Section Ⅰ

Engine

HFC4DA1(4DA1-1)
Introduction

We prepare this manual to help technicians get to know and understand 4DA1

Series engine so that they are able to master quick maintenance and service.

The manual gives you instructions on assembly and disassembly of parts and

systems of 4DA1 Series engine, general maintenance standards, special tools

as well as common fault diagnosis and troubleshooting.

Our products are subject to continuous innovation. If any information in this

manual is not applicable for the innovative products, the discrepancies will be

modified in a second edition.

No part or parts of this manual may be reproduced or illegally used in any form

or by any means without written consent of Jianghuai Automobile.

1
Table of Contents
1. Maintenance.......................................................................................................................................... 5
1.1 Diagnosis and troubleshooting ..................................................................................................... 5
1.1.1 Start problems..................................................................................................................... 5
1.1.2 Unstable idle speed ............................................................................................................ 7
1.1.3 Insufficient power................................................................................................................ 8
1.1.4 High fuel consumption ........................................................................................................ 9
1.1.5 High oil consumption ........................................................................................................ 10
1.1.6 Engine overheating........................................................................................................... 10
1.1.7 White smoke coming out of engine exhaust .................................................................... 10
1.1.8 Black smoke coming out of engine exhaust......................................................................11
1.1.9 Low oil pressure.................................................................................................................11
1.1.10 Abnormal engine noise ....................................................................................................11
1.1.11 Engine cooling problem .................................................................................................. 12
1.2 Data and specifications............................................................................................................... 20
1.2.1 Data and specifications............................................................................................................ 20
1.2.2 Engine cooling .................................................................................................................. 21
1.2.3 Starting system ................................................................................................................. 21
1.2.4 Charging system............................................................................................................... 22
1.3 Maintenance standards............................................................................................................... 22
1.3.1 Engine mechanical system............................................................................................... 22
1.3.2 General terms for diesel performance.............................................................................. 24
1.4 Maintenance work ....................................................................................................................... 26
1.4.1 Air filter .............................................................................................................................. 26
1.4.2 Lubricant system............................................................................................................... 27
1.4.3 Fuel system ...................................................................................................................... 28
1.4.4 Cooling system ................................................................................................................. 30
1.4.5 Drive belt adjustment ........................................................................................................ 32
1.4.6 Engine control (governed speed, valve clearance, injection timing, compression pressure)
................................................................................................................................................... 33
1.5 Tightening torque ........................................................................................................................ 39
1.5.1 Torque for cylinder head, cylinder head cover and rocker shaft support ....................... 39
1.5.2 Torque for crankshaft, bearing cap, connecting rod bearing cap, crankshaft damper pulley,
flywheel and oil pan ................................................................................................................. 41
1.5.3 Torque for timing pulley chamber, timing pulley, timing gear and camshaft race ............ 42
1.5.4 Engine fuel system ........................................................................................................... 42
1.5.5 Torque for cooling system and lubricant system .............................................................. 43
1.5.6 Torque for intake manifold, exhaust manifold and exhaust pipe ...................................... 44
1.5.7 Engine electrical system................................................................................................... 45
1.5.8 Torque for engine mounting bracket................................................................................. 46
1.6 Special tools ................................................................................................................................ 47
2. Engine mechanical system ............................................................................................................... 49

2
2.1 Cylinder head .............................................................................................................................. 49
2.2 Valve spring, valve guide oil seal, valve guide and push rod ..................................................... 56
2.3 Camshaft and tappet................................................................................................................... 64
2.4. Rocker arm assembly ................................................................................................................ 72
2.5 Oil pump...................................................................................................................................... 75
2.6. Crankshaft.................................................................................................................................. 80
2.7. Piston and connecting rod ......................................................................................................... 95
2.8 Cylinder block............................................................................................................................ 106
3.4 DA1 Series Engine ......................................................................................................................... 118
3.1 General.......................................................................................................................................118
3.2 Right support of engine..............................................................................................................119
3.3 Left support of engine .......................................................................................................................... 121
3.4 Air-intake manifold..................................................................................................................... 123
3.5 Exhaust manifold....................................................................................................................... 125
3.6 Oil cooler ................................................................................................................................... 127
3.8 Cylinder head cover .................................................................................................................. 130
3.9 Rocker shaft assembly.............................................................................................................. 131
3.10 Valve stem oil seal and valve spring ...................................................................................... 134
3.11 Timing gear.......................................................................................................................................... 138
3.12 Cylinder head assembly and gasket....................................................................................... 146
3.13 Oil pan ..................................................................................................................................... 157
3.14 Oil pump assembly ................................................................................................................. 160
3.15 Piston, Piston ring and connecting rod ................................................................................... 164
3.16 Camshaft and tappet............................................................................................................... 177
3.17 Crankshaft front oil seal .......................................................................................................... 197
3.18 Crankshaft rear oil seal ........................................................................................................... 200
3.19 Crankshaft and main bearing.................................................................................................. 207
4 Engine cooling system ..................................................................................................................... 229
4.1 General...................................................................................................................................... 229
4.2 Water pump............................................................................................................................... 232
4.2.1 On-vehicle repair ............................................................................................................ 232
4.2.2 Single-piece repair.......................................................................................................... 236
4.3 Thermostat ................................................................................................................................ 239
4.4. Radiator.................................................................................................................................... 241
4.5 Drive belt adjustment ................................................................................................................ 244
5 Fuel system........................................................................................................................................ 246
5.1 General...................................................................................................................................... 246
5.2 Fuel filter assembly ................................................................................................................... 250
5.3 Fuel injector............................................................................................................................... 253
5.4 Injection pump assembly .......................................................................................................... 258
5.5 Fuel system related parameters ............................................................................................... 266
5.6 Fuel tank.................................................................................................................................... 267
5.7 Fuel lever gauge ....................................................................................................................... 269
6 Starting system（To mention in a reference） .............................................................................. 270
6.1 General...................................................................................................................................... 270

3
6.2 Starting circuit............................................................................................................................ 271
6.3 Starter motor ............................................................................................................................. 272
7 Intake/exhaust system ...................................................................................................................... 281
7.1 General...................................................................................................................................... 281
7.1 Air filter ...................................................................................................................................... 282
7.2 Exhaust pipe and charger assembly......................................................................................... 284

4
1. Maintenance
1.1 Diagnosis and troubleshooting

1.1.1 Start problems

1. The starter motor fails to work.
Check Causes Remedies
The battery terminal post is loose. Clean and/or tighten the loose terminal
There is bad connection caused by post(s)
oxidation or corrosion.
Battery
The battery is uncharged or in Charge the battery or replace the old
shortage of charge. battery with a new one
The belt of fan is loose or broken. Adjust the belt of fan, or replace it
Fuse The fuse is short circuited. Replace the fuse with a new one
Starter switch The starter switch or relay has failed. Replace the starter switch or relay
The solenoid switch has failed. Repair or replace the solenoid switch
Starter motor
The starter motor has failed. Repair or replace the starter motor
2. The starter motor works well, but the engine fails to run.
The battery terminal post is loose. Clean and/or tighten the loose battery
There is bad connection caused by terminal post(s)
oxidation or corrosion.
Battery
The battery is uncharged or in Charge the battery or replace the old
shortage of charge. battery with a new one
The belt of fan is loose or broken. Adjust the belt of fan, or replace it
The pinion is broken. Replace the broken pinion
The solenoid switch has failed. Repair or replace the solenoid switch
Starter motor
The brush is worn or the brush spring Replace the brush and/or the brush
is too soft. spring
The piston or crankshaft bearing is Repair or replace the damaged part(s)
Engine
jammed or damaged.

