【EN】2 Chassis-S3 E100

WORKSHOP MANUAL
HFC7151M1V-U221B
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Chassis
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Version No：JAC-201511030415001
江淮汽车部门：客户服务部
Chassis
FOREWORD CONTENT
This Manual is helpful for technical maintenance
staff for JAC and provides effective and correct
Overview & maintenance
maintenance and service for JAC vehicle. To ensure
the customer satisfaction of the JAC products, it is
extremely essential that the professional maintenance Engine
technicians for JAC have the friendly service and the
capability of proper operation; therefore, the
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maintenance technicians must fully understand the
Body structure& electrical
contents in this Manual. This Manual shall be
accessible for reference at any time.
All contents in this Manual, including pictures, 25 Chassis

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technical parameters are the latest. But if product
modification affects maintenance, JAC will provide Circuit
technical bulletin or supplementary volume. Therefore,
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please obtain the latest information about this Manual.

JAC reserves the right to make change in design,
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addition or improvement for the product.

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This manual is a guide for vehicle maintenance, maintenance personnel must be strictly in
accordance with the maintenance manual operation. This product is a product that has precise
requirements, maintenance personnel must be professional with relevant skills, and
non-professional personnel are forbidden to disassemble vehicle privately. Due to complexity of
actual problem, for items not contained in the manual, please contact with company's customer
service, and operate under its guidance.
During the process of maintaining JAC vehicle, if genuine parts that are not from JAC or
disqualified oil, the vehicle may be damaged.
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All rights reserved, without the written consent of JAC, it may not be translated all or a part
of this manual.
Tel：0086-551-62296644
Fax：0086-551-62296633
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JAC International Customer Service Depart.
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Overview
Overview
I Warning and precautions
(I) Warning and precautions
Definition of “Warning”, “Important precautions” and “Caution”
The diagnosis and repair procedure in this maintenance manual consist of general and specific
“Warning”, “Important precautions” and “Caution”. Jianghuai Automobile Co., Ltd is committed to provide
maintenance information to after- sales service technician for diagnosing and repairing the system and
making the vehicle work normally. However, if the technician does not operate according to the
recommended ways, some procedure may cause danger to the technician.
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The “Warning”, “Important precautions” and “Caution” are complied to prevent above risk but not all
risks can be predicted. These information lie at the conspicuous position of the manual and are complied to
prevent the occurrence of the following circumstances:
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· Cause severe injury to personnel
· Damage the vehicle
· Unnecessary vehicle repair
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· Unnecessary replacement of parts
· Improper repair or replacement of parts
Definition of “Warning”
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A “Warning” request you to strictly follow these dos and don’ts. It may cause following result if you
ignore the “Warning”:
· Cause severe injury to personnel
· Cause severe injury to driver or passenger if repaired improperly

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Definition of “Important precautions”

“Important precautions” means you need pay attention to these dos and don’ts. It may cause following
result if you ignore the “important precautions”:
· Vehicle damage
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· Unnecessary vehicle repair

· Unnecessary replacement of parts
· Abnormal state of the repaired system or parts’ operation or performance
· Damage to relevant system or parts
· Damage to fasteners, general tools or special tools
· Leakage of the engine coolant, lubricant or other important oil liquid
Definition of “Caution”
“Caution” emphasizes the necessity of diagnosing or repairing some procedure and for below purposes:
· Definite procedure
· Add information for completing a procedure

· Clarify the reason for operating according to recommended procedure
· Provide information to help complete the procedure in a more efficient way
· Provide previous experience to technician so as to complete the procedure more easily
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Warning on lifting the vehicle
△Warning: In order to avoid damage to vehicle, severe personnel injury or fatalities, when you remove
main parts from the vehicle and use a lifting machine to support the vehicle, use a lifting jack to sustain the
parts relative to the parts to be removed.
Warning on handling the anti-lock braking system components

△Warning: Some parts of the ABS system cannot be repaired individually. Removing or disconnecting
some system component can cause personnel injury or make the system run abnormally. Only these
components with license to be removed and installed can be repaired.
Warning on colliding and repairing the permitted equipment

△Warning: In order to avoid injury caused by exposure in welding arc or plating (Zinc Oxide) metal toxic
smoke when grinding or cutting metal or flake molded part of any type, you must work in good ventilation
environment and wear licensed respirator, goggles, ear plugs, protective gloves and protective clothes.
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Warning on assistant driving
△Warning: When the technician is inspecting the failure parts, the vehicle must be operated by the
assistant, or it may cause personnel injury.
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Warning on disconnecting the battery
△Warning: Before repairing the electrical components, make sure the ignition key is at “OFF” or “LOCK”
and all the electrical load are “OFF”(closed) unless otherwise specified in the operation program. If the
tools or equipment are easy to be contacted with the exposed live electrical terminals, you need disconnect
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the battery negative electricity. Violating these safety instructions may cause personnel injury or damage to
the vehicle and components.
△Warning: When repairing the airbag, you must disconnect the battery negative electricity for at least
90seconds and then take other operation.
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Warning on brake dust

When repairing the wheel brake components, please avoid following operation:
· Do not repair or wear the brake friction lining.
Do not sand the brake friction lining.
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· Do not use a dry brush or compressed air to clean the wheel brake parts.
△Warning: Some models or after-sales installation of braking components may contain fiber which will be
mixed with the dust. Inhalation of the dust containing fiber will do severe harm to health. Please use a wet
cloth to clean any dust on the brake components.
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Warning on braking fluid

· △Warning: Braking fluid is extremely easy to absorb moisture and wetness. Do not use the braking fluid in
the open container which may be polluted by water. Using improper or polluted braking fluid may cause
system failure, losing control of the vehicle and personnel injury.
Warning on braking fluid irritant

Braking fluid is irritant to skin and eyes. Please take following measure if contacted: Eyes contact--use clean water
to wash thoroughly
· Eyes contact—use clean water to wash thoroughly
· Skin contact—use soap and clean water to wash thoroughly
· Warning on braking pipe replacement
· △Warning: Carefully install and fix it when replacing the braking pipe. Make sure you use the correct
fastener, or it may cause damage to the braking pipe and braking system which lead to personnel injury.
Warning on clutch dust

△Warning: When repairing the clutch, do not polish or sand the clutch disc nor use dry brush or
江淮汽车 compressed部门：客户服务部
air to clean components because these operations will produce dust. You should use a wet cloth
dipped in the water (but not soaked). The clutch may contain fiber. If dust produced during repairing, the
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fiber will be mixed in the air. Inhalation of dust containing fiber will do severe harm to human health.
Warning on collision and cutting

△Warning: Only cut the recommended parts, or it will damage the vehicle integrity and cause injury
during a crush.
Warning on eye protection

△Warning: When you execute this program, you should wear approved safety goggles and gloves to
reduce the risk of getting injured.
Warning on moving parts and heat surface

△Warning: When working beside the running engine, you should avoid contact with the moving parts and
hot surface to prevent injury.
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Warning on goggles and gloves
· △Warning: Make sure to wear goggles and gloves when removing exhaust emission parts, otherwise the
rust and sharp edges from the worn exhaust system pats will do severe harm to human health.
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Warning on removing the reservoir lid
△Warning: In order to prevent being scalded, do not remove the reservoir lid before the engine cooled. If
you remove the reservoir lid before the engine and the radiator cooled, the cooling system will release boiling high
pressure liquid and steam.
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Warning on cooling system repair
△Warning: If the cooling system is with pressure, even though the solution in the radiator is not boiling, the
solution temperature will much higher than the boiling temperature. If you open the reservoir lid and repair
the cooling system with the engine uncooled and with high pressure, the engine coolant will boil immediately
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and burst to personnel to cause severe scald.
Warning on road test

△Warning: Operate road test of vehicle in the premise of safety and obey all traffic laws and regulation. Do
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not try any operation to endanger the control of the vehicle. Violating above safety instruction will do severe
harm to human health and damage the vehicle.
Warning on goggles and fuel

△Warning: Do wear goggles when handling fuel in order to prevent the fuel splashing into eyes.
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Important precaution on fulfilling braking fluid in braking system

△Important precaution: When adding braking fluid to brake master cylinder reservoir, you can only use the
braking fluid in clean and sealed braking fluid container and meet DOT4 standard.
Important precaution on brake caliper
△Important precaution: When removing the brake caliper, use a steel wire to hang the brake caliper to avoid
damage to the brake pipe.
Special precaution on brake fluid’s impact on paint and electrical components
△Important precaution: Avoid the brake fluid to splash on paint, electrical connector, wire or cable. The
brake fluid will damage the paint and lead to electrical components corrosion. If the brake fluid is exposed
to paint, rinse the contacted position immediately. If the brake fluid is exposed to electrical connector, wire
or cable, use a clean cloth to wipe the brake fluid.
Important precaution on fastener

△Important precaution: Use correct fastener in correct position. The part NO of fastener replacement must
be correct. The fastener need to be replaced or need to be used with thread lock adhesive or sealants are
specially noted in the maintenance program. It is prohibited to use oil, paint, lubricant, or rust inhibitor on
fastener or fastener connector surface unless stated otherwise.
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These pigmentum will impact the fastener’s torque and clamping force and will damage the fastener. When
fixing the fastener, make sure to follow correct fastening order and torque so as to avoid damage to system and
components.
Important precaution on not twisting or bending the soft pipe during installing
△Important precaution: It is prohibited to twist the entrance and exit of the soft pipe during installing. It is
prohibited to bend or deform the soft pipe for easier installation or it will damage the components.
Important precaution on machined surface damage

△Important precaution: Do not cut, scratch or damage the sealed surface. The sealed surface is machined
surface. The machined surface damage will cause leakage.
Important precaution on removing ring gear

△Important precaution: Do not remove the ring gear from the differential housing, or it will damage the ring
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gear or differential housing.
Important precaution on sealant

△Important precaution: Do not let the room temperature hardening sealant get into the tapped blind hole, or
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the fastener will generate hydraulic locking effect when fastened which will damage the fastener or other
components. It will also make the fastener unable to get correct clamping force when fastened that make the
components to be sealed incorrectly and lead leakage. When the fastener is not fastened correctly, it will
make the components loose or separate that will cause severe damage to the engine.
Important note about the steer turning to the limited position
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△Important note: Do not keep the steer at the limited position for more than five seconds, or it will damage
the motor.
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Overview
II Vehicle inspection
(I) Inspection list when operating the vehicle
Vehicle and positioning operation

Keep vigilant when the steering wheel or seat vibrates at normal driving speed. This situation shows there
might be a need to balance the wheel, besides, running on left and right deviation on a flat straight road means it
may need to adjust pressure or align the wheels.
Steering system operation
Keep vigilant at changes of steering action. It requests inspection when it is hard to rotate the steering wheel
or the free travel is too long or there is abnormal sound when turning or parking.
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(II) Inspection list for at least once per month
Wheel and pressure check
Check the wheel whether there is abnormal wear or damage. Check the pressure in cold state. Check the
spare tire and keep the pressure recommended on the label.
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Oil leakage inspection
When the vehicle is parked for a period of time, regularly check the ground under the vehicle if there is
water, engine oil, fuel or other liquid. It is a normal phenomenon that the air conditioner system drips after using. If
you find fuel leakage or smoke, you should find out the reason and handle the failure.
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(III) Inspection list for at least twice per year
Liquid level of brake master pump storage tank
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Check the oil liquid and ensure it is at correct level. When the level is too low, it may indicate the pad
of the brake disc is worn and need to be repaired. Check the ventilation hole on the lid of the liquid storage
tank and ensure no dirt and airway to be patent.
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Clutch pedal free travel

Check the clutch pedal free travel and adjust it if necessary. Refer to clutch pedal free travel adjustment.
Lubrication of the doors and windows sealing strip
Use a clean cloth to coat the sealing strip with a layer of silicon grease film.
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Overview
III Vehicle lifting
(I) Lifting the vehicle
Refer to “Warning on lifting the vehicle” in “Warning and Important precautions”. To
avoid getting injured, when performing any work on or under the vehicle which is
only supported by a jack, make sure to use jack seat.
Vehicle lifting point

△Caution: The rear lifting padding block cannot touch the outside of the sill plate and frame rail and
floor.
Put the rear lifting padding block at below position:
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Under the connector between the rear frame rail and side frame rail.
△Caution: The front lifting padding block cannot touch the outside of the sill plate and frame rail and
floor.
Put the front lifting padding block at below position:
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Under the connector between the front frame rail and side frame rail.
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Overview
IV Maintenance
(I) Specification
Main liquid parameters
Name Trade mark Volume
Unleaded gasoline Above 93# unleaded gasoline 45L

Engine cooling liquid Ethylene glycol antifreeze concentration of 50% 5.5 L
Manual transmission
lubricant 75W/90 GL-4 gear oil 2.2 L
CVT transmission
lubricant MOBIL,ESSO EZL 799 or Idemistu CVTF-EX1 4.2±0.05L
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Engine oil SAE10W-30 SJ or grade above 4L
Air conditioner
compressor lubricant PAG56 0.12 L
Braking liquid DOT4 650ml±50ml
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Power index
Item Unit 1.5 6MT 1.5 CVT
Continuous acceleration time (0-100km/h) S ≤ 14 ≤ 15

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Direct gear acceleration performance(80-
120Km/h) S ≤ 15 ≤ 11
Maximum speed Km/h ≥ 175 ≥ 170
Maximum gradability % ≥ 30 ≥ 30
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Fuel consumption index

Item 1.5 6MT 1.5 CVT
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Comprehensive (L/km) ≤ 5.9 ≤ 7.2
90km/h constant speed (L/km) ≤ 5.6 ≤ 6.1
Transmission gear ratio

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Item Reference value
Shift type 6MT CVT

Maximum torque N·m/
rpm 180/4000 190
First 3.769 Manual 1st 2.28~2.41

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Second 2.053 Manual 2 1.51
Third 1.393 Manual 3rd 1.10 Automatic model

ratio range
Gear position Fourth 1.031 Manual 4th 0.83
Gear ratio th 0.443~2.416
Fifth 0.778 Manual 5 0.65
Sixth 0.681 Manual 6th 0.52
Reverse 3.583 Manual reverse 2.68
Final ratio 4.056 5.76
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Alignment
Item Reference value（°）
paramter
0°±30′ (Difference value between left and right is

Camber angle within 30′)
Kingpin 12.3°±30′(Difference value between left and right is
inclination angle within 30′)
Kingpin camber 3.8°±30′(Difference value between left and right is
Front wheel
angle within 30′)
Total toe-in -1°±30′

Single wheel toe-
in 0±5′
-1°±15′ (two side angle difference is not bigger
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Camber angle than 20′)
Rear wheel Total toe-in 24′±20

Single wheel toe-
in 12′±10
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Tyre specification and cold inflation
pressure
Item Parameter
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Tyre specification 1 205/55R16 94V
Cold inflation pressure 1
(kpa) 220±10
Tyre specification 2 185/65R15 88H

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Cold inflation pressure 2

(kpa) 240±10
Spare tyre 205/55R16 94V
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Regular maintenance instructions

Normal use of the vehicle
The maintenance projects listed in the maintenance plan is on the supposition that the vehicle is used for
below purposes:
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Carry passengers and goods under the limited condition instructed by the label on the edge of the
driver’s door.
Drive on proper road and abide by traffic laws and regulations.
Description of planned maintenance programs

Details for maintenance projects listed in the maintenance plan are as follows. Before proceeding below
maintenance projects, make sure to finish all components replacement and all necessary repair. After that,
you can drive on the way and make sure to use proper oil and lubricant.
Wheel inspection and transposition

Check the wheel to see whether it is worn or damaged abnormally. In order to get uniform abrasion and
extend service life, you should take transposition. If abnormal or premature wear occurs, please check the
wheel positioning first and then check if it is damaged.
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V Maintenance information system
(I) Instruction for arrows and symbols used in the manual
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VI Health and safety

(I) Instruction
Many operations related to vehicle maintenance and repair will impact human safety and health. This
section lists some of the related dangerous operation, material and equipment. Besides, it also lists the safety
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rules to avoid those hazards.

This section does not contain all instructions related to safety and health, so all work, program and
material handling should be operated in the premise of safety and health. Before using any product, you
should consult the product instruction provided by the manufacturer or supplier.
(II) Acid and soda
For example, corrosive sodium carbonate and sulfate.
Used in battery and other materials cleaning.
Having stimulus and erosion impact to eyes, skin, smell and throat, and may cause burns to human body
and damage general protective clothes.
Avoid splashing in eyes, skin and clothing. Wear proper protective clothes, gloves and goggles. Avoid
inhalation of spray.
Make sure to allocate cleaning equipment around such as eye washing bottle, showerhead and soap etc.
It can provide first aid when spray or spill occurs.
Mark a signal of “DANGER OF EYES” in an eye-catching position.
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(III) Braking fluid
You may feel a light irritation if the braking fluid sprays into skin or eyes, so try to avoid the braking
fluid to contact your skin and eyes. The risk of inhaling braking fluid vapor at room temperature is not high
because the vapor pressure is very low.
(IV) Chemical material
Take special attention when using, storing and handling chemical material like solvent, sealant, binder,
paint, resin foam, battery acid, engine coolant, braking fluid, fuel, lubricant, lubricating grease and etc. They
may be poisonous, harmful, erosive, irritant, high combustible and contain severe dangerous smell and dust.
The impact of long-term excessive exposure to environment with chemical substances may be instant or
chronic, transient or eternal, accumulative, exterior, fatal or may possibly affect longevity.
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Chemical material—operations you should take are as following
· Read carefully and follow the warnings and precautions on the material container, any enclosed
leaflets, posters or other product instructions. You can get the safety and health information about the
raw material from the manufacturer.
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· If you get touched with chemical material, remove it from your skin or clothes as quick as you can,
take off the seriously immersed clothes immediately and rinse it thoroughly.
· Strictly follow the working procedure instruction and wear protective clothes to avoid direct touch
with your skin and eyes.
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· During chemical material handling process, you must wash before you rest, eat and drink, smoke or
use toilet facilities.
· Keep the working area clean and tidy. Do not make the chemical material spray out.
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Chemical material—operations you should not take are as following

· Do not mix the chemical material together except there is instruction provided by the manufacturer.
Substance of some chemical material may contain other poisonous or harmful substance which may
release other poisonous or harmful substance when mixed or cause explosion or other accident.
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· Do not spray chemical material in a closed environment.

· Do not heat chemical material except there is instruction provided by the manufacturer because some
chemical materials are high combustible and some may release poisonous and harmful gas.
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· Do not keep the chemical material container open because the emitted gas may accumulate to be
poisonous, harmful or explosive. Some gas is heavier than air so they can be accumulated in a closed
space.
· Do not put chemical material in a container without a mark.
· Do not use chemical material to clean your hands or clothes. Chemicals, especially solvent and fuel
will make skin dry. They also may cause skin allergy, skin inflammation or absorb poisonous and
harmful substance through skin to affect your health.
· Do not put other chemical material in an empty container unless the container is cleaned under
supervision.
· Do not smell chemical material at will. A short exposure to gas of high density may get poisoned or
harmed.
·
(V) Dust
Powder and dust may be irritated, poisonous and harmful. Try to avoid inhalation of powder chemical
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material or dust caused by operation friction in dry temperature. If ventilation is poor, you should wear
protective device such as breathing mask to avoid inhalation of dust.
Small dusts of combustible matter may lead to explode. Please avoid explosion and fire.
(VI) Electric shock

It may cause electric shock if you use electrical devices wrongly without following instructions or abuse
equipment in good condition.
Do arrange maintenance for electrical devices within required time and test it regularly. Those failed
electrical devices should be marked or it will be better to remove them out of working area.
It is prohibited to make the wire, cable, plug and socket to be worn, twisted, cut off or damaged in other
way. Do not make the electrical devices and wire to be in contact with water.
Make sure that the electrical devices are under protection of proper fuse.
It is prohibited to misuse electrical devices and use these electrical devices with failure, or it will risk
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your safety.
Make sure the cables for mobile electrical device are not pressed or damaged.
Arrange general aid training for special electrical devices operator.
If electric shock happens:
·Turn off the power before contacting with the victim.
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· If the power cannot be turned off, use dry insulating material to remove the electric devices from the
victim.
· Arrange first aid immediately if you have been trained.
· Ask for medical assistance.
(VII) Exhaust
Exhaust contains poisonous and harmful substance such as carbon oxides, nitrogen oxides, aldehyde,
lead, aromatic hydrocarbons and etc. The engine can only run when there is proper exhaust equipment or
general ventilation equipment and in an open space.
(VIII) Fiber isolation
To be used for isolation of noise and sound.
The fibrous nature or sharp edge of the surface may cause skin irritated.
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During operation, strictly follow working procedure instructions and wear gloves to avoid the skin from
excessive exposure to fiber.
(IX) Fire
Many materials related to vehicle repair are extremely combustible. Some material will release
poisonous and harmful gas after burning.
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Do follow fire safety instructions when storing or handling combustible material or solvent especially
when you are around electrical devices or there is welding.
Ensure there is no fire risk before using electrical devices or welding equipment.
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Prepare a proper fire extinguisher around the working area before using welding or heating equipment.
(X) First aid
It is better to be with personnel with first aid training in the working place and confirm to laws and
regulations.
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If the eye gets sprayed, rinse it with clean water for at least ten minutes.
If the skin gets polluted, rinse the polluted area with soap and clean water.
If the skin gets frostbite, rinse the frostbite part into icy or cold water.
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If poisonous gas is inhaled, remove the victim to fresh air. If the adverse reaction phenomenon
persists, send the victim to hospital immediately for medical aid. If liquid is swallowed accidentally,
tell the information marked on the container or volume label to the doctor. Do not guide the victim to
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split blindly unless there is instruction on the volume label.
(XI) Foam -polyurethane

