-proof tightness M(%) ≥95 Rain-proof tightness(miniature) ≥93 Noise: Exterior noise of accelerating travel dB(A) ≤74 Interior noise of 50km/h constant speed travel dB(A) ≤79 Noise around ear of diver dB(A) ≤90 Emission: Meet Europe II emission standard CO≤2.2g/km, (HC＋NOx)≤0.5 g/km Low idle-speed emission of pollutant: (750±50)r/min CO≤0.1%, HC≤50ppm High idle-speed emission of pollutant: (2000±50)r/min CO≤0.07%, HC≤50ppm Engine For the structure and main technical parameter of engine see Table 2. Table 2 Structure and main technical parameter of engine Serial No. Item Specification and parameter 1 model 4G64S4M 2 style 3 Fuel oil supply method Multi-point fuel oil injection(MPI) 4 Measuring method of inlet capacity Speed compact style 5 Combustion room style Single-slope roof 6 Cylinder diameter × stroke(mm) 86.5×100 7 Total displacement (L) 2.351 8 Compression ratio 9.5:1 9 Max. power and corresponding speed (kW/r/min) 93/5250 10 Max. torque and corresponding speed (N·m/rpm) 190/2500 11 Min. fuel consumption (g/kW·h) ≤254 12 Idle stable speed(r/min) 750±30 13 Idle-speed control Electronic closed loop control 14 Mean piston speed(m/s) 17.5 15 Mean effective pressure (kPa) 1036 16 Cylinder compression pressure: in 250r/min (kPa) 1320 17 Ignition sequence and control 18 Spark plug gap(mm) 19 Spark plug model 20 Manufacturer of spark plug 21 Valve clearance(mm) 4-cylinder, straight-line, water-cooling, single top cam shaft, 4-stroke engine 1-3-4-2; without distributor block, electronic controlled direct ignition 1.0～1.1 BKR5E-11 or K16PR-U11 or RC10YC4 BKR6E-11 or K20PR-U11 or RC8 NGK or DENSO or Xiang huo ju 0(hydraulic column ) 18 °before upper stop point/ 53 °after lower stop 22 Port timing: Opened inlet/closed inlet point Opened outlet/closed outlet 50°before lower stop point/ 18 °after upper stop point 23 24 Lubrication method Combined method of pressure and splash Pressure of engine oil of main oil channel, in idle (≥78.5)/(245-490) speed of 3000rpm (kPa) 25 Max. engine oil temperature(℃) 130 26 Consumption ratio of engine oil(g/kW·h) 2 Overview of the entire car-5 Table 2 Structure and main technical parameter of engine(continued) Serial No. 27 Item Specification and parameter Consumption ratio of engine oil and fuel oil ≤0.8 (%) 28 Cooling method Closed forced water cooling 29 Starting method Electric motor 30 Net weight(kg) 167 31 Outline dimension: L×W×H (mm) 730×653×667 32 Idle-speed emission CO(%)/HC(ppm) ≤0.5/≤100 With three unique catalytic converter, air-fuel 33 Emission control degree of operating ratio closed loop control, the equipped light condition regulation car meets the standard of GB 18352.2－ 2001 Air inlet system Dry-type air cleaner. Exhaust air system Primary muffler, with two-stage three-way catalyst device. Fuel supply system Adjustment of accelerator pedal The stroke of accelerator pedal is 155mm; adjust the adjusting nut on wire bracket if it does not consist with the standard. The fuel tank is plastic tank with capacity of 67L; the oil supply control is the mechanical pedal oil control and internal-type electric fuel pump; the type of fuel evaporation is the activated carbon can and electric valve control. Cooling system Forced circulation water cooling, electric fan and aluminum tube radiator. Clutch The friction, disc, single-diaphragm spring clutch, hydraulic control mechanism. The external diameter of friction disc D=225mm, internal diameter d=150mm, material is F810. Adjustment of clutch pedal: 1. Measure the height of clutch pedal (from pedal pad surface to floor) and free stroke of clutch pedal (fork bar pin clearance). Standard height of clutch pedal: flush with the brake pedal, free stroke of clutch pedal is 5-15mm; 2. Readjust the free stroke of pedal after adjust the height of pedal; rotate the push bar to the standard value, then fix the bolt and nut; 3. If the free stroke of clutch pedal is not within standard value, it should rotate the adjusting bolt to standard value, then fix the bolt and nut. Do not move the push bar to main cylinder when adjust the free stroke of pedal; 4. If the free stroke of clutch pedal and clearance between the clutch pedal and floor when the clutch is disengaged de not consist with the standard, this may by caused by the air in hydraulic system and failure of main cylinder or clutch. It can discharge the air of system or dissemble and inspect the main cylinder or clutch. Transmission For the structure and main technical parameter of transmission see Table 3. Table 3 Serial Item No. 1 Structure and main technical parameter Specification and parameter Model SC5M2D-C SC5M4D-C 2 style manual mechanical step transmission of full synch, 5 forward steps, 1 reverse step, direct manipulation manual mechanical step transmission with torque divider of full synch, 5 forward steps, 1 reverse step, direct manipulation 3 Center distance(mm) 72 72(transmission), 222.25 (torque divider) 196 196 4 5 Max. input torque (N. m) Max. input torque (r/min) 5500 Step I Step II Step III Step IV Step V Step R(Reverse) Step H(high) Step L(low) 6 Speed ratio 7 Gear pair of speedometer 8 Total net weight(kg) 38 68(include torque divider) 9 Outline dimension: L×W ×H 1070mm×466mm× 399mm( not include height of steering level) 1070mm×460mm×380mm( not include height of steering level) 8:25 Drive shaft The structure of rear drive shaft assembly of CC6460K wagon is the three cross-axle universal joints, two drive shafts with extens intermediate support free-maintenance segmental structure. The front and rear drive shaft assembly of CC6460KY wagon has the universal joints, one drive shaft with extension spline, free-maintenance integral structure respectively. Front shaft/axle CC6460K wagon has the two-cross arm, independent suspension, breakaway front axle. CC6460KY wagon has the two-cross arm, independent suspension, breakaway steering drive axle , hyperbolic gear single-stage main reducer, plain bevel gear differential mechanism, universal drive semiaxle, Birfield ball-joint, main reduction ratio i0=4.55, Max. input torque is 900N m. Rear axle Non-breakaway drive axle, integral stamping-welded axle housing, hyperbolic gear single-stage main reducer, plain bevel gear differential mechanism, semi-floating semiaxle, main reduction ratio i0=4.55, Max. input torque is 900N m. Wheel and tyre The type, specification and main parameter of wheel and tyre see Table 4. Table 4 Type, specification and main parameter of wheel and tyre Overview of the entire car-7 Suspension The front suspension is the torsion bar spring, double-cylinder inflatable hydraulic damper, transverse stabilizer rod, double cross-arm independent suspension. The distance between the center of front shaft of lower arm fixing nut and level ground is 295mm±1mm. The rear suspension is the four-connecting rod, coil spring, double-cylinder inflatable hydraulic damper, transverse stabilizer rod, no independent suspension. Carriage Peripheral trapezoidal structure; welded by two box section longitudinal beams and several box or tube section cross beams. Steering system Pinion-and-rack power steering-gear, hydraulic assists steering. Breakaway front steering trapezoidal structure. Diameter of quadriradistus steering disc φ380mm, adjustable angle, power-absorbing steering pipe. For main technical parameters of steering system refer to Table 5. Table 5 Main technical parameter of steering system Serial No. Item Parameter Serial No. 1 wheel camber 0°±30′ 6 2 kingpin inclination 12°30′±30′ 7 3 kingpin castor 3°30′±30′ 8 4 toe (mm) 0～2 9 Item Rotary round of steering disc n Angle drive ratio of steering system i0ω Force drive ratio of steering system i0p Normal efficiency of steering gear η+ Parameter 3.64 18.2 198.0 ≥75% Steering angle of Reverse efficiency of internal and external 32/28 10 ≥60% steering gear ηwheel (°) 1．Adjustment of .4-Wheel Alignment Test and adjust the front wheel alignment value and adjust the toe on the 4-Wheel Alignment meter. a. Adjustment of kingpin castor: The standard value is 3°30′±30′(adjust the difference of left and right kingpin castor to within 30′); b. Adjustment of toe: The toe with standard value of 0～2mm is adjusted by rotating the steering cross rod. When adjust the toe, it should rotate the cross brace in left and right side evenly. Tighten the lock nut after adjustment, the torque is 55 - 65N·m. c. Centering and fix of steering wheel: according to the display of the alignment gauge, turn the front wheel to right ahead, after removing the steering wheel without changing the position of steering lever, mount the steering wheel with center aligned, the radials of the steering wheel shall be in the bilateral symmetry position, and the symbol of Great wall on the steering wheel shall be in the confrontation position of the driver, tighten the nut, with a tightening torque of 25 - 35N·m. Left wheel left steering: 32 , right wheel left steering: 28 ; Left wheel right steering: 28 , right wheel right steering: 32 ; b. Under the light condition of the car, the height between the center of front axis fixed bolt of the lower suspension arm to the ground is 295 1mm, if the dimension is not within this scope, reach it through adjusting the torsion bar adjustment arm bolt; c. The reference dimension of the height of the car is : the left and right deviation is less than 10mm; 3. Checking the free gap of steering wheel: Turn the orientation of the car to front, stop the engine, exert a force of about 4.9N on the steering wheel along the circumferential direction to make the it turning to the left, there is resistance force, stop turning when the resistance force is growing; then turn the steering wheel to the right, stop turning when the resistance force is felt to be growing; the radian value that the external edge of steering wheel runs is the free gap of the steering wheel, its standard value shall be less than or equal to 20 , and the corner from the central position to the left or right shall be no larger than 10. 5 Brake system The front wheel brake is ventilation coil type, the rear wheel brake is disk and drum type. The service brake type is that the doubleloop vacuum assist hydraulic brake is applied on the front and rear disc brake. The parking brake is mechanical dragline acting on the drum brake of the rear wheel. The free stroke of brake pedal is 20mm 30mm, and the operating stroke of the pedal is 120mm. The operating stroke of the brake handle is 17 (3 teeth) 30 (8 teeth). 1. The adjustment of brake pedal Measure the operating stroke of the brake pedal, the standard value is 120mm. When the eighth is no in compliance with the requirement, make adjustment according to the following procedures: a. Separate the brake lamp switch wire connector, loosen the blocking nut, and turn the brake lamp switch to the position that the stopper is not touched; b. Unscrew the blocking nut of the operation connecting rod, use the thinnose pliers to turn the operation connecting rod, adjust the brake pedal height to standard value, after reaching the standard value, tighten the lock nut; c. Turn the brake lamp switch to the position that the stopper of brake pedal is just touched, continue the turning for 1/2 1 circle, and tighten the blocking nut; d. Connect the brake lamp switch wire connector; e. The brake lamp should not be light when the brake pedal is in release status. 2. Standard value of brake pedal free stroke: 20-30 mm a. Under the stopping status of the engine, step on the brake pedal for 2 3 times, clear the influence of brake assistor, then use hand to push the brake pedal to the position that there is resistance, measure the amount of movement (free stroke). It shall be in compliance with the regulation of standard value; b. If the gap is less than the regulation value, check to see whether the gap between the carrier rod of brake lamp switch and the brake pedal is in compliance with the regulation. If this gap is exceeding the regulation, it means that the gap between the drive rod clevis pin and the brake pedal arm is exceeding the regulated value. 3. Start the engine, step down the brake pedal with a force of about 700N,ehck the main brake pump, whether there is oil leakage on the connection positions of the brake pipeline. If there is, maintain it. 4. Operating status test of brake assistor Conduct the operation status test of the brake assistor according to the following methods: a. Start the engine, stop if after operating for 1 2 minutes. Step on the brake pedal for several times with normal force. Expect that the pedal can be fully stepped down a the first stepping, the height of the brake pedal shall be raised on and on with the stepping, thus means that the brake assistor operates normally, if the height of the pedal is not changed, it means that the brake assistor is damaged; b. Under the stopping status of the engine, step on the brake pedal for several times, confirms that the height of brake pedal is elevated on and on, under the status that the brake pedal is stepped down, start the engine. At this time, the brake pedal will move down a bit, it means that the brake assistor is working normally. If the brake pedal is moving upwards, it means that the brake assistor is damaged; c. Under the operation status of the engine, step down the brake pedal to stop the operation of the engine. AT this time, the there shall be no change of the height of brake pedal within 30 seconds, it means that the brake assistor is working normally. If the brake pedal is moving upwards, it means that the brake pedal assistor is damaged. 5. Adjustment of the parking brake system: a.For positioning, pull the brake bar to the limit position for over 3 times, use a force of about 400N to pull the brake parking lever, count the number of knocking teeth. The standard value of stroke of parking brake : 17 (3 teeth) 30 (8 teeth); b.If the stroke of brake parking lever is too big and not in compliance with the requirement, adjust it with the following methods: Loosen the brake parking lever, unscrew the adjusting nut. Remove the adjuster hole cap from the brake assembly, use screwdriver to turn the adjustor in the arrow direction to the limit that the brake drum cannot turn. Rotate 5 teeth in the counter arrow direction. Rotate the adjusting nut, adjust the brake parking lever stroke to the standard value. c. If the stroke is less than the standard value, unscrew the adjusting nut to make it reach the standard value. d. Check to see whether the adjusting nut and the rod are loosened, whether the adjusting nut is fixed in the fixed seat. e. After adjustment, jack up the rear part of the car. Loosen the brake parking lever, the brake disc shall not be dragged when checking the rear wheel. f. The breaking in of the parking brake: use the force of about 200-250N to pull the brake parking lever,drive the car for about 400m with a speed of about 60km/h, repeat for 2-3 times, then test on the slope of 30%, the car shall be able to be parked. Overview of the entire car-9 Car body The structure shape and parameters of the car body is shown in table 6. Table 6 The structure shape and parameters of the car body Serial No. Item structure and parameter 1 Car body Structure shape of car body Long head two boxes five doors five seats totally metal enclosed type hard top no carrier type car body 1.1 1.2 White car body 1.3 Door assembly 1.4 Engine bonnet Internal and external decoration and auxiliary components of car body Opening upwards and backwards, single arm hinge Internal decoration Softening design, in compliance with the man-machine engineering and comfort ability requirement Meter board A, B, C pole and inter door protection plate Injection molding type structure, metallic framework 2 2.1 2.2 2.3 2.4 Cab handle 2.5 Windscreen Punching, welding, totally metal enclosed type structure Frame type, card plate type door lock, hinge type hinges, with side protection rod, four side doors open outwards by turns, rear door open upwards. Centralized controlled door lock, electric drive glass frame riser Injection molding, set with sundries box on the door protection plate Metallic frame, PVC surface, PUR foaming layer in the middle Panorama curved surface windscreen. Front wind window: triplex glass, with a thickness of 4.76mm. Rear wind window: toughened glass, with electrical heating defrosting resistance wire, with thickness of 3.5mm. Other windows: toughened glass, with thickness of 3.5mm 2.6 Rearview mirror External rearview mirror: electric drive, electrical heating defrosting, anti dazzle type, the left and right side are all convex mirror, with a radius of curvature of 1400mm. The internal rearview mirror: manual, anti dazzle type, plane endoscope. 2.7 Seat Pilot and co pilot seat: independent seat, front and back position, the backrest angle and seat headrest, etc. can be adjusted. Back seat: independent seat, the backrest angle and seat headrest, etc. can be adjusted. 2.8 Safety belt Back seat middle seat two points fixed type, three pointes fixed emergency blocking mechanical safety belt for other seats. 2.9 Sun visor Luxurious type, with lamp and cosmetic mirror 2.10 Skylight Front and bumper 2.11 Electric drive skylight rear Overall design type, PP injection molding Checking and commissioning of the auxiliary components of car body: Stop the car stably, check the doors, engine cover, fuel filling port cover, meter and tools box cover, front and rear ash tray cover, floor center console sundries box cover, CD disc conveyer (VCD disc conveyer), power socket cover, etc. they shall be reliable and flexible during starting, opening and closing, without blocking and insufficient closing and abnormal sound; Electrical system The structure and parameter of the electrical system are shown in table 7. Table 7 Structure And Parameter of Electrical System No. Item 1 Power, starting and charging system Structure and Parameter 1.1 Lines 1.2 Accumulator 1.3 Starter 12V, 1.2kW 1.4 generator Internally furnished with adjustor type generator. 14V, 90A 2 Singe line system, voltage DC 12V, negative earth 55D26R maintenance free type, voltage 12V, 20 hours capacity 60Ah, storage capacity 101min, low temperature starting current 475A Illumination and signal system white, major high beam 60W,1 on the left and right respectively, auxiliary high beam 55W,1 on the left and right respectively, passing lamp 55W,1 on the left and right respectively. Head light base center height H: 920mm±20mm Front position lamp: white, 5W,1 on the left and right respectively. Rear parking lights: red, 5W,1 on the left and right respectively. Amber 。Front and rear turn light: 21W,1 on the left and right respectively. Side turn light: 5W,1 on the left and right respectively, Front fog light: white, 55W, 1 on the left and right respectively. Rear fog light: red, LED,1 on the left and right respectively. Red, 21W, 1 on the left and right respectively, high position brake light, 10W, 2 in the middle 2.1 Front illumination light 2.2 Position light 2.3 turn light 2.4 Fog light 2.5 Brake light 2.6 License light White, 5W, 1 on the left and right respectively. 2.7 Backup light White, 21W, 1 on the left and right respectively. 2.8 Danger warning signal light All the turning signal lights, danger alarm switch control 2.9 Back repeating reflector 2.10 Front, middle and back ceiling light in the room Red, none triangle shape, forming combination light with the rear fog light White. Front indoor ceiling light: 10W, 2 pieces. Middle indoor ceiling light: 10W, 1 piece. Back indoor ceiling lights: 5W, 1 piece 2.11 Cigar lighter illumination Blue, 3W, 1 piece 2.12 Ash tray illumination White, 3W, 1 piece 3 Meter system 3.1 Combined instrument Car speed odometer, engine speed indicator, water temperature meter, fuel gage 3.2 Indicator lamp Refer to the drawing 4 Auxiliary electrical system Front and rear rain wiper DC motor. Front rain wiper: four rods type, electric drive three gears (high and low speed + adjustable interval), scraper 2 pieces, 55W. Rear rain wiper: single arm type, electric drive one gear, with 1 scraper plate, 21W Front wind window hearing type, back wind window heating type glass, switch control Drive side general control, independent control oh other windows and doors 4.1 Rain wiper system 4.2 Defogging, defrosting device 4.3 Electric drive glass frame riser 4.4 Central control lock With remote control 4.5 Camborne power socket 12V, 2 pieces 4.6 Radio, CD and loudspeaker Stereo radio, six discs CD, four sound channels Overview of the entire car-11 4.7 Cigar lighter 12V, 1 piece 4.8 Horn Treble and bass 4.9 Safety airbag Electric main and auxiliary airbag Checking and commissioning of the auxiliary components of car body: 1. Stop the car stably, check the doors, engine cover, fuel filling port cover, meter and tools box cover, front and rear ash tray cover, floor center console sundries box cover, CD disc conveyer (VCD disc conveyer), power socket cover, etc. they shall be reliable and flexible during starting, opening and closing, without blocking and insufficient closing and abnormal sound; 2. The major lamp high beam and city beam, the alternating light, taillight, turn light, brake light, front and rear mist light, malfunction alarm light, indoor light, instrument panel light, ignition switch light, etc. shall operate normally, without the failure of no lighting,constant lighting and error lighting , etc; 3. Checking the performance of front head light a. The high beam luminous intensity of each head light 20000 cd/ piece b. Beam center left and right deviation (when the beam is irradiating on the screen of 10 m away): Left light high beam: left 17 cm right 35 cm Right light high beam: left 35 cm right 35 cm Left light city beam: left 17 cm right 35 cm Right light city beam: left 17 cm right 35 cm c. Beam center height (when the beam is irradiating on the screen of 10 m away): Head light city beam 0.7 0.9 H; head light high beam 0.9 1.0 H H means the head light center height 920 20mm. 4. The adjustment of multi functional meter: a. Drive the car onto the trench, insert the car speed transducer, drive the car to open places, press the ADJ switch for no less than 3 seconds, the orientation indicator begins to flash. Drive the car slowly for one circle within 2 minutes, the orientation indicator will stop flashing, it shall points to the practical normal direction. Note: E east, W west, S south, N north. b. The adjustment of time: Press the “MODE” switch for over 2 seconds, the time can be adjusted, press the MODE switch to adjust the minute, then press the MODE again to adjust the hour, adjust the time through pressing the “ ”and “ ” key. After the time is adjusted, press the ”MODE” switch for over 2 seconds to quit the time adjustment mode. c. Check to see whether the absolute altitude meter and the car speed response display are working normally. d. Drive the car onto the trench again, pull off the car speed transducer plug. 5. The adjustment of rain wiper nozzle cleaning mixture ejection height: a. Put the ignition switch to the ”ON” position, open the rain wiper nozzle switch, the position of front cleaning mixture nozzle shall be evenly distributed along the middle height of the front windshield glass from left to right. b. The position of the rear cleaning mixture nozzle is deviated to right of the center of rear windshield glass for about 20mm120mm, and the height is within the scope of 50mm at the center of the glass. If the deviation is large, the nozzle needs to be adjusted. Air-conditioning system The structure and parameter of the air-conditioning system is shown in table 8. Table 8 The structure and parameter of the air-conditioning system Serial No. 1 2 Item Structure and Parameter Structure and Front and rear heating and cooling air conditioner, vapor compression type shape Performance and parameters cooling, hot-water heating Refrigerating capacity 3.5kW, heat exchange capacity 3.5kW, fan capacity 350m3/h Control board button type operation, temperature auto control, air door micro 3 Operation motor drive, the temperature in the car can be controlled automatically, the fanning position mode, heating/cooling mode, air intern/external cycling mode and wind speed and temperature can be selected and adjusted 4 Refrigerant R134a 5 Compressor SD7V16 variable capacity compressor, with a maximum capacity of 160ml 6 Condenser Parallel stream mode structure, flat pipe thickness of 26mm 7 Evaporator 8 Drying fluid collector Refrigerating 9 pipe and warm water pipe 10 Transducer 11 pressure switch Two boxes structure, cascading evaporator, F expansion valve, centrifugal blower External diameter φ60.5mm Refrigerating pipe: complex structure of rubber refrigeration soft tube and aluminum tube. The warm water pipe: rubber molding pipe Outdoor temperature sensor, indoor temperature sensor, evaporator temperature sensor Three-state pressure switch Chapter 2 Fuel supply system and exhaust system Fuel supply system : Disassembly of the fuel tank ........................................................................3 Installation and disassembly of the Fuel pump ..............................................4 Disassembly of the components of fuel supply system...................................4 Disassembly and adjustment of the accelerator pedal operating system ........5 Exhaust system : Disassembly of the blast pipe assembly.........................................................8 Installation of the blast pipe assembly............................................................9 Fuel supply system adjustment nut throttle pull wire accelerator pedal assembly carbon tank exhaust rubber tube snap fitting steel strip type elastic hoop generator oil-in rubber tube generator of return rubber tube soft tube fixing clipper carbon carbon tank b type air inlet worm drive tank rubber tube type hoop fuel filter filter rubber tube for gas out vaporizer tube 2 back part of fuel tank oil-out tube back part of fuel tank cleaner bracket vaporizer soft tube 2 fuel tank vaporizer filter rubber rubber tube tube for gas-in front part of the oil-out tube of fuel tank vaporizer tube1 vaporizer soft tube1 the middle connection rubber tube of the oil return tube oil return tube fuel tank oil return tube hard tube bracket fuel tank gland fuel pump front taps of fuel tank fuel tank protection plate fuel tank lock refill opening cushion pressing board refill opening cushion seal packing ring fuel tank gland fuel tank assembly oil filing port assembly steel strip type elastic hoop fuel tank protection plate N m: specified torque Caution: When maintaining the fuel supply system, if the oil path needs to be removed, the pressure of the fuel system must be released to avoid the ejection of high pressure fuel. Disassembly of the fuel tank 1. First remove the oil-in and oil return hard tube of the generator, the oil return hard tube of fuel tank, and the connection rubber tube between the back parts of hard vaporizer tube. Release the pressure of oil path system slowly, block the joints with cotton cloth, lest there is ejection of high pressure oil. 2. Remove the oil filling port at the back of the fuel tank and the clip of the connection rubber tube of ventilation tube, there are two clips altogether. 3. Remove the bolts fixing the fuel tank, there are 6 bolts altogether; 4. Remove the oil-in and oil-out tube from the fuel tank, remove the vaporizer tube joints and line bundle connector; The disassembly and installation of the fuel pump Removal of components of fuel supply system Gasoline filter disassembly 1. Firstly, use the straight screwdriver to remove the hose clamp and remove the connecting rubber hose on both sides of gasoline filter; 2. Loose the bolt on the gasoline filter bracket, then remove the gasoline filter for complete replacement. Removal of carbon tank The disassembly of the fuel filler pipe Removal of fuel pipe 1. Remove the connection between the in/return fuel connector of engine fuel track and the fuel supply pipe: a. Remove the elastic hoop firstly; b. Remove the package connector; press down the button of package connector by hand, then pull it out outwardly. c. Remove the three-line plastic clip. 2. Removal of front section of fuel hard pipe b. Pull out the fuel pipe form the clip fixing base, then remove the hard pipe; c. Remove the fixing base on the longitudinal beam if necessary rotate the fixing base for 90 degree in clockwise or anticlockwise, the take out it. 3. Removal of rear section of fuel hard pipe a. Remove the connecting elastic hoop of two ends of rear section of fuel hard pipe; b. Pull out the fuel pipe form the clip fixing base, then remove the hard pipe ; Removal and adjustment of throttle control system 1. Removal of accelerator pedal Remove the two fixed bolts which fix the pedal ; 2. Removal of throttle pull-wire a. Firstly, disconnect the connection on motor, then loose the fixed bolt ; b. Remove the plastic clip of throttle pull-wire on pedal, remove the end of throttle pull-wire; c. Use the pliers to clamp the clip on the side of engine compartment to remove the fixing base of pull-wire on the fa ade of engine compartment. Exhaust system end washer assembly exhaust pipe outlet nut 100 wahser assembly front section of exhaust pipe hexagon flange nut rear section assembly cleaner cushion of exhaust pipe assembly 1 catalytic converter 63 5 fastening bolt of hoop cleaner heat insulation cover clip cleaner discharge pipe three-hole rubber block cleaner cushion assembly 2 muffler port decoration cover hexagon flange nut hexagon flange nut muffler damping ruber block assembly 9 muffler assembly N.m Specific torque Used component which can not be used any more. 23 Warning : All components of the exhaust air system should be disassembled 30 minutes after shut down to avoid the human injury caused by hot parts. Removal of exhaust pipe assembly Removal of exhaust tail tube 1. Firstly, use the M15 box spanner, ratchet wrench and extension bar to remove the connecting nut of the rear flange of muffler assembly and rear section flange of exhaust pipe, take out the seal bush between the flanges. 2. Remove the three-hole rubber block on the back of the rear section of exhaust pipe. 3. Remove the three-hole rubber block on the front of the rear section of exhaust pipe. Caution: The bush between the rear flange of muffler and rear section flange mainly has the function of sealing; it may cause the great pressure and distortion after one installation, the sealing effect is worse, and the bush cannot be used repeatedly. Removal of the muffler 1. If necessary, dismantle the back section of exhaust pipe according to the method of dismantling the exhaust pipe, if not necessary, only remove the coupling nut between the muffler and back flange of the exhaust pipe; 2. Use the M15 sleeve, ratchet wrench or open-end (box) spanner to remove the coupling nut between the front flange of muffler assembly and the rear flange of the cleaner; when implementing this operation, there must be somebody to pull the muffler to prevent it from falling only to cause damage; brick of the muffler; 3. Use the M13 sleeve, ratchet wrench to loosen the four nuts fixing the shock absorption rubber 4. Then the muffler assembly can be removed. Caution: The cleaner cushion assembly 2 between the cleaner and the front section of the exhaust pipe mainly plays a role of sealing; there may be great pressure and distortion after one installation and the sealing effect is worse, this bush cannot be used repeatedly. Removal of cleaner 1. If necessary, remove the rear section of the exhaust pipe and the muffler according to the dismantling methods of the exhaust pipe and muffler; if not necessary, just loosen the two nuts fixing the shock absorption rubber brick of the muffler; 2. Remove the coupling nut between the front flange and the rear flange of the front section of exhaust pipe; 3. If the muffler has been removed, the cleaner can be taken out directly; if the muffler is not removed, push the cleaner backwards tenderly, keep certain space between the cleaner and the muffler to make the welding bolt of the cleaner to quit; 4. At this time, the cleaner can be removed. Caution: The cleaner cushion assembly 1 between the cleaner and the front section of the exhaust pipe mainly plays a role of sealing there may be great pressure and distortion after one installation, and the sealing effect is worse, this bush cannot be used repeatedly. Disassembly of front section of exhaust pipe 1. Remove the cleaner according to method of removal of cleaner; 2. Use the M18 box spanner, heavy-duty extension bar, ratchet wrench to loose and remove the nut of exhaust pipe outlet, then takes off the front section of exhaust pipe; Caution: The two flat flanges use the interface cushion to ensure the sealing, which is stainless steel punching unit, and can be used for only once. Installation of exhaust pipe assembly Clutch-1 Chapter 3 Clutch Troubleshooting........................................................................2 Inspection and adjustment of clutch pedal..................................3 Bleed air of clutch.....................................................................3 Disassembly of clutch master cylinder and clutch cylinder ..........5 Cautions for installation of clutch operation device.....................5 Disassembly of clutch assembly.................................................6 Inspection of clutch component.................................................7 Installation of clutch..................................................................9 Clutch-2 Troubleshooting failure Shift difficulty or can not shift cause inspection content Large free stroke of clutch pedal clutch Pipe Adjust the free stroke of pedal has air Discharge the air in clutch system Failure of clutch cylinder Replace Failure of clutch master cylinder replace The installation position of clutch disc is not Inspect the clutch disc; replace in position; large deviation; oil on the friction Repair if necessary lining or broken Replace The clutch disc is dirty or with foreign material Failure of clutch cover Disengagement of transmission Slide of clutch The clutch guide bearing is worn. Replace the guide bearing insufficient free stroke of clutch pedal Adjust the free stroke of pedal oil on the clutch disc friction lining or broken Inspect the clutch disc and replace it failure of press disc Replace the clutch cover separation rocker arm assembly is blocked Check the separation rocker arm assembly oil on the clutch disc friction lining or broken clutch clamping stagnation/vibration Soft of clutch pedal Loud noise of clutch failure of press disc clutch membrane spring Inspect the clutch disc and replace Replace the clutch cover is bend Correct the clutch membrane loose of engine bracket Repair if necessary clutch pipe has air Discharge the air in clutch failure of clutch cylinder replace failure of clutch master cylinder replace Component in clutch housing is loose Repair if necessary Throw-out bearing is worn or dirty replace guide bearing is worn replace separation rocker arm assembly or pull-rod is Repair if necessary blocked Clutch-3 the adjustment point of push rod Inspection and adjustment of clutch pedal stroke 1. Check the correctness of pedal height and stroke of push rod The pedal height starting from the meter: LHD 157.5mm The push pole travel at the top of the pedal: RHD 151.0mm If not correct, adjust the pedal height and push rod stroke. the adjustment point of pedal height pedal height 2. Adjust the pedal height and stroke of push bar if necessary a. Screw off the locknut, rotate the locking bolt until to the correct height. Screw on the locknut. b. Screw off the locknut, rotate the push rod until the stroke of push rod is correct. push rod stroke Screw on the locknut. 3. Check the correctness of free stroke of pedal Step on the pedal lightly until fell the clutch start to generate the front wall resistance. Free stroke of pedal: 5 15mm 4. Adjust the free stroke of pedal if necessary a. Screw off the locknut, rotate the push rod until the free stroke is correct. b. Tighten the lock nut c. Check the height of the pedal after adjusts the free stroke of pedal. d. On the condition that ensure the free stroke of clutch pedal assembly: free stroke The height difference between the brake pedal, clutch pedal and the front apron is 0 8mm. Air discharge of clutch Remarks: It should discharge the air if there is residual air in the clutch system. Caution: Do not leave the clutch liquid on the painted surface, otherwise it should be washed off immediately. Fill the brake fluid in the clutch storage tank Check the liquid tank frequently. Filling if necessary. Clutch-4 Cluch control mechanism clutch master cylinder N m: specified torque Clutch-5 Removal of clutch master cylinder, clutch cylinder 1. Use the No. 16 open-end wrench to remove the hose connecting bleed bolt, use the cloth to cover the oil outlet of auxiliary pump to avoid the splash of 0brake fluid; step on the clutch pedal for several times to drain the clutch. 2. Remove the split pin and cylinder pin connected the master pump connecting fork to the pedal; use the No. 13 socket spanner to remove two nuts Q32008 which is used to install the master pump. Check the clutch master cylinder, replace the complete master pump if the internal of master pump has the abnormal noise and damage of leakage etc. Cautions for installation of clutch operation device: 1. Installation of clutch hard pipe : Check the hard pipe for deformation, check to see whether the curling at the port of connection pipe is complete and without damage, if there is no problem after confirmation, it can be installed and fixed in the front wall clip and hard-tube clip. 2. Coat each rotary parts of peal with the lithium base grease. 3. Check the surface of clutch hoes, no surface cracking, oil leakage and dog leg is allowed, use the split washer and spring clip to fix the clutch hose on the support frame of car body. 4. Connect the joints of the general pump oil pipe and the general pump and sub pump according to the required tightening torque. 5. The air in the clutch oil path needs to be exhausted after filling oil (except the vacuum filling): step on the clutch pedal after filling the oil tank, when feeling difficult in stepping, use the open-end wrench with specification of 11 to loosen the air bleed plug screw to exhaust the air, then tighten the plug screw, repeat the operation for several times. Tighten the air bleed plug screw of the sub pump when there is no foam in the flowing oil liquid. Supplement the oil of the oil tank to the level between the Max and the Min. Clutch-6 Clutch release bearing assembly profile spring separation rocker arm assembly separation rocker arm ball support leather cup bolt, spring and washer assembly clutch cover assembly clutch disc assembly N m: specified torque Removal of clutch assembly 1.Remove the transmission Remarks: Do not dry the transmission oil. 2.Remove the clutch cover and clutch disc a. Make the alignment mark on the clutch cover and flywheel b. Remove the fixed bolt gradually, until release the tension of spring c. Remove the fixed bolt, pull out the clutch cover and clutch disc. 3. Remove the bearing and separation fork form the transmission a. Remove the clip and pull out the bearing . b. Remove the separation rocker arm assembly and leather cup. 4. Disassembly procedure: a. Clutch cover assembly, clutch disc assembly b. Profile spring, throwout bearing assembly c. Dustproof cover, separation rocker arm assembly d. Separation rocker arm ball support Warning: When maintaining the clutch assembly, it is now allowed to use the sand mill or dry brush and compressed air for cleaning, lest there is powder (use wet cloth). The clutch disc has the “asbestos fiber”, if there is powder scrap during maintaining, the asbestos fiber in the powder scrap will floats in the air, when human inhales the air containing the asbestos fiber, it will cause great damage to human health. Clutch-7 Checking the clutch components 1. Whether there is breakage of the clutch disc The maximum of the rivet head: 0.3mm If there is problem, the clutch disc needs to be replaced. 2. Check the radial run-out tolerance of the clutch disc Use dial gauge to check the radial run-out tolerance of the clutch disc. The maximum radial run-out tolerance: 0.8mm If the radial run-out tolerance exceeds the maximum value, the clutch disc needs to be replaced. 3. Measure the radial run-out tolerance of the flywheel Use the dial gauge to measure the radial run-out tolerance of the flywheel. Maximum radial run-out tolerance: 0.2mm If the radial run-out tolerance exceeds the maximum value, the flywheel needs to be replaced. 4.Check the guide bearing Rotate the bearing with hand along the direction of the axis. If the bearing cannot be rotated or there is great resistance, the guide bearing needs to be replaced. The bearing is lubricated eternally, so there is no need for cleaning and lubrication. 5. If necessary, replace the guide bearing. special tools Use the special tools to remove the guide bearing. Clutch-8 b. Use special tools to install the guide bearing special tools Remarks: Install the guide bearing into the flywheel, make sure that the bearing can rotate well. 6. Check to see whether there is wearing of the diaphragm spring Use caliper to check the wearing depth and width of the diaphragm spring Limit value: maximum depth 0.6mm Maximum width 5.0mm 7. Check the throwout bearing Rotate the bearing with hand along the axis direction. If the bearing can not rotate or the resistance is too large, it is necessary to replace the throwout bearing. Remarks: The bearing is permanent lubricated, so cleaning and lubricating is unnecessary. Clutch-9 Installation of clutch 1.Install the clutch disc on the flywheel Use the special tools to install the clutch disc on the flywheel. 2.Installtion of clutch cover a. Align the matching mark of clutch shell with that of flywheel . matching mark b. Tighten the bolt evenly. Exert force along the edge of the clutch cover repeatedly until binding tightly. Tighten the bolt. Tightening force: 19N m Remarks: First tighten the upper most bolt of the 3 bolts near the location pin. 3. Check the end surface runout of diaphragm spring clutch finger. Use the special tools to check the alignment of diaphragm spring. Maximum displacement: 0.5mm If the displacement is greater than the specified value, use the special tools to adjust the face runout amount of the diaphragm spring clutch finger. special tools 4. Coat the following components with the molybdenum disulfide lithium base grease (NLGI NO.2) or multi-purpose grease : contacting point of separation rocker arm assembly and bearing bush contacting point of separation rocker arm assembly and subcylinder push bar separation rocker arm assembly supporting point gear box 1st axle spline 5. Install the leather cup, separation rocker arm assembly, clutch cover assembly and throwout bearing in the transmission. 6. Install the transmission Chapter 4 Specification of transmission.......................................................................2 Repair of transmission (SC5M2D C).....................................................4 Disassembly of transmission (SC5M2D C)............................................6 Disassembly of transmission housing assembly/bearing housing assembly....18 Operating instruction of transmission (SC5M4D C).............................24 Repair of transmission (SC5M4D C)...................................................25 Disassembly of rear housing assembly ......................................................28 Disassembly of transfer case assembly......................................................30 Rear output shaft assembly .......................................................................35 Specification of transmission Structure diagram of SC5M2D-C and SC5M4D-C transmission: shown in figure Structure diagram of SC5M2D-C transmission Structure diagram of SC5M4D-C transmission 1. 2. Speed ratio of transmissio Gear Ⅰ Ⅱ Ⅲ Ⅳ Ⅴ R Speed ratio 3.967 2.136 1.360 1.000 0.856 3.578 Speed ratio of transfer case SC5M4D-C Gear synchronizer Speed ratio 3. H L 1.000 1.925 Central distance of main shaft transmission transfer case 72 mm 222.25 mm 4. Instruction for repair specification of transmission Inspection item Repair specification End clearance of gear of Axle 1 (mm) 0～0.06 Adjusted by axial retainer. Clearance between bearing block and bearing of Axle 1 (mm) 0～0.1 End clearance of gear hub of Gear 3/ 4 synchronizer (mm) 0～0.08 Adjusted by axial retainer. Clearance of rear end cone bearing of intermediate shaft (mm) 0～0.05 Adjusted by adjusting shim. End clearance of gear hub of high and low gear (mm) 0～0.08 Adjusted by axial retainer. Adjusted by adjusting shim. SC5M4D-C Clearance between the rear output shaft rear bearing and back cover (mm) 0～0.1 Adjusted by adjusting shim. SC5M4D-C Clearance of rear input shaft bearing (mm) SC5M4D-C 0～0.06 Adjusted by adjusting shim. oil filling screw plug (SC 1701005) Inspection of SC5M2D-C transmission: 1.Check the oil level of transmission: Screw off the oil discharge plug of the transmission; discharge all lubricate oil; screw on the oil discharge plug to the specified torque; the torque is: 30 35N m. Fill the transmission with the transmission oil through the oil filling port, oil number is hyperbolic gear oil SAE80W/ 90, which meet API GL-4, oil capacity are 2.2L. Tighten the oil-filling plug to the specified torque of 30 oil-drain screw-plug assembly (JK72 1701071) 35N m. (for area with high or low temperature refer to the maintenance specification) 2. Replacement of oil seal of rear hosing: The replacement of the oil seal of rear housing is shown in figure. Disconnect the drive shaft from the rear housing; remove the oil seal by the flat screwdriver, then use the special tools to knock the rear housing oil seal in the rear housing. It should pay attention to the installation of oil seal, shown as figure. Coat the lip of oil seal with the rear housing oil seal specified transmission oil. 3. Removal, installation and inspection of transmission The preoperation before removal and after installation of transmission is: Remove and install the manipulator cover assembly, drain and fill the transmission oil accordance with the regulation; after remove and install the drive shaft. Separate each plug-in part from the vehicle transmission . 4 Inspection of manipulator cover assembly bolt A(SC-1704004) Shown as figure, remove the adhesive on the surface before installation, use the screwdriver( M8 1.25) to clean the adhesive in the screw hole; coat the installed part of bolt screw with the specified screw adhesive. Firstly, install two positioning bolts A, then install other two bolt A and bolt C respectively. The tightening torque of all bolts is 15 bolt C(SC-1704003) 22N m. SC5M2D-C transmission assembly handle of gearlever manipulator cover assembly pin 6 22 spring cylindrical pin elastic cylindrical rear housing assembly reverse lamp switch bracket dustproof seal cover select & shift seating bearing housing assembly clutch housing assembly oil seal 39.6 52 odometer driven gear assembly bush location compression cylindrical pin cylindrical compression spring 1.0 N 5.8 m: specified torque Used component which can not be used any more. Pregummed component Use the special tools 41 odometer seating lock plate 10 Disassembly of transmission (SC5M2D-C) 1.Remove the hexagon bolt M8 18 and lock plate. Caution: The tightening torque is 14-19N m when install the hexagon bolt; 2.Remove the odometer driven gear assembly Use the special tools to remove the odometer driven gear assembly 3.Remove the rear housing assembly a. Remove 6 M10 1.25 30 hexagon bolts Caution: The tightening torque is 14-19N M10 1.25 m when installs 6 30 hexagon bolts. b. Use the rubber hammer to knock the rear housing and take out the rear housing assembly. 4. Remove 2 location pins and bushes. Manipulator cover assembly master control lever assembly pin 7 40 rubber cover bulb bush bulb base nut M8 stop plate of main rod bush bulb jacket reverse lock assembly N m: specified torque Used component which can not be used any more. gearbox assembly (one) rubber choke plug bleed plug assembly selection and shifting shaft bush elastic cylindrical pin 6 22 gearbox selection and shifting block steel ball 7. aluminum gasket 938 location pin oil guiding plate bush 6 N m: specified torque Used component which can not be used any more. Pregummed component reverse lamp switch in 6 22 reverse gear 5 shift fork gear 3/4 declutch shift shaft declutch shift shaft pin 5 22 gear 3/4 shifting block gear 1/2 shifting block odometer drive gear declutch shift shaft for ball bearing circlip for shaft steel ball first and secondea circlip for shaft bush circlip for shaft gear 5 drive gear ball bearing lower cover plate assembly aluminum N washer m: specified torque Used component which can not be used any more. Pregummed component Use the special tools earbox assembly (three) reverse driven gear assembly reverse gear 5 synchronizer assembly reverse needle bearing bushing gear 5 driven synchronizer gear ring support axial lock plate gear assembly needle bearing gear 5 needle grease baffle of air duct bearing bushing thrust washer needle bearing steel ball 4.762 needle bearing reverse shaft gear 3/4 shift fork reverse gear gear 1/2 shift fork pin 6 N 22 m: specified torque Used component which can not be used any more. Pregummed component Use the special tools split pin spacing ring adjusting shim reverse drive gear thrust washer 5. Remove the reverse lamp switch M12×1.25 Caution: When install the reverse lamp switch M12×1.25, the tightening torque is 26-36 N·m 6. Remove the gearbox a.Use the wrench to remove the 5 M8×55 bolts, 1 M8×6 bolt and 2 M8×110 bolts Caution: When install 5 M8×55 bolts, 1 M8×6 bolt and 2 M8×110 bolts. tightening torque is b. Remove the gearbox assembly 7. Use the circlip pliers to remove the circlip for shaft 8. Remove the odometer drive gear 9. Use the magnetic rod to take out the steel ball 10. Use the circlip pliers to remove the circlip for shaft 11. Use the circlip pliers to remove the circlip for shaft Caution: It is necessary to circlip for shaft when install the circlip for shaft 12. Use the drawing die to remove the axle 2 ball bearing 13. Use the circlip pliers to remove the circlip for shaft 14. Use the opener to pry out the riveted place of lock nut of intermedi ate shaft 15.Remove the self-locking screw plug, spring, steel ball a. Use the special tools to remove 3 locking screw plugs M10× 1.25×19 Caution: The tightening torque is 14-19N·m when install the locking screw plug M10×1.25×19. b. Use the magnetic rod to remove 3 springs c. Use the magnetic rod to remove 3 steel balls 16. Remove the lower cover plate assembly a. Use the wrench to remove the 12 bolt M8×16 Caution: When install 12 bolts M8×16, the tightening torque is 15-20N·m b. Remove the lower cover plate assembly 17. Remove the declutch shift shaft assembly a. Use the punch to remove the reverse gear 5 shift fork elastic cylindrical pin b. Use the punch to remove the Gear 1/2 shift fork elastic cylindrical pin c. Use the punch to remove the Gear 3/4 shift fork cylinder pin. d. Remove the reverse gear 5 declutch shift shaft assembly e. Remove the gear 3/4 declutch shift shaft assembly f. Remove the reverse gear 5 shift fork 18. Remove the lock nut of intermediate shaft Caution: When install the lock nut of intermediate shaft , the tightening torque is 160-190N·m 19.Remove the Gear 1/2 declutch shift shaft assembly, intermediate shaft rear ball bearing, 5th-Gear drive gear 20. Remove the Gear 1/2 shift fork 21.Use the special tools to remove the second shaft lock nut Caution: When install the second shaft lock nut, the tightening torque is : 250-270N·m 22.Remove the thrust plate 23.Use the magnetic rod to remove the steel ball. 24.Remove the 5th-Gear driven gear assembly Caution: When install the 5th-Gear driven gear assembly, it should use the plug gage to test the 5th-Gear driven gear assembly axial clearance, ensure the axial clearance is within 0.170-0.284mm 25.Remove the 5th-Gear driven gear needle bearing 26. Remove the synchronizer gear ring Caution: When install the synchronizer gear, it should use the plug gage to test the synchronizer gear ring axial clearance, ensure the axial clearance is within 1.25-1.65mm 27. Use the pliers to remove the split pin on the reverse shaft lock nut. 28. Use the special tools to remove the reverse lock nut Caution: when install the reverse lock nut, the tightening torque is within 20-60N·m 29. Remove the thrust plate 30. Remove the 5th/reverse -Gear synchronizer assembly a. Use the special tools to remove the 5th/reverse -Gear synchronizer assembly b. Remove the sleeve and 5th/reverse -Gear synchronizer assembly 31. Remove the reverse gear 32. Remove 2 needle bearings of reverse gear 33. Remove the reverse driven gear 34. Remove the needle bearing of reverse driven gear 35. Remove the reverse drive gear 36. Remove the intermediate shaft spacing ring 37. Remove 8 countersunk screws Caution: when install the countersunk screw, the tightening torque is within 15-22N·m 38. Remove the support axial lock plate 39. Remove the air duct grease baffle Clutch housing assembly / Bearing housing assembly throwout bearing assembly washer 8 ¦ non-standard spring first bearing bush first shaft assembly second shaft assembly oil seal needle bearing ¦circles for shaft leather cup clutch cylinder assembly aluminum waher ¦adjusting shim separation rocker arm ball support separation rocker arm assembly front space ring of intermediate shaft Specified torque Used component which can not be used any more. intermediate shaft assembly Disassembly of clutch housing assembly /bearing housing assembly 40. Use the special tools to remove the reverse shaft Use the magnetic rod to take out 2 interlocking pins Remove the first bearing block assembly a. Use the special tools to install 6 M8 bolts. Caution: When install 6 M8 bolts, the tightening torque is 1013N·m b. Remove the first bearing blocks assembly ; take out the adjusting shim Caution: It should select the adjusting shim when install the adjusting shim Mark 43. Remove the bearing snap ring 44 Remove the intermediate shaft assembly 45. Remove the first shaft assembly 46. Remove the needle bearing 47. Remove the 3rd/4th-Gear shift fork Remove the second shaft assembly a. Use the rubber hammer to knock the second shaft b. Remove the needle bearing bushing of reverse driven gear c. Remove the double inner-race ball bearing assembly d. Remove the second shaft assembly Secondary shaft assembly ¦circlips for shaft synchronizer gear ring needle bearing 3rd-Gear driven gear assembly second shaft 3rd/4th-Gear synchronizer assembly 1st-Gear driven gear assembly 2nd-Gear driven gear assembly needle bearing sleeve 2nd-Gear synchronizer gear ring 1st-Gear synchronizer gear ring double inner-race N m: specified torque 1st/2nd-Gear synchronizer assembly Used component which can not be used any more. 49. Disassembly of second shaft assembly a. Remove the second shaft rear retainer Caution: It should select the circlip for shaft when install the circlip for shaft. b. Remove the 3rd/4th-Gear synchronizer assembly c. Remove the 3rd/4th-Gear synchronizer gear ring Caution: When install the 3rd/4th-Gear synchronizer gear ring, it should use the plug gage to measure the end surface clearance of gear ring to ensure it is within 1.25-1.65mm d. Remove the 3rd-Gear driven gear assembly Caution: When install the 3rd-Gear driven gear assembly, it should use the plug gage to measure the 3rd-Gear driven gear assembly axial clearance to ensure it is within 0.17-0.284mm e. Remove the 3rd-Gear driven gear needle bearing f. Use the special tools to press the second shaft to remove the inner race of double inner-race ball bearing. Remove the 1st-Gear driven gear Caution: When install the 1st-Gear driven gear, it should use the plug gage to measure the 1st-Gear driven gear axial clearance to ensure it is within 0.17-0.284mm. h. Remove the 1st-Gear driven gear needle bearing Transmission-23 i. Remove the sleeve j. Remove the 1st-Gear synchronizer gear ring k. Remove the 1st/2nd-Gear synchronizer assembly l. Remove the 2nd-Gear synchronizer gear ring , 2nd-Gear driven gear and second shaft Caution: When install the 2nd-Gear driven gear, it should use the plug gage to measure the 2nd-Gear driven gear axial clearance to ensure it is within 0.17-0.284mm Operating instruction of transmission SC5M4D-C hand hall of main steering column 1.The schematic diagram of transmission operating gear position is on the handle of steering column. During the process after vehicle is started and in traveling, it must step the clutch pedal to bottom before the shifting. If need shift from 5th-Gear to reverse-Gear, it should move the shifting bar to the neutral position of 3rd/4th-Gear. Shift to R-Gear after stop the vehicle stably, otherwise, it can not shift. hand ball of auxiliary steering column During the traveling process. It should always pay attention to the shifting to make the vehicle matches to the speed of engine. The correct shifting can improve the economical efficiency and prolong the service life of engine. Do not shift from high-Gear to low-Gear on the condition that the pointer of tachometer may enter into red area, otherwise, the engine will be damaged. Warning: Do not shift to reverse-Gear when the vehicle moves forwardly, otherwise the transmission will be damaged. 