3. The engine rotates but it cannot be ignited to start.

Check Causes Remedies
Brake mechanism The fuel cut-off solenoid valve is Replace the fuel cut-off solenoid
of engine broken.
The fuel fails to flow into the injection pump.
Fuel The fuel tank is empty. Fill in the fuel tank
Fuel pipe system The fuel pipe is clogged or broken. Repair or replace the fuel pipe
The fuel tube joint is loose. Retighten the fuel tube joint
Fuel filter The fuel filter overflow valve cannot be Repair or replace the fuel filter
closed. overflow valve

5
A fuel filter component is clogged. Replace the fuel filter component or
the filter element
Fuel system There is air in the fuel system. Release the air from the fuel system
Fuel feed pump The fuel feed pump is broken. Repair or replace the fuel feed pump
The fuel flows into the injection pump.
The fuel in service is incorrect. Use the correct fuel
Fuel
There is water in the fuel system. Replace the fuel
Fuel system There is air in the injection pump. Release the air from the fuel system
The fuel injector is jammed. Replace the fuel injector
The opening pressure of fuel injector is Adjust or replace the fuel injector
Fuel injector
too low.
Atomizing is bad.
The damage of fuel injector results in Replace the delivery valve
fuel dripping after injection.
Something is wrong with the control Repair or replace the control rack of
rack of injection pump. injection pump
The injection pump plunger is worn or Repair or replace the injection pump
Injection pump
jammed. plunger assembly
The drive shaft of injection pump is Replace the drive shaft
jammed or damaged.
The governor spring of injection pump Replace the governor spring of
is jammed. injection pump

4. Quick start system

Preparation work
1. Disconnect the connector of temperature switch
2. Verify whether the glow plug is power on
a) Confirm the start switch is at OFF position
b) Use voltmeter to connect cylinder wall with any glow plug
c) Switch the start switch to the ON position
If the glow plug is power on, the voltmeter indicates 12 V. If the pointer of voltmeter doesn’
t
move, it means the glow plug is power off.
3. Trouble shooting
The glow plug is power on.
Check Causes Remedies
The indicator lamp of glow The indicator lamp is broken. Replace the indicator lamp
plug is off.
Quick start timer The quick start timer is broken. Replace the quick start timer
The indicator lamp of glow The quick start timer is broken. Replace the quick start timer
plug is on for 0.3 s.

6
The indicator lamp of glow After the engine is started, switch Replace the quick start timer
plug is on for 3.5 s. the start switch from ST (start) to
ON. If the relay of glow plug keeps
closed for less than 14 s, it
indicates something is wrong with
the quick start timer.
Switch the start switch from OFF Replace the quick start timer
to ON. If the relay of glow plug
keeps closed for less than 14 s, it
indicates something is wrong with
the quick start timer.
Temperature switch The temperature switch is broken. Replace the temperature switch
Connectivity of glow plug The connectivity of glow plug is Replace the glow plug
bad.
The glow plug is power off.
The indicator lamp of glow The fuse of indicator lamp blows Replace the broken fuse
plug is off. out.
Quick start timer The quick start timer is broken. Replace the quick start timer
The indicator lamp of glow The glow plug relay is broken. Replace the glow plug relay
plug is on for 3.5 s. When the start switch is switched
from OFF to ON, the glow plug
relay is not switched on.
The quick start timer is broken. Replace the quick start timer
A line fault occurs in the circuit of Repair or replace corresponding
glow plug relay. line(s)
The fuse blows out or there is a Replace the fuse or
line fault. corresponding line(s)
When the start switch is switched
from OFF to ON, the glow plug
relay is switched on.

1.1.2 Unstable idle speed

Check Causes Remedies
Idle speed system The idle speed is not proper. Adjust the idle speed
High idle speed control The high idle speed control device Repair or replace the high idle
device is broken. speed control device.
Throttle control system The adjustment of throttle control Adjust the throttle control system
system is not proper.
Leakage or blockage occurs in the Repair or replace the fuel system
fuel system.
Fuel system There is air in the fuel system. Release the air from the fuel
system
There is water in the fuel system. Replace the fuel

7
A fuel filter component is clogged. Replace the fuel filter component
Fuel filter
or the filter element.
The fuel feed pump is broken. Repair or replace the fuel feed
Fuel feed pump
pump.
The fuel injector is jammed. Replace the fuel injector
The opening pressure of fuel Adjust or replace the fuel injector
Fuel injector
injector is too low.
Atomizing is bad.
The damage of delivery valve
results in fuel dripping after Replace the delivery valve
injection.
Injection timing is not proper. Adjust injection timing
The injection volume is too low. Increase injection volume
The idle speed spring is broken. Replace the idle speed spring
Injection pump
The shifter is broken Repair or replace the shifter
The regulator valve is not at Adjust or replace the regulator
proper position. valve
The plunger spring is broken Replace the plunger spring
The plunger is worn. Replace the plunger assembly
The cam is worn. Replace the worn cam
Valve clearance The valve clearance is not proper. Adjust the valve clearance
The gasket of cylinder head is
worn.
Compression pressure Replace relevant parts
The cylinder liner is worn.
The piston ring is sticky.

1.1.3 Insufficient power

Check Causes Remedies
An air filter component is Clean or replace the filter
Air filter
clogged. component
Fuel There is water in the fuel. Replace the fuel
Replace the fuel filter component
Fuel filter A fuel filter component is clogged.
or the filter element
Repair or replace the fuel feed
Fuel feed pump The fuel feed pump is broken.
pump
The fuel injector is jammed. Replace the fuel injector
The opening pressure of fuel
Fuel injector
injector is too low. Adjust or replace the fuel injector
Atomizing is bad.
The high pressure fuel pipe is Replace the high pressure fuel
High pressure fuel pipe
damaged or blocked. pipe
Repair or replace the regulator
Injection pump The regulator valve is damaged.
valve

8
The delivery valve is damaged. Replace the delivery valve
The timer is broken. Repair or replace the timer
The cam is worn. Replace the worn cam
The control lever doesn’
t work
Adjust or replace the control lever
well.
Adjust injection timing
The injection timing is not correct. Repair or replace the injection
pump timer
The governing spring is too soft. Replace the governing spring
The plunger is worn. Replace the plunger assembly
The gasket of cylinder head is
worn.
Compression pressure Replace relevant parts
The cylinder liner is worn.
The piston ring is sticky.
Valve clearance The valve clearance is not proper. Adjust the valve clearance
The valve spring is too soft or
Valve spring Replace the valve spring
broken.
Exhaust system The exhaust pipe is clogged. Clean the exhaust pipe
Seal of full-load adjusting The seal of adjusting screw is Properly adjust the seal of
screw opened or improperly adjusted. adjusting screw and seal again

1.1.4 High fuel consumption

Check Causes Remedies
Repair or replace corresponding
Fuel system There is a fuel leak.
parts of fuel system
Clean or replace the air filter
Air filter An air filter component is clogged.
component
The idle speed is not adjusted
Idle speed Adjust the idle speed
properly.
The opening pressure of fuel
Fuel injector injector is too low. Adjust or replace the fuel injector
Atomizing is bad.
Fuel injection timing Fuel injection timing is not correct. Adjust the fuel injection timing
The damage of delivery valve
Injection pump results in fuel dripping after Replace the delivery valve
injection.
Valve clearance The valve clearance is not proper. Adjust the valve clearance
The gasket of cylinder head is
worn.
Compression pressure Replace relevant parts
The cylinder liner is worn.
The piston ring is sticky.
The valve spring is too soft or
Valve spring Replace the valve spring
broken.