Curing foam is a buffer pad for seat and decoration.
Follow the instructions provided by manufacturer.
The components without chemical effect are irritated and may be harmful to eyes and
skin. Wear gloves and goggles for operation. Those who have chronic breathing disease,
asthma, bronchi or hereditary allergy should not handle or approach the uncured material.
The spare parts, vapor and sprayer of fiber will cause direct irritation and allergic reactions and may be
poisonous and harmful.
Do not inhale vapor and sprayer which can only be handled in good ventilation and with breathing
protective devices equipped. You cannot put the gauze mask off immediately after finish spraying unless the
vapor and sprayer disperse completely.
The combustion of the uncured assembly and cured foam will release poisonous and harmful gas.
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During bubble operation, it is prohibited to smoke, use open flame and electrical devices unless the vapor
and sprayer are removed completely. Any thermal cutting of foamed material or special foamed material
should be operated in good ventilation environment.
(XII) Fuel
Try to avoid the skin from direct contact with fuel. If contacted, rinse the contacted skin with soap and
clean water.
Gasoline
Easily combustibles should follow no-smoking ban.
If gasoline is carelessly swallowed, it will cause irritation to mouth and throat. When absorbed by the
stomach, it will cause general weakness and confusion. A little of gasoline will threaten a child’s life. Thus, it
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is very dangerous if liquid enters into lungs.
Gasoline will make skin dry. Long-term or regular contact will cause skin allergy and skin inflammation.
It will cause severe pain in the eyes if liquid enters into eyes.
Gasoline used in vehicle may contain large amount of benzene. Inflation of gasoline will get poisoned.
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Thus, the density of gasoline vapor must be kept at a very low stage. Gasoline vapor of high density will
cause irritation to eyes, nose and throat, nausea, headache, depression, drunkenness and etc uncomfortable
phenomenon. Gasoline vapor of extreme high density will cause quick loss of consciousness.
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Gasoline must be handled in good ventilation environment. Take care to avoid inflation of gasoline
vapor by spilling when operates in a closed space.
Pay special attention when cleaning and maintaining gasoline container.
It is absolutely prohibited to use gasoline as detergent and suck it with mouth.
(XIII) Gas cylinder bottle
Gases such as oxygen, acetylene, argon and propane are usually stored in cylinder bottles with pressure
of 13.8Mp (2001psi). Take special attention when handling these cylinders. Try to avoid mechanical damage
to the cylinders and valves. The filled gas in the cylinders should be marked clearly and properly.
Cylinder bottles should be stored in good ventilation environment and avoid to be put in snow, ice, or
environment with direct sunlight. Fuel gases such as acetylene and propane should not be stored together
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with oxygen cylinder.
Take special attention and try to avoid leakage of gas cylinders and piping and fire source.
Only these trained personnel can take operations related to cylinders.
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(XIV) General workshop tools and equipment
It is very important to keep good working condition of all tools and equipment and operate them
correctly during using process.
The tools and equipment should not be used against the function designed. Do not make the equipment
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such as crane, lifting jack, axle and chassis frame, sling to bear the load that exceed its maximum limit. The
damage caused by overloading may not emerge immediately but it can cause severe accident when used next
time.
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Do not use the equipment which are damaged or in poor condition especially high-speed equipment like
grinding wheel. The damaged grinding wheel will break without warning and cause serious injury.
Wear eyes protective equipment when using grinding wheel, a chisel or sand blasting equipment.
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Wear proper breathing mask when using sand blasting equipment or spraying equipment , or handling
materials containing asbestos.
Make sure there is ventilation equipment that can control the content of dust, sprayer and soot.
(XV) Lubricant and grease
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Try to avoid long-term and repeated contact with mineral oil. All lubricant and grease will cause
irritation to skin and eyes.
· Try to avoid long-term and repeated contact with engine oil especially the used one.
· Wear protective clothing including impermeable gloves.
· Do not put the wiping cloth stained with engine oil into the pocket.
· Try to prevent the clothing from being contaminated by engine oil especially the underwear.
· Do not wear the clothes and shoes contaminated by dense engine oil. The working clothes should be
rinsed regularly and kept clean.
· Take first aid for open wounds timely.
· During working process, smear sun cream on the skin so as to avoid direct contact with engine oil.
· Use soap and clean water to rinse and remove all engine oil. Smearing protective agent containing
lanolin will help to replace natural oil removed on the skin.
· If the skin occurs lesion, go to seek medical assistance.
· Try to remove the residual oil on the components before working.
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· Wear goggles such as chemical goggles or mask if the oil may possibly get direct contact with eyes.
In addition, devices for eyes flushing should be equipped with.
Precautions on environmental protection
The engine oil and oil filter used should be handled by authorized or licensed waste disposal business or
waste engine oil recyclers. If you have any query, please contact the relevant department of local authorities.
It is illegal to pour the used engine oil into ground, sewer or draining equipment.
(XVI) Noise
Some operations can cause high decibel noise and may do harm to your hearing, so appropriate hearing
protective devices should be worn.
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VII Fastener specification
(I) Fastener specification chart
In order to reduce the number of fasteners size, Jianghuai Automobile Co., Ltd engineering standard has
already adopted a part of the standard metric fasteners size defined by ISO and keeps each thread size the
best thread quality. As shown in the above metric bolt, the strength grade increases by the digital.
(II) Main fastener tightening torque chart

SN Name Tightening torque (N·m)
1 Connecting nut between front shock absorber and vehicle body 21~25
Connecting bolt(nut) between front shock absorber and steering
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2 knuckle 110±10
Connecting bolt between steering knuckle and ball head of lower
3 sway arm 110±10
4 Connecting bolt between steering gear and steering knuckle 50~55
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5 Connecting bolt between left suspension and vehicle body 55±5
6 Connecting bolt between left suspension and gear box 70±10

Connecting bolt between right suspension bracket and right
7 suspension 70±10
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Connecting bolt between right suspension bracket and vehicle
8 body 55±5
9 Connecting nut between right suspension and engine 55±5
10 Connecting bolt between rear suspension bracket and gear box 70±10
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Connecting bolt(nut) between rear suspension and rear suspension

11 bracket 130±15
12 Connecting bolt between rear suspension and side frame 130±15
13 Front connecting nut between sub-frame and vehicle body 180±10

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14 Rear connecting bolt between sub-frame and vehicle body 180±10
15 Connecting bolt between steering gear and sub-frame Main: 100~110 Auxiliary :110~120
16 Connecting bolt between stabilizer bar and sub-frame 60±5

17 Connecting nut between stabilizer bar and stability pulling rod 60±5
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Connecting nut between stability pulling rod and vibration damper

18 cylinder 50±5
Connecting bolt between brake hose and brake caliper(piercing
19 bolt) 25~30
20 Front connection bolt between lower sway arm and side frame 180±10
21 Rear connection bolt between lower sway arm and side frame 110±10
22 Connecting bolt between brake caliper and steering knuckle 65~75
23 Connecting bolt between rear shock absorber and vehicle body 50±5
Connecting bolt between rear shock absorber and rear torsion
24 beam assembly 140±10
25 Connecting bolt between rear suspension and brake 70±10

Connecting bolt between rear torsion beam assembly and vehicle
26 body 110±10
27 Driving shaft mounting nut 240~260
28 Mounting bolt 90~110
29 Mounting bolt between gear box and engine 35~45

30 Clutch mounting bolt(bracket bolt) 20~28
Overview
31 Mounting bolt between oil tank and vehicle body 60~70
32 Mounting bolt between universal joint and steering 30~35
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Overview
SN Name Tightening torque (N·m)
33 Connecting bolt between direction pipe column and universal joint 30~35
Connecting bolt between direction pipe column and dashboard
34 framework 上：20~25 下：20~30
35 Mounting bolt for clutch pedal and brake pedal 20~28
36 Steering wheel mounting nut 42~52
VIII Vehicle identification

(I) Vehicle identification number
Vehicle identification number
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Vehicle Identification Number (VIN) is legal mark of
the vehicle.
Carving position of VIN

The VIN is engraved on the installing cross beam of the
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right front seat.
Plate position
The VIN label is located in the upper left corner of the
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instrument panel and can be seen through the front
window glass out of the vehicle.
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(II) Label
Label-vehicle certification
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Information label
The label is permanently posted side down of the
driver’s door. You can refer to the content for tire
information. The label marks the maximum load of the
vehicle, tire size(include spare tire) and cold inflation
pressure（include spare tire).
Overview
Transmission identification number and location
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Carving position of manual transmission identification number
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IX Noise, vibration and abnormal noise
(I) Diagnosis information and steps
Wind noise and air sound
△Warning Refer to “Warning on assistant driving” in “Warning and Precautions”.
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△Caution The vehicle should be driven by assistant when the technician is inspecting the failure part
or it may cause accidents.
In order to accurately confirm the location of the wind noise, you must drive the car by yourself for a
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test. Generally, there are main leakage and secondary leakage in wind noise. If you cannot repair all leakage
during maintaining process, you can only reduce the wind noise but cannot eliminate it completely. During
testing driving, in order to confirm the location of wind noise, the repairman must take below tools:
· Stethoscope
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· Masking tape
· Caulking strip
· Sharpie
· Screwdriver
· Take a road test
according to below
procedures:
· Choose a road path with straight streets in four different directions of east, south, west and north.
· Choose the street with less traffic flows and less noise to avoid the detection being impacted.
· Make the road test at a speed which the customer thinks the noise is most
obvious and will occur. It is prohibited to drive over the legally limited speed. The
wind noises occurring in below case are external noises:
Overview
· You can hear wind noise immediately after you lower the window glass and drive the vehicle.
· The wind noise will appear when you stick a tape on all decoration
seal and gap. Internal wind noise is caused when the air escapes out of
the vehicle. You should follow below approaches for repair:
· Tape the pressure relief valve of the door lock pillar when you confirm the leakage location. The
inside pressure will be formed and make wind noise enhanced.
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Overview
· Use a stethoscope to confirm the leaking location.

· Use a masking tape to repair the leaking location temporarily.
· Continue the road test and check if wind noise is eliminated completely or there is other leakage
location.
· After confirmation of all leakage location by road test, return to the repair workshop and repair them
permanently with professional and reasonable method as well as sealing material.
Vibration
Most high speed vibrations are caused by dynamic imbalance of the wheel. The reasons for vibration
after dynamic balance are as follows:
· Tires are out of round
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· Wheel hubs are out of round
· Tires have hardness deviation
Not all causes of vibration can be detected by measuring tire and wheel free runout. The three reasons
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above are called load radical runout. Repair the vehicle by replacing the original tire and wheel assembly
with good tire and wheel assembly you know.
Low speed vibration which occurs when the vehicle speed is under 64km/h is generally caused by beat.
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High speed vibration which occurs when the vehicle speed is above 64hk/h is generally caused by imbalance
or beat.
Correcting uneven tire
Generally, there are two ways to correct the tires which still vibrate after being balanced. One is to use
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automatic machines. Install the tire on the machine tool and rub a small amount of rubber from the high
point of the tire thread on the left and right sides. Correcting tires in this way is permanent. It will not cause
significant impact on the tire appearance and tire thread life if operate by following instructions. Do not use
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edge-type machine tool to repair tires during correction because it will shorten the tire using life and cannot
solve the problem fundamentally.
Another way is to disassemble the tire and turn the tire for one hundred and eighty degree on the rim.
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This method can only be used when the vibration is confirmed to be caused by the tire and wheel assembly
because it may also cause intact wheel assembly to vibrate.
Abnormal sound
Check the heating shield if contacted with the bottom of the vehicle body when there is creak while the
vehicle engine is at a high speed.
· Lift the vehicle and inspect visually.
· Bent the heating shied slightly to produce a gap with the bottom of the vehicle body.
Squeak occurs in front of the vehicle in cold weather
Check the isolation pouches of the front balance bar
- Make a road test when the vehicle is not heated and pass over potholes to make the front
suspension to reach its maximum stroke.
- Remove the isolation pouch and wrap the front balancing bar with tape and then re-install
the isolation pouch on the tape.
Dull and abnormal sound occurs in the rear part of the vehicle when bumps
Check the spare tire in the trunk to be correctly secured.
江淮汽车 - Open 部门：客户服务部
the trunk and check the spare tire and vehicle tools.
Overview
- Re-fix the spare tire and vehicle tools.

- Make a road test to see if the abnormal sound disappears.
Glass percussion sound occurs in the rear part of the vehicle when driving on a bumpy road.
Check the rear door lock to be properly adjusted.
- Make a road test to confirm the rear door lock state.
- Loosen the lock nut and adjust the latch.
Creaks on the vehicle door
Check the wiring harness connector inside the door trim panel if creaks.
- Tap the interior trimming panel and observe carefully if there is creak.
- Remove the door interior trimming panel and wrap the harness connector with foamed pad
based on real cases.
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Squeak occurs when using the vehicle door
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Overview
Check the door hinge if it is lack of lubricant.
- Operate the door back and forth and listen carefully whether the door squeaks.
- Use rust remover to lubricate the door hinges and apply grease on it.
Squeak occurs when shifting gear in manual transmission (occurs in cold weather and during cold start).
Check the sheath under the manual shift devices assembly.
- Switch the shift lever and observe if there is squeak.
- Remove the floor console and change the shift lever sheath or coat it with gypsum powder.
(II) Maintenance instruction
Wind noise and air sound
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External wind noise
The repairing method for wind noise is very close to the repairing method for liquid leakage. You can
refer to “diagnosis information and steps”. The actual repairing program depends on the type of sealing
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material maintained.
Vibration
Wheels and tires balance on the vehicle
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Use electric vehicle wheel balancing machine to get dynamic balance. The dynamic balancing machine
is easy to be used for both static and dynamic balance. Different from balancing on the vehicle, the
balancing machine under the vehicle cannot correct imbalance of the braking disc. However, the accuracy of
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the balancing machine under the vehicle overcomes this shortcoming. Fix the wheel on the balancing
machine, and then use a cone to pass through the back side of the central hole but through the wheel nut
hole.
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Wheels and tires balance under the vehicle

Wheels and tires balance on the vehicle can correct the vibration caused by imbalance of the braking
disc.
△Warning Make the lower controlling arm to support in normal position in order to avoid damage to the driving
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axle. Do not shift into gear when the wheel is sank to its maximum trip.
· When operate dynamic balancing on the vehicle, it is forbidden to remove the balancing block
installed on the wheel during dynamic balancing under the vehicle.
· If you need to increase the balancing block for more than 25g in dynamic balancing, divide the
counterweight into two pieces and put them respectively on the inside rim and outside rim.
· Use the engine to rotate the driven wheel and wheel assembly.
Directional allocation of wheels and tires
Wheels and tires are packed in the factory. Equipment is matching the thicker part of the radial tire(high
point) with the minimum radius(low point) of the wheel.
When the tires leave from the factory, the high point of the tire is marked with a red paint mark
originally or a label is attached to the outer wall of the wheel.
The low pint position of the wheel is the valve core.
Before removing the tires from the wheel, mark the valve core position to ensure it can be installed to
the original 部门：客户服务部
江淮汽车 position.
Overview
Abnormal sound
Repair for abnormal sound
Abnormal sound mainly comes from relative movement between the components which should not exist.
There are three ways to repair the abnormal sound:
· Strongly fasten the components to avoid any relative movement in the driving process.
· Separate the components to avoid any contact during working.
· Isolate the components to avoid any abnormal sound during moving. Uniform surfaces with low
friction can be used to eliminate the viscous sliding among components.
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Clutch
Clutch
I．Overview
(I) Structure overview

Structure description
The clutch assembly is located between engine and transmission. The clutch pressure plate is mounted on the back plate of
flywheel through bolts. The clutch driven disk is connected with transmission input shaft through spline, rolls in axial direction, and
transmits torque circumferentially. During driving a vehicle, the driver can press or release clutch pedal to realize temporary
separation and gradual junction between engine and transmission, so as to cut off or transmit the power from engine to transmission.
The clutch system mainly consists of following components:
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· Driving part: clutch pressure plate
assembly. The clutch pressure plate
assembly is mounted on the flywheel
through bolts.
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· Driven part: clutch driven disk. The clutch driven disk is connected with transmission input shaft through spline. The
driving part and driven part keeps connection through spring pressure, which is imposed by diaphragm spring in the
pressure plate assembly.
· Controls: clutch operating system consists of clutch pedal, master cylinder, oil pump, wheel cylinder, release fork, and
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release bearing. When pressing clutch pedal, the main cylinder pushes wheel cylinder and release fork through hydraulic
pressure, and then pushes diaphragm spring disengaging pawl through release bearing, release pressure plate, so as to
release the clutch.
Clutch operating system
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Clutch
Clutch pressure plate & Clutch driven disk、
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3. Clutch pressure
1. Engine flywheel plate assembly
2. Clutch driven disk
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(II) Maintenance parameters

Maintenance parameters
SN Item Parameter
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1 Clutch free travel 6~20mm
Grease
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SN Item Grease type
1 Master cylinder master pin Kunlun No. low-temperature grease

(III) Torque
parameter
SN Item Torque (N.m) （N·m）
1 Clutch master cylinder mounting bolts 20~28
2 Clutch master cylinder mounting nuts 20~28
3 Oil pump mounting bracket 20~28

4 Exhaust bolts 8~12
5 Clutch pressure plate installation bolts 20~28
Clutch
(IV) Precautions for maintenance
Precautions
· The recommended clutch hydraulic fluid is brake fluid “DOT 4”. “DOT 4”
· Please do not repeatedly use the discharged clutch hydraulic fluid.
· Do not splash clutch hydraulic fluid onto vehicle body.
· Do not use mineral oil such as gasoline or kerosene. Otherwise, the rubber components in hydraulic system will be
corroded.
· Please do not disassemble master cylinder and hydraulic release bearing.
△Warning: Please use cleaner to clean the clutch and do not use compressed air to clean.
Main points for maintenance
△ It is prohibited to use vacuum pump or any type of emptying power device to operate on this system. Check the level of
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clutch hydraulic fluid and ensure the level is normal. Do not splash clutch hydraulic fluid on vehicle body or
other components. If clutch hydraulic fluid splashes on the vehicle body or other components, please use a dry
cloth to clean completely.
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(V) Special tools
SN No. Tool Outline drawing Description

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1 JAC-T1F011 Flywheel brake Mounting flywheel
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II. Malfunction Diagnosis

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(I) Common malfunction diagnosis

The performance diagnosis of clutch assembly and clutch operating system should be conducted by a skilled driver or a
professional automotive repairing technician.
The following (malfunction) diagnosis consists of common problems and possible reasons. After conducting proper diagnosis,
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please adjust or replace the parts as requested according to the respective solutions in the diagnosis chart and the proper chapters
corresponding with each specific procedure in the service manual.
During the maintenance, the clutch pressure plate and clutch driven disk cannot be repaired. If any one of them is broken, please
replace the whole assembly.
If the rivets of clutch driven disk are damaged or polluted by engine oil or grease, this clutch driven disk cannot be used.
If you need to replace a new part, please use a qualified new part to replace it.
This diagnosis chart helps to diagnose the malfunction of clutch system caused by the following situations: unreleased,
incomplete release, incomplete junction, slipping, noise, and vibration.
The numbers in the diagnosis chart does not represent the checking sequence, and there is no precedence relation among all
kinds of possible reasons.
Clutch
(II) Malfunction
Diagnosis chart
Malfunction
SN phenomenon Malfunction reason analysis Solution Remark
Clutch release lever deforms Replace deformed part
diaphragm spring deforms Replace deformed part
1 Unreleased diaphragm spring support ring breaks Replace deformed part
Clutch pedal spring breaks Replace worn and damaged part

Clutch driven disk sticks with flywheel or
clutch pressure plate
Adjust clutch system
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Clutch driven disk deforms, and swings when Replace deformed, worn, damaged
it rotates and exceed-fixed-parameter part
Clutch driven disk damages Replace driven disk
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If clutch driven disk cannot match
with transmission input spline,
replace clutch driven disk. If
necessary, replace transmission input
shaft.
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Clutch driven spline does not match with
transmission input shaft spline, or spline tooth
damages
Incomplete
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2 release Clutch driven disk sticks with flywheel or

seizes clutch pressure plate
Replace undesirable part
Thickness of flywheel, clutch pressure plate,

clutch driven disk exceeds prescribed
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parameter
Adjust clutch system to kill

unnecessary clearance and eliminate
Clutch pedal control system and clutch wire
mechanical failure
drawing have mechanical failure or improper
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Reinstall improperly installed part

adjustment
Clutch driven disk is polluted by engine oil or

grease Clean grease or replace driven disk
Replace deformed, worn, and
Clutch driven disk damages damaged part
Correctly adjust clutch pedal free
Clutch pedal has no free travel travel
Incomplete
Diaphragm spring/clutch pressure plate/clutch
3 junction
release lever/clutch driven disk spline Replace clutch driven disk or
deforms or damaged problematic clutch assembly
Adjust clutch system to kill

unnecessary clearance and eliminate
Clutch pedal control system and clutch wire
mechanical failure
drawing have mechanical failure or improper
Reinstall improperly installed part
adjustment
Clutch driven disk damaged Replace driven disk
Clutch
grease Clean grease or replace driven disk
Same with the respective solution for
“incomplete release” and “incomplete
junction” “ ” “
Clutch incomplete junction
”
Thickness of flywheel, clutch pressure plate,
clutch driven disk exceeds prescribed
parameter, friction surface exceeds specified
4 Slipping standard / ／
，
Switch off the engine, cool down the
temperature of clutch (if temperature
is high), and then conduct further
Extreme high temperature in clutch due to diagnosis，
improper driving
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（），
Clutch installed improperly Reinstall clutch
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Clutch
Malfunction
Unfit clutch driven disk Install prescribed clutch driven disk

If a part has improper balance, replace
clutch assembly，
Improper balance
5 Noise
Adjust clutch wire drawing
Reinstall improper installed part
Clutch thrust bearing fails
Clutch driven disk torsion shock absorber Replace deformed, worn, and
spring damaged damaged part、
Clutch driven disk shock absorber spring does
not conform parameter Replace driven disk
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Clutch driven disk does not conform
6 Vibration parameter Replace driven disk
grease Replace driven disk
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Clutch
(III) Malfunction diagnosis flow chart
Clutch unreleased flow chart
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Clutch
Incomplete release flow chart
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Clutch
Incomplete junction flow chart
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Clutch
Clutch slipping flow chart
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Clutch
Clutch noise flow chart
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Clutch
III Clutch Pedal Free Travel Adjustment
(I) Special tool (No)
(II) Adjustment
1. Adjust clutch pedal free travel
1). Press clutch pedal to the dead point, and measure the clutch
pedal travel from starting position to the dead position.
2). Loosen the locking nuts and rotate bolts, and adjust clutch pedal
travel. After adjustment, fasten the locking nuts.
△Caution: When adjusting clutch pedal height, do not push lever

to clutch master cylinder.
3). Use hands to press gently clutch pedal, and ensure clutch pedal
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has free travel when there is resistance for pedal falling.
Standard parameter 6~20mm
4). Loosen the locking nuts and push the lever, and adjust clutch
pedal free travel. After adjustment, fasten the locking nuts.
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Tightening torque 20~28N·m
5). Clutch pedal free travel should be within the standard value.
△Caution: If clutch pedal free travel is not within the standard
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value, then there is air in clutch hydraulic pipe or
clutch master cylinder has malfunctions. Please
conduct system exhaust, and disassemble and check
master cylinder or clutch.
IV Hydraulic Clutch Exhaust

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(II) Exhaust operation procedure
△Caution: When disassemble clutch pipe, clutch master cylinder,
hydraulic release bearing and clutch pedal rubber,
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please conduct system exhaust.