2. Operation of 4WD The operating auxiliary steering column can be shifted to 4WD status. For position of auxiliary steering column and corresponding operating condition refer to table. Auxiliary steering column position drive 2H 2WD 4H High speed 4WD N Neutral gear 4L Low speed 4WD Operating condition Use this gear position when run in the general railway and high speed highway. Use this gear position when run in the deep snowland, sand ground or uneven road in normal speed. When use the gear position during using of winch, it could not drive the vehicle. Use this gear-position when run in uneven road such as mud land or climbing or downward （especially when need increase the power）. 3. Caution for operation: a. Do not use 4WD in good surface, otherwise the tyre and components of drive system will be damaged easily and increase the consumption of fuel, and cause the noise of drive system. b. Please run in 1st-Gear under “4L” gear position when run in very low speed in field. Transmission-25 oil filling screw plug oil filling screw plug Repair of transmission SC5M4D-C 1. Inspection of oil level of transmission and transfer case: Screw off the oil drainage screw plug of main box and transfer case; drain all lubrication oil, tighten the oil drain plug to specified torque. The torque is: 30 35N m. Fill the main box and transfer case with the transmission oil through the oil filling port. The number is hyperbolic gear oil SAE80W/90, comply with API GL-4. The oil quantities are transmission transfer case oil-drain screw-plug assembly (JK72 1701070) main box : 2.2 L, transfer case : 2.7 L. (for high and low temperature environment refer to maintenance specification). Tighten the oil filling screw plug to specified torque. The torque is: 30 35N m. rear output shaft oil seal (SC 1802323) 2.Replacement of oil-seal of transfer case The replacement of transfer case oil seal is shown as figure. Disconnect the drive shaft from the transfer case, use the flat head screwer to remove the oil seal Caution: Do not damage the housing hole during the disassembly. Then use the special tools to knock the transfer case oil seal into front output shaft oil the transfer case. It should pay attention to the installation dire seal (SC tion of oil seal. The oil seal is flush with the port of transfer case. 1802504) Shown as figure. Coat the lip of oil seal with the specified general synthetic gear oil. 3. Disassembly and check of transmission The preoperation before the removal and after installation of transmission is : When remove and install the manipulator cover assembly, drain and fill with the specified transmission and transfer case lubrication oil. When remove and install the front and rear drive shaft, separate each plug-in part of transmission from the vehicle. Inspection of manipulator cover assembly: bolt bolt bolt The bolt dimension is different for different installation position. Do not confuse it during the installation. It should install the fixing bolt A firstly. The tightening torque of bolt A and B bolt is 15 installation position of fastening blot 22N m. Transmission SC5M4D C assembly manipulator cover assembly elastic cylindrical pin test switch bracket washer reverse lamp switch bracket select & shift seating wire clip cylindrical compression spring wire clip steel ball 6.35 cylindrical transmission compression spring separated case spring cylindrical pin bush stud M10 washer location spring cylindrical pin cylindrical compression spring N m: specified torque Used component which can not be used any more. 1.25 Transmission-27 Manipulator cover assembly handle of transfer case auxiliary steering column assembly handle of gearlever pin washer ball head base bush master control lever assembly auxiliary steering column stop plate rubber cover ball head base ball head bush manipulator cover assembly rubber cover washer pin reverse lock assembly stop plate of ball head main bar ball head nut N hood m: specified torque Used component which can not be used any more. Rear housing assembly 26-36 30-42 24-33 mushroom lock spring steel ball 7.938 (3) 26-36 aluminum gasket rear housing aluminum gasket adjusting shim mushroom lock spring dustproof seal guide bushing 24-33 oil seal 14-19 odometer driven gear assembly odometer seating lock plate N m: specified torque Used component which can not be used any more. Pregummed component Use the special tools 14-19 Disassembly of rear housing assembly 1.Remove the M8 18 hexagon bolt and the lock plate Caution: When install the M8 torque is 14-19N 18 hexagon bolt, the tightening m 2.Remove the odometer driven gear assembly Use the special tools to remove the odometer driven gear assembly 3.Remove the rear cover assembly Caution: When install 6 M10 1.25 30 hexagon bolts, the tightening torque is 14-19N m b.Use the plastic hammer to knock the rear cover slightly and take out the rear cover c.Take out the adjusting shim Caution: It should select the adjusting shim as follows when install it. mark Transmission-29 Transfer case assembly (one) aluminum gasket 18 30-35 30-35 high speed gear chain waved spring aluminum gasket 18 front output shaft assembly 26-36 rear output shaft assembly transfer case cover transfer case housing assembly N m: specified torque Used component which can not be used any more. Pregummed component Transfer case assembly 2 n d / 4 th d r i v e pin 5 26 2nd/4th drive declutch shift shaft interlocking cylinder pin shifting block cylindrical compression spring split retainer spring base spacing ring 2 nd/ 4 th d r i v e shift fork high/low gear high/low gear shift fork assembly declutch shift shaft transfer case housing assembly needle bearing O-RING high/low gear duplicate gear 14-19 bush side cover plate 15-20 N rear intermediate shaft thrust washer needle bearing spacing ring m: specified torque Used component which can not be used any more. thrust washer lock plate Transfer case assembly (three) circlips for hole disk spring duplicate ball bearing oil seal circlips for back plate auxiliary gear spacing ring shaft bowel patch rear input shaft circlips for shaft ball bearing front output shaft ball bearing transfer case housing dustproof seal guide bushing N oil seal m: specified torque Used component which can not be used any more. Disassembly of transfer case assembly 4.Remove the shouldered lock screw plug Use the wrench to remove the shouldered lock screw plug M16 1.5 12 Caution: The tightening torque is 26-36N shouldered lock screw plug M16 1.5 m when install the 12. 5.Remove the upper and lower drive switch M12 1.25 Caution: When install the upper and lower drive switch M12 1. 25, the tightening torque is within 26-36N m 6.Remove the 2nd/4th drive switch M14 1.25 Caution: When install the 2nd/4th drive switch M14 tightening torque is with in 26-36N m 1.25, the Transmission-31 7.Remove the shouldered lock screw plug M14 1.5 10 Caution: When install the shouldered lock screw plug M14 1.5 10, the tightening torque is within 26-36N m 8.Remove the shouldered lock screw plug a. Use the wrench to remove the shouldered lock screw plug M12 1.25 10 Caution: When install the shouldered lock screw plug M14 1.5 10, the tightening torque is within 26-36N m b.Takeout mushroom lock spring c. Use the magnetic rod to take out the steel ball. 9.Remove the transfer case cover a. Use the wrench to remove 12 connecting bolts M10 1.25 65 between the transfer case cover and tranafer case housing. Caution: The tightening torque is 26-36N bolt M10 1.25 65. m when install the b. Remove the select & shift seating elastic cylindrical pin c. Remove the high/low drive declutch shift shaft elastic cylindrical pin d. Remove the 2nd/4th declutch shift shaft elastic cylindrical pin e. Use the circlip pliers to remove the bearing snap ring f. Use the rubber hammer to knock out the transfer case cover assembly slightly and remove the transfer case cover assembly. Transmission-33 10. Remove the high and low gear drive declutch shift shaft 11.Remove the second and fourth drive declutch shift shaft 12. Use the plastic hammer to knock out the rear output shaft assembly, front output shaft assembly and chain out slightly 13. Remove the second/fourth shift block and high and low gear shift fork 14. Remove the housing of transfer case a. Use the wrench to remove 4 bolts M10 1.25 35 and 2 nuts M10 1.25 connected the gearbox and tranafer case housing Caution: The tightening torque is 30 42 N•m when install the connecting bolt of gearbox and housing of transfer case b. Remove the housing of transfer case 15.Remove a location pin For the disassembly of gearbox refer to “Disassembly of gearbox in SC5M2D C” Transmission-35 Rear output shaft assembly low-speed driven gear rear output shaft high and low gear hub needle bearing sprocket needle bearing bushing oil guide plate assembly drive sprocket 87-120 circlips for shaft needle bearing high and low gear sleeve N second/fourth needle drive geared sleeve bearing second/ fourth drive gear hub Used component which can not be used any more. spacing plate Use the special tools m: specified torque ball bearing spacer of drive sprocket ball bearing assembly Disassembly of rear output shaft assembly a. Use the special tools to remove the lock nut Caution: The tightening torque is 87-120N m when install the lock nut. b. Remove the ball bearing c Remove the oil guide plate d Remove the spacing ring e. Use the magnetic rod to remove the steel ball. f. Remove the drive sprocket and needle bearing Caution: When install the drive sprocket, it should use the plug gage to measure the drive sprocket axial clearance and ensure within 0.19-0.338mm g Remove the drive geared sleeve h. Use the magnetic rod to remove the steel ball. i. Dismantle the drive gear sleeve. Transmission-37 j Remove the gear hub k Remove the spacing plate l. Use the circlip pliers to remove the circlip. Caution: It should select the circlip for shaft according the angle when install it. Mark Thickness (mm) White Blue Green m.Remove the high and low geared sleeve and gear hub n. Remove the low-speed driven gear, needle bearing and rear output shaft Caution: When install the low-speed driven gear, it should use the plug gage to measure the axial clearance of low-speed driven gear axial clearance to ensure the axial clearance is 0.17-0.284 mm Automatic transmission-1 Chapter 5 Automatic transmission (M88) Instruction for automatic transmission .........................................2 Operation and display interface ..................................................5 Control system...........................................................................7 Power transmission system..........................................................22 Power transmission ...................................................................26 Diagnosis and test.......................................................................45 Adjustment................................................................................53 Disassembly /Assembly...............................................................55 Specification and special tools ...................................................90 Annex.........................................................................................92 Automatic transmission-2 Instruction for automatic transmission 1. M88 4-speed automatic transmission is equipped with the hydraulic torque converter and electric control system with locking. When keep the stable forward status, the hydraulic torque converter can be locked automatically when the engine operates in low speed, then reduce the unnecessary slide. 2. The main advantage of the transmission is the application of transmission control unit (TCU). The control unit is the control system based on the microprocessor system.. TCU control the shifting sensing and realize the Gear position shifting through the signal of opening degree of throttle position, opening frequency of throttle position, engine speed, vehicle speed, transmission oil temperature, gear position, mode selection and forced Gear reduction application. 3. TCU drives a variable pressure regulating solenoid valve to control three regulation valves and control the feeling of shifting. Different transmission fluid temperatures are taken as one the main parameters to control the output pressure of the solenoid valve, so as to keep consistent feeling of shifting within the normal operation scope. 4. The planning of shifting is very flexible. According to the car model, the different shifting plan is stored in the same TCU. Generally speaking, the “economical mode” can increase the economical efficiency of the fuel and the driving performance of the car to the maximum limit. The “dynamic mode” can bring into full play the drive performance of the car to the maximum limit. The “winter mode” can make the car starting from shift 2. Figure 1.1 Electric automatic transmission control system Figure 1.2 M88 4 speeds automatic transmission appearance figure (applied to 2 wheels driving) Automatic transmission-3 8. Use two bolts to install the back device on the extended case of the transmission, these lengths are important. If it is too long, it will hinder the end of the bolt and affect the threads on the case. Ensure the proper length and special torque of the bolt. 9. Pay attention that the height of the oil has been determined before delivery from the ION Company. The oil height needs not checking or correction, except that improper oil is suspected to be used, or additional oil is needed because of leakage. Automatic transmission-4 10. The gross weight of the transmission is 76kg; mostly weight is on the front of the transmission (side of torque converter). This should be considered when design the handling/assembly tools. 11. The crankshaft speed/position sensor is installed on the top of transmission torque converter housing which must be installed after the transmission is installed on the engine. The sensor will be damaged if it is installed before the installation of transmission. 12. The transmission use the breathing tube connected to rear end of transmission. The tube must not be restricted or blocked otherwise the air pressure in transmission will be increased. It is unallowable that the water/dirty/dust enters into the breathing tube; otherwise the transmission will be damaged. Removal of transmission If the transmission needs removing for any reasons, following is the preventive measure to help the remove. 1. Must not only support the oil pan in middle of transmission for it will be deformed and leaked. The oil pan will not be deformed when supports its external edge. 2. It must not allow the transmission to connect to the engine when the rear end is without connection, otherwise the exhaust system of vehicle will be damaged. 3. Remove all torque converter bolts and push back the torque converter before remove the bolt connected the torque converter housing to engine. Once all bolts connected the torque converter housing to engine are removed, use the torque converter the push the transmission from the location pin, then ensure the torque converter is on the transmission and the transmission is separated form location pin. 4. Install the dustproof cover on the cooler connector rapidly after open the oil cooler pipe; otherwise the oil leakage from the torque converter will be 2L. The odometer dustproof cover can prevent the dirty from entering into the transmission and avoids the leakage of oil form transmission. 5. The engine speed sensor is installed on the top of transmission and should be removed before the transmission is removed form the engine, for the sensor will be damaged during the removal process of the transmission. Operation and display interface The four-speed automatic transmission has three types of operation display interface which are shown as follows: Gear selection The transmission uses the traditional gear selection shifting handle, which is shown in figure. The gear rod can be moved on the gear slide way according to the requirement. The relationship between the related gear and its function. Figure 2.1 Gear selection interface mode selection gear slide way gear selection indication Automatic transmission-5 Table 2.1 Gear selection and its function Gear selection 1st-Gear (manual 1st-Gear ) function The first gear is using for climbing and braking. It is a function which limits the speed of the car. The speed limitation by engine is realized by reduce the opening degree of throttle position. In economic mode, it can process the 1st and 2nd shifting operation when engage the 2nd 2nd-Gear (automatic, manual nd 2 -Gear) –Gear. The limitation of vehicle speed by engine is realized through reducing the opening of throttle position. in 4WD 4 high, , the transmission will maintain 2nd-Gear position The manual mode and winter-Mode will only maintain 2nd-Gear 。 In economic mode and dynamic mode, it can process the shifting operation of 1st, 2nd and 3rd-Gear when engage the 3rd-Gear, and can reaches the very high vehicle speed. At 3rd-Gear (automatic, manual 3rd-Gea) this time the locking clutch can process the locking action, refer to vehicle user manual. The limitation of vehicle speed by engine is realized by reduce the opening of throttle position. In 4WD 4 low, the transmission should be maintained in 3rd –Gear position. Under manual mode, the transmission will be kept in 3rd-Gear. It can process the 1st, 2nd, 3rd and 4th –Gear position operation and gear-shifting operation of (1-2), (1-3), (2-3), (2-4), (3-4), (4-3), (4-2), (3-1) and (2-1). This shifting operation is D-gear processed by taking the vehicle speed, throttle position, throttle position switching (drive) frequency (or forced Gear-decreasing) as the parameter. The locking clutch can process the locking action in 3rd –Gear, 4th-Gear according to the type of vehicle. Refer to user manual of vehicle. N-Gear (neutral gear) R-Gear (reverse gear) P-gear (parking gear) Only the rear brake belt is engaged at this time. It determines whether the function can be realized according to the vehicle speed, engine speed and throttle position. But the gear-position sensor allows the starting of engine. Allow the slide of N-Gear. Set the anti-misoperation in forward function according to the vehicle speed, engine speed and throttle position opening to realize the reverse operation. The gear-position sensor can start the reverse lamp. Only the rear brake belt is engaged at this time. The function can be determined according to the vehicle speed, engine speed and throttle position. The output shaft of transmission is locked. The gear-position sensor can start the engine. Automatic transmission-6 Operation instruction automatic automatic automatic Having anti-slide function It is allowable that the D-Gear in “W” mode is used in snowland and M-A integration mode. Function 5 Brake function Can decrease the gear-position in slope to improve the brake effect and increase the vehicle safety. 6 Speed-up function It can select the manual shifting to increase the vehicle speed completely during the speed-up. cautions 7 It must place the transmission in the P-Gear or N-Gear when start the engine. 8 It must place the transmission in P-Gear during the parking. 9 It must place the transmission in N-Gear when trail the car. 10 It must be powered off when remove the transmission. 11 It must be powered off when install the transmission. The transmission processes the communication and calculation with the engine electronic control computer by the precision central on-line computer. It not only save the fuel, but also provide the maximum mode function, including field, winter and manual selection. It provides the two conditions, manual and electric for the fast race of racing player. It has racing capacity which can compete the speed increasing with the manual transmission. Selection of drive mode The selection of drive mode includes a mode selection switch and indicator lamp. The drive mode selection switch is located on the operating panel. It can provide the different mode selection according to the different type of car. It has the optimal fuel economy when select the “normal” mode. At this time, the indicator lamp is not light. When select the “dynamic” mode, the car will have the maximum dynamic performance and the “dynamic” mode indicator lamp is light. When select the “snowland” mode, it will realize the starting of “2nd-Gear”, the “snowland” mode indicator lamp is light, meanwhile the “dynamic” mode indicator lamp will be closed. When select the manual mode, press down the “snowland” switch firstly, the “manual” light will be light when the gear is in 3, 2, 1. When in manual mode, 1-2, 2-3, 3-4, 3-2, 2-1, 1-3, 3-1 is shifted by driver manually and can not be shifted automatically. It can be used in car-racing etc. for the special mode of each model of car refers to operation manual of user. Automatic transmission-7 Indicator lamp Figure 2.2 control system General The transmission has two sets of control system, a electric control system and a hydraulic control system. The electric control system monitors the vehicle parameter and adjusts the transmission performance; the hydraulic control system executes the command of electric control system. Electric control system The electric control system consists of the sensor, TCU and 7 solenoid valves. TCU read in the data and make the output under the control of software based on the value stored in Read Only Memory (ROM). TCU controls the hydraulic control system and the control is realized through the valve and pump assembly. The system includes 7 solenoid valves, in which 6 valves are used to control the line pressure, operate the shift valve and hydraulic torque converter lock clutch and switch on and off two regulating valves (Two regulating valves control the shift feel). The seventh solenoid valve is the pressure regulating solenoid valve (VPS) which controls the shift feel with other three regulating valves. Figure 3.1 is the typical TCU control system plan. The figure includes all elements of electric control system involved in the section. Solenoid valve 1 Solenoid valve 2 throttle position open sensor Solenoid valve 3 K line Engine speed vehicle speed Solenoid valve 4 shifting logic Solenoid valve 5 hydraulic Transmission fluid temperature mode selection (instrument panel /console ) Gear sensor Forced stepdecreasing shifting sensing line pressure control system Solenoid valve 6 Solenoid valve 7 pressure regulating solenoid valve Mode indicator lamp Gear indicator lamp set and other necessary equipment indication Automatic transmission-8 Automatic transmission-9 Table 3.1 Feature parameter of temperature /resistance 13,638 17,287 5,177 2,278 6,616 2,723 177 75 196 85 ohm -20 Temperature Centigrade degree Figure 3.2 Pin number of temperature /resistance Pin No. Wire color Connected solenoid valve 1 Red solenoid valve 1 2 Blue solenoid valve 2 3 yellow solenoid valve 3 4 orange solenoid valve 4 5 green solenoid valve 5 6 violet solenoid valve 6 7 brown solenoid valve 7 8 green solenoid valve 5 9 white temperature sensor 10 white temperature sensor Automatic transmission-10 solenoid valve 4 (orange ) ground wire (2) temperature sensor ground wire solenoid valve (green ) solenoid valve (red ) ground wire solenoid valve (yellow ) ground wire solenoid valve (blue ) ground wire solenoid valve 7 power supply connector ground wire olenoid valve 6 (violet ) Figure 3.3 Schematic diagram of temperature sensor position and solenoid valve wiring 2.Throttle position sensor Figure 3.4 gear sensor Automatic transmission-11 Diagnosis input solenoid valve 1and 2 solenoid valve 3and 4 S1 and S2 is the normal open solenoid valve, which is used to set the gear-position with other switch solenoid valve. It determines the static gear-position by operating the gear shift valve. Refer to Table 3.5, S1 and S2 also send the pressure single to allow or prohibit the engagement with rear brake belt. S3 and S4 are the normal-opened solenoid valve which is used to control the shifting quality and sequence in combination. S3 control the open or close of the clutch. S4 is used to control the on and off of the front brake belt regulating valve. S5 is the variable pressure solenoid valve which can release the pressure of gear-position shifting. It provides solenoid valve 5 the pressure signal to the clutch and brake belt regulator and controls the shifting pressure. S5 also provides the pressure single to the torque converter clutch regulating valve. solenoid valve 6 solenoid valve 7 S6 is the normal-opened solenoid valve, which is used to the set the H/L level of pipeline pressure. The pipeline pressure is high when the solenoid valve is closed. S7 is the normal-opened solenoid valve which is used to control the engagement status of torque converter licking clutch. It makes the clutch to generate the action when the S7 is in opened status. Table 3.4 Status and function of solenoid valve Gear-position 1st-Gear 2nd-Gear 3rd-Gear 4th-Gear S1 S2 On On Off On Off Off On Off One of them is in On position R-Gear at least. N-Gear Off Off P-Gear Off Off Table 3.5 Logic status of solenoid valve in static gear-position Automatic transmission-12 Shifting 1－2 Initial shifting status Current variation of S5 Finished shifting status S1 Off 950mA－650mA S4 Off 900mA－400mA S3 Off S4 On S1 Off 1－3 S2 Off S4 Off S3 On S4 On S2 Off 1－4 S3 On 850mA－750mA S4 Off S4 On S2 Off 2－3 S3 On 700mA－200mA S1 On S3 Off S4 Off S4 On 3－4 S3 Off 950mA－550mA S4 Off S4 On 4－3 S4 On 950mA－700mA 4－2 S3 On 800mA－500mA S1 Off S4 Off S1 Off S2 On S3 Off 4－1 3－2 S3 On 1000mA－600mA S4 On S2 On S4 On S2 On S3 Off S4 Off 550mA－400mA @ 20kph 800mA－600mA@60kph S4 Off 1000mA－800mA@100kph S1 On 3－1 S3 On S4 On 1000mA－750mA S2 On S3 Off S4 Off S1 On 2－1 S4 On Torque converter clutch On Off S7 On 1000mA－500mA 1000mA－500mA 900mA－600mA Table 3.6 Operation of solenoid valve during shifting period S4 Off S7 Off Automatic transmission-13 Symbol of solenoid valve (On/off solenoid valve) Figure 3.5 Normal-opened type 1.Variable pressure regulating valve regulating system The shifting pressure of abrasion unit is controlled by the variable pressure regulating valve. The line pressure is independent of the shifting pressure and determined by the thro position, shifting status and engine speed. S5 is a proportional or variable pressure regulating valve which provides the pressure signal control shifting pressure for the clutch and brake belt regulating valve. In automatic shifting period, it process the integral times enlarging and contracting regulation for the clutch regulating valve, brake belt regulating valve, torque converter regulating valve and VPS. The hydraulic pressure generated by variable pressure regulating valve is in inverse ratio with current. During the shifting, TCU will increase or decrease the current of solenoid valve according to the program. The current is variable in the range of 200mA to 1000mA. The increasing of the current will decrease the S5 output pressure; the decreasing of current will increase the output pressure of S5. Lin 500 pressure (about 440 to 560kPa) is the reference pressure of VPS, meanwhile, the VPS output pressure equals to the pressure on line 500 always. When the VPS is in waiting status, it means there is not the generation of shifting action. VPS current is 200mA. At this time, it gives the maximum output pressure. In stable status, the brake belt and clutch regulating solenoid valve is in closed status. In this condition, the pressure of line 500 is applied on the piston. For the line 500 pressure is more than S5 pressure always, so it pushed the oil in S5 to the place between the regulating valve and piston. At this time, oil pressure applied on the friction unit equals to the product of pressure on line 500 and magnification factor. During the starting of shifting, the used on/off solenoid valve is in opened status which cut off the oil loop supply from line 500 to piston. At the same time, VPS pressure is decreased to starting pressure valve, pressure set by regulating valve and pressure setting value required by execution of VPS by pushing the piston from the valve. The shifting is finished through the on/off solenoid valve, VPS returns to the waiting status Pointed to each gear-position, the system can make the brake belt; clutch or both realize the electronic control. Mode indicator lamp: the mode indicator lamp can be used to indicate the current selected and whether the overpeed status exists. The mode indicator lamp is located in instrument panel generally. (Refer to Part 2.3) Automatic transmission-14 Hydraulic control system The hydraulic control system is located in the valve, pump and main box. The valve includes the following types: Manual-operated valve sequence valve Three shift valves electromagnetic pressure control valve line pressure control valve clutch connection regulating valve brake belt connection regulating valve solenoid valve 1 to solenoid valve 6 reverse lock valve The pump includes the following types: primary regulating valve (control line pressure) torque converter clutch regulating valve torque converter clutch control valve solenoid valve 7 The main box includes: BIR blow-off valve 1. Valve Figure 3.7 shows the valve unit in the view of transmission fluid tank. Figure 3.8 illustrates the pump cover. 2. Manual-operated valve The manual-operated valve (refer to Figure 3.9) is connected to the car gear selection mechanism. It controls the transmission fluid flow to the forward or reverse loop. Except in manual 1st-Gear position, the function of manual-operated valve is same in all forward gear. In manual 1st-Gear, the transmission fluid will enter into the shift valve 1 2 to make the rear brake belt and C4 overspeed gear clutch is engaged respectively. Automatic transmission-15 Figure 3.6 Hydraulic control circulation flow Automatic transmission-16 Figure 3.9 manual-operated valve 3. 3 1-2 shift valve 1-2 shift valve (refer to Figure 3.10) has two position status. It must be in the position (2, 3, 4) for the convenience of raising gear in 1st-Gear. It is using for all 1-2 and 2-1 shift. Through the power supply of S1 and (or ) S2, the 1-2 shift valve can acquire its On/Off status. During 1-2 shift period, drive the transmission fluid from manual-operated valve to the 2nd-Gear loop. During the shifting form 2 to 1, the brake belt is engaged and drain the oil through the 1-2 Gear shift valve. When in 1st-gear position, the 1-2 gear shift valve operates with the 3-4gear shift valve (described as follows) combinedly to separate the clutch C4; if in 2nd-Gear position, engage the clutch C4. When select the manual Gear-1, the clutch C4 engages with the rear brake belt (B2). Automatic transmission-17 9. Clutch combination regulating valve Clutch combination regulating valve (refer to Figure 3.15) is a constant ratio regulating valve which provide the regulating pressure of clutch C1 to control the change ratio of shifting quality clutch status. The ratio is about 2.25:1. When the S3 is opened, the oil of 3rd-Gear is provided to the valve and adjust the pressure (CAF) to 2.25 times of S5 signal pressure. When S3 is in closed status, the output pressure is 2.25 times of pressure of line 500. Figure 3.10 1-2 gear shift valve Automatic transmission-18 Figure 3.11 2-3gear shift valve Figure 3.12 3-4gear shift valve Figure 3.13 4-3sequence valve Figure 3.14 Electromagnetic pressure regulating valve and line pressure impelling valve Automatic transmission-19 10. Figure 3.15 clutch combination regulating valve Brake belt combination regulating valve a P-Gear or N-Gear, vehicle speed 3km/h 10km/h b R-Gear , speed c Speed of engine : 1250rpm d Diesel vehicle , Opening degree of throttle position: 25 e Gasoline vehicle, opening degree of throttle position: 12 In this condition, the TCU control solenoid valve S1 and S2 are closed. The reverse lock valve is affected by the pressure form S1-S2 transmission fluid; connect the line pressure to loop B2. The transmission fluid flows to servo internal and external attachment area, the B2 is engaged. When none of above condition is met, TCU control the solenoid valve S1 and S2 to be opened. The pressure of S1-S2 is released and the spring control valve body is in locking status at the same. In this condition, the B2 attachment is prohibited. The feature can realize the protection for transmission by controlling the B2 in high speed and providing the reverse-gear locking. If the transmission is in failure mode, then the rear brake belt will be attached in P-Gear, R-Gear and N-Gear. Figure 3.16 brake belt combination regulating valve Automatic transmission-20 Figure 3.17 reverse lock valve 12. Primary regulating valve Primary regulating valve (PRV) (refer to Figure 3.18) can regulate the line pressure of transmission (or pump output pressure). The valve can give the high or low line pressure according to the on/off status of S6. When S6 is in on or off status, the pressure S6 is applied on PRV, move it and has the action of spring force. Open the line pressure loop to turn on the inlet of pump to reduce the line pressure. Generally, the line pressure is small when the throttle position is opened lightly and in patrol status. It will cause the closing of S6 when the opening degree of throttle position is large and because the high line pressure valve For all shifting pressures are controlled by output of separation brake belt , clutch regulating valve and S5, so all step control of line pressure has not affect on effect of shifting sensing. By the oil inlet of torque converter, PRV also adjust the oil supply of hydraulic torque converter. The level effect of PRV should ensure the priority of valve, i.e. it can keep the line pressure in low engine speed condition. When the speed of engine is increased and the pump supplies excess oil, the PRV acts to open the torque converter oil inlet cover to increase the pressure of torque converter. If the oil amount is beyond the requirement of transmission, PRV will act further to allow the oil return to the suction inlet. Figure 3.18 Primary regulating valve 13. Torque converter on/off regulating valve The torque converter regulating valve (refer to Figure 3.19) adjusts the pressure applied on torque converter clutch oil. According to the signal pressure form loop S5, adjust the oil flow status from line pressure loop in valve. With the change of pressure signal of loop S5, the engagement and disengagement of torque converter clutch can be finished by electric control. Figure 3.19 Torque converter on/off regulating valve Automatic transmission-21 Figure 3.20 torque converter clutch control valve Figure 3.21 C1 eccentrically arranged valve . Figure 3.22 BIR blow-off valve Automatic transmission-22 Power transmission system The power transmission system includes: Torque converter equipped with single lock clutch. 4 multi-plate clutch assemblies 2 brake belts 2 one-way clutches Planetary gear assembly parking mechanism A traditional planetary gear assembly composed by six pinions is used in four-speed transmission. It realizes the 4 Gear power transmission through the drive gear bracket. So, the cross arrangement is the main arranging method. In the box, there are four subassemblies, shown as follows: Gear bank central support C1-C2-C3-clutch C4 subassembly Pump assembly Valve assembly One piece or one set of optional shim is located between the input shaft flange and center of stator support shaft axle of and used to control the end flotation of transmission. The structure arrangement allows the inspection for the subassembly during the product manufacturing period. For description of power transmission system refer to table 4.1 and Figure 4.1: When the clutch C2 is engaged and 1-2 one-way clutch is engaged, the gear is in 2nd-Gear at this time. During the 1-2 shifting process, B1 brake belt is combined and the 1-2 one-way clutch is separated (OWC). During the 2-3 shifting period, the clutch C1 is engaged and the B1brake belt is released. During the 3-4 shifting period, B1brake belt is engaged and 3-4 one-way clutch is released. For reverse gear, the clutch C3 and B2brake belt is engaged. When the gear position is in manual 1st, 2nd and 3rd gear position, the engagement of the clutch C4 can provide the brake of engine. Additionally, in the drive scope of 2nd and 3rd Gear, the engagement of clutch C4 can eliminate the unfavorable freewheel inertia. In the scope of manual 1st-Gear, the low speed shifting is realized by the engagement of B2brake belt. The front and rear servo has the figure surface design which requires the accurate friction and need not the secondary regulating valve. When use the transmission fluid with new static factor, the design of the friction unit can meet the requirement that need low shifting energy and high static holding force. The transmission uses the non-asbestos friction material. Name of participated unit Gear position Gear ratio 1st-Gear 2.393 2 -Gear 1.450 3 -Gear 1.000 4 -Gear 0.677 R-Gear 2.093 Manual 1 2.393 nd rd th C3 C4 B1 B2 * For operation of specified vehicle refer to user’operation manual. LU: hydraulic torque converter lock clutch Table 4.1 Participated unit and gear ratio in different gear position LU Automatic transmission-23 Figure 4.1 Power flow chart Torque converter The torque converter (refer to Figure 4.2) consists of the turbine, stator, impeller and a lock throttle brake and piston assembly. Same as that of the traditional torque converter, the impeller is connected to the end cover of the torque converter. The turbine is connected to the input shaft through the spline. The stator is installed on the pump housing through the one-way clutch . Figure 4.2 Section of torque converter The buffer and piston assembly can make the torque converter is locked in proper condition. The locking action only occurs in the condition of specified throttle position opening and vehicle speed. When the hydraulic force makes the buffer and piston assembly is coupled on the cover of torque converter, it can acquire the locking status. In this status, it can eliminate the unnecessary sliding. It can increase the economical efficiency of fuel oil when the locking action is generated. When in locking status, the torque buffer spring in the buffer and piston can absorb the torque fluctuation of engine. Clutch assembly It has four types of clutch assembly (refer to Figure 4.3). All clutch assemblies are composed of several layers of steel plate and friction disk. Clutch C1 When it is engaged, the drive shaft drive the planet carrier. The condition occurs in 3rd and 4th Gear. Clutch C2 When it is engaged, the drive shaft drive the forward central gear through the 3-4 one-way clutch. The conditio occurs in 1st, 2nd and 3rd-Gear condition. Clutch C3 When it is engaged, the drive shaft drive the backward central gear. The condition occurs in R-Gear position. Clutch C4 It can provide the brake of engine during overspeed when is engaged, The condition occurs in manual 1st, 2nd and 3rd –Gear, also in automatic 2nd and 3rd-Gear to avoid the unfavorable inertia rotation of freewheel. Automatic transmission-24 Figure 4.3 Clutch assembly Brake belt The transmission has two brake belts, brake belt B1 (named as 2-4 brake belt sometimes ) and brake belt B2 (named as low-speed – reverse gear brake belt ) refer to Figure 4.4. The brake belt B1 is a flexible brake belt which is engaged with front servo piston. When it is in 2nd and 4th –Gear, the brake belt B1 starts to act. When the brake belt acts, it can prevent the rotation of reverse central gear by maintaining the clutch C3 assembly is in static. In 2nd –Gear, only the external surface of piston is used. In 4thGear, both sides are used to acquire more clamping force. The brake belt B2 is a solid brake belt which is meshed with the rear servo piston. When the B2 acts, it prevents the rotation of planet carrier assembly. When in manual 1st-Gear, only the external surface of piston is used. In reverse-Gear, both sides are used to acquire more clamping force. Front servo and brake belt Rear servo and brake belt Figure 4.4 brake belt One-way clutch The transmission has two one-way clutches, 1-2 one-way clutch and 3-4 one-way clutch (notice that the third one-way clutch is located on torque converter, also called as retainer) 1-2 one-way clutch is located between the planet carrier assembly and central shaft. The structure makes the planet carrier only can rotate in single direction around the central shaft. The one-way clutch is only engaged in automatic 1st-Gear. 3-4 one-way clutch is located between the clutch C4 and clutch C2.The structure makes the clutch C2 drive the front planetary gear in 1st, 2nd and 3rd –Gear, but is disengaged in 4th-Gear and overspeed. Planetary gear assembly The planetary gear block used in transmission is the traditional lavena gear block consisted of6 pinions. Parking mechanism When select the parking-Gear, the steering column will move the parking lever backwardly to engage with the parking ratch (refer to Figure 4.5). The ratchet is engaged with the tooth of external gear ring fear to lock the output shaft axle in the transmission. When it is not in parking-gear, the return spring will release the parking ratchet and unlock the output shaft to prevent the occurrence of accident parking action. Automatic transmission-25 Figure 4.5 Parking mechanism Automatic transmission-26 Power transmission Introduction It has the following power transmission pointed to different Gear-position: power transmission N-Gear and P-Gear power transmission power transmission R-Gear manual 1 power transmission power transmission power transmission Automatic 1st-Gear Automatic 2nd -Gear Automatic 3rd -Gear power transmission power transmission power transmission Automatic 3rd-Gear locking Automatic 4th -Gear (overspeed -gear) Automatic 4th -Gear locking For description of each kind of power transmission condition, refer to following parts. Table 5.1 describe the on-off condition of each unit in all gear condition. Name of participated unit Position C1 C2 C3 C4 B1 B2 1-2 OWC 3-4 OWC LU clutch Parking and neutral position － － － － － X － － － X － － － － X － X Reverse － － X － Manual 1st -Gear － X － X － X － － － － X － － X － X X － － X － X X － X － － － X － X X － X － － － X X X X － － X － － － － X X － － X － － － X Automatic 1 st- Gear nd Auto 2 -Gear and manual 2 nd -Gear Automatic 3 rd –Gear and manual 3 rd-Gear Automatic 3 rd -Gear locking and manual 3 rd -Gear locking Automatic 4 th -Gear (overspeed -gear) Automatic 4 th -Gear locking In P-Gear or N-Gear, the planetary gear assembly has not the drive. The rear brake belt is used to eliminate the voice generated in engagement with reverse gear and increase the application of 4WD. It is without the engagement of clutch and brake belt. In parking-Gear, the locking of mechanism is realized through the engagement of brake lever installed on housing and tooth of output shaft gear ring. Control In stable status, to maintain the arrangement, the status of solenoid valve and valve is shown as follows: solenoid valve S1 and S2 is powered off. The line (pump) pressure is applied on the primary regulating valve (PRV) and electromagnetic supply valve. The torque converter, oil cooler and lubrication loop are filled up with the transmission fluid from the primary regulating valve. The line pressure 500 loop is filled up with the transmission fluid from the electromagnetic supply valve. S5 will be filled up with the transmission fluid through the variable pressure \regulating valve (S5) . The line pressure is prohibited form entering into the drive loop through the manual-operated valve . B1 loop and all clutch loop are opened to drainage port. Automatic transmission-27 Refer to Figure 5.1and table 5.2. Name of participated unit Gear-position clutch Parking and neutral position Table 5.2 The participation status of each unit in parking and neutral position Figure 5.1 parking and neutral position Automatic transmission-28 Automatic transmission-29 In reverse-Gear position, the drive of transmission is sent to the clutch hub through the input shaft and rear clutch piston. In this condition, the description of each function unit of transmission is shown as follows: The clutch C3 is engaged and drive the reverse central gear to rotate in clockwise. The engagement of B2 brake belt cause the rest of the planetary gear carrier, then make the long planetary gear rotates around its shaft anticlockwise. The long planetary gear drives the internal gear ring rotates anticlockwise . Use the spline to connect the inner gear ring to the output shaft and drive the gear ring rotate anticlockwise or in reverse. Control: In stable status, to maintain the arrangement, the action of solenoid valve and valve is shown as follows: A solenoid valve S1 or S2 is closed at least. (Refer to the part in section 3.3.11, related to condition when S1 and S2 is closed.) The line pressure reaches the internal surface and external surface of rear servo piston through the reverse lock valve directly. The line pressure urges the reverse-Gear loop oil pass through the manual-operated valve. The reverse-Gear loop oil is circuited to clutch C3 through the manual-operated valve. In the transmission whiteout HP pump shell, the reverse-Gear loop also can reaches the spring end of the primary regulating valve to support the spring and push the line-pressure regulating valve. The oil loop of execution line of all other clutches and brake belts is opened to leaking port. Refer to Figure 5.2 and Table 5.3. Table 5.3 The participating condition of each unit in reverse-Gear position Name of participated unit Gear-position Reverse gear Figure 5.2 Reverse-Gear Automatic transmission-30 Automatic transmission-31 Power transmission manual 1st-Gear st In manual 1 –Gear, the drive of transmission is send to the rear clutch cylinder through the input shaft. In this condition, each function unit of transmission is shown as follows: The clutch C2 is engaged through the 3-4 one-way clutch (OWC) to drive the front sun gear. The engagement of B2 brake belt make the planetary gear carrier to stop. The front sun gear drive the short planetary gear to rotate in anticlockwise. The short planetary gear drive the long planetary gear to rotate in clockwise. The long planetary gear rotate around its axial to drive the internal gear ring and output shaft to rotate in clockwise to realize the movement in forward direction. In overspeed, clutch C4 can provides certain brake force through 3-4 one-way clutch . Control: In stable status, the action of solenoid valve and valve is shown as follows: The solenoid valve S1 and S2 is powered on. In the action of pressure of line 500, the gear shift valve of 1-2, 2-3, 3-4 gear are kept in position of 1st-Gear. The manual-operated valve transmission fluid (line pressure ) makes the clutch C2 to engagement. LO-1st (line pressure) oil flows to the clutch C4 through the 1-2 Gear switching valve to engage the B2 brake belt. Refer to Figure 5.3 and Table 5.4. Table 5.4 The participating condition of each unit in manual 1st-Gear Name of participated unit X X Figure 5.2 Reverse-Gear Automatic transmission-32 Automatic transmission-33 Power transmission automatic 1st-Gear In automatic 1st -Gear, the drive of transmission reaches the reaches the front clutch cylinder through the input shaft. In this condition, the operating principle of each function unit of transmission is shown as follows: The engagement of clutch C2 drives the front sun gear The front sun gear drive the short planetary gear to rotate in anticlockwise. The short planetary gear drives the long planetary gear to rotates in clockwise. 1-2 one-way clutch (OWC) stops the rotation of planetary gear carrier in counteracting force. At the same time, the long planetary gear rotates around its axial to drive the ring gear and output shaft to rotate in clockwise to realize the forward movement. Control: In stable status, the status of solenoid valve and valve is shown as follows: Solenoid valve S1and S2 is powered on In the action of line 500 pressure, the gear shift valve of 1-2, 2-3, 3-4 Gear is maintained in 1st-gear position. The transmission drive oil (line pressure) from the manual-operated valve makes the engagement of clutch C2. Refer to Figure 5.4and Table 5.5. Table 5.5—participating condition of each unit in automatic 1st-Gear Name of participation unit Gear position Automatic 1st-Gear Figure 5 4 Automatic 1st –Gear Automatic transmission-34 Automatic transmission-35 Power transmission automatic 2nd-Gear and manual 2 In automatic 1st and manual 2nd-Gear, the drive of transmission reaches the front clutch cylinder through the input shaft. In this condition, the operating principle of each functional unit of transmission is shown as follows: The engagement of clutch C2 drives the forward central gear. The forward central gear drives the short planetary gear to rotate in anticlockwise. The short planetary gear drives the long planetary gear to rotate clockwise. The engagement of brake belt B1 makes the stop of reverse central gear to make the long planetary gear rotates around the reverse central gear, then make the internal gear and output shaft rotates in clockwise to make the vehicle moves forwardly. The clutch C4 is engaged through the 3-4 one-way clutch (OWC) and provides the brake force of engine during overspeed. Control: In stable status, the status action of solenoid valve and valve is shown as follows: The solenoid valve S1 is powered off ; The solenoid valve S2 is powered on. The drive oil (line pressure) from the manual-operated valve makes the engagement of clutch C2. When the solenoid valve S1 is powered off, the S1 oil pressure form line pressure 500 pushes the 3-4 Gear shifting valve moves to left. At the same time, the S1 oil flows into the 1-2 Gear shifting valve to push the 1-2 Gear shifting valve to the 2nd –Gear. The line pressure oil from the 1-2 Gear shifting valve flows into the brake belt combination regulating valve, and 2-3 Gar shifting valve. The brake belt engagement regulator valve provides the 2nd-Gear oil (controlled by product of line pressure and valve rate) to brake belt feed loop (BAF). The brake belt engagement feed loop directly provides the oil to: External engagement part of front servo piston. 1-2 Gear shifting valve can provide a oil drainage port when the transmission is shifted to 1st-Gear. Use the 3-4 Gear shifting valve when the transmission is in 4th-Gear position. The drive force (line pressure) is sent to the clutch C4 through the 3-4 Gear shifting valve to realize the engagement of clutch C4. Refer to Figure 5.5 and table 5.6 Table 5.6 The participating condition of each unit in automatic 2nd-Gear and manual 2nd-Gear Name of participation unit Automatic 2nd-Gear and manual 2nd-Gear Figure 5.5 Automatic 2nd-Gear manual 2nd-Gear Automatic transmission-36 Automatic transmission-37 power transmission Automatic 3rd-Gear and manual 3rd-Gear In automatic and manual 3rd-Gear, the drive of transmission reaches the front cylinder through the input shaft. In this condition, the operating principle of the transmission is shown as follows: The engagement of clutch C2 drives the front sun gear The engagement of clutch C1 drives the planetary gear carrier The forward central gear and planetary gear carrier rotate in the same speed clockwise. So, there is not relative motion between the forward central gear and planetary gear. The gear ring and output shaft rotate in the speed of output shaft, and makes the moves forwardly. The engagement of clutch C4 is through the 3-4 one-way clutch (OWC) and make the engine to provide the brake force in overspeed. Control: In stable status, the status of solenoid valve and valve is shown as follows: The solenoid valve S1 is powered off; Solenoid valve S2 is powered off When the solenoid valve S1 and S2 is powered off, 2-3 and 3-4 shift valve are kept in 3rd-Gear position through the line pressure 500. 