9
1.1.5 High oil consumption
Check Causes Remedies
The oil type is not correct. Replace the engine oil
Engine oil
The oil volume is too high. Adjust the oil level
The oil leaks from the oil seal
Oil seal and gasket Replace the oil seal and/or gasket
and/or gasket.
Air vent The air vent is blocked. Clean the air vent
Intake valve and exhaust The valve stem and valve guide Replace intake valve, exhaust
valve are worn. valve and valve guide

1.1.6 Engine overheating

Check Causes Remedies
Cooling water The cooling water is insufficient. Supply enough cooling water
Fan clutch The oil leaks from the fan clutch. Replace the fan clutch
Fan belt Loose or damaged fan belt results Replace the fan belt
in slipping.
Radiator The radiator cap is damaged or Replace the radiator cap or clean
the radiator core is blocked. the radiator core
Water pump The water pump is broken. Repair or replace the water pump
Cylinder head and cylinder Damaged cylinder head results in Replace the sealed cap
block leakage of cooling water.
Sealed cap
Thermostat The thermostat is broken. Replace the thermostat
Cooling system The cooling system is clogged by Remove foreign matters from the
foreign matters. cooling system
Fuel injection timing Fuel injection timing is not correct. Adjust the fuel injection timing

1.1.7 White smoke coming out of engine exhaust

Check Causes Remedies
Cooling water The cooling water is insufficient. Supply enough cooling water
Fuel There is water in the fuel system. Replace the fuel
Fuel injection timing Fuel injection timing is delayed. Adjust the fuel injection timing
The gasket of cylinder head is
worn.
Compression pressure Replace relevant parts
The cylinder liner is worn.
The piston ring is sticky.
Intake valve and exhaust The valve oil seal is worn.
Replace valve oil seal, valve and
valve The valve stem and valve guide
valve guide
Valve oil seal are worn.

10
1.1.8 Black smoke coming out of engine exhaust
Check Causes Remedies
Air filter An air filter component is clogged. Clean or replace the air filter
component
Fuel injector The opening pressure of fuel Adjust or replace the fuel injector
injector is too low.
Atomizing is bad.
Fuel injection timing Fuel injection timing is not correct. Adjust the fuel injection timing
Injection pump The damage of delivery valve Replace the delivery valve
results in fuel dripping after
injection.
The injection volume is too high. Reduce injection volume

1.1.9 Low oil pressure

Check Causes Remedies
Engine oil The oil viscosity is not correct. Replace the engine oil
The oil volume is too low. Increase the oil volume
Oil pressure gauge or The oil pressure gauge or Repair or replace the oil pressure
assembly assembly is broken. gauge or assembly
Oil pressure indicator light The indicator light is broken. Replace the indicator light
Oil filter An oil filter component is clogged. Replace the oil filter component or
the filter element
Safety valve and bypass The safety valve is jammed and/or Replace the safety valve and/or
valve the bypass valve spring is too soft. bypass valve spring
Oil pump The oil pump strainer is blocked. Clean the oil pump strainer
A component in the oil pump is Replace relevant parts in the oil
worn. pump.
Rocker shaft The rocker shaft bearing is worn. Replace the rocker shaft bearing
Camshaft The camshaft and its bearing are Replace the camshaft and its
worn. bearing
Crankshaft and bearing The crankshaft and its bearing are Replace the crankshaft and/or its
worn. bearing

1.1.10 Abnormal engine noise

1. Engine slap
Verify the engine is completely warmed up before troubleshooting.
Check Causes Remedies
Fuel The fuel is not correct. Replace the fuel
Fuel injection timing Fuel injection timing is not proper. Adjust the fuel injection timing
Fuel injector The opening pressure of fuel Adjust or replace the fuel injector
injector or atomizing is not proper.

11
Compression pressure The gasket of cylinder head is Replace the gasket of cylinder
worn. head or piston ring
The piston ring is broken.
2. Air leak noise
Exhaust pipe The connection of exhaust pipe is Tighten the connection of exhaust
loose. pipe
The exhaust pipe is broken. Replace the exhaust pipe
Fuel injector and/or glow The fuel injector and/or glow plug Replace the gasket
plug are loose. Tighten the fuel injector and/or
glow plug
Exhaust manifold The connection to exhaust Tighten the connection to exhaust
manifold is loose. manifold
Cylinder head gasket The cylinder head gasket is worn. Replace the cylinder head gasket
3. Continuous noise
Fan belt The fan belt is loose. Adjust the tightness of fan belt
again.
Cooling fan The cooling fan is loose. Retighten the cooling fan
Water pump bearing The water pump bearing is worn Replace the water pump bearing
or damaged.
Alternator or vacuum pump The alternator or vacuum pump is Repair or replace the alternator or
broken. vacuum pump
Valve clearance The valve clearance is not proper. Adjust the valve clearance
4. Clapping noise
Check Causes Remedies
Valve clearance The valve clearance is not proper. Adjust the valve clearance
Rocker arm The rocker arm is broken. Replace the rocker arm
Flywheel The flywheel bolt is loose. Retighten the flywheel bolt
Crankshaft and thrust The crankshaft and/or thrust Replace the crankshaft and/or
bearing bearing is worn or damaged. thrust bearing
Crankshaft and connecting The crankshaft and/or connecting Replace the crankshaft and/or
rod bearing rod bearing is worn or damaged. connecting rod bearing
Connecting rod bushing and The connecting rod bushing and Replace the connecting rod
piston pin piston pin are worn or damaged. bushing and/or piston pin
Piston and cylinder liner The piston and cylinder liner is Replace the piston and cylinder
worn or damaged. liner

1.1.11 Engine cooling problem

Check Causes Remedies
Engine overheating The coolant level is too low. Fill in the coolant
The thermostatic control is Replace the thermostatic control
broken.
The thermostat is broken. Replace the thermostat

12
Something is wrong with the Repair or replace the cooling
cooling element. element
The radiator is blocked. Clean or replace the radiator
The radiator cap is damaged. Replace the radiator cap
The oil level is too low or the oil is Fill in or replace the oil
disqualified.
The cylinder head gasket is worn. Replace the cylinder head gasket
The exhaust system is blocked. Clean the exhaust system or
replace the damaged parts
The fan belt is loose. Adjust the fan belt
The fuel injection volume is too Adjust the fuel injection
high.
The injection timing is not correct. Adjust the injection timing
Engine overcooling The thermostat is broken. Replace the thermostat
Long engine preheating The thermostat is broken. Replace the thermostat
time The thermostatic control is Replace the thermostatic control
broken.

Check the battery and make the following diagnosises.

13
The starter doesn’
t run.

Check the battery

Charging is invalid or the life of

battery is expired. The battery is normal.

Check the battery

Check the terminal post

Connection is interrupted.
The terminal post is OK.

Clean the battery terminal post and reconnect it. Check the starter or the starter switch

Faulty

Repair or replace

Turn on the headlamp and starter switch

The headlamp is off or dim. The headlamp is bright.

a) The starter circuit has open circuit.

a) The battery has insufficient charge.
b) The starter coil has open circuit.
b) The starter coil is short-circuited.
c) The starter switch is faulty.
c) A starter part is faulty.

14
The engagement between the pinion and tooth
flank is not good.

When the starter switch is switched to ST (start)

position, check whether there is voltage at the
terminal post "S" of solenoid switch.

Yes No

Or
In this case, check whether the voltage at 3BW
connector of solenoid switch on the starter relay is
normal
The pinion and gear The sliding resistance
ring are worn badly. of starter is too high.

Normal Abnormal
Repair or replace the Repair or replace the
starter, and replace starter
the gear ring.
There is an open circuit Check there is voltage at
between the starter switch 3BW connector of starter
and the solenoid switch, or switch on the starter relay
the connection between them
is faulty.

Repair

Yes No

The connection of starter There is an open circuit

switch is faulty. between the starter
switch and the battery, or
the connection between
them is faulty.