1. Exhaust air in the pipe
1). Loosen exhaust bolts on clutch
wheel cylinder.
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2). Slowly press down clutch pedal, until air is completely exhausted.
3). Press the pedal completely and maintain, and tighten exhaust bolts.
4). Add hydraulic oil in clutch hydraulic system.
△Caution: Always keep the fluid level between MIN and MAX.
5). Repeat the above procedures, until the exhausted clutch hydraulic
oil is clean and free of bubble.
2. Confirm clutch works normally.
1). Start the engine, press clutch pedal, and shift into reverse gear
after two seconds. If there is noise during shifting gear,
completely press down clutch pedal for 5 times to exhaust air
for the system.
2). After 30 seconds, check the working condition of clutch. If there is
still big noise, please repeat exhaust.
Clutch
V Clutch Master Cylinder

(I) Special Tool (No)
(II) Removal
1. Remove the battery and its mounting frame.
2. Remove instrument panel lower shield. Refer to Instrument Panel.
3. Remove clutch master cylinder.
1). Exhaust clutch hydraulic oil from clutch exhaust bolts.
2). Disconnect the connecting hose between clutch master cylinder
and brake master cylinder, and the connecting hard pipe
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between clutch master cylinder and clutch wheel cylinder.
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3). Disconnect the locking pin between clutch master cylinder push rod and clutch pedal.
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4). Remove clutch master cylinder and the connecting bolts and mounting nuts on the vehicle body.
Clutch
5). Take out clutch master cylinder.
(III) Check
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1. Check clutch pipeline
1). Check whether the clutch
pipeline is congested or not.
2). Check clutch hose and hard pipe for damage or rust.
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(IV) Installation
1. Install clutch master cylinder
1). Install clutch master cylinder, and tighten mounting
nuts of clutch master cylinder.
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2). Connect the locking pin between clutch master

cylinder push rod and clutch pedal.
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Clutch
3). Connect the connecting hose between clutch master cylinder and
brake master cylinder, and the connecting hard pipe between
clutch master cylinder and clutch wheel cylinder.
2. Add clutch hydraulic oil, and exhaust. Refer to
Hydraulic clutch exhaust.
3. Install instrument panel lower shield.
4. Install battery frame and connect battery cable.
VI Clutch Wheel Cylinder
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(II) Removal
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1. Remove battery and frame.
2. Remove Clutch wheel cylinder
1). Remove clutch wheel cylinder oil pipe
bolts, and disconnect pipeline.
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2). Remove clutch wheel cylinder mounting bolts, and take down clutch wheel cylinder
△Caution: The anti-dust cover and lever of wheel cylinder easily
fall off. When taking out wheel cylinder, please
avoid falling off.
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Clutch
(III) Installation
1. Install clutch wheel cylinder
1). Connect clutch cylinder onto the transmission housing and tighten
the bolts.
Tightening torque 20N·m
2). Smear grease on the connecting area between push
rod and release lever.
△Caution: Do not stain anti-dust cover.
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3). Connect clutch oil pipe onto clutch wheel cylinder and tighten the
bolts.
4). Add clutch hydraulic oil, and exhaust.
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VII Clutch Master Cylinder Oilout Hard
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Pipe
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(II) Removal
1. Remove air filter assembly. Refer to air filter assembly.
2. Remove clutch master cylinder oilout
hard pipe assembly.
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1). Loosen exhaust screws, and exhaust

clutch fluid.
2). Disconnect oilout hard pipe with clutch wheel
cylinder.
Clutch
3). Disconnect oilout hard pipe with clutch master cylinder.
4). Remove the connecting bracket between oilout hard pipe and transmission.。
5). Remove the connecting bracket between oilout hard pipe and frame.。
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6). Take out clutch master cylinder oilout hard pipe assembly.。
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(III) Installation
1. Install clutch master cylinder oilout hard pipe
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assembly
1). Connect oilout hard pipe with clutch master
cylinder, and tighten.
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2). Connect oilout hard pipe with clutch wheel cylinder, and tighten the mounting nuts.
Clutch
3). Install transmission bracket.
4). Add clutch hydraulic fluid.
2. Hydraulic clutch exhaust.
3. Install air filter assembly.
VIII Clutch Pedal
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(II) Removal
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1. Remove clutch pedal
1). Disconnect the locking pin between clutch
master cylinder push rod and clutch pedal.
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2). Remove 2 bolts connecting clutch pedal upper part and vehicle
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body, and 2 bolts connecting clutch lower part and clutch

master cylinder.
3). Take out clutch pedal.
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(III) Check
1. Check clutch pedal
1). Check clutch pedal for twist, damage or cracked welded
junction.
If there is above situation, please replace clutch pedal assembly.
Clutch
(IV) Installation
1. Install clutch pedal
1). Install clutch pedal, and tighten clutch pedal mounting nuts and bolts.
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2). Connect the locking pin between clutch master cylinder push rod and clutch pedal.
2. Adjust clutch pedal free travel
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IX Clutch Pressure Plate Assembly And Driven Disk

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(I) Special tool
SN Tool No. Tool Name Tool drawing

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1 JAC-T1F011 Flywheel stopper
(II) Removal
1. Remove manual transmission assembly. Refer to transmission assembly.
Clutch
2. Remove clutch pressure plate assembly
1). Use flywheel stopper to fix flywheel.
2). Equably loosen clutch pressure plate mounting bolts.
△Caution: Each time please loosen each bolt for one or two
rounds, to avoid damaging flange of clutch housing.
3). Take out clutch pressure plate and clutch driven disk.
(III) Check
1. Check clutch driven disk
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1). Check whether there are rivet looseness, single side contact, and fire
burns leading to cracking, and oil appendage on the surface. If any,
please replace clutch driven disk.
2). Measure the immersed length of rivet. If it exceeds the ultimate
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value, please replace clutch driven disk.
Ultimate value：0.3mm
3). Check whether damper spring is loose or damaged. If any, please
replace clutch driven disk.
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4). Install clutch driven disk on input shaft, and check sliding mode and
looseness of rotation direction. If the sliding is poor, please clean.
After assembly, please replace if the sliding is still poor. If the
looseness is obvious, please replace clutch driven disk or input
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shaft, or replace both of them.

2. Clutch pressure disk
1). Check whether diaphragm spring head is worn and there is height
difference. If there is obvious wear or the height difference exceed
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ultimate value, please replace clutch driven disk.
Ultimate value：0.5mm
2). Check whether there are wear, crack, and color change on the
surface of pressure disk.
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3). Check whether the rivet of pressure disk is loose. If it is loose,

please replace clutch pressure disk.
(IV) Installation
1. Clean and smear grease
1). Clean clutch driven disk and input shaft keyway, and eliminate
grease and worn metal chips.
2). Smear oil on input shaft key groove.
△Caution: Recommended oil: SAE J310 or similar product.
Ensure the oil is smeared on the set position.
Otherwise, it will cause clutch produces noise, poor
separation or damage. Too much oil will lead to
sliding or vibration.
2. Install clutch pressure disk assembly
1). Use a special tool to conduct positioning installation of
clutch driven disk and clutch pressure disk.
Clutch
2). Conduct in 1-2-3-4-5-6 sequence as shown in the picture, to evenly
tighten clutch mounting bolts successively.
Caution: Tighten each bolt for 1-2 rounds in proper sequence.

3. Install manual transmission
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Drive shaft
Drive Shaft
I Overview
(Ⅰ) Structure overview

The drive shaft is on the front sub-frame, and divides into left drive shaft assembly and right drive shaft assembly, and
transmits the torque and speed output from transmission to wheels.
Drive shaft inner side connects with transmission differential through spline, and depends on universal joint of inner side to roll
axially so as to offset the length change caused by wheel steering and jumping, and depends on universal joint of outside to
rotate in large angle, and connects with wheel hub inner ring through spline at the end of shaft, and locks through self-locking
nuts.
Drive shaft assembly structure
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(II) Torque specification

SN Item Tightening torque (N·m)
1 Drive shaft self-locking nut 240~260

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Connecting nut of Lower sway arm ball joint and steering

2 knuckle 100~120
3 Steering knuckle and steering tie-rod ball joint 50~55
4 Wheel nut 90~110

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(III) Precautions for maintenance

1. Relevant issues needing attention during
maintaining drive shaft
1). None-overhaul parts such as steering
joint cannot be disassembled.
2). Try your best to operate on the platform
without dust.
3). Please clean the surface of parts first before dismantlement and assembly.
4). During operation, please be careful to avoid staining the parts and foreign materials entering. The disassembled parts should
be carefully re-assembled by following the correct sequence. If the operation is interrupted, please use clean cover to cover
the parts.
5). Please use paper cloth, and prevent cloth scraps sticking on the parts when using fiber cloth.
6). Please use kerosene to clean the dismantled parts (except rubber parts), and dry or use paper cloth to wipe dry.
2.
Relevant issues needing attention during checking and repairing system or replacing parts
1) It is obliged to conduct the prescribed torque check on the mounted parts after assembly.
2) Please conduct necessary alignment after assembly.
3) Disposable parts cannot be repeatedly used.
4) Please check completely before repairing or replacing the parts.
Drive shaft
(IV) Special tool
SN Tool Number Tool Name Outline drawing Usage
Remove
JAC-T1D003 Steering driving rod steering ball
1 drawing die joint
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Install oil
2 Oil seal installation tool seal
II Malfunction diagnosis
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(I) Malfunction diagnosis chart
Malfunction
Drive shaft steering knuckle wears Replace

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Vehicle running Wheel bearing has wear, friction, or crack

1 deviation sound Replace
Front suspension and steering have defects. Adjust and replace
Drive shaft wears, damages or bends Replace

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Drive shaft and wheel hub have abnormal

2 Vibration noise Replace
Wheel bearing has wear, friction, or crack
sound Replace
Wheel unbalanced Adjust and replace

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3 Jump
Front axle steering knuckle has defects Adjust and replace
Drive shaft wears, damages or bends Replace
Drive axle wheel hub wears Replace
Drive shaft wheel hub wears Replace

4 Big noise
Wheel bearing wears, burns or has abnormal
noise Replace
Wheel hub nuts become loose Adjust and replace
Front suspension and steering have defects. Adjust and replace
Drive shaft
III Drive shaft
(I) Special tool
SN Tool Number Tool Name Outline drawing
1 JAC-T1D003 Steering driving rod

drawing die
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(II) Removal
1. Lift the vehicle.
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2. Remove front wheel. Refer to wheel.
3. Remove front brake caliper assembly. Refer to front brake caliper (for the model with front disc and rear drum).
4. Remove wheel speed sensor. Refer to front wheel speed sensor.
5. Remove drive shaft.
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1). Loose drive shaft self-locking nuts.
20
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2). Remove the two connecting locking nuts between steering knuckle
and lower sway arm.
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Drive shaft
3). Disconnect the connection point between transverse stabilizer bar and stabilizer pull rod lower end.
4). Disconnect steering knuckle and steering transverse pull rod ball joint.
△Caution: Please use a special tool, and avoid damaging ball joint anti-dust cover.
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25
14
5). Separate the drive shaft from wheel hub and bearing assembly.
6). Pry drive shaft out from transmission, and pull out drive shaft assembly from wheel hub.
△Caution: When removing drive shaft, the placed angle of drive

20
shaft universal joint should not be too large. Please

do not excessively pull the slip joint to avoid the
third ball pin falling from ball basket to damage it.
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(III) Check
1. Rotate the universal joint to check whether it rotates smoothly and has serious looseness.
2. Check anti-dust cover for crack, damage and grease leakage.
3. If there is any abnormal situation, please disassemble drive shaft and replace the problematic part.
Drive shaft
(IV) Installation
1. Install drive shaft
1). Replace a new transmission side oil seal.
2). Insert drive shaft into transmission and ensure snap rings are set at positions.
3). Install drive shaft on wheel hub and bearing assembly.
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4). Tighten the connecting nuts of steering knuckle and steering transverse pull rod ball joint.
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5). Tighten the connection point between transverse stabilizer bar and stabilizer pull rod lower end.
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6). Tighten the two connecting nuts between steering knuckle and lower sway arm.
Drive shaft
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IV Differential oil seal
(I) Special tool
SN Tool Number Tool Name
25 Outline drawing
14
1 JAC-T1D003 Steering driving rod
drawing die
20
Oil seal installation

C-
2 tool
(II) Removal
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1. Remove the wheel. Refer to wheel.

2. Remove front constant velocity drive shaft. Refer to drive shaft.
3. Remove differential oil seal.
1). Use a pinch bar to pry the outer lip of seal, and remove differential oil seal.
△Caution When using a pinch bar to pry seal, please be very
careful for not damaging transmission housing.
(III) Check
1. Check oil seal for crack, damage, and grease leakage.
Drive shaft
2. Check anti-dust cover for crack, damage, and grease leakage.
3. If there is any abnormal situation, please replace the oil seal.
(IV) Installation
1. Install differential oil seal
1). Smear transmission oil on the lip of new
transmission oil seal.
2). Use a special tool to install the new transmission oil
seal.
2. Install drive shaft.
3. Install wheel.
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Front Suspension
Front Suspension
I Overview
Front suspension structure
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Front shock absorber upright column assembly structure

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Front Suspension
Front sub-frame assembly structure
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Front wheel hub assembly structure
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Front Suspension
(II) Technical parameter
Item Parameter and Specification
Front suspension
type McPherson independent suspension with coil spring
Type Bidirectional hydraulic cylinder
Travel 168mm
Shock absorber
Stretch 549N±91N （0.3m/s）
Damping force
Compression 405N±85N （0.3m/s）
Coil spring Free height: 329mm (Reference) Color mark: a white yellow line
Wheel toe-in (front) 0°±10′
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Wheel camber angle 0°±30′
Wheel alignment
(Non-loading)
Kingpin inclination angle 12.3°±30′
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Kingpin caster angle 3.8°±30′
Kingpin offset -1.2mm

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(III) Torque
specification
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1 Mounting bolts of front transverse stable rod mounting bracket and sub-frame 45~55
2 Connecting nuts between front transverse stable rod and transverse stable rod tie rod 55~65
Connecting nuts between front transverse stable rod tie rod and front upright column
3 assembly 55~65
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4 Front shock absorber and vehicle body installing nuts 21~25

5 Upper self-locking nuts of front shock absorber 49~68.6
6 Connecting bolts between front shock absorber and steering knuckle 100~120
7 Connecting bolts between lower sway arm ball pin and steering knuckle 60~70
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8 Connecting nuts between lower sway arm ball pin and lower sway arm 100~120
9 Connecting bolts between lower sway arm front bushing and sub-frame 170~190
10 Connecting bolts between lower sway arm rear bushing and sub-frame 100~120
11 Front mounting nuts of front sub-frame 170~190
12 Rear mounting nuts of front sub-frame 170~190

1. When installing suspension or rubber bushing, the final tightening must be conducted when tyres are on the ground and in non-
loading status.
2. After maintaining suspension parts, please check wheel alignment.
3. Engine oil will shorten service life of rubber bushing. Please clean the overflowed engine oil.
4. Non-loading condition means fuel, engine coolant, and lubricant are normally filled and spare tyre, jack, basic hand tool, and
foot pads are in specified position.
5. Locking nuts cannot be repeatedly used. It is obliged to use new nuts when installing. During replacement, do not wipe out the
rust-proof oil on the locking nuts before tightening them.
Front Suspension
(V) Special tool
SN Tool number Tool name Outline drawing Usage
Disassemble
steering ball
1 JAC-T1D003 Steering driving rod die joint
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Disassemble and
install damper spring
2 JAC-T1D004 Damper spring disassembler
3 Wheel hub installer

25 Install front and
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rear wheel hub
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II Malfunction Diagnosis
Malfunction
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Front wheel alignment is improper Adjust or replace

Steering exceeds lower sway arm ball joint Replace
1 Heavy steering
Tyre air pressure is too low Inflate
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No power steering Repair or replace

Shock absorber has failure Repair or replace
2 Poor return Transverse stabilizer bar wears or damages Replace
Coil spring wears or damages Replace
Lower sway arm bushing wears Replace

Abnormal tyre
3 wear Tyre air pressure is too low or too high Adjust air pressure

Vehicle running Lower sway arm ball joint connecting
4 deviation steering resistance is poor Replace
Lower sway arm bushing is loose or wears Replace
Front Suspension
Malfunction

Vehicle Lower sway arm ball joint connecting
running steering resistance is poor Replace
deviation
5 unilaterally
Lower sway arm bends Replace
Coil spring wears or damages Replace

Lower sway arm ball joint connecting
Steering wheel steering resistance is poor Replace
6 shimmies
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Lower sway arm bushing is loose or wears Replace
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III Lower Sway Arm Assembly
(II) Disassembly
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△Caution: The methods of disassembling left and right lower sway arm assembly are similar.
2. Disassemble front wheel. Refer to wheel.
3. Disassemble lower sway arm assembly.
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1). Pull out split pin, and disassemble lower sway arm ball pin and
the mounting groove nuts of lower sway arm.
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2). Disassemble lower sway arm and sub-frame rear mounting bolts.
Front Suspension
3). Disassemble lower sway arm and sub-frame front mounting bolts.
△Caution: During removal, please fasten lower sway arm ball joint,
and then loosen locking nuts, to avoid rotation.
4). Take lower sway arm down.
(III) Check
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Check lower sway arm assembly.
1. Check whether bushing wears or damages. If any, please replace.
2. Check whether lower sway arm deforms or has other damages. If
any, please replace.
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3. Check whether lower sway arm ball joint anti-dust cover has crack. If
4. Check whether all the mounting bolts and nuts have damage. If any,
please check.
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(IV) Installation
1. Install lower sway arm assembly.
1). Install lower sway arm assembly on the correct position.
2). Tighten lower sway arm and sub-frame front mounting bolts.
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3). Tighten lower sway arm and sub-frame rear mounting bolts.
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4). Tighten lower sway arm ball pin and the mounting groove nuts of
lower sway arm, and install split pin.
2. Install front wheel.
Front Suspension
IV Front Upright Column Assembly
(I) Special tool
(II) Disassembly
△Caution: The methods of disassembling left and right front upright column assembly are similar.
△Caution: In order to keep wheel balance, please mark relative position
of wheels before disassembling tyres.
2. Disassemble front wheel. Refer to wheel.
3. Disassemble front stabilizer connecting rod.
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4. Disassemble front upright column assembly.
1). Disconnect the harness and oil pipe on front column, and
disconnect front brake oil pipe and wheel speed sensor from
shock absorber.
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2). Disassemble the two connecting bolts between steering knuckle and front shock absorber.
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3). Remove the three mounting nuts on front shock absorber.

4). Disassemble front upright column assemble from wheel cover side.
Front Suspension
(III) Installation
1. Install front upright column assembly
1). Install front upright column from wheel cover side.

2). Tighten the three mounting nuts on front shock absorber.
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3). Tighten the connecting bolts between steering knuckle and front
shock absorber.
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4). Install front brake oil pipe and wheel speed sensor on shock
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absorber, and connect the harness and oil pipe on front upright
column.
2. Install front stabilizer connecting rod.
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Front Suspension
V Front Shock Absorber Parts And Spring
(I) Special tool
SN Tool number Tool name Outside drawing
1 JAC-T1D004 Damper spring remover
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(II) Disassembly
△Caution: The methods of disassembling and installing left and right front shock absorber parts and spring are similar.
1. Disassemble front upright column assembly. Refer to front upright column.
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2. Disassemble front shock absorber parts and spring
1). Install two nuts and one bolt on the bracket of shock absorber,
and then mount front absorber assembly on bench vice.
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20
2). Use a spring compressor to compress coil spring.

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△Caution: It is prohibited to use a pneumatic wrench to avoid damaging spring compressor.

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Front Suspension
3). Disassemble front shock absorber upper pedestal anti-dust cover,
and use a tool to mount spring seat and remove locking nuts.
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4). Disassemble front shock absorber upper pedestal assembly, upper
pedestal, coil spring upper shock mount pad, coil spring, anti-
dust cover, buffer block, and front coil spring lower shock
mount pad.
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(III) Installation
1. Install front shock absorber parts and
spring
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1). Use a spring compressor to compress

coil spring.
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2). On shock absorber bracket, install front coil spring lower shock
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mount pad, buffer block, anti-dust cover, coil spring, coil spring
upper shock mount pad, upper pedestal, and front shock
absorber upper pedestal assembly.
△Caution: Install the lower side of coil spring on the recess of

shock absorber spring seat.
Front Suspension
3). Install locking nuts, and close front shock absorber upper pedestal anti-dust cap.
Tightening torque 49~68.6N·m
2. Install front upright column assembly
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VI Front Transverse Stabilizer Bar
(II) Disassembly
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3. Disassemble stabilizer bar tie rod lower mounting point.
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20
4. Remove front transverse stabilizer bar.

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1). Remove left and right stabilizer bar mounting bracket

mounting bolts, and take down mounting bracket and bushing.
2). Take down front transverse stabilizer bar assembly.
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(III) Installation
1. Install front transverse stabilizer bar assembly.
1). Install front transverse stabilizer bar
assembly on the correct position.
2). Install mounting bracket and bushing, and

tighten left and right stabilizer bar mounting
bracket mounting bolts.
Front Suspension
2. Tighten stabilizer bar tie rod lower mounting bolts.
VII Stabilizer Bar Tie Rod Assembly
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(II) Disassembly
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△Caution: The methods of disassembling and installing left and right
stabilizer bar tie rod are similar.
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3. Disassemble stabilizer bar tie rod.
1). Remove stabilizer bar tie rod connecting ball joint and
front upright column assembly mounting nuts.
2). Remove stabilizer bar tie rod connecting ball joint and front
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stabilizer bar assembly mounting nuts.
(III) Installation
1. Install stabilizer bar tie rod assembly.
1). Place front stabilizer bar assembly at
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the correct position.

2). Tighten stabilizer bar tie rod connecting ball joint and front
stabilizer bar assembly mounting nuts.
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3). Tighten stabilizer bar tie rod connecting ball joint and front
upright column assembly mounting nuts.
Front Suspension
VIII Lower Sway Arm Ball Joint Assembly
(I) Special tool
(II) Disassembly
△The methods of disassembling and installing left and right lower sway arm ball joint assembly are similar.
3. Disassembly lower sway arm ball joint assembly.
1). Remove the two connecting bolts between lower
sway arm ball joint and steering knuckle.
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2). Pull out split pin, and disassemble the mounting groove nuts between lower sway arm ball joint and lower sway arm.
3). Disconnect the connection between lower sway arm ball joint and lower sway arm.
4). Use a special tool to remove lower sway arm ball joint.
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△Caution: Please only use a special tool to disconnect lower
sway arm ball joint and steering knuckle. It is
prohibited to use hammer or pinch bar to remove
lower ball joint from steering knuckle. If do not use
the recommended tool, it will result in the damage of
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lower ball joint and sealing.

(III) Installation
1. Install lower sway arm ball joint assembly
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1). Install lower ball joint and lower sway arm assembly, and tighten groove nuts.
2). Install split pin.
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3). Tighten the two connecting bolts between lower sway arm ball joint and steering knuckle.
Front Suspension
IX Front Sub-Frame Assembly
(II) Disassembly
3. Disassemble lower sway arm assembly. Refer to lower sway arm
assembly.
4. Remove the connecting bolts between stabilizer bar tie rod lower
side and transverse stabilizer bar.
5. Remove front sub-frame
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assembly
1). Use jack to support
sub-frame.
2). Remove the four

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mounting bolts between
steering gear and sub-frame.
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3). Remove the two

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mounting bolts between

engine rear suspension and
front sub-frame.
4). Remove the two mounting bolts

between sub-frame and the front section of vehicle body.
Front Suspension
5). Remove the two mounting bolts between sub-frame and the rear section of vehicle body.
6). Take down front sub-frame assembly.
(III) Installation
1. Install front sub-frame
assembly
1). Install front sub-
frame assembly.
2). Tighten the two mounting bolts between sub-frame

and the rear section of vehicle body.
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3). Tighten the two mounting bolts between sub-frame
and the rear section of vehicle body.
20
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4). Tighten the two mounting bolts between engine rear

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suspension and front sub-frame.

5). Tighten the four mounting bolts between steering

gear and sub-frame.
Front Suspension
2. Tighten the connecting bolt between stabilizer bar tie rod lower side and transverse stabilizer bar.
3. Install lower sway arm assembly.
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X Front Wheel Hub Assembly
(I) Special tool
25
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Wheel hub
1 installation tool
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(II) Removal
C-
3. Remove brake caliper. Refer to front brake caliper (For Vehicle Model with front disc and rear drum).
4. Remove front brake disc. Refer to front brake disc (For Vehicle Model with front disc and rear drum).
5. Remove lower sway arm. Refer to lower sway arm assembly.
6. Remove front wheel speed sensor. Refer to front wheel speed sensor.
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7. Remove steering transverse tie rod ball joint. Refer to steering gear and tie rod assembly.
8. Remove front wheel hub
assembly.
1). Disconnect steering
knuckle and shock absorber.
2). Remove axle nuts, and disconnect wheel hub and drive shaft.
3). Take down steering knuckle.
Front Suspension
4). Remove front wheel hub mounting circlip.
5). Use a special tool to remove front wheel hub from

steering knuckle.
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(III) Installation
1. Install front wheel hub assembly.
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1). Place a wood block under wheel hub, and install front
wheel hub into front steering knuckle.
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2). Install front wheel hub mounting circlip.
Front Suspension
3). Install axle nuts.