1-2 Gear shifting valve is kept in 3rd-Gear position by the oil pressure of S1 and S2. The (line pressure)oil form the 1-2 Gear shifting valve flows into the brake belt combination regulating valve directly and flows into the 2-3 Gear shifting valve. The brake belt combination regulating valve provides the 2nd-Gear oil (controlled by the product of line pressure and valve) to the brake belt feed loop(BAF). The brake belt feed loop directly provides the oil to: External combination part of front servo When the transmission is shifted to 1st-Gear, the 1-2 Gear shifting valve provides the oil drainage port. When the transmission is in 4th –Gear position, it will use the 3-4 Gear shifting valve. The 2nd-Gear oil of 2-3 Gear shifting valve flows into the 3rd-gear loop directly . The 3rd-Gear oil from the 2-3 Gear shifting valve flows into the clutch combination regulating valve and sequence valve of 4-3 Gear directly. The clutch combination regulating valve provides the oil of clutch attachment feed loop (controlled by the product of line pressure of 500 and valve ratio) (CAF). CAF directly provides the oil to : clutch C1 Sequence valve of 4-3 Gear In 4-3 Gear shifting valve, the CAF oil is changed to the release fluid of B1 (B1R-F), it cause the closing of brake belt 1 through the 3-4 Gear shifting valve to spring bottom of 4-3 gear sequence valve and release side of front servo. The drive force (line pressure ) is sent to the clutch C4 through the 3-4 Gear shifting valve to engage the clutch C4 . Refer to Figure 5.6 and Table 5.7. Name of participation unit Clutch Automatic and manual 3rd –Gear Table 5.7 Table of participating condition of each unit in automatic and manual 3rd –Gear Figure 5.6 Automatic 3rd –Gear-manual 3rd-gear Automatic transmission-38 Automatic transmission-39 Power transmission locking of automatic and manual 3rd-Gear When the automatic 3rd-Gear and manual 3rd-Gear is locked, the drive of transmission is basically same as that in automatic 3rdGear. But it provide the variable torque drive without slide for the application of torque converter locking clutch. Control: The control for the automatic 3rd-Gear locking and manual 3rd-Gear locking is basically same as that for automatic 3rd –Gear. But it should be described additionally that the automatic 3rd-Gear and manual 3rd-gear locking needs the action for variable torque clutch loop by solenoid valve S7. When the solenoid valve S7 is opened, the variable torque clutch control valve is closed and allow the oil feed of S7 loop pass through the solenoid valve S7 to drainage port. It makes the control valve moves to the clutch combination position. The loop oil from the line 500 flows into the combination part of variable torque clutch through the converter clutch control valve through the action of variable torque clutch control valve. The variable torque clutch release oil is drained from the variable torque clutch control valve. The torque converter loop oil flows into the oil cooler and lubrication loop through the variable clutch control valve. Refer to Figure 5.7 and table 5.8. Name of participation unit Automatic 3rd-Gear locking and manual 3rd-gear locking Table 5.8 Participating condition of each unit in automatic and manual 3rd-Gear locking Figure 5.7 Automatic 3rd –Gear locking and manual 3rd-Gear locking Automatic transmission-40 Automatic transmission-41 In automatic 4th-Gear (overspeed gear), the drive of transmission is sent to the front clutch cylinder through the input shaft. The operation principle of each function assembly of transmission is shown as follows: The engagement of clutch C1 drives the planetary gear carrier rotates in clockwise rotation. The engagement of B1 brake belt makes the reverse sun gear to stop. When the planetary gear carrier rotates, the long planetary gear rotates around the static reverse sun gear, at the same time, it rotates around its axial line to drive the gear ring and output shaft to generate the forward movement in the speed higher than that of input shaft (i.e. overspeed) clockwise. The forward central gear rotates in the speed higher than input shaft and is more than the speed when 3-4 one-way clutch (OWC) is engaged. The engagement of clutch C2 is used to reduce the speed difference generated by 3-4 one-way clutch (OWC). Control: In the stable status, the status of solenoid valve and valve is shown as follows: The solenoid valve S1 is powered on ; S2 is powered off. When the solenoid valve S1 is powered on, the small end of 3-4 shift valve is in 4th-Gear position for the pressure of line 500. When the solenoid valve S2 is powered off, the large opening of 2-3 shifting valve is in 4th- Gear position for the pressure of line 500. The 1-2 Gear shifting valve is kept in 4th-Gear position for the pressure of S2 oil loop. The 2nd-Gear loop oil (line pressure) from the 1-2 shift valve flows into the brake belt combination regulating valve and 2-3 shift valve directly. The brake belt combination regulating valve provides the 2nd-Gear loop oil for the brake belt attachment loop (BAF) (adjusted by product of line pressure and valve ratio) The brake belt combination lip oil is directly supplied to: External combination part of front servo Enter into the internal combination part of front servo piston through 3-4 shift valve The 1st-Gear-2 switch valve provides a oil-drain port when the transmission is switched to 1st-Gear. The 2nd-Gear loop oil in 2-3shift valve flows into the 3rd-Gear loop directly. The 3rd-Gear loop oil from the 2-3 shift valve flows into the clutch combination regulating valve and 4th-Gear-3 sequence valve directly The clutch combination regulator valve supplies the oil for the clutch combination loop (CAF) (Regulated by the product of line pressure and valve rate) CAF oil is directly supplied to: clutch C1 4th-Gear-3 sequence valve The drive oil(line pressure) form the manual-operated valve forces the engagement of clutch C2 Refer to Figure 5.8 and Table 5.9. Table 5.9 Participating condition of each unit in automatic 4th –Gear (overspeed Gear) Name of participation unit clutch Automatic 4th-Gear (overspeed Gear) Figure 5.8 Automatic 4th-Gear (overspeed Gear) Automatic transmission-42 Automatic transmission-43 Power transmission Automatic 4th-Gear locking In automatic 4th –gear locking, the drive of transmission is same as that in automatic 4th –gear basically. But for the application of variable torque locking clutch, it provides the variable torque drive without slide. Control: The automatic 4th –Gear locking is same as that in automatic 4th-Gear basically. But it should be described that when the automatic 4th-Gear is locked, it has the action for variable torque loop by solenoid valve S7. When the solenoid valve S7 is opened, the variable torque clutch control valve is closed and allow the S7 loop oil flows to the drainage port through the solenoid valve S7, then control the valve to move to the clutch engagement position. The line pressure loop regulating oil from the torque converter clutch regulating valve flows into the combination side of torque converter clutch directly. The release oil of torque converter clutch is drained from the control valve of torque converter clutch.. The torque converter loop oil flows into the oil cooler and lubrication loop directly through the control valve of torque converter clutch.. Refer to Figure 5.9 and Table 5.10. Name of participation unit Clutch Table 5.10 The participating condition of each unit in automatic 4th-gear locking Figure 5.9 Automatic 4th –Gear locking Automatic transmission-44 Automatic transmission-45 Diagnosis and test Test system 1. Recommended test equipment and program The test equipment and control unit for design will be used for the test of all vehicles. The parts for transmission test includes: Tester for service after sales Special vehicle for test 2. Tester for service after sales After the special programming, the tester equipped with special car test software can be used to test the specified system and unit. The program allows the normal communication between the transmission control units (TCUs) . The computer needs the required information from the customer and select the necessary data through the manual. For example: view the code, clear the error code and make the real-time operation. For detailed operating instruction refer to user’s manual. The equipment can be used by the trained specialized persons, such as technician, machinist to test the electronic and loop problem related to transmission. The testable information includes: the engine speed, rode (shaft speed), transmission fluid temperature, position of throttle position, status of solenoid valve and gear and position of operating lever. Additionally, it can be used to detect the current and stored problem. 3. Description of TCU pin The description of TCU pin code had been listed in Table 6.1.1 For description of wire bunch refer to Figure 6.1.1 Pin No. A14 A13 A12 Function Type Public grounding GND Nonuse －－ Mode indicator lamp OP Snowland mode 2WD ● ○ ● Parking-Gear indicator lamp OP Reverse-Gear indicator lamp OP N-Gear indicator lamp OP A8 Nonuse －－ ○ A7 Nonuse －－ ○ Mode indicator lamp OP A11 A10 A9 A6 dynamic mode ● ● ● ● description Negative pole of TCU supply, connected to negative pole of battery. －－－－－ Indicate that select the “Snowland Mode” operating method. The drive instrument panel indicator lamp indicates that is in the “Parking Gear” The drive instrument panel indicator lamp indicates that is in “Reverse Gear” The drive instrument panel indicator lamp indicates that is in “Idle N Gear” －－－－－ －－－－－ Indicate that select the “dynamic mode” operating method. A5 Nonuse ―― ○ －－－―― A4 Nonuse ―― ○ －－－－－ A3 Nonuse ―― ○ Mode switch IP A2 －－－－－ The switch is used to select the “economic mode”, “dynamic ● mode” and “snowland mode”. The voltage is variable in range of 0 V－2V . A1 A30 A29 A28 A27 Nonuse ―― Power supply PWR Nonuse ―― 1 st-Gear 2nd-Gear A25 lamp OP indicator lamp OP /2nd-Gear position rd A26 indicator /1 st-Gear position﹡ 3 -Gear indicator lamp OP /3 rd -Gear position﹡ Automatic gear indicator lamp /4 th –Gear position OP ○ ● ○ ● ● ● ● －－－－－ Power supply for TCU; is the main power source of drive unit and solenoid valve. －－－－－ Drive the instrument panel indicator lamp indication, indicate that the gear-position is in “1 st-Gear” Drive the instrument panel indicator lamp indication, indicate that the gear-position is in “2 nd -Gear” Drive the instrument panel indicator lamp indication, indicate that the gear-position is in “3 rd-Gear” Drive the instrument panel indicator lamp indication, indicate that the gear-position is in “automatic-Gear” Automatic transmission-46 P in N o. A24 A23 A22 A21 A20 A19 A18 A17 A16 A15 CA N (-ve) CA N (+ ve) K line com m un ication connection N onuse N onuse Shaft speed sensor signal N onuse N onuse N onuse N onuse T ype 2W D I/O I/O ○ ○ I/O ● ―― ―― ○ ○ IP ○ ―― ―― ―― ―― ○ ○ ○ ○ IP ● IP ● B6 G ear-position B5 transm ission tem perature B4 solenoid valve 4 OP ● B3 solenoid valve 1 OP ● B2 N onuse Return solenoid valve 5 G ear-position － grounding transm ission fluid tem perature － grounding ―― ○ IP ● GND ● GND ● B1 B 14 B 13 fluid CAN h idden com m unication end CAN exposed co m m unication end D iagnosis inform ation and car code －－－－－ －－－－－ The sensor sends the shaft speed signal to T CU －－－－－ －－－－－ －－－－－ －－－－－ The switch has the variable-voltage; indicate the gear-position steering colum n selected (PR ND 321). T he voltage is variable in the range of 0V --5 V. The sensor indicates the transm ission fluid tem perature. H igh R= Low tem perature Low R = High temperature The voltage is variable in the range of 0V to 5V N /O FF norm al-opened solenoid valve, co m bined w ith the O N /O FF w itch of solenoid valve 3; ensure the shifting quality and sequence O N /O FF norm al-opened solenoid valve; com bined w ith other solenoid valve; used to determ ine the selected gear-position. －－－－－ U sing for grounding of VP S and current of circuit can be detected, then process the feedback control for the V PS. P RN D 321 Gear-position sw itch groun ding Co nnected to groundin g pin of tem perature sensor. B 12 solenoid valve 6 OP ● B 11 solenoid valve 2 OP ● B 10 solenoid valve 3 OP ● B9 solenoid valve 7 OP ● B8 N onuse ―― ○ B7 solenoid valve 5(+ve) OP ● ● = connected line O P= output G N D = groundin g D escription O N /O FF norm al-opened solenoid valve, determ ine the high or low of line pressure O N /O FF norm al-opened solenoid valve, com bined w ith other solenoid valves; used to determ ine the selected gear-position. O N /O FF norm al-opened solenoid valve, com bined w ith the O N /O FF sw itch of solenoid valve 4; ensure the shifting quality and sequence O N /O FF norm al-opened solenoid valve, hydraulic torque converter locking; increase the efficiency of m edium speed run. －－－－－ It is the solenoid valve w hich can change the pressure during the shifting and on/off o f solenoid valve. ○ = unconnected line ＊ = only IP =input I/O = input/output R E F= reference P W R=pow er Table 6.1.1 Description of TCU pin Automatic transmission-47 reverse pin Gear sensor(black) gear indication pin Figure 6.1.1 Description for wire bundle pin 4. Operating mode of transmission TCU realizes the effective control for the transmission according to the accurate information acquired form the input data and complete control for the output data. To ensure the input and output of TCU is actual and effective, TCU executes the data sense command for hardware and software. For the failure information found in the following operating mode described in detail, TCU will give the corresponding response. Similarly, it exists the possibility that could not find out the failure cause. If encounter the condition, the operation for transmis sion is determined difficultly. Following condition will effect the operation of transmission, but will not appear the detection failure information. a. Power supply failure The transmission adopts the 3-Gear lame Home Mode (LHM) irrelevant to car speed. If occur the intermittent power supply, then TCU will start form 4-Gear and is switched to the proper gear to meet the requirement of current work. At this time, it will not monitor the power supply status. b. The transmission fluid temperature is higher than 135 If found the transmission temperature is high: The torque converter lock clutch will start in low speed and the car will have the vibration. Some cars will have the condition that the mode indicator lamp is flash. The reason for the condition may be the transmission fluid temperature is high or acquire the inaccurate single form the temperature sensor. If occurs the temperature failure, it may find the high temperature operating condition. c. Failure of ON/OFF solenoid valve If one of the solenoid valves has the mechanical failure, TCU will not find the failure. At this time, the failure operation of transmission will be determined according to the solenoid valve with failure. The characteristic of different solenoid valve failure is listed in Table 6.1.2. Automatic transmission-48 solenoid valve Condition Transmission operation 1 Opened always 1st-Gear replaces 2nd-Gear; 4th-Gear replaces 3rd-Gear. It causes the car form the Gear shift of 1 →1→4→4 when accelerate form static. The transmission stay longer time in Gear; worse 1→4 shift feeling. Closed always 2nd-Gear replaces 1st-Gear; 3rd-Gear replaces 4th-Gear. It causes the car form the Gear shift of 2 →2→3→3 when accelerate form static. It is said that starts form 2nd-Gear. Closed always 4th-Gear replaces 1st-Gear; 3rd-Gear replaces 2nd-Gear. It causes the car form the Gear shift of 2 →2→3→3 when accelerate form static. That is saying that start form 4th-Gear. Opened always 2nd-Gear replaces 3rd-Gear; 1st-Gear replace 4th-Gear. It cause the car is shifted form 1st-Gear to 2nd-Gear, then from 2nd-Gear to Gear when accelerate form static. It will feel the transmission is in free gear position after 2→1 Gear shift. 1&2 Opened always Can not realize the reverse gear; only has 1st-Gear operation. 3 Closed always 2 Opened always 4 Closed always Opened always 6 Closed always Opened always 7 Closed always Opened always Following shifts are bad. (2→3 is worst ):1→3, 1→4, 2→3, 2→4, 4→2, 4→1 Following gear shifts are worse: 3→4, 4→3, 3→2。 It may cause the gear slide when the hydraulic torque converter is locked. Following gear shifts are worse: 1→2, 1→3, 1→4, 2→3, 2→4, 3→1, 3→2, (including manual) 3→4, 4→1, 4→3 Following gear shifts are worse: (1→2 is worst) 2→4, 3→2 It may cause the gear slide when the hydraulic torque converter is locked. The line pressure is high always. The line pressure is low always. So it cause the slide between gears. The clutch C1 and brake belt B1 will be burned. The hydraulic torque converter is without lock. The hydraulic torque converter is locked in 3rd-Gear and 4th-Gear. It cause the car generates the vibration in low-speed status. Table 6.1.2 Operation of transmission when ON/OFF solenoid valve is faulty Mechanical detection 1.Inspection of transmission on car It should process the following detections before disassemble the transmission: process the on-road drive test to determine the failure cause .(according to requirement) Detect the standard of transmission fluid. (refer to 7.2.1) Ensure the transmission fluid in not overheated. (Normal color and smell) Detect the failure information. Check the battery terminal and grounding for corrosion or loose. The engine speed is within the specified value in manual. Check the cooling system for normal operation. All power supply and plug wires is tight and not loose. Check the transmission fluid, ensure the oil pan is without other martial material or pollutant. 2. Oil leakage detection It should wash the polluted part of the transmission before select the oil leakage part, then drive the car. When detect the leakage part of the rear servo system, it should lift the car by lifter firstly, then switch the gear to reverse gear within 10s. When detect the leakage part of front servo system, it should lift the car by lifter firstly, then switch the gear to gear-2 (winter mode). The time switched to 2nd-Gear should be no more than 10s to avoid the oil in the torque converter is overheated. 3. FAQ table Automatic transmission-49 The distribution of FAQ table is shown as follows: Table 6.2.1 Drive failure Table 6.2.3 Shift quality failure Table 6.2.2 Shift mode failure Table 6.2.4 Disassembly failure failure Possible reason Corresponding measure “D”-Gear operation has not drive The automatic transmission fluid is insufficient. The oil-entering of C1/C2 piston is blocked. The “Z” is assembled incorrectly. The primary regulating valve plug is opened. The overspeed shaft or input shaft sealing ring is failure. 3→4, 1→2 single-way clutch is installed in reverse or failure. Check the liquid level. Fill it up if necessary. Check and wash the C1/C2 oil inlet device. Reinstall the “Z” connection. Remove, wash and reinstall the primary regulating valve. Check and replace it if necessary. Check and replace it if necessary. The reverse shifting operation is without drive. The manual 1st-Gear has not engine brake. The engine brake is normal in manual 1st-Gear. “D” –Gear and reverse –Gear operation is without drive. Only can 2→3 shifting (can not realize the 4th-Gear and 1st-Gear) Only can 1→4 shifting 1→3→4 shifting (1 →2 shifting delay). Only can 4→3 shifting The input shaft oil seal ring is damaged. The rear brake belt or servo system is faulty. C3, C3 wheel shaft or C1/C2 cylinder are out of work. The primary regulating valve is blocked. The pump gear is damaged. Take out the output shaft clasp. S1 is closed always. S1 is opened always S2 is closed always. 1→2→neutral position shifting (1st-Gear transition) S2 is opened always Only can 1→3 shifting B1 is out of work The brake belt is loose. The front servo piston or oil seal is out of work. S1/S2 ball spool is reinstalled in wrong place. Check and replace it if necessary. Test the servo system or replace the rear brake belt according to the requirement. Test the failure C3, C3 wheel axle or C1/C2 cylinder. Repair it in time if necessary. Detect and clean the primary regulating valve. Check and replace the pump gear if necessary. Check and repair it if necessary. Test the S1. Repair or replace it if necessary. Test the failure of S1 12V power supply voltage or wire bundle. Test the S1. Repair or replace it if necessary. Test the failure of S1 12V power supply voltage or wire bundle. Test the S2. Repair or replace it if necessary. Test the failure of circuit break or wire bundle. Test the S2. Repair or replace it if necessary. Test the failure of circuit break or wire bundle. Test and adjust it according to the requirement. Test and maintain it according to the requirement. Test and replace or reinstall it according to the requirement. Only can 1→3→4 shifting The small O-ring of front servo piston is invalid or lost. 2→3 Gear position shifting valve is blocked. Detect the O-ring. Process the replacement or reinstallation if necessary. Detect the 2→3 Gear shifting valve; Process the maintenance or replacement according to the requirement. Only can 1→2→1 shifting C1 is invalid or 3rd-Gear and 4th-Gear is loose. (give to 1st-Gear in 3rd-gear; give to 2nd-Gear in 4th-Gear) Detect the clutch C1. Repair or replace it if necessary. Overspeed clutch /ball spool has displacement. C4 is invalid. Detect the ball spool. Process the replacement or reinstallation according to the requirement. Detect the C4. Repair C4 or replace the C4 wave pan according to the necessary. Can not realize the manual 4→3, 3→2, 2 →1 Automatic transmission-50 T h e s m a ll O -rin g o f fro n t ser v o p is to n is in v a lid o r lo s t. 2 → 3 G ea r p s itio n s h iftin g v a lv e is b lo ck ed . D et e ct th e O -rin g . P r o c es s th e rep la c e m e n t o r rein s ta lla tio n if n e c es s a ry . D ete ct th e 2 → 3 G ea r s h iftin g v a lv e; P ro c es s th e m a in ten a n c e o r r ep la c e m en t a c co r d in g to th e r eq u ir e m e n t. C 1 is in v a lid o r 3 rd -G ea r a n d 4 th -G ea r is lo o s e . (g iv e to 1 st -G ear in 3 rd -g ea r; g iv e to 2 n d -G ea r in 4 th -G ea r) D et e ct th e clu tc h C 1 . R ep a ir o r r ep la c e it if n e c es s a ry. O v ersp e ed clu tc h /b a ll s p o o l h a s d isp la c e m en t. C 4 is in v a lid . D et e ct th e b a ll s p o o l. P r o c es s th e rep la c e m en t o r r ein s ta lla tio n a c co rd in g to th e r eq u ire m e n t. D et e ct th e C 4 . R ep a ir C 4 o r rep la c e th e C 4 w a v e p a n a c c o rd in g to th e n e c es sa ry . W ith o u t m a n u a l 1 st-G ea r T h e rea r b ra k e b e lt is lo o s e w h en th e t e m p era tu r e is h ig h . T h e R -G ea r/L o w s p e e d 1 st-G ea r b a ll s p o o l h a s d is p la c e m e n t. T h e in tern a l “ O ” – rin g o f rea r s er v o is lo s t. C 4 is in v a lid . D et e ct th e r ea r b ra k e b elt, a d ju s t id n e c es s a ry. D et e ct th e b a ll sp o o l, R ein s ta ll o r r ep la c e it if n e c es s a ry. D et e ct th e O -rin g , R e in s ta ll o r r ep la c e it if n e c es s a ry. D et e ct th e C 4 . R ep a ir o r r ep la c e it if n e c ess a r y. O n ly ca n 1 → 2 → 2 → 4 g ea r . T h e d im en s io n o f so ck et o f fro n t s er v o is la rg e . H a s th e p o s s ib ilit y o f lo o s e o f p lu g . It h a s th e tre n d th a t ca n n o t rea liz e th e re v ers e-G ear if d riv e th e v e h ic le in th is co n d itio n co n tin u o u sly . R ep a ir o r r ep la c e it if n eces s a r y. D et e ct th e C 3 p is to n O -rin g , rep la c e it if n e c es s a ry. O n ly a n 1 st- g ea r, 2 n d -G ea r, 4 th -G ea r o r 1 st -G ea r, 2 n d -G ea r a n d 3 rd -G ea r.(3 rd -G ear is tig h te n ed ) T h e g ea r s e n s o r h a s fa ilu r e, o n ly ca n 1 → 2 → 3 s h iftin g . 3 → 4 G ea r s h iftin g v a lv e is b lo c k ed . D et e ct th e g ea r-p o s itio n s e n s o r. R ep a ir o r rep la ce it if n e c es s a ry . D ete ct th e 3 → 4 g ea r s h iftin g v a lv e. R ep a ir o r r ep la c e it if n e c ess a r y. O n ly ca n 1 → 3 → 4 s h iftin g O n ly ca n 1 → 2 → 1 s h iftin g C a n n o t rea liz e th e m an ual 4 → 3, 3 → 2, 2 →1 Automatic transmission-51 Bad 1→2 Gear shifting quality The throttle position sensor has failure. The brake belt is adjusted incorrectly. The front servo piston O-ring is damaged. The variable pressure solenoid valve (S5) is damaged or has failure. S1, S4 has the failure. The brake belt combination regulating valve (BAR) has the failure. The front servo release spring is installed incorrectly. Bad 2→3 Gear shifting quality B1brake belt release valve is blocked. S3, S2 has the failure. The clutch combination regulating valve has failure. The clutch combination oil feed ball spool is lost or damaged. The input shaft oil seal is damaged. C1 piston O-ring is damaged. C1 piston oil feed ball spool is damaged. Bad 3→4 Gear shifting quality S1, S4 has failure. B1brake belt release valve is blocked. The brake belt is adjusted incorrectly. The front servo piston O-ring is damaged. The variable pressure solenoid valve (S5) is damaged or has failure. The brake belt combination regulating valve has failure. The engine has the extinguishing condition when select the automatic gear or R-gear. Has unstable vibration condition. Detect the resistance, replace the sensor if necessary. Detect and replace the rake belt if necessary. Detect and replace the O-ring if necessary. Detect, repair or replace the S5 if necessary. Detect, repair or replace the S1, S4 if necessary. Detect, repair or replace the BAR if necessary. Detect and repair it if necessary. Detect the blow-off valve. Replace or maintain it if necessary. Detect the S3, S2.Replace or maintain it if necessary. Detect the regulating valve. Replace or maintain it if necessary. Detect the ball spool .Reinstall or replace it if necessary. Detect the sealing ring. Reinstall or replace it if necessary. Detect the O-ring .Reinstall or replace it if necessary. Detect the ball spool .Reinstall or replace it if necessary. Detect the S1, S4.Reinstall or replace it if necessary. Detect the blow-off valve. Replace or repair it if necessary. Detect the brake belt. Adjust it if necessary. Detect the O-ring .Replace or maintain it if necessary. Detect the S5.Replace or maintain it if necessary. Detect the regulating valve. Replace or maintain it if necessary. The torque converter clutch control valve is blocked or solenoid valve 7 has failure. Detect and clean the torque converter clutch valve (CCCV) S7 has the failure. Process the necessary detection, maintenance and replacement according to the requirement. Table 6.2.3 Shifting quality failure Automatic transmission-52 Failure C2 is burnt. Reason Corresponding measures T operation lever linkage is beyond the Monitor and repair the C2 if necessary and normal adjusting scope. adjust the linkage device. Repair the C2; detect, repair or replace the S6 is invalid.-Operating lever is hard. S6 if necessary. Repair the C2; detect and replace the The over speed Gear/output shaft sealing sealing ring or shaft if necessary. ring is damaged. The clutch C4 assembly clearance is incorrect. Detect the C4. Detect and adjust the clutch C4 assembly clearance if necessary. Repair the C4; detect and replace the oil C4 is burnt. The over speed Gear/output shaft sealing seal or shaft. ring is damaged. Repair the C4, detect or modify the OWC 3→4 one-way clutch is in rear position. if necessary. Repair the C4, detect or modify the ball st The over speed clutch (OC) /1 -Gear low spool if necessary. speed ball spool has displacement. B1R spring is damaged. Detect and repair the or replace the spring if necessary. B1 is burnt. The dimension of oil inlet hole of front Replace the socket if necessary and detect servo is large and has the possibility of the C3 piston O-ring. loose. Replace the sealing ring. The input shaft sealing ring is damaged. Repair the B1; modify the ball spool if C1/B1R ball spool has displacement. necessary. B1Rspring / plug is lost. Detect and repair C1 or replace the spring if necessary. The over speed Gear/input shaft sealing Repair the C1; detect and replace the ring is damaged sealing ring or shaft if necessary. C1 is burnt. Repair the C1; detect and modify the valve 4→3 sequence valve is in rear position. if necessary. Repair the C1; detect and replace the ball Clutch attachment oil feed inlet (CAF). spool if necessary. B1Rball spool is lost. B2 brake belt is burnt. In R-Gear- without manual 1st-Gear. The torque converter is locked hardly or is not locked. The rear brake belt is adjusted incorrectly or Detect and adjust the brake belt if damaged. necessary. st The low speed R-Gear /1 -Gear ball spool Detect and reinstall the ball spool if has displacement. necessary. The torque converter combination regulator is in rear position. Detect and modify the valve if necessary. Adjustment Hydraulic system Following parts is the detailed description for self-detection procedure pointed to the condition occurred in chapter 6. including the condition indicated the failure, to point the problem existed in the hydraulic system. It should select the proper procedure from the following primary detection when adjust the transmission. Detection process of transmission fluid Detect the manual linkage adjusting system(refer to factory manual of car) Detect the engine idle speed Anchoring test (beyond the scope of the maintenance manual) On-road test (beyond the scope of the maintenance manual) Detection procedure of transmission fluid level 1. General The process is used to detect the level of vehicle transmission fluid. It will cause the failure or delay of transmission shifting if the level is low than required value and the vehicle does not reach the drive temperature. Firstly, process the transmission diagnosis information detection for vehicle (refer to chapter 6). If found the failure of sensor, then it maybe caused by transmission fluid level is less than specified value. It should detect whether has the abnormal delay and Gear-position condition when select the forward or reverse-gear by driving the vehicle. One feature of oil level less than normal value is that the vehicle has the gear-position delay and lack condition when the vehicle is in steering. The previous problem will occur when the transmission fluid temperature is low. When the oil temperature is medium and vehicle speed failure is recorded, the gear-position lose condition will not occurs any longer, it means that needs to fill the transmission with the transmission fluid. 2. Detection of transmission fluid level When fill up or replace the transmission fluid, it must use the Castrol TQ95 automatic transmission fluid (ATF) or other permissive oil. It will damage the performance and service life of transmission if use the unpermissive transmission fluid. Please ensure the transmission fluid level is correct. The transmission also can be damaged if the transmission fluid level is incorrect. The setting procedure of transmission fluid level is shown as follows: Caution: When the transmission is in operating temperature, the hot transmission fluid may flow out form the housing if remove the filling plug. a. If the vehicle is in operating temperature, allow two hours time for cooling before add the transmission fluid, but it must not more than 4 hours (this will make the transmission locate in the correct temperature range). When the temperature is overheating, the transmission fluid level will higher than the plug port. Removal of plug will cause the transmission fluid flows out from the oil filling port, then cause the low level of transmission fluid. b. The gear-position of transmission is in parking-Gear (P-Gear), shut off the engine. c. Lifting the vehicle (or parking above the trench). d. Clean the around of plug when remove it. Then remove and clean the plug and check the O-ring for damage. Install the oil filling pump in the oil filling hole. e. Lower the vehicle; the oil filling pump will be connected to the vehicle at this time. Fill the transmission with the oil partially. Then start the vehicle in P-Gear to rotate the engine in idle speed. Step down the foot brake, pull the shifting lever in each gear-position in circulation and add the transmission fluid until the action of each gearposition can be sensed. f. Shut down the engine; lift the vehicle; ensure the vehicle is always in horizontal. g. Remove the filling plug 3 minutes after the engine is shut off, but must not be no more than1 hour. At this time, the correct level position should be in the bottom of oil filling hole. If does not reach the liquid level position, then fill with few transmission fluid to make it reach the correct level. h. Replace the transmission; clean the residual transmission fluid on the transmission and vehicle. i. Tighten the transmission plug to the specified torque of 30 35N m. 3. Oil filling of service after sales Set the liquid level position correctly; the procedure is shown as follows: a. Shut down the engine; place the gear-position in the P-Gear. b . Lift the vehicle (or place it above the trench). c. Clean the around of plug before remove it. Remove the oil plug and check the O-ring for damage, finally connect the oil filling pump to the oil filling hole. d. Lower the vehicle and oil filling pump to the ground; fill with the transmission fluid partially. The general oil filling amount is shown as follows: If in the status of transmission hydraulic torque converter is empty: 8.0 L If in the status of transmission hydraulic torque converter is full: 3.8 L e. When start the vehicle in P-Gear, rotate the engine in idle speed. Step down the foot brake, pull the shifting lever in each gearposition in circulation and add the transmission fluid until the action of each gear-position can be sensed. f. Then fill with 0.5L transmission fluid (ATF) additionally. g. Shut off the engine, lift the vehicle; take off the pump and replace the plug. Ensure the plug is tightened according to the specification. h. Then pull the vehicle throttle position for slight opening to make the vehicle runs for 3.5 4.5km; the rotary speed of engine is no more than 2500r/min; then the transmission fluid temperature will in the scope of 50 60 . i. The engine is in idle-speed; pull the hand brake to make the shifting lever circuits in each gear-position horizontal status. k. Remove the filling plug 3 minutes after the engine is shut off, but must be no more than1 hour. At this time, the correct level position should be in the bottom of oil filling hole. If does not reach the liquid level position, then fill with few transmission fluid (ATF) to meet the requirement. l. Reinsert the transmission fluid plug, remove the residual transmission fluid around the vehicle and transmission; tighten the plug to the specified torque. 4. Replace the ATF Please notice that the color of TQ95 automatic transmission oil will be faded in the normal operation of transmission; it will be turn into the deep brown or even in black. It will not affect the performance of ATF. It means that the fading of transmission fluid not always means to replace the transmission fluid. If the transmission temperature is raised, the ATF will be burnt. In this condition, ATF will change into black and with special sulfur smell. The smell of the ATF means the oil is burnt. If the ATF is burnt, it will cause the damage of transmission (the clutch assembly is damaged at least).At this time, it should disassembly the transmission and process the necessary detection. Electronic calibration 1. Idle-speed calibration The idle-speed calibration is introduced in detail in the vehicle factory manual. 2 Calibration of position of throttle position If the throttle position information stored in TCU is lost or not in application scope. It can be reestablished according to the following program as the diagnosis error information. a. Check whether the engine idle speed is in required range. b. In the status of shutting off of air-condition, make the engine is in “D” –Gear for 60s,then the reference point with opening degree of 0 of throttle position is reset in TCU. Shut off the engine; switch on the ignition device, step the accelerator pedal to bottom for 60s, then the reference point with opening degree of 100 of throttle position is reset in TCU. 3. Clear of throttle position The clear process set by learning throttle position is necessary for M88 transmission TCU. 4. Car code For M88 transmission, the car code is unnecessary. Disassembly /assembly Cautions for assembly It should notice the following items before reassemble the transmission system: 1. Ensure the cooler pipeline is washed and all chip is removed when replace the transmission. It can be realized by using the compressed air to enter into the rear cooler pipeline to remove the oil and all foreign material in the front cooler. 2. It should check the cooler after the transmission is installed. Ensure the front and rear cooler pipeline is connected to the proper container. Rotate the vehicle in P-Gear in idle-speed, measure the flow rate within 15s. 3. The flow within 15s should be more than 1L. 4. It should avoid any water entering into the transmission. This will cause the transmission fluid to generate the foam or make the transmission fluid flows out form the respirator. 5. Ensure that two grounding wires in vehicle (one end to battery, one end to vehicle) are connected before the installation of the anode of battery. 6. If the power control module and transmission control unit is exchanged, then calibrate the program refer to related throttle position in Part Removal 1. Transmission Caution: It should remove the gear-position sensor before wash the transmission in solvent or hot abluent. When need to remove the transmission from the vehicle, it should drainage the transmission fluid, and use the special removal tools. The removal of the transmission should be processed in module method, the details of removal of each module is described in following section in detail. Refer to details of special tools listed in table 9.10 and 9.6 when remove it. The technician needs a set of quality tools when inspect the transmission, especially for dual hexagon spanner of model 30, 40, 50 and 8mm, 10mm, 12mm. It should abide by the following procedure when disassemble the transmission: a. Remove the shell of torque converter and torque converter. b. Place the transmission on the saddle platform. c. Remove the oil pan and oil pan sealing. d. Remove the filter retainer of each valve and remove the filter. e. Remove the wire on solenoid valve, place it in side. f. Remove the protection screw in the valve and remove the valve from the main housing (remove the model Z connecting bar). g. Remove the front servo circlip, cover and piston. Caution: The plastic servo block on used for piston return spring. h. Remove the flange shaft fork, then remove the transmission housing (2WD and Chairman). Use the 8mm hexagon wrench to move the pump to the housing bolt. Figure 8.1 Removal of typical pump i. Use the pump remover to remove the pump, refer to Figure 8.1. g. Remove the input shaft , front clutch cylinder and overspeed –Gear shaft as an integral. Take it out from the front of housing. k. Remove the clutch C3 cylinder and central gear . l. Remove the brake belt support and brake belt. m. Use the 50 special tools to remove two central support connecting bolts. n. Remove the central support retainer, refer to Figure 8.2. Figure 8.2 central support retainer Caution: Do not take out the central support by knocking the output shaft , otherwise, it will damage the surface of thrust bearing permanently o. Remove the central support, 1-2 one-way clutch and planetary gear block. p. Use the T40 special tools to remove the parking lever cum disc. q. Remove the rear brake belt support and rear brake belt. r. Remove the output shaft assembly. 2. Transmission case It should follow the following procedure when remove the transmission: a. Use the tools to take out the fixed pin from one side of cross shaft gear sensor (2WD and 4WD mode). b. Remove the gear sensor from the case. Use the special tools to take out the cross shaft seal. c. Take out the circlip from the cross shaft. Pull up the cross shaft and take out the drive pin from the sector gear-position selection plate. d. Use the tools, press down the cross-shaft pin and take out the shaft , reset spring and bolt from the housing. Refer to Figure 8.3. Figure 8.3 Installation and disassembly of cross-axle pin e. Take out the manual-operated valve operating lever and parking operating lever. f. Take out the 10 pin socket connector form the wire bunch bracket adjacent gear sensor. g. Press down the raised part of 10-pin plug and take out the 10-pin connecting plug from the box. h. Separate the NO.7 solenoid valve wire bunch form the front end of housing. i. Remove the brake bar pivot, brake shaft and spring. j. Remove the shaft and rear servo operating lever. k. Remove the rear servo cover and piston assembly. l. Remove the BIR circlip, valve and spring. m. Remove two brake belt adjusting shims. n. Check the output shaft bush in box, replace it if necessary. o. Check the cooler pipeline, replace it if necessary. p. Check the box for damage. Caution: It must not remove the operating lever of parking gear in normal condition. q. It needs to remove the P-Gear operating lever: take out the circlip from the pivot, knock the external of shaft until it can move freely in box. Then use a width and thin object to table out the bolt form the box, operating lever and spring. 3. Front clutch cylinder When take out the front clutch cylinder, please refer to Figure 8.4. The procedure is shown as follows: Figure 8.4 Assembly of front clutch cylinder a. Place the assembly on a level surface. b. Remove the thrust bearing and adjusting shim from the input shaft . c. Remove the retainer and input shaft form the front end of clutch . d. Remove the overspeed gear shaft and clutch C1 hub assembly from the clutch cylinder. e. Take out the clutch disk C1 form the cylinder. f. Take out the retainer which fix the clutch C3 hub on the rear end of clutch cylinder, then take out the hub. g. Take out the C2\clutch C4 hub assembly and remove the thrust bearing form the C4 hub. h. Take out the clutch C2 disc. i. Reverse the clutch cylinder and take out the clutch C4 sleeve, clutch disk and two wave washers. The 3-4 one-way clutches is located between the C2 and clutch C4 hub. The other wheel axle can be taken out by rotating a wheel axle in clockwise. j. Remove the thrust block form the clutch C4 cylinder hub. Caution Ensure the spring keeping device does not be clamped in the spring groove and all spring pressure is released. k. Put end surface of C2\clutch C4 upwardly, connect the clutch cylinder with the tools. Pressed down the piston reset spring, take out the spring fixing retainer (Refer to Figure 8.5). Remove the tools and take out the ring spring, fixing part and spring. Figure 8.5 Impressed clutch reset spring Figure 8.6 Removal of C1, C2 and clutch C4 piston l. Reverse the clutch cylinder on the pressure machine; and remove the clutch C1 reset spring with same method. m. Send the compressed air into the cylinder through the cylinder hole, remove the clutch piston from the clutch cylinder. Refer to Figure 8.6. 4.clutch C3 cylinder The procedure of removal of clutch C3 cylinder is shown as follows: a. Remove the front sun gear assembly, thrust bearing and thrust washer from the clutch C3 cylinder asse bly , shown as Figure 8.7. b. Remove the nylon thrust bearing, bearing block, needle thrust bearing and thrust bearing . From the clutch cylinder hub. Figure 8.7 Clutch C3 and central gear assembly Figure 8.8 Removal of clutch C3 piston c. Install the clutch assembly on the special tools, press down the piston out-back spring; take out the retainer and release spring. Caution: Ensure the spring keeping device does not be clamped in the spring groove and all spring pressure is released. d. Take out the tools, retainer, retainer and spring. e. Take out the gasket from the clutch C3 cylinder. f. Take out the clutch disk fixed spring ring and take out the clutch disk. g. Send the compressed air into the hole between the iron sealing ring and support shaft neck of cylinder; remove the clutch piston from the clutch cylinder. Refer to Figure 8.8. h. Take out the cylinder forms the reverse sun gear and C3 washer. 5. Planet carrier and central support The disassembly procedure of planet carrier and central support, the procedure is shown as follows: a. Separate the planet carrier and central support from the output shaft; remove the thrust bearing and planet carrier form the output shaft. b. Rotate the planet carrier in anticlockwise and separate the central bracket. c. Raise the one-way clutch form the planet carrier d. Remove the spring ring on the planet carrier; maintain the periphery of one-way clutch on the planet carrier and take it out. Refer to Figure 8.9. e. Remove the one-way clutch fixed mount form the planet carrier. Figure 8.9 Planet carrier and external race way 6. Pump Cautions: the following valves are installed in the pump cover: solenoid valve 7 C1 eccentric valve ( only for early stage mode, no valve in M88) torque converter control valve torque converter regulating valve primary regulating valve The disassembly procedure of pump is shown as follows: a. Remove the wire bunch fixing disc and use the special tools T30 to remove the solenoid valve 7. b. Use the 8mm sleeve to remove 5 bolts and washers. c. Use the tool NO.30 to remove 5 screws form the cover plate. It should notice that the odd number screw has the function of connecting the pump body to the pump cover plate. Caution: Do not release the pump by the method of knocking the torque converter support. d. Separate the pump body from the pump cover. e. Lift the pump cover disc form the pump cover. f. Remove two ball spool detection valves and a spring from the pump cover. Caution: Some valves and plugs are connected by the spring and may fall down form the housing when remove the pin. g. Press down the socket inwardly to remove the fixed pin of 4 valves. h. Take out 4 valves, plugs and springs. i. Take out the pump gear form the gear. j. Remove the edge sealing from front of pump when replace it. 7. Valve The removal procedure of valve is shown as follows: a. Use the special tools T40 T orxbit to remove the ratchet spring and retainer plate. Caution: The manual-operated valve may fall down form the valve. b. Slide the manual-operated valve to out of lower valve. c. Pay attention to the angle relationship between the electromagnetic end and valve, remove the solenoid valve and valve assembly according to the following procedure : Solenoid valve 1 Solenoid valve 2 Solenoid valve 3 Solenoid valve 4 Solenoid valve 5 Solenoid valve 6 d. Place the valve on the platform with the top upwardly. e. Use the model NO.30 Special tools to remove the 24 fixing screw. Lift the upper valve and separating disk to separate the upper valve form the lower valve f. Reverse the upper part, place the separating disk on the platform upwardly. g. Lift the separating disk and washer from the upper valve. h. Remove 5 exposed nylon detection ball spools of valve. i. Remove the locking nut disc, spring and reverse lock valve. j. Remove two cleaners (and large nylon detection ball spool ) from the lower valve. Caution: Once the pin is removed, the disc in the valve may be loose and slid form the valve when reverse the valve. k. Remove the locking nut disc and bolt form 1-2, 2-3, 3-4, BAR,CAR valve; the bolt can be removed by the bolt. l. Remove the 1-2, 2-3 and 3-4 shift valve. Caution: Some valves are pulled by the spring and may fall down form the valve. m. Press down the plug of 4-3 sequence valve and take out the locking nut disc. n. Take out the plug, valve and spring. o. Press down the solenoid valve 5 gate. Remove the fixed pin, valve and spring. Caution: The valve is pulled by the spring and may fall down form the valve. p. Press down the line pressure blow-off valve , then remove the fixed pin, disc (if proper) spring and valve. q. Take out the roller pin and remove the spring and ball spool detection valve adjacent BAR. Assembly The transmission is assembled in the method of module. The detailed assembly process of each module is described in the following chapter in detail. Refer to Table 8.1 (end of section 8.3) for the description of used torque specification. The Table 9.10 in section 9.6 describes the necessary special tools for assembly. The technician also needs to select the quality Torx tools, especially for the two-screw socket wrench with code of 40, 50, 8mm,10mm and 12mm to detect the transmission completely. 1.Transmission Caution: Ensure the BIR retainer is proper for the case (otherwise, the valve will damage the separation disk). Ensure the E clip is installed on the cross shaft. Ensure all parts of parking machine can operate normally. The assembly procedure of transmission is shown as follows: a. Place the upper transmission on the platform upwardly and place it on the transmission bracket. b. Install all accessories, bolts and bleed devices. Paint the sealant on the sealing place. Tighten all components according to the specification. Ensure the cleanness of all bleed devices. Ensure the rear oil filling nozzle of housing is correct and without blocking material. Refer to Figure 8.19. c. Assemble the BIR valve and spring; ensure the retainer is installed correctly, refer to Figure 8.10. Ensure the retainer is fixed in the groove completely. d. Install the rear servo bar and pin shaft. Refer to Figure 8.11. Caution: Ensure the crown bar can rotates freely. Caution: Figure 8.11 Rear servo bar Figure 8.12 Parking operating lever Pay attention to do not coat the sealant between the bolt and crown bar. e. Install the parking operating lever (as Figure 8.12), including the return spring and shaft pin. Coat the external end of shaft pin with small sealant. f. Use the circlip to protect the shaft pin. Pay attention to ensure the operating lever can rotate around the shaft pin freely and the spring can make the parking operating lever returns to the correct position. Figure 8.13 Typical parking brake shaft pin and spring g. Install the parking brake lever pin and spring. Refer to Figure 8.13.Caution: ensure the rake lever can rotate freely. h. Connect the parking brake lever to the manual-operated valve connecting rod. Shown as Figure 8.14. Ensure the spring and cam axle ring are installed on the connecting rod fixedly. i. Check the cam axle ring for smooth sliding on rod. j. Install the cross shaft in the box in reverse direction of Gear-position sensor, then install the concussion spring on the shaft. Figure 8.14 Parking lever and manual shaft Figure 8.15 manual-operated valve brake lever k. Install the manual-operated valve detent connecting rod (shown as Figure 8.15), align it with the cross shaft hole. l. Push the shaft by the positioning operating lever, until start from one side of box operating lever. m. Use the special tools to install the operating lever drive bolt on the shaft, and ensure the adaptor covers the bolt. n. Press the bolt into the shaft until the tools reaches the bottom. o. Take out the tools and install the spring fixing ring spring on the shaft p. Use the tools to install the new cross shaft seal. q. Install the Gear-position sensor on the box; install the screw according to the specified torque. Use the tools to press the bolt on the shaft. r. Check the connection of wire bunch port completely to ensure the normal operation. s. Install the wire bunch and install the connecting point of solenoid valve 7 and ring flange matched to the pump. Refer to Figure 8.16. The connecting wire of solenoid valve 7 is organized under the parking lever and in box cross shaft. t. Install the 10-pin connecting socket in the box, ensure the flange of connecting socket matches to the notch on box. u. Pull out the wire bunch part form the box and prohibition switches; install the 10-pin connecting socket on the wire bunch bracket (only for rear-wheel drive mode). Figure 8.17 Installation of 10-pin connecting plug Figure 8.16 Connecting position of coil 7 2.output shaft and gear assembly The assembly procedure of output shaft and gear assembly (Refer to Figure 8.19),is shown as follows: a. Check the output shaft bush for damage, replace it if necessary. b. Check the parking detent on the ring gear for damage ; replace it if necessary. c. Check the sealing ring groove for damage. d. Use the automatic transmission liquid to lubricate the gasket. e. Place the scarfing notch upwardly and install the sealing ring on the output shaft. f. If has been removed., it should use the ring spring for reinforcement when install the ring gear on the output shaft. Ensure the ring spring is fixed in the groove. g. Use the Vaseline oil for lubrication; install the thrust bearing assembly NO.10 on the output shaft. h. It should be carefully when install the output shaft on the box to avoid the damage of sealing ring. 3. Rear brake belt assembly The assembly procedure of rear brake belt assembly (Refer to Figure 8.18) is shown as follows: a. Check the rear brake belt for leakage or damage; check its corresponding bush and metal back . Figure 8.18 Rear servo and brake belt b. Install the reaction reinforcement bar on the main box, need not shim. Caution: Place the new brake belt in the automatic transmission liquid for about 5 minutes before install it. c. It should be careful when install the rear brake belt on the transmission. Ensure the brake belt is installed on the correct position. d. Install the application support bar on the rear brake belt, then connect it to the servo motor bar. e. Install the cam disc and tighten the screw according to the instruction. Figure 8.19 Position of thrust bearing and sealing pad 4. Rear servo assembly Install the rear servo assembly (Refer to Figure 8.18), the procedure is shown as follows: a. Check the servo piston O-ring and washer for damage. b. Use the transmission fluid to lubricate the servo piston O-ring and install the O-ring on the piston groove. c. Install the piston on the housing; ensure the O-ring is compressed to position, but do not excess. d. Adjust the spring and piston sleeve; then install the rear servo brake bar on the sleeve. Caution: Do not coat the washer with the Vaseline. e. Install the housing installed with washer on the case. f. Provide the bolt with the Loctite567 sealant and install it; ensure the bolt is tightened according to the specification. 5. Planet carrier assembly and central support The installation process of planet carrier assembly and central support is shown as follows: a. Check the bracket and planet assembly for damage or abnormal and ensure all pinion rotates freely and the pinion axle end floats in the allowable range; described as 9.2. b. Install the one-way clutch fixing plate on the planet carrier and ensure the internal edge points to the downwardly. Check the one-way clutch and brake accessory for damage; replace it according to the requirement. c. Install the external race on the drum. Press sown the ring race to bottom of drum and install the fixing ring spring. Ensure the ring spring is installed in the groove stably. Refer to Figure 8.20. d. Install the one-way brake on the external race with the lip upwardly. Use the automatic transmission liquid to lubricate the brake accessories. Refer to Figure 8.20. Figure 8.20 planet carrier assembly and central support e Check whether the socket has the proper central support, then install the central support on the one-way clutch, ensure the support can rotate in anticlockwise. Refer to Figure 8.20 f. Use the Vaseline to lubricate the NO.9 needle thrust bearing and thrust washer, and install it on the rear of planet carrier. Refer to Figure 8.19 g. Install the planet assembly and central support on the box and align the central support installation bolt hole. h. Install and tighten the central support bolt. i. Install the ring spring fixing plate; ensure the ring spring is installed in the box correctly. j. Remove the central support bolt and provide the Loctite243 or similar material for screw; install and tighten the bolt to specified standard. 