Replace the starter

switch
Repair

15
The starter switch is switched to ST (start) position, but
the solenoid switch doesn't work.

When the starter switch is switched to ST (start)

position, check whether there is voltage at the terminal
post "S" of solenoid switch.

Yes No

Check the grounding cable Check whether the instrument

indicator light is normal

Good Bad Normal Abnormal

Repair
Verify the circuit between the There is an open circuit
starter switch and the between the battery and
terminal post "S" of solenoid the starter switch, or the
Or connection is faulty.
switch.

The sliding The solenoid switch or

part of pinion coil has an open circuit
doesn’ t move. or is burned out. Repair

Check the starter The starter switch

relay connection is faulty.

Repair or replace the starter. Check the clutch Replace the starter
and starter switch switch

16
The pinion engages with the gear ring well, but
the engine doesn't run.

Check the grounded cable

Good Bad

Repair or replace the

grounding cable

A fault occurs between The solenoid starter The exciting coil has The armature coil The clutch of
the brush and rectifier. switch is burned out. an open circuit or is has an open circuit or pinion slips.
damaged. is damaged.

Repair or replace the starter

17
The starter switch is switched from ST to ON,
but the starter doesn't stop.

Disconnect the wiring of starter switch and verify the operation of starter switch

Connector No.

Terminal Post No.

The position of
starter switch Terminal Post No.
key

OFF
Locked

Accessory
ON
ON

Start

Besides the wiring mentioned above, other circuits should be opening.

Yes No

The solenoid switch contact is Replace the solenoid switch

melted and hard to move.
Otherwise, the return spring is
broken or damaged.

Replace the starter switch

18
4DA1 Series oil filter and oil cooler
with bypass-type filter

Battery
Indicator
light

Oil pressure switch

Vertical cylinder oil gallery

Regulator
Oil filter and cooler
valve
Idler gear
shaft Camshaft Vacuum
bearing pump
Bypass Full-flow Safety Oil
filter oil filter valve nozzle
Crankshaft Rocker
bearing shaft
Oil Safety Oil pipe
cooler valve
Rocker
Piston arm

Connecting
Oil pump Relief Timing rod bearing
valve gear

Oil
strainer

Oil pan

① Opening pressure of relief valve at oil filter: 430-470kPa

② Opening pressure of safety valve at oil filter: 960-100kPa

The lubrication system for 4DA1 Series engine is full-flow type.

The lubricant flows from the oil pump to the vertical cylinder oil gallery through oil cooler
and oil filter pump (the replaceable oil filter is equipped on the oil filter).And then, the
lubricant is delivered from the vertical cylinder oil gallery to the main parts of engine.

19
1.2 Data and specifications

1.2.1 Data and specifications

Engine model
4DA1 4DA1-1
Item
Turbocharged
Natural admission (NA)
Engine type Inter-cooling (TCI)
Four strokes, high mounted valve, water cooling
Combustion chamber type ω type direct injection
Dry type, thin-wall chrome-plated steel cylinder
Cylinder liner type
liner
Cylinder number - cylinder bore  stroke mm 4— 93×102
Number of piston ring 2 gas rings, 1 oil ring
Total piston displacement L 2.771
Compression ratio 18.2 17.5
Design compression pressure kPa 3040
Engine weight (net) kg 230 240
Fuel injection sequence 1— 3— 4— 2
16 to the top dead 12 to the top dead
Fuel injection timing 
center (before) center (before)
Above -5 Above -14 Above -29
Ambient temperature Above 4 ℃
Required fuel type ℃ ℃ ℃
Light diesel fuel type 0# -10 # -20 # -35 #
Idle speed r/min 750±50
Valve clearance Intake valve mm 0.30～0.40
(cold) Exhaust valve mm 0.30～0.40
Valve clearance Intake valve mm 0.30
(hot) Exhaust valve mm 0.30
Open (before top dead center)  24.5
Intake valve Close (after bottom top dead
55.5
center) 
Open (before bottom top dead
54
Exhaust valve center) 
Close (after top dead center)  26
Lubricant system
Lubrication method Pressure feed lubrication and spray lubrication
Required oil (class AP1) CF-4 15W-40
Oil pump type External gearing
Oil filter type Full-flow type, paper element, replaceable
Oil volume (including oil filter) L 6
Oil cooler type Water cooling

20
Engine model
4DA1 4DA1-1
Item
Fuel system
Injection pump type VE dispensing pump
Speed governor type Mechanical, all-speed
Injector type Small pressure cell, cellular type
Injector opening pressure MPa 19.0-20.0 18.6-19.6
Main fuel filter type Paper cartridge and water separator
Air filter type Dry-type paper filter element
Alternator output V-A 14-60
Starter motor output V-kW 12-2.8

1.2.2 Engine cooling

Coolant pump Centrifugal impeller
Pulley drive ratio 1.12
Thermostat type Wax-type thermostat, dual valves
Valve opening temperature ℃ 82
Valve full opening temperature ℃ 95
Coolant total volume L 10

1.2.3 Starting system

Type S14-204A
Rating
Voltage V 12
Output kW 2.8
Time s 30
Number of pinion 9
Rotation direction (view from the pinion end) Clockwise
Weight (approximate) kg 5.4
No load characteristics
Voltage/current V/A 11/160 or less
Revolution speed r/min 4100 or above
Load characteristics
Voltage/current V/A 11/350 or less
Torque N·m 8.5
Revolution speed r/min 1750 or above
Brake characteristics
Voltage/current V/A 3/1300 or less
Torque N·m 31

21
1.2.4 Charging system
Type JFB161
Rated voltage V 14
Rated output A 60
Regulation voltage V 14.4-15
Rated revolution speed r/min 5000
Rotation direction (view from the pulley end) Clockwise
Polarity Negative earth
Operate mode Continuous rating
Regulator type IC regulator
Pulley effective diameter mm 80
Weight (with pump) kg 6.1

1.3 Maintenance standards

1.3.1 Engine mechanical system

Standard dimension Ex-work
Wear
configuration
No. Designation Fitting way limit
4DA1 4DA1-1 Clearance
(mm)
(mm)
Contact width of valve and
retainer
1.
Intake valve 1.7 2.2
Exhaust valve 2 2.5
Valve sinkage
2. Intake valve 0.65 1.28
Exhaust valve 0.65 1.20
3. Valve retainer bore angle 15°，45°， 75°
4. Flank clearance 0.10-0.17 0.30
5. Axial runout clearance of idler A 0.07 0.20
0.010
Tappet outer diameter Φ13  0.028
6. Gapping 0.01~0.046 0.10
0.018
Tappet bore Φ13 0

7. Push rod radial runout 0.3

8. Rocker shaft deflection 0.3
0
Rocker shaft outer diameter Φ19 0.02
9. Gapping 0.01~0.05 0.20
0.03
Rocker bore Φ19  0.01

22
0.039
Intake valve stem diameter Φ8 0.054
10. Gapping 0.039~0.071 0.20
0.017
Valve guide bore Φ8 0

0.064
Exhaust valve stem diameter Φ8 0.079
11. Gapping 0.064~0.096 0.25
0.017
Valve guide bore Φ8 0
Free height of valve spring 48
12.
Squareness of valve spring Φ1.4
0.025
Idler A bearing outer diameter Φ45 0.055
13. Gapping 0.025~0.080 0.20
0.025
Idler A bearing inner diameter Φ45 0
Cylinder liner bore 0.060