4). Install steering
knuckle and shock
absorber.
2. Install steering transverse tie
rod ball joint.
3. Install front wheel speed
sensor.
4. Install lower sway arm
assembly.
5. Install front brake disc.
6. Install front brake caliper.
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Rear Suspension
Rear Suspension
I Overview

Rear suspension structure
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Rear Suspension
Shock absorber upright column assembly structure
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Rear torsion beam assembly structure

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Rear Suspension
Rear wheel hub assembly structure
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Rear wheel hub assembly installation diagram 25
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(II) Technical
parameter
Rear suspension type Torsion beam
Rear Suspension
Type Bidirectional hydraulic cylinder
Travel 223mm
Shock absorber
Stretch 451N79N 0.3m/s
Damping
force
Compression 202N52N 0.3m/s
Type Coil straight spring
Coil spring Free height 365mm (Reference)
Color mark Same color on both sides
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Wheel total toe-in 2420
Wheel alignment Single wheel toe-in 1210
Wheel camber angle -130
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(III) Torque
specification
SN Item Tightening torque (Nm) Nm

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1 Rear shock absorber and vehicle body installing bolt 45~55
2 Rear shock absorber upper self-locking nut 24.5~34.3

Rear shock absorber and rear torsion beam connecting
3 bolt 100~120
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4 Rear wheel hub and torsion beam connecting bolt 55~75
5 Rear torsion beam and vehicle body installing bolt 130~150

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1. When installing suspension or rubber bushing, the final tightening must be conducted when tyres are on the ground and in non-
loading status.
2. After maintaining suspension parts, please check wheel alignment.
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3. Engine oil will shorten service life of rubber bushing. Please clean the overflowed engine oil.
4. Non-loading condition means fuel, engine coolant, and lubricant are normally filled and spare tyre, jack, basic hand tool, and
foot pads are in specified position.
5. Locking nuts cannot be repeatedly used. It is obliged to use new nuts when installing. During replacement, do not wipe out the
rust-proof oil on the locking nuts before tightening them.
(V) Special tool
SN Tool number Tool name Outside drawing Usage
Remove and install

damper spring
1 Damper spring remover
Rear Suspension
Malfunction
Loose installation Tighten
1 Abnormal noise Wheel bearing fatigue or damaged Replace

Shock absorber assembly damaged Replace damaged part
Tyre air pressure is too high Adjust air pressure
Shock absorber assembly damaged Replace damaged part
2 Vibration Wheel nuts become loose Tighten
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Coil spring becomes short or breaks Replace
Tyre quality is poor Replace

Vehicle body
3 sway Coil spring becomes short or breaks Replace
III Rear Shock Absorber

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(II) Removal
Caution: The methods of removing left and right rear shock absorber are similar.
20
2. Remove wheel. Refer to wheel.

3. Remove rear shock absorber.
1). Remove the connecting bolts
between shock absorber and vehicle
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body.
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2). Remove the connecting bolts between shock absorber and rear torsion beam.
Rear Suspension
(III) Check
1. Check shock absorber
1). Check shock absorber for oil leakage. If
2). Check whether piston push rod damages, wears and deforms. If any, please replace.
2. Check buffer block and anti-dust cover
1). Check buffer block and anti-dust cover for wear or
damage. If any, please replace.
3. Check rear shock absorber upper installation plate
1). Check rear shock absorber upper installation plate for wear or damage. If any, please replace.
4. Check pedestal for limiting position and upper installation vibration
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isolation pad.
1). Check pedestal for limiting position and upper installation vibration
isolation pad for wear or damage. If any, please replace.
25
(IV) Installation
1. Install rear shock absorber
2). Install shock absorber and rear torsion beam, and tighten connecting bolts.
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Tightening torque 100~120Nm
20
3). Tighten the connecting bolts between shock absorber and vehicle body.
C-
Caution: It is prohibited to use damaged parts. Under non-loading

condition, please conduct final tightening on each
part removed during disassembling shock absorber.
2. Install wheel.
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3. Check wheel alignment.
IV Rear Coil Spring

(I) Special tool
Damper spring
1 remover
Rear Suspension
(II) Removal
Caution: The methods of disassembling and installing left and right rear coil
spring are similar.
Caution: In order to keep wheel balance, please mark the relative position of
wheel before removing tyres.
2. Remove tyre. Refer to tyre.
3. Disassemble rear coil spring.
1). Remove the connecting bolts between
rear shock absorber and rear torsion
beam.
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2). Take down rear coil spring upper rubber pad, rear coil spring, rear coil
spring lower rubber pad.
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(III) Check
1. Check rear coil spring upper rubber pad and rear coil spring lower rubber
pad
1). Check rear coil spring upper rubber pad and rear coil spring lower
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rubber pad for wear or damage. If any, please replace.
2. Check coil spring
1). Check coil spring for wear or damage. If any, please
20
replace.
(IV) Installation
1. Install rear coil spring.
1). It is prohibited to use damaged
C-
parts.
2). Install rear coil spring upper rubber pad, rear coil spring, and rear coil
spring lower rubber pad.
3). Use a spring compressor to compress coil spring
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Rear Suspension
4). Tighten the connecting bolts between rear shock absorber and rear torsion beam.
5). When installing spring lower cushion, please align lower cushion rubber
column with the respective spring cushion holes on rear torsion beam, and
install to the position. Place big diameter side of coil spring downward, and
align with spring lower cushion.
6). Check whether installation mark is correct. Conduct the final tightening
on each part under non-loading codition.
2. Install wheel.
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3. Check wheel alignment.
V Rear Torsion Beam Assembly

(I)
(II)
Special tool (No)
Removal 25
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1. Remove wheel. Refer to wheel.
2. Remove shock absorber. Refer to rear shock absorber.
3. Remove rear brake drum assembly.
4. Remove rear brake device assembly. Refer to rear drum brake device (for Vehicle Model with front disc and rear drum).
20
5. Remove rear torsion beam

assembly.
1). Take down coil spring
and accessories.
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2). Use a jack to support rear torsion beam assembly.

Caution: During removal, it is prohibited to let jack slipping.
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Rear Suspension
(III) Installation
1. Install rear torsion beam
1). Tighten the two mounting bolts between rear torsion beam and
the left and right side of vehicle body.
2). Use a jack to support rear torsion beam assembly.
27
4). Tighten the connecting bolts between rear torsion beam and shock
absorber.
2. Install rear brake device assembly.
25
3. Install rear brake drum assembly.
4. Install shock absorber.
5. Install wheel.
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VI Rear Wheel Hub Assembly
20
(II) Removal
Caution: The methods of disassembling and installing left and right rear
C-
wheel hub assembly are similar.

Caution: In order to keep wheel balance, please mark the relative position of
wheel before removing tyres.
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2. Remove rear wheel. Refer to wheel.

3. Remove rear wheel hub
assembly.
1). Disconnect rear wheel
speed sensor.
Rear Suspension
2). Remove rear brake drum mounting screws, and take down rear brake drum.
3). Remove the four rear wheel hub assembly mounting bolts from the inner side of torsion beam.
4). Take down rear wheel hub assembly, and keep brake device on the torsion beam bracket.
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(III) Installation
1. Install rear wheel hub assembly.
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14
1). Connect left rear parking brake assembly and rear wheel hub
unit with torsion beam successively.
Caution: The installation direction of wheel hub unit is the installation convex end forwardness of sensor.
2). Install rear wheel hub assembly from the inner side of torsion beam, and tighten the four connecting bolts.
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3). Tighten rear wheel speed sensor.

Wheel and Tyre
Wheel and Tyre
I Overview
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Wheel and Tyre
Spare tyre structure
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Tyre pressure
The air pressure of tyres has a decisive effect on the wear of tyres, fuel consumption, failures, etc. Thus, for a safe driving, it is
necessary to keep a standard air pressure and check air pressure periodically.
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The loading capacity of tyres is corresponding to the inflation pressure. Please confirm the reasonable pressure according to the
vehicle’s loading situation. The change of climate and season should be the reason to adjust the air pressure of tyres.
Incorrect tyre pressure may cause:

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1). Insufficient air pressure will result in easy wear of tyres, twisting
of tyres, and the increase of rolling resistance.
Wheel and Tyre
2). Excessive air pressure will make the middle part of tyre tread
wear easily, and reduce cushioning capacity of tyres.
Change of position of tyres
27
The wear situation of a vehicle’s front and rear tyres is different
due to their loading capacity is different during operation. Thus, in order
to avoid tyre wearing in a single direction, periodically change the
positions of tyres will make tyres wear evenly so as to extend the life of
25
tyres. It is necessary to change the positions when replacing new tyres.
Note: Recommended change of position of tyre shown in the picture.
Replace tyres
14
1. Please replace tyres after normally running 50,000km.
2. If one of the following situations happens,
please also replace:
1). There are at least three wear signs on tyre
20
tread.
2). There is cord fabric or cord fabric line on
tyre rubber.
3). There is crack on the tread or shoulder of tyre, and there is cord
C-
fabric layer.
4). Tyres bump, bulge, or layer.
5). Tyres are punctured, lacerated, or have other damages which
cannot be repaired.
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Four-wheel alignment
The correct four-wheel alignment plays an important role in ensuring
a vehicle’s stability and nice control, eliminating abnormal wear of tyres,
and reducing tiredness of drivers.
Parameters of four-wheel alignment include:
·Toe-in
Toe-in is the difference value between the distance of front
sections of two wheels and the distance of rear sections of the same
two wheels. If two wheels are parallel, the toe-in is zero. If wheel
front section inclines to a vehicle’s center line, the toe-in angle is
positive. Otherwise, it is negative.
The function of toe-in is to compensate the trend of inward or
outward rolling due to camber angle and surface resistance, to
ensure a vehicle’s straightness.
Wheel and Tyre
·Camber angle
Camber angle is an angle of inclination that a tyre is relative to a vertical reference line. When the top of a wheel inclines
outward, the angle is positive. Otherwise, it is negative. The setting of camber angle can influence the control of direction of a
vehicle and the wear of tyres.
Improper setting of camber angle can cause quick or uneven wear

of tyres. Excessive big positive camber angle can cause the outer wear
of tyre tread. When outer tread loading is higher than inner tread
loading, this uneven wear will happen.
Excessive big negative camber angle can cause the inner wear of
tyre tread. When inner tread loading is higher than outer one, this
uneven wear will happen.
27
·Caster angle
Caster angle is an included angle between caster axis of a wheel
25
and vertical plane of the ground. Caster angle can ensure the
stability of straight-line travel: if a vehicle has a positive caster
angle, when a wheel moves left, the left wheel will move left
around caster. Due to caster line inclines backward, the ground
14
point of wheel has the trend of moving downward in vertical
direction, and in fact the vehicle body of this side is lifted upward.
After steering and release steering wheel, the lifted vehicle body
20
weight will force the steering knuckle moves downward. In this

way, axle journal returns back to the original position of sharp
forward direction.
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Wheel and Tyre
（I）Maintenance parameter
Item Parameter
Tyre pressure (Cold state) 1 220±10KPa
Tyre pressure (Cold state) 2 240±10KPa
Tyre size 1 205/55 R16 94V
Tyre size 2 185/65R15 88H
Radial direction Aluminum wheel 0.3mm

Wheel run-out value
Axial direction Aluminum wheel 0.3mm
Balance weight 5g/10g/15g/20g/25g/30g/35g/40g
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Front wheel camber
angle 0°±30′
Caster angle 3.8°±30′
Kingpin inclination
25
Front wheel angle 12.3°±30′
Front wheel single toe-in
angle 0°±5′
Four-wheel alignment parameter
Front wheel toe-in angle 0°±10′
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Rear wheel toe-in 12′±10′
Rear wheel Total toe-in 24′±20′

Rear wheel camber
angle -1°±30′
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（I）Torque parameter
SN Item Tightening torque (N.m)
1 Wheel nut 90~110

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（I）Precautions for maintenance

1. Please use the original factory wheels.
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2. During the running-in period of new tyres, please avoid sudden starting, sudden turning, and sudden braking. Avoid operate
under severe working conditions to prevent quick wear of new tyres.
3. Before using new tyres, please conduct wheel balance.
Diagnosis chart
Malfunction
Excessive wobbling of tyre and wheel hub Replace
Wheel nuts loose Lock tightly
Tyre unbalance Adjust

Steering wheel Uneven wear of tyre Adjust or replace
1 circular vibration
Insufficient tyre pressure Adjust
Front wheel bearing damages or wears Adjust or replace
Steering system malfunction Adjust or replace

Suspension system malfunction Adjust or replace
Wheel and Tyre
Tire pressure is not correct Adjust
Tyre wear in
2 advance Adjust toe-in or replace
Wheel positioning error
Rear wheel need change torsion beam
Incorrect tyre pressure Adjust

3 Tyre noise
Tire metamorphic Replace

Road noise or Tire uneven Adjust
body shake
4
Rims or tire deformation Repair or replace
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Uneven tyre wear Adjust or replace
Tyres and rims excessive deflection Replace
Wheel nut loose Lock tightly
25
Steering wheel up
5 and down shaking Tire uneven Adjust
Engine bracket break or wear of rubber Replace

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Transmission bracket break or wear of
rubber Replace
Incorrect tyre pressure Adjust
Steering wheel
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Excessive wear or tyre wear is not average Adjust or replace

inclines to one
6 side

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Uneven tyre pressure on two sides Adjust
Wheel hub or tyre deforms Repair or replace
7 Driving instability Wheel nuts loose Lock tightly

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Braking inclines Uneven tyre pressure on two sides Adjust
8 to one side
Brake system malfunction Adjust or replace

Steering wheel
9 becomes heavy Steering system malfunction Adjust or replace

Steering wheel
return ability is
10 poor Steering system malfunction Adjust or replace
Wheel and Tyre
III Four-wheel alignment
(II) Four-wheel alignment check and adjustment

1. Check four-wheel alignment parameter
1). Whether meet the requirement. If not, please timely adjust front
wheel toe-in. Check the reasons if other parameters do not meet the
requirement, and replace the parts.
Front wheel single toe-in 0°±5′

Front wheel toe-in 0°±10′
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Caution: This model’s camber angle, caster angle, kingpin
inclination angle of front wheel, and rear wheel toe-
in and camber angle are determined during design,
which cannot be adjusted.
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2. Adjust toe-in
1). When wheel is at the position of straight-line travel, if toe-in
exceeds standard value, loosen the locking nuts of left and right
steering tie rods, use a wrench to respectively rotate left and right tie
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rod to adjust toe-in to standard value, and then lock the locking nuts.
When adjusting the length of left and right tie rod, please pay
attention to keep the lengths of left and right tie rod are the same
(reverse direction).
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Wheel and Tyre
IV Wheel
(I) Special tool(No)
(II) On-vehicle check
1. Check tyre appearance

1). Confirm wheels free of wear, improper inflation, crack, or
other damages.
2. Check wheel tyre
1). Use a high quality tyre pressure gauge to check wheel tyre
pressure. If not within standard value, please inflate or deflate.
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Standard value ：
220±10KPa
Standard value ：
240±10KPa
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3. Check tyre tread
1). Check the depth of tyre tread.
Note: Tyre size 205/55 R16 94V
Tyre size 185/65R15 88H
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△Caution: When the depth of tyre tread approaches limit value
or even smaller, wear sign will exist on tyre tread.
When there is wear sign, please replace tyres.
2). Check whether there is foreign material in tyre tread. If any, please clean.
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(III) Removal
1. Remove wheel.
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1). Loosen the five nuts on the wheel.

2). Lift the vehicle.
3). Remove wheel nuts.
4). Remove the wheel.
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(IV) Installation
1. Install wheel
1). Follow the pictured sequence 1-2-3-4-5 to install wheel nuts, and
slightly tighten.
2). Put down the
vehicle.
3). Follow the pictures sequence to tighten wheel nuts.
Wheel and Tyre
V Wheel Balance
(I) Removal
1. Remove the wheel needed adjustment. Refer to wheel.
2. Remove the old balance weight at the two sides of wheel, and clean the foreign material on the tyre tread.
△Caution:
1. During removal, be careful not scratching the wheel.
2. If new tyres, please remove the adhesive tape on the
tyres.
(II) Adjustment
1. Wheel dynamic balance
1). Take center hole as guide, install wheel on the balance machine,
and start wheel balance machine.
2). When the unbalance values of inner and outer sides are shown on
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the monitor of wheel balance machine, select a balance weight
near to the shown value and install on the position of inner and
outer side of wheel as shown on the balance machine.
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△Caution: After installing outer balance weight, please then install
inner balance weight. Before installing balance weight,
please clean the fitting surface on the wheel.
3). Install balance weight on the pictured position.
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4). When installing balance weight on the wheel, as the right picture
shows, please place in the trench area of wheel, and make the
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center of balance weight align with the position (or angle)

indicated by wheel balance machine.
5). If the calculated balance weight exceeds 50g, install the two
balance weights on the same straight line.
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△Caution: Balance weight cannot be repeatedly used. Replace a

new one every time. Only install maximum three
pieces of balance weights. Always use original
balance weights. It is prohibited to place one balance
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weight on the other one.

6). Re-start wheel balance machine.
7). According to the position (or angle) indicated by wheel balance
machine, tap balance weight into the inner side of wheel.
8). Start balance machine, and confirm the unbalance value of inner
and outer side is only 5g or less. If any side exceeds, please re-
calibrate and add balance weight.
△Caution: Use balance weight on demand. The usage size refers to maintenance technical parameter sheet.
VI Spare Tyre
(II) Removal
1. Remove spare tyre
1). Open the trunk.
2). Open trunk cover.
I Overview
(I)Structure overview
Front disc brake structure
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2
1 25 4
5
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9
20
7
10 6
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1. Mounting bolts for

brake caliper bracket 6. Brake pad
2. Steering knuckle 7. Guiding piece for bake pad
Dust cover for disc
3. brake 8. Brake caliper bracket
4. Hub assembly 9. Floating pin seal
5. Brake disc 10.Brake caliper
Rear drum brake structure
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25
14
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Installation location chart for rear disc brake
1 2
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4 25 3
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1. Rear brake caliper assembly 3. Rear wheel hub assenbly
4. Rear brake disc
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2. Rear brake hose assembly
Vacuum brake booster assembly

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1. Vacuum booster 4. oil input hose

2. Brake master cylinder 5. small oiler
3. Brake master oiler
(II) Principle of operation
Hydraulic brake system
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25
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1. Brake master pump 2. ABS module assembly ABS
1.3 Technical parameter

1.3 Technical parameter
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Item Specification
Type Cascade
Brake master pump

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Cylinder bore 22.22mm
Type Vacuum
Brake booster Specification(size) 10 inch

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Power ratio 7.3:1
Clamp- floating / ventilated discs

Type
Brake disc diameter 256mm
Rear brake Brake disc thickness 22mm
Friction block thickness 10.8mm
Cylinder bore 54mm
Type Drum brake
Sub-pump diameter 17.46mm

Rear parking brake
Brake drum diameter 204mm
Friction block thickness 4mm
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(IV) Torque parameters
Serial NO. Item Tightening torque(Nm)
1 Connecting bolt between the front brake caliper and steering knuckle 65~75
2 Connecting bolt between the rear brake and rear wheel hub 65~85
3 Exhaust bolt of the front and rear brake caliper 7~13
4 Fixing bolt for the bracket on the brake pedal 20~25
5 Brake pedal fixing pedal 20~25
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6 Connecting bolt between the brake hose and brake caliper 25~30
7 Brake pipe joint 16~18
(V) Maintenance precautions

1.
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All brake oil lines are forbidden to be excessively bent, twisted or stretched.
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2. Make sure all brake oil lines do not contact with other parts at rest or steering.
3. Brake oil lines are important safety parts, so make sure all its fixtures are always tightened. If any damaged parts are found, replace
them with new application parts.
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4. When disconnect the brake oil lines, make sure the connector ends are tightly sealed to avoid any dust entrance.
5. It is recommended to use DOT4 braking liquid.
6. Do not reuse the drained braking liquid.

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7. Take care to avoid spraying the braking liquid on painted surface because it will damage the paint. If the painted surface is sprayed
with brake liquid, rinse it clean with water.
8. Use clean brake liquid to wash all parts in the brake cylinder.
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9. Do not use gasoline, kerosene or other mineral oil to avoid any damage to the rubber parts in the brake hydraulic system.
10. Use a special wrench to remove and install the oil pipe. Make sure to check the tightening torque when install the oil pipe.
11. After repair or replace the brake disc and brake shoe, or spongy brake appears after a short travel, make use to run in the brake
combination surface.
12. Make sure there is no braking liquid on the brake disc. Do not spay braking liquid on the brake disc or it will result in brake failure.
(VI) Special tool
SN Tool NO. Tool name Outline drawing Usage
Remove and
install the oil
1 Oil pipe wrench pipe
II Malfunction diagnosis
Malfunction diagnosis chart for braking system
Serial Malfunction
NO. phenomenon Malfunction reason analysis Solution Remark
The left and right tire pressure are different. Adjust
The front wheels parameters are adjusted incorrectly. Adjust
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The brake pads or shoes are poorly contacted. Adjust
1 The vehicle There is grease or oil on the braking pads or shoes surface. Replace
deviates to one
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side when brakes.
The brake drum is eccentric or worn unevenly. Replace
The brake sub-pump is installed incorrectly. Adjust

14
The self-adjusting mechanism is faulty. Adjust
Supply or
The braking liquid is not enough or polluted replace
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System
There is air in the braking system exhaust
The braking booster is faulty Adjust

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Insufficient The braking pads or shoes are contacted poorly. Adjust

2 braking force
There is grease or oil on the braking pads or shoes surface. Replace
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The self-adjusting mechanism is faulty. Adjust
The braking rotation parts are overheated caused by braking Adjust

pads or shoes dragging.
System
There is air in brake system. exhaust
Brake fluid leaks. Adjust
3
Increased pedal
travel(The distance
between the pedal
and floor is
reduced) The self-adjusting mechanism is faulty. Adjust
The gap between the pushing rod and brake master cylinder
is too large. Adjust
The return spring of the braking pedal is worn. Replace
The oil returning port of the braking master cylinder is

blocked. Adjust
4 Brake lag
The return spring of the rear drum brake is damaged. Replace
The return spring of the brake master cylinder plunger is

defective. Replace
Malfunction diagnosis chart for the rear brake
Serial Malfunction
NO. phenomenon Malfunction reason analysis Remark
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Solution
Tighten or
There is leakage in the pipe joints or rear brake cylinder replace after
cups. cleaning
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The residual air in the pipeline is not exhausted completely. Exhaust
The braking force

1 is insufficient. The gap between the brake shoe and drum is too large. Re-adjust
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The brake shoe is stuck with oil spots or hardening. Rub or replace
The drum is overheating and the pipeline is with gas Replace, cool,
resistance. exhaust
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The rear brake shoes are severely worn. Replace
Boring cut and

balancing
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performance
2 The brake drum is not circular. verification
Remove
foreign body
Braking is hard to
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The rear brake shoe surface is too smooth and with low and use coarse
be released.
friction. When the braking pressure is large, the smooth sandpaper to
surface will produce friction noise during sliding or there is rub the rear
foreign body that will squeeze the friction surface. brake shoe.
SN Malfunction phenomenon Malfunction reason Solution Remark
analysis
Brake clearance and brake When facing this situation,
pedal free just follow instructions to r
e-adjust brake clearance.
travel are extremely small.
When loosening brake
pedal, brake force is not
completely eliminated,
which makes long-time
fraction state; difficult
start-up, weak driving, and
you can feel hot when
Brake drum overheating
3 caused by braking drag touching wheel drum
surface.
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The energy generated by Rear brake disk should be
braking make return spring examined or replace return
hot and deformed, elastic spring, then the malfunction is
force falls or disappears, eliminated.
and braking assembly
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cannot be timely returned.
Braking malfunction cannot
be timely eliminated, which
causes brake drum hot.
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III Front braking bushing (vehicle model with front disc and rear drum)
(I) Special tool(no)
20
(II) Disassembly
Caution The disassembly method for front left and front right braking pads are similar.
1. Lifting the vehicle
Caution: In order to maintain wheel balance, remark the relative position of the wheels before removing the tire.
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2. Remove the front wheels. Refer to vehicle wheels