6.Ttransmission rear housing assembly The installation procedure of transmission rear housing assembly is shown as follows: a. Check the condition of transmission rear housing roller bearing (2WD and Chairman mode), replace it if necessary (rear drive mode). Install the new bearing form the end of transmission rear housing; only can press the bearing side with mark. b. Install the new sealing material on the transmission rear housing or adaptor rear housing. Refer to Figure 8.21. output shaft o-ring oil seal locking nut oil seal gasket needle bearing connecting housing (4WD) connecting housing Figure 8.21 Connecting and extension housing Caution: Do not use the Vaseline to fix the washer. c. Install the transmission rear housing or adaptor rear housing with the new washer. Caution: Refer to the description in section 8.3.17 related installation of output flange assembly (rear wheel drive). d. Install the transmission rear housing (rear wheel drive) or adaptor rear housing (4WD ) and tighten the bolt. e. Provide the Loctite202 or equivalent sealant to the rear housing or connector and process the installation. Ensure the bolt is tightened according to the specification. (Refer to Figure 8.1) 7. Front servo assembly Caution: Ensure the front servo clamp ring is installed correctly; ensure the ring spring and spark gap points to the bottom. Refer to Figure 8.22. The assembly procedure of front servo assembly (Refer to Figure 8.22) is shown as follows: a. Use the automatic transmission liquid to lubricate the housing O-ring and install it on the housing. b. Use the automatic transmission liquid to lubricate the housing O-ring and install it on the piston. c. Install the piston, brake lever, spring, washer, base and fixing ring. d. Install the piston brake lever assembly on the front servo housing. e. Install the front servo plug and spring in the box. f. Install the front servo assembly in the box. g. Press down the servo housing and install the fixing ring spring of servo housing. Align the spark gap and coil track and ensure it is installed in the groove properly. Figure 8.22 front servo and brake belt 8. Brake belt assembly The assembly process of brake belt assembly is shown as follows: a. Install the reaction reinforcement lever on the housing. b. Check the brake belt for crack or damage; check the bush and metal back. c. Install the support retainer on the brake belt (Refer to Figure 8.23).Note that the later transmission modes will not adopt the support retainer. Caution: Place the new brake belt in the automatic transmission liquid for about 5 minutes before install it. Figure 8.23 Installation of brake belt press lever d. Install the brake belt on the transmission, ensure it is installed on the correct position. e. Install the reaction support on the fixing plate and connect it to the brake belt and reinforcement lever. Install the application support on thea fixing plate and connect it to the brake belt and servo piston bar. 9.C2/clutch C4 assembly Caution: Check the piston for crack, especially for piston C2. Must not mix the clutch piston out and back spring. Ensure the correct installation of clip ring The assembly procedure of C2/clutch C4 assembly (refer to 8.24) is shown as follows: a. Ensure the cleanness of internal oil inlet of cylinder; check the discharge outlet of piston C2 for cleanness; use the transmission liquid to lubricate the O-ring. Caution: The O-ring must not be winded in groove. Figure 8.24 Typical C2/C4clutch assembly b. Install the small O-ring in the inner groove; install the large O-ring in the external groove of piston; check the discharge outlet of C4 piston for cleanness. c. Use the transmission liquid to lubricate the O-ring; install the small O-ring in the inner groove; install the large O-ring in the external groove of piston. d. Make the C2/clutch C4 hole face upwardly; install the clutch cylinder; place the C4 piston in the original position proper for C2 piston during the calibration.. e. Install the C2/C4 piston assembly on the cylinder; ensure the external hole of cylinder align with the discharge outlet of piston, until the external diameter of C2 piston enters into the internal diameter of cylinder. Caution: The diameter of spring wire bunch is 4.3mm. f. Install the piston out and back spring on the piston and install the spring fixing plate on the spring. g. Use the special tools and press down the spring to ensure the installation for fixing ring spring. And ensure the spring is fixed in the groove tightly, then remove the tools. h. Check the C1 piston detection valve for damage and free movement. Ensure the cleanness of cylinder oil inlet. Caution: Ensure the O-ring is not bent in the groove. i. Use the automatic transmission liquid to lubricate the O-ring and install it in the respective groove. j. with the clutch C1 hole upwardly, installs the cylinder. Install the piston into the cylinder until the external diameter of piston enters into the inner diameter of cylinder. Caution: The diameter of wire bunch of spring is 5.26mm. k. Install the spring and spring fixing plate on the piston. Use the special tools and press down the spring to ensure the installation of fixing ring spring, then remove the tools. l. Install the C2 wave washer on the cylinder; ensure one of wave washers cab cover the C2 piston drainage outlet. m. Measure and record the thickness of C2 sleeve ring flange. Refer to Figure 8.25. n. Install the clutch C4 disc and wave washer on the clutch C2 sleeve. Ensure the round edge steel disc is disassembled according to the following sequence: friction disk steel disc friction disk steel disc friction disk Wave washer C2 pressure disc clutch C4 load pressure disc housing load is 3500N Figure 8.25 C4 clutch assembly o. Maintain the horizontal position of cylinder , install the sleeve and clutch disk assembly on the cylinder; ensure the top of washer and external hole of cylinder are in order until the sleeve can contact the C2 wave plate. Caution: For the C2 wave spring is compressed and the clutch disk can endure the weight of 19.6N. The dimension form the lower side of C2 pressure disc to the gear selection steel plate is 1.4 1.8mm. if the clutch need to start the accuracy from the top of pressure plate, then the accurate value should be the actual size of pressure plate plus 1.4 1.8mm. p. Use the special tools to check the C4 clutch assembly. Refer to Figure 8.25. Caution: It should take out the clutch clearance assembly before immerse the assembly into the automatic transmission fluid (ATF). q. Use the gear selection plate to reach the correct specification. If need to install the new friction disk, it should remove the clutch assembly and immerse the friction disk in the automatic transmission fluid for 5 minutes at least before the installation. Reinstall the sleeve and clutch assembly and place it in the cylinder. Ensure the wave washer is arranged consisting with the cylinder hole. Install the clutch C2 disk in the cylinder according to the following procedure: friction disk steel disc friction disk steel disc The steel disc transmission use the G32 model engine; the 5th friction disk should replace the steel disc (reference table 9.3). steel disc (optional) friction disk steel disc (optional) friction disk Caution: For the clutch assembly can endure the weight of 19.6N, the dimension from the clutch C3 wheel axle to the friction disk should be within 0.80-1.05mm. r. Use the tool to test the clutch assembly; ensure the weight is in the acceptable range. Refer to Figure 8.26. C3 hub positioning clutch C2 loading Figure 8.26 C2clutch assembly Caution: It should take out the clutch clearance assembly before immerse the assembly into the automatic transmission fluid (ATF). s. Use the gear selection plate to reach the correct specification. It should remove the clutch assembly and immerse the friction disk in the automatic transmission fluid for 5 minutes at least before the installation if install the new friction disks. Lubricate and install the 3-4 one-way clutch and install the sleeve on the C2 wheel axle. Adjust the handle rear and install the nylon thrust washer on the C4 wheel axle. Refer to Figure 8.27. t. Adjust and install the clutch C4 wheel axle on the clutch C2 and one-way clutch assembly. Check the rotary direction of clutch C2 wheel axle, when keep the C4 wheel axle in static, C2 wheel axle should rotate in clockwise and is locked in anticlockwise. Refer to Figure 8.27. u. Use the Vaseline to lubricate the N0.5 thrust bearing and install it on the C4 gear wheel axle ,separate the clutch C2 disc form the clutch cylinder. Figure 8.27 C2 hub rotation v. Install the thrust disc on the cylinder internal wheel axle. Refer to Figure 8.24and 8.19. w. Connect the C2 /clutch C4 wheel axle assembly in clutch C4 disc, install the clutch C2 disc. Install the C3 wheel axle and reinforce it by ring spring; ensure the ring spring is installed in the groove fixedly. Please refer to Figure 8.24. 10. Clutch C3 and reverse central gear system The assembly procedure of clutch C3 and reverse central gear assembly (refer to Figure 8.28) is shown as follows: Check the cleanness of hole on cylinder. Figure 8.28 clutch C3 and reverse central gear b. Check the damage of external diameter and central support diameter of C3 cylinder sleeve. Coat the sealing ring with the automatic transmission fluid and install it on the C3 cylinder groove. c. Check the condition of reverse central gear spline, notch and thrust surface; coat the O-ring with transmission liquid and install it in the reverse sun gear groove. Use the Vaseline to lubricate the C3 washer and install it in the reverse sun gear. d. Install the reverse central gear in the C3 cylinder; ensure the O-ring is compressed properly but not excess. Caution: The O-ring notch can not be bent. e. Coat the C3 piston O-ring with the transmission liquid and install the small O-ring on the C3 piston inner ring; install the large O-ring on the C3 piston external ring. f. Check the piston drainage hole for cleanness and block material. Caution: Must not remove the O-ring without permission. g. Install the C3 piston on the cylinder until the external diameter of piston enters into the inner diameter of cylinder. h. Install the spring and spring retainer on the piston. Use the tools to press down the spring to install the ring spring better. Ensure the ring spring is installed in the groove fixedly, then remove the tools. i. Install the C3 wave plate on the C3 piston surface; ensure the a hole on wave disc of C3 piston surface is not in line with the piston hole. j. Install the clutch disk and other disc in the following sequence: steel disc friction disk steel disc (optional) friction disk steel disc (optional) friction disk k. Adjust and install the pressure disc; make its counterbore is opposite with the clutch disk. l. Install the ring spring. Caution: For the clutch assembly can endure the weight of 19.6N. so the clearance between the screw and top of preset disc should be 1.20-1.45mm. m. Use the tools to check the clearance of clutch C3, refer to Figure 8.29. The method is as follows (only use the weights): Place the weights on the pressure disc and measure the distance between the bottom of cylinder and top of pressure disc. Record the data. Remove the weights. Lift the weights plate and press down the ring spring; measure the distance between the bottom of cylinder and top of pressure disc Record the data. The clutch assembly clearance can be acquired by 1st record minus 2nd record. Caution: It should take out the clutch assembly clearance before immerse the assembly into the transmission liquid. n. It should remove the clutch and immerse the assembly into the transmission liquid for 5 miniatures at least before the reassembly. 11. front sun gear and clutch C3 assembly The installation procedure of front sun gear and clutch C3 assembly (Refer to Figure 8.30) is shown as follows: a. Install the N0.7 needle thrust bearing on the front sun gear ensure the thrust washer is between the bearing and central gear. b. Use the Vaseline to lubricate the thrust plate and install it on the reverse sun gear. Refer to Figure 8.32. c. Adjust and install the clutch C3 assembly on the front sun gear. d. Use the Vaseline to lubricate the NO.6 needle thrust bearing and install it on the thrust disc. Ensure the wire connecting plate on the bearing external diameter is proper for the hole on the thrust bearing. Refer to Figure 8.33. e. Adjust and use the Vaseline to install the plastic thrust washer on the thrust disc. f. Install the assembly on the reverse sun gear in the position opposite to the NO.6 thrust bearing. g. Install the assembly on the other side. Figure 8.30 Forward-Gear central gear and C3clutch assembly 12. Clutch C1 overspeed shaft and input shaft assembly Caution: a. Ensure the correct installation of snap ring. b. Check the piston for crack. c. Must not mix the clutch piston out and back spring. d. If the connector of clutch C1/ C2 is disconnected form the clutch C3, ensure the NO.6 bearing can not slide down from the bearing retainer. The installation procedure of clutch C1 overspeed shaft and input shaft assembly is as follows: a. Check the overspeed shaft groove for damage. b. Coat the big and small sealing ring with the Vaseline and install it on the overspeed shaft. It can use few Vaseline to fix the sealing ring on its correct position. c. Install the clutch disk and other disc on the cylinder according to the following sequence: steel plate abrasion plate steel plate abrasion plate steel plate steel plate steel plate (optional) friction disk steel plate (optional) friction disk Caution: The clutch assembly can support the weight of 19.6N; the distance form the fixing point of input shaft to the friction disk is 0.70 0.90mm. Caution: It should take out the clutch assembly before immerse the assembly in the transmission fluid. d. Use the tools to check the clutch assembly clearance. Refer to Figure 8.31. Use the proper selected disc plate to acquire the correct required clearance. clutch C1 Figure 8.31 clutch C1 assembly clearance 19.6N load clutch clearance0.7-0.9mm0.7-0.9mm input shaft position e. If need to install the new friction disk, please remove the clutch assembly and immerse the friction assembly into the transmission fluid for 5 minutes at least before the installation. f. Check whether the clutch C1 wheel axle is matched with the overspeed shaft. It should replace the wheel axle and wheel axle assembly if loose. g. Coat the small nylon thrust insulation plate with the Vaseline and installs it on the overspeed shaft. Refer to Figure 8.19. h. It should be carefully when install the overspeed shaft on the C1 cylinder to avoid the damage of sealing ring. i. Use the Vaseline to install the small copper C1 wheel axle thrust washer, shown as Figure 8.19. j. Check the input shaft for problem. Install the input shaft on the cylinder and use the ring spring to install the wire safety of input shaft and cylinder. Ensure the coil is in groove completely. k. Use the petroleum jelly to install the gasket and place it on the input shaft. l. Assemble the C1/C2/C4 clutch, clutch C3 and sun gear, shown as figure 8.24, 8.32 m. Install the assembly in the transmission case. Figure 8.32 and 8.33 assembly number: 6 bearing and pressure disc to clutch C3 assembly 13. Pump housing and torque support Caution: a. Do not clean the solenoid valve by solvent. b. Ensure the O-ring is installed in the correct position. c. Do not blow off the first drop and mix it with the ball spring blowed off by the torque converter. ( only for the condition of installing the transmission to STD pump housing) d. Do not damage the line bearing on the assembly; avoid any impact for bearing during the loading. e. Check the end floating of transmission; it is help for the lose and incorrect assembly of any assembly. Caution: Figure 8.35 The orientation of crossing part is shown in Figure 8.36 to 8.42. The assembly procedure of pump housing and torque converter is as follows: a. Check the pump for damage, chip and abnormity; check whether the sleeve of drive gear is fixed. b. Wash the pump and pump gear carefully; remove all redundant oil and dirt. c. Install the pump gear and pump. Use the micrometer to measure the depth from the surface of pump to gear surface. The measured value is the side clearance of pump. The side clearance should be in the range of 0.020-0.040mm. d. Remove the pump gear from the pump. e. If had been removed, please replace the pump sealing. Ensure the cleanness of pump sealing. f. Use the transmission liquid to lubricate the pump gear, pump, washer and sealing and install the pump gear on the pump. pump cover assembly pump housing cover oil seal pump assembly o-ring (pump ) Figure 8.34 pump, cover and torque converter support g. Use the automatic transmission liquid to lubricate the pump O-ring and install it on the pump. Place the pump on the other side. h. Ensure the pump housing cavity and hole are not blocked. i. Use the automatic transmission liquid to lubricate all loose part before the installation. g. Install the primary regulating valve on the pump housing, ensure the valve slide freely; then install the plug of regulating valve and O-ring. Refer to Figure 8.36. k. Install the fixed bolt, install the torque conversion clutch regulating valve, plug and O-ring. Refer to Figure 8.37 l. Install the fixed bolt. Refer to Figure 8.39 m. Install the torque conversion clutch control valve, spring and O-ring. Refer to Figure 8.38 Figure 8.35 Assembly of pump cover n. Install the fixed bolt, shown as Figure 8.39 o. Install the torque converter detection ball spool and spring, shown as Figure 8.41 p. Install the washer on the pump body. Install the housing disc and solenoid wire maintaining cover on the pump housing; ensure the edge of disc close to the pump housing. Shown as Figure 8.34, Tighten the bolt according to the sequence of (1-5), shown as Figure 8.42. Caution: Check the smooth of wire and connector. To ensure whether the wire and connector have connection and abrasion on the input shaft or clutch C1/ C2 cylinder; check the wire and connector for over extension. q. Tighten the screw of solenoid valve 7.Refer to Figure 8.39 r. Install the pump on the pump housing, tighten all bolts; ensure the pump can be washed without pump housing. Tighten the bolt in certain sequence; shown as figure 8.42. s. Install the pump on the washer of transfer case of housing. t. Make the O-ring is proper for the external diameter of pump. u. Ensure the pump housing hole in main housing is clean and without dirt. v. Ensure the plastic connector of solenoid valve 7 is installed on the correct position of main housing. w. Install the pump and pump housing on the input shaft carefully and avoid the damage of gasket spring. Tighten the pump housing spring. Refer to Figure 8.43 Figure 8.44. x. Check whether the transmission end float is fixed in the clearance of part 9.2. Refer to It the end float without filling metal plate is more than that in instruction, then the metal plate should be placed in surface of NO.4 bolt and input shaft bolt. Refer to Figure 8.19. if the end float is less than 0.5mm or more than 0.8mm; then the transmission can not be installed correctly and is beyond the specification partly. Check the end floating by executing the following procedure: Connect the disc indicator to the front end of the transmission; place the pointer on the end of input shaft. Apply about 250N or 25kg force on the input shaft. Zero the indicating pointer. Install a small lever on rear of the front clutch cylinder. The recorded measuring value is the end floating value or called as the clearance of No.4 bearing on torque converter tube support. After the completion of the process, adjust the front and rear brake belt according to the specification of details in part 8.4. Figure 8.36 Primary regulating valve Figure 8.37 Torque converter clutch regulating valve Figure 8.39 Valve fixing plug and pin Figure 8.40 Torque converter release ball and spring Figure 8.41 Position of test ball Figure 8.42 Tighten the pump bolt in the sequence shown in figure Figure 8.43 Connect the pump to the housing in the sequence shown in figure 14. Valve Caution: a. Must not clean the solenoid valve pipe port by solvent. b. Pay attention to the position of ball on upper of valve. c. Pay attention to the position of 1-2 Gear and 3-4 Gear gear shift valve which may be exchanged. d. Check the 4-3 Gear sequence valve and spring for position. e. Check the 12mm ball on the lower of valve. f. It should ensure install the correct pump housing (HPPC). Please must not mix the 1st-Gearlow position ball spool with the torque converter ball spool . g. Check the rag of line pressure relief valve and pay attention to replace the iron shim. h. The hole on the valve is used for fixation and safety and could not be extended. i. When repair the transmission, it should ensure the solenoid 5 damp coil spring is not broken. The installation procedure of valve is shown as follows: a. Use the cleaning solvent (refer to 8.45, 8.46) to wash the upper and lower valve completely and dry it by air; check the valve cavity, port and hole for damage or block. b. Install the cushioning baffle positioning bolt and clean all loose parts completely. c. Check all valves for smooth sliding on its position. d. Install the proper pump housing, spring and ball. Check the valve and rolling bolt. e. Install the 1-2 Gear gear shift valve, plug and fixed bolt. Refer to Figure 8.48. Install the 3-4 Gear gear shift valve and fixed bolt. Refer to Figure 8.49. Install the 2-3 Gear gear shift valve and fixed bolt. Refer to Figure 8.50. Install the 4-3 sequence valve, spring, plug and fixed disc. Refer to Figure 8.51. f. Install the brake belt action regulating valve (BAR) spring, piston and fixed bolt. Refer to Figure 8-52 g. Install the force and action regulation valve (CAR)spring, piston and fixed bolt. Refer to Figure 8-53 Caution: The aluminum valve is damaged easily. h. Install the solenoid pressure-supply valve, spring and fixed disc. Refer to Figure 8.54. i. Install the solenoid valve 6 bolt , spring and fixed bolt. Figure 8.45 Lower valve Figure 8.46 Position of upper valve and detection ball Figure 8.47 solenoid valve 5 and damper Figure 8.48 1 Figure 8.49 3 2gear shift valve 4 gear shift valve Figure 8.50 solenoid 2 and 2 Figure 8.51 4 3gear shift valve 3sequence valve Figure 8.52 brake belt combination regulating valve and solenoid 4 Figure 8.53 clutch combination regulating valve and solenoid 3 Figure 8.54 solenoid combination valve and solenoid 6 Figure 8.55 reverse lock valve j. Position the 3rd feed ball (large nylon ) on the valve and solenoid supply valve filter, shown as Figure 8.54. k. Check the separating disk for abrasion, repair or replace if necessary. l. Check the washer of upper and lower valve for damage, replace it if necessary m. Install the upper shim of lower position valve. n. Install the reverse lock valve, spring and fixed disc; ensure the correct installation of valve; shown as Figure 8.55. o. Install 5 nylon balls on the upper valve, shown as Figure 8.46. Install the upper valve shim; install the separating disk on the upper valve. p. Lift the separating disk to the upper valve; prevent the detection ball from falling ; install the upper valve on the low pressure valve. Tighten all screws. Refer to Figure 8.56. Figure 8.56 The tighten sequence of valve bolt from upper to lower q. Install the solenoid valve 1, 2, 3, 4 and 6. Ensure the solenoid valve is clamped by the clip tightly and the bolt is tightened to the specified torque. Caution: The wire harness ground wire port is protected by the solenoid valve fixing plate r. Install the solenoid valve 5. Ensure the solenoid valve close to valve through the clip. s. When install the valve with line pressure relief valve, it should install the tapering port of line pressure relief valve, then install and fix the spring and disc. t. Install the pin spring; ensure the screw is tightened to the specified torque. Check the damaged spring. u. Install the manual gear shift valve .Refer to Figure 8.57. Figure 8.57 Manual gear shift valve v. It should ensure the position lever is in the position of manual 1st-Gear before install the valve on the transmission. w. Adjust the valve on the transfer case and install the connection of manual-operated valve steering column and manual-operated valve. Make the long end of connecting object is proper for the 1st manual-operated valve. Install the protecting spring and tighten it according to the specification. Refer to Figure 8.58. x. Check the positioning drum and manual-operated valve . Caution: All hardware must be installed and meet the specification. y. Connect the wire of connecting solenoid according to the following details: Solenoid valve 1 Solenoid valve 2 red blue Solenoid valve 3 Solenoid valve 4 yellow orange Solenoid valve 5 Solenoid valve 6 green purple Refer to Figure 8.58. Figure 8.58 Tighten sequence of bolt form valve to box 15. Installation of oil filter and oil bottom shell Caution: a. It should replace the filter when a important mechanical component is damaged and assemble a transmission. b. To assist the assembly of sealing gasket groove, please coat the surface of oil pan and washer with thin Vaseline to ensure the sealing gasket is in the groove. Do not rotate the washer, otherwise it will cause the distort or incline of groove. Figure 8.59 Bushing of engine oil filter Figure 8.60 Installation of engine oil filter Figure 8.61 Tightening sequence of oil pan bolt It should abide by follows when assemble the oil filter and oil sump tank (Refer to Figure 8.59and Figure 8.60): a. Use the automatic transmission liquid to lubricate the spring ring of gasket of lubrication oil. b. Install the oil filter on the valve carefully. During the installation, the socket must be inclined. Refer to Figure 8.59. c. Fix the oil cleaner assembly. d. Check whether the magnet is installed in the recess on the corner of oil bottom shell. e. Assemble the groove on the oil bottom shell. The groove must be bent during the installation. f. Make the installation of oil bottom shell is proper for transfer case and the tighten the safety valve according to the specification and sequence (Refer to Figure 8.61). do not distort it. 16.Torque converter and support sleeve assembly Install the hydraulic torque converter and housing assembly, the procedure is shown as follows: a. Install the hydraulic torque converter housing on the main case. Caution: All hardware should be installed correctly and comply with the specification. b. Use the Loctite243 or equivalent to fix the torque converter housing; install and tighten it to standard specification. c. Install the torque converter; ensure the pump gear sealing is installed correctly. 17. Rear wheel drive mode of output ring flange assembly Assemble the output shaft assembly, the procedure is shown as follows: a. Place the paw of transmission operating rod on the parking position and lock the output shaft. b. Wash the output shaft upper line; use the loctite243 or equivalent. c. Install and tighten the ring flange, O-ring and nut. Caution: In the heavy steel slide plate, place the ring flange on the upper nut; avoid the damage of bearing. d. Tighten the nut on the output shaft T o r q u e ty p e s p e c ific a tio n N .m F t/lb tra n s m is s io n a s s e m b ly to r q u e c o n v e r te r h o u s in g to h o u s in g M 12× 32 4, 8or 9 5 4 -6 8 4 0 -5 0 r e a r e n d h o u s in g to h o u s in g -C h a ir m a n M 12× 32 4 5 4 -6 8 4 0 -5 0 C o n n e c to r h o u s in g to h o u s in g -4 W D M 8× 25 10 3 5 -4 0 2 6 -3 0 r e a r e n d h o u s in g to h o u s in g -2 W D M 8× 25 10 3 5 -4 0 2 6 -3 0 r e a r s e r v o c o v e r to h o u s in g M 8× 25 6 3 0 -3 5 2 2 -2 6 O il p a n to h o u s in g M 6× 16 9 4 -6 3 -4 .5 2 4 0 -4 5 2 9 .5 -3 3 O il c o o le r p ip e c o n n e c tio n V a lv e t o h o u s in g M 6× 26 7 8 -1 3 6 -9 .5 V a lv e t o h o u s in g M 6× 45 5 8 -1 3 6 -9 .5 B r a k e b a r s p rin g M 8× 16 1 2 0 -2 2 1 5 -1 6 c e n tra l s u p p o rt to h o u s in g M 10× 34 2 2 0 -2 7 1 5 -2 0 C a m d is c to h o u s in g M 8× 16 2 1 6 -2 2 1 2 -1 6 G e a r -p o s itio n s e n s o r to h o u s in g 1 0 -2 4 × 1 3 2 4 -6 3 -4 .5 O u tp u t s h a f t lo c k n u t M 2 4 × 1 .5 1 1 0 0 -1 1 0 7 4 -8 1 .5 o il fillin g p lu g M 20 1 3 0 -3 5 2 2 -2 6 P u m p h o u s in g a s s e m b ly P u m p to p u m p c o v e r M 8× 55 5 2 4 -2 7 1 8 -2 0 P u m p c o v e r to h o u s in g M 8× 40 6 2 4 -3 4 1 8 -2 5 P u m p c o v e r to h o u s in g M 8× 58 2 2 4 -3 4 1 8 -2 5 P u m p c o v e r d is c to p u m p cover M 6× 16 5 1 3 -1 6 9 .5 -1 2 P u m p c o v e r d is c to c re s c e n t M 6× 54 1 1 3 -1 6 9 .5 -1 2 U p p e r v a lv e to lo w e r v a lv e M 6× 30 24or 25 1 1 -1 6 8 -1 2 L in e s o c k e t M6 1 4 -7 3 -5 s o le n o id v a lv e ( o n /o f f ty p e a n d V P S , in c lu d in g S 7 ) M 6× 16 7 8 -1 2 6 -9 V a lv e a s s e m b ly Table 8.1 Torque specification Adjustment of front and rear brake belt 1. Setting procedure of brake belt The setting procedure of brake belt is shown as follows: a. For the calculating method of front servo mechanism thrust lever refer to Figure 8.62, dimension; standard A. .Allow the air pressure is in 650/700kPa in the operating area of front servo mechanism (external of B1), (refer to Figure 8.63). . The forward dimension of thrust lever minus 3mm. Dimension requirement for selection of shim: Caution: The small shim requires that the shim size is 1mm always; the available thickness is listed in Table 8.2. . Release air. b. Proper shim to end of thrust lever pole. Check the shim for damage, worn or corrosion; replace it if necessary. The shim is installed on the support surface between the transmission and pole flange, refer to Figure 8.62. Install the shim by hand, and not the hammer or pressure. Press the shim by hand until has the click the noise. The noise means the shim is clamped by the housing correctly. c. Recheck the stroke of thrust lever 3mm 0.25mm. 2. Setting procedure of rear brake belt The setting procedure of rear brake belt is shown as follows: a. The setting of distance A is form the back surface of servo piston to inner surface of transmission, use the vernier caliper. Refer to Figure 8.64. A allows the air pressure of 650/700kPa is in the front servo mechanism operating area (external of B2), (refer to Figure 8.63). Deduct 3.75mm from the movement of piston and use the 2.5 mm shim to divide the rest distance. Caution: The small shim requires that the shim size is 1mm always; the available thickness is listed in Table 8.2. . Release air. b. Select the proper shim for end of thrust lever pole. Check the shim for damage, worn or corrosion; replace it if necessary. The shim is installed on the support surface between the transmission and pole flange, refer to Figure 8.64. Install the shim by hand, and not the hammer or pressure. Press the shim by hand until has the click the noise. The noise means the shim is clamped by the housing correctly. c. Recheck the stroke of piston for 3.75mm thickness 0.625mm. Component No. thickness Component No. Table 8.2 Effective thickness of shim Figure 8.62 Setting of brake belt Figure 8.63 External port position of B1 and B2 Figure 8.64 Setting of rear brake belt Oil filling procedure According to the procedure described in 7.2. Specification and special tools Type and specification hydraulic torque converter maximum torque multiplier factor 179K stalled speed (80 to 100 ℃ rpm) (179K torque converter ) Gear ratio First gear Second gear Third gear Fourth gear Reverse gear Specification 2.00: 1 2090 2.393:1 1.450:1 1.000:1 0.677:1 2.093:1 Lubricant type dry system alternative of maintenance Castrol TQ95 9.0 L (approximation) 4.5L (approximation) Axial movement of gear assembly 0.50-0.65 mm Fixed pinion axle movement 0.10-0.50 mm Table 9.1－ Type specification Pressing factor of clutch 0588-000001 C1 structure (friction disk ) steel 5 5 (2) C2 structure (friction disk ) steel 5 4 (2) C3 structure (friction disk ) steel C4 structure (friction disk ) steel 4 4 (2) 3 4 (1) Table 9.2 Shifting point of clutch assembly details Shifting point Opening degree throttle position Shifting 1/2 2/3 of 3/4 4L Opening shifting degree of 1/2 2/3 throttle position 3/4 4L 0% 10 20 34 63 0% 14 26 41 87 40% 26 47 82 95 40% 30 56 76 113 100% (WOT) 53 93 126 150 100% (WOT) 53 94 127 152 decreasing 55 89 137 152 decreasing 55 96 137 152 Table 9.3- Shifting point-km/h Maximum speed of typical Gear-decreasing of vehicle The Gear-decreasing will be disabled when beyond the following speed. Gear-decreasing type Speed point for disable of Gear-decreasing Manual 2-1 In 59 km/h Manual 3-2 89 km/h Manual 4-3 119 km/h Manual 4-2 (4-2 direct) 68 km/h Manual 4-2 (sequence of 4-3-2) 89 km/h Figure 9.4 - Special tools for maximum disable speed of manual Gear-decreasing Special tools tools Part No. Platform bracket of transmission oil pump remover Cross shaft disassembly /installation (brake lever) clutch spring compressing tools clutch assembly clearance positioning tools Shaft end floating connector Shaft end floating measuring tools cross shaft seal disassembly tools cross shaft seal installation tools Pump sealing installation tools Sealing ring expander extender /compressor Cross shaft lever disassembly /installation (disable switch) solenoid valve /electric heating regulator, electric meter solenoid valve, platform meter Assembly ball spool Sealing gasket disc Figure 9.5 Special tools Annex Description for oil inlet hole of main housing Chapter 6 Drive shaft Cautions Do not clamp the drive shaft bushing too tightened by the bench vice to avoid the deformation. failure Noise vibration Possible causes Method The spline of universal-joint fork is worn The intermediate bearing is worn The cross-axle bearing is worn or jammed Replace the universal-joint fork Replace the intermediate bearing Replace the cross-axle bearing Runout of drive shaft Unbalance of drive shaft The rear bearing bushing of transmission extended housing is worn The spline of universal-joint fork is jammed Replace the drive shaft Replace the drive shaft Replace the bushing Replace the universal-joint fork universal-joint fork front section of rear axle propeller shaft universaljoint fork circlip rear section assembly of rear axle propeller shaft intermediate support assembly N m: shim Specified torque nut cross-axle assembly Front axle propeller shaft (4WD) assembly flange fork circlip cross-axle assembly front axle drive shaft assembly N m: Specified torque axle tube assembly Rear axle propeller shaft (4WD) assembly cross-axle assembly universal-joint fork drive shaft axle pipe assembly N m: Specified torque circlip flange fork Disassembly of drive shaft: Remove the intermediate support bolt of drive shaft firstly (CC6460KY is without intermediate support connecting bolt ), then remove the connecting bolt between the drive shaft and rear axle , lastly, pull out the drive shaft assembly from the transmission output spline shaft and remove it in integral. transmission drive shaft assembly rear axle assembly front axle drive shaft assembly rear axle assembly transmission transfer case rear axle drive shaft assembly Installation of drive shaft: 1. Firstly, check the drive shaft for damage, spline for corrosion and connecting surface for deficiency of damage or sand hole by itself. 2 Install the connecting spline bushing of drive shaft on the transmission output spline shaft carefully; then install the drive shaft intermediate support on the intermediate support bracket ofcarriage. 3. Use the special drive shaft bolt, nut and spring shim to connect the drive shaft to the vehicle axle ring flange and tighten it. The tightening torque is 78 5N m 4. Tighten the drive shaft intermediate support nut, the tightening torque is 63 5N m (the front and rear drive shaft in CC6460KY model are the integral and has the installation content) Chapter 7 Suspension and vehicle axle Rear suspension …………………………………112 Troubleshooting Failure Cause The tyre is worn or charged improperly. Repair content Charge the tyre to the proper pressure or replace the tyre. The front wheel alignment is incorrect. Check the condition of front wheel alignment. Floating/pulling Subsidence of vehicle body Left-right swing/up-down bounce The wheel bearing is adjusted too tightened. Adjust the wheel bearing The front /rear suspension components is loose or Tighten damaged partTighten The steering linkage is loose or worn linkage The steering device is connected unsound or worn. Adjust or replace the steering device Overload of vehicle Check the load weight vibration damper is worn Replace the vibration damper spring is weak Replace the spring The tyre is charged improperly Charge the tyre to the proper pressure The stabilizer bar is bend or damaged Replace the stabilizer bar The vibration damper is worn Replace the vibration damper The tyre is worn or is charged improperly Replace the tyre or charge it to the proper or replace or the replace suspension the steering pressure. Front wheel vibration Abnormal abrasion of tyre Unbalance of each wheel Balance all wheels The vibration damper is worn Replace the vibration damper The front wheel alignment is incorrect Check the condition of front wheel alignment The wheel bearing is worn or adjusted badly Replace or adjust the wheel bearing The ball joint or bushing is worn Check the ball joint or bushing The steering system is loose or worn Tighten or replace the steering linkage The steering mechanism is adjusted badly or damaged Adjust or repair the steering device The tyre is charged improperly Charge the tyre to the proper pressure The vibration damper is worn Replace the vibration damper The front wheel alignment is badly Check the condition of front wheel alignment Oil leakage of differential The suspension part is worn Replace the suspension part High oil level or incorrect oil grade Drain the oil to the specified level or replace the oil The oil seal is worn or damaged Replace the oil seal The matching flange is loose or damaged Tighten or replace the flange The oil grade is low or incorrect Fill with the lubrication oil or replace the oil according to the specification The clearance of the pinion, ring gear or side gear is Check the clearance large. The axle has the noise The ring, pinion gear or side gear is worn or broken Check each gear The pinion gear bearing is worn Replace the bearing The bearing of rear axle half shaft is worn. Replace the bearing The differential bearing is loose or worn Tighten or replace the bearing Front wheel alignment 1. Process the following inspection and eliminate all problems a. Check the wear condition of tyre and proper inflation. Tyre inflation pressure: 230kPa b. Check the wheel bearing of front wheel for loose. c. Check the front suspension for loose. d. Check the steering drive device for loose. e. Process the standard elastic test; check thefrontvibration damper for normal operation. 2. Adjust the height of car A:Adjust the height of car to the standard value for theconvenience of processing the front wheel alignmentinspection. B: Front fixed bolt of lower suspension arm The standard no-load height is: the center of front fixed boltof lower suspension arm is 295 1mm away form theground. 3. Install the 4-Wheel alignment instrument Processed according to the detailed description of equipment manufacturer. 4. Adjust the wheel angle Remove the cover of spacing bolt of steering knuckle; check the internal wheel’s steering angle A. Internal wheel’s steering angle: 32 Caution: The wheel should not touch the brake hose of car body when the steering wheel is rotated to limit. 6. Adjust the wheel toe Adjust the wheel toe according to the following method a. Shake the car upwardly and downwardly to make the suspension reach the stable status. b. Push the car forwardly for 5m in flat ground when the front wheel is in the straight forward position. c. Mark the center of each rear wheel; measure the distance “B” between the marks of left and right tyre. d. Push the car forwardly to move the mark on the back of tyre to the position of front instrument. Remarks: if the tyre moves too far, repeat the procedure (b). e. Measure the distance “A” ‘between the marks on front of tyre. f. Measure the toe of wheel. toe =B-A Inspection standard: 0-2mm If the toe does not consist with the specified value, it can be adjusted by the left and right draw-bar. Move the vehicle forwardly g. Adjustment of toe: the standard value is 0 2mm. The toe is adjusted by rotating the cross draw-bar. When adjust the toe, it should rotate the cross draw-bar on left and right side uniformly. After the adjustment, tighten the lock nut, the tightening torque is 55 65N m. h. Check the sideslip Sideslip: Within 5m/km Front hub and steering knuckle (2WD) stabilizer bar spring shim brake caliper assembly upper suspension arm flat shim split pin connecting rod of stabilizer bar steering knuckle tight nut lock washer flat shim lower suspension arm disk shim fill block shim fill block disk shim screw split pin absorber spring shim brake cover oil seal bearing hub and brake disc N m: specified torque Used component which can not be used any more precoated component bearing hub cap Front hub Disassembly of front hub 1. Remove the disc brake Remove the brake caliper and hang it by steel cable. Remarks: Do not remove the brake pipe and brake hose. 2. Remove the hub cap Use the inner hexagon spanner to screw off the fastening blot and remove the hub cap. 3. Remove the hub and brake disc a. Use the Philips screwdriver to screw off the lock screw and remove the lock washer. b. Use the special tools to remove the lock nut. special tools c. Remove the hub and brake disc with the external bearing. 4. Remove the oil seal and inner bearing a. Use the screwdriver to pry out the oil seal. b .Remove the inner race of inner bearing from the hub. Check and repair of front hub 1. Check each bearing Wash the inner and outer race of each bearing and check them for damage or wear. 2. Replace the bearing outer race a. Use the brass bar and hand hammer to knock out the bearing outer race. b. Use the special tools to knock in the new bearing outer race. special tools diagram of special tools Assembly of front hub 1. Coat the inner surface of hub and bearing outer race with the grease. grease The grease is the Jin HP-R grease or the grease met the requirement in following table. Item Typical data Dropping point, C 289 Leakage amount (104 C, 6h), g 0.48 EP performance OK value , N 178 grease 2. Place in the bearing inner race; use the fill the gap between the inner and outer race of the bearing up with the HP-R grease. grease 3. Install the inner bearing and oil seal a. Place the inner bearing in the hub. diagram of special tools b. Use the special tools to knock the new oil seal into the hub. c. Coat the oil seal lip with HP-R grease. special tools 4. Install the hub on the steering knuckle a. Install the hub on the steering knuckle. b. Install the external bearing. 5. Adjust the pre-applied load diagram of special tools a. Use the special tools to screw on the locknut to specified torque. Tightening force: 80-100N m b. Rotate the hub to right and left 1/3 1/4 round respectively. c. Screw off the nut until the nut can be loosed by hand. d. Use the special tools to retighten the lock nut. special tools Tightening force: 28N m e. Use the spring tension meter to check the pre-applied load. Pre-applied load (for starting): 28-56N Remarks: If the screw installation hole on the lock washer can not align with the screw hole on the lock nut, then it can remove the lock washer and adjust he lock nut slightly (rotate in the direction of Min. adjusting range ); then install the lock washer. 7. Recheck the pre-applied load Use the spring tension meter to recheck the pre-applied load. Pre-applied load (for starting): 28-56N If the pre-applied load does not meet the specified value, it must remove the lock washer and adjust it by the adjusting nut. 8. Install the hub cap a. Coat the silicon rubber surface sealant on the matching surface of hub and hub cap. b. Coat the screw of the inner hexagon bolt with the screw lock sealant. c. Use the inner hexagon bolt to fix the hub cap and ring flange on the hub; tighten the bolt to the specified torque. Tightening force: 45 5N m 9. Install the disc brake Install the disc brake on the steering knuckle and tighten the bolt to the specified torque. Tightening force: 140 10N m Steering knuckle Disassembly of steering knuckle 1. Remove the disc brake and front hub (Refer to section “Front Hub”) 2. Remove the brake cover 3. Disconnect the steering cross rod from the steering knuckle arm a. Remove the split pin and nut on the ball pin. special tools 4. Disconnect the connecting rod of stabilizer bar from lower arm Use the inner hexagon spanner to fix the ball pin; remove the selflocking nut. 5. Remove the steering knuckle a. Remove the split pin and nut on the upper ball pin special tools b. Use the special tools to disconnect the steering knuckle from the upper ball pin. c. Remove the split pin and nut on the lower ball pin. d. Use the special tools to disconnect the steering knuckle from the upper ball pin. e. Remove the steering knuckle. special tools Check and replacement of steering knuckle Use the dye penetrant to check the steering knuckle for crack.It should replace the steering knuckle if has crack. Installation of steering knuckle 1. Install the steering knuckle a. Install the lower ball pin on the steering knuckle and install the slotted nut temporarily. b. Press down the upper arm and connect the upper ball pin to the steering knuckle. Install and tighten the nut to the specified torque. Tightening force: 145 15N m c. Install the new split pin. Remarks: It should align the notch of nut with the pinhole when install the split pin; the nut can be tightened but not loosed during the alignment. Tightening force: 230 20N m e. Install the new split pin. Remarks: It should align the notch of nut with the pinhole when install the split pin; the nut can be tightened but not loosed during the alignment. Tightening force: 63 5N m 3. Connect the steering cross rod to the steering knuckle arm. a. Tighten the slotted nut according to the specified torque. Tightening force: 170 15N m b. Install the new split pin. Remarks: It should align the notch of nut with the pinhole when install the split pin; the nut can be tightened but not loosed during the alignment. Tightening force: 23 3N m 5. Install the front hub and disc brake (see section of front hub) Front suspension (2WD) shim upper arm shaft upper arm bush front stabilizer bar upper arm bush shim upper arm shaft rubber cover clip upper ball pin flat shim split pin lower arm long bush connecting rod of stabilizer bar rear shaft of lower arm torsion bar flat shim torsion bar base upper adjusting block front shaft of lower arm lower arm short bush fixed arm eccentric shim lower arm lower adjusting block disk shim fill block fill block shim disk shim lower ball arm split pin shock absorber front wheel hub and steering knuckle assy N m: specified torque Used component which can not be used any more. Pregummed component N m: specified torque adjusting bolt Ball pin Inspection of ball pin 1. Check the lower ball pin for loose a. Raise the front of the car by jack and support it by the frame. b. Ensure the front wheel is in straight advancing position and step down the brake pedal. c. Move the arm upwardly and downwardly; check the clearance of lower ball pin. Max. vertical clearance: 0mm 2. Check the upper ball pin for loose; move the wheel upwardly and downwardly and check the gap of upper ball pin. Max. vertical clearance: 0mm 3. Check the rotation of ball pin a. Remove the ball pin. b. Shown as figure, shake the ball pin stud forwardly and backwardly for several times before install the nut. c. Rotate the nut continuously by torsion meter and 2-4s for a cycle; record the readout of torsion meter in the fifth cycle. tightening torque (for rotary): lower ball pin 0.1 4N m upper ball pin 0.1 4N m Disassembly of ball pin 1.Take down the steering knuckle and front wheel hub assy. Disassembly of ball pin (Refer to section “Front Hub and Steering Knuckle”) 2. Remove the lower ball pin form the lower arm 3. Remove the upper ball pin from the upper arm. Installation of ball pin 1. Install the upper ball pin on the upper arm Tightening force: 78 5N m 2. Install the lower ball pin on the lower arm Tightening force: 140 10N m 3. Install the steering knuckle and front hub assembly (Refer to section Front Hub and Steering Knuckle) Torsion bar spring Disassembly of torsion bar spring Installation of torsion bar spring Caution: There are the L and R indication marks, which must not be exchanged on the read end of the torsion bar spring. Mark L means the left andRforright. 1. For reused torsion bar spring a. Coat thin grease on the spline of torsion bar spring. b. Align the assembly mark, install the torsion bar spring on the torsion bar. c. Align the assembly mark; install the adjusting arm onthtorsion bar spring. d. Tighten the adjusting bolt to make the extension length of the bolt equal to the length before remove. 2. For new torsion bar spring a. Remove the wheel. b. Coat thin grease on the spline of the torsion bar spring. c. Install the torsion bar spring on the torsion bar base. d. Lower the lower arm to the lower limitation position; install the adjusting arm in the torsion bar spring with the angle that the adjusting bolt just can be screwed on the upper adjusting block. e. Tighten the adjusting bolt to the specified torque. Nut tightening limitation: A is about 30-35mm; if A> 35mm, then it is adjusted through height of adjusting arm. f. Install the wheel; remove the bracket; bounce the vehicle for several times to make the suspension enters into the stable status. g. Rotate the adjusting bolt and adjust the ground clearance of chassis (Refer to 4-Wheel Alignment). Lower suspension arm Removal of lower suspension arm 1. Disconnect the connecting rod of stabilizer bar from the lower arm a. Use the jack to support the lower arm. b. Remove the connecting nut; disconnect the connecting rod of sta bilizer bar form the lower arm. 2. Disconnect the vibration damper from the lower arm. 3. Disassembly of torsion bar spring (Refer to Section “Torsion Bar Spring”) special tools 5. Remove the front shaft of lower arm a. Make the mark on the adjusting cam. b.Remove the nut and front shaft of lower arm. 6. Remove the rear shaft of lower arm Screw off the nut; remove the rear shaft of lower arm shaft; remove the lower suspension arm. Replacement of lower suspension arm bush 1. Removal of short bush of lower suspension arm Use the special tools to press the short bush from the lower arm. special tools 2. Installation of short bush of lower suspension arm Use the special tools to press the new short bush in the lower arm. Remarks: Do not coat the bush with the grease. special tools 3. Removal of long bush of lower suspension arm Use the special tools to remove the long bush. special tools 4. Installation of longbushoflowersuspensionarmUse the special tools to install the new bush. Remarks: Do not coat the bush with the grease. special tools Installation of lower suspension arm 1. Installation of lower suspension arm a. Install the rear shaft of lower arm and tighten the nut to the specified torque. Tightening force: 290 25N m b. Install the front shaft of lower arm and screw on the nut temporarily. 2. Installation of front hub and steering knuckle assem bly (Refer to section “Front Hub and Steering Knuckle”) 3. Install the vibration damper on the lower suspension arm. Install the vibration damper on the lowersuspensionarmbracket. Tightening force: 90 10N m 4. Connect the stabi lizerbar to the lower suspension arm Tightening force: 63 5N m 5. Install the torsion bar spring (Refer to “Torsion Bar Spring”) 6. Tighten the nut of front shaft of lower arm to specified torque a. Install the wheel, remove the bracket and bounce the vehicle for several times to make the vibration damper enters into the stable status. b. Align the assembly mark and tighten the nut to specified torque. Tightening force: 240 20N m 7. Check the wheel alignment parameter (Refer to 4-Wheel Alignment) special tools Upper suspension arm Disassembly of upper suspension arm 1. Disconnect the upper ball pin from the steering knuckle Remove the split pin and nut; use the special tools to disconnect the upper ball pin from the steering knuckle. 2. Remove the brake oil pipe on the upper arm shaft a. Use the open-end wrench to screw off the oil pipe tight nut. b. Pull out the brake oil pipe and plug it by the rubber plug. Remarks: There are two two-way valves for rear brake oil pipe beside the right upper arm shaft ; when remove the right upper suspension arm, it must remove four oil pipe tight nuts in the place and plug it by the rubber plug to prevent the brake fluid from overflowing. 3. Disconnect the brake hose form the brake caliper Remove the hollow bolt and disconnect the brake hose form the brake caliper Remarks: Must not lose the copper gasket seal. 4. Disconnect the brake hose from the upper arm oil pipe bracket. Use the pliers to pull out the sheet steel spring clip and disconnect the brake hose from the upper arm oil pipe bracket. 5. Remove the upper suspension arm Remove two bolts and remove the upper suspension from the arm carriage. Remarks: Keep the adjusting shim and don’t lose it. Record the thickness of front and rear adjusting shim for convenience of reinstalling them in the original position. Replacement of upper arm bush 1. Remove the bush a. Remove the bolt and washer. b. Use the special tools to push out the bush. c. Remove the upper arm shaft; remove another bush in same procedure special tools 2. Install the bush a. Use the special tools to press in the bush. special tools b. Install the upper arm shaft; use the special tools to press inanother bush. special tools 3. Tighten the upper arm shaft to specified torque. a. Coat the screw of both ends of upper arm shaft with the screw lock sealant; install the washer and nut. Remarks: Adjust the position of upper lower; make the installation plane of ball pin is vertical to the installation plane of upper arm shaft. b. Tighten the upper arm shaft nut to specified torque. Tightening force: 210 10N m Installation of upper suspension arm 1. Install the upper suspension arm on the carriage a. Install the upper suspension arm and camber adjusting shim. b. Tighten all bolts to the specified torque. Tightening force: 200 10N m Remarks: Install the shim with same quantity and thickness to the original position. 2. Connect the brake oil pipe of upper arm shaft Tighten the oil pipe compression nut to specified torque. Tightening force: 15-17N m Remarks: It should tighten four connector of two two-way valves to the specified torque if disassemble the right upper arm. 3. Connect thebrakehosetotheupperarmoilpipebracket a. Thread the brake hose from the hole on upper arm oil pipe bracket. b. Use the hand hammer to knock in the sheet steel spring clip to fix the brake hose. 4. Connect the upper ball pin to the steering knuckle a. Tighten the slotted nut according to the specified torque. Tightening force: 145 15N m b. Install the new split pin. Remarks: It should align the notch of nut with the pinhole when install the split pin; the nut can be tightened but not loosed during the alignment. Connect the copper gasket seal and tighten the hollowbolttospecified torque. Tightening force: 50 5N m 6. Discharge the air in front brake system (refer to relevant chapter) Remarks: It must discharge the air in the rear brake system if disassemble the right upper arm. 7. Check the brake fluid for leakage 8. Tighten the upper arm front shaft nut to the specified torque Install the wheel, remove the bracket and bounce the vehicle for several times to make the vibration damper enters into the stable status. 