14. Overtopping height of the Φ93  0.021

cylinder liner to the body 0~0.08
Axial runout clearance of 0.05~0.114 0.20
15. camshaft Gapping
Cam height of camshaft 42.02±0.05 0.38
0.025
Inner diameter of camshaft 0
Φ50
16. bearing bush Gapping 0.025~0.080 0.12
0.025
Camshaft journal diameter Φ50 0.055
Camshaft bearing bush
17. 0.02 0.10
deflection
0 0 0.002~0.015
Piston pin Φ31 0.005 Φ34 0.005
18. Gapping 0.03
0.010 0.010
Piston pin hole Φ31  0.002 Φ34  0.002
Connecting rod big end 0

thickness 33 0.04
19. Gapping 0.175~0.290 0.35
Crankshaft connecting rod 0.250

journal bore 33  0.175

Intake/exhaust valve cold
20. Gapping 0.3~0.4
clearance
0.068
Main shaft diameter Φ70 0.086
21. Main bearing halfshell (after Gapping 0.031~0.066 0.11
0.003
assembly) Φ70 0.033

0 0
Piston pin outer diameter Φ31 0.006 Φ34 0.006
22. Connecting rod bushing inner Gapping 0.008~0.026 0.05
0.020 0.020
diameter Φ31  0.008 Φ34  0.008

23
Crankshaft connecting rod 0.070

journal Φ53 0.085

23. Gapping 0.029~0.069 0.10
Connecting rod bearing 0.016

halfshell hole (after assembly) Φ53 0.041

Piston outer diameter
grouping
Group A 92.957~92.970
Group B 92.970~92.983
Group C 92.983~92.996 Grouping
24. 0.051~0.077
Cylinder liner grouping (after Gapping
pressing in)
Group A 93.021~93.034
Group B 93.034~93.047
Group C 93.047~93.060
Piston ring end gap 1.5
First gas ring 0.2~0.4 0.2~0.4
Second gas ring 0.2~0.4 0.6~0.85
Oil ring 0.1~0.3 0.35~0.65
25.
Piston ring end gap
First ring 0.09~0.125 0.078~0.139 0.15
Second ring 0.05~0.075 0.045~0.09 0.15
Oil ring 0.03~0.07 0.03~0.07 0.15
Vertical height of injector to
0.36 0.53
26. cylinder head lower 3.94  0.23 mm 2.41  0.31 mm
undersurface

1.3.2 General terms for diesel performance

Net power
The correction value for effective power outputted by the engine with all on-board parts
Total power
The correction value for effective power outputted by the engine with essential parts for operation
Rated power
The total output power given by the manufacturer at the specified rated speed according to the
specific engine application, as indicated on the nameplates of engine HFC4DA1 and 4DA1-1
Maximum power
The maximum total power outputted by the engine at full-load working condition, which is generally
greater than or equal to the rated power
Load
The ratio between the actual engine output power and the possible maximum power at the same
speed, which is expressed by percentage
Maximum no load governed speed
The speed which the engine reaches when the accelerator reaches its limit and the engine runs
under no load working condition
To avoid diesel overspeed, the speed indicates the maximum speed control given by the injection

24
pump governor. The maximum no load governed speed of HFC4DA1 and 4DA1-1 is 4000～4200
rpm.
Maximum rated speed
The maximum speed that the governor allows at full load.
The maximum rated speed of HFC4DA1 and 4DA1-1 is 3600 rpm.
Minimum rated speed
1. The allowable minimum speed at the following three maximum speed of engine: 45% of
maximum rated speed, 1000rpm and the speed provided by the idling governor, whichever is
greaterThe minimum rated speed of HFC4DA1 and 4DA1-1 is 1620 rpm.
2. The minimum speed specified by the manufacturer
Full load filter paper type smoke
Under full load (i.e. external characteristics) working condition, the blackening of filter paper in a
specific area (working diameter: 32 mm) by the smoke in a specified length of air column taken
from the engine exhaust pipe
To measure the speed range from the minimum to the maximum rated speed, arrange proper
testing points including full load working conditions at the maximum power speed and maximum
torque speed.
Free accelerating working condition
When the engine runs at idle speed, the condition that pedaling the accelerator pedal rapidly but
gently to make the injection pump provide maximum fuel
Keep this condition before the engine reaches the allowable maximum speed given by the
governor. Once it reaches the maximum speed, release the accelerator pedal to make engine
returns to idling.
Free accelerating filter paper type smoke
Under free accelerating working condition, the blackening of filter paper in a specific area (working
diameter: 32 mm) by the smoke in a specified length of air column taken from the engine exhaust
pipe
Speed characteristics
The characteristics of main performance index (torque, power, oil consumption, exhaust
temperature and smoke, etc.) changes depending on the speed when the engine fuel governing
mechanism keeps the same
External characteristic
The speed characteristic when the engine fuel governing mechanism is fully opened
It is also called full load speed characteristic.
Load characteristic
The characteristic of performance index changes depending on load when the engine keeps
running at the same speed

25
1.4 Maintenance work

Only qualified personnel should be allowed to

perform general maintenance work.

Type marking
Engine Serial Number
The engine serial number is stamped at the left
side of the rear end of cylinder block.

1.4.1 Air filter

Dry-type paper filter element
Depending on the type of filter element, the
method for cleaning a filter element is different.

Dust accumulated at the filter element

Turn the filter element by hand and blow the
compressed air into the filter element in order to
blow off the dust.
Pressure of compressed air (392-490 kPa)
Caution:
Protect the filter element from colliding by
other objects in cleaning. Otherwise, the filter
element may be damaged.

Carbon and dust accumulated at the filter

element
1. Prepare the cleaning liquid for air filter
(DonaldmnDl400) originally provided by JAC,
and dilute it with water.

2. Immerse the filter element in the cleaning

liquid for 20 minutes.

26
3. Take the filter element out of the cleaning
liquid and flush it with running water.
The water pressure should be less than 274 kPa.

4. Dry the filter element at a place with good

ventilation.
Use a fan for quick drying.

Note:
Never use the compressed air or open fire for
quick drying.
It may result in damage of filter element.
Generally, it will take two to three days to
completely dry a filter element. In this case, a
standby should be prepared for temporary
use.

1.4.2 Lubricant system

Main oil filter (paper filter element)
Replace procedure

1. Loosen the oil drain plug to drain out the oil.

2. Several minutes later, retighten the oil drain

plug.

3. Unscrew the used filter counter-clockwise

with a filter wrench.

4. Clean the fitting surface of oil cooler to

ensure suitable fitting with the new oil filter.

5. Apply a thin layer of oil to the O-ring.

6. Screw in the new oil filter until the filter O-ring

makes perfect contact with the sealing
surface.

7. Further screw in the filter by 1+1/4 turn with a

filter wrench.

Filter wrench: 1010300FA-9101

27
8. Check the oil level. If necessary, fill in some
oil until the oil level reaches the specified
level. The filling oil volume is approximate
0.7 L.

9. Start the engine and verify there is no oil leak

from the main oil filter.

1.4.3 Fuel system

Fuel filter
Replace procedure
1. Unscrew the used filter counter-clockwise
with a filter wrench.

2. Clean the fitting surface of the filter upper

cover to ensure suitable fitting with the new
fuel filter.

3. Screw in the fuel filter until it makes perfect

contact with the sealing surface.

4. Further screw in the filter by N 2/3 turn with a

filter wrench.

28
5. Loosen the bleeder plug on the overflow
valve of injection pump.
6. Operate the priming pump until the fuel flows
out of the fuel filter.
7. Retighten the bleeder plug.
8. Repeatedly operate the priming pump and
verify there is no fuel leak.
Note:
It is strongly recommended that you should
use a fuel filter provided by JAC or an original
one.