3. Disassemble the front braking bushing
1). Loosen the two connecting bolts between the brake caliper and
the upper and lower ends of the installation bracket. 2
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2). Remove the one connecting bolt between the brake caliper and the
lower end of the installation bracket. 1
3).Take down the braking pads and spring piece.
(III) Installation
1. Check the braking bushing
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Standard thickness11mm11mm
Wear limited thickness2mm2mm
Replace the front braking pad if the braking pad thickness
is smaller thanthe minimum value.
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(IV) Installation
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1. Install the braking pad

1). Install the pad spring piece to the
respective braking pad.
Caution: Install according to the fixed direction of the muffler
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piece.
2). When install the braking pad, press the plunger and then install
the sub-cylinder to the installation bracket.
3). Install the braking pad on the installation bracket of the braking
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sub-cylinder.
Caution: Take note the braking liquid level of the braking oiler.
4). Close the braking caliper and tighten the two connecting bolts
between the braking caliper and the upper and lower ends of the
installation bracket. 2
2. Install the front wheels

IV Front brake caliper (vehicle model with front disc and rear drum)
(I) Special tool
Serial
NO. Tool NO. Tool name Outline Drawing
Oil pipe
1 wrench
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(II) Disassembly
Caution: The disassembly method for the front left and front right brake caliper are similar.
Warning: Refer to warning about lifting the vehicle and special precautions about braking liquids effect to paint and
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electrical parts in warning and precautions.
Caution: In order to maintain wheel balance, remark the relative position of the wheels
before removing the tire.
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2. Disassemble the front wheels. Refer to vehicle wheels
3. Disassemble front brake caliper
1). Remove the braking pipe bolt in the braking sub-cylinder and
then disconnect the brake hose. Plug the brake caliper inlet and
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brake hose to avoid braking liquid from lossing or polluting.
Caution: Take care to avoid the drop of the copper washer at the
two ends of the bolts.
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2). Remove the two connecting bolts between the installation bracket
of the brake caliper assembly and steering knuckle and then
take down the brake caliper parts. 2
(III) Installation
1. Install the front brake caliper
1). Install the front brake caliper parts and tighten the two
connecting bolts between the installing bracket of the brake
caliper assembly and steering knuckle.
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2).2)Connect the braking hose and tighten the braking hose bolt.
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2. Braking pipe exhaust. Refer to hydraulic
braking system exhaust
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V Front brake disc (vehicle model with front disc and rear drum)
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(I) Special tool

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SN Tool NO Tool name Outline drawing
Oil pipe
1 wrench
(II) Disassembly
Caution: The disassembly method for the front left and front right brake disc is similar.
1. Remove the front wheels. Refer to vehicle wheels
2. Disassemble the brake caliper assembly. Refer to front brake caliper (vehicle model with front disc and rear drum).
3. Remove the front brake disc.
1). Remove the cruciform screw from the brake disc.
2). Take down the brake disc.
Caution: Make marks on the brake disc and wheel hub.
(III) Inspection
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1. Visually check whether there is uneven wear, cracks and damage on the
brake disc surface. If it is, replace the brake disc.
2. Swash check
1). Fix the brake disc on the wheel hub.
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Caution: Before measurement, make sure the gap
Between the wheel bearing and axial direction is not too large.
2). Use a dial gauge to measure the swash value.( Make
measurement about 10mm inside the brake disc edge) 10mm
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Swash limited value0.05mm
3). If the swash is over than the requested value, replace it or make
necessary processing.
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4. Thickness check
Use a dial gauge to measure the brake disc thickness. If the thickness is
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lower than the wear limited value, please replace the brake disc.
Standard thickness22mm
Wear limited thickness20.4mm
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(IV) Installation
1. Install the front brake disc
1) Make marks with alignment of the brake disc and wheel hub and
install the brake disc.
2) Tighten the cruciform screw on the brake disc.
2. Install the brake caliper assembly

3. Install front wheels
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VI Rear drum brake (vehicle model with front disc and rear drum)
(I) Special tool
SN Tool NO Tool name
25 Outline drawing
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Oil pipe
1 wrench
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(II) Inspection on the vehicle

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2. Check the brake shoe wear.

1). Check the thickness of the brake shoe from the
checking hose of the braking bottom plate.
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(III) Disassembly
Caution The disassembly method for the rear left and rear right brake is similar.
1. Remove the rear wheels. Refer to vehicle wheels
2. Remove rear brake drum. Refer to rear wheel hub assembly
3. Disassemble the rear wheel speed sensor. Refer to rear wheel speed sensor
4. Discharge braking liquid
5. Disassemble rear drum brake
1). Remove the four connecting bolts between the rear wheel hub
and torsion beam.
2). Loosen the parking brake and remove the circlip and head of the
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parking brake wiring.
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14
20
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3). Remove the rear brake pipe joint.

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4). Take down the rear drum brake assembly.
(IV) Inspection
1. Check the brake drum
Check whether the brake drum diameter and round jumpiness are
within the standard value. If they are not, make processing or
replacement.
Standard value204mm
Round jumpiness<0.05mm
2. Check the brake shoe

1).Measure the brake shoe thickness and its contact with the brake
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drum. If they are not within standard vale, make replacement.
Standard thickness of brake shoe (A):4mm
Allowed ultimate thickness(A):1mm
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3. Check the brake bottom plate
Check whether the brake bottom plate is worn or damaged.
4. Check the sub-cylinder A
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Check whether there is oil leakage in the sub-cylinder.
(V) Installation
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1. Install the rear drum brake

1). Put the rear drum brake assembly in the
correct position.
2). Install the rear drum brake pipe joint.
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3). Install the circlip and head of the parking brake wiring and pull
tightly the handbrake.
4). Install the four connecting bolts between the rear wheel hub and rear
torsion beam.
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2. Install the rear wheel speed sensor.
3. Install the rear brake drum 25

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4. Add braking liquid

Caution: Add clean braking liquid to the master pump
Reservoir to correct level.
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5. Air exhaust of the braking system. Refer to hydraulic braking system exhaust
6. Install the rear wheels
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VII Braking pads (vehicle model with front disc and rear disc)
(I) Special tool (no)
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(II) Disassembly
Caution: The disassembly method for the front, rear, left and right braking pads are
similar.
Caution: In order to maintain wheel balance, mark the wheel relative position before
removing the tire.
2. Remove the wheels. Refer to vehicle wheels
3. Remove the front braking pads.
1). Loosen the two connecting bolts between the brake caliper
and upper and lower ends of the installing bracket.
2). Remove the one connecting bolt between the brake

caliper and lower end of the installing bracket.
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25
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3).Take down the braking pads and spring piece.
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(III) Inspection
1. Check the braking pad
Standard thickness: 9.5mm
Wear ultimate thickness: 2mm
If the braking pad thickness is smaller than the minimum value, replace.
(IV) Installation
1. Install the braking pad
1). Install the spring piece to respective braking pad.
Caution: Install according to the muffler piece fixed direction.
2). Press the plunger when installing the braking pad and then install
the sub-cylinder to the installing bracket.
3). Install the braking pad to brake sub -cylinder bracket.
Caution: Take note of the braking liquid level in the braking liquid oiler.
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4). Close the brake caliper and tighten the two connecting bolts
between the brake caliper and upper and lower ends of the
installation bracket.
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14
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VIII Font brake caliper (vehicle model with front disc and rear disc)
(I) Special tool
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1 oil pipe wrench
(II) Disassembly
Caution: The disassembly method for the front left and front right brake caliper are similar.
Warning: Refer to warning about lifting the vehicle and precautions
about braking liquids effect to paint and electrical parts
in warning and precautions.
Caution: In order to maintain wheel balance, mark the wheel relative position before
removing the tire.
2. Disassemble the front wheels. Refer to vehicle wheel.
3. Remove the front brake caliper.
1). Remove the braking pipe bolt in the braking sub-cylinder and
brake hose to avoid braking liquid from lossing or polluting.
Caution: Take care to avoid the drop of the copper washer at the
two ends of the bolts.
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2). Remove the two connecting bolts between the installation
bracket of the brake caliper assembly and steering knuckle and
then take down the brake caliper parts.
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14
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(III) Installation
1. Install the front brake caliper
1). Install the front brake caliper parts and tighten the two
connecting bolts between the installing bracket of the brake
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caliper assembly and steering knuckle.

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2). Connect the braking hose and tighten the braking hose bolt.
2. Braking pipe exhaust. Refer to hydraulic braking system exhaust

IX Rear disc brake caliper (vehicle model with front disc and rear disc)
(I) Special tool
SN Tool NO. Tool name Outline drawing
Oil pipe
1 wrench
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(II) Removal
Caution: The disassembly method for the rear left and rear right brake disc are similar.
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1. Disassemble the rear wheels. Refer to vehicle wheels.
2. Loosen the parking brake.
Disconnect the parking brake wiring. Refer to parking brake assembly and wiring assembly (vehicle
model with front disc and rear disc)
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3. Disassemble the rear disc brake caliper
1).Remove the braking pipe bolt in the braking sub-cylinder and
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brake hose to avoid braking liquid from losing or polluting.

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2). Remove the two connecting bolts between the brake caliper
assembly and installation bracket and then take down the brake
caliper parts.
(III) Installation
1. Install the rear disc brake caliper assembly
1). Install the brake caliper parts to correct position and tighten the
two connecting bolts between the brake caliper assembly and
installation bracket.
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2). Connect the braking hose and tighten the braking hose bolt.
2. Install the parking brake cable.
3. Braking pipe exhaust. Refer to hydraulic
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braking system exhaust.
4. Install the rear wheels.

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20
X Braking disc. ( vehicle model with front disc and rear disc)
(I) Special tool

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Oil pipe
1 wrench
(II) Disassembly
Caution: The disassembly method for the front, rear, left and right brake disc are similar.
1. Disassemble the front wheels. Refer to vehicle wheels.
2. Release the parking brake.(This operation is performed during removing the rear brake disc)
3. Remove the parking brake wiring. (This operation is performed during removing the rear brake disc)
Refer to parking brake assembly and wiring assembly(vehicle model with front disc and rear disc)
4. Disassemble the brake caliper assembly. Refer to front brake caliper.(vehicle model with front disc and rear drum)
5. Remove the front brake disc.
1). Remove the cruciform screw on the brake disc.
2). Take down the brake disc.
Caution: Mark on the brake disc an axle hub.
(III) Inspection
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1. Visually check whether there is uneven wear, cracks and severe
damage on the brake disc surface. If it is, replace the brake disc.
2. Swash check
1). Fix the brake disc on the axle hub.
25
Caution: Before measurement, make sure the wheel axial gap is not
too large.
2). Use a dial gauge to check the swash. (Measure about 10mm
inside the brake disc edge).
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Swash ultimate value0.05mm
3). If the swash is over than the requested value, replace it or make
necessary processing.
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4. Thickness check
Use a microcalliper to measure the brake disc thickness. If it is lower
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than the wear limit, replace the break disc.
Standard thickness: 25mm

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Wear ultimate thickness: 23mm
(IV) Installation
1. Install the front brake disc.
1). Install the brake disc and mark with alignment to the brake disc
and wheel axle hub.
2). Tighten the cruciform screw on the brake disc.
2. Install the front brake caliper assembly

3. Install the parking brake cable (Install the rear brake disc)
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XI Braking pedal
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(II) Check and adjust
1.Adjust the gap between the braking pedal and brake limiting switch bolt.
1). Disassemble the protection plate assembly on the driving side.
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2). Disconnect the braking lamp switch connectors and loosen the
braking limiting switch nut. Release the braking pedal and rotate the
switch bolt to make the gap between the switch bolt and braking
pedal is 0.5mm~1mm.
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Standard value: 0.5mm~1mm

Tightening torque: 8~10Nm
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2. Free travel of the braking pedal

1). Step down the braking pedal two or three times
when the engine is off.
2). Make sure the vacuum in the brake vacuum booster is eliminated and press down
the braking pedal with hand.
Standard value: 3mm~8mm
3). Check whether the free travel of the braking pedal is within the
standard value before any resistance occurs.
Caution: If the free travel is not within the standard value, replace
the damaged parts.
(III)Disassembly
1. Open the engine compartment cover
2. Disconnect the negative cable of the battery
3. Disassemble the upper and lower cover of the dashboard. Refer to dashboard upper cover and dashboard lower cover.
4. Remove the braking pedal
1). Service Brake System

2). Disassemble the lockpin connected with the brake vacuum booster and disconnect the brake vacuum booster.
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3). Disassemble the connection bolt between the braking pedal and
vehicle body and fixing nut connected with the brake vacuum
booster.
4). Take down the braking pedal.
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20
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(IV) Check and adjust

1. Braking pedal
1). Check whether the movable pin of the braking pedal is worn or deformed.
2). Check whether there is cracks, twist or other damage on the braking pedal.
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2. Lockpin and bushing

1). Check whether the lockpin and bushing are damaged or deformed. If it is, replace them.
3. Braking light switch
1). Use a multimeter to check whether the two terminals
Of the braking light switch are conducted when pressing and releasing the braking light switch.
2). If the terminals are not conducted when the switch is

pressed more than 4mm and are conducted when the switch
Is released, the braking light switch works normally.
5nn
(V) Installation
1. Install the braking pedal
1). Install the braking pedal to corresponded position and tighten the two
fixing bolts between the braking pedal and vehicle body and four
fixing nuts connected to the brake vacuum booster.
2). Install the lockpin connected with the brake vacuum booster to connect the brake vacuum booster.
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3). Install the braking light switch connectors.
4). Check whether the braking pedal is operated smoothly. Check
the free travel of the braking pedal and the gap between the
braking pedal and braking light switch.
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2. Install the upper and lower cover of the dashboard.
XII Brake master cylinder

(I) Brake master cylinder
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(II) Removal
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3. Disassemble the air filter assembly. Refer to air filter assembly.
4. Disassemble the braking liquid level sensor. Refer to braking liquid level sensor.
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5. Service Brake System
1). Use an oil wrench to disconnect the two brake
pipes of the master cylinder.
Caution: Do not twist or damage the brake pipe.
2). Discharge the braking liquid.
3). Disconnect the connecting pipe between the brake master cylinder
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and clutch master cylinder.
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4). Disassemble the two fixing nuts between the brake master cylinder
and vacuum booster.
5). Remove the master cylinder parts.
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Caution
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(III) Installation
1. Install the brake master cylinder
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1). Before installing the master cylinder, daub grease such as SAEJ310;
NLGINo2 or similar products on the master cylinder pin roll.
2). Install the master cylinder parts.
3). Install the connecting pipe between the brake master cylinder and
clutch master cylinder.
4). Tighten the two fixing nuts between the brake master cylinder and vacuum booster.
5). Tighten the brake pipe of master cylinder.

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2. Install the braking liquid level sensor and switch connectors.
4. Braking system air exhaust. Refer to hydraulic
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5. Install the air filter assembly

6. Connect the negative cable of the battery
7. Close the engine compartment cover
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XIII Front braking pipe and braking hose

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(I) Special tool
Oil pipe
1 wrench
(II) Disassembly
1. Lift the vehicle
2. Disassemble the front wheels. Refer to vehicle wheels
3. Disassemble the front braking pipe and braking hose
1). Disassemble the braking hose bolt.

2). Discharge part of braking liquid.
3). Use an oil wrench to remove the braking hose and braking pipe
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connector and take down the piece.
4). Disassemble the fixing bolt in the middle part of the braking
hose from the front absorber and vehicle body.
5). Take down the braking hose and braking pipe.
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(III)Installation
1. Install the front braking pipe and braking hose.
1). Install the front braking hose and braking pipe
2). Tighten the fixing bolt in the middle of the braking hose on
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the front absorber and vehicle body.

3). Install new piece and tighten the braking hose and braking
pipe connector.
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Caution: Take note of the installing direction of the braking

hose connector.
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4). Replace new copper washer and tighten the braking hose
bolt.
2. Install vehicle wheels

4. Braking system air exhaust. Refer to hydraulic braking system
exhaust
5. Check leakage.
XIIII Rear braking pipe and braking hose (vehicle model with front disc and rear drum)
(I) Special tool
Oil pipe
1 wrench
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(II) Disassembly
1. Lift the vehicle
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2. Disassemble the rear wheels. Refer to vehicle wheel
3. Disassemble the rear braking pipe and braking hose
1). Disassemble the braking pipe connector on the rear brake end.
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3). Use an oil pipe wrench to remove the braking hose and braking
pipe connector and take down the piece.
4). Disassemble the fixing bolt in the middle of the braking hose
from the rear torsion beam and vehicle body.
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5). Take down the braking hose and braking pipe.

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(III) Installation
1. Install the rear braking pipe and braking hose
1). Install the rear braking hose and braking pipe.
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Caution: Take note of the installing direction of the braking hose connector.
2). Tighten the fixing bolt in the middle of the braking hose on the rear torsion beam and vehicle body.
3). Install new card and tighten the braking hose and braking pipe
connector.
4). Replace new copper washer and tighten the braking hose bolt.
Caution: Please do not reuse the gasket and oil pipe card.
2. Install the wheels.
3. Add braking fluid.
4. Braking system air exhaust. Refer to hydraulic braking system exhaust.
5. Inspection for any leakage.
XV Rear braking pipe and braking hose (vehicle model with front disc and rear disc
(I) Special tool
Oil pipe
1 wrench
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(II) Disassembly
1. Lift the vehicle
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2. Disassemble the rear wheels. Refer to vehicle wheels.
3. Disassemble the rear braking pipe and braking hose
1). Disassemble the rear braking pipe connector on the rear brake end.
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3).Use an oil wrench to remove the braking hose and braking pipe
connector and take down the card.
4). Remove the fixing bolt in the middle of the braking pipe from
the rear torsion beam and vehicle body.
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5). Take down the braking hose and braking hard pipe.
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(III) Installation
1. Install the rear braking pipe and braking hose
1). Install the rear braking hose and braking pipe
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Caution: Take note of the installing direction of the braking hose connector.
2). Tighten the fixing bolt in the middle of the braking hose on the rear torsion beam and vehicle
body.
3). Install new card and tighten the braking hose and braking hard pipe connector.
4). Replace new copper washer and tighten the braking hose bolt.
Caution: Do not reuse the gasket and oil pipe card.
2. Install the wheels
3. Add braking fluid
4. Braking system air exhaust . Refer to hydraulic braking system exhaust
5. Check if there is any leakage.
XVI Brake master cylinder and braking hard pipe of the ABS module assembly (vehicle
model with front disc and rear drum + ABS)
(I) Special tool
Oil pipe
1 wrench
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(II) Disassembly
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3. Disassemble the air filter assembly. Refer to air filter assembly
4. Disassemble the brake master cylinder and ABS module assembly ABS
1). Disassemble the two oil pipe connectors of the brake master cylinder.
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2). Disassemble the two oil pipe connectors of the ABS module assembly.
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4). Disassemble the two fixing nuts in the middle of the braking hard pipe and then remove the brake cylinder parts.
5). And then disconnect the four oil pipe connectors of the ABS module assembly in turn.
Caution: Do not drain the braking liquid in the ABS module
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assembly completely or disassemble the ABS module
assembly.
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(III) Installation
Caution: Do not make the brake pipe deformed because of
installation difficulty. When install each pipe assembly,
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make sure every fixed pipe clamp and jacket to be installed

correctly.
1. Install the brake master cylinder and ABS module assembly ABS
1). Install the four oil pipe connectors of the ASB module assembly.
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2). Install the brake master cylinder parts and tighten the two fixed nuts in the middle of the brake hard pipe.
3). Install the two oil pipe connectors of the ABS module assembly.
4). Tighten the two oil pipe connectors of the brake master cylinder.
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3. Braking system exhaust. Refer to hydraulic braking system exhaust
4. ABS system exhaust. Refer to ABS system exhaust ABS
Caution: If there is leakage in the connector of the braking pipe and
braking hose, re-tighten it or if some parts are damaged, replace them.
5. Install the air filter assembly

6. Connect the negative cable of the battery
7. Close the engine compartment cover 25
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XVII Brake master cylinder and braking hard pipe of the ABS module assembly (vehicle
model with front disc and rear disc + ESP model) ABS ( +ESP )
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(I) Special tool

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Oil pipe
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1 wrench
(II) Disassembly
1. Open the engine compartment cover.
2. Disconnect the negative cable of the battery.
3. Disassemble the air filter assembly. Refer to air filter assembly.
4. Disassemble the brake master cylinder and ESP module assembly.
1).Disassemble the two oil pipe connectors of the brake master
cylinder.
2). Disassemble the two oil pipe connectors of the ABS module
assembly.
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4). Disassemble the two fixed nuts in the middle of the brake hard
pipe and remove the master cylinder parts.
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5). And then disconnect the four oil pipe connectors of the ESP
module assembly in turn.
Caution: Do not drain the braking liquid in the ESP module
assembly completely or disassemble the ESP module
assembly.
(III) Installation
Caution: Do not make the brake pipe deformed because of installation
difficulty. When install each pipe assembly, make sure every fixed pipe
clamp and jacket to be installed correctly.
1. Install the brake master cylinder and ESP module assembly ESP
1). Install the four oil pipe connectors of the ESP module
assembly.
2). When install the master cylinder parts, tighten the two
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alignment nuts in the middle of the brake hard pipe.
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3). Tighten the two oil pipe connectors of the ESP module
assembly.
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4). Tighten the two oil pipe connectors of the brake master
cylinder.

3. Braking system exhaust. Refer to hydraulic braking system
exhaust.
4. ESP system exhaust. Refer to ESP system exhaust ESP
Caution: If there is leakage in the connector of the braking pipe
and braking hose, re-tighten it or if some parts are
damaged, replace them.
5. Install the air filter assembly.
6. Connect the negative cable of the battery.
7. Close the engine compartment cover.
XVIII Vacuum booster assembly
(II) Inspection
1. Operation inspection
1). Turn off the engine and step down the braking pedal for several
times to make the vacuity in the vacuum booster is even to the air.
Step down the braking pedal to the end and start the engine. When
the vacuity reaches standard value, check whether the gap between
the braking pedal and floor is shortened.
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Caution: The interval time to step down the braking pedal is five
seconds.
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2. Airtight check
1). Start the engine and keep at idle running for one minute and turn
off the engine when the vacuum brake vacuum booster reaches
vacuity. Step down the braking pedal normally to eliminate the
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vacuity. Check whether the gap between the braking pedal and floor
is increasingly widening.
2). Step down the braking pedal when the engine is running and then
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turn off the engine while stepping the braking pedal. After step down
the braking pedal for more than thirty seconds, check if the braking
pedal travel changed.
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(III) Disassembly
Caution: 1. Do not make the brake pipe bent when removing the
brake vacuum booster.
2. Replace the damaged lockpin.
3. Do not damage the thread of the fixed bolt on the
vacuum booster.
3. Disassemble the upper and lower cover of the dashboard. Refer to
upper and lower cover of the dashboard.
江淮汽车
6. Disassemble 部门：客户服务部
the upper and lower cover of the dashboard. Refer to
7. Disassemble the braking pedal. Refer to braking pedal.
8. Disassemble the brake master cylinder. Refer to brake master cylinder.
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Disassemble the upper and lower cover of the dashboard. Refer to upper and lower cover of the dashboard.
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1). Take down the vacuum hose clamp and remove the vacuum hose
from the brake vacuum booster.
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2). Remove the vacuum booster from the engine compartment.

Caution: The vacuum hose assembly on the MT model has no vacuum booster valve.
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Caution: The vacuum hose assembly on the CVT model has vacuum booster valve.
(IV) Inspection
1. Inspect the pushing rod length.
1). Use a hand-operating vacuum pump to apply a vacuum pressure
of -66.7KPa to the brake vacuum booster.
2). Check the pushing rod length
Pushing rod length116.7~117.3mm
2. Vacuum hose
1). Check whether the vacuum hose is
damaged or cracked. If it is, replace it.
(V) Installation
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1. Install the vacuum booster assembly
1). Install the brake vacuum booster from
the engine compartment
Caution: The vacuum hose assembly on the MT model has no vacuum
booster valve.
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Caution: The vacuum hose assembly on the CVT model has vacuum
booster valve. 14
2). Connect the vacuum hose on the brake vacuum booster and install the
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clamp of the vacuum hose.