9. Check the wheel alignment parameter (Refer to 4-Wheel Alignment) Stabilizer bar Disassembly of stabilizer bar 1. Disconnect the connecting bar which supports both ends of the stabilizer bar form the stabilizer bar. Use the inner hexagon spanner to fix the ball pin; remove the selflocking nut. 2. Remove the bush and clip of stabilizer bar; remove the stabilizer bar Installation of stabilizer bar 1. Install the stabilizer bar on the carriage Place the stabilizer bar in position; install the stabilizer bar bush and clip on the carriage. Screw on and pretighten the bolt. 2. Connect the stabilizer bar to the connecting bar Installand tighten the new nut to the specified torque Tightening force: 63 5N m 3. Tighten the clip position bolt to specified torque. Tightening force: 23 3N m Front hub and steering knuckle (4WD) stabilizer bar spring shim disc brake upper suspension arm flat shim drive shaft split pin connecting rod of stabilizer bar oil seal steering knuckle lock nut flat shim screw lower suspen- needle sion arm bearing lock washer split pin disk shim fill block Shim fill block lock washer disk shim shock absorber spring shim brake cover oil seal bearing flange bearing circlip hub and brake disc adjusting washer hub cap N m: specified torque Used component which can not be used any more. precoated component Front hub Disassembly of front hub 1. Remove the disc brake Remove the brake caliper and hang it by steel cable. Remarks: Do not remove the brake pipe and brake hose. 2. Remove the hub cap and flange a. Use the inner hexagon spanner to screw off the fastening blot and remove the hub cap. b. Use the pliers to remove the circlip and remove the adjusting washer. c. Remove the flange. 3. Remove the hub and brake disc a. Use the Philips screwdriver to screw off the tight screw; remove the lock washer. special tools b. Use the special tools to remove the lock nut. diagram of special tools c. Remove the hub and brake disc with the outer bearing. 4. Remove the oil seal and inner bearing a. Use the screwdriver to pry out the oil seal b. Remove the inner race of inner bearing form the hub. Check and repair of front hub 1. Check all bearings Wash the inner race and outer race of each bearing and check them for wear and damage. 2. Replace the bearing outer race a. Use the brass bar and hand hammer to knock out the bearing outer special tools race. diagram of special tools Use the special tools to knock in the new bearing outer race. Assembly of front hub 1. Coat the inner surface of hub and bearing outer race with the grease. grease The grease is the Jin HP-R grease or the grease met the requirement in following table. Item Dropping point, C Leakage amount (104 C, 6h), g EP performance OK value , N Typical data 2. Place in the bearing inner race; use the fill the gap between the inner and outer race of the bearing up with the HP-R grease. grease grease 3. Install the inner bearing and oil seal diagram of special tools a. Place the inner bearing in the hub b. Use the special tools to knock the new oil seal into the hub. special tools c. Coat the oil seal lip with HP-R grease. 4. Install the hub on the steering knuckle a. Install the hub on the steering knuckle b. Install the outer bearing. 5. Adjust the pre-applied load diagram of special tools a. Use the special tools to screw on the locknut to specified torque. Tightening force: 80-100N m b. Rotate the hub to right and left 1/3 1/4 round respectively. special tools c. Screw off the nut until the nut can be loosed by hand. d. Use the special tools to retighten the lock nut. Tightening force: 28N m e. Use the spring tension meter to check the pre-applied load. Pre-applied load (for starting): 28-56N 6. Install the lock washer Install the lock washer with the surface with counterbore outwardly and fix it on the lock nut by screw. Remarks: If the screw installation hole on the lock washer can not align with the screw hole on the lock nut, then it can remove the lock washer and adjust he lock nut slightly (rotate in the direction of Min. adjusting range ); then install the lock washer. 7. Recheck the pre-applied load Use the spring tension meter to recheck the pre-applied load Pre-applied load (for starting): 28-56N If the pre-applied load does not meet the specified value, it must remove the lock washer and adjust it by the adjusting nut. 8. Install the ring flange a. Install the ring flange on the hub. b. Install the adjusting washer. c. Install the circlip. 9. Install the hub cap a. Coat the screw of the inner hexagon bolt with the screw lock sealant. b. Use the inner hexagon bolt to fix the hub cap and ring flange on the hub; tighten the bolt to the specified torque. Tightening force: 78 5N m 10. Install the disc brake Install the disc brake on the steering knuckle; tighten the bolt to the specified torque. Tightening force: 140 10N m Steering knuckle Disassembly of steering knuckle 1. Remove the disc brake and front hub (Refer to section “Front Hub”) 2. Remove the brake cover 3. Disconnect the steering cross rod from the steering knuckle arm a. Remove the split pin and nut on the ball pin. b. Use the special tools to disconnect the steering cross rod from the steering knuckle arm. special tools 4. Disconnect the connecting rod of stabilizer bar from lower arm Use the inner hexagon spanner to fix the ball pin; remove the self-locking nut. 5. Remove the steering knuckle special a. Remove the split pin and nut on the upper ball pin tools b. Use the special tools to disconnect the upper ball pin from the steering knuckle. c. Remove the split pin and nut on the lower ball pin. d. Use the special tools to disconnect the upper ball pin from the steering knuckle. special tools e. Use the jack to raise the lower arm; remove the steering knuckle. Check and replacement of steering knuckle 1. Check of steering knuckle Use the dye penetrant to check the steering knuckle for crack. It should replace the steering knuckle if has crack. 2. Remove the steering knuckle oil seal Use the screwdriver to pry out the oil seal from the steering knuckle. 3. Take out the thrust plate 4. Remove the needle bearing Use the copper bar and hand hammer to knock out the needle bearing. 5. Installation of needle bearing special tools Use the special tools and hand hammer to knock in the new needle bearing slightly. Remarks: The thicker end of needle bearing should be upwardly when knock in. with thicker end. 6. Installation of thrust plate chamfer Coat the installation position of thrust plate of steering knuckle with the HP-R grease; place the thrust plate with the surface with chamfer facing the steering knuckle. Remarks: It must measure the thickness of the thrust plate steering knuckle before the installation; it should install the new thrust plate if the thickness is less than 1.5mm. The nominal thickness of the new thrust plate is 2mm. 7. Installation of steering knuckle oil seal Use the special tools and hand hammer to knock in the new special tools steering knuckle oil seal slightly. Installation of steering knuckle 1. Install the steering knuckle a. Coat the drive shaft and inner of drive shaft dustproof cove with the lithium base grease. b. Insert the drive shaft into the steering knuckle, meanwhile connect the lower ball pin to the steering knuckle and install the slotted nut temporarily. c. Press down the upper arm and connect the upper ball pin to the steering knuckle. Install and tighten the nut to the specified torque. Tightening force: 145 15N m d. Install the new split pin. Remarks: It should align the notch of nut with the pinhole when install the split pin; the nut can be tightened but not loosedduringthealignment. e. Install and tighten the lower ball pin nut to specified torque. Tightening force: 230 20N m f. Install the new split pin. Remarks: It should align the notch of nut with the pinhole when install the split pin; the nut can be tightened but not loosedduringthealignment. 2. Connect the stabilizer bar to the lower arm Support the lower arm by jack; use the inner hexagon spanner to fix the ball pin and tighten the self-locking nut to specified torque. Tightening force: 63 5N m 3. Connect the steering cross rod to the steering knuckle arm a. Tighten the slotted nut according to the specified torque. Tightening force: 170 15N m b. Install the new split pin. Remarks: It should align the notch of nut with the pinhole when install the split pin; the nut can be tightened but not loosedduringthealignment. 4. Install the brake cover Tightening force: 23 3N m 5. Install the front hub and disc brake (Refer to section “Front Hub”) Front suspension (4WD) shim upper arm shaft upper arm bush front stabilizer bar upper arm bush shim upper arm rubber sleeve clip upper ball pin flat shim lower arm long bush split pin connecting rod of stabilizer bar rear shaft of lower arm torsion bar flat shim Torsion base front shaft of lower arm lower arm short bush upper adjusting block fixed arm eccentric shim l ower arm lower adjusting block disk shim fill block fill block shim disk shim lower ball pin split pin shock Absorber front hub and steering knuckle assembly N m: specified torque Used component which can not be used any more. Pregummed component adjusting bolt Ball pin Check of ball pin 1. Check the lower ball pin for loose a. Raise the front of the car by jack and support it by the frame. b. Ensure the front wheel is in straight advancing position and step down the brake pedal. c. Move the arm upwardly and downwardly; check the clearance of lower ball pin. Max. vertical clearance: 0mm 2. Check the upper ball pin for loose move the wheel upwardly and downwardly and check the gap of upper ball pin. Max. vertical clearance: 0mm 3. Check the rotation of ball pin a. Remove the ball pin. b. Shown as figure, shake the ball pin stud forwardly and backwardly for several times before install the nut c. Rotate the nut continuously by torsion meter and 2-4s for a cycle; record the readout of torsion meter in the fifth cycle. Tightening torque (for rotary): Lower ball pin 0.1 4N m Upper ball pin 0.1 4N m Disassembly of ball pin 1. Remove the steering knuckle and front hub assembly (Refer to section “Front Hub and Steering Knuckle”) 2. Remove the lower ball pin form the lower arm 3. Remove the upper ball pin from the upper arm Installation of ball pin 1. Install the upper ball pin on the upper arm Tightening force: 78 5N m 2. Install the lower ball pin on the lower arm Tightening force: 140 10N m 3. Install the steering knuckle and front hub assembly (Refer to section “Front Hub and Steering Knuckle”) Torsion bar spring Disassembly of torsion bar spring 1. Make the assembly mark on the torsion bar spring, torsion base and adjusting arm 2. Measure the length A of extension section of bolt according to the length shown in figure. Remarks: The measuring value is for reference when adjust the ground clearance of chassis. 3. Loose the adjusting bolt until the torsion bar spring has not the tension. 4. Remove the fixed arm and torsion bar spring Installation of torsion bar spring Remarks: There are the L and R indication marks, which must not be exchanged on the rear end of the torsion bar spring. Mark L means the left while R for right 1. For reused torsion bar spring a. Cost the spline of torsion bar spring with grease thin. b. Align the assembly mark and install the torsion bar spring on the torsion bar. c. Align the assembly mark and install the adjusting arm on the torsion bar spring. d. Tighten the adjusting bolt and make the extension length of the bolt equal to the value before disassembly. 2. For new torsion bar spring a. Remove the wheel. b. Coat the spline of torsion bar spring with thin grease. c. Install the torsion bar spring on the torsion bar base. d. Lower the lower arm to the lower limitation position; install the adjusting arm in the torsion bar spring with the angle that the adjusting bolt just can be screwed on the upper adjusting block. Remarks: It can repeat for several times until proper when adjust the angle. e. Tighten the adjusting bolt to the specified torque. Nut tightening limitation: A is about 20-35mm; if A>35mm, then it is adjusted through height of adjusting arm. f. Install the wheel; remove the bracket; bounce the vehicle for several times to make the suspension enters into the stable status. g. Rotate the adjusting bolt and adjust the ground clearance of chassis (Refer to 4-Wheel Alignment). Lower suspension arm Disassembly of lower suspension arm 1.The disassembly of the front hub and steering knuckle assembly includes the removal of vibration damper, stabilizer bar and steering cross rod. (Refer to the section “Front Hub and SteeringKnuckle”) 2. Disassembly of torsion bar spring (Refer to section “Torsion Bar Spring”) 3. Remove the front shaft of lower arm a. Make the assembly mark on the adjusting cam b. Remove the nut and front shaft of lower arm. 4. Screw off the rear shaft of lower arm Screw off the nut; remove the rear shaft of lower arm shaft and remove the lower suspension arm. Replacement of bush of lower suspension arm 1. Remove the short bush of lower suspension arm Use the special tools to press out the short bush form the lower arm. special tools 2. Installation of short bush of lower suspension arm Use the special tools to press the new short bush into the lower arm Remarks: Do not coat the bush with the grease. special tools 3. Removal of long bush of lower suspension arm Use the special tools to remove the long bush. special tools 4. Install of long bush of lower suspension arm Use the special tools to install the new bush. Remarks: Do not coat the bush with the grease. special tools Installation of lower suspension arm 1. Installation of lower suspension arm a. Install the rear shaft of lower arm and tighten the screw to the specified torque. Tightening force: 290 25N m b. Install the front shaft of lower arm and pretighten the nut. 2. Installation of front hub and steering knuckle assembly (Refer to section “Front Hub andSteeringKnuckle”) 3. Install the vibration damper on the lower suspen sion arm Install the vibration damper on the lower suspension arm bracket. Tightening force: 90 10N m 4. Connect the stabi lizer barto the lower susp ension arm. Tightening force: 63 5N m 5. Connect the steering cross rod to the steering knuckle arm a. Connect the steering cross rod to the steering knuckle arm. Tightening force: 120 b. Install the new split pin. 10N m Remarks: It should align the notch of nut with the pinhole when install the split pin; the nut can be tightened but not loosed during the alignment. 6. Install the torsion bar spring (Refer to the section “Torsion Bar Spring”) 7. Tighten the nut of front shaft of lower arm to the specified torque a. Install the wheel, remove the bracket and bounce the vehicle for several times to make the vibration damper enters into the stable status. b. Align the assembly mark and tighten the nut to the specified torque. Tightening force: 240 20N m 8. Check the wheel alignment parameter (Refer to 4-Wheel Alignment) special tools Upper suspension arm Disassembly of upper suspension arm 1. Disconnect the upper ball pin form the steering knuckleRemove the split pin and nut; use the special tools to disconnect the upper ball pin from the steering knuckle. 2. Remove the brake oil pipe on the upper arm shaft a. Use the open-end wrench to screw off the oil pipe tight nut. b. Pull out the brake oil pipe and plug it by the rubber plug. Remarks: There are two two-way valves for rear brake oil pipe beside the right upper arm shaft ; when remove the right upper suspension arm, it must remove four oil pipe tight nuts in the place and plug it by the rubber plug to prevent the brake fluid from overflowing. 3. Disconnect the brake hose form the brake caliper Remove the hollow bolt and disconnect the brake hose form the brake caliper Remarks: Must not lose the copper gasket seal. 4. Disconnect the brake hose from the upper arm oil pipe bracket. Use the pliers to pull out the sheet steel spring clip and disconnect the brake hose from the upper arm oil pipe bracket. 5. Remove the upper suspension armRemove two bolts and remove the upper suspension from the armcarriage. Remarks: Keep the adjusting shim and don’t lose it. Record the thickness of front and rear adjusting shim for convenience of reinstalling them in the original position. Replacement of upper arm bush 1. Remove the bush a. Remove the bolt and washer. b. Use the special tools to push out the bush. c. Remove the upper arm shaft; remove another bush in same procedure. special 2. Install the bush a. Use the special tools to press in the bush. special b. Install the upper arm shaft; use the special tools to press in another bush. special 3. Tighten the upper arm shaft to specified torque. a. Coat the screw of both ends of upper arm shaft with the screw lock sealant; install the washer and nut. Remarks: Adjust the position of upper lower; make the installation plane of ball pin is vertical to the installation plane of upper arm shaft. b. Tighten the upper arm shaft nut to specified torque. Tightening force: 210 10N m Installation of upper suspension arm 1. Install the upper suspension arm on the carriage a. Install the upper suspension arm and camber adjusting shim. b. Tighten all bolts to the specified torque. Tightening force: 200 10N m Remarks: Install the shim with same quantity and thickness to the original position. 2. Connect the brake oil pipe of upper arm shaft Tighten the oil pipe compression nut to specified torque. Tightening force: 15-17N m Remarks: It should tighten four connectors of two two-way valves to the specified torque if disassemble the right upper arm. 3. Connect the brake hose to the upper arm oil pipe bracket a. Thread the brake hose through the hole on upper arm oil pipe bracket. b. Insert the sheet steel spring clip by the hammer to fix the brake hose. 4. Connect the upper ball pin to the steering knuckle. a. Tighten the slotted nut according to the specified torque. Tightening force: 145 15N m b. Install the new split pin. Remarks: It should align the notch of nut with the pinhole when install the split pin; the nut can be tightened but not loosed during the alignment. 5. Connect the brake hose to the brake caliper. Install the copper gasket seal and tighten the hollow bolt to the specified torque. Tightening force: 50±5N·m 6. Discharge the air in front brake system (Refer to relevant chapter) Remarks: It must discharge the air in the rear brake system if disassembly the right upper arm. 7. Check the brake fluid for leakage 8. Tighten the upper arm front shaft nut to the specified torque a. Install the wheel, remove the bracket and bounce the vehicle for several times to make the vibration damper enters into the stable status. b.Align the assembly mark and tighten the nut to the specified torque. Tightening force: 240±20N·m 9. Check the wheel alignment parameter (Refer to 4-Wheel Alignment) Stabilizer bar Disassembly of stabilizer bar 1. Disconnect the connecting bar which supports both ends of the stabilizer bar form the stabilizer bar. Use the inner hexagon spanner to fix the ball pin; remove the selflocking nut. 2. Remove the bush and clip of stabilizer bar; remove the stabilizer bar Installation of stabilizer bar 1. Install the stabilizer bar on the carriage Place the stabilizer bar in position; install the stabilizer bar bush and clip on the carriage. Align the mark on the stabilizer bar to keep the left and right gap of stabilizer bar are same. Then install the bolt temporarily and pretighten it. 2. Connect the stabilizer bar to the connecting rod. Install and tighten the new nut to the specified torque. Tightening force: 63 5N m 3. Tighten the clip position bolt to specified torque. Tightening force: 23 2N m Constant-speed drive shaft assembly Installation and disassembly drawing of front drive shaft assembly on front drive axle constant-speed drive shaft assembly hanger plank R universal-joint bearing circlip front reducer and electric clutch assembly circlip Power plug of electric clutch circlip universal-joint bearing universal-joint oil seal hanger plank L lower segment of vent tube of front drive axle circlip constant-speed drive shaft N m: specified torque Pregummed component N m: specified torque 1. Place the car in the middle of repair platform or trench, support the front of the car steadily(support on the carriage) then remove the left and right front wheel. (make the car in 2WD status before the disassembly) 2. Remove the beam on the lower of front drive axle assembly. 3. Disconnect the connection of front drive axle flange and drive shaft and make the assembly mark 4. Drain the lubrication oil in reducer. adjusting washer set circlip bolt flange front hub cover disconnect three ports in this position 9. Use the wrench to screw off the bolt which fixes the lower segment assembly of front drive axle vent tube on the vent tube bracket. wrench 10. Support the front drive axle by the jack; screw off the lifting bolt of hanger plank and carriage. supporting position 11. Remove the complete drive axle. 12. Screw off the connecting bolt of hanger plank and front drive axle assembly. 13. Pull out the left and right front drive shaft assembly with the oil seal, hanger plank and bearing. circlip pliers se the circlip pliers to remove the outside circlip of bearing. 15. Use the special tools pull out the bearing. support the lower end 16. Use the circlip pliers to remove the circlip on another side of bearing. Caution: During the disassembly, support the lower end of hold drive shaft and prevent the drive shaft from sliding out from special tools the inner jacket, meanwhile, it could not damage the inner and outer jacket. shim support the lower end Constant-speed drive shaft assembly inner trumpet connector circlip inner jacket three-pin section assembly large clip of inner jacket small clip of outer jacket small clip of inner jacket outer jacket large clip of outer jacket outer trumpet connector dustproof cover Disassembly of constant-speed drive shaft assembly 1. Check the front drive shaft assembly a. Check the inner trumpet connector; it could slide in axial direction smoothly. b. Check the universal-joint position; it should be without the clear clearance in radius direction. c. Check the inner and outer jacket for damage. Caution: It should use the pad when clamp the front drive shaft to avoid the damage of it. 2. Remove the large clip of inner jacket Caution: Do not damage the inner and outer jacket pliers a. Make the assembly mark on the inner trumpet connector and assembly mark three-pin section assembly. Caution: remove the grease in the connector before make the mark and don’t make the mark by the hard object such as punch. b. Remove the inner trumpet connector. 4. Disassembly of three-pin section assembly a. Use the circlip pliers to remove the circlip. b. Use the adz and hand hammer to make the assembly mark on the shaft and three-pin section assembly. assembly mark c. Use the cooper bar and hand hammer to remove the three-pin section. Caution: Remove the cooper chip on the shaft or three-pin section assembly if has. 5. Remove the inner jacket a. Use the pliers to disassemble the small clip of inner jacket. b. Pull out the inner jacket. Caution: Remove the grease in the jacket and maintain the clean field. 6. Use the straight screwdriver to disassemble the large and small clip of outer jacket. 7. Remove the outer jacket Caution: Clean the protective jacket and remove the grease on the outer trumpet connector. Do not disassemble the outer trumpet connector. 8. Use the screwdriver and hand hammer to remove the dustproof cover. Assembly of constant-speed drive shaft assembly 1. Use the hand hammer and screwdriver to install the dustproof cover Caution: The dustproof cover should be replaces when itisdeformed heavily. 2. Install the large clip of outer jacket, outer jacket and small clip of outer jacket. Caution: The outer jacket should be replaced when it is damaged or aged heavily and warp the end of the shaft with the plastic band and coat with small grease before insert it. 3. Insert the small clip of inner jacket, inner jacket and large clip of inner jacket. Caution: The inner jacket should be replaced when it is damaged or aged heavily. 4. Install the three-pin section assembly on the front with chamfer drive shaft. a.Let the end of three-pin section assembly with chamfer faces the shaft inner direction. Caution: The three-pin section assembly should be replaced if its needle bearing position is damaged. b.Align the assembly mark made before disassembly. c. Use the hand hammer and copper bar to install the three-pin sec tion assembly to the front drive shaft. d.Use the circlip pliers to install the new circlip. 5 Install the outer jacket on the outertrump etconn ector. Fill the jacket with the grease supplied with the jacket before install the jacket. (Recommend used grease is CAPLEX or KY1) Grease using amount: About 110g 6 Install the inner trumpet connector on the front drive shaft a. Fill the inner trumpet connector and inner jacket with the grease supplied with the jacket (Recommend used grease is CAPLEX or KY1). Amount About140g b. Align the assembly mark made during disassembly; covered with inner trumpet connector. assembly mark c. Cover the inner jacket on the inner trumpet connector. 7 outer jacket clip Use the inner and outer jacket clip pliers to clamp the inner and outer jacket. inner jacket clip non-ear clip pliers a. Use the special non-ear clip pliers to lock the large clip of inner jacket. b. Use the nutcracker to lock the small clip of inner jacket. Caution: Ensure the large and small connecting place of jacket is in the corresponding groove of trumpet connector and shaft. nutcracker c.Use the special pneumatic pliers to lock the large and small clip of special tools outer jacket. d.Ensure the jacket of both sides does not be prolonged or shortened when the front drive shaft has the standard length. Standard length: 400.5mm If only need to replace the outer components of front drive shaft assembly on car, it can remove the left and right steering knuckle of car, then disconnect the inner trumpet connector of front drive shaft assembly, then take out the threepin section assembly and shaft from the inner trumpet connector for replacement. Installation of constant-speed drive shaft assembly on front drive axle circlip pliers 1. Insert the hanger plank into the drive shaft, inserted with oil seal; use the circlip pliers to install the inner circlip. Caution: It should replace the oil seal if damaged. support the lower end Use the special tools to knock bearing in slightly. Caution: Support the lower end of the drive shaft assembly special tools when knock the bearing in. The lower end must not slide out. 3. Use the circlip pliers to install the outer circlip on the front drive shaft assembly. 4. Repeat the previous method to install the hanger plank, oil seal, circlip, bearing and circlip on another support the lower end end. 5. Insert the spline of connecting end of drive shaft and reducer into the differential halfaxle gear spline hole of electric clutch and reducer slowly. 6. Drip 1-2 drop of screw lock agent on the middle of screw of connecting bolt of hanger plank andreducer. 7. Use the wrench to tighten the connecting bolt of hanger plank and drive axle to specified torque. specified torque : 90-110N m Caution: It should screw on all bolts before tighten them, then tighten them in diagonal direction. Check the hanger plank for levelness after tightened the bolt to the specified torque. Remove the hanger plank and reinstall it if is not planished. 8. Install the vent tube connector assembly; connect all ports to front drive axle. (Refer to “Assembly of Front Reducer Assembly”) Specified torque : 200-220N m Caution: Drip 1-2 drop of screw lock agent on the middle front part of the lifting bolt 10 Use the bolt to connect the front drive axle flange and drive shaft according to the mark mage before disassembly and tighten it to the specified torque. specified torque: 73-83N.m 11. Install the beam under the front drive axle. Tighten the beam connecting bolt to the specified torque. specified torque: 73-83N.m Replacement of drive gear oil seal of front reducer assembly front reducer assembly washer bearing spacer drive oil seal bevel gear front reducer drive gear flange, N m: specified torque Used component which can not be used any more. main gear flange and dustproof cover assembly 1. Support the front of car; remove the left and right assembly mark front wheel and the beam under the reducer. 2. Drain the lubricant oil in the front reducer; remove the left and right steering knuckle 3. Disconnect the front reducer assembly flange from the drive shaft and use the jack to remove the front drive axle Caution: Make the assembly mark on the reducer and drive shaft before separate them. 4. Remove the front differential assembly (Caution: Drain the oil in front differential before the disassembly) 5. Remove the drive gear flange and dustproof cover assembly a. Use the hand hammer and chisel to loose the riveted part on nut. special b. Use the special tools to clamp the drive gear flangeandremove the drive gear nut. c. Use the cooper bar to knock down the drive gear flange and dustproof cover assembly. 6. Remove the drive gear oil seal Use the special tools to remove the oil seal; do not damage the inner wall of reducer housing. special rotate the wrench in clockwise. 7. Install the new drive gear oil seal special a. Use the special tools to knock into the new oil seal. b. The top of the oil seal is level to the top of reducer housing. Caution: Coat the oil seal lip with the lithium base grease and the oil seal should be in correct position. 8 Install the drive gear flange and dustproof cover assembly a. Match the drive gear flange and dustproof cover assembly on the front drive gear. b. Coat the new nut with the lithium base grease. c. Use the special tools to clamp the flange and tighten the nut to the specified torque. Tighten torque:140-160N.m 9 Adjust the pre-applied load of the drive bevelgear bearing a. Use the torque meter to measure the pre-applied load of the gap between the drive bevel gear and driven bevel gear. pre-applied load: 1.2-1.7N.m b. Is should be replaced by the thicker washer if the pre-ap plied load is more than specified value (The step of thickness of washer is 0.03mm) c. Is should be replaced by the thinner washer if the pre-applied load is less than specified value. Repeat the previous operation until meet the requirement. Caution: Do not reduce the load by loosing the nut. 10. Check the axial and radial run-out tolerance offlange. a. Use the dial indicator to measure the axial runout of flange. Max. axial runout: 0.1mm b. The max. radial run-out tolerance is 0.1mm It should check the bearing if the radial run-out tolerance is large. 11 Rivet the drive gear nut after meet the previ- ous requirements. 12 Install the reducer assembly on the front drive axle assembly and assemble the front drive shaft assembly (refer to Assembly of Front Reducer Assembly and Assembly of Front Drive Shaft Assembly) 13 Install the oil drain plug; screw off the oil filling plug and filled with the hypoid gear oil. Tightening force of oil drain plug: 30-35N m Model of lubrication oil: GL-5 Filling amount: Flush to the lower edge of oil filling open 14 Insert the oil filling plug washer and tighten the oil filling plug to the specified torque. Specified torque : 140-150N m 15 Install the front drive axle assembly on the carriage. 16 Connect the drive shaft to the flange a. Align the assembly mark; use four bolts and nuts to connect the flange of drive shaft and front drive axle. b.Tighten the nut to the specified torque. specified torque: Remarks: Keep the clean of the field during the maintenance. Front reducer assembly front drive shaft assembly hanger plank oil seal bearing R front vibration damper front vibration damper circlip front reducer electric clutch assembly circlip Power plug of electric clutch circlip bearing oil seal front vibration damper front vibration damper front drive axle vent tube connector assembly hanger plank L circlip front drive shaft assembly N m: specified trque Pregummed component 1. Support the front of the car; remove two front assembly mark wheels and the beam under the front reducer assembly. 2. Drain the lubrication oil in the front reducer assembly. 3. Remove the flange of front reducer assembly from the drive shaft Caution: Make the assembly mark on the flange of front reducer assembly and drive shaft before disconnect them. 4. Disconnect the connector of power wire of electric clutch disconnect three connectors in this place 5. Disconnect three rubber connectors on the front drive axle vent tube connector assembly. 6. Use the wrench to screw off the bolt on the vent tube bracket, which is used to fix the vent tube connector. 7. Disconnect the connection between the front drive shaft assembly and steering knuckle front hub assembly. a. Screw off the connecting bolt which is used to fix the front hub cover; remove the front hub cover. b. Use the circlip pliers to remove the circlip from the front drive shaft and remove the adjusting washer. c. Remove the steering knuckle of both sides and separate it form the front drive shaft assembly. electric clutch connector N m: specified torque 8. Use the jack to support the front reducer assembly 9. Remove the lifting bolt of front drive axle hanger plank and carriage. 10. Remove the front drive axle assembly Caution: Do not damage the drive shaft and front drive shaft jacket 11. Remove the front drive shaft assembly of both sides from the front drive axle assembly. 12. Use the wrench to remove the bolt and nut which is used to fix the front reducer housing. 13. Remove the clump weight assembly and clump weight bracket welded assembly (Refer to “Disassembly of Front Reducer Assembly”) Replacement of oil seal and major semiaxle oil seal of front reducer assembly Replacement of front reducer assembly oil seal 1. Remove the front drive axle assembly (Refer to “Removal of Front Reducer Assembly”) 2. Remove the left and right front drive shaft assembly from the front drive axle assembly. 3. Remove and replace the lower oil seal according to the removal and installation procedure of front drive shaft assembly and install the new side oil seal on the front drive shaft, then install them in the front reducer assembly. (Refer to “Removal and Installation of Front Drive Shaft Assembly”) major semiaxle oil seal circlip major semiaxle pressing assembly mechanical wheel of separator N m: Specified torque Pregummed component Replacement of major semiaxle oil seal 1. Make the electric clutch is in the 4WD status, them stop the engine and remove the front drive axle assembly (see the disassembly of front reducer assembly) 2. Use the wrench to screw off the bolt which fix the front axle vent tube connectorassemblyonventtubeb racket bolt disconnect the place 3. Disconnect the connector between vent tube of electric clutch housing and front drive axle vent tube connector assembly 4. Disconnect the connector between the vent tubes on the electric clutch and vent tube connector assembly. 5. Remove the bolt which is used to fix the electric clutch housing and front axle tube flange; use the brass bar to open the electric clutch housing and take disconnect the place out the mechanical wheel of separator. Caution: The lubrication oil will flow out when separate the electric clutch housing from the front axle flange. It should use the container to hold it. mechanical wheel of separator 6 circlip Use the circlip pliers to remove the circlip which clamp the major semiaxle bearing outer race. circlip pliers liftout bolt Pad bolt pin special tools 7 Use the special tools to remove the major semiaxle and bearing, circlip assembly. 8. Use the special tools to remove the major semiaxle oil seal. Caution: Do not scratch the inner surface of flange. special tools 9. Remove the sealant on the matching surface between the flange and electric clutch housing by knife. Caution: Do not scratch the matching surface. 10. Use the special tools to knock the new seal in the oil seal position in flange. Caution: Before install the new oil seal, it should coat the lip with thin lithium base grease, and the oil seal should be in alignment position. 11. Insert the spline of small end of major semiaxle in the spline of front reducer half axle gear slightly, then use the brass bar and hand hammer to knock it in. Caution: When knock in the major semiaxle, must not damage the inside needle bearing of large end spline of major semiaxle. 12. Use the circlip pliers to install the circlip in the flange and clamp the bearing outer race. Caution: The circlip should be replaced if it has serious deformation. 13. Use the clean cloth to wipe the matching surface of flange and electric clutch housing respectively. 14. Align the spline of mechanical wheel of separator with the spline in front drive shaft and separator shift fork sleeve, and install it in the front drive shaft and separator shift fork sleeve. 15. Coat the flange matching surface with the 1596 silicon rubber plane sealant uniformly and level it by plate. Caution: Ensure the continuity of sealant and avoid the sealant enter into the screw hole. 16. Align the shift fork bush with the spline on the major semiaxle to make the mechanical wheel of separator enters into the major semiaxle, then use the bolt to connect the electric clutch housing and front axle pipe flange and tighten it to the specified torque. In which the bolt should be precoated with the screw locking agent (drip one or two drops on the middle of screw). specified torque : 90-110N m Caution: Prevent the foreign material from entering into the front drive axle during assembly. 17. Use the wrench to tighten the bolt of vent tube bracket to tightening torque. Tightening force: 23-26N m 18. Screw off the oil filling plug on the electric clutch housing, remove the washer and fill it with the gear lubrication oil until flush with the bottom of oil filling port. Number of lubrication oil: GL-5 19. Place the washer of oil filling plug, tighten the oil filling plug to specified torque. Specified torque: 140-150N.m 20. Connect the vent tube on the electric clutch connect the place housing to the front axle vent tube connector assembly. 21. Connect the electric clutch vent tube to the front axle vent tube connector assembly. connect the place Disassembly and assembly of front reducer assembly and electric clutch adjusting shim bearing bearing gland differential housing half axle gear thrust plate half axle gear planetary gear shaft driven bevel gear planetary gear clump weight and bush assembly bolt clump weight bracket front drive axle housing washer clump weight bracket welded assembly oil filling plug vent tube needle bearing location pin front drive gear flange and dustproof cover assembly electric clutch circlip oil seal major semiaxle small bearing major semiaxle oil seal drive bevel gear front axle vents tube connector assembly adjusting washer front reducer housing spacer clip circlip mechanical wheel of separator big bearing declutch shift sleeve adjusting washer electric clutch housing drive bevel gear oil filling plug vent tube N m: Specified torque Pregummed component Used component which can not be used any more. disconnected in disconnected in this place this place Disassembly of front reducer assembly 1. Remove the front drive axle and left and right front drive shaft assembly. (Refer to “Removal of Front Reducer Assembly” and “Removal of Front Drive Shaft Assembly”) 2. Disconnect three interface positions of front drive axle vent tube connector assembly. disconnected in this place 3. Use the flat screwdriver to pry off the clip fixed the vent tube connector assembly and take out the vent tube connector assembly. 4. Screw off the bolt fixed the electric clutch and use the brass bar to knock down the electric clutch. 5. Use the wrench to remove the oil filling plug; remove the washer and pull out the vent tube. 6. Use the wrench to remove the bolt connected to the electric clutch housing and front axle tubeflange; take out the shift fork sleeve and mechanical wheel of separator. Caution: The leaked gear oil during disassembly should be stored in the container to avoid the pollution for environment. 7. Use the circlip pliers to remove the circlip fixed the major semiaxle bearing outer race. 8. Use the special tools to pull out the major semiaxle and major semiaxle bearing with the major semiaxle inner race circlip. (Refer to “Replacement of Major Semiaxle Oil Seal”) 9. Use the special tools to remove the major semiaxle oil seal. (Refer to “Replacement of Major Semiaxle Oil Seal”) 10. Pull out the vent tube on the front axle tube. 11. Use the circlip pliers to remove the circlip. Fasten the major semiaxle bearing inner race. 12. Press out the major semiaxle bearing on press machine. (Or knocked out by hand hammer) Caution: Don’t damage the end spline of major semiaxle. special tools 13. Use the special tools to pull out the needle bearing in major semiaxle. Caution: It should use the pad when use the vise to clamp the major semiaxle. 14. Use the wrench to remove the bolt which is used to fix the clump weight and axle bush assembly, take off the clump weight and axle bush assembly. 15. Use the wrench to remove the bolt fixed the clump weight bracket welded assembly. 16. Use the wrench to remove the bolt and nut used to fix the front reducer assembly and front axle housing. 17. Use the brass rod or hand hammer to knock the front reducer housing to separate it from the front drive axle housing. 18. Check the run-out of driven bevel gear. Rotate the flange; use the dial indicator to measure the run-out of driven bel gear. Max. Runout: 0.07mm It should replace the drive and driven bevel gear totally if the runout is more than 0.07mm. 19 Check the running clearance of drive and driven bevel gear. a. Install the dial indicator and ensure the side axis is vertical to contact tooth surface. b. Hold the drive gear flange and rotate the driven bevel gear in clockwise and anticlockwise to measure the clearance. Specified range of clearance: 0.15-0.25mm Remarks: Check three average points on circumference of driven bevel gear at least. 20. Check the engaging mark of drive and driven bevel gear. (Refer to “Assembly of Front Reducer Assembly”) 21. Measure the pre-applied load of drive bevel gear bearing. Use the torque measuring meter to measure the preapplied load on the gap between the drive and drivenbevel gear. Range of pre-applied load: 1.2-1.7N.m 22. Measure the total pre-applied load of drive bevel gear. 23 Remove the drive gear flange and dustproof cover assembly. a. Use the hand hammer and chisel to loose the riveted part of drive gear nut. b. Use the special tools to clamp the drive gear flange and remove the drive gear nut. c. Use the brass rod to knock down the drive gear flange and dustproof cover assembly. 24. Use the special tools to remove the drive gear oil seal. holding special tools pliers rotate the wrench in clockwise 25. Use the special tools to remove the small bearing inner race, and then reverse the reducer to slide out the spacer. Remarks: The bearing should be replaced by new one if damaged. 26. Use the wrench to remove two bearing glands. Remarks: It should distinguish the left and right of the bearing gland when remove it to avoid the confusion. 27. Use the brass rod to vibrate the differential assembly upwardly, then take out the differential assembly. Remove the side bearing outer race and marked with L and R. 29. Remove the left and right adjusting washer; measure its thickness; marked with left and right. 30. Remove the drive bevel gear, then take out the adjusting washer under spacer. Check and replacement of reducer 1. Replace the big bearing of drive bevel gear . a. Use the special tools to press out the big bearing of drive bevel gear. special Caution: It should replace the drive and driven bevel gear in pair before replace the big bearing if the drive bevel gear is damaged. b. Install the washer on the drive bevel gear, Use the special tools to install the new big bearing . special 2. Replace the big bearing outer race of drive bevel gear. a. Use the brass bar and hand hammer to knock down the big bearing outer race. special b. Use the special tools to press in the new big bearingouter race. Special tools 3. Replace the small bearing of drive bevel gear. a. Use the brass rod and hand hammer to knock down the small bearing outer race of drive bevel gear. b. Use the special tools to press in the new bearing outer race. c. Replace it by the new bearing inner race when installs the special tools small bearing.. 4 Remove two side bearing inner races from the differential housing. a Use the special tools to remove the side bearing inner race on the side of differential assembly with bolt. b. It should pay attention to does not damage the driven bevel gear when use the vice for clamping to remove the bearing inner race on another side. rubber pad 5. Use the wrench to remove the bolt fastened the driven bevel gear Caution: It should make the assembly mark on the driven bevel gear and differential housing before disassembly. assembly mark rubber pad 6 special tools Disassembly of differential assembly a. Use the hand hammer and special tools to knock out the pin after remove the driven bevel gear. b. Knock out the planetary gear shaft, rotate the half axle gear to take out the planetary gear, then take out the half axle gear and thrust plate. 7. Assembly of differential assembly. a. Wash the differential housing. b. Cover the half axle gear thrust plate with the half axle gear, then installs it in the differential housing. c. Rotate the half axle gear; install the planetary gear in rolling and insert the planetary gear shaft. d. Use the special tools to hit the pin to fix the planetary gear shaft, and rivet the inserted hole to prevent the loose of pin. Remarks: The rotation of half axle gear and planetary gear should be smooth and without block; push the planetary gear to inside, then use the dial indicator to measure the clearance between the half axle gear thrust plate and differential housing. Rational clearance range: 0.4-0.75mm It is necessary to replace the half axle gear thrust plate if the clearance is beyond the previous range, at the same time ensure the special tools thrust plate in left and right side has the same thickness. e. Check the clearance between the half axle gear thrust plate and differential housing. f. Clean the surface of differential housing; use the brass rod to install the driven bevel gear on the differential housing. Caution: It should align the marked assembly mark when install the driven bevel gear and knock it in uniformly in circumference ; it should remove the cooper chip in time if it is adhered on the driven bevel gear. g. Coat the fastening bolt of driven bevel gear with the screw lock agent, then tighten it to the specified torque. Specified tightening force: 80-95N m Caution: It should be in the diagonal sequence to tighten the bolt and tighten it for little, then tighten it to the specified torque uniformly. h. On press machine, use the special tools to press the inner special tools race of bearing into the bearing position on both sides of differential housing. special tools bearing bearing adjusting shim adjusting shim i. Place an adjusting shim in the position of front reducer housing side bearing near exterior. j. Install another adjusting shim and the other side bearing outer race in the front reducer housing with thedifferentialassembly k. Install two bearing glands, left and right and use the wrench to tighten the bolt to the specified torque. Specified torque : 90-115N.m 1.Rotate the driven bevel gear, check the runout of driven bevel gear. Max. Runout: 0.07mm Assembly of front reducer assembly 1.Install the adjusting washer in the drive bevel gear, install the big bearing inner race of drive bevel gear by press. 2. Clean the front reducer housing, install the outer race of big and small bearing on the reducer housing by press.. 3. Install the drive bevel gear into the front reducer housing, then install the washer, spacer and small special tools bearing inner race. 4.Use the special tools to install the drive bevel gear oil seal. Caution: It should coat the lip with the oil seal lithium base grease before install it and the rear surface of rear oil seal should flush with the top of front reducer housing after knocked in. 5. Install the drive gear flange and dustproof cover assembly. (Refer to “Replacement of Drive Bevel Gear Oil Seal”) 6.Use the special tools to tighten the drive gear nut to the specified torque; the nut should be precoated with the lithium base grease. specified torque : 140-200N m 7. Use the torque measuring meter to measure the pre-applied load of big and small bearing of drive bevel gear. Range of pre-applied load: 1.2-1.7N m 8. Place the differential assembly on the corresponding position of front reducer housing. 9.Select an adjusting shim and insert it in a side of side bearing outer race; push the differential assembly to the side with adjusting shim. 10. Use the dial indicator to measure the gear side clearance of driven bevel gear and drive bevel gear; select out the adjusting shim in the side which meets the rational clearance of 0.15mm. 11.Measure the thickness of the adjusting shim. 12. After select out one side adjusting shim, then select theadjusting of another side according to that the theoreticthickness of the adjusting shimofanother side equals to subtracting the thickness of selected shim and oppositiondistance L2 between outer race of two side bearings of differential assembly from the opposition distance L1 between two side bearings of front reducer housing. 13. Place an adjusting shim in the position of front reducer housing side bearing and close to exterior. 14. Install the other adjusting shim and the bearing outer race of another side with the differential assembly into the front reducer housing. Remarks: Ensure the selected adjusting shim has not gap with front reducer housing. 15. Rotate the driven bevel gear to make the differential assembly closed to the front reducer housing. 16. Use the dial indicator to measure the tooth side gap between the drive and driven bevel gear. The rational range of gap is: 0.15-0.25mm. If the measured gap is beyond the range, then adjust it by adding or reducing the thickness of shim. ( When add in one side, the other side should be reduced with same thickness) Caution: Ensure the selected adjusting shim is without clearance form front reducer housing. 17. Adjust the pre-applled axial load of side bearing. a. Remove two adjusting shim, remeasure the thickness of two adjusting shims. b. Install the new adjusting shim with thickness 0.06-0.09mm more than that of removed adjusting shim, then install it with the differential in the reducer housing. c. Remeasure the tooth side clearance between the drive bevel gear and driven bevel gear. Rational range of clearance: 0.15-0.25mm Remarks: If the measured gap is beyond the range, then adjust it by adding or reducing the thickness of shim. ( When add in one side, the other side should be reduced with same thickness) Caution: Ensure the selected adjusting shim has not the clearance with the front reducer housing. 18. Install the bearing gland of both sides and use the wrench to tighten it to the specified torque. specified torque : 90-115N m Remarks: Distinguish the left and right during assembly. 19. Use the torque measuring meter to measure the total pre-applied load of front reducer. specified torque : 1.8-2.4N m 20. Check the meshing mark of drive and driven bevel gear. a. Paint 3-4 teeth with the red lead in three different positions of driven bevel gear. b. Hold the flange of drive gear; rotate the driven bevel gear in clockwise and anticlockwise. c. Check the contacting condition of gear tooth.If the meshing mark of drive and driven bevel gear does not consist with thatshown in figure, it should select the proper adjusting washer for modification according to the detailed form of meshing mark. convex of driven concave of driven bevel large end contact toe contact select the adjusting washer which can make the drive gear close to the driven bevel gear small end contact dedendum contact sound contact select the adjusting washer which can make the drive gear away form the driven bevel gear r d. Remove the drive bevel gear and use the special toolsto remove the large bearing of drive bevel gear beforereplacethe adjusting washer. e. Insert the new adjusting washer and usethespecial tools to press in the large bearing of drivebevel gear. f. Place the adjusting washer above the large bearing on the drive bevel gear, install the spacer in the reducer housing; install the drive gear flange andtighten the nut to the specified torque. g. Remeasure the pre-applied load of drive gear bearing clearance and the total pre-applied load of reducer; ensure it meets the requirement. 21. Use the dial indicator to measure the axial and radial run-out tolerance of . Drive bevel gear flange. Max. Axial runout : 0.1mm Max. Radial run-out tolerance: 0.1mm Remarks: It should check the big and small bearing of drive bevel gear when the runout is more than 0.1mm. 22. Rivet the nut of drive bevel gear. 23. Use the bolt coated with screw lock agent toconnect the clump weight bracket welded assembly to the front reducer housing and tighten it to the specified torque. Specified torque : 20-26N m 24.Use the bolt coated with screw lock agent to connect the clump weight assembly to the clump weight bracket assembly and tighten it to the specified torque. Specified torque : 20-26N m The amount of screw lock agent could cover the screw. 25.Use the pneumaticto screw two studs on the correspon ding screw hole on the front axle housing until the limitation. (It should coat the screw of the stud which is screwed in the front axle housing with the screw lock agent, and the amount should be just can cover the screw which is screw in the front axle housing) Caution: The position of stud should consist with that before disassembly. 26. Coat the plane of front axle housing with the continuous 1596 silicon rubber plane sealant, scrape it to level by plate. Caution: Avoid the screw hole when paint the sealant; prevent the sealant enters into the screw hole. 27. Install the front reducer assembly on the front drive axle housing and screw on the hexagon bolt and spring washer combination; cap the spring washer on the stud, tighten the nut to the specified torque. (The screw of all bolts should be precoated with screw lock agent) The specified tightening force of hexagon bolt and spring washer combination, stud and nut should be: 18-25N m Caution: The bolt should be tightened in diagonal sequence evenly; check the reducer housing and axle housing contacting surface for gap; check the sealant from break. It should remove the reducer for reinstallation if has the gap or break. 28. Screw the oil filling plug with washer on the front drive axle. Caution: Do not tighten it. 29. Screw the oil drain plug on the front drive axle. Specified torque : 30-35N m 30. Use the special tools to install the major semiaxle oil seal in the front axle tube. Caution: Precoat the lip of oil seal with thin lithium base grease and the oil seal should be installed in position. 