Procedure of water drain from the fuel filter

If water content in the water separator exceeds
the specified value, the indicator light will light up.
Discharge water and other impurities from the
water separator according to the following steps.
1. Park the vehicle at a safe place.
2. Open the engine hood and put a container
(approximate 0.2 L) at the end of ethylene
hose under the water drain plug of water
separator.
3. Unscrew the water drain plug
counter-clockwise (about five turns) and
operate the priming pump about ten times
until approximate 0.1 L water drains out.
4. Once the water drains is finished, screw in
the water drain plug clockwise and manually
operate the priming pump several times.
5. Verify there is no fuel leak from the water
drain plug after the engine starts.
Also, verify the indicator light of fuel filter is
off.
If frequent water drain from a water separator
is required, you may ask for a fuel tank for
water drain from a local JAC distributor.

29
Bleeding
1. Loosen the bleeding screw on the overflow
valve of injection pump.
2. Operate the priming pump until the fuel with
foam flows out of the bleeding screw.
3. Tighten the bleeding screw.
4. Repeatedly operate the priming pump and
verify there is no fuel leak.

1.4.4 Cooling system

Coolant level
Check the coolant level. If necessary, fill in the
radiator reservoir.
If the coolant level falls under “MIN”, carefully
check whether there is a leakage in the cooling
system. And then, fill in the coolant until it reaches
“MAX”.
Reservoir

Note:
Never make a reservoir overflow.
The radiator filler cap should be opened only if it
Long life coolant is very necessary.
Freezing point (C)

Coolant level check can only be performed when

the engine is cold.
For mixing ratio between the cooling water and
anti-freezer, please refer to the left figure.

Mixing ratio (%)

Cooling System Check

Place an American tester for radiator filler on the
radiator.
Apply test pressure on the cooling system and
check the leakage.
The test pressure shall not exceed the specified
pressure.
Test pressure: 196kPa

30
Radiator filler cap check
The radiator filler cap is designed to keep the
pressure at 105 kPa in the coiling system. Use
radiator filler cap tester to check the cap.If the
radiator filler cap doesn’ t keep at the specified
pressure in testing, it shall be replaced by a new
one.
The pressure of radiator filler cap

Pressure valve 88-118 kPa

Negative pressure valve (reference value) 1.0 -3.9 kPa

Thermostat test
1. Completely immerse the thermostat in the
water.
2. Heat up the water.
Continuously stir the water to avoid directly
heating the thermostat.
3. Check the initial opening temperature of
thermostat.
The initial opening temperature of thermostat:
82℃
4. Check the full opening temperature of
thermostat.
The full opening temperature of thermostat:
95℃
The valve lift at full opening: 8mm

31
1.4.5 Drive belt adjustment
Check whether the drive belt is worn or damaged.
If necessary, replace it with a new one. Check the
belt tension. If necessary, make proper
adjustment.
· Check the belt tension.
· Press the central section of belt by a force of
Air conditioning compressor
drive belt and power steering 100N and check deflection of each belt.
pump drive belt
· Standard deflection
mm
Alternator and fan pulley
drive belts
Air conditioning 8-10
compressor drive belt
Alternator and fan
pulley drive belts Power steering pump
drive belt

Alternator drive belt

· Mount the alternator drive belt and adjust the
belt tension.
· Mount fixing bolts and tighten them to the
specified torque.
Alternator
Fixing bolt torque 37.5
Adjusting plate fixing bolt torque 25

Air conditioning compressor pulley

drive belt and power steering pump
drive belt
· Move the oil pump to adjust the oil pump drive
belt tension
Tighten the bolt to the specified torque.
Adjuster locking bolt torque 37 N·m

32
1.4.6 Engine control
(governed speed, valve
clearance, injection timing,
compression pressure)
Idle speed check
1. Handle the parking brake and brake driving
wheels.
2. Place the transmission at neutral position.
3. Start the engine and warm it up.
4. Remove the engine control cable from the
control lever.
5. Mount the tachometer on the engine.
6. Check the engine idle speed.
If the engine idle speed exceeds the
specified range, you must make adjustment.
Engine idle speed:750±50 r／min

Adjust the idle speed

1. Loosen the locking nut (s) of idle adjusting
bolt (s) on the injection pump.
2. Use idle adjusting bolt to adjust idle speed to
the specified range.
3. Use the locking nut (s) to lock the idle
adjusting bolt (s).
4. Check the idle speed control cable is
tightened (no looses).
If necessary, eliminate any loose of the
cable.

Accelerator control cable adjustment

1. Loosen clamp bolts for the accelerator
cables.
2. Check whether the control knob is turned to
the idle speed position.
3. Place the accelerator lever at the fully closed
position, and then tighten the control cable in
the arrow direction to eliminate any loose.

33
Valve clearance adjustment

1. Turn the crankshaft until the to the crankshaft

damper reaches the top dead center. When
the line aligns the timing pointer, either the
first cylinder piston or the fourth cylinder
piston locates at the top dead center of
compression stroke.

2. Check whether there is any loose rocker

shaft seat nut.
Before adjust the valve clearance, tighten
any loose rocker shaft support nut.
Torque of rocker shaft support nut 55 N·m

3. Check the clearance at the intake valve push

rod and exhaust valve push rod in the first
cylinder.
If there is clearance at the intake valve push
rod and exhaust valve push rod in the first
cylinder, the piston in the first cylinder locates
at the top dead center of compression stroke.
If there is compression force applied on the
intake valve push rod or exhaust valve push
rod in the first cylinder, the piston in the
fourth cylinder locates at the top dead center
of compression stroke.

Adjust the valve clearance in the first or fourth

cylinder when corresponding cylinder piston
locates at the top dead center.

34
Valve clearance (cold) :
0.3-0.4 mm(optimum value: 0.35 mm)

4. Loosen each valve clearance adjusting

screw as shown in the figure.
5. Insert a proper clearance gauge between the
rocker arm and valve stem.
6. Turn the valve clearance adjusting screw
until you feel there is slight resistance on the
clearance gauge.
7. Screw down the locking nut.
8. Turn the crankshaft 360°.
9. Realign the timing marking at the crankshaft
damper pulley to the line of top dead center.
10. Adjust clearance for other valves as shown in
the figure.

35
Adjust injection timing

Step 1 Remove the front screw (at the rear end of

Dial indicator Gauge stand
injection pump) on the injection pump distribution
plunger.
Step 2 Mount special tools for injection advance angle
adjustment: dial indicator and gauge stand.
Step 3 Turn the engine crankshaft clockwise to a position
with approximate 45°to the top dead center of the first
Special tools
cylinder.
Step 4 Turn the engine crankshaft about 8°to left or right,
the pointer of dial indicator shall stand still.
Step 5 Turn the dial indicator to zero the pointer. The
position of dial indicator shall not be changed after zero
adjustment.
Step 6 Turn the crankshaft clockwise to the top dead
Use a tool to turn the
center. For assembly, to determine the top dead center,
crankshaft
use a lever indicator to measure the height difference
between top surface of piston in the first cylinder and
upper surface of body. For commissioning and
inspection, alignment timing marking (position marking of
crankshaft pulley top dead center and timing marking on
the gear case) is allowed to use.
Step 7 Unscrew two tight nuts to the injection pump
flange and the connecting bolt to the injection pump
support. Crankshaft position timing marking
marking
Step 8 Pull the injection pump inward or outward to make
the reading of dial indicator show X mm. Dial indicator
zeroing
Step 9 Screw down two tight nuts to the fuel pump flange
and the connecting bolt to the injection pump support.
Fuel pump running shall be avoided in screwing.
Step 10 Repeat Step 3 to verify zero adjustment.If the
zero adjustment is not proper, return to Step 5.
Step 11 Repeat Step 6 to verify the reading of dial
indicator. If the reading is not correct, return to Step 7.
Step 12 Remove the special tools: dial indicator and
gauge stand.
Step 13 Mount the front screw on the injection pump The crankshaft locates at the
top dead center.
distribution plunger. Injection advance angle adjustment
is over.
Type X Value（mm）

HFC4DA1 1.60

HFC4DA1-1 1.50

36
The essential torque is given below.
Tightening torque for the tight nuts to the injection pump flange: 25±5Nm;
Tightening torque for the connecting bolt to the injection pump support: 25±5Nm;
Tightening torque for the bolt to the distributive head of injection pump: 35±5Nm;
Tightening torque for the nut to the high pressure fuel pipe: 30±5 Nm
If the special tools like dial indicator and seat stand are not available, it is allowed to use “Overflow”
method to make injection advance angle adjustment.
Note:
A new cooper gasket must be used when you mount a plug at the top of distributor.