2. Install the braking pedal and pushing rod pin roll of the vacuum booster.
3. Install the brake master cylinder. Adjust the free travel of the braking
pedal. Refer to braking pedal.
4. Install the brake master cylinder.
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5. Install air filter assembly

6. Install dashboard
7. Add braking liquid and make braking system to exhaust. Refer to hydraulic
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8. Connect negative cable of the battery

9. Close the engine compartment
XVIIII Hydraulic braking system exhaust

(II) System exhaust

1. Preparation:
Caution: The air in the hydraulic brake regulator cannot be exhausted
by manual operation. If the ABS hydraulic regulator is
mixed with air or if the ABS hydraulic brake regulator is
not fulfilled with oil, a malfunction diagnostic instrument
should be used to exhaust the air in the braking system.
The ABS hydraulic brake regulator is full with oil and
exhausted when leaving the factory. During normal
maintenance procedure regarding to the regulator, the air
will enter the ABS hydraulic brake regulator. In this
case, the exhaust can be operated manually.
1). While the engine is off, step down the braking pedal
several times until the pressure in the booster is
eliminated.
2). Add braking liquid to brake master cylinder reservoir. During
exhausting, the level of the brake master cylinder reservoir
must be kept more than a half.
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2. Brake master cylinder exhaust
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Caution: If the brake master cylinder is re-installed or the reservoir
is empty, the brake master cylinder must exhaust.
1). Step down the braking pedal slowly to the end and keep that state.
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2). Loosen one brake oil pipe on the brake master cylinder and
tighten the brake oil pipe connector when braking liquid flows
from the terminals.
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3). Loosen another brake oil pipe on the brake master cylinder and
tighten the brake oil pipe connector when braking liquid flows
from the terminals.
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Caution: Put a cleaning cloth or rag on the painted surface to avoid
the braking liquid from being stuck with the paint.
4). Make repetitive operation from step one to step three for three to
four times.
3. Braking pipe exhaust.

1). Open the exhaust screw cover.
2). Connect a transparent tube to the exhaust screw of the left
and rear brake and immerse the tube in the braking liquid in the
transparent reservoir.
3). Step down the braking pedal slowly several times to the end
and keep this state.
Caution: Do not step down the braking pedal sharply and furiously.
4). Loosen the exhaust screw while stepping on the braking pedal
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and exhaust.
5).Tighten the exhaust screw when the braking liquid does not spill
and release the braking pedal slowly.
6).Take repetitive operation from step three to step five until the air
in the braking liquid is exhausted completely.
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7).When loosen the exhaust screw, there is no bubbles in the
reservoir. That means the air is exhausted completely.
Caution: During exhausting, the level of the brake master cylinder
reservoir must be kept more than a half.
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8).Tighten the exhaust screw
9). Operate according to step one to eight to exhaust air in rest

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reservoir.
10).After exhaust of air in all brake, check whether the braking pedal
is limp. If it is, repeat whole exhaust procedure until it is
normal.
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XX Braking liquid level sensor

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(II) Disassembly
3. Disassemble the air filter. Refer to air filter assembly.
4. Disassemble the braking liquid level sensor.
1). Disconnect the harness connector of the
braking liquid level sensor.
2). Remove the braking liquid level sensor from the bottom of the braking liquid reservoir.
Caution: No need to discharge the braking liquid.
(III) Installation
1. Install the braking liquid level sensor
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1).Install the braking liquid level sensor to correct bottom
position of the reservoir.
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2).Connect the harness connector of the braking liquid level sensor.
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2. Install the air filter assembly.

4. Close the engine compartment cover.
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Parking Brake System
1. Overview
1.1 Structure overview

Parking brake control handle with bracket assembly structure
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1. Parking brake handle assembly 3. Adjusting nuts

2. Left parking brake switch 4. Adjusting thread rod
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Parking brake system structure (Vehicle
model with front disc and rear drum)
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1. Parking brake handle assembly 3.Right parking brake wire drawing assembly
2. Left parking brake wire drawing assembly 4. Circlip
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Parking brake system structure (Vehicle model
with front disc and rear disc)
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3. Right parking brake wire

1. Parking brake handle assembly drawing assembly
2. Left parking brake wire drawing assembly 4. Circlip
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1.2 Maintenance
parameter
Item Parameter
Tpye Drum brake

Pump
Rear parking brake (Vehicle Model diameter 17.46mm
with front disc and rear drum)
Brake drum
diameter 204mm
Brake pad
thickness 4mm
Floating caliper /
Type Ventilated disc
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Brake disc
diameter 275mm
Rear parking brake (Vehicle Model Brake disc
with front disc and rear disc) thickness 9mm
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Brake pad
thickness 8mm
Cylinder
diameter 34mm
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1.3 Torque specification

Parking brake wire drawing
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1 upper bracket mounting bolt 20~25

Parking brake control mechanism
2 mounting bolt 20~25
2. Malfunction
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Diagnosis
2.1 Malfunction diagnosis
chart
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Malfunction Malfunction Rema

SN phenomenon reason analysis Solution rk
Check whether indication lamp has
performance damage Replace indication lamp
1
Indication lamp is
always ON or OFF Adjust
Check whether the screw
connection between indication
lamp and toothed plate seat is
loose
Parking brake is not completely
released Release
2 Brake lag
Improper parking brake
adjustment Adjust
Rear brake shoe damages Adjust

Rear brake show surface has
grease or oil Replace
3 Parking brake zipper jammed Adjust

Parking brake
江淮汽车
insufficiency部门：客户服务部
Self-adjusting mechanism has
malfunction Adjust
Parking brake handle travel is
too big Adjust
Parking brake
4 does not work
Common wire drawing or jacket
corroded, stiff spring breaks,
falls off, or loses elasticity,
Please check brake control wire
which lead to parking brake
drawing and brake system parts
control wire drawing or brake
surface for damage, whether control
wire drawing cannot be
handle operates smoothly, or has
smoothly pulled in jacket. As a
jammed situation; wire drawing
result, parking brake handle
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connecting point and mounting
cannot be released and fails to
section is loose or damaged. If
work.
necessary, please repair or replace.
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3. Parking Brake Control Mechanism Assembly
Switch
3.1 Special tool (No)
3.2 Disassembly
1. Disconnect the negative wire of the battery.
2. Disassemble the rear section of auxiliary fascia console. Refer to
auxiliary fascia console.
3. Disassemble parking brake control
mechanism assembly switch.
1) Release parking brake control
mechanism assembly.
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2) Disconnect parking brake control mechanism assembly switch
harness connector.
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3) Remove parking brake control mechanism assembly switch
mounting screws, and take down the switch.
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3.3 Installation
1. Install parking brake control mechanism assembly switch
1) Install parking brake control mechanism assembly switch on the
parking brake control handle.
2) Pull up parking brake control mechanism assembly.
3) Connect parking brake control mechanism assembly switch harness connector.
2. Install auxiliary fascia console.
3. Connect the negative wire of the battery.
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4.2 Disassembly
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2. Disassemble auxiliary fascia console. Refer to auxiliary fascia console.
3. Disassemble parking brake control mechanism assembly switch. Refer to parking brake control mechanism assembly switch.
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4. Disassemble parking brake control mechanism assembly.
1) Remove the four connecting bolts between parking brake
control mechanism assembly and vehicle body.
2) Release parking brake zipper assembly.
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3) Take out parking brake control mechanism assembly.

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4.3 Installation
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1. Install parking brake control mechanism assembly.

1) Install parking brake control mechanism assembly onto vehicle
body, and tighten the four mounting bolts.

2) Install parking brake zipper assembly.
2. Adjust parking brake control mechanism assembly.
3. Install parking brake control mechanism assembly switch.
5. Parking Brake Assembly Zipper Assembly
(Vehicle Model With Front Disc And Rear Drum)
5.1 Special tool
5.2 Disassembly
2. Disassemble auxiliary fascia console. Refer to auxiliary fascia
console.
3. Disassemble parking brake control mechanism assembly. Refer to
parking brake control mechanism assembly.
5. Remove brake drum. Refer to rear wheel hub assembly.
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6. Remove parking brake zipper
assembly.
mechanism assembly.
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2) Remove parking brake zipper assembly adjusting nuts.
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3) From zipper balance clip, disconnect left and right parking brake
zipper.
4) Lift the vehicle.
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5) Disconnect left and right rear parking brake shoe circlip, and
remove parking brake wire drawing assembly head from brake
shoe with parking handle assembly.
6) Remove the four mounting bolts which mount the bracket on parking zipperper.
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7) Take out parking brake zipperper from vehicle bottom pipe installation hole.
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5.3 Installation
1. Install parking brake zipperper assembly.
1) Install the four mounting bolts on parking brake control
mechanism.
2) Install parking brake zipperper assembly head, and tensioning
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left and right rear parking brake shoe circlip.
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3) Tighten the four mounting bolts which mount the bracket on

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parking brake zipper.

4) Install left and right rear parking brake zippers on the zipper balance clip.
5) Tighten parking brake zipper assembly adjusting nuts.
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6) If necessary, adjust parking brake control mechanism assembly.
2. Install brake drum.
3. Install rear wheel.
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6. Parking Brake Assembly Zipper Assembly (Vehicle Model With Front Disc And Rear
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Disc)
6.2 Disassembly
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2. Disassemble auxiliary fascia console. Refer to auxiliary fascia console.
3. Disassemble parking brake control mechanism assembly. Refer to parking brake control mechanism assembly.
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5. Remove brake drum. Refer to rear wheel hub assembly.
6. Remove parking brake zipper
assembly.
mechanism assembly.
2) Remove parking brake zipper assembly adjusting nuts.
3) From zipper balance clip, disconnect left and right parking brake
zipper.
4) Lift the vehicle.
5) Loosen adjusting nuts, and remove parking brake wire drawing
assembly head from brake caliper clip.
6) Remove the four mounting bolts which mount the bracket on

parking zipper.
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7) Take out parking brake zipper from vehicle bottom pipe installation hole.
6.3 Installation
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1. Install parking brake zipper assembly.
1) Install the four mounting bolts on parking brake control mechanism.
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2) Install parking brake zipper assembly head into brake shoe wire
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drawing clip, and tighten adjusting nuts.

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3) Tighten the four mounting bolts which mount the bracket on parking brake zipper.
4) Install left and right rear parking brake zippers on the zipper
balance clip.
5) Tighten parking brake zipper assembly adjusting nuts.
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6) If necessary, adjust parking brake control mechanism assembly.
2. Install brake drum.
3. Install rear wheel.
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Adjustment
7.1 Special tool
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7.2 Adjustment
1. Release parking brake control mechanism assembly.
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3. Check whether parking brake control mechanism assembly wire

drawing can move freely.
4. Put down the vehicle.
5. Disassemble auxiliary fascia console. Refer to auxiliary fascia
console.
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6. Disassembly rear bracket assembly of auxiliary fascia console. Refer to

parking brake control mechanism assembly switch.
7. Parking brake control mechanism assembly
adjustment
1) Lift the vehicle slightly, and make wheels
move freely.
2) Tight parking brake control mechanism assembly wire drawing
adjusting nuts, until wheels cannot move.
3) Loosen the nuts, until rear wheel can just move freely, and gear is the
position of seventh to ninth gear.
4) Put down the vehicle.
5) Pull up parking brake.
8. Install rear bracket assembly of auxiliary fascia console.
ABS Anti-lock Braking System / ESP Electronic Stability Program
I、Summary
（I）Structure abstract
Braking system structure
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Instructions: The arrow direction of number two refers to the force direction born by the braking
pedal. The arrow direction of number three refers to the booster implement direction. All other
arrows refer to the liquid movement direction.
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ESP alarming lamp instruction:

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Functions of ESP (Electronic Stability Program)
ESP is an active-safety system. It is a non-independent system which is built based on other traction
controlling systems. ESP contains not only all functions of ABS, but is added with function of TCS (Traction
Controlling system) and ESP (Electronic Stability Program). Moreover, many optional functions can be achieved
by increasing some sensor or signal input.
The controlling unit of the ESP system monitors the vehicle operating status through signals such as turning
sensor, wheel sensor, side skidding sensor, lateral accelerator sensor etc and issue controlling instructions
accordingly. It analyzes the vehicle operating information from sensors and then issue corrective instruction to the
ABS and ASR in order to keep the vehicle dynamically balanced and best stabilized in various situation. This
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effect is more obvious in the case of over steering and under steering.
Functions of the ABS
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The anti-lock braking system is to control the hydraulic braking pressure of all four wheels in the case of
emergency braking and braking on dangerous roads so as to prevent the wheels from blocking. Using ABS has
following advantages:
(1) The vehicle can steer well when meets with an obstacle during emergency braking.
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(2) The vehicle can be parked stably and operationally during emergency braking in the corners.
Caution:
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1. If the electrical system is interrupted, the failure-protection mode will be activated. The ABS enters
non-operational status and the alarming lamp will be lit up.
2. The ABS electrical system can be diagnosed by special diagnostic apparatus provided by JAC.
3. During the braking process, the braking pedal will vibrate lightly and some mechanical noise can be heard.
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Those are normal working phenomenon of the ABS.
Functions of EBD
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The Electronic Brake Distribution (EBD) can accurately control the braking force of each wheel and ensure
stability of the vehicle during braking process. In normal braking conditions, it can efficiently balance the wheel
speed equally required for braking. ESD mains the braking pressure of each wheel by making use of the inlet
valve and outlet valve in the ABS hydraulic adjustment module so as to achieve efficient braking and vehicle
stability.
Functions of TCS
The Traction Control System (TCS)s function is to monitor the slipping rate of the driving wheel. When the
slipping rate is too large, the TCS will issue a directive to the engine to decrease fuel injection or reduce throttle
opening so as to reduce torque output. It also can guarantee the driving wheel to get larger adhesion when the
slipping rate is optimal. When the road adhesion difference between left and right wheels is too large( for
example, one side is asphalt, the other side is ice), the TCS will actively exert a braking force on the driving
wheel with low adhesion to prevent wheel-slipping and inject the driving wheel with high adhesion to get a
driving force as large as possible .
Fault protection functions
When the ABS and ESP electrical system fails, the ABS and ESP alarming lamp will be lit up. If the EBD
electricity fails, the braking alarming lamp and ABS alarming lamp will be lit up. At the same time, the ABS will
be changed to one of the following fault protection functions:
1. If the ABS fails, only the EBD can be activated, and the vehicle status will be same as the vehicle without
ABS system.
2. If the EBD fails, neither the EBD nor the ABS can be workable, and the vehicle status will be same as the
vehicle without ABS and EBD.
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（II）Principle of Operation
ABS hydraulic system working principle diagram
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EPS hydraulic system working principle diagram
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1. Brake master pump 6. Reflux pump
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2. Hydraulic unit 7. Input valve

3. High-pressure valve 8. Output valve
9. Pressure
4. Loop control valve accumulator
10. Pressure
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5. Reflux pump motor sensor
Anti-lock braking mode
The ABS enters anti-lock braking mode when the wheels slip during braking process. In the anti-lock braking
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mode, the pressure of the hydraulic reflux of each wheel is under control so as to prevent the wheels from
slipping. Each wheel is equipped with separate hydraulic pipeline and valve. The ABS can reduce, maintain or
enhance the hydraulic braking pressure of each wheel. But the ABS cannot increase the hydraulic pressure to
exceed the value transferred by the master cylinder during braking process. In the anti-lock braking, a series of
rapid vibrations can be felt on the braking pedal which is caused by rapid change of each valve position according
to the required wheel speed. The vibration on the braking pedal occurs in anti-lock braking and stops in normal
braking or when the vehicle is parked completely. Action noise can be heard due to rapid cycling of the solenoid
valve. When anti-lock braking is activated on dry pavement, the tires will issue intermittent sharp sound when
approaching slipping. These sounds and vibrations on braking pedal are normal phenomenon when the anti-lock
braking operates. The braking pedal operation during normal braking is same for the vehicle with or without the
ABS system. Keeping a balanced force on the braking pedal can achieve vehicle stability and the shortest
stopping distance.
1. Pressure maintenance
When the ABS controlling module monitors wheel slipping, it will close the oil input valve and output
valve in the hydraulic assembly so as to isolate the system. This can help to keep the braking pressure stabilized
and the hydraulic pressure cannot be increased or reduced.
2. Pressure reduction
If the ABS controlling module monitors wheel slipping in pressure maintenance mode, it will reduce the
pressure of the wheel impacted. The input valve will be closed and the output valve will be opened. The
excessive liquid and pressure will be temporarily stored in the hydraulic accumulator assembly until the pump
motor transports the braking liquid back to the reservoir of the master cylinder.
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3. Pressure increase
If the ABS controlling module monitors reduction of the wheel slipping in pressure maintenance or pressure
reduction mode, it will increase the pressure on the impacted wheel by making use of the master cylinder pressure.
The input valve will be opened and output valve will be closed. A part of or all pressure from the braking master
pump will be put on the wheels.
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4. ABS working process ABS
During the vehicle moving process, each wheel speed sensor will produce a voltage signal in proportion to
the rotating speed of the wheels. The ABS controller receives the wheel speed data and determines whether is
one or more wheels decelerating too fast (compared with the reference vehicle speed) which is called slipping.
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The ABS controller activates necessary module to control the braking pressure of each wheel and make it
optimized.
The ABS controlling module inspection
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Caution: please check the braking system basically.

1. Basic inspection for braking system
1). Check the braking liquid level. Add more braking liquid if the liquid level is too low.
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2). Check whether there is any leakage in the braking lines or the area near the ABS hydraulic assembly. If
any leakage found, check by following steps
(1). If the connector of the ABS hydraulic assembly loosens, tighten the pipe tubing nut to specified
torque (16 18Nm). Re-check and ensure no braking liquid leakage.
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(2). If the tubing nut of the connector and the thread part of the actuator damaged, replace the damaged
parts. Re-check and ensure no braking liquid leakage.
(3). If leakage is found outside of the actuator connector, wipe it with a clean cloth and then check again.
If leakage still exists, replace the damaged parts.
(4). If leakage is found on the hydraulic assembly, wipe it with a clean cloth and then check again. If
leakage still exists, replace the hydraulic assembly.
Caution: Do not dismantle the ABS hydraulic assembly (include controlling module) without any special
need.
3). Check the braking pad or shoe part if any wear exists.
4). Check the battery and the power circuit if loosens.

Caution: Check the positive and negative terminal of the battery if loosens and confirm the battery voltage is
江淮汽车
normal.
部门：客户服务部
2. Inspection for the ABS alarming lamp and braking alarming lamp
1). Confirm when the ignition switch turned to ON, the ABS alarming lamp will lighten for about three
seconds and the braking alarming lamp will lighten. If they are not lit, please refer to ABS common
symptoms and analysis procedure.
2). Check the ABS alarming lamp will extinguish or not after the ignition switch turned to ON for about three
seconds, and the braking alarming lamp will extinguish or not after the engine started. If they are
extinguished, please refer to ABS common symptoms and analysis procedure.
3). If the ABS alarming lamp does not extinguish ten seconds after the engine started, please refer to ABS
common symptoms and analysis procedure.
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Caution: The braking alarming lamp lights up in parking braking operation (when the ignition switch is at
ON) and the braking liquid level sensor works (braking liquid shortage).
3. Use diagnostic instrument to check ABS controlling module and detect fault code of the controlled
data and memory. If there is something abnormal, repair it according to fault prompt, please refer
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to failure diagnosis.
（III）Technical parameters
Description table for ABS controlling module pin
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Description Description
Pin number Pin number
Supplying terminal of motor power
(positive pole)
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1 20 N.C.
Wheel speed sensor output(front right
wheel)
2 21 N.C.
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Active EBD alarming lamp

3 22 N.C.
Wheel speed sensor signal ends( front
right)
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4 23 N.C.
5 N.C. 24 N.C.
K-line diagnosis Power terminal of valve relay
6 25
CAN-high
7 N.C. 26
Grounding terminal of the power Active ABS alarming lamp
8 27 ABS
Power terminal of ECU( ignition cable)
9 N.C. 28
Wheel speed sensor signal ends( rear
right)
10 N.C. 29
Braking lamp switch input
11 N.C. 30
Supplying terminal of wheel speed
sensor(rear left)
12 N.C. 31
Grounding terminal of the power
13 32 N.C.
Vehicle speed signal input
14 CAN-low 33
15 N.C. 34 N.C.
sensor(front right)
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16 35 N.C.
sensor (rear right)
17 36 N.C.
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Signal ends of wheel speed sensor( rear
left)
18 37 N.C.
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sensor( front left)
19 38 ECU grounding lines
ABS controlling module pin position diagram

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（IV）Torque parameters
SN Item Tightening torque (Nm)

Mounting bolt of wheel speed sensor
1 8~10
Brake hard pipe joint nut
2 20~25
（V）Maintenance cautions
Follow below general cautions when repairing ABS and ESP, or it may damage them.
1. Disconnect all connectors from the ABS and ESP controlling module before performing welding work.
2. The anti-lock braking system components are particularly sensitive to EMI(electromagnetic interference).
Check carefully the traces of all anti-lock braking system components, location, installation and positioning,
wiring, connectors, clamps and brackets if any interference occurs.
3. Do not use a quick charger to start the engine or charge the battery which still connected, otherwise, it may
result in battery failure or damage to components of the anti-lock braking system.
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4. Make sure to turn off the ignition switch first and then disconnect the negative pole of the battery. After that,
disconnect the connectors from the ABS and ESP controlling module assembly.
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5. Do not attempt to repair any components of the anti-lock braking system. All ABS and ESP components can
only be repaired by replacement.
6. In order to avoid any damage to the wheel speed sensor harness, it is forbidden to hang the suspension parts
on it.
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7. The ABS and ESP controlling module should not be placed in an environment with temperature higher than
one hundred and five degree.
8. The braking circuits should not contain minerals like chlorine and sulfur, mineral oil or ester plasticizer and
softer (include components which can dissolute these substances).
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9. It is normal phenomenon that the braking pedal vibrates lightly and mechanical noise can be heard when the
ABS and ESP operates.
10. After turning the ignition switch to ON and starting the vehicle, the braking pedal may vibrate or working
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noise may be heard from the ABS and ESP hydraulic assembly motor. This is normal state of operational
inspection.
11. When the vehicle is traveling on rough, gravel or snow( deep snow) roads, the braking distance may be longer
than the vehicle without ABS and ESP.
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12. When the braking system fails, distinguish the reason between the ABS and ESP and general braking system
such as vacuum booster, braking hydraulic system, braker or other parts.
13. If the tire size and type are used in incorrect combination or the braking shoes are not authentic components
provided by JAC, the braking distance or turning stability may get worsen.
（VI）Special tools
SN Tool No. Tool Name Outside drawing Usage
1 ABS failure Diagnose ABS failure

diagnostic apparatus
II、Failure diagnosis
（I）General introduction of failure diagnosis

1)Diagnose the failure and get a thorough understanding of each system of the vehicle(control and
organization)
2) Get to know customers complaints before inspection. Consult the customer carefully about dissatisfaction
after getting full knowledge of symptoms.
3)Symptom check must be started from the beginning stage so as to repair the fault completely. For
intermittent fault, it is very important to reproduce the symptoms according to talks with customer and
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passed cases. Do not check according to some special cases. Most intermittent faults are caused by poor
contact which can be effectively solved by shaking the suspected harness or connector.
4)Do execute clear fault codes after diagnosis finished.
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（II ）Failure diagnosis table
ABS fault code table
SN Fault code Fault code
Fault code
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1 C190004 ECU Voltage supply: high voltage
2 C190104 ECU Voltage supply: low voltage
3 C100004 ECU error (hardware, Micro-controller error)