31.Use the special tools to install the needle bearing in the major semiaxle. special tools 32.Use the special tools to install the major semiaxle special tools bearing by press.. 33. Use the circlip pliers to install the circlip to clamp the bearing inner race of major semiaxle. special tools 34.Insert the spline on small end of major semiaxle into the spline of front reducer half axle gear; use the brass rod and hand hammer to knock the major semiaxle into the front reducer. Caution: Does not damage the inside needle bearing. On spline of large end of major semiaxle when knock in the major semiaxle. 35.Use the circlip pliers to install the circlip in the flange and clamp the major semiaxle bearing outer race. 36. Push the mechanical wheel of separator into theneedle bearing inner race in major semiaxle until can not move. 37. Detect the electric clutch assembly . electric clutch detector a. Measure the clearance between the shift fork and shift fork sleeve. Range of clearance : 0.2-0.4mm It should replace the electric clutch assembly and shift fork sleeve when the clearance is not in the range. b. Connect the electric clutch assembly to the electric clutch detector and power the electric clutch detector with 220V power supply to test the electric clutch (Before the test, adjustthe test controller status to make the motor starting time is 3s ,the time form found the actuator is not in position to restartingis 2.5s and the time of controller to redrive the electric clutch is2s) The motor starts for 3s when the gear switch is shifted form 2WD to 4WD, the lamp flashes at the same time, the clutch is in 4WD status, the indicator lamp is light always. If does not reach the 4WD status in the first time, then the controller restarts it for 2s after 2.5s delay, the lamp flashes at the same time; if it is still not in position, then the indicator lamp flashes twice continuously, the indicator lamp is extinguished for 1s, the motor is stopped. That means the electric clutch is unqualified and should be replaced by the qualified product. The motor starts for 3s normally when the clutch is shifted form 4WD to 2WD, the lamp flashes at the same time, when the clutch is in 2WD status, the indicator lamp is extinguished always. If does not reach the 2WD status in the first time, then the controller restarts it for 2s after 2.5s delay, the lamp flashes at the same time; if it is still not in 2WD status, then the indicator lamp flashes twice continuously, the indicator lamp is extinguished for 1s, the motor is stopped. That means the electric clutch is unqualified and should be replaced by the qualified product. 38. Cover the shift fork sleeve on the major semiaxle spline. 39. Install the separator housing on the front axle tube flange and use the bolt to tighten it to the (The bolt should be precoated specified torque with the screw lock agent and the amount should be just can cover the complete screw) specified torque : 90-110N m Caution: Before installation, remove the foreign material on two matching surfaces of separator housing and front axle tube flange; and precoat the 1596 silicon rubber plane sealant on the front axle tube flange. Caution: Prevent the sealant from entering into the screw hole. 40. Press in the plastic vent tube on the electric clutch housing and front axle tube. 41. Install two location pins in the location pin hole of electric clutch housing respectively. 42. Coat the connecting surface of electric clutch housing and electric clutch with 1596 silicon rubber sealant uniformly; level it by plate. Caution: The connecting surface should be cleaned and must not have the oil and other foreign matters. The sealant must not enter into the electric clutch housing and screw hole. 43. Install the electric clutch assembly on the electric clutch housing. a. Make the shift fork cross on the shift fork sleeve. b. Align the location pin hole of electric clutch with two location pins, and tighten it by bolt; tighten the bolt to the specified torque. (Precoat the medium screw of bolt with one or two drop of screw lock agent) Specified torque : 23-26N m 44.Insert the clip into the vent tube bracket. 45. Clamp the vent tube clip on the front drive axle vent tube connecting tube assembly. 46. Connect the front drive axle vent tube connecting tube assembly to three ports, the front axle tube, electric clutch and electric clutch housing. 47. Screw off the oil filling plug of front drive axle housing, then fill the axle housing with the hypoid gear oil; then tighten the oil filling plug to the specified torque. Gear oil number: GL-5 Filling amount: The oil level is flush with the lower edge of oil filling port. specified torque : 140-150N m 48. Fill the electric clutch housing with the gear oil ; then tighten the oil filling plug to the specified torque. Gear oil number: GL-5 Filling amount: The oil level is flush with the lower edge of oil filling port. Specified torque: 140-150N m Installation of front reducer assembly 1. Install the front drive shaft assembly on the reducer assembly (Refer to “Assembly of Front Drive Shaft”) 2. Use the jack to support the front drive axle, insert the hanger plank bolt with washer and tighten it to the specified torque. Remarks: Do not insert the previous two bolts in reverse direction. Specified torque : 200-220N m 3. Use the bolt to connect the front drive axle flange to the drive shaft according to the mark made before disassembly, and tightens it to the specified torque. assembly mark Specified torque : 73-83N m 4. Install the beam under the front drive axle; tighten the connecting bolt of the beam to the specified torque. Specified torque : 73-83N m 5. Connect the power sire connector of the electric clutch to the power output wire of the car. Axle drving assembly oil seal pressing block brake caliper assembly parking brake assembly circlip oil seal bearing oil seal base rear axle brake disc N pull-wire assembly m: Specified torque Used component which can not be used any more. Removal of semiaxle 1. Remove the wheel. 2. Disconnect the manual brake pull-wire from the carriage; loose the small bracket. 3. Remove the brake caliper; remove the brake disc . 4. Remove the rear halfaxle assembly from the rear axle housing a. Use the bolt to connect the special tools to the semiaxle flange surface. b. Use the hammer of special tools to remove the rear axle. 5. Remove the circlip from the halfaxle assembly. Use the circlip pliers to remove the circlip. limitation limitation Check and repair of rear axle components 1. Check the rear axle and flange for wear, damage and run-out. Max. Run-out of axle: 2mm Max. Run-out of flange: 0.2mm It should replace the rear axle if the rear axle or flange is worn or damaged, or the measured run-out is beyond the specified value. 2. Check the external oil seal a. Check for the wear or damage; especially for the lip of oil seal. b. Replace it if necessary. 3. Check the bearing and oil seal holder Check for wear and damage, replace it if necessary. 4. Remove the bearing and oil seal holder a. Move the brake and oil seal pressing block to the limit position along flange direction; move the external oil seal to the limit position of oil seal. b. Place the hook of the special tools in sequence, the position is shown as figure; make the hook holds the bearing tightly; then use the bolt to connect the hook to the hammer fixedly; at last, place it on the pad with halfaxle spline end facing ground. c. Hold the hammer to beat downwardly with force for several times to remove the bearing and oil seal holder. Caution: Do not damage the oil seal . 5. Install the new external oil seal a. Clean the semiaxle. b. Coat the lip of external oil seal with proper HP-R grease. Caution: When install the oil seal, the lip of oil seal must not contact the semishaft to avoid scratching the oil seal . 6. Replace the bearing and oil seal holder a. Heat the oil seal pressing block in 22# engine oil to 100 . Caution: The end of oil seal pressing block with larger chamfer faces the halfaxle spline. Install it immediately after taken out. b. Use the hydraulic press to install the new bearing and new oil seal pressing block by press. 7. Install the circlip Use the circlip pliers to install the new circlip in the slot of semiaxle. 8. Check the inner oil seal for wear or damage. special tools special tools 9. Remove the inner oil seal Use the special tools to remove the inner oil seal. 10. Install the new inner oil seal a. Coat the lip of oil seal with proper HP-R grease. b. Use the special tools to knock in the new oil seal. Installation of rear axle 1. Install the halfaxle assembly in the axle housing a. Use the kerosene to clean the semiaxle and inner oil seal holder. b. Assemble the halfaxle spline and halfaxle gear spline firstly, then use the brass rod to beat knock the halfaxle assembly into the axle housing. Caution: Protect the lip of inner external oil seal and pull-wire assembly during assembly; do not damage the oil sleeve assembly; align the brake bolt with the flange bolt of rear axle. Tightening force: 95-105N m brake disc axle housing 2. Install the rear brake disc flange halfaxle assembly 3. Install the brake caliper Tightening force: 95-105N m 4. Connect the manual brake wire. 5. Install the wheel. 6. Discharge the air of brake system by test. Reducer adjusting ring side bearing driven bevel gear adjusting washer differential housing locking plate drive bevel gear rear bearing bearing spacer lock washer with double ears oil baffle disc dustproof cover flange plain washer front bearing stop plate oil seal N bearing gland m: Specified torque Used component which can not be used any more. Replace the oil seal on the car assembly mark 1. Disconnect the reducer from the drive shaft. a. Make the assembly mark on two flanges. b. Remove four bolts and nuts. 2. Remove the flange and dustproof cover assembly 3. Remove the oil seal Use the special tools to remove the oil seal. 4. Install the new oil seal a. Coat the lip of oil seal with the HP-R grease. b. Use the special tools to knock in the new oil seal. Insertion depth of oil seal: 1.0mm 5. Install the flange and dustproof cover assembly special tools insertion depth: 1mm 6. Rivet the drive bevel gear nut. assembly mark 7. Connect the drive shaft flange to the reducer flange Align the assembly mark ; then connect them by bolt. Tightening force: 78 5N m 8. Check the oil level of reducerReplace the hyperbolic gear oil if necessary. Oil number : GL-5 hyperbolic gear Viscosity : SAE80W/90 Amount: Filled with oil until the oil flows out form oil filling port. Removal of reducer assembly mark 1.Remove the oil drain plug; drain the oil from the reducer 2. Remove the rear axle (Refer to Step 2 in “Disassembly of Rear Axle”) 3. Disconnect the drive shaft from the reducer (Refer to step 1 in “Replace the Oil Seal on Car”) 4 Remove the assembly of reducer. Disassembly of reducer Remarks: If the noise of differential is loud, process the following inspection before disassembles the differential to determine its reason. When the differential has serious problems, it can be disassembled for repair if necessary. 1. Check the internal clearance of driven bevel gear. If the clearance is beyond the specified range; adjust the preapplied load of bearing or repair if necessary. (Refer to step 13 “Assembly of Reducer”) Standard internal clearance: 0.15-0.25mm 2. Check the intertooth contact of drive bevel gear and driven bevel gear. (Refer to Step 14 in “Assembly of Reducer”) Record the contact position of tooth. 3. Check the clearance between the thrust plate of axle shaft gear and differential housing. Use the feeler to measure the clearance between the thrust plate of axle shaft gear and differential housing. Standard clearance: 0.45-0.75mm It should be replaced by the proper thrust washer if the clearance is beyond the specified range. (Refer to Step 2 in “Replacement of Differential Components”) 4. Measure the pre-applied load of drive bevel gear Use the torsion meter to measure the pre-applied load on the internal clearance between the drive small gear and driven bevel gear. Pre-applied load: 0.4-0.6N m 5. Total pre-applied load Use the torsion meter to measure the total pre-applied load. Pre-applied load : 0.9-1.3N m 6. Remove the differential and driven bevel gear a. Make the assembly mark on the differential bearing gland and reducer housing. b.Remove two stop plates. c.Remove two bearing glands and two adjusting rings. d.Remove the bearing outer race. e.Remove the differential form the reducer housing. Remarks: Mark the label on the removed components to indicate the position of reassembly. 7. Remove the flange and dustproof cover assembly special tools a.Use the hammer and chisel to loose the riveted part of nut. b.Use the special tools to clamps the flange; then remove the nut. Caution: The used nut can not be used any more. c.Remove the flange and dustproof cover assembly. 8. Remove the oil seal Use the tools to pry out the oil seal. 9. Remove the drive bevel gear and spacer special tools Remove the drive bevel gear, bearing and spacer from the reducer housing. 10. Remove the oil baffle disc and front bearing inner race 11. Replace the rear bearing of drive bevel gear a. Use the press machine and special tools to pull out the rear bearing from the drive bevel gear. b.Use the press machine and special tools to install the reused adjusting washer and new rear bearing on the drive bevel gear. special tools 12. Replacement of front and rear bearing outer race of drive bevel gear. a. Use the hammer and brass bar to knock out the front and rear bearing. b. Use the press machine and special tools to install the new bearing outer race by press. 13. Remove the side bearing form the differential housing. Use the special tools to pull out the side bearing from the differ ential housing. 14. Remove the driven bevel gear a.Remove the connecting bolt and lock plate of driven bevel gear. b.Make the assembly mark on the driven bevel gear and differen tial housing. c.Use the rubber hammer or brass rod to knock down the driven bevel gear. Assembly of reducer 1. Install the bearing outer race of drive bevel gear. (Refer to Step 12 in “Disassembly of Reducer”) 2. Install the rear bearing of drive bevel gear and ad justing washer special tools a. Select the proper adjusting washer according to “Meshing Condi tion of Drive Bevel Gear and Driven Bevel Gear”. b. Install the rear bearing and selected adjusting washer by press machine. 3. Install the spacer. a.Select the adjusting washer between the rear bearing and spacer based on the experience. b.Install the spacer. 4. Install the front bearing inner race, oil baffle disc special tools and oil seal of drive bevel gear a. Place the front bearing inner race in the reducer housing; place the oil baffle disc. b. Coat the position of reducer housing oil seal and lip of oilseal with grease uniformly; place the oil seal in position. Start the press machine for installation. level 5. Install the drive bevel gear, flange and dustproof cover assembly a. Install the flange and dustproof cover assembly in the reducer housing, Press it to level by hand. b. Insert the drive bevel gear installed with the spacer, rear bearing and adjusting washer into the flange through the spline; screw on the nut. c. Use the nut to tighten the flange, plain washer and drive gear. 6 Use the special tools to clamp the flange; use the Special tools torque wrench to tighten the nut. Tightening force: 140 160N m 7. Measure the rotation pretightening force of bearing For new bearing : 1.2 1.7N m For reused bearing : 0.4 0.6N m If does not meet the requirement, replace the adjusting washer under the spacer until meet the requirement. Tightening torque : 0-3.5N m a. Reduce the thickness of adjusting washer if the measured value is less than standard value; b. Increase the thickness of adjusting washer if the measured value is more than standard value. 8. Install the driven bevel gear on the differential housing. a. Use the bolt and lock plate to connect the driven bevel gear to the differential housing. b. Screw on for three rounds at least by hand; then use the pneu matic wrench to tighten it properly. c. Use the torque wrench to tighten it. Tightening force: 65-95N m Caution: Tighten the bolt in diagonal . Use the hand hammer and flat head punch to lock the lock plate. 9. Install the differential side bearing by press. special tools Use the press machine and special tools to install the side bearing on the differential housing by press. special tools 10. Install the differential assembly a.Remove the bearing gland. Do not mix the left up with right. b.Install the differential assembly in the reducer housing. 11.Install the adjusting ring Use the adjusting ring to press the bearing outer race in position; tighten it properly. Adjust the clearance between the drive and driven gear to the proper dimension. 12. Install the bearing gland a. Align the assembly mark on the bearing cover with that on re ducer housing; Press down the press cover by hand. b. Install the lock washer with double ears and nut; tighten the hexagon nut by pneumatic wrench properly. assembly mark 13. Adjust the engagement clearance between the drive and driven gear. a. Use the torque wrench to tighten four bolts on bearing cover by torque wrench. Tightening force: 78-115N m b. Adhere the measuring meter base on the end surface of reducer housing; the measuring head contacts the tooth surface; rotate the driven gear by hand and measure the engagement clearance be tween the drive and driven gear. c. If the engagement clearance does not meet the requirement, use the special tools to adjust the left and right adjusting ring until it meets the requirement. d. Recheck the engagement clearance between the drive and driven gear. Engagement clearance: 0.13-0.18mm 14. Check the meshing mark of drive and driven bevel gear. a. Paint 3-4 teeth with the red lead in three different positions of driven bevel gear. b. Rotate the driven bevel gear in clockwise and anticlockwise by hand.Check the engagement of gear. arge end contact toe contact select the shim which can make the small drive gear close to the driven bevel gear small end contact dedendum contact sound contact select the shim which can make the small drive gear away from the driven bevel gear rear bearing washer Select the proper washer from the table for correction if the intertooth contacting status is bad. The thickness tolerance of washer is 0.01mm. Set NO. Thickness Set NO. Thickness 15. Install the stop washer and stop plate a. If the drive and driven gear engagement mark meets the requirement, then use the hand hammer and punch to lock the stop washer. b. Install the stop plate, spring shim and bolt; tighten the bolt. Tightening force: 18-25N m c. Use the punch and hand hammer to knock the lower end of stop plate in the adjusting ring hole. 16. Measure the total pre-applied load Pre-applied load : 1.8-2.4N m If the pre-applied load is beyond the specified; it should replace the shim between the spacer and rear bearing until meet the requirement. a. It should replace the adjusting washer if the pre-applied load is more than specified value. b. If the pre-applied load is less than specified value, it can retighten the nut slowly and the torque should be no more than 160N m. Caution: When tighten the nut, if is beyond the Max. torque, replace the adjusting washer and repeat the pre-applied load process. Do not reduce the pre-applied load by the method of screw off the drive gear nut to loose. 17. Check and adjust the run-out of flange. a.Adhere the dial indicator base on the reducer housing; make the probe of dial indicator contact with the end surface of flange; rotate the flange and watch the rotation range of the dial. Full run-out tolerance of end surface: 0.10mm b.Adhere the dial indicator base on the reducer housing; make the probe of the dial indicator contact with the inner diameter of flange; rotate the flange by hand , and watch the rotation range of the dial.Radial full run-out tolerance: 0.10mm 18. Rivet the nut of drive bevel gear Installation of reducer and differential assembly assembly mark 1.Install the new stiffening ring 2.Install the reducer and differential assembly Install the reducer and differential assembly in the rear axle housing; place the washer and nut. Tighten the nut to the specified torque. Tightening force: 18-25N m 3.Install the reducer and differential assembly flange on the drive shaft flange and align the assembly mark; use four bolts and nuts to connect them. Tighten the bolt and nut to the specified torque. Tightening force: 78 5N m 4.Install the oil drain plug; fill the differential with the gear oil oil number : GL-5 hyperbolic gear oil Viscosity: SAE80W/90 Amount: Filled with oil until the oil flow out from the oil filling port. Tighten the oil filling plug. Tightening force: 140-150N m Differential thrust plate straight pin differential housing half axle gear lock washer planetary gear planetary gear shaft half axle gear planetary gear thrust plate lock washer Differential 1 Remove the reducer and differential assembly (Refer to “Removal of reducer”) 2 Remove the differential from the reducer and dif ferential assembly. (Refer to “Disassembly of reducer”) Replacement of differential components 1.Disassembly of differential Use the hammer and punch to knock out the pin. Remove the planetary gear shaft, two half axle gears, two planetary gears and two lock washers, two thrust plates. 2. Assembly of differential a.Install the half axle gear and thrust plate of axle shaft gear (Unit: mm) Set NO. 1 2 Thickness 1.2 1.5 b.Install the planetary gear and planetary gear lock washer in the differential by rolling. (Unit: mm) Set NO. Thickness c.Use the feeler to measure the clearance between the thrust plate feeler and differential housing; it can be replaced by the thrust plate with different thickness if the clearance is beyond the specified range. Standard clearance: 0.45-0.75mm d.Install the straight pin Use the hammer and punch to knock in the pin through the hole on the differential housing and planetary gear shaft. Rivet the pin with the differential housing. Installation of differential 1 Install the differential assembly in the reducer hous ing (Refer to “Assembly of Reducer”) 2 Install the differential (Refer to “Installation of Reducer and Differential Assembly”) Rear suspension upper support pad of coil spring long longitudinal pull-rod assembly coil spring rear axle assembly short longitudinal pull-rod assembly short longitudinal pull-rod fixed bolt long longitudinal pull-rod assembly short longitudinal pull-rod assembly cross pull-rod short longitudinal pull-rod fixed bolt connecting bolt rubber pad long longitudinal pull-rodassembly long longitudinal pull-rod fixed bolt cross pull-rod assembly rear vibration damper rear stabilizer bar rear connecting rod of stabilizer bar assembly bush plain washer bush clip N m: specified torque Removal of vibration damper 1. Use the lifter to raise the car firstly, then support the rear axle by bracket. 2. Remove the upper and lower fixing nut which is used to fix the vibration damper; compress the vibration damper by hand. Remove the upper end firstly, then the lower end; take out the vibration damper . Installation of vibration damper: 1. Lower tightening force of vibration damper: 170 5N m. Upper tightening torque : Compress the rubber block to 2/3 of total height. Caution: If the fixing nut of vibration damper is the lock nut, it should be replaced by the new lock nut after replace the vibration damper. Removal of coil spring: 1. Remove the vibration damper (As previous ) 2. Use the special tools to clamp the coil spring. 3. Place the car in the bounce status, take out the coilspring 4. Remove the special tools from the coil spring. Installation of coil spring: special tools 1. Firstly, use the special tools to clamp the coil spring to certain height (height when car is in bounce status). 2. Cautions for installation: Adjust the rubber gasket on the spring to ensure the spring in flat status. 3. Remove the special tools. Removal of connecting rod of stabilizer bar: 1.Shown as figure, firstly screw off the nut in the con necting place between the connecting rod of stabi lizer bar and carriage. (Need the inner hexagon spanner ). 2.Screw off the nut connected to stabilizer bar in same method; screw off the connecting rod. Installation of connecting rod of stabilizer bar: Tighten it to the specified torque during installation: 5N m 63 Brake-1 Chapter 8 Brake Cautions...................................................................................... 2 Troubleshooting............................................................................2 Check and adjustment..................................................................5 Brake pedal..................................................................................7 Parking brake...............................................................................8 Front brake...................................................................................9 Rear brake...................................................................................16 Rear parking brake......................................................................22 Sensor load proportional valve.....................................................29 Antilock Braking System (ABS)..................................................31 Brake-2 Cautions Troubleshooting Failure Pedal is low or soft Lag of brake Brake is stagnant cause Inspection content brake pad is worn Replace the brake shoe brake block is worn Replace the brake block brake system is leaked Repair the leakage master pump has failure Repair or replace the master pump Brake system has air Drain the air from brake system Brake pump has failure Replace the brake pump Auto adjuster of rear brake has failure Repair or replace the adjuster Parking brake is adjusted badly. Adjust the parking brake Pull wire of parking brake is locked Repair if necessary Assist push rod is adjust badly Adjust the push rod Extension spring or return spring has fault Replace the extension spring Pipeline is blocked Repair if necessary brake pad is broken or deformed Replace the brake shoe brake block is broken or deformed Replace the brake block Auto adjuster is damaged Replace the adjuster Master pump has failure. Replace the master pump Improper inflation of tyre Charge the tyre to the proper pressure. There is grease spot or lubricant oil on the Find out the cause. Replace the brake shoe or block. brake shoe or brake block. Replace the brake shoe The brake shoe is deformed ; the brake pad Replace the brake block is worn or smoothed Replace the brake drum or brake disc The brake block is deformed, worn or Replace the spring smoothed Repair the wheel pump The brake drum or brake disc is deformed Replace Extension spring or return spring has failure Replace the brake block Wheel pump has failure Pump has failure Brake block is blocked brake pedal is hard There is the grease spot or lubrication oil on Find out the cause . the brake disc or brake block. Replace the brake shoe or brake block The brake shoe is deformed; the brake pad is Replace the brake block worn or smoothed Replace The brake block is deformed, worn or Replace the assist smoothed Repair if necessary Brake pump has failure. Repair if necessary Brake assist has failure Improper vacuum degree The brake pipeline is blocked. Brake-3 Troubleshooting (continued) failure cause Inspection content (drum brake) The brake shoe is blocked in the rear apron flange Filled with lubricated oil The brake generates the The rear apron flange is worn Replace the lubricant flange crack The brake shoe pull-out piece spring is loose or lost Replace The fixed bolt of rear apron is loose (disc brake ) tighten Brake block support plate is loose or lost replace Installation bolt is loose tighten The brake shoe gasket or brake block is worn Replace, if the scratch is heavy, The brake caliper and wheel or rotor are disturbed then fine machine the brake drum or mutually rotor again It has the rustle or rattler The dustproof cover and rotor, rear apron and brake Replace it according to requirement when use the brake drum are disturbed mutually Correct or replace Failure of other brake system component Repair or replace it according to Tyre generates the abrasion with the tyre and chassis requirement clatter during operation. Check or maintain The brake drum and brake shoe gasket, rotor and Check, repair or replace scream, rattler or vibration brake block is worn or scratched. clean or replace noise when use the brake . The brake pad or block is dirty, with oil or smoothed. check, replace The brake pedal or assistor push bar is adjusted check and adjust incorrectly replace It has the squeak, continuous Caution: The abrasion material in the brake will generate the inherent noise (disc brake ) replace The brake block silencing plate is lost or damaged. clean or remove the flash abrasion, then emit the The abrasion of the brake block makes the brake check, repair or replace heat. So it is normal that block abrasion indication plate contacts the rotor generate the The brake caliper has burr or is corrosive and heat accident. during The the squeak by condition (drum brake) will be serious in extreme The pull-out piece spring of brake shoe is soft, environment, such as cold, damaged or improper. The pull-out piece spring pin hot, and spring of brake shoe is loose or damaged; and high snowing, humidity, saliferous and mud. The accident squeak will not cause the fatal failure of the brake, and will not reduce the effective performance of the brake. rear apron flange has crack Brake-4 failure It has the continuous scream and squeak when does not use the brake cause Inspection content The brake pedal or assist push bar is adjusted incorrectly Check and adjust The return of brake assist or master pump or wheel pump is bad Check, repair or replace (disc brake ) The piston is corrosive or blocked Check and fill with lubrication oil if The brake block in brake caliper is in improper position necessary. Repair or replacement Shell abrasion of rotor and brake caliper The brake block support plate in disc brake is Repair or replacement Repair or replacement installed improperly The brake block abrasion indication plate contacts Repair the rotor for the abrasion of brake block (drum brake) The press spring of brake shoe is soft, damaged or improper. The flange of rear back rear apron is cracked The rear apron interfere with the brake drum mutually after bent or warp Improper machining of brake drum, cause the mutual Repair Repair or replacement Repair or replacement Replace the brake drum interference of rear apron and brake shoe components of other brake system: Brake system has loose or redundant components The brake pad is smoothed for the rear brake drum is Check, maintain necessary. and replace if adjusted too tight The wheel bearing is worn damaged or under lubricated It still has the rattler, click or cackle noise when does not use the brake. The stone or foreign enters into the inside of wheel protecting hood Remove the foreign materials such as the stone The hub nut is loose Tighten it to the specified torque, it should be replaced if the bolt hole is The brake pedal or assistor push bar is adjusted enlarged Check and adjust improperly The wheel bearing is worn, damaged or lubricated Check, lubricate or replace insufficiently (disc brake ) The muffler spring is soft or lost; the brake block support plate or external end of brake block is coiled Repair or replacement silencing plate is unsound The slide bush is worn Check and replace if necessary The installation bolt is loose Piston returns unsoundly (drum brake) Have loose or redundant component Check and replace if necessary Check and tighten if necessary Check , repair or replace Check, take out or repair Brake-5 Check and adjustment Check and adjustment of brake pedal 1. Check the correctness of height of pedal Distance from pedal to lower front apron: 152mm, Operating stroke of pedal push bar is 1mm. pedal push rod parking lamp switch a. Disconnect the brake lamp switch wire connector; loose the tightened nut; rotate the brake switch to the position not contacted to limit block of brake pedal b. Loose the lock nut of operating connecting rod; use the thinnose pliers to rotate the operating connecting rod to adjust the height of brake pedal to the standard value; lock the block nut tightenedly when reach the standard value. c. Rotate the brake lamp switch to contact with the limit block of brake pedal; then rotate 1/2 1 round continuously; tighten the block nut; d. Connect the wire connector of brake lamp switch; e. The brake lamp should not be light when the brake pedal is released. pedal push rod 3. Check the free stroke of pedal Free stroke of pedal: 4 6mm In the status of engine is stop, step on the brake pedal for 2 3 times after eliminate effect of the brake assist, push down the brake pedal by hand to just with the resistance, then measure its displacement (free stroke). It should be in accordance with the standard value. free stroke of pedal Brake-6 4. Adjust the stroke of pedal if necessary a. Rotate the pedal push bar to adjust the free stroke if the stroke length is improper. b. Start the engine to confirm the free stroke of pedal. c. Check the height of pedal after adjusts the free stroke of pedal. d. The height difference of brake pedal and clutch pedal to front apron is 0 8mm. e. The height difference of brake pedal and accelerator pedal to the front apron is 45 5mm. Vacuum assist Remarks: Use the vacuum assist tester to check the operation of vacuum assist if possible. 1. Operation inspection a. Step on the brake pedal for several times before start the engine and check the reserved distance which should not be changed. b. Step down the brake pedal and start the engine. If the pedal moves downwardly a little, then it means the normal operation; if the brake pedal moves upwardly, then it means the brake assist is damaged. 2. Air tightness inspection a. Start the engine and shut off it after 1 2 minutes. Step down the brake pedal slowly for several times. If the pedal moves downwardly all long at the first time, but moves upwardly little by little after second or third times, then it means the vacuum assist has the sound air tightness. If the pedal height is without variety, then it means the brake assist is damaged. b. Step down the brake pedal when the engine is operating; then shut off the engine but step down the pedal, if the pedal keeps the stroke without variety within 30s, then it means the vacuum assist has the sound tightness; if the brake pedal moves upwardly, then it means the brake pedal assist is damaged. Brake-7 Air discharge of brake system Remarks: It should discharge the air if operate on the brake system or assume the brake system pipeline has the air. Caution: Must not keep the brake fluid on the paint surface, wipe off it if has. 1. Fill the liquid reservoir up with the brake fluid. Check the liquid level in liquid reservoir after discharge the air of each wheel pump. Filled with the brake fluid if necessary. 2. Connect the polyethylene resin pipe to the overflow hole plug of wheel pump;insert the other end of pipe into the container with half of brake fluid. Remarks: When discharge the air of wheel brake pump, it should begin from the longest pipeline. 3. Air discharge of brake system pipe a. Step down the brake pedal slowly for several times. b. Let the assistant presses down the pedal, at the same time screw off the overflow hole plug until the brake fluid flows out. Then switch off the overflow hole plug. c. Repeat the procedure until the liquid is without air bubble. Tightening torque of overflow hole plug: 11N m 4. Process the same procedure for each wheel pump. Brake pedal support sleeve return spring screw bar bush brake bracket welded assembly pin shaft pedal cover block hexagon flange nut rocker arm welded assembly Brake-8 fork pin shaft Replacement of pin shaft Remarks: When the connecting fork pin shaft and pin hole is over worn, it should replace the pin shaft bush. Remarks: push bar lock nut inner distance When the clearance between the brake pedal shaft and bush is large, it should remove the pedal and replace the bush. Parking brake rear parking brake pull wire (R) parking crank assembly brake pull wire clip switch assembly rear parking brake pull wire (L) 1. Adjust the parking crank assembly in position, 6 8 teeth. 2. When the parking brake pull wire is tightened, the torque should be no more than 400N m. Brake-9 Front brake front brake oil pipe cooper washer tong guide pin rubber cover guide pin dustproof cover air-bleed bolt cover piston Piston dustproof cover location pin guide pin dustproof cover square seal ring upper circlip of brake block (I) upper circlip of brake block (II) lnner silencing plate combination cliper bracket Inner brake block silencing plate wear limitation alarm plate of brake block lower circlip of brake block outer silencing plate combination lower circlip of brake block N m: Specified torque brake block assembly Replacement of brake block Remarks: When brake during the travel process, if the front wheel has the continuous screams noise, then it should check the wear limitation alarm plate of brake block. If the alarm plate has the abrasion mark with brake disc, then it should replace the brake block . 1. Remove the front wheel 2. Check the thickness of abrasion material of brake block. Check the thickness of abrasion material of brake block by the watch hole on the tong. Replace it if is not within specified range. Min. thickness : 2.0mm Brake-10 3 Lift the main body of brake caliper. a. Remove the hexagon flange bolt. b. Lift the brake pump and hang it by rope to protect the brake oil pipe. Remarks: Do not screw off the brake oil pipe and bleed plug. 4. Remove the following components a. Two pieces of brake block b. One piece of silencing plate c. Two piece of silencing plate combination d. One wear limitation alarm plate of brake block e. Four brake block circlip plates 5. Measure the thickness of brake disc (Refer to step 2 of “ Inspection of component of front brake” ) 6. Measure the circular runout of brake disc. (Refer to step 3 of “Inspection of component of front brake”) 7. Install the brake block circlip plate Brake-11 8. Install the new brake block a. Install a wear limitation alarm plate of brake block on the inner brake block. b. Install a silencing plate and a silencing plate combination on the inner brake block. c. Install a silencing plate combination on the on the outer brake block. d. Install two brake blocks; let the wear limitation alarm plate is in the inside of brake caliper. Caution: It is unallowable that the operating surface of brake block and brake disc is polluted by the grease and paint. e. Suck a few of brake fluid form the liquid reservoir (prevent the brake fluid from overflowing from liquid reservoir). f. Use the special tools to press the piston . 9. Install the brake pump Install and tighten the hexagon flange bolt. Tightening force: 25 35N m Remarks: Only can replace the brake block on a wheel in one time to avoid the piston on another wheel is pushed out. 10. Install the front wheel Tightening force of the wheel fixing nut is 120N m 11. Check whether the brake fluid level is in the specified position. Brake-12 Removal of brake pump 1. Remove the brake pipeline Remove the brake pipeline. Use a container to contain the brake fluid. 2. Remove the brake pump from the clamp bracket a. Remove the hexagon flange bolt, location pin and guide pin. b. Remove the brake pump. 3. Remove the brake block a. Two brake blocks b. One silencing plate c. Two silencing plate combinations d. One wear limitation alarm plate of brake block e. Four brake block circlips Disassembly of brake pump 1. Remove the piston form the tong a. Place the wood block between the tong bracket and tong body . b. Use the air gun or air pipe to aim at the brake oil pipe hole; remove the piston form the tong. c. Use the clean rag or soft cloth to take out the piston. Warning: It must not place the finger in front of the piston when use the compressed air. 2. Remove the piston gasket from the tong body. Use the paper clip to remove the piston gasket. Caution: The used tools must not be sharp to prevent from scratching the piston gasket. Brake-13 Check the component of front brake 1. Measure the thickness of the brake block bush. standard thickness: 9.0mm minimum thickness: 2.0mm It should replace the brake block if less than minimum thickness or has uneven abrasion. 2. Measure the thickness of the brake disc. standard thickness: 26.0mm minimum thickness: 24.0mm It should repair or replace the brake disc if the brake disc is damaged or worn or its thickness is less than minimum thickness. 3. Measure the circular runout of the brake disc. Remarks: It should ensure that the bearing is adjusted correctly before the measurement . maximum circular runout : 0.11mm 4. Replace the brake disc if necessary. a. Remove the tong bracket form the steering knuckle. b. Remove the hub and brake disc. (Refer to section “Front hub”) c. Install the new brake disc; tighten the connecting bolt to the specified torque. Tightening force: 90 100N m. d. Install the hub and brake disassembly. (Refer to section “Front hub”) e. Install the tong bracket on the steering knuckle; tighten the connecting bolt to the specified torque. Tightening torque 140 10N m. Brake-14 Assembly of brake pump 1. Preparation work All components should be washed, dried by wind and without foreign material before the assembly. During the assembly, cost the guide pin and location pin with proper vacuum silicon based grease; coat the working surface of piston and square gasket with proper rubber lubricant. 2. Install the piston gasket in the tong body. a. Screw the bleed screw into the bleed hole; tightening torque 7 10N m. b. Install the square gasket in the sealing groove of two cylinders of pump respectively after coat its working surface with proper rubber lubricant. 3. Install the piston with dustproof cover in the tong a. Cover the dustproof cover on the piston. b. Lengthen the dustproof cover to expose the bottom of piston from the dustproof cover clip ring; use the tool (for example: steel wire about 2mm ) to assist insert the clip ring into the cylinder hole clip ring groove. Caution: The used tools must not be sharp to prevent the damage of dustproof cover. c. Press the piston to the bottom of cylinder hole by hand. 4. Pre Install the guide pin and location pin on the tong bracket. a. Install the guide pin dustproof cover on the guide pin and location pin respectively. b. Screw the guide pin and location pin in the tong bracket respectively. Caution: Do not damage the guide pin dustproof cover. Brake-15 Installation of brake caliper 1. Install the brake block 2. Install the brake pump a. Install the brake pump. b. Install and tighten the hexagon flange bolt. Tightening force: 25 35N m 3. Connect the brake pipeline Connect the brake oil pipe to the tong body. Tightening force: 50 5N m 4. Fill up the brake liquid reservoir with the brake fluid and dis charge the air in brake system. 5. Check for the leakage of brake fluid. Caution: Discharge the air after the completion of replacement. Brake-16 Rear brake (Disk-and-drum type) brake oil pipe fastening blot 55 guide pin 25 copper washer 30 rectangle seal ring bleed screw dustproof cover bleed screw rear brake oil pipeline cylinder hole dustproof cover piston location pin 25 30 wire clip tong body (left) pin rubber cover outside brake block silencing plate inside brake block silencing plate tong bracket N m: combination brake block wearing indication plate brake caliper locking bolt 100 specified torque Replacement of brake block Remarks: if the rear wheel generates the cheep during the braking, it should check the abrasion indication plate of brake block. If the indication plate has the abrasion mark with brake disc, then it should replace the brake block . 1. Remove the rear wheel 2. Check the thickness of brake block bush. Measure the thickness of the brake block bush (abrasion material) from the eyehole of tong. If the thickness is not within the specified range, then it should replace the brake block. minimum thickness: 2.0mm. peephole Brake-17 3. Uplift the brake pump a. Remove the location pin. b. Uplift the brake pump and hang it with a rope to protect the brake oil pipe. Remarks: do not remove the brake oil pipe. 4. Remove the following components: a. Two brake blocks b. Two silencing plates c. Two silencing plate combinations d. One brake block bush wearing indication plate e. Two brake block circlips 5. Measuring the depth of brake discs (refer to the step 2 of measuring the components of rear brake) 6. Measuring the brake disc circular runout (Refer to step 3 of measuring the components of rear brake) 7. Install the brake block Circlip Brake-18 8. Install new brake block a. Install a brake block bush wearing indication plate on the internal brake block. b. Install one silencing plate and one silencing plate combination on each brake block. Remarks: Coat the two sides of silencing plate with disc brake oil (which cannot be replaced with oil of other models). c. Install two brake blocks, make the wearing indication plate in the lower position (near the tank cylinder). Remarks: The working surface of the brake block and brake disc are not allowed to be contaminated by grease and paint. 9. Install the sub pump a. Unscrew the release screw, absorb some of the brake fluid. b. Press the plunger with hammer beam or similar tools, and unscrew the release screw at the same time. Tightening force: 8 13N m Remarks: Only the brake block of one wheel can be replaced for once, lest the plunger on the opposite side be bounced. c. Install and tighten the location pin. Tightening force: 25 30N m 10. Install the rear wheel Tightening force: 120N m 11. Fill up with the brake fluid and drain the air in the brake system after the completion of replacement. Brake-19 Removal of brake pump 1.Remove the brake pipeline Remove the brake pipeline. Use a container to contain the brake fluid. 2. Remove the pump form the bracket a. Remove the location pin and guide pin. b. Remove the tong. 3. Remove the brake block a. Two pieces of brake block b. Two pieces of silencing plate c. Two pieces of silencing plate combination d. One piece of brake block bush abrasion indicating plate e. Two brake block circlips Disassembly of brake pump 1. Remove the piston form the tong a. Insert the cleaning cloth or other soft cloth into the place between piston and tong. b. Use the compressed air to remove the piston and cylinder hole dustproof cover from the tong. Warning: it must not place the finger in front of the piston when use the compressed air. 2. Remove the piston gasket form the tong Use the screwer to remove the piston gasket. Brake-20 Check the components of rear brake 1. Measure the thickness of the brake block bush. Standard thickness: 8.0mm Minimum thickness: 2.0mm It should replace the brake block if less than minimum thickness or has uneven abrasion. 2. Measure the thickness of brake disc. standard thickness: 18.0mm minimum thickness: 16.0mm It should repair or replacement brake disc if it is scratched or worn or its thickness is less than minimum thickness. 3. Measure the circular runout of brake disc. Remarks: It should ensure that the rear bearing is adjusted correctly before the measurement. Maximum circular runout : 0.11mm 4. Replace the brake disc if necessary. a. Remove the bracket form the rear axle flange. b. Remove the rear brake disc and install the new brake disc . c. Install the bracket and tighten the fastening brake caliper bolt. Tightening force: 100 5N m Brake-21 Assembly of pump 1. During the assembly, coat the guide pin with the proper vacuum sili con based grease; coat the operating surface of piston and square gasket with proper rubber lubricant. 2. Install the piston gasket and piston in the tong 3. Install the cylinder hole dustproof cover and wire clip in the tong. 4. Install the rubber pin cover on the tong bracket. Installation of brake caliper 1. Install the brake block Brake-22 2. Install the piston gasket in the tong body. a. Screw the bleed screw into the bleed hole; b. Install the square gasket in the sealing groove of two cylinders of pump respectively after coat its working surface with proper rubber lubricant. Tightening torque 7 10N m. 3. Connect the brake pipeline Connect the brake oil pipe to the tong. 5N Tightening force: 50 m 4. Fill up the brake system with the brake fluid and drain the air in the brake system. 5. Check for leakage of brake fluid. Rear parking brake pull-out piece spring draw bar stopper push pedal release spring upper release spring push pedal saddle type washer brake shoe pulling arm rear brake disc rear brake shoe pulling arm pin hand brake stay wire front brake shoe lower tension spring clearance-adjusting bolt pull-out piece spring seat clearance-adjusting bolt head clearance-adjusting gear Used component which can not be used any more. Removal of rear brake Remarks: When the brake torque of the hand brake cannot meet the brake requirement, the thickness of the brake shoe gasket shall be tested. If it is less than the minimum value of brake show gasket, the brake shoe shall be replaced. minimum thickness: 1.0mm Brake-23 1. Remove the rear wheel 2. Remove the rear brake caliper 3. Remove the rear brake disc Remarks: If the brake disc is difficult to remove, remove the adjust ment spout plug, insert the screwdriver into the adjust ment spout of the rear brake bedplate, Release the brake shoe adjustment device through twisting the clearance-adjusting gear. 4. Remove the shoe plate, pull-out the piece spring , pull-out piece spring seat, pull-out piece spring draw bar 5. Remove the lower tension spring and clearance-adjusting device Use clipper to remove the extension spring, release the clearance adjusting device and remove it. 6. Remove the two upper extension springs 7. Remove the brake shoe a. Remove the brake shoe, baffle, baffle return spring. b. Remove the band brake stay wire from the stay and brake pulling arm. Brake-24 8. Remove the parking brake pulling arm Use the screw driver to remove the parking brake pulling arm Check and maintain the components of brake 1. Check the dismantled components Check to se whether the dismantled components are wearing, rusted or damaged. 2. Measure the internal diameter of the brake disc Standard inter diameter: 210mm maximum internal diameter: 212mm 3. Measure the thickness of the brake shoe standard thickness: 4.0mm minimum thickness: 1.0mm If the thickness of the brake shoe is less than the minimum value, or there is uneven wearing, the brake shoe shall be replaced. Remarks: If any one of the brake shoes needs to be replaced, all the brake shoes need to be replaced to keep the even brake performance. 4. Check whether the contact between the brake shoe gasket and brake disc is sound. If the contact between the brake shoe gasket and brake disc is bad, it should use the brake shoe grinding device to repair or replace the brake shoe assembly. Brake-25 Assembly of rear parking brake Remarks: Assemble the component according to the direction shown in figure; It is prohibited strictly that the working surface of brake drum and abrasion disk is polluted by the paint and grease. It should be removed by the fine abrasive paper if the abrasion disk has little dirty. The brake shoe should be replaced when the polluted area is large, otherwise it will cause the serious effect of insufficient brake force. left wheel right wheel front front 1. Install the clearance-adjusting device assembly Insert the clearance-adjusting shaft head into the clearance-adjusting wheel; screw the clearance-adjusting screw rod into the clearance adjusting wheel. Remarks: The screw direction of left clearance-adjusting screw rod is the left hand. The screw direction of right clearance-adjusting screw rod is the right hand. 2. Coat the following components with the proper anti-high tem perature grease : a. Contact position of brake soleplate and brake shoe. b. Contacting surface of push plate and shoe plate; contacting surface of clearance-adjusting device assembly and shoe plate. Brake-26 2. Install the parking brake pulling arm Install the parking brake pulling arm and use a new saddle washer. 3. Install the rear brake shoe a. Install the parking brake pull wire on the parking brake pulling arm. b. Insert the end of rear brake shoe into the support pin of brake soleplate. Insert the pull-out piece spring pull bar into the brake soleplate and brake shoe assembly, then insert the pull-out piece spring and pullout piece spring base. Use the pull-out piece spring fork to rotate the pull-out piece spring base in position. 4. Install the front brake shoe install the front shoe plate; insert one of its ends into the fixed pin of soleplate. Insert the pull-out piece spring pull bar into the brake soleplate and brake shoe assembly, then insert the pull-out piece spring and pullout piece spring base. Use the pull-out piece spring fork to rotate the pull-out piece spring base in position. 5. Install the brake push plate Insert the push plate release spring into the push plate; then install the push plate on the place between the front and rear brake shoe assemblies. Brake-27 6 Install the lower tension spring Install the lower tension spring between the front and rear shoe plate. 7. Install the clearance-adjusting device. Install the clearance-adjusting device after poke the brake shoe by screwer. 8. Install two upper release springs Insert the block into the support pin, then install the upper release spring on the place between two brake assemblies. 9. Check the operating process of automatic adjusting mechanism. a. Pull the manual brake pill-wire, then release it. Check the clearance-adjusting gear for rotation. If can not rotate, check the rear brake and find the problem. b. Adjust the clearance-adjuster to the length as short as possible. Brake-28 10. Adjust the clearance between the brake drum and brake shoe. Poke the adjusting hole plug on the brake drum, insert the screwdriver into the clearance-adjusting hole; rotate the clearance-adjusting gear to expand the brake shoe until the brake disc can not be rotated by hand. Then rotate it for 3-5 teeth in anticlockwise, rotate the brake disc by hand at the same time, it is proper that it can rotate freely and without the contact between the abrasion and disc. It is allowable that the non-running-in brake shoe has the slight abrasion sensing. When adjust the clearance, the left and right wheel must be adjust at the same, install the adjusting hole plug after the completion of adjusting . 11.Rear brake caliper assembly 12.Rear wheel assembly Tighten torque :120N.m Brake-29 Adjustment load-sensing proportional valve The action of load-sensing proportional valve is to prevent the rear wheel is braked before the front wheel is braked by adjusting the distribution of front and rear brake force according to the difference of vehicle rear shaft load, then avoid the risk of vehicle rotation. The adjustment of proportional valve is shown as follows: a. The rear shaft load can be 820Kg after adjustment (including driver). b. Install the brake pressure measuring meter and drain the air. c. Increase the front brake pressure to 12Mpa, the rear brake pressure should be within 8 9 Mpa. d. If necessary, adjust the hydraulic pressure. 