37
Compression pressure measurement
1. Start the engine and keep idling until the
coolant temperature reaches 70-80℃.

2. Remove the following parts:

★ All glow plugs (or injectors)(Measuring
at the injector hole or the glow plug hole
is optional depending on different gauge
outfits.)
★ Fuel cut solenoid connector
★ Fuse for Quick On Start System(QOS) on
a connector

3. Mount the joint and pressure gauge in the

glow plug hole in the first cylinder (or in the
injector hole).
Compression pressure gauge
(with joint): 1002100FA-9101
Joint: 1002100FA-9102

4. Use the starter motor to run the engine and

record the readings on the pressure gauge.
Compression pressure at 200 r/min
Nominal Limit
3040 2158

5. For other cylinders, repeat Step 3 and 4.

If the measured value is less then the limit
value, refers to the section “Diagnosis and
troubleshooting”in this manual.

38
1.5 Tightening torque

1.5.1 Torque for cylinder head, cylinder head cover and rocker
shaft support (N·m)

Step 1 Step 2 Step 3

39
40
1.5.2 Torque for crankshaft, bearing cap, connecting rod
bearing cap, crankshaft damper pulley, flywheel and oil pan
(N·m)

Step 1 Step 2 Step 3

Step 1 Step 2

Step 1 Step 2 Step 3

41
1.5.3 Torque for timing pulley chamber, timing pulley, timing
gear and camshaft race (N·m)

1.5.4 Engine fuel system (N·m)

42
1.5.5 Torque for cooling system and lubricant system (N·m)

43
1.5.6 Torque for intake manifold, exhaust manifold and exhaust
pipe (N·m)

44
1.5.7 Engine electrical system (N·m)

Cold district is
excluded.

45
1.5.8 Torque for engine mounting bracket (N·m)

Independent
suspension

Left-mounted
Right-mounted

46
1.6 Special tools

Illustration Tool No. Tool Name

1010300FA-9101 Oil filter wrench

1003016FA-9101 Valve oil seal erector

1003102FA-9101 Valve guide replacer

Compression pressure
1002100FA-9101
gauge

1002100FA-9102 Pressure gauge joint

1100300FA-9101 Measuring unit

1002420FA-9101 Front oil seal erector

1002430FA-9101 Rear oil seal erector

Valv spring
1003015FA-9101
compressor

1007017FA-9101 Camshaft gear puller

47
Camshaft bearing
1002107FA-9101
replacer

1002430FA-9102 Rear oil seal remover

1002106FA-9101 Cylinder liner erector

1002106FA-9102 Cylinder liner remover

Piston mounting taper

1004001FA-9102
sleeve

1007011FA-9101 Timing gear puller

Crankshaft timing gear

1007011FA-9102
erector

1002420FA-9101 Front oil seal erector

48
2. Engine mechanical system

2.1 Cylinder head

Disassembly sequence
1. Thermostat chamber assembly
2. Injector body
3. Glow plug and glow plug connector
4. Rocker shaft and rocker
5. Push rod
6. Cylinder head

Reassembly sequence
Reassemble all parts in reverse
sequence.

Note:
· In disassembly, you should collect all
parts of valve set and identify each
part so that they will return to their
original positions by assembling.
· Before you remove the cylinder head
from the engine and disassemble the
valve mechanism, you should carry
out a compression test and record
the test result.

49
Disassembly
1. Thermostat casing and water outlet
assembly
2. Injector body
1) Unscrew the injector body support nut.

2) Use an injector remover and a sliding

hammer to disassemble the injector and
its support together.

3. Glow plug and glow plug connection

board
4. Rocker shaft and rocker
5. Push rod
6. Cylinder head
· Unscrew the cylinder head bolts in
several times according to the sequence
number given in the figure. Unscrew a
bolt in at least two times.
Note:
If you don’t unscrew the cylinder head bolts in
several times according to the sequence
number, bad effect like warping may incur on
the undersurface of cylinder head.

50
Cleaning
· Cylinder head bolt
· Cylinder head
Carefully clean up any oil sludge, smoke and
carbon deposit until the natural color of metal is
exposed. Never use an electrical wire brush on
any gasket or sealing surface.

Inspection and repair

If excessive abrasion and damage is found during
checking, adjust, repair and replace parts in time.
· Check whether there is leakage, corrosion or
blow-by gas of cylinder head gasket and
contact surface. If a gasket fails, investigate
the causes:
- Improper assembling
- Loose or warping cylinder head
- Insufficient tightening torque for the
cylinder head bolt
- Warping cylinder block surface
1. Check whether the cylinder head bolt thread
is damaged or drawn out. Also, check
whether the cylinder head is damaged
caused by improper tool usage.

Caution
Any questionable bolt must be replaced by a
new one.
2. Check whether there is any crack on the
cylinder head, particularly the valve edge and
exhaust port.
3. Check whether there is any corrosion at the
cylinder head cover plate, any sand or loose
hole inside the cylinder head.

Caution
Never repair the key surface of cylinder head.
If it is broken, replace it with a new one.
4. There are strict requirements for flatness of
cylinder head undersurface and contact
surface of intake and exhaust manifolds.
Use grinding process to repair these
surfaces. If the surface ”flatness” exceeds
the specified value, you should grind the
surface until the flatness meets the
requirement. If the flatness exceeds the
specified value too much, the part shall be
replaced by a new one.

51
mm
Nominal Limit
Warpage of
cylinder head 0.05 or less 0.20
undersurface
Height of
92 91.55
cylinder head
5. Check the contact surface of water jacket
bowel-like plug.
6. Use a ruler or clearance gauge to measure
the warpage of contact surface between the
exhaust manifold and cylinder head.
If the measurement value is greater than the
nominal value but less than then limit value,
you should regrinding the contact surface
between the exhaust manifold and cylinder
head.
If the measurement value exceeds the
specified limit, the manifold has to be
replaced.

Warpage of exhaust manifold mm

Nominal Limit
0.05 or less 0.20

Reassembly
6. Cylinder head
1) Mount the valve seat
1. Carefully place the attachment ①
(its outer diameter is slightly less
than that of valve seat) on the valve
seat ②.
Note
Make sure that the surface contacting
with the valve seat is the smooth side of
attachment.
2. Use a table press ③ to gradually
press the attachment until the valve
seat seats in place.

52
Note
Never apply excess compressive force
on the valve seat when you use a table
press. Otherwise, the valve seat may be
damaged.
Measure upper height of valve guide from the
upper surface of cylinder head.
Upper height of valve guide (H) (reference value)
13 mm

Note
If a valve guide has been disassembled,
you should replace the valve and valve
guide in pairs.

2) Lower spring seat

3) Valve stem oil seal
· Mount a new oil seal to the valve.
· Use a special tool to guide.
Oil seal erector: 1003016FA-9101
4) Valve
· Apply oil to the part above the borehole
diameter of valve stem before you install a
valve.