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4 C101008 ECU error (general software problem)
ABS/ESP implausible control (control time too

5 C006B06
long, etc.)
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Wheel-speed sensor, front left: (signal failure)

6 C003108 out of range, lost, noise, Intermittent
7 C003200 Wheel-speed sensor, front left: open
8 C00A000 Wheel-speed sensor, front left: short to GND

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SN Fault Fault code Fault code
code
9 C00A100 Wheel-speed sensor, front left: short to UBATT

10 C00A900 Wheel-speed sensor, front left: general error
Wheel-speed sensor, front right: (signal failure)

11 C003408 out of range, lost, noise, Intermittent
12 C003500 Wheel-speed sensor, front right: open
13 C00A200 Wheel-speed sensor, front right: short to GND
14 C00A300 Wheel-speed sensor, front right: short to UBATT
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15 C00AA00 Wheel-speed sensor, front right: general error
Wheel-speed sensor, rear left: (signal failure)out

16 C003708 of range, lost, noise, Intermittent
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17 C003800 Wheel-speed sensor, rear left: open
18 C00A400 Wheel-speed sensor, rear left: short to GND
19 C00A500 Wheel-speed sensor, rear left: short to UBATT

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20 C00AB00 Wheel-speed sensor, rear left: general error
Wheel-speed sensor, rear right: (signal failure)

21 C003A08 out of range, lost, noise, Intermittent
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22 C003B00 Wheel-speed sensor, rear right: open
23 C00A600 Wheel-speed sensor, rear right: short to GND
24 C00A700 Wheel-speed sensor, rear right: short to UBATT

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25 C00AC00 Wheel-speed sensor, rear right: general error
Wheel-speed sensor generic error (sensor swap,

26 C109904
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multiple sensors error )
27 C001004 valve fault, inlet valve FL
28 C001104 valve fault, outlet valve FL
29 C001404 valve fault, inlet valve FR
30 C001504 valve fault, outlet valve FR
31 C001804 valve fault, inlet valve RL
32 C001904 valve fault, outlet valve RL
33 C001C04 valve fault, inlet valve RR
34 C001D04 valve fault, outlet valve RR
35 C109504 Valve relay error
36 C002004 Return pump fault
General Valve fault (overheat protection, signal invalid,
37 C007208 hardware fault )
Pressure sensor fault

38 C004460 (signal)
39 C004510 Pressure sensor fault (wiring lines)
40 C004008 Braking lamp switch fault
41 C006108 Lateral accelerator sensor signal fault
42 C006208 Vertical accelerator sensor signal fault
43 C006308 Yaw angle speed sensor fault
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44 C019604 Yaw angle speed sensor fault
Yaw angle speed sensor uncalibrated or
45 C00A800 calibration failed
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46 U000500 CAN bus voltage: too high
47 U000700 CAN bus voltage: too low
48 C100104 CAN bus fault: hardware
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49 U000104 CAN bus fault: closure
50 U100104 External CAN bus fault
51 U010004 EMS CAN message timeout
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52 U010008 EMS date break or signal ineffective

53 C106600 SAS steering wheel angle sensor calibration fault
54 C046008 SAS steering wheel angle sensor fault(signal)
SAS steering wheel angle sensor fault(message
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55 U012604 timeout)
SAS steering wheel angle sensor fault(date break
or signal ineffective)
56 U012608
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57 U010104 TCU CAN message timeout

58 U010108 TCU data break or signal ineffective
59 C104C04 ESP closing switch fault
60 C121208 Configuration coding error
Reversing gear switch signal ( too high or too
61 C108C08 low)
62 U015504 ICM CAN communication timeout
63 U042308 ICM data break
64 C003129 Front left wheel speed sensor fault: direction
65 C003429 Front right wheel speed sensor fault: direction
66 C003729 Rear left wheel speed sensor fault: direction
67 C003A29 Rear right wheel speed sensor fault:direction
68 C101038 Two wheels speed sensor fault: direction
ABS fault diagnosis chart
Fault
SN phenomenon Fault reason analysis Solution Reamrk
Poor contact of diagnostic terminals Inspect and connect
Inspect and connect

ABS controlling module ungrounded
Refer to ABS
The ABS
data flow
controlling
ABS controlling module without Inspect and connect diagnosis
module data
voltage provided by battery diagram
unreadable
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1
ABS controlling module without Inspect and connect
voltage provided by ignition switch
Data circuit : disconnected or short
circuit Inspect, connect or replace
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Data circuit: resistance is too high
ABS alarming lamp bulb fault/socket

Inspect and replace
Inspect, connect or replace

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loosen
Refer to ABS
alarming lamp
not light and no
ABS alarming diagnostic code
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lamp not light Instrument panel fuse disconnect Inspect and replace diagnosis flow
up chart
Instrument warning lamp driving
module fault Inspect and replace
2
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Inspect and replace

ABS controlling module fault
Disconnected or short circuit between
instrument panel and ABS controlling Inspect, connect or replace
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module
Open circuit between instrument panel Inspect or connect
and ABS controlling module
Short circuit between instrument panel Inspect and replace Refer to ABS
and ABS controlling module alarming lamp
not light and no
diagnostic code
ABS alarming diagnosis flow
lamp not light ABS alarming lamp not light up Inspect and replace chart
3 up
Inspect or repair
ABS controlling module ungrounded
Inspect and replace
江淮汽车 Bulb fault or socket loosen

部门：客户服务部 Inspect, connect or replace
Refer to
braking
alarming lamp
not light and no
diagnostic code
diagnosis flow
chart
Instrument panel fuse disconnect Inspect and replace
Braking
alarming lamp
not light up
Instrument panel fault Inspect and replace
4
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Circuit between ABS controlling Inspect and replace
module and instrument panel ground
Inspect and replace
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14
20
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（III）Fault diagnosis flow chart
ABS alarming lamp not light and no diagnostic code diagnosis flow chart
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25
14
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ABS alarming lamp not light and no diagnostic code diagnosis flow chart (Continued)
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25
14
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ABS data flow unreadable diagnosis flow chart
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25
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ABS data flow unreadable diagnosis flow chart (Continued)
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25
14
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ABS warning lamp is on but no diagnosis fault
code diagnosis flow chart
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25
14
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Braking alarming lamp is off and no diagnostic code diagnosis flow chart
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Braking alarming lamp is off and no diagnostic code diagnosis flow chart (Continued)
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（IV）Diagnosis information and process

1. Self-diagnosis
ABS controlling module can make self-diagnosis to detect the system fault. If any fault is found, the ABS
controlling module will set diagnostic trouble code (DTC) as well as lighten ASB alarming lamp and close the
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ABS.
2. Displaying of diagnosed fault code

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Special tools (diagnostic instrument) can be used to display

the diagnostic trouble code.
3. Delete diagnostic trouble code
The diagnostic trouble code in the memory of the ABS controlling module can be cleaned up by scanning
tools (diagnostic instrument).
Caution: After cleaning, verify the system to see whether is can operate normally and the diagnostic trouble
code will not occur again. The diagnostic fault code should not be deleted by dismantling
connectors of the ABS controlling module, disconnecting battery terminals or switching off the
engine.
4. Intermittent failure or intermittent failure of poor
contact are mostly caused by following reasons

1).Electrical wiring error.
2). Electrical connection

江淮汽车部门：客户服务部 error.
3). Binding of relay or solenoid valve.
5. Initialization sequence
The ABS controlling module will make initialization test in the beginning of every ignition cycle.
The initialization sequence is: electromagnetic valve and pump motor, to check whether the operation of the
components is normal. If any fault is detected, the ABS controlling mode will set corresponding diagnostic fault
code. It is normal operation of the system when you can hear some action sound when the initialization sequence
is proceeding. If the ABS controlling module detects no signal input for the braking switch (You foot dost not
step on the braking pedal), initialization will take place immediately. If there is signal input for the braking switch
(Your foot is stepping on the braking pedal), initialization will not proceed unless no signal input is detected for
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the braking pedal (Your foot does not step on the braking pedal) or the vehicle speed reaches 25KM/H
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（V）Inspection for diagnostic circuit
1. Systematic introduction
Diagnosis for circuit can detect the problems caused by ABS/EBD systematic failure. Inspection for
diagnostic circuit will guide the maintenance technician to next step for diagnosing the fault.
2. Diagnosis procedure
Steps for maintaining the ABS/EBD system
1). Check the vehicle if any mechanical failure relating to the braking system exists
(1). The level of the braking liquid tank is correct.
(2). The level of the braking liquid tank is correct.
(3). Check the braking master pump and ABS hydraulic assembly to be without leakage
(4). Check braking parts of all wheels.
(5). Check if any braking dragging exits.
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(6). Check if the braking is stabilized (without rear-pulling or front punching)
(7). Check the braking shoes to be without wear or damage.
(8). Check the wheel bearing to be without damage.
(9). Check the wheel (speed) sensor and harness.
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(10). Check the speed sensor connectors/gear rim with damage or not/ check the tires thread depth/ wear
degree.
(11). Make a road test and make necessary correction according to actual situation.
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2). Inspection for diagnostic circuit should be performed in accordance with applicable diagnostic fault
procedure. The ABS diagnostic fault code should be removed with following steps after all system failure
is ruled out:
Inspection chart for diagnostic circuit
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Next step
Step Measures
No
Yes
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If possible, connect or install all components which are disconnected or

dismantled originally.
Turn to Turn to step

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step two four

1 The engine is turned off when the ignition switch is at ON.
Install applicable diagnostic instrument to DLC to see whether it can be
communicated to the ABS controlling module.
Is there any fault code saved currently or in the past? step three seven
2
Record the current fault code.
Record the past fault code.
Record past data, such as the setting times of each diagnostic fault code,
setting times after the diagnostic fault code is set for the first time;
setting times after the diagnostic fault code is set last time; the speed
when the diagnostic fault code is set; other data which is helpful for the
diagnosis; Do not rule out the diagnostic fault code before recording
information from the diagnostic instrument.
step five six
3
Does the diagnostic instrument can communicate with other module of
the same data line?
4
Refer to No communication of the ABS controlling module in the ABS
5 controlling module fault procedure
Refer to the data connector unit of the electrical terminals.
6
Flameout
Wait for ten seconds Turn to Turn to step

step eight nine
Start the engine
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7
Observe the ABS alarming lamp after started.
Is there any lamp that always lights? Turn to Turn to step
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8 step nine ten
9 Refer to the Open failure procedure of corresponded lamp.
10 Refer to the Malfunction failure procedure of corresponded lamp.
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（VI）Diagnosis for code fault and general diagnostic methods
1. C190004; C190104 ECU Power failure

The failure may be caused by following reasons:
(1). The battery voltage is too high or too low ;

(2). The vehicle
body is ungrouned.
Maintenance and
diagnosis method
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(1). Measure the battery voltage and charge the battery if necessary ( voltage standard value 9.3V~16.8V).
(2). Check the two grounding points of the ESP, including the electrical controlling unit grounding of the
ESP and reflux pump motor grounding.
(3). Turn on all electrical appliances with high-power and measure the supplying voltage of the ESP.
High-power load may result in electricity shortage.
25
(4). Measure the voltage fluctuation produced when the vehicle is started and high-power electrical
appliances are switched on and off. Potential electrical appliance failure may lead to voltage
fluctuation by a large margin of the supplying circuit.
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2. C100004; C101008 ECU failure
Possible reason for failure:
The ECU is damaged.
Maintenance and diagnosis method: replace the ESP assembly and make the braking pipe to exhaust.
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3. C006B06 Abnormal operation of the braking system( The ABS/ESP works for too long time)
Possible reason for the failure:
(1). Drive intensely and continuously or brakes continuously for a long time;
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;
(2). The speed sensor signal is incorrect.
;
(3). The turning sensor of the steering wheel and speed sensor of the yawing angle are abnormal.
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Maintenance and diagnosis method

(1). Use a diagnostic instrument to read the data stream of the speed sensor and observe whether there is a
speed sensor that sustains too high or too low.
(2). Make a test driving in the shape of number eight. During the test, the steering wheel needs to be
turned to left and right side to its limit and read the failure code again.
(3). If there is no failure code relating to the turning sensor of the steering wheel and speed sensor of the
yawing angle, check the installation position of the ESP to be horizontal and tightened.
4. C003200; C00A000; C00A100; C003500; C00A200; C00A300; C003800; C00A400; C00A500; C003B00;
C00A600; C00A700 wiring failure of the speed sensor
Possible reasons for the failure are as follows:

(1). The wheel speed sensor wiring is disconnected or the plug is loosen or broken.
(2). The signal wiring of the speed sensor is connected in the opposite direction with the power line.
(3).The signal
wiringis short circuit
to the ground.
(1). Check if there is open circuit or short-circuit of the speed sensor harness.
(2). Check if there is any loose or disconnection for the connectors of the speed sensor wiring.
(3). Check if there is opposite connection for the speed sensor power line and signal wiring.
(4). Make the ESP system to self-check after speeding up the vehicle to more than 40km/h.
(5). Replace the speed sensor if the failure cannot be ruled out after dynamic self-checking.
5. C003108; C00A900; C003408; C00AA00; C003708; C00AB00; C003A08; C00AC00; C109904 Signal
failure of the speed sensor
Possible reasons for the failure:
(1). The speed sensor harness is twisted and the connector is loosen or broken.
(2). The signal wiring of the speed sensor is short-circuit.
(3). The power line of the speed sensor is short-circuit to the ground.
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(4). The gear ring is not installed or there is missing tooth, or the gear ring is dirty, demagnetized or
eccentric.
(5). The gap between the sensor and gear ring is too large.
(6). The speed sensor is interfered by external magnetic field( The wheels or axles are not demagnetized) ;
(7). The speed sensor body fails.
25
(8). The gear tooth error.
(9). The tire size is not standard.

14
(1). Check if the speed sensor harness is twisted.
(2). Check if there is any loose or disconnection for the connectors of the speed sensor wiring.
(3). Check if the speed sensor harness is short-circuit to the ground.
(4). Check if the speed sensor is fixed correctly.
(5). Use a diagnostic instrument to read the data stream of the speed sensor and record whether each
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wheel speed is same to the accelerator displayed and the speed displayed is correct or not.
(6). If the wheel speed is displayed inconsistently, check the corresponded gear ring of the speed sensor if
there is any missing, dirt, foreign matter, demagnetization or eccentric phenomenon.
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(7). After any maintenance to the speed sensor, make the ESP to self-check dynamically after speeding up
the vehicle to more than 40km/h.
(8). Replace the speed sensor if the failure cannot be ruled out after dynamic self-checking.
8. C004460; C004510 Pressure sensor failure
(1). Braking lamp switch failure or circuit failure; ;

(2). Pressure sensor
failure.
(1). Check if the braking lamp switch and circuit are normal.
(2). Replace the ESP assembly if ESP damage is confirmed through cross-validation, make the braking
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pipe to exhaust.
9. C004008 braking light switch(BLS) faultC004008 (BLS)
(1). The braking light switch wiring is open or disconnected.
25
(2). The braking light switch is installed incorrectly.
(3). The braking light
switch is damaged
14
(1). Check the braking light switch and its harness.

20
(2). Replace the braking light switch.

10. C006108; C006208; C006308; C019604; C00A800 C006108; C006208; C006308; C019604; C00A800
The yawing rate sensor failure, the yawing rate sensor includes three signals: lateral accelerator, vertical
accelerator and yawing angle speed. The yawing rate sensor is integrated within the ESP9i controller.
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(1).The ESP is installed incorrectly.( The ESP must be installed horizontally and without inclination in
vertical direction).
(2). The yawing rate sensor is not calibrated incorrectly.
(3). The yawing rate
sensor is damaged.
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(1). Check if the ESP installation bolt or bracket is loosen or deformed.

(2). Re-calibrate the yawing rate sensor.
(3). Replace the ESP assembly if ESP damage is confirmed through cross-validation, make the braking
pipe to exhaust.
11. U000500; U000700; C100104; U000104; U100104 CAN bus line failure
(1). The battery voltage is too high or too low.( voltage value9.3v~16.8v).
(2). The CAN bus network is failed.
(3). The ECU is
damaged.
Maintenance and diagnosis

method
(1). Measure the battery voltage and charge the battery if necessary.
(2). Investigate the CAN bus and all bus nodes.
(3). Replace the ESP assembly if ESP damage is confirmed through cross-validation and make the braking
pipe to exhaust.
12. C106600; C046008; U012604 Steering wheel angle sensor failure
(1). The steering angle sensor is not calibrated correctly.

(2). The steering angle sensor wiring is failed.
(3). Check and re-insert the steering wheel sensor plug.
(4). The steering angle sensor is damaged.
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(1). Cancel the steering angle sensor calibration and re-calibrate.(The steering wheel must be in the middle
position).
(2). Check the steering wheel sensor harness.
(3). Check and re-insert the steering wheel sensor plug.
(4). When the steering wheel sensor failure is confirmed after cross-validation, replace the sensor and
25
calibrate the new sensor.
13. U010004; U010008; U010104; U010108; U015504; U042308 CAN Bus nodes failure
14
(1). The CAB bus communication is interrupted.

(2). The CAN bus nodes are badly powered.
(3).The CAN bus nodes are failed(The bus nodes are off from the CAN bus or the ECU is failed).
20
C-
JA
(1). Check if the CAN bus communication is normal.

(2). Turn off the ignition switch and measure the resistance of the CAN-H and CAN-L wiring from the
CAN bus nodes to the ESP.( Standard value: under5).
(3). Measure the resistance between CAN-H wiring and CAN-L through the connectors of the CAN bus
nodes.(Keep the plug connected);(standard value:60)
(4). Check if the CAN bus nodes are well powered.
(5). Read the fault code of the CAN bus nodes and inspect it accordingly.
12. C001004; C001104; C001404; C001504; C001804; C001904; C001C04; C001D04; C000104; C000204;
C000304; C000404; C007208 Electromagnetic valve
(1). Re-read the fault code after cooling for 10minutes.The system is overheated. ;
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(2). The electronic control unit of the ESP is damaged.
25
(1). Re-read the fault code after cooling for 10minutes.
(2). Replace the ESP assembly if ESP damage is confirmed through cross-validation and make the braking
pipe to exhaust.
13. C109504 Electromagnetic valve relay failure
14
(1). The electromagnetic valve is badly powered. (Low voltage, damaged fuse or poor contact).
(2). The electronic control unit of the ESP is badly contacted to the ground.ESP
(3). The electronic control unit of the ESP is damaged.
20

(1). Check the power supplying line, fuse and voltage of the electromagnetic valve replay.
(2). 21W ESP ; 0.2V
(3). 21W ESP ESP ECU ; 0.2V
(4). Make the ESP to self-check dynamically after speeding up to more than 40km/h. 40km/h ESP ;
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(5). Replace the ESP assembly if ESP damage is confirmed through cross-validation and make the
braking pipe to exhaust.
14. C002004 Reflux pump power
15. Possible reasons for the failure:
(1). The system is overheated.
JA
(2). The pump motor is badly powered. (Low voltage, damaged fuse or poor contact)
(3). The pump motor is badly powered. (Low voltage, damaged fuse or poor contact)
(4). The pump motor is damaged.
(1). Re-read the fault code after cooling for 10minutes.

(2). Check the power supplying line, fuse and voltage of the pump motor.
(3). Check the power supplying line, fuse and voltage of the pump motor.
21W ESP ; 0.2V
(4). 21W ESP ; 0.2V
(5). Make the ESP to self-check dynamically after speeding up to more than 40km/h.
(6).Replace the ESP assembly if ESP damage is confirmed through cross-validation and make the braking
pipe to exhaust.
15. C104C04 ESP Close the
switch failure
Possible reasons for the
failure:
(1). ESP closed switch things down ;
(2). ESP close switch or damage of the circuit ;
(1). Through the ESP close switch manually close and reopen the ESP function;
(2). Check the ESP close switch.
16. C121208ESP
configuration failure
Possible reasons for the
failure:
(1). The configuration information is not input.
(2). The configuration information is not matching.
(1). Input correct configuration information with diagnostic instrument.
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17. C108C08 Brake light switch / Normally on reverse signals
Possible reasons for the failure.
25
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20
C-
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(1). The braking lamp switch signal is
abnormal.
(2). The braking lamp switch harness
is open or short circuit.
(3). The reversing
signal is abnormal.
(1). Check the braking lamp switch.

;
(2). Check the braking lamp switch
harness. ;
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(3). Check the reversing signal. ;
(4). Check the TCU and diagnose according to the TC
U fault code.
TCU TCU
III、Front wheel speed sensor

（I）Special tool (No) 25
14
（II）Disassembly
1. Disconnect the negative cable of the
battery.
2. Dismantle the front wheel. Refer to Wheel
20
3. Dismantle the front fender liner, refer to

Fender liner.
4. Disconnect the front wheel speed sensor.
C-
1) Disconnect the connector of the front

wheel speed sensor.
JA
2) Unlock the buckle of the

sensor harness.
3). Dismantle the fixing bolt of the front

wheel speed sensor.
4). Dismantle the front wheel speed sensor.
（III）Installation
1.Install front wheel speed sensor
1). Install the front wheel speed sensor.
2). Tighten the fixing bolt of the front wheel sensor.
Tightening torque 8~10N.m
Caution:
1. Do not pull the harness of the wheel speed sensor hardly.
2. Pay attention to the gap between the wheel speed
sensor and signal gear ring during installation.
27
Standard value: 0.2~1.1mm
25
3). Install the sensor harness buckle.
14
20
4). Install the connector for the front wheel speed sensor.
C-
2. Install front fender liner.

JA
IV、Rear wheel speed sensor

（I）Special tool (No)
（II）Disassembly
2. Dismantle the rear wheel. Refer to wheel.
3. Dismantle the rear fender liner. Refer to fender liner.
4. Dismantle the trunk side trim. Refer to decorating plate under the column.
5. Disassemble rear wheel speed sensor
1). Disconnect the connector

of the rear wheel speed
sensor.
27
25
2). Unlock the sensor harness buckle.
14
20
3). Disassemble the fixing bolt of the rear wheel speed

sensor.
C-
4). Dismantle the rear wheel speed sensor.

JA
1. Installation of the rear wheel speed sensor.
1). Install the rear wheel speed sensor.
2). Tighten the fixing bolt of the rear wheel speed sensor.
Caution:
1. Do not pull the harness of the wheel speed sensor
hardly.
2. Pay attention to the gap between the wheel speed
sensor and signal gear ring during installation.
Standard value 0.2~1.1mm
3). Install the sensor harness buckle.
27
4). Connect the connectors for the rear speed sensor.
2. Install the trunk side trim.

3. Install the rear fender liner.
25
4. Install the rear wheel.
14
V、ABS hydraulic assembly
（I）Special tool
20

C-
1 Diagnostic instrument
for ABS fault
JA
（II）Dismantlement
2. Dismantle the air filter. Refer to Air filter assembly.
3. Dismantle the air intake hole of the engine. Refer to Air filter assembly.
4. Discharge the braking fluid.
5. Step down the braking pedal.
6. Dismantle the ABS hydraulic assembly.
1). Press the card pin of the plug and pull the lock buckle
up and disconnect the harness connector of the
hydraulic assembly.
27
2). Dismantle the connector nut of six braking oil pipe from the
ABS hydraulic assembly and wipe the over spilled braking fluid.
25
14
3). Using a tag or making records to mark the location for re-
connection.
20
4 5
3 6
C-
2 1
JA
4). Dismantle two fixing nuts of the ABS hydraulic assembly

bracket and take the ASB hydraulic assembly down.
1. Installation of the ABS hydraulic assembly ABS

1) Install the hydraulic control unit and tighten the fixing nut.
2) Install and tighten six connector nuts of the braking pipe
27
25
14
3) Press down the lock buckle and connect the harness connector of the hydraulic electronic control unit.
2. Release the braking pedal.

20
3. Fill brake fluid.