1. Move the sensing spring bracket on the rear axle, the right hook of sensing spring moves to right; the rear brake pressure is increased . 2. Vice versa, the rear brake pressure decreases, the adjustment scope of the frame is 20mm. 3. The extension amount of spring of load sensing proportional valve is controlled within 84 95mm. Brake-30 output manometer input manometer Replace of load-sensing proportional valve 1. Removal Disconnect the brake pipeline form the valve; remove the lock nut and remove the adjusting bolt from the suspension arm bracket; remove the installation bolt and take off the load-sensing proportional valve assembly. 2. Installation a. Use two installation bolts to fix the load-sensing proportional valve. The bolt tightening torque is 23N m, b. Tighten the adjusting bolt locking nut, c. Connect each brake pipeline. The tightening torque of the connector is 16N m, d. Filled with the brake fluid, discharge the air from the brake system; check the brake pressure and leakage. Brake-31 Antilock Braking System (ABS) Cautions 1. It must not remove or install the electric elements and wire bunch plug when the ignition switch is in ON to avoid the damage of ECU. It should turn off the ignition switch if needs disassembly. 2. Pay attention to do not knock or impact the ABS ECU during the maintenance and repair, for it will damage the ABS ECU easily. 3. The wheel speed sensor and hydraulic unit (integrated with ECU) of BOSCH ABS8.0 can not be repaired, it should be replaced in integral if damaged. 4. After the brake system is maintained, the brake pedal maybe soft. Discharge the air according to the normal brake system. 5. It must use the brake fluid from original manufacturer; the brake fluid of different number cannot be used in mixed, otherwise it will cause the failure of brake system. Select the tyre of original type as most as possible Repair of Antilock Braking System (ABS) 1. It should process the failure diagnosis for the brake system before process the ABS failure diagnosis. It can diagnose out the failure rapidly by using Table 1. In Table 1, the small number means the failure which occurs most possibly. Check each element according to the sequence and maintain or replace it if necessary. 2. Check the following elements for normal operation before the diagnosis: Brake fluid level and brake fluid quality Pressure of tyre, size of tyre, shape and depth of tyre figure Other brake component These components will affect the brake effect of the ABS. Check the system sensor, connecting wire and connector for correct installation, arrangement and connection. Ensure the completeness of fuse, repair or replace it if necessary. 3. Process the analysis and diagnosis according to the ABS advanced by owner. Use the diagnosis instrument (Annex 1) for final check and confirmation. It must process the run inspection after the competition of all ABS maintenance. The test condition is shown as follows: 4. a. Confirm the tyre complies with the requirement, the tyre pressure is normal. b. The brake system (including brake light ) is normal c. The brake system is without leakage. d. The position and installation of wheel speed sensor is correct. e. All fuses are normal. test method: Run for 1 min at least when the vehicle speed is beyond 40Km/h, process a proper brake. Then read out the failure code to ensure the ABS is without failure code. Brake-32 Brake-32 Table 1 Name of element (failure) Brake is low or soft Brake system (leakage of brake fluid) 1 1 Brake system (with air) 2 2 Lag of brake Block of brake brake shoe (worn) Piston oil seal (worn or damaged) 3 1 4 11 parking brake (brake shoe is out of round) 4 parking brake (improper adjustment) 2 parking brake pull-wire (lag) 3 Assist push bar (improper adjustment) Brake noise 3 brake pedal (small free stroke) Brake main pump (failure) The brake is very hard but has bad effect 5 9 8 Tension or release spring (failure) 8 brake shoe (crack or deformation) 5 5 Piston (lag) 6 1 brake shoe (with oil) 8 2 Piston (block) 7 assist system (vacuum leakage) 10 4 1 5 3 9 brake shoe support plate (loose) 4 fixed bolt (loose) 2 Slide pin (worn) 5 brake drum (crack) brake shoe (with foreign material) 4 7 3 6 6 brake shoe (harden ) 7 Noise reduction plate (worn) 9 Press spring (damaged) 10 Steering-1 Chapter 9 Steering Precautions...............................................................................2 Troubleshooting........................................................................2 Inspection on vehicle.................................................................3 Steering linkage........................................................................4 Hydraulic power steering system...............................................6 Steering-2 Steering-3 Steering-4 Steering-5 Technical requirements 1.The fastening torque of the mounting bolts of the integral power steering gear assembly is 2.The fastening torque of the connecting bolts of the steering drive subassembly and the integral power steering gear assembly is 3. The fastening torque of the connecting bolts of the steering drive assembly and the left horizontal beam of the frame is 4. The fastening torque of the mounting bolts of the power steering pump is 40N.m. 5. The tension force of multi-wedge belt 4PK1100 is 4PK1100. 6. Centering fastening of the handwheel: steer the front wheel to the right front and remove the handwheel without changing the position of the steering stem, install the handwheel aligning the center, the radials of the handwheel should be at the left & right centering state; the symbol of “the Great Wall” on the steering wheel shall be in driver’s straight view position, secure the nut firmly with the fastening torque of 7. Inspection of free clearance of the handwheel Steer the car in a straight direction and stop the engine, apply a 5N force to the handwheel along the circumference, left turn the handwheel and stop the turning when the resistance is increasingly felt with each turn; then right turn the handwheel and stop the turning when the resistance is increasingly felt with each turn; the angle rotated along the circumference is the free clearance of the handwheel, whose standard value shall be below 20 , and the angle from the center to the right shall not be more than 10 Steering-6 Steering-7 B-Black Br- Brown G- Green Gr- Gray L- Lake blue Lg- Light green Or- Orange P- Pink R- Red V- Violet W- White Y- Yellow Wire Harness Wire harness middle link number pin function diagram 1 linked to instrument wire harness 2 linked to engine bay 2 Figure VIII 2.2-1 Controller of the Central Door Lock 1. Positive pole of the power supply (12V) is connected to the positive pole of car’s battery through a 15A fuse; when the engine is started, the voltage is not less than 10V. 2. Output of the central door lock. The unlock cable connected to the executor of the central door lock is usually grounded through the normally-closed contact of the internal relay; when the door is unlocked by the remote controller or unlocked manually, the public contact of the relay will get through with the normally-open contact, realizing an output of 12V voltage. 3. Output of the central door lock. The lock cable connected to the executor of the central door lock is usually grounded through the normally-closed contact of the internal relay; when the door is locked by the remote controller or locked manually, the public contact of the relay will get through the normally-open contact, realizing an output of 12V voltage. 4. Key detection cable. This cable is connected to the ignition lock of the car and will get through with the grounding wire when the key is inserted into. (negative input) 5. Right direction indicator. The cable is connected to the positive pole of the right direction indicator of the car; an output of 12V voltage will be available when this cable is at work. 6. Left direction indicator. The cable is connected to the positive pole of the right direction indicator of the car; an output of 12V voltage will be available when this cable is at work. 7. Negative input of door switch, which is connected to the door switch of the car; this cable will be earthed when the door is opened. (Interior lights will be on) a. Open the door and then close it, the reading light will be on for 10 seconds; if during this period, it is detected that the key has been inserted into the ignition lock or the door closed, then the reading light will turn off. b. When the key is pulled out of the ignition lock, then reading light will turn on, during this period, if the key is reinserted into the ignition lock or the door lock, the reading light will be off; if there is not any action when the door is closed within 1 minute, the reading light will automatically turn off. 8. ON power supply detection cable. A conductive wire connected to the ON gear of the ignition lock. (When the key is turned to the ON position, a 12V output will be available) 9. Car speedometer detection cable, which is connected to the detection cable of car's speedometer. (When the car is accelerated to the speed of 15km/h, the instruments unit will output a 500mS rectangular positive pulse to the central door lock controller, which will control the locking of the central door lock when this 500mS rectangular positive pulse signal is detected by the controller.) 10. Output of window closing signal. When the door is locked by the remote controller, this line will be available with an output of 12V positive current for one second and then be off. (No output) 11. Locking signal. The locking signal line connected to the central door lock of car's left front door is connected through with the grounding line when at work. (Earthing) 12. Unlocking signal. The unlocking signal line connected to the central door lock of car's left front door is connected through with the grounding line when at work. (Earthing) 13. Negative pole of the power supply, which is connected to the car body, (earthing) line shall be as short as possible, over-length will produce the interference. Function of controller of the central door lock 1. Locking. When all the car doors are closed, press LOCK button of the remote controller once, at this time, the direction indicator will flash once and the central door lock is closed. 2. Unlocking. At the locking state, press UNLOCK button of the remote controller once, at this time, the direction indicator will flash two times and the central door lock is opened. 3. Car-finding function. At the locking state, press LOCK bottom of the remote controller once, and at this time, the direction indicator will flash ten times quickly. Press UNLOCK button of the remote controller to quit the car-finding function. 4. Automatic prevention function. At the locking state, press UNLOCK button of the remote controller to open the lock; if the CD Player and Air Conditioning System-1 Chapter 11 CD Player and Air Conditioning System CD Player and Air Conditioning System-2 CD Player Function Overview This product is a kind of car audio system with VFD multi-information integrated display screen with such functions as PLL electronic tuning radio, CD playing and operation & control of air conditioning system, it can receive AM, FM and FM stereo radio broadcast programs, play CDs, electronically operate and control the air conditioning system of the car. The integrated display screen can display the working state of the radio, CD player, air conditioning system, operating mode as well as information concerning the equalizer, clock and the temperature inside and outside. Wiring Instructions(see the diagram) with the speakers: the amplifier of main unit of this system is designed with 4-channel BTL output, each speaker must be wired individually; the phase position and place of the speaker must be connected correctly; please disconnect the player from the power supply before connecting the speaker so as to avoid the short-circuit. 2. Connecting main unit with the integrated display screen: Use the specially-supplied 12-pin connector cable to connect the VFD integrated display screen and main unit. 3. Connection of power supply, output and communication line of main unit: At first, connect the communication cable of the 20-pin connector plug to the air conditioner ECU, then connect the speaker output line to other lines, finally connect the yellow memory power supply cord (10A fuse tube) directly to the positive role of accumulator; when all the wiring is completed, connect the red power supply cord (1A fuse tube) to the positive power supply of the ignition lock. 4. Connecting main unit with the antenna Typical antenna: insert the plug of coaxial cable of car’s antenna into the antenna socket of main unit. Automatic antenna: insert the plug of coaxial cable of car’s antenna into the antenna socket of main unit, then connect the blue antenna control cable in the 20-pin connector to the automatic antenna control end, connect the positive pole line of power supply of automatic antenna to the positive pole of accumulator and the negative pole line to the earth. 5. Connecting main unit with CD-change box CD player and the CD-change box are connected with the signal cables. Prior to the installation, please be sure to remove three protective screws on the CD-change box and have it pasted with ant-dust paper. If the protective screws are not removed, CD can not be played normally. Attention: Improper wiring may result in the damage to the player! 12-pin connector cable 20-pin connector cable antenna adaptor integrated display screen main unit (Figure 7-1) Wiring Diagram CD Player and Air Conditioning System-3 A-side View (Figure 7-2) cable position of 2-pin connector socket Pos. No. Color Function Pos. No. Color Function 1 White Send the data (TX) 11 Shielded cable Earthing of data cable 2 Red Receive the data (RX) 12 — — 3 Brown Telephone mute (TEL) 13 Blue Automatic antenna (ANT ) 4 Orange Lighting (LAMP) 14 Red Ignition power supply (ACC) 5 — — 15 6 — — 16 Yellow Memory power supply B+ Front left speak (-FL-) 17 Green and black Rear left speak (-RL-) Front left speak (+FL+) 18 Green Rear left speak (+RL+) Front right speak (-FR-) 19 Violet and black Rear right speak (-RR-) Front right speak (-FR+) 20 Violet 7 White and black 8 9 White Gray and 10 black Gray Grounding wire {Rear right speak (+RR+) Possible Troubles of CD Player, Inspection and Analysis Trouble Descriptions No programs received for AM and FM Impurity of sound after radio auto-searching No sound of one speaker Refuse to work No power supply Possible causes, inspection and solutions Check if the antenna is pulled out and socket becomes loosened. Tune to the correct radio station with manual tuning method Check the speaker and the socket or adjust the balance(front, back, left and right) Check the power supply, or disconnect and connect the power supply and restart the player. Check if the plug-in fuse and output plug is loosened and if the fuse is burned down. Single channel when played Check if the speaker is in open-circuit and examine its plug Not read CD Check the CD type and if it is placed in reverse or scratched. Display screen displaying bad Check the connecting wire of display screen or adjust the brightness level higher Air conditioner refuses to start Inspect the ECU of air conditioner and air conditioning system Button failure of air conditioner Inspect the ECU of air conditioner and air conditioning system CD Player and Air Conditioning System-4 Air Conditioning System Composition of Air Conditioning System Air conditioning system mainly consists of air conditioner control unit, display unit, sensors and executor elements. outside temperature sensor fresh air damper executor inside temperature sensor mode damper executor integrated display screen temperature sensor of the evaporator emperature damper executor of the air conditioner CD Player CD Player and Air Conditioning System-5 1. integrated display screen 2. CD player 3. Air conditioner ECU 4. Temperature sensor the evaporator 5. Outside temperature sensor 6. Outside temperature sensor 7. Speed-adjusting module 8. Temperature damper executor 9. Mode damper executor 10. Fresh air damper executor Definition of each button on CD player of air conditioner panel [1] Button to increase the temperature [7] wind conveying mode button [2] Button to decrease the temperature [8] button to start air conditioner [3] automatic operation button [9] button to decrease the wind amount [4] front-defrost button [10] power-off button of air conditioner [5] rear-defrost button [11] button to increase the wind amount [6] external circulation button Definition of each button in air conditioning display zone of the integrated display screen [1] display of inside temperature setting of air conditioner [5] switch button of outside temperature display [2] display of automatic operation of air conditioner [6] display zone of outside temperature [3] display zone of wind conveying mode of air conditioner [7] clock display zone [4] display zone of wind amount of air conditioner Control and display unit:Control and display unit of the air conditioner mainly consists of: Air conditioner ECU: The CC6460K model is designed with the individual air conditioner ECU to control the overall operation of air conditioning system; Air conditioner ECU is installed under the bottom of CD player.The control panel of air conditioner is designed with an integrated pattern with the control panel of CD player: to regulate, control and set the operation of the air conditioning system. Integrated display screen: display the working condition of air conditioning system of the car; relevant functions of air conditioning system can be found to be displayed in different zone in the integrated display screen. The sensor Sensors of CC6460K Model automatic air conditioning system include: inside temperature sensor, outside temperature sensor, temperature sensor executor of the evaporator. Executor components include: mode selection executor motor, cold & hot executor motor, internal & external circulation executor motor. Trouble Diagnosis and Repair of Automatic Air Conditioning System 1. Self-diagnosis of the system CC6460K air conditioning system is designed with the system self-diagnosis function. When the air conditioning system fails to work, the self-diagnosis function designed for the car can be activated for the initial trouble diagnosis. Operating directions: At first, start the engine (turn the ignition switch from OFF to ON) and press OFF,A U TO, RR and MODE successively and the pressing of MODE switch shall last at least 2 seconds. The button must be pressed down within 10 seconds when the engine is started (the ignition switch is turned to ON position).If the system is supposed to be released, then press A U TO switch or turn off the ignition switch (OFF) .If one step is supposed to switch to another step, then press TEMP (HOT) or TEMP (COLD) switch based on the needs. CD Player and Air Conditioning System-6 The inspection procedures Turn the ignition switch from OFF to ON During the period of 10 seconds after the engine is started(turn the ignition switch from OFF to ON), press OF F, A U TO, RR and MODE once more, and the pressing of MODE switch shall last at least 2 seconds . NO The display symbols all light up failure of the switch or display tune Press down “Temp+” switch NO Enter into self-diagnosis procedur1? “ Temp +” switch failure Step 1: Display “01” (set the temperature zone) Press down “Temp+” switch Step 2: Display “02”(set the temperature zone) All sensors are good. all other display symbols turn off Display “000”(outsidetemperature) CD Player and Air Conditioning System-7 Sensor failure Code of failure The code of the sensor with failure is showed on the display screen. Sensor failure 100 Open circuit of outside temperature sensor 200 Short circuit of outside temperature sensor 010 Open circuit of inside temperature sensor 020 short circuit of inside temperature sensor 001 Open circuit of temperature sensor of the evaporator 002 Short circuit of temperature sensor of the evaporator Press down “Temp+” switch Step 3: Display “03”(set the temperature zone) Display the outside temperature value Press down “Temp+” switch Step 4: Display “04”(set the temperature zone) Display the inside temperature value Press down “Temp+” switch Step 5: Display “05” (set the temperature zone) Press down “Temp+” switch Display the temperature value of the evaporator CD Player and Air Conditioning System-8 Step 6: Display “06”(set the temperature zone) Code number Code Meaning 0x0 Temperature damper executor works normally Display the detection code of mode/ 0x1 Detection for temperature damper executor is in progress. temperature damper executor 0x2 Temperature damper executor failure 00x Mode damper executor works normally 01x Detection for mode damper executor is in progress. 02x Mode damper executor failure Press down “Temp+” switch Note: X is a digital number without specific meaning; the code number is displayed in the outside temperature display zone. Step 7: display “07”(set the temperature zone) Action of the executor mechanism: Mode damper: wind to the person Circulation damper: internal circulation Temperature damper: cold end Wind amount: the maximum Compressor: enabled Press down “Temp+” switch display “08” C CD Player and Air Conditioning System-9 Action of the executor mechanism: Mode damper: wind to the person and the fee Circulation damper: internal circulation Temperature damper: in the middle Wind amount: bigger Compressor: enabled Press down “Temp+” switch Step 9: display “09” Action of the executor mechanism: Mode damper: wind to the person and the feet Circulation damper: external circulation Temperature damper: hot end Wind amount: medium Compressor: enabled Press down “Temp+” switch display “10”(set the temperature zone) Action of the executor mechanism: Mode damper: wind to the feet and defrost Circulation damper: external circulation Temperature damper: in the middle Wind amount: small Compressor: off CD Player and Air Conditioning System-10 Press down “Temp+” switch Step 11: display “11”(set the temperature zone) Action of the executor mechanism: Mode damper: defrost Circulation damper: external circulation Temperature damper: cold end Wind amount: the minimum Compressor: off Attention: during the inspection period from step 7 to step 11, the controller will forcibly transit the output signal based on the code number displayed on the integrated display screen to the functioned executor; the inspection must be done with such methods as visual inspection, listening to abnormal sound or touching the air vent by hand so as to judge whether there is any improper operation. Trouble Diagnosis and Troubleshooting of A i r Conditioning System Air cooling system Refrigeration of air conditioner failed Trouble Descriptions Analysis of the Cause 1. fuse burned down, compressor’ s relay damaged 2. pressure switch contact disconnected, short circuit or open circuit of the routing 3. open circuit of clutch’s winding 4. switch burned down 5. master relay burned down 6. slide of the clutch 1.No pick-up of compressor 7. belt of the compressor broke or too loose 8. compressor failure 9. sensor failure(judged by reading the failure code) R efrigeration air 10. insufficient cold media, lower systempressure(< 0.97MPa) of conditioning 11. system pressure above 1.37MPa system failed 12. water temperature of the engine too high 13.V oltage of the clutch below 7V 1. normally-open contact of the compressor’ s relay stuck and serious leakage 2. Pick-up of Compressor of system cold media, systemrunning short of cold media 2. no wind from the blower 1. fuse burned down 2. motor brush of the blower damaged 3. no wind from the blower 3. switch of the blower damaged 4. coming off of distribution wire connectors or circuit disconnected 5. speed-adjusting module damaged 6. no wind from the blower when at high speed, high-speed relay damaged CD Player and Air Conditioning System-11 b .Insufficient refrigeration output T rouble Descriptions Analysis of the Cause 1. compressor works normally (1) low-level pressure at high-pressure and low-pressure sides a. block of expansion valve b. openness of expansion valve too narrow (2) high-level pressure at high-pressure and low-pressure sides a. failure to high-voltage pipeline, flow not smooth b. malfunction of thermo resistor c. openness of expansion valve too wide d. too much refrigeration oil e. too much refrigerant f. poor heat dissipation of the condenser (3) pressure at high-voltage side too low a. low-pressure pipeline damaged b. block of low-pressure pipeline (4)pressure at low-pressure side too low a. the evaporator frosted b. block of expansion valve c. low-pressure pipeline not smooth d. malfunction of thermo resistor (5)pressure at low-pressure side sometime normal, sometimes with negative pressure, Inadequate 1. wind amount moisture and ice block in air cooling system refrigeration is normal (6)negative pressure at low-pressure side, pressure at high-pressure side too low, block of air cooling system (7)pressure at low-pressure side too low, pressure at high-pressure side too high a. internal block of drier of fluid reservoir b. block of high-pressure pipeline (8)pressure at low-pressure side too high, pressure at high-pressure side too low a. leakage of the compressor b. damaged valve of compressor (9)poor heat radiation of condenser due to small wind amount from the condensing blower 2. compressor works improperly (1)internal malfunction of compressor (2)belt of compressor too loose or sliding (3)failure of electromagnetic clutch a. low voltage of power supply b. mutual interference of the stator and rotor c. malfunction of amplifier stabilizing the idle speed d. circuit disconnected, coming off of the joints e. poor operation of the switch and relay f. short circuit and open circuit of the routing g. poor earthing 3. other causes bad sealing of wagon CD Player and Air Conditioning System-12 c. T he cooling system sometimes works while sometimes refuses to work. T rouble T he cooling system sometimes produces refrigeration effect while sometimes not. Descriptions 1. compressor works normally compressor works improperly d. A nalysis of the Cause 1. ice block in the cooling system 2. failure of thermal resistor or temperature sensing bulb 3. poor contact of A /C switch 4. condensing blower damaged 1. slide of the clutch 2. coming off of the clutch’ s winding 3. poor earthing of clutch’ s winding Noise of the air cooling system T rouble Noise of the air cooling system too loud Descriptions Noise too loud A nalysis of the Cause (1) belt too loose or worn too much (2) fastening screw of mounting holder of the compressor loosened (3) mounting holder of the compressor damaged (4) internal parts of the compressor damaged (5) too much refrigeration oil or none (6). slide of the clutch (7). B earing of the clutch running short of oil or damaged (8). motor bearing of the blower damaged (9) holder of the blower broken or loosened (10) blade of the blower broken or loosened (11). Friction of the blower’ s blade with other components e . Precautions for the overhaul of air cooling system When the air cooling system encounters the trouble, the cause for such trouble shall be analyzed inlightof trouble varieties, followed with the examination and report work. CD Player and Air Conditioning System-13 2.air heating system T rouble Heating not supplied or not sufficiently supplied No rotation of blower leakage of water Overheat Insufficient hot air volume for defrosting C auses of the trouble 1. blower of air conditioner failure 2. relay of the blower damaged 3. heating water pipe blocked 4. cooling water pipe blocked 5. cold/hot damper executor damaged 6. insufficient cooling liquid 1. fuse burned down or poor contact of the switch 2. motor of the blower burned down 3. open circuit of high-speed relay of the blower 4. speed-adjusting module damaged 5. short circuit W ater pipe of air heating aged, insecure joint 1. speed-adjusting resistor of the fan damaged 2. cold/hot damper executor damaged 1. 2. 3. 4. 5. 6. 7. mode executor damaged falling off of the drive rod damper not in position air vent blocked inadequate heating supply installation of wind tunnel not fit circuit disconnected Volume of Refrigeration Oil Addition and its Methods 1. CC6460K air conditioning system is designed with SD7V16 compressor, whose refrigeration oil type as specified is SP-10PAG; hence application of other type of refrigeration oil may damage the parts and compo nents of the compressor. When the air conditioning system goes through maintenance and replacement of parts, it should be added with new refrigeration oil, whose volume is listed as follows: the evaporator and condenser: 30ml; the drier: 20ml; the pipeline: 10ml. Addition of refrigeration oil can be available with two methods: The direct addition and the vacuum suction 2. Direct addition method a. remove the oil filler plug and fill with the specified SP-10PAG refrigeration oil. b. observe through the hole of oil filter plug and rotate front plate of clutch to make the piston connecting rod right position in the center of the hole of oil filter plug. c. insert the dipstick along the right side of piston connecting rod till the top of dipstick touches the case of the compresso r d. pull out the dipstick and examine the graduations (grooves) of refrigeration oil, the readings shall be within the range of 4-6 scales. e. screw firmly the oil filter plug with the fastening torque of 14.7± 4.9N. m 3. Vacuum suction method: Firstly pump out the refrigerating system to the vacuum of 0.2x105Pa, and then fill with the specified 0.2x105 Pa refrigeration oil; the detailed steps are as follows: a. switch off the high-pressure manual valve and the auxiliary valve. b. dismantle the high-pressure side hose from the manifold pressure gauge and insert it into the oil cup c. open the auxiliary valve and have the refrigeration oil sucked into the refrigerating system from the oil cup. d. when the refrigeration oil in the oil cup is almost pumped out to the vacuum, then immediately turn off the auxiliary valve to prevent the air from being sucked into the system. e. secure the hose adapter at high-pressure side to the manifold pressure gauge, start the vacuum pump and turn on the highpressure manual valve, then turn on the auxiliary valve to pump the system to the vacuum state of 0.2x10 5Pa, keep such state for 15mins so as to discharge out the air flowing into the system along with the oil. CD Player and Air Conditioning System-14 4. Attention: a. when a new compressor is used to substitute for the old one, the oil must be released to some extent that its oil volume is the same as that of old compressor so as to avoid the influence over the refrigeration effect due to too much oil. b. when an old or repaired compressor is employed, the volume of the refrigeration oil in the compressor must be kept the same as that of the replaced compressor. Pumping Out of A i r Conditioning System to the Vacuum and Addition of Refrigeration Oil Connect the manifold pressure gauge with the pipe of air conditioner (compressor) and the multi-purpose adapter of the vacuum pump for the purpose of pumping out of the system to the vacuum state. Before pumping out to the vacuum, turn on the high-pressure and low-pressure valve of the manifold pressure gauge and the end valve (if provided) of the vacuum pump, then press the button ON to start the vacuum pump, the duration shall be more than 20 minutes. When the reading of manifold pressure gauge is -760mmHg or below, turn off the high-pressure and low-pressure valve (if opened), and press the switch to turn off the vacuum pump. low pressure high pressure manifold pressure gauge blue quick coupler manifold pressure gauge low pressure gauge high pressure gauge red quick coupler low-pressure pump high-pressure pipe yellow quick coupler blue yellow Red vacuum pump 1. check the air tightness Continue to check the pressure reading of the manifold pressure gauge after turning off the vacuum pump. If the pressure reading remains unchanged within 20 minutes after the vacuum pump stops running, then it indicates that th e refrigerating system has no leakage, the operator can proceed with next work; while change of the reading indicates that the system has the leakage. Launch the examination and pump out to the vacuum after the leakage is fixed. 2. Injection of the refrigerant When the air tightness of the system is verified correct, connect the refrigerant reservoir (or gas bottle) with one end of the yellow air-charging hose, while other end of yellow air-charging hose is connected with the liquid injection port in the middle of the manifold pressure gauge. Ensure that the refrigerant reservoir is connected firmly with the nut of air-charging hose, then turn on the valve of refrigerant reservoir; at this time, the high-pressure and low-pressure is closed, use a tip screw driver or other similar tools and press the by-pass valve spool for 1~ 2 seconds to discharge out the air in the air-charging hose and the manifold pressure gauge. CD Player and Air Conditioning System-15 low-pressure off air washing off blue off red blue yellow low-pressure pipe tip screw driver high-pressure on red yellow high-pressure pipe refrigerant reservoir refrigerant reservoir Turn on the high-pressure valve on the manifold pressure gauge and inject the refrigerant to the system from high-pressure pipeline. At this time, the attention shall be given to the readings of high-pressure meter and low-pressure meter, and make sure that these two pressure all go up. If the refrigerant is being injected while the pressure does not go up, then the joints of the pipeline may be loosened or the seals damaged, inject the refrigerant once more after finding out the cause and the fixing. When the increase of pressure stops, turn off the high-pressure valve of the manifold pressure gauge and then start the engine. Operate the switch in a way as follows: Turn the switch of air conditioner to “ON” Regulate the temperature controller to the coolest position, Enable the air conveying to the maximum, Select the internal air circulation between the internal/external air circulation, During this process, the door and windows will be all opened. Adjust the engine’s speed to the specified free running speed. Erect the refrigerant reservoir or gas bottle (have the refrigerant injected into the refrigerating system in a gas state), turn on the low-pressure valve of the manifold pressure gauge. When the compressor is at work, please do not turn on the high-pressure valve. Before checking the refrigeration level, please confirm the injection volume of the refrigerant specified for air conditioning system. When injecting the refrigerant, carefully observe the high-pressure side of the manifold pressure gauge and the flow condition of the refrigerant (clear, foaming or turbid), all these could be viewed through the inspection window, by which the moment of stop injecting the refrigerant can be reasonably judged(turning off the low-pressure valve). CD Player and Air Conditioning System-16 low pressure high pressure on on blue red low-pressure pipe high-pressure pipe yellow refrigerant reservoir When judging the injection volume of the refrigerant, please make the settings based on the following working conditions: Water tank temperature of the engine: stable Speed of the engine: normal free running speed Switch of air conditioner: ON Switch of the fan: “High” gear Temperature controller: air return temperature inside the car is between 25 and 30 . Fresh air control: internal circulation Door: all opened Window: all opened Repair and replacement of pipeline a. Before installation of parts and components, the negative pole of the accumulator must be disconnected. cut off b. When the air entries of the refrigerating system, water tank of the engine and the air conditioner are opened, please make sure that all openings are capped to prevent the penetration of the dust, foreign matters or water. protective cap protective cap protective cap must be installed. CD Player and Air Conditioning System-17 At ends of each pipe the protective caps should be installed till the pipe is connected to the refrigerating system. compressor oil fasten it by using two wrenches at the same time d. When connecting the pipe, apply little compressor oil to the O-ring and fasten the nut with two wrenches. Attention: never spatter the compressor oil to the painted parts or the plastic components to avoid the corrosion. If these components are spattered with the oil, please clean it immediately. e. When connecting the pipe, please follow the torque listed in the following table to fasten the screws or the nuts: Diameter of Pipe Fastening Torque (N·m) ￠8mm 12-15 ￠16mm 30-35 30－35 Daily Maintenance of Air Conditioning System In order to ensure normal operation of air conditioning system, maintenance and care services shall be frequently performed for the air conditioning system. The daily maintenance of air conditioning system is illustrated as follows: 1. Inspect, wash and clean the condenser of air conditioning system, requiring that radiator pins are clean and there is no dirt between the pins. After the car runs in the rain or on the muddy road, the fan of the condenser should be inspected to find whether it bears the earth, sand, stone and etc, and remove them if any. 2. Check the quantity of the working media of the refrigerating system; when the compressor set works normally, observe the liquid viewing glass, under the normal circumstance, there shall be not air bubbles in the glass. 3. Inspect the drive belt. The belt between the compressor and the engine should be tensioned. 4. Check if there is any abnormal noise or odor in the air conditioning system. 5. Check if the temperature difference between the air inlet and outlet of the compressor is normal. 6. Check if the hose of the refrigerating system is in an apparent good condition and connections of all joints are secure. 7. Check if the pipeline of the refrigerating system collides with other parts and components, and if there is any oil leakage trace left at each joint. 8. Check if the circuit connection of the refrigerating system is secure and if there is an occurrence of short circuit and falling off 9. Check if fastening bolts of the compressor are firmly secured or broken. Safety airbag-1 Chapter 12 Safety airbag Safety airbag-2 Instructions for maintenance For your safe operation, please read the following instructions prior to your operation. 1. The maintenance of SRS safety airbag must be operated under the procedure and directions instructed in this chapter. 2. The operation must be done with the test instruments and special tools designated by the chapter. 3. The following parts must be replaced by new ones providing something wrong with them. a. SRS safety airbag control unit (SRS-ECU) b. Clock spring module c. The driver’s side safety airbag module d. The passengers’ side safety airbag module. e. Safety airbag wiring harness. 4. The safety airbag electric principles figure and definitions of connector clips are in Figure 1,SRS-ECU stitch definition in Table 1 and the position and form of safety airbag failures indicator lamp in combined instrument in Figure 2. Table 1 SRS-ECU stitch description Wire# Name Description Diagnosis of serial data I/O (K-line) The driver’s side safety airbag, high position The driver’s side safety airbag, low position Passengers’ side safety airbag, high position Passengers’ side safety airbag, low position Diagnosis request 5. The maintenance operation must be started after 60 seconds following the removal of negative connection of accumulator, wrap the negative with insulating tape for insulation. Due to the capacitance in SRS-ECU to maintain certain power to make the safety airbag release within a certain time after the power-off of accumulator, the operation must be started after a while to avoid any possible major damaging accident caused by the safety airbag’s improper release. 6. The parts such as SRS-ECU, safety airbag module as well as clock spring should be removed off and well preserved providing the temperature is high enough to cause any damage(above93¡æ) in the painting operation. The failure codes must be debugged with the diagnostic scanner following the repairing of SRS safety airbag system so as to make alarm lamp work functionally. Safety airbag-3 Safety airbag-4 safety airbag system alarm lamp impact sensor and diagnosis module passengers’ side inflation elements and airbag insulating tape battery wire Safety airbag-5 Test instrument Instrument Name Utility Test the systematic failures in diagnostic scanner SRS safety airbag system, debug ECU. failure codes. The basic failure diagnosis process The failure code DTC of both present and history-accumulated failures may co-exist. Caution The safety airbag alarm lamp flashes for 6 times and then extinguishes when the ignition switch is in ON position after the installation of new safety airbag system electronic control unit, which demonstrates the normal function of SRS safety airbag system. In this case the system does not need to be tested, otherwise it should be diagnosed and repaired. If the alarm lamp does not illuminate when the ignition switch is in ON position, repair the alarm lamp relevant circuit and, then further operate to get it into work. The alarm lamp Scan the ECU by connecting keeps illuminating. the scanner with k-line Failure detection Failure Debug the handling failure codes The test for SRS safety airbag alarm lamp safety airbag system alarm lamp SRS-ECU will execute a series of diagnosis and test to check whether the function of airbag system is prepares. The check can prevent the restriction system from mis-explosion and ensure the necessary explosion during collision. If found the failure, SRS-ECU will save a proper failure code and light the alarm lamp to indicate a failure status for the convenience of maintenance. If connect the pin 2# wire 488# (diagnosis request wire) on the diagnosis port to the ground (wire 50#) for more than 2s, the safety airbag alarm lamp will flash the code. For detailed position refer to following figure. Safety airbag-6 brown white red diagnosis plug black Failure judgment 1. Failure record (failure code storage) When ECU determines the error through the cyclic diagnosis and test, SRS-ECU should saves the corresponding code, first judgment time, final judgment time and number of occurrence in EEPROM. RS-ECU can stores 6 failures at most, under voltage failure and two collision records (front and side). Failure code approved by SRS-ECU Serial No. Failure description Debugging 1 Ignition loop 1 (driver’s front airbag), resistance is too high or open-circuit. Can 2 Ignition loop 1 (driver’s side front airbag), resistance is too low or short-circuit Can 3 Ignition loop 1 (driver’s side front airbag), grounding Can 4 Ignition loop 1 (driver’s side front airbag), connected to power supply Can 5 Ignition loop 2 (passenger side front airbag), resistance is too high or open-circuit. Can 6 Ignition loop 2 (passenger side front airbag), resistance is too low or short-circuit Can 7 Ignition loop 2 (passenger side front airbag), connected to power supply Can 8 Ignition loop 2 (passenger side front airbag), connected to power supply Can 9 Power voltage is high Can 10 Power voltage is low Can 11 Alarm light failure, connected to power supply or lamp is short-circuit Can 12 Alarm lamp is failure- grounding or filament is open-circuit. Can 13 Shortage/failure of algorithm parameter 14 The front collision is recorded 15 Communication failure 16 Internal failure (refer to following table) Cannot (replace the SRS-ECU) Cannot (replace the SRS-ECU) Can Cannot (replace the SRS-ECU) Safety airbag-7 The failure code transmission is completed by SRS-ECU’s input to the defined diagnostic scanner through the maintenance system’s serial data interface. (X-431 diagnostic scanner) Failure code of diagnosis Description of flash code Failure Failure code Flash code 1 No storage error $12 2 Front airbag driver’s, high resistance $9,021 $21 3 Front airbag driver’s , low resistance $9,022 $22 4 Front airbag driver’s, short-circuit of GND $9,024 $24 5 front airbag driver’s , short –circuit of VBATT $9,025 $25 6 front airbag passenger, high resistance $9,015 $15 7 front airbag passenger, low resistance $9,016 $16 8 front airbag passenger , short-circuit of GND $9,018 $18 9 Front airbag passenger , short-circuit of VBTT $9,019 $19 10 High voltage of battery $9,031 $31 11 Low voltage of battery $9,032 $32 12 Failure of alarm lamp $9,061 $61 13 Internal failure (replace SDM) $9,071 $71 14 Front collision record $9,051 $51 15 Side collision driver’s record $9,056 $56 16 Side collision passenger record $9,057 $57 17 Retightened safety belt collision $9,058 $58 18 Beyond the allowable repeat usage times $9,054 $54 3. Interior failure The micro controller can test the following items not only in starting detection but also in cyclic diagnosis detection. a. Ignition circuit triggers the transistor: The high-side transistor is detected not only in the starting detection but also in the circulation diagnosis. But for the low-side transistor is opened when is connected to power supply directly, so the low-side transistor only can be detected in the starting detection to avoid the misexplosion. b. The ignition voltage is provided by the booster transformer. c. The acceleration sensor is detected by itself when start the detection. d. Allowable deviation scope of acceleration sensor in circulation diagnosis. e. Micro controller includes (AD converter, ROM, RAM etc.) f. Status of safety sensor Cautions: Connector of explosion tube circuit has the short-circuit bar. When the connector is not connected, the end (+) of explosion tube is connected to end (-) directly to prevent the failure outspread caused by static. When the connector is bas and short-circuit bar is connected, the failure may not be eliminated. An external watch dog can detect the operating status of micro controller. It can trigger the watchdog when the micro con troller has failure. The watch dog will reset the micro-controller and light the alarm lamp. Safety airbag-8 Internal failure determined by SRS-ECU Serial No. List of failure 1 Micro-controller 2 Driver’s front airbag ignition loop 3 4 5 6 7 8 Description of failure AD converter or EEPROM is faulty (the micro controller will be reset and alarm lamp is light when the RAM has failure.) Enable the failure Measure the failure of loop Passenger front airbag ignition loop (if realized) Seat safety belt preloaded ignition loop (if realized) Enable the failure Measure the failure of loop Enable the failure Measure the failure of loop Passenger side safety belt preloaded ignition loop (if realized) Driver’s side airbag ignition loop (if realized) Enable the failure Measure the failure of loop Enable the failure Measure the failure of loop Passenger side airbag ignition loop (if realized ) Maximum times of explosion of safety belt pre-tightener Enable the failure Measure the failure of loop Reach the maximum value 6 Holding time of ECU energy (self-supply time) Too short 10 Accelerometer Deviation range Sensor not in constant, stable model Sensor tests the failure itself 11 The measurement of ignition loop is rejected continuously No cycling diagnosis test 12 Safety sensor Calculate the safety sensor open-loop using the method that power-off for 2 or more than 2 seconds is considered as passing 13 Initial firing current 14 The ignition of side airbag is not determined. 9 (duplicated calculation) All initial firing current in normal status when the front airbag releases. Though SRS-ECU has received ignition information for 5 times during HSIS cycling ignition, the ignition can not be determined due to the side safety.. Debug the failure codes Approach 1. The failure codes will be debugged following the ECU’s receipt from the X-431 diagnostic tester of the debugging failure codes order through the serial interface, however, if an internal failure code is recorded or one impact is recorded, the debugging will not be executed. Approach 2. Ground 488# line for 5 times in 10 seconds to debug the failure codes. Failure status display (alarm lamp keeps illuminating). 1. Bulb test SRS-ECU will light the alarm lamp in order to test the bulb after working voltage is provided to it through the battery. The lamp will flash for 6 times and then extinguish at 1HZ in the initial phase. The alarm lamp will keep illuminating after the working voltage is provided in order to inform the driver’s system failures. The alarm lamp will keep illuminating for 6 seconds after the ignition on and then be extinguished if the history-accumulated failures are less than five times. In the initial phase, SRS-ECU will not prepare to test impact and stop release till the circuit is stable. Therefore, alarm lamp’s display manner will be one of following projects in the initial phase. (Table 4.9). Project 1. If the impact is recorded or the number of history accumulated failures is or more than 5,the alarm lamp will keep illuminating, simultaneously, it will also keep illuminating if there is a possible explosion failure. Safety airbag-9 Project 2. The number of history- accumulated failures is or more than one and less than 5. (The case of low power is excluded) Project 3 functional working (neither possible explosion failure or historical failure). Table 4.9 indicator lamp’s activities after ignition 2.Failure indication The alarm lamp will indicate it in case any failure arises. If the external failure is a historical one, the indication will be called off. If the number of history-accumulated failures is or more than 5, the alarm lamp will keep illuminating albeit no failure emerges. The case of low power will be excluded. A displayed or historical failure can but only be reconfigured by the service personnel. An internal failure or impact record can not be reconfigured, in these cases, SRS-ECU must be replaced. 3.Micro controller-independent alarm lamp illumination The micro-controller in clear failure status can not work therefore can not control the alarm lamp. In this case, the alarm lamp will be directly lighted via suitable circuit despite of the micro-controller. As following, The battery for SRS-ECU fails, the alarm lamp will be continuously lighted through the lamp drive function. b. No internal working voltage, the alarm lamp keeps illuminating c. Reconfiguration caused by watchdog’s trigging failure, the alarm lamp flashes. d. No work of micro-controller, the alarm lamp keeps illuminating e. Incomplete plugging-in of SRS-ECU connector, the alarm lamp keeps illuminating via shoring bar Next explain the diagnostic procedure by taking some examples If the alarm lamp is found keeping illuminating, please test it according to the following procedure even it extinguishes finally. First test the failure region with the scanner followed by the test in the failure region with the corresponding approaches and steps. a If an internal failure or the explosion of safety airbag is scanned, replace the SRS-ECU b.Troubleshooting Safety airbag-10 Troubleshooting Extinguishments or normal-light of alarm lamp NO. Troubleshooting item The warning lamp of safety airbag 1 system is not displayed. 2 Description Safety airbag system warns circuit failure The warning lamp of safety airbag Safety airbag system warns circuit failure or external system is light normally. failure. 1. Extinguishments of safety airbag system alarm lamp 1 Extinguishments of safety airbag system alarm lamp Test status Safety airbag system warns circuit failure. No voltage (fuse shutoff) Possible causes Combined instrument failure Failure of wiring harness between instrument cluster and ECU unit Diagnostic procedure When first carry out failure test, joggle the wiring harness and plug to test whether there is periodical bad contact in the circuit, if it so, please confirm whether the plug, terminal and wiring harness well connected and in good condition. If it is not any of previous cases, operate according to the following steps. Procedure Test Test other wiring harness and instrument cluster 1 Operation Yes indicator lamp ·place the ignition switch in ON position ·light other alarm and indicator lamps Bulb test Place the ignition switch in LOCK position followed by next step Test the instrument cluster power-supply No system and grounding system (fuse), then go to step 5. Yes Next step Warning: Incorrect handling with the safety airbag system units will cause the safety airbag’s improper release and pretension of safety belt, which will lead to serene accidents. Please read safety airbag 2 service warning before handling the safety airbag units. ·Place the ignition switch in LOCK position。 ·shut off accumulator negative line and keep the status for at least 60 seconds. ·Remove the combined instrument. Test the connection between the two corresponding stitches of safety airbag alarm lamp No Replace the bulb of alarm lamp. Safety airbag-11 Procedure Test Operation Test the wiring harness connection between ECU Yes Next procedure. unit and instrument cluster. ·Place the ignition switch in LOCK position。 3 ·shut off accumulator negative line ·shut off the instrument cluster plug No Replace the wiring harness and get into step 5 ·test the connection between alarm lamp circuit and its relative circuits 2. Normal-light of safety airbag system indicator lamp 2 Normal-light of safety airbag system alarm lamp Test status Normal-light of safety airbag system alarm lamp Insufficient battery voltage ECU internal failure Combined instrument safety airbag alarm lamp failure ECU plug misconnects Possible causes Combined instrument plug bad-contact ECU power-supply fuse shutoff or bad contact Misconnection of ECU plug terminal Bad contact between ECU plug terminal and grounding wiring harness. Driver’s or passengers’ side safety airbag circuit failure. Safety airbag-12 Begin the test with diagnostic communication with special diagnostic device (X-431 diagnostic tester) and ECU to find out the failure causes, do the next test providing communication is not successful. Procedure Test Operation Yes Test the battery 1 Next procedure Insufficient battery supply. Test the battery voltage Is the voltage higher 9V? No Test Yes Next step the charging/discharging system, then go to step 5. Test the wiring harness connection between ECU and combined instrument. Place the ignition switch in LO C K position。 Shut off the battery negative. O pen the central channel guard plate. 2 No Shut off the instrument combined connector clip Connect the negative of battery Check the circuit and continue the operation according to step 5. Place the ignition switch in ON position. Check whether the instrument connector clip terminal voltage is 12V(power supply and instrument line) Place the ignition switch in LO C K position。 Yes Check the connection of corresponding terminals between 3 instrument connector clip and diagnostic interface Next step Repair No (diagnose the two ends of K-line) or replace the wiring harness and continue according to step 5 M ake sure the shutoff of accumulator negative line and Yes Next step keep the status for at least 1 minute. Shut off ECU connector clip 3 Shut off the instrument cluster plug. No Connect the ECU plug terminal 5,7,9 and instrument Replace the wiring harness and step 5 cluster plug? Remove EC U to check the condition of term inal and 4 whether the shorting bar is broken. Yes No M ake sure that the failure will never reoccur after Reconnect EC U connector clip and next step. Troubleshooting followed b y the Yes repairing. Replace ECU Place the ignition switch in LO C K position。 