5) Valve spring
· Mount the valve spring on the upper
spring seat.
Caution
· The section with painting on the
valve spring shall be placed
downwards.
· Supply compressed air from glow
plug hole to cylinder until the valve
seats in place.
· Install the valve cotter with special
tools.
Valve spring compressor: 1003015FA-9101

53
6) Valve cotter
· Use a spring compressor to press the
valve spring to the proper position.
· Mount the spring seat and valve cotter.
· Use a soft-faced hammer to tap the cotter
head until it seats in place.
Valve spring compressor: 1003015FA-9101

5. Push rod

4. Rocker shaft and rocker

· Tighten the rocker shaft fixing bolt.
55±5 N·m

3. Glow plug and glow plug connection

board
· Tighten the glow plug.
25±5 N·m

2. Injector body
1) Install the injector copper gasket ① and
O-ring ② onto the injector body ③.
Make sure tight contact between the
O-ring and injector groove.
2) Apply oil in the cylinder head hole where
the injector body seats.
3) Mount the injector body and injector
pressure plate together to the cylinder
head.
40±5 N·m
4) Tighten the injector body nut and gasket
⑤ to the specified torque.
40±5 N·m

54
2. Fuel injector
· Use a wrench or a special tool to tighten
the nut (s) on the fuel injector to the
specified torque as shown in the figure.
Caution
· When you mount the return pipe, injector
and injection pipe, use air to blow off dust.
Injector tightening torque 34±5N·m

1. Thermostat casing assembly

· Tighten the thermostat casing assembly
fixing bolt.
25 ±5 N·m

55
2.2 Valve spring, valve guide oil seal, valve guide and push rod

Disassembly sequence
1. Rocker assembly
2. Valve cotter
3. Valve spring
4. Valve
5. Valve guide oil seal
6. Valve guide

Reassemble sequence
Reassemble all parts in reverse
sequence.

Disassembly
1. Rocker assembly
2. Valve cotter
Use a special tool to compress the valve spring.
Valve spring compressor: 1003015FA-9101
3. Valve spring
4. Valve
5. Valve guide oil seal
6. Valve guide
Valve guide replacer: 1003102FA-9101

56
Inspection and repair
If excessive abrasion and damage is found during
checking, adjust, repair and replace parts in time.
Valve spring
Caution
Visually check the valve spring. If there is
damage or obvious abnormal abrasion, you
should replace it with a new one.

1. Free height
· Measure the free height of valve spring.If the
height is less than the specified limit value,
the spring shall be replaced.
Free height mm
Nominal Limit
48.0 47.10

2. Squareness
· Use a steel square to measure the
squareness of valve spring. The
measurement value shall be less than 1.2
mm.
· If measurement value exceeds prescribed
limit, the valve spring shall be replaced.
Limit 1.5 mm

3. Spring tension
· Use a spring tester to compress the spring to
the installation height. Measure the
compression spring tension.
If the measured tension is lower than the
prescribed limit, the spring shall be replaced.
Tension N
Installation
Nominal Limit
height
38.9mm 296 268

57
Valve guide
Caution
Carefully clean up the carbon deposit at the
valve head to protect the valve seat contact
surface from damaging.
Carefully check whether there is any damage
or abnormal abrasion on the valve stem.
If so, replace the valve and valve guide in
pairs.
1. Valve guide clearance
· Use a micrometer to measure the outer
diameter of valve stem.
If the out diameter of valve stem is lower than
the specified limit, replace the valve and
valve guide in pairs.
Mm
Nominal Limit
Valve Intake valve 7.946-7.961 7.880
stem Exhaust valve 7.921-7.936 7.850
diameter
· Use a micrometer to measure the inner
diameter of valve guide.
· Make a subtraction between the valve guide
inner diameter and the valve stem outer
diameter.
If the subtraction value is lower than the
specified limit, replace the valve and valve
guide in pairs.

Valve guide clearance mm

Nominal Limit
Inlet clearance 0.200 7.880
Exhaust 0.250 7.850
clearance

58
Valve guide replacement
1. Use a special tool to knock the valve guide
out from one side of combustion chamber.
Valve guide replacer: 1003102FA-9101

2. Apply oil to the outer surface of valve guide.

Use a special tool to mount a new valve
guide from one side of cylinder head upper
surface and check the valve guide height.
Valve guide replacer: 1003102FA-9101
Height 13 mm

Note
If a valve guide has been disassembled, you
should replace the valve and valve guide in
pairs.

Valve thickness
1. Measure the valve thickness.
2. If the meausred value is lower than the
specified limit, replace the valve and valve
guide in pairs.

Valve thickness mm
Nominal Limit
Intake valve 1.76 1.25
Exhaust value 1.5

59
Valve seat conical surface angle on the
valve
1. Measure the valve seat conical surface
angle.
2. If the measurement value exceeds the limit,
you should replace the valve, valve guide
and valve seat together.
Nominal: 45°

Valve sinkage
1. Mount the valve (1) to the cylinder head (2).
2. Use a depth gauge or a ruler and steel
square to measure the valve sinkage from
the bottom surface of cylinder head.
If the measurement value exceeds
prescribed limit, the valve seat shall be
replaced.

Valve sinkage mm
Nominal Limit
Intake valve 0.65 1.28
4DA1
Exhaust
Series 0.65 1.20
value

Valve contact width

1. Check the roughness and flatness of valve
contact surface. Make sure that the contact
surface is smooth.
2. Measure the valve contact width.
If the measurement value exceeds
prescribed limit, the valve seat shall be
replaced.

Contact width mm
Nominal Limit
Intake valve 1.7 2.2
Exhaust value 2 2.5

60
Valve seat replacement
Disassemble valve seat
1. Perform arc welding at the inside periphery
① of valve seat ②.
2. Cool down the valve seat for several
minutes.
The contraction will facilitate the disassembly
of valve seat.
3. Use a screwdriver ③ to pry off the valve
seat.
Carefully pry off it. Otherwise, the cylinder
head ④ may be damaged.
4. Carefully clean up carbon deposits and other
foreign matters on the valve seat installation
hole of cylinder head.

Assemble valve seat

1. Carefully place the attachment ① (its
borehole diameter is slightly less than that of
valve seat) on the valve seat ②.
Note
Make the smooth side of attachment
contact with the valve seat.
2. Use a table press ③ to gradually press the
attachment until the valve seat seats in
place.
Note
Never apply excess compressive force
on the valve seat when you use a table
press. Otherwise, the valve seat may be
damaged.

Valve seat correction

1. Clean up the carbon deposit on valve seat
surface.
2. Use a milling cutter (blade angle of 15°, 45
°and 75°) to minimize abrasion and rough
areas of valve seat so that the contact width
reaches the nominal value.
You should only eliminate abrasion and
rough areas. Don’ t cut off too much.
Carefully avoid cutting off good areas on
valve seat surface.

61
Valve seat angle: 45°

Note
You may use an adjustable milling cutter
guide lever. It is not allowed to stir the
milling cutter guide lever in the valve
guide hole.

3. Apply grinding paste on valve seat surface.

4. Insert the valve into the valve guide.

5. Turn the valve for perfect fitting with the valve

seat while tapping it from top or bottom.
6. Check the valve contact width is proper.
7. Check whether the valve seat surface has
completely contacted with the whole valve
periphery.

Bending of push rod

1. Put the push rod on a platform.
2. Roll the push rod along the platform and use
a feeler gauge to measure bending of push
rod. If the measurement value exceeds
prescribed limit, the push rod shall be
replaced.
Push rod bending limit:
0.4 mm or less
3. Visually check whether there is any excess
abrasion or damage at both ends of push
rod.
If so, replace the push rod.

Reassembly
6. Valve guide
· Apply oil to the outer surface of valve guide.
Use a special tool