4. Bleed air of the hydraulic braking system.
Refer to Emission of the hydraulic braking system.
C-
5. Bleed the air of the ABS.

Refer to Emission of the ABS.
6. Check if there is any leakage in the braking system.

JA
VI、 Exhaust of the ABSABS
（I）Special tool
Diagnostic
instrument for
1 ABS faul
27
（II）Exhaust condition for the ABS
The ABS exhaust program should be performed if any one of the following cases occur:
ABS exhaust program:
1）Exhaust for the braking pipe according to traditional method cannot achieve the needed pedal height or
25
feel.
2）The ABS hydraulic assembly is replaced.
3）High fluid loss occurs.
4）Air inhalation is doubted.
This program uses the diagnostic instrument to drive the system valve and run the pump motor and remove
14
air from the secondary circuit. These secondary circuits are usually closed and only opened when the vehicle is
started and the ABS is operating. The automatic exhaust program makes these secondary circuits open and collect
all air to the hydraulic assembly and exhaust it out from the system.
20
（III）Exhaust of the ABS.

1. Required items
C-
1). Diagnostic instrument

with correct software
2). Braking fluid.

JA
3). Lifting machine.

4). Exhaust bottle equipped with pipe to recycle the liquid from the vehicle.
5). Safety equipment including protective glasses.
6).Two repair personnel: one steps on the braking pedal and control the diagnostic instrument, another one
keeps the hydraulic oil level of the braking master pump cavity and turn on and off the exhaust screw
according to the diagnostic instrument process.
2. Preliminary inspection
1). Check the charging state of the battery and repair the
battery and charging system if needed.

2). Connect the diagnostic instrument and choose current and past diagnostic fault code. Rule out all fault code
before ABS exhaust. Please troubleshoot first if rule-out is failed. ABS

3). Check if there is any damage or leakage of the appearance. Repair it if needed.
Caution: Pressing down the EXIT key of the diagnostic instrument can terminate the automatic exhaust
program any time.
3. Exhaust of部门：客户服务部
江淮汽车 the ASB
1). Choose Automatic exhaust program on the diagnostic instrument and proceed
according to the instructions.
2). During the process of general exhaust and automatic exhaust, step the braking
pedal and keep the braking liquid level of the braking master pump.
3). When exhaust a wheel, ensure the hose is connected with the exhaust screw and empty it into the cavity
with braking fluid. In order to prevent the air inhalation into the braking hose, the cavity must be 30mm
higher than the bolt of the hose with braking fluid.
4). The first step is general exhaust. This must be finished before automatic exhaust in order to get better
braking pedal height as well as feel and to ensure the best performance of the ABS.
27
5). The first step of the automatic exhaust program is to rotate the pump and pressure absorber for about thirty
seconds. There is no need to open or close the exhaust bolt during this step. The braking pedal is consistently
compressed or depressed in the whole process.
25
14
20
C-
JA
6). In the next step, the diagnostic instrument requires the repair personnel to open one of the exhaust bolts and
then make circulatory inspection for the pressure valve and pump motor for about thirty seconds.
7). Regarding the rest exhaust bolts, the diagnostic instrument will exhaust according to the sixth step.
8). The diagnostic instrument will display corresponded information after the automatic exhaust program is
finished
9). Calculate the height and feel of the braking pedal by stepping down the pedal. Make adjustment according
to step one to step eight until the pedal location is accepted.
Caution: During repeated operations, the automatic
27
exhaust program may stop temporarily and
enter Cool down waiting mode.
Caution: It will continue proceeding when the timer is over and this process cannot be got over.
25
10).Enter JAC PV Exclusive Malfunction Diagnosis System.
14
20
11). Choose JAC PV Exclusive V10.01 System.

C-
JA
12). Enter into automatic exhaust program and proceed

according to the instructions.
,
13). First step of system exhaust.
14). The exhaust is going on.
27
15). The first step is finished.
25
14
16). The second step of exhaust.
20
C-
JA
17). The exhaust is going.
18). The third step.
27
20). The third step is finished.
25
14
21). The fourth step.
20
C-
JA
23). The fourth step is finished.
29;61
24). The fifth step.
27
25
14
20

C-
26). The exhaust is finished.

JA
Electronic Power Steering
Ⅰ.Overview
（I） Structure overview
Decomposition chart of Electronic Power Steering System
27
25
14
20
C-
JA
（II）Working principle of the system
Principle diagram
27
25
14
20
C-
（III）Maintenance parameter
Maintenance data and specification
Item Specification
JA
Mechanical steering type Pinion and rack
Steering wheel diameter φ375mm
Steering column and lower axle Third stage collapse
Steering wheel operating torque ≤ 5N·m
Rack travel of the power steering gear 130±1mm
Line angle ratio 45.3
Steering wheel ring number 2.87±0.1
（IV）Torque parameter
1 Fixing nut of the steering wheel 42~52
2 Installation nut of the steering column 20~25
3 Installation bolt of the steering column 20~30
Connecting bolt between the steering column assembly

4 and the intermediate axle assembly 30~35
27
Connecting bolt between the intermediate axle assembly
5 and the mechanical steering gear 30~35
25
6 Master fixing bolt of the mechanical steering gear 100~110
7 Subsidiary fixing bolt of the mechanical steering gear 110~120

14
Adjusting nut for the front beam of the steering horizontal
8 rod 50~55
20
9 Slotting nut for the outer ball head of the steering gear 50~55
C-
（V） Maintenance precautions

1. Make the vehicle to be on level and dry ground when checking the steering system.
2. All the bolts of the steering system components should be tightened according to the required torque.
JA
3. Check the wheel positioning after the repair for the steering column assembly, steering gear or other steering
parts is finished.
4. The maximum voltage for the system should not exceed 18V and the minimum voltage should not be less than
9V.
5. Check the tire regularly and maintain the tire pressure as required.
6. Once some abnormal phenomenon such as gap, hairpin or swinging head occurs, please analyze whether the
problem is in the steering rotation equipment or power steering system or a part of the steering rod system and
then solve it accordingly.
7. Check the steering system components regularly and carefully that whether they are suffered from abnormal
impact. The damaged or faulty parts should be replaced promptly.
8. The components of the steering gear and system rod should not be welded in any way.
9. Check regularly that whether there is interference wear for the EPS harness or the connectors are loose. Replace
it timely if any abnormal phenomenon occurs.
（VI） Special tool
SN Tool number Tool name Outline drawing Usage
Dismantle the
1 JAC-T1D002 Steering wheel puller steering wheel
27
2 JAC-T1D003
Steering rotating
mould
25 Dismantle steering
ball head
14
20
C-
JA
Ⅱ. Fault diagnosis
（I） EPS ECU fault code chart
SN Fault code Description
1 C1111 Fault in the main signal of the sensor
2 C1115 Fault in the subsidiary of the sensor
3 C1114 Fault in the power supply of the sensor
27
4 C1113 Sensor main and auxiliary fault
5 C1141 Open current of the motor
7
C1142
C1145 25
Abnormal current of the motor 1
Abnormal current of the motor 2

14
8 C1153 Low power voltage
9 C1112 High power voltage

20
10 C1154 Abnormal electric relay
11 C1121 Fault in the speed signal 1

C-

JA
14 C1122 Fault in the engine speed sensor
15 C1155 Abnormal temperature or ROM error
（II）Fault diagnosis
SN Phenomenon Fault cause Solution Remark
The steering wheel ball

head is loose or the front
wheel is improperly Adjust the front wheel alignment
aligned. and steering wheel ball head.
The steering rod is

deformed because of
27
Vehicle twist or excessively Check and adjust every connector
1 deviation worn. of the steering system Refer to vehicle
accordingly to instructions. deviation diagram
25
The preload of the
steering rack is Adjust or repair the preload of
imbalanced. the steering rack.
14
The harness connector is
loose or poorly contacted. Check and re-connect the poorly
The steering contacted harness stably.
power is
20
effective Power
steering goes and
comes, or when
vehicles restarts,
C-
it resumes
normal
The motor fuse is loose or
poorly contacted. Re-install the fuse well.
JA
2 Refer to steering
power goes and
comes flow chart.
The motor is faulty. Replace the motor.
The electronic steering Replace the electronic steering

controller is faulty. controller.
（III）Diagnosis flow chart
Flow chart for vehicle deviation
27
25
14
20
C-
JA
Flow chart of steering power goes and comes
27
25
14
20
C-
JA
Ⅲ. Inspection for the vehicle steering system

(II) Check
1. Inspection for the installation
1). Check the installation of the steering device
assembly, front suspension, axle and steering column.

2). Check whether there is a moving gap when the steering wheel is moved up and down, left and right and
axially.
3). Check whether the fixing nut and bolt of the steering device assembly is loose.
27
2. Check the free travel of the steering wheel
1). Turning the steering wheel to make the front wheels to be in straight ahead position. Start the engine and
turn the steering wheel to left and right slightly until the front wheels begin to move. Measure the movement
of the steering wheel in the outer circle.

Free travel of the steering wheel is 30mm.
25
2). When the measurement exceeds the standard value, check every connector of the steering column and
14
installation of the steering device. Correct or replace related parts according to the situation.
3). If the idle stoke is still more than 30mm, turn off the engine and make the front wheels to be in running
20
state of a straight line. Apply a force of five N along the circumference of the steering wheel and check the
idle stroke which should not be more than 10mm. If it is more than 10mm, check whether the steering gear
C-
assembly is qualified.
4). If the stoke is still at its limited value, turn the steering wheel to the neutral position when the engine is
off. Apply a force of 4±0.6N to the circumference of the steering wheel and check its free travel.
JA
The standard value is less than 15mm.

5). If it exceeds the standard vale, remove the steering gear and check the general toque of the small pinion.
3. Check the intermediate position
1). Check the installation of the steering device
assembly, steering column and steering wheel.

2). After the wheels are aligned, check the intermediate position. Refer to “Alignment and inspection for front
wheels”.
3). Park the vehicle in straight ahead direction, make sure that the steering wheel is in the middle position.
4). Loosen the locked nut of the lateral rod and fine-tune the lever to left and right so as to confirm whether
the steering wheel is in the middle position.
4. Check the stationary steering force of the steering
wheel
1). Park the vehicle on level and dry ground and pull
up the handbrake.
2). Start the engine.
△Precautions: the tire pressure should be within the standard values.

3). Turn the steering wheel by three hundred and sixty degree from the central position. Check the steering
force and whether there is significant fluctuation.
Steering force of the steering wheel should be less than 3.4N and the allowed fluctuation is less than 5.9N.
4). If the steering force of the steering wheel exceeds the standard value, check or adjust below items:
(1). Check whether the lower swinging arm and ball head of the steering lateral rod are damaged.
(2). Check preload of the steering pinion and rotating torque of the ball head for the steering bilateral rod.
27
(3). Check the rotating torque of the ball head for the lower swinging arm.
5. Inspection for the automatic return of the steering wheel
△Caution: Turn slowly and sharply to feel the force and check whether there is any difference in return
between left and right. This step must be performed in a safe road and traffic condition and be careful.
25
1). Turn the steering wheel by 90° and drive at 35km/h. Keep this state for several seconds and then release the
steering wheel which should return for at least more than 70%.
6. Inspection for the steering angle of front wheels
14
1). Check the steering angle of front wheels after inspection for
front wheel beam is finished. Put the front wheels
on the steering angle device (Front wheels align the

20
steering wheel) and check the largest inner and outer
steering angle of the left and right wheels.

C-
Inner wheel:
36°±1.5°
Outer wheel:
JA
30°±1.5°
2). When the engine is idling, turn the steering wheel to left and
right to the end and measure the steering angle.
△Caution: Adjust the lateral rod if the measurement is

not within the standard value.
Adjust the steering angle by following steps:
When the steering angle exceeds the standard value,
loosen the lock nut of the lateral rod in left and right sides.
Use a wrench to rotate the lateral rod in left and right sides
to adjust the steering angle to standard value, and then lock the
nut and tighten the torque by 50~55N·m. Adjust the exposed
length of the thread for the left and right lateral rod. Make sure
the lateral rod length of the left and right should be consistent.
△Caution: When the inner wheel steering angle exceeds the standard value, adjust the lateral rod of this
side outwards to increase the inner wheel steering angle. When the outer wheel steering angle
exceeds the standard, adjust the lateral rod of this side outwards to reduce the outer wheel
steering angle. The toe-in is interrelated with the rest wheel alignment parameters and
adjustment of the steering angle.
7. Inspection for the dust cover of the ball
head
27
1). Press the dust cover with a finger to
check whether it’s cracked or damaged.

2). Replace the ball head of the lateral rod when the dust cover is cracked or damaged.
△Caution: When the dust cover is cracked or damaged, it may cause associated damage to the ball head.
8. Inspection for the ball
head of the steering

25
14
lateral rod
1). Sway the lateral rod fast
for ten times.

20
2). Use a spring balance to measure the swing resistance of the lateral rod.
Standard value: 0.5~3N Replace the lateral rod if the measurement is not within the standard value.
Ⅳ. Steering wheel assembly

C-
(I) Special tool

JA
SN Tool Number Tool Name Outline Drawing
Steering
wheel
1 JAC-T1D002 puller
(II) Removal
△Caution: Disconnect the negative cable of the

battery and wait for more than three
seconds in order to prevent the airbag
from deploying in the disassembling
process.
2. Dismantlement for the drivers's airbag module, refer to “ Airbag for the Driver”.
3. Dismantlement for the steering
1） Lock the steering wheel and disassemble the fixing nut

of the steering wheel.
2） Pull out the steering wheel from the steering column
axle.
△Caution: If the steering wheel cannot be pulled out easily,
please use the steering wheel puller.
27
25
1. Installation for the steering wheel
1). Install the steering wheel to the steering column.
2). Install the fixing nut.
Tightening torque: 42~52N·m
14
2. Install the driver’s airbag module.
3. Connect the battery cable.

20
C-
V. Controller assembly
JA
1. Disassemble the steering cover. Refer to “Steering Cover”.

2. Dismantle the controller assembly.
1). Disconnect the connectors of the controller harness.
2). Remove the two fixing bolts of the controller bracket.
3). Remove the three fixing bolts of the controller bracket and take the controller assembly from it.
27
1. Install the controller assembly.
1). Install the controller bracket to the controller and tighten the three fixing bolts.
25
14
20
2). Install the controller and bracket assembly to the steering column and tighten the two fixing bolts.
C-
JA
3). Connect the harness connector of the controller.
VI. Motor assembly for the EPS

1. Remove the steering cover. Refer to “Steering Cover”.
2. Disassemble the steering column assembly. Refer to “Steering column assembly”.
3. Dismantle the motor assembly of the EPS.
1). Disconnect the harness connector of the EPS motor wiring.
27
25
2). Remove the two fixing bolts between the motorand fixing bracket.
14
20
C-
1. Install EPS motor assembly.

1). Install the two fixing bolt between the motor and bracket.
JA
2). Connect the harness connector of the EPS motor wiring.
2. Install the steering column assembly.

3. Install the steering cover.
VII. Steering column assembly

△Caution: Disconnect the negative cable of the battery and wait for more than three seconds in order
to prevent the airbag from deploying.
2. Disassemble the driver’s airbag module. Refer to “Driver’s airbag module”.
3. Remove the steering wheel. Refer to “Steering wheel”.
4. Dismantle the upper and lower cover of the steering column. Refer to “Upper and lower cover of the
steering column”.
27
5. Remove the clock spring. Refer to “Clock spring”.
6. Dismantle the combined switch assembly. Refer to “Combined switch assembly”.
7. Remove the ignition lock. Refer to “Ignition lock”.
8. Dismantle the steering column assembly.
25
1). Disconnect the harness connector of the EPS.
14
20
2). Remove the connecting bolt between the steering column and lower axle to separate the steering
column and steering gear.
C-
JA
3). Remove the two fixing nut between the upper side of the steering column assembly and bracket.
4). Remove the bolt between the lower side of the steering column and bracket.
5). Lower the steering column and remove the steering column assembly.
27
（III）Inspection
1. Inspection for the steering column.
1). Check whether the steering column is cracked, deformed or damaged. Replace it if above phenomenon
occur.
25
2). Check whether the spline of the steering column axle is worn or broken. Replace if if above
phenomenon occur.
14
20
（IV）Disassembly
1. Disassemble the intermediate axle assembly.
C-
1). Loosen the connecting bolt between eh steering column and universal joint of the connecting axle.
JA
2. Dismantle the steering lock

1). Use a drill to drill a hole on the screw bolt which isenough to
put a bolt in.
2). Use a thread screw to remove the two special bolt.
3). Remove the steering lock from the steering column.
△Caution: This fixed screw is disposable and must be replaced
after removal.
3. Removal for the adjustable bracket.
1). Remove the fixed bolt and nut.
27
（V）Inspection
25
1. Check the adjustable bracket and steering lock mechanism.
1). Check whether the adjustable bracket and spring are cracked or damaged.
14
2). Check whether the operation of the steering lock mechanism is normal.
20
C-
（Ⅵ）Installation
1. Install the steering lock
JA
1). Install the steering lock assembly and steering lock bracket
on the steering column assembly.
2). After the steering lock is confirmed to be correctly installed,
tighten the special bolt until the bolt head is broken.
1. 2. Install the adjustable bracket

1). When installing the steering lock assembly and steering lock
bracket on the steering column assembly, turn it
towards the steering column gap and temporarily lock the steering lock.
3. Install the intermediate axle assembly
1). Install the intermediate axle assembly on the steering column.
2). Fix the internal nut and tighten the fixing bolt.
（Ⅶ）Installation
1. Install the steering column assembly
1). Install the steering column assembly on the vehicle.
2). Install the connecting bolt between the lower part of the steering
column and the bracket and make it tightened.
3). Install the two fixing nut between the upper part of the steering column and the bracket and make it
tightened.
27
25
14
4). Connect steering column and steering gear and tighten the fixing bolt.
20
C-
JA
5). Connect the harness connector of the EPS.
2. Install the ignition lock.

3. Install the combined switch assembly.
4. Install the clock spring.
5. Install the upper and lower over of the steering column.
6. Install the steering wheel.
7. Install the driver’s airbag module.
（Ⅷ）Steering gear and rod assembly
1. Special tool
SN Tool number Tool name Outline Drawing
1 JAC-T1D003
Steering rod
drawing tie
27
2. Dismantlement
1. Lifting the vehicle.
2. Remove the front wheels. Refer to “Wheels”.
3. Remove the ball head assembly of the lower swing arm. Refer to “Ball head assembly of the lower swing
25
arm”.
4. Remove the stability rod lever. Refer to “Stability rod lever assembly”.
5. Remove the front sub-frame and steering assembly.
14
1). Remove the connecting bolt between the intermediate axle
assembly and mechanical steering gear from the driving room
to separate the steering column assembly and steering gear.

20
C-
2). Remove the lock nut of the lateral rod ball head.
JA
3). Use a special tool to remove the ball head of the steering
lateral rod form the steering joint. KBD.U2E114
4). Remove the fixed bolt between the rear suspension of the
engine and the front sub-frame.
5). Dismantle the four fixed bolt connecting the sub-frame
and the vehicle body and put down the sub-frame and steering
27
assembly slowly.
6. Remove the steering gear and rod assembly 25

14
1). Remove the four fixed bolt of the steering gear from
the sub-frame.
20
2). Remove the steering assembly from the sub-frame.
△Caution: Remove the steering assembly carefully and
slowly and try to avoid any damage to the dust cover of the
C-
lateral rod.
JA
（III）Inspection
1. Inspection for the mechanical steering gear.
1). Check whether the gear and rack works smoothly and whether they are worn.
2. Inspection for the preloading of the gear.
1). Rotate the gear at 4-6 seconds per lap and measure the gear preloading in the full rack stroke range.
2). If the measurement exceeds the standard value, adjust the block first and then re-check the gear preloading.
3). If it still fails to get the required gear preloading after adjusting the block, check or replace the blocking parts.
3.Inspection for the rotating torque for the lateral rod.
1). Sway the lateral rod for ten times quickly.
2). Use a spring balance to measure the swinging resistance of the lateral rod.
江淮汽车Standard value：0.5~3N
部门：客户服务部
3).Replace the lateral rod if the measurement is not within the standard value.
△Caution: If there is no excessive gap when the lateral rod swings slowly, it can be used even though the
measurement is lower than the standard value. The lateral rod should be replaced if the measurement is larger
than 4.3N·m.
4. Inspection for the dust cover of the lateral rod.
1) Check whether the dust cover is damaged and replace it if it is.
2) Check whether the dust cover is installed in correct location.
(Ⅳ) Installation
27
1. Installation for the steering gear and rod assembly
1). Install the steering gear assembly on the sub-frame.
2). Install the fixing bolt between the steering gear assembly
25
and sub-frame and tighten it.
14
2. Installation for the sub-frame and steering gear assembly
20
1). Use a lift to support the sub-frame and steering assembly.

2). Install the four fixing bolt of the sub-frame and tighten them.
C-
JA
3). Install the fixing bolt between the rear suspension of the engine and the front sub-frame.
4). Install the ball head of the lateral rod on the steering joint and tighten the fixing nut.
27
5). Install the steering gear to the universal joint of the intermediate axle and tighten the fixing bolt.
25
14
20
C-
JA
27
25
14
20
C-
JA
ANHUI JIANGHUAI AUTOMOBILE CO., LTD
Compiling Champion.Wong
Audit Youwang.Zhang
Approve

【EN】2 Chassis-S3 E100

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WORKSHOP MANUAL

All contents in this Manual, including pictures, 25 Chassis

please obtain the latest information about this Manual.

addition or improvement for the product.

· Cause severe injury to driver or passenger if repaired improperly

Definition of “Important precautions”

· Unnecessary vehicle repair

· Add information for completing a procedure

Warning on handling the anti-lock braking system components

Warning on colliding and repairing the permitted equipment

Warning on brake dust

Warning on braking fluid

Warning on braking fluid irritant

Warning on clutch dust

Warning on collision and cutting

Warning on eye protection

Warning on moving parts and heat surface

and burst to personnel to cause severe scald.

Warning on road test

Warning on goggles and fuel

Important precaution on fulfilling braking fluid in braking system

Important precaution on fastener

Important precaution on machined surface damage

Important precaution on removing ring gear

Important precaution on sealant

Vehicle and positioning operation

Clutch pedal free travel

only supported by a jack, make sure to use jack seat.

Vehicle lifting point

Unleaded gasoline Above 93# unleaded gasoline 45L

Braking liquid DOT4 650ml±50ml

Continuous acceleration time (0-100km/h) S ≤ 14 ≤ 15

Maximum speed Km/h ≥ 175 ≥ 170

Fuel consumption index

Comprehensive (L/km) ≤ 5.9 ≤ 7.2

90km/h constant speed (L/km) ≤ 5.6 ≤ 6.1

Transmission gear ratio

Item Reference value

Shift type 6MT CVT

First 3.769 Manual 1st 2.28~2.41

Third 1.393 Manual 3rd 1.10 Automatic model

Sixth 0.681 Manual 6th 0.52

Reverse 3.583 Manual reverse 2.68

Final ratio 4.056 5.76

0°±30′ (Difference value between left and right is

Total toe-in -1°±30′

Rear wheel Total toe-in 24′±20

Tyre specification 2 185/65R15 88H

Cold inflation pressure 2

Spare tyre 205/55R16 94V

Regular maintenance instructions

Description of planned maintenance programs

Wheel inspection and transposition

VI Health and safety

rules to avoid those hazards.

Chemical material—operations you should not take are as following

· Do not spray chemical material in a closed environment.

(VI) Electric shock

split blindly unless there is instruction on the volume label.

(XI) Foam -polyurethane

(II) Main fastener tightening torque chart

4 Connecting bolt between steering gear and steering knuckle 50~55

6 Connecting bolt between left suspension and gear box 70±10

9 Connecting nut between right suspension and engine 55±5