explanations to customers upon the repairing procedure. Shut off accumulator negative line and keep the status for at least 1 minute. Connect all ECU plugs Connect 5 the driver’s side safety airbag combined instrument plug Connect the passengers’ side safety airbag combined instrument plug Connect the driver and passengers’ side pretension safety belts plugs. (Vehicles with pretension safety-b elts) Connect clock spring plug Connect the accumulator negative line Place the ignition switch in ON position Does the safety airbag alarm lamp work functionally? Retest No the failure symptoms; repeat from step 1 if the failure reoccurs. Safety airbag-13 Internal failure Failure code SRS safety airbag system unit internal failure $9071 Warning The test condition of this failure is the failure code that may not emerge before the test, Test condition DTC conducts the test, and the preparatory work must be done before the test because the damage to working personnel or system may be caused by the incorrect operation during the test. SRS safety airbag system electronic-control unit internal circuit failure. Possible causes SRS safety airbag system unit internal failure Operation With regard to replacing SRS safety airbag system unit, take references in the removal/installation of safety airbag system Safety airbag-14 Power-supply Failure code Low power-supply voltage for SRS safety airbag system electronic-control unit $9032 Warning The test condition of this failure is the failure code that may not emerge before the test, DTC conducts the test, Test condition and the preparatory work must be done before the test because the damage to working personnel or system may be caused by the incorrect operation during the test. The voltage for SRS safety airbag system unit connector clip is stitch 5 and 6 is under 9V Possible causes Procedure 1 Accumulator low voltage Failure with the wiring harness between accumulator and SRS safety airbag system electronic-control unit Test Operation Check accumulator Yes Next step Test accumulator voltage No Accumulator low voltage, test the Is the voltage above 9V Check the wiring harness between accumulator and fuse recharging/discharging system Yes Next step No Check the wiring harness Yes Next step No Replace wiring harness panel 2 Remove fuse panel without releasing the connector clips Place the ignition switch in ON position Test the potential of two fuse corresponding contactors, the potential above 9V? Check the wiring harness between fuse panel and SRS safety airbag system unit connector clip Warning: If not correctly handled, the safety airbag module as well as pretension safety belt may possibly be trigged, released and tensioned, thus make serene damage to people. Therefore, please carefully read the repairing warning before trouble handling. Please take references in safety airbag system repairing warning Place the ignition switch in LOCK position Release accumulator negative wire and wait for 1 minute 3 plus Remove steering pillar shell Release the clock spring connection clips Remove the PAB trim cover, glove box (passengers’ side safety airbag is under the trim cover) Release passengers’ side safety airbag module connector clips Release all SRS safety airbag system unit connector clips Install back the accumulator negative wire, Place the ignition switch in ON position Is the potential of SRS safety airbag system unit connector clips stitch 5,6(grounding) above 9V? Safety airbag-15 Drive side failure Failure code $9021 $9022 $9024 $9025 4 Test condition Possible causes Procedure 1 Present failure codes Place the ignition switch in LOCK position Replace SRS safety airbag system unit Release accumulator negative wire and wait for 1 minute See he removal/installation of SRS plus Driver’s side safety airbag failure (high or low resistance, shorting grounding, etc.) Yes safety airbag system unit Remove the left trim cover History accumulated failure codes Shut off SRS safety airbag system unit translation The end of failure diagnosis connector clips Install back the accumulator negative wire, place the Warning switch in ON the position If ignition not correctly handled, safety airbag module as well as pretension belt may possibly be trigged, released No safety Replace wiring harness Is tensioned, the potential of make SRS safety unit connector and thus serene airbag damagesystem to people. Therefore, please carefully read the repairing warning before clips stitch 5,6(grounding) above 9V?in safety airbag system repairing warning trouble handling. Please take references Driver’s side safety airbag The resistance between the SRS safety airbag system connector clips connectors not within the designated scope SRS safety airbag system driver’s side airbag relative wiring harness shorting or shutoff Driver’s side safety airbag module failure Clock spring internal failure Failure of circuit connector clips between clock spring and SRS safety airbag system electronic-control unit Shutoff or shorting of wiring harness between clock spring and SRS safety airbag system electronic-control unit. Misconnection of SRS safety airbag system driver’s side airbag generator connector clip Test Operation Check the clock spring Warning If not correctly handled, the safety airbag module may possibly be trigged and released thus make serene damage to people. Therefore, please carefully read the repairing warning before trouble handling. Please take references in safety airbag system repairing warning. Are the relative parts of clock spring normal? (The relation between stitches, unnecessary shutoff or shorting?) if the present clock spring can be replaced by a better one. Next step Confirm the failure in driver’s side safety airbag module or other parts. Normal Abnormal Replace the clock spring Take references in the removal/installation for safety airbag system and clock spring Replace the driver’s side safety airbag module Safety airbag-16 4 5 6 7 8 Confirm the failure in clock spring or other parts configure the special tools fuel and temperature diagnostic instrument at 2Ω position Install back the accumulator negative wire Place the ignition switch in ON place Any failure code in display? Check the wiring harness between clock spring and SRS safety airbag system electronic-control unit Place the ignition switch in LOCK position Release accumulator negative wire and wait for 1 minute plus Remove PAB trim cover, glove box (passengers’ side safety airbag is under the trim cover) Release the passengers’ side safety airbag module connector clip Release all SRS safety airbag system unit connector clips Check whether the following troubles are with the harness between connector clips terminals of SRS safety airbag system unit and clock spring Grounding Power-supply shorting Shutoff Is the previous wiring harness normal? Check the clock spring connector clip Remove the steering pillar shell Release the clock spring connector clip Is the clock spring connector clip normal? Check clock spring Remove clock spring Take references in removal/installation of safety airbag system as well as clock spring Check clock spring Take references in the test for safety airbag system and clock spring. Is the clock spring normal? Check the wiring harness between clock spring and SRS safety airbag system electronic-control unit Place the ignition switch in LOCK position Release accumulator negative wire and wait for 1 minute plus Remove PAB trim cover, glove box (passengers’ side safety airbag is under the trim cover) Release the passengers’ side safety airbag module connector clip Release all SRS safety airbag system unit connector clips. Check whether the following troubles are with the harness between connector clips terminals of SRS safety airbag system unit and spring clock. Grounding Power-supply shorting Shutoff Is the previous harness normal? Yes Next step No Replace clock spring Take references in the removal and installation for safety airbag system and clock spring. Normal Replace SRS safety airbag system unit; take references in removal/installation of SRS safety airbag system unit. Abnormal Replace the wire harness Normal Next step Abnormal Replace the wiring harness or connector clips Normal Next step Abnormal Replace clock spring Take references in the removal/installation of safety airbag system and clock spring. Normal Next step Abnormal Replace clock spring Take references in the removal/installation of safety airbag system, and clock spring Safety airbag-17 Passengers’ side failure Failure code $9015 $9016 $9018 $9019 Test condition Possible causes Procedure 1 Passengers’ side safety airbag module (high or low resistance or shorting grounding) Warning If not correctly handled, the safety airbag module as well as pretension safety belt may possibly be trigged, released and tensioned, thus make serene damage to people. Therefore, please carefully read the repairing warning before trouble handling. Please take references in safety airbag system repairing warning If with passengers’ side safety airbag failure The resistance between SRS safety airbag system unit connector clip stitch 13 and stitch 14 not within the designated scope. The wiring harness shorting between safety airbag system unit stitch 13 and stitch 14 Open loop between SRS safety airbag system unit connector clip stitch 13 and stitch 14, Passengers’ side safety airbag module failure The failure of connector clip between passengers’ side safety airbag module and SRS safety airbag system electronic-control unit The failure of connector clip between SRS safety airbag system unit and grounding jumper. The circuit shutoff or shorting between passengers’ side safety airbag module and SRS safety airbag system electronic-control unit The circuit shutoff or shorting between SRS safety airbag system unit and grounding jumper SRS safety airbag system unit failure Test Is the vehicle with passengers’ side safety airbag module Check passengers’ side safety airbag connector clips Operation Yes Next step No Step 5 Present failure code Safety airbag-18 Impact-vehicle diagnosis Test SRS-ECU diagnostic signals 1. Connect the (X-431 diagnostic test’s) diagnostic joint 2. Read the diagnostic results with X-431 diagnostic tester Repairing procedure 1.When safety airbag is released. The following parts should be replaced with new ones a. Passengers’ side safety airbag module b. SRS-ECU c. Driver’s side safety airbag module 2 Check the following parts; replace them with new ones providing something wrong with them. a. Clock spring b. Steering-wheel, steering column, bottom steering shaft module 3.Driver’s side safety airbag module’s installation status towards the steering wheel. a. Check whether abnormal knocking is with the steering wheel, its activity is in good condition and its clearance is normal. b. Check whether the wiring harness joint is broken and its terminal is deformed. Caution: Due to the impact, the diagnostic instrument cannot communicate with SRS-ECU when accumulator is lack of power, in this case, check and maintain the instrument panel wiring harness or utilize the extension power supply. Safety airbag-19 1. Check whether depression, crack or deformation is with the SRS-ECU bracket. 2. Check whether the joint is broken and terminal is deformed 3. Check SRS-ECU bracket’s installation status a. Check whether depression, crack or deformation is with the shroud b. Check whether the joint is broken, terminal is deformed and wiring harness is meshed. c. Check whether depression, crack or deformation is with the gas generator shield. d. Make sure the direction of the arrow is straightforward 4. Check the installation status of safety airbag module. Driver’s side safety airbag module (the following Figure) connect the horn generator connect the driver’s side module bracket Clock spring (right Figure) 1. Check whether the joint and protecting tube are broken and the terminal is deformed. 2. Check whether the shield is deformed. Steering wheel, steering column and bottom steering shaft module 1. 2. Check the installation status of driver’s side safety airbag module Check whether abnormal knocking is with the steering wheel and its clearance is normal Passengers’ side safety airbag module (the following Figure) 1. 2. Check the installation status of passengers’ side safety airbag module Check whether the shield is deformed Safety airbag-20 Passenger side airbag (PAB) Wiring harness joint (instrument cluster wiring harness) Check whether the wiring harness is well installed, the joint is broken and the terminal is deformed. Warning The attentions for use and maintenance for SRS safety airbag are displayed in the Figure. Operate according to the sign and, the destructed and dirty sign must be replaced with a new one steering wheel in Figure6-1 Driver’s side safety airbag module in Figure 6.2 Clock spring in Figure 6.3 SRS-ECU in Figure 6.4 Sun visor in Figure 6.5 Passengers’ side safety airbag module in Figure 6.6 Safety airbag-21 warning signs Figure 6 1 Figure 6 2 Figure 6 4 warning signs Figure 6 3 passengers’ side safety airbag module warning signs Figure 6 5 Figure 6 6 Removal methods for all the parts Safety airbag electronic-control unit Caution Continue the operation 60 seconds after the removal of accumulator negative. Wrap the removed negative with insulating tape for insulation. 2. The SRS-ECU must not be separated nor repaired replace the failed SRS-ECU with a new one. 3. Prevent the SRS-ECU from shock and vibration, replace the SRS-ECU with depression, crack or deformation with a new one. 4. Do replace the SRS-ECU with a new one after the safety airbag is released. 5. Do not damage the SRS-ECU when removing or maintaining the parts next to it. Safety airbag-22 1. Operations before removal a. Place the ignition switch in OFF position. b. Remove the accumulator negative and well preserve it somewhere or wrap it with tape. 2. Removal procedure. a. Central channel’s side panel (or remove the co-instrument panel) b. Remove the connector clip connecting with the safety airbag ECU 3. Installation sequence a. SRS-ECU; b. Install the connector clip connecting with the safety airbag ECU c. Central channel’s side panel (or remove the co instrument panel) d. Connect the grounding jumper. 4. Some points for installation a. SRS-ECU installation b. Post-installation test Place the ignition switch in ON position SRS alarm lamp flashes in 6 seconds and extinguishes. c. If not extinguishes, the failure test and troubleshooting must be done. 5. Test a. Whether the depression, crack or deformation is with the SRS-ECU shield. b. Whether the terminal is broken or deformed. Caution: The SRS-ECU safety airbag will not work normally if the SRS-ECU is not correctly installed. Caution: The SRS-ECU with depression, crack or deformation must be replaced with a new one. For the inspection of SRS-ECU besides the previous refer to related item of troubleshooting Safety airbag-23 Driver’s and passengers’ side safety airbag module (DAB, PAB), clock spring Caution 1. Continue the operation 60 seconds after the removal of accumulator negative. Wrap the negative with insulating tape for insulation. 2. Safety airbag module and clock spring must not be separated nor repaired, replace the failed ones with new ones. 3. Please pay high attention when using the safety airbag module and clock spring, do not let them fall on the ground nor fall into water or oil. Moreover, replace the depressed, crack or deformed ones with new ones. 4. After the safety airbag module is released, keep the released side up, store it somewhere flat and do not lay anything on it. 5. The safety airbag module must not be stored in a place with the temperature above 93 . 6. The released safety airbag module must be replaced with a new one, at the same time test the clock spring, replace it with a new one if something unusual with it. 7. Use gloves and protection glasses during operating the released safety airbag. 8. The unreleased safety airbag must be abandoned after its release. Caution During the removal, the wring harness connector clip must be removed before the removal of other wring harness connector clips in order to avoid the possible improper release caused by static interferences, which is reversal to the case of installation. 1. Removal and installation Driver’s side safety airbag module, passengers’ side safety airbag module, clock spring. 2. Operations before removal. a. Take out the ignition switch key after the steering wheel and front wheel in straightforward direction. b. Remove the connections of accumulator negative 3. Driver’s side safety airbag module removal procedure a. Screw off the bolts of two sides, as showed in Figure 8-1 b. Shut off the wiring harness connector clip c. Remove the safety airbag module assembly d. Remove the steering wheel 4. Passengers’ side safety airbag module removal procedure a. Remove all the trim covers and glove boxes of instrument panel separate the PAB module’s airbag wiring harness connector clip from the safety airbag’s PAB side one. b. Remove M6 bolts and separate PAB module from instrument panel armed beam. c. Remove the instrument panel itself. d. Remove the M5bolts of two sides of four PAB modules. 5. Clock spring removal procedure a. Remove DAB module (shut off the connecting connector clip) b. Carefully remove the steer c. Open the combined switch upper shield, find and shut off the bottom wring harness connector clip d. Remove the clock spring from the steer 6. Driver’s side safety airbag module (DAB) and its installation procedure Safety airbag-24 7. Passengers’ side safety airbag module (PAB) and its installation procedure. a. Test before installation Carefully take PAB module, justify both of them and plug four trim cover M5bolt into the mounting holes of the module’s both sides Well install together the module with trim cover bracket and instrument panel mounting bracket with four M5 bolts. After the installation of the entire instrument assembly to the vehicle, tightly fix the PAB module to the vehicle transverse beam with 2 matted M6 bolts at the glove box site. Well mutually plug the PAB module airbag wiring harness connector clip and safety airbag wiring harness PAB side connector clip it is the end of PAB module installation. b. Connection of accumulator terminal c. Post-installation test 8. Clock spring installation procedure a. Test before installation Cross the line of upper clock spring through the hole in steer. connect and fix the clock spring and steer install the combined switch upper cover install the steering wheel steering wheel and safety module assembly b. Connect accumulator’s terminal c. Post-installation test Figure 8 1 Figure 8 2 The removal of steering wheel (Figure 8.2) Safety airbag-25 d. Remove the steering wheel by removing the mounting screw from the mid-position. (Shut off the horn connector) Caution It is difficult to separate the steer from steering column due to the over meshing between spline and steering column, in this case, do not forcibly remove the steer but screw off the bolt on the steering column and lift up the steer instead (the forced removal will damage the clock spring since the connection between the steer and the spring) Caution Diagnose the safety airbag module circuit with electric diagnostic instrument without separating it. Let the removed driver’s side safety airbag module bottom-side up and store it at a clean and dry place. Store the clock spring in a clean and dry place. 9. Installation operation instructions a. The test before installation The new safety airbag or clock spring must be tested before installation. Caution The safety airbag module must be abandoned after its release according to the procedure Connect the accumulator negative Connect the K-431 diagnostic instrument with the diagnostic interface (16 plug) Caution Place the ignition switch in OFF place when connect or shut off the diagnostic instrument. Place the ignition switch in ON position Read the diagnostic circuit, check whether the safety airbag module is in normal condition except the failure regions. Place the ignition switch in OFF position Remove accumulator negative and wrap it with the tape for insulation. Caution Continue the operation 60 seconds after the removal of accumulator negative Install the clock spring to the steer after its involution Clock spring’s central involution, clockwise screw the clock spring to the end, then turn it for 3 circles anticlockwise and make the involution with the marked sites Figure 8.3 Safety airbag-26 Caution If without the clock spring central involution, the steering wheel will not be able to rotate at midway, or the clock spring circuit will be damaged so that jeopardize SRS safety airbag’s normal activities. The spacer must be removed after replacing a clock spring with a new one, otherwise it will damage the clock spring. c. Steering wheel and safety airbag module assembly installation. Install the steering wheel and safety airbag module assembly after clock spring’s central involution. Caution Do not jam the clock spring wiring harness during the steering wheel and safety airbag module assembly installation. After the installation, rotate the steering wheel to left and right positions as enough as possible to confirm whether something abnormal is with it. d. Post-installation test. lightly rotate the steering wheel to the left and right to confirm whether something abnormal and noises will arise.(Driver’s side safety airbag module, clock spring) Place the ignition switch in ON place. SRS alarm lamp flashes in 6 seconds and then extinguishes. safety airbag system failure alarm lamp Do the troubleshooting if the alarm lamp re-illuminates after its extinguishments following the 6-second-flashing (or it keeps illuminating from the very beginning) 10. Test a. Driver’s side airbag module test (Figure8-3) Check the following items and replace the corresponding safety airbag module part with anything abnormal with a new one. Abandon the safety airbag’s old parts after its release according to the instructed procedure. Caution The safety airbag module (squib) circuit resistance can even not be tested by the designated tester. When testing the resistance with an experimental instrument, sometimes the improper release will be caused by the static interference because of the current in explosion pipe and cause some major damaging accidents. Whether depression, crack or deformation is with the shroud. Whether the joint is broken and the terminal is deformed. Whether depression, crack or deformation is with the gas generator shield. Safety airbag module. Installation status. Caution Replace the safety airbag with depression, crack or deformation with a new one. Its old parts must be abandoned after its release. Safety airbag-27 b. Clock spring test (figure 8.5,figure 8.6) Check the following items and replace the clock spring with anything abnormal (even it is quite tiny) with a new one Whether the joint and protection tube are broken and the terminal is deformed. Whether the shield is damaged. Check the connection between clock spring’s upper joint terminal and it’s corresponding bottom terminal. Plug in a thin probe from the 3# joint of clock spring. Caution Do not directly plug in the probe from the bottom of the joint. Figure 8 5 As showed in Figure 8.5,Plug a thin probe into the current tester to check the connection of the terminal. Safety airbag-28 Safety airbag module abandoning instruction Carry out the operation according to the following procedure to abandon a safety airbag module or a vehicle with the SRS safety airbag. First of all, release the safety airbag. Unreleased safety airbag module abandoning Caution First release the SRS safety airbag when abdbdon it. Release the safety airbag outside the vehicle to replace the safety airbag module. Conduct the operation somewhere next to a smoke tester due to the smoke during the safety airbag’s release. Tell the people to cover their ears and try to conduct the operation somewhere far away from the residential area due to the big noise during the safety airbag’s release. Remove the accumulator positive and negative and remove the accumulator off the vehicle. Caution Continue the operation 60 seconds after the removal of accumulator positive and negative. Release the safety airbag module according to the following procedure. 1. Driver’s side safety airbag module a. Remove the blocking lever b. Remove the clock spring 2# joint and instrument panel wiring harness joint (yellow)(figure 8.6) the shroud protection tube Caution The clock spring joint will short automatically after the removal of clock spring from the instrument wiring harness, which can prevent any possible major accident caused by the incorrect release of driver’s side safety airbag module duo to the static interference from happening. c. Connect the SRS safety airbag translation wring harness with 2 6m plus release wiring harnesses, wrap the joint part with insulating tape for insulation. shorting site SRS translation wiring harness 6m plus releases wring harness Safety airbag-29 Mutually connect (short) the other end of release wring harness to avoid the possible incorrect release caused by the static interference. d. At the clock spring’s 2# joint, tract the translation wiring harness out of the vehicle with the release wiring harness (Figure 9.2) clock spring clock spring connector clip srs translation wiring harness release wiring harness e. Close all the windows and doors and wear the guard to reduce the noises. Caution The guard should be worn because the glass with cracks is very fragile. f. Shut off the joint of driver’s side safety airbag release wiring harness somewhere far from the vehicle, and connects the joint with the accumulator and makes the safety airbag release. auto body outer panel. releases wring harness. Caution Continue the operation after the confirmation of nobody is in or next to the vehicle. Its gas generator is quite hot after the driver’s side safety airbag’s release, it can be used after its cooling down for more than 30 minutes. Contact with the local service station of the Great Wall Auto Stock Corporation if the driver’s side safety airbag module cannot be released. g. Abandon the released driver’s side safety airbag module according to the instructions. auto body outer panel. release wiring harness Safety airbag-30 2. Release outside the vehicle Caution Release the safety airbag somewhere open and plain as well as 6m plus from the obstacles and people When release the safety airbag outdoors, try to avoid the strong wind and ignite windward in the breeze. a. Remove the accumulator negative and positive and remove the accumulator. Caution Continue the operation 60 seconds after the removal of the accumulator. b. Release the safety airbag module according to following procedure driver’s side safety airbag module remove the driver’s side safety airbag module off the vehicle. Caution The two ends of the terminal will short automatically without the joint connection of driver’s safety airbag module, therefore the possible improper release caused by static interference can be avoided; if it improperly releases, keep the released side up and store it somewhere plain, do not lay anything on it. Prepare 2 6m plus release wiring harnesses and mutually connect the other ends(short-circuit) of them to avoid the possible improper release caused by static interference.( refer to figure 9-4) wiring harness for release shorting site 6m plus Touch the vehicle with your hands to eliminate the static electricity. Caution Strictly execute the previous procedure for it can prevent the possible incorrect release caused by the static interference from happening. Shut off the driver’s side safety airbag module wiring harness and connect it with two release wiring harnesses( refer to figure 9-5) release wiring harness passengers’ side safety airbag module shoring site insulating tape Safety airbag-31 Installed the stand-by bolts on the driver’s side safety airbag module’s inside bolt and fasten a thick wire to the wheel rim to fix it. Connect the release wiring harness connecting with the driver’s side safety airbag module with the low part of an old tire loading the wheel rim. ( refer to figure 9-6) driver’s side safety airbag module release wiring harness Lay three wheel-hub-free old tires on the tire fixing the driver’s side safety airbag module (Figure 9-7). wheel-hub-free old tires release wiring harness Shut off the joint of driver’s side safety airbag release wiring harness somewhere far from the vehicle, and connect the joint with the accumulator and make the safety airbag release (Figure9-8). release wiring harness. Caution Release the driver’s side safety airbag module after the confirmation of nobody close to it. Its gas generator is quite hot after the driver’s side safety airbag’s release, it can be used after its cooling down for more than 30 minutes. Contact with the local service station of the Great Wall Auto Stock Corporation if the driver’s side safety Safety airbag-15 Place the ignition switch in L OC K position R elease accumulator negative wire and wait for 1 minute plus R emove the left trim cover Shut off SR S safety airbag system unit translation connector clips Install back the accumulator negative wire, place the ignition switch in ON position Is the potential of SR S safety airbag system unit connector clips stitch 5,6(grounding) above 9V ? 4 Y es Present failure codes R eplace SR S safety airbag system unit See he removal/installation of SR S safety airbag system unit History accumulated failure codes T he end of failure diagnosis No R eplace wiring harness Drive side failure Failure code $9021 $9022 $9024 $9025 Driver’s side safety airbag failure (high or low resistance, shorting grounding, etc.) Test condition Warning If not correctly handled, the safety airbag module as well as pretension safety belt may possibly be trigged, released and tensioned, thus make serene damage to people. Therefore, please carefully read the repairing warning before trouble handling. Please take references in safety airbag system repairing warning Driver’s side safety airbag The resistance between the SRS safety airbag system connector clips connectors not within the designated scope SRS safety airbag system driver’s side airbag relative wiring harness shorting or shutoff Possible causes Driver’s side safety airbag module failure Clock spring internal failure Failure of circuit connector clips between clock spring and SRS safety airbag system electronic-control unit Shutoff or shorting of wiring harness between clock spring and SRS safety airbag system electronic-control unit. Misconnection of SRS safety airbag system driver’s side airbag generator connector clip Procedure Test 1 Check the clock spring Warning If not correctly handled, the safety airbag module may possibly be trigged and released thus make serene damage to people. Therefore, please carefully read the repairing warning before trouble handling. Please take references in safety airbag system repairing warning. Are the relative parts of clock spring normal? (The relation between stitches, unnecessary shutoff or shorting?) if the present clock spring can be replaced by a better one. 2 Confirm the failure in driver’s side safety airbag module or other parts. Replace the DAB module with a better one Install back accumulator negative wire Place the ignition switch in ON position Is the failure code still in display or can be debugged? 3 Check clock spring wiring harness connector clip Place the ignition switch in LOCK position Release accumulator negative wire and wait for 1 minute plus Remove steering pillar shell Release the clock spring connector clip, is it in normal condition? Operation Normal Next step Abnormal Replace the clock spring Take references in the removal/installation for safety airbag system and clock spring Can Replace the driver’s side safety airbag module Take references in the removal/installation for driver’s side safety airbag in safety airbag system No Next step Normal Abnormal Next step Replace harness the wiring Safety airbag-16 4 5 6 7 8 Confirm the failure in clock spring or other parts configure the special tools fuel and temperature diagnostic instrument at 2Ω position Install back the accumulator negative wire Place the ignition switch in ON place Any failure code in display? Check the wiring harness between clock spring and SRS safety airbag system electronic-control unit Place the ignition switch in LOCK position Release accumulator negative wire and wait for 1 minute plus Remove PAB trim cover, glove box (passengers’ side safety airbag is under the trim cover) Release the passengers’ side safety airbag module connector clip Release all SRS safety airbag system unit connector clips Check whether the following troubles are with the harness between connector clips terminals of SRS safety airbag system unit and clock spring Grounding Power-supply shorting Shutoff Is the previous wiring harness normal? Check the clock spring connector clip Remove the steering pillar shell Release the clock spring connector clip Is the clock spring connector clip normal? Check clock spring Remove clock spring Take references in removal/installation of safety airbag system as well as clock spring Check clock spring Take references in the test for safety airbag system and clock spring. Is the clock spring normal? Check the wiring harness between clock spring and SRS safety airbag system electronic-control unit Place the ignition switch in LOCK position Release accumulator negative wire and wait for 1 minute plus Remove PAB trim cover, glove box (passengers’ side safety airbag is under the trim cover) Release the passengers’ side safety airbag module connector clip Release all SRS safety airbag system unit connector clips. Check whether the following troubles are with the harness between connector clips terminals of SRS safety airbag system unit and spring clock. Grounding Power-supply shorting Shutoff Is the previous harness normal? Yes Next step No Replace clock spring Take references in the removal and installation for safety airbag system and clock spring. Normal Replace SRS safety airbag system unit; take references in removal/installation of SRS safety airbag system unit. Abnormal Replace the wire harness Normal Next step Abnormal Replace the wiring harness or connector clips Normal Next step Abnormal Replace clock spring Take references in the removal/installation of safety airbag system and clock spring. Normal Next step Abnormal Replace clock spring Take references in the removal/installation of safety airbag system, and clock spring Safety airbag-17 Passengers’ side failure Failure code $9015 $9016 $9018 $9019 Test condition Possible causes Procedure 1 2 3 Passengers’ side safety airbag module (high or low resistance or shorting grounding) Warning If not correctly handled, the safety airbag module as well as pretension safety belt may possibly be trigged, released and tensioned, thus make serene damage to people. Therefore, please carefully read the repairing warning before trouble handling. Please take references in safety airbag system repairing warning If with passengers’ side safety airbag failure The resistance between SRS safety airbag system unit connector clip stitch 13 and stitch 14 not within the designated scope. The wiring harness shorting between safety airbag system unit stitch 13 and stitch 14 Open loop between SRS safety airbag system unit connector clip stitch 13 and stitch 14, Passengers’ side safety airbag module failure The failure of connector clip between passengers’ side safety airbag module and SRS safety airbag system electronic-control unit The failure of connector clip between SRS safety airbag system unit and grounding jumper. The circuit shutoff or shorting between passengers’ side safety airbag module and SRS safety airbag system electronic-control unit The circuit shutoff or shorting between SRS safety airbag system unit and grounding jumper SRS safety airbag system unit failure Test Is the vehicle with passengers’ side safety airbag module Check passengers’ side safety airbag connector clips Warning If not correctly handled, the safety airbag module may possibly be trigged and released thus cause serene damage to people, therefore, please carefully read the maintenance warning. Take references in safety airbag maintenance warning. Place the ignition switch in LOCK position Release accumulator negative wire and wait for about 1 minute plus Remove the PAB trim cover, glove box (passengers’ side safety airbag is under the trim cover) Release passengers’ side safety airbag module connector clip Is the previous connector clip normal? Confirm whether the failure cause is with passengers’ side safety airbag module or some other parts Connect a better module to the terminal A and B of passengers’ side safety airbag connector clip Connect the accumulator negative wire Place the ignition switch in ON position Any failure code in display? Operation Yes Next step No Step 5 Present failure code Next step History- accumulated failure codes Next step Yes No Replace the wiring harness Yes Next step No Replace passengers’ side safety airbag module Take references in the removal/installation of passengers’ side safety airbag module in safety airbag system. Safety airbag-18 Check the wiring harness between passengers’ side safety airbag module and SRS safety airbag system electronic-control unit Present failure code Place the ignition switch in LOCK position Replace SRS safety airbag system Release accumulator negative wire and then wait for about 1 unit minute plus Take Remove steering pillar shell Release clock spring connector clip Normal Release driver’s and passengers’ side safety airbag module 4 references removal/installation in of SRS safety airbag system unit in safety airbag system. connector clips History-accumulated Release all SRS safety airbag system unit connector clips failure codes Check whether the following troubles are with the circuit of the The end of failure diagnosis connector clips terminals between SRS safety airbag system electronic-control unit and passengers’ side safety airbag module Grounding Power-supply shorting Abnormal Shutoff Replace the relative wiring harness Is the previous circuit normal? Impact-vehicle diagnosis Test SRS-ECU diagnostic signals 1. Connect the (X-431 diagnostic test’s) diagnostic joint 2. Read the diagnostic results with X-431 diagnostic tester Repairing procedure 1.When safety airbag is released. The following parts should be replaced with new ones a. Passengers’ side safety airbag module b. SRS-ECU c. Driver’s side safety airbag module 2 Check the following parts; replace them with new ones providing something wrong with them. a. Clock spring b. Steering-wheel, steering column, bottom steering shaft module 3.Driver’s side safety airbag module’s installation status towards the steering wheel. a. Check whether abnormal knocking is with the steering wheel, its activity is in good condition and its clearance is normal. b. Check whether the wiring harness joint is broken and its terminal is deformed. Caution: Due to the impact, the diagnostic instrument cannot communicate with SRS-ECU when accumulator is lack of power, in this case, check and maintain the instrument panel wiring harness or utilize the extension power supply. Appendix-1 Appendix A important parts assurance and request.........................................1 B non-metal materials consumption table.......................................12 C Special tools.............................................................................14 D important working regions and tightening torque important working region............................................................17 E Electric wiring diagram ..............................................................18 Appendix A-1 Control item fixing to the Torque wrench 23 2N m Steel plate gauge 100mm hexagon flange nut (Q32012) Control item locate the riage and fix it with some bolts(Q32012), 10N m. hexagon flange nut (Q32012) 90 Torque wrench Appendix A-2 Torque wrench Connection of steering linkage co- fixed torque of nut 1 in the Figure is 25 assembly and connection of steering linkage co- the fixed torque of nut 2 in the Figure is 70 the torque is: 70 10N m the fixed assembly and left carriage 10N m Torque wrench Torque wrench cross universal joint steering linkage co-assembly integral power steering general assembly Connection of left right long longitudinal the fixed torque of nut 1 in the Figure is tie assembly and carriage and rear axle Torque wrench Connection of left right short longitudinal the fixed torque of nut 2 in the Figure is Torque wrench tie assembly and rear axle assembly. Connection of left right short longitudi- the fixed torque of nut 3 in the Figure is Torque wrench nal tie assembly and carriage Connection of cross tie assembly and rear the fixed torque of nut 1 in the Figure is Torque wrench axle assembly Connection of cross tie assembly and the fixed torque of nut 1 in the Figure is Torque wrench carriage. short longitudinal tie assembly (L) short longitudinal tie assembly (R) long longitudinal tie assembly Appendix A-3 Locate the rear transverse stabilizer rob in the corresponding Viewing confirmation position of carriage, symmetries the left and right during installation. Connection of rear transverse the fixed torque of nut 2 in the Figure is 23 3N m Torque wrench 5N m Torque wrench stabilizer rod and rear axle Connection of rear transverse the fixed torque of nut 1 in the Figure is 63 stabilizer rod and rear transverse stabilizer robs connecting bar assembly. rear transverse stabilizer bush rear transverse stabilizer rod connecting bar assembly Upper suspension arm and upper suspension the fixed torque of nut 1 in the Figure is arm steering knuckle ball pin 145 Steering gear cross tie ball pin the fixed torque of nut 2 in the Figure is120 10N 15N Torque wrench m Torque wrench m Lower suspension arm and lower suspension the fixed torque of nut 3 in the Figure is 230 arm steering knuckle ball pin 20N Torque wrench m 1. (upper suspension arm steering knuckle ball pin nut) bolt 2. (steering gear cross tie ball pin nut) left steering knuckle and wheel hub brake assembly 4. left steering knuckle and steering knuckle and wheel hub brake assembly. 3. (lower suspension arm steering knuckle ball pin nut bolt Appendix A-4 the fixed torque of nut 1in the Figure is 25 3N m Torque wrench Connection of front transverse stabilizer rob the fixed torque of nut 2in the Figure is 63 5N m Torque wrench Connection of front transverse stabilizer rod and carriage. and front transverse stabilizer rod connecting bar assembly front transverse stabilizer rod bush front transverse stabilizer rod bush clip Drive shaft assembly installation connecting bar assembly Plug the front part of drive shaft into transmission assembly Viewing and handle splinded shaft, after their good meshing, screw the central bearing confirmation hexagon bolt into the corresponding screw hole of the carriage Center bearing connecting bolt the fixed torque of bolt 1 in the Figure is 65 5N m Torque wrench Drive shaft bolt the fixed torque of bolt 2in the Figure is 65 5N m Torque wrench transmission assembly rear axle assembly drive shaft assembly Appendix A-5 the fixed torque of bolt 1 in the Figure is 78 drive shaft bolt 5N m front axle drive shaft assembly rear axle drive shaft assembly transmission assembly petrol lien joint petrol pipe joint two way valve petrol line joint tightening torque is 16 rear axle assembly 2N torque wrench Appendix A-6 Driver steering oil pump installation Fixed torque of tubular hexagon bolt 1 in the Figure is 40N Multi-wedge belt Torque m Multi-wedge belt 4PK1100 tension is 500 50N Torque driver steering oil pump multi-wedge belt 4PK1100 cover lock mounting bolt cover lock mounting bolt’s torque is 9 effect the cover lock can be opened freely, the position is reliable 2N m without any jam. cover lock cable cover lock buckle fastening blot cover lock mounting bracket Appendix A-7 Out handle can be normally and efficiently used, no linkage Handle confirmation falling off, the backup door can be opened and closed freely without any jam nor unlocking. rear door assembly backup door bottom buckle backup door lock The fixed torque of bolt 1 in the Figure is 6 backup door out handle 1N m The door can be opened and closed smoothly without any jam nor unlocking. door lock assembly Torque wrench Appendix A-8 Apply washer on the front windshield Evenly apply it on the sticking region with the width of about Viewing confirmation glass-sticking region 25mm and completely volatilize it. Apply base-coater on the front windshield glass-sticking region Shake the base-coater to be sufficiently even followed by the Viewing confirmation even application on the sticking region with the width of about 20mm and dry it for 2-15 minutes Apply washer on front windshield Wash the glass frame with the width of about 25mm, glass instantly clean it and volatilize the washer completely. Apply base-coater on front Shake the glass base-coater to be sufficiently even followed Viewing confirmation by the even application on the glass frame with the width of windshield glass Viewing confirmation about 20 and dry it for 2-15 minutes Apply adhesive on front windshield Vertically apply the glass adhesive on the glass frame and Viewing confirmation glass make it even and continuous. Height: 18mm, width: 12mm Front windshield glass fixing Instantly install and fix the glass after the glass adhesive Viewing confirmation application. Set the left and right clearance between front windshield glass and the glass frame to be 12mm front windshield glass Wash, base-coat and stick according to the corresponding positions showed by the broken line in the Figure Appendix A-9 Apply washer on the glass-sticking Evenly apply it on the sticking region with the width of about Viewing confirmation region of the backup door 25mm and volatilize it completely. Apply base-coater on the glass- Shake the base-coater to be sufficiently even followed by the sticking region of the backup door Viewing confirmation even application on the sticking region with the width of about 20mm and dry it for 2-15 minutes Apply washer on the backup door Wash the glass frame with the width of about 25mm and glass frame volatilize the washer Apply base-coater on the backup Shake the glass base-coater to be sufficiently even followed door glass frame by the even application on the glass frame with the width of Viewing confirmation Viewing confirmation about 20 and dry it for 2-15 minutes Apply adhesive on the backup door Vertically apply the glass adhesive on the glass frame and make Viewing confirmation glass frame it even, continuous. Height: 12mm, width: 8mm Backup door glass fixing Instantly install and fix the glass after the glass adhesive Vi e w i n g / h a n d l e application confirmation backup door backup door glass Wash, base-coat and stick according to the corresponding positions showed by the broken line in the Figure Appendix A-10 Control item Apply washer on side Request Control mean Evenly apply it on the sticking region with the width of about Viewing confirmation window sticking region 25mm and completely volatilize it. Apply base-coater on side Shake the base-coater to be sufficiently even (for at least 1 window sticking region minute) followed by the even application on the sticking region Viewing confirmation with the width of about 20mm and dry it for 2-15minutes Apply washer on side Wash the glass frame with the width of about 25mm and window glass frame volatilize the washer completely. Apply base coater on side Shake the base-coater to be sufficiently even followed by the window glass frame even application on the glass frame with the width of about Viewing confirmation Viewing confirmation 2omm and dry it for 2-15 minutes. Apply adhesive on side Vertically apply the glass adhesive on the glass frame and make window glass frame it even, continuous. Height: 12mm, width 8mm Side window fixing Instantly install and fix the glass after the glass adhesive Viewing confirmation Viewing /handle confirmation application. side window glass the auto body Wash, base-coat and stick according to the corresponding positions showed by the broken line in the Figure Appendix A-11 Driver seat assembly installation bolt 1 in the Figure tightening torque:is 33 43N m Torque wrench The headrest can be up and down smoothly, angle-adjuster Viewing and handle handle can be normally used, driver, co-driver seat can move confirmation freely and transmission trim cover can be freely opened. seat assembly Wheel nut fixing procedure Installation order is A-C-E-B-D-F as showed in the Figure Wheel nut fixed torque the fixed torque of nut 1 in the Figure is 135 brake disc assembly 15N m Appendix B-12 Non-metal materials consumption table Name Brand, specification and technical condition Transmission lever. Three-hole Measuring unit Suitable Kg Suitable L Suitable Installing ring flange L Suitable Radiator and co-tank - Kg 7 3# Twisted bar spline, speed shaft L Suitable 5001TF Glass base coat m 0.03 L Suitable Silicon oil Thread Utility rubber block Note Short, longitudinal front fixed block 1271 sealing agent bolt, hub cap bolt, transmission lever bolt, carriage fixing Silicone rubber surface sealing 1596 (super gray) agent Anti-freeze vinyl-EG --35℃ liquid antifreeze liquid Molybdenum disulfide pressed lithium base grease Glass base coater Air-filtering suction tube, door Butyl tape Attraction 6×2×700 seal film DEXRON3 (ATF-3) Steering fuel cup assembly L 1 Clutch oil DOT4 Clutch master cylinder L 0.15 Brake fluid DOT4 Vacuum assist fluid reservoir L 0.525 steering fluid For the exported vehicle for Auto gear oil GL-4 75W/90 Transmission L 2.2 extremely cold areas For the exported vehicle for Auto gear oil GL-4 75W/90 Transfer case L 2.7 extremely cold areas Auto gear oil GL-4 80W/90 Transmission L 1.4 Auto gear oil GL-4 80W/90 Transfer case L 2.5 For the exported vehicle for Auto gear oil GL-5 75W/90 Rear axle L 2.9 extremely cold areas 2.9L=5.14PTS Auto gear oil GL-5 80W/90 Rear axle L 2.9 2.9L=5.14PTS Appendix B-13 For the exported Auto gear oil GL-5 140 Transmission L 1.4 vehicle for extremely hot areas For the exported Auto gear oil GL-5 140 Transfer case L 2.7 vehicle for extremely hot areas For the exported Auto gear oil GL-5 140 Rear axle L 2.9 vehicle for extremely hot areas 2.9L=5.14PTS For the exported Auto gear oil GL-5 140 Front axle L 1.4 Auto gear oil GL-5 75W/90 Front axle L 1.4 Auto gear oil GL-5 80W/90 Front axle L 1.4 Glass adhesive HV3 Front windshield glass L 0.6 Glass adhesive 7120 L 0.9 vehicle for extremely hot areas 1.4L=2.46PTS Clearance adhesive Liquid adhesive Windshield washer Refrigerant Backup door glass, side window glass LY-22 Luggage rack Kg Suitable LY-609 Warming pipe, speed lever L 0.02 Q35 Front and rear windows L 3 R134a Air-conditioning system Kg 0.73 1.4L=2.46PTS Non-metal Materials Consumption Table. Name Engine lubricating oil Brand, specification and technical condition SL 10W-40 Utility Oil pan Measuring unit L Quantity 4.3 Note Available for 4G64S4M engine Available for 4G64S4M Engine lubricating oil SL 5W-30 Oil pan L Suitable VP04604 Glass L Suitable Kg Suitable Kg Suitable engine and exported vehicles for extremely cold areas. Glass activator Lithium base grease Industrial Vaseline Grease HP-R Front axle, chassis parts Seat support, accumulator points Appendix C-14 only for 1.4kw starter front bearing valve guide bush removing or repairing tool valve spring presser crankshaft pulley remover crankshaft pulley fixing tool camshaft bearing removing and repairing tools plugging plate A bolt nut shaft A pin removing and replacement removing and replacement Appendix C-15 crankshaft front oil seal replacing tool crankshaft oil seal replacing tool Appendix C-16 *1. only for 1.0kw starter front injection pump crankshaft bearing cone tool bearing *2. only for high-speed, small rotor front bearing *1. starter bearing injection pump spline shaft remover alternator pulley assembly nut wrench assembly *2. high-speed, small rotor front bearing assembly only for high-speed, small ones Appendix D-17 Serial Working region and Torque Serial No. specification N·m No. 200 25 270±25 26 320±30 27 63±5 28 78±10 29 140±10 30 wheel nut M12×1.25 135±15 140±10 31 steering wheel lock nut M12×1.25-8 30±5 145±15 32 steering gear-carriage fixing nut M12×1.25-8 90±10 1 upper arm shaft fixed bolt M14×1.5-10.9 front shaft of lower arm 2 connecting bolt M16× 1.5-10.9 rear shaft of lower arm 3 connecting bolt M18× 1.5-10.9 Working region and specification engine suspension connecting bolt M10× 1.25-10.9 transmission suspension connecting bolt M10× 1.25-10.9 transmission-engine connecting bolt M10× 1.25-10.9 Torque N·m 78±10 78±10 50±5 bottom arm limiting 4 stopper fixed bolt M10 drive shaft connecting bolt M10×1.25-10.9 78±5 ×1.25-8.8 upper arm ball pin 5 pedestal connecting bolt drive shaft bearing fixed bolt M10×1.25-8.8 65±5 M10×1.25-10.9 bottom arm ball pin 6 pedestal connecting bolt M12×1.25-10.9 front twisted bar 7 pedestal connecting bolt M12×1.25-10.9 8 9 upper arm ball channel fixing nut M16×1.5-10 front vibration damper Bush upper fixing nut M10× compressed 1.25-8 by 1/3 70±10 33 1.5-9.8 bottom arm ball pin 10 channel fixing nut M18 230±20 steering angle drive co-carriage bolt M10× 34 ×1.5-10 steering system universal-joint lock bolt M8× 1.25-8.8 50±5 25±3 front vibration damper 11 bottom connecting bolt 90±10 35 steering linkage ball fixing nut M14×1.5-8 120±10 M12×1.25-8.8 12 rear vibration damper Bush upper fixing nut M10× compressed 1.25-8 by 1/3 36 rear vibration damper 13 bottom fixing nut M14 170±15 37 23±3 38 ×1.5-8 front cross stabilizer rod 14 -carriage fixed bolt M8 ×1.25-8.8 steering linkage adjustment lock nut M14× 1.5-8 front axle front shackle connecting bolt M14× 1.5-10.9 front axle rear shackle connecting bolt M14 ×1.5-10.9 60±5 180±20 180±20 Appendix D-18 front cross stabilizer rod 15 -connecting bar bottom 63±5 39 brake petrol pipe joint M10×1.25 16 200±20 40 180±15 41 safety belt seat connecting bolt 7/16″-8.8 40±2 200±20 42 body suspension connecting bolt M10×1.25-9.8 63±5 200±20 43 Engine oil pan drain bolt 40±5 180±15 44 Transmission/transfer case refueling/drain bolt 30～35 23±3 45 front drive axle refueling bolt M20×1.5 145±5 63±5 46 Front drive axle drain bolt Rc1/2 30～35 63±5 47 rear drive axle refueling/drain bolt M20×1.5 145±5 25±3 48 Starter and wheel box connecting bolt 30±3 arm bolt M10×1.25-8 long longitudinal tie 16 connecting bolt M14× safety belt body connecting bolt 7/16″-8.8 40±2 1.5-10.9 short longitudinal tie 17 front connecting bolt M14×1.5-10.9 short longitudinal tie rear 18 connecting bolt M14× 1.5-10.9 cross tie -carriage 19 connecting bolt M14× 1.5-10.9 20 cross tie -rear axle fixing nut M14×1.5-8 rear cross stabilizer rod 21 -rear axle fixed bolt M8 ×1.25-8.8 rear cross stabilizer rod 22 -connecting bar -carriage bolt M10×1.25-8 23 24 standby tire bracket fixed bolt 10×1.25-8.8 standby tire lifter fixed bolt M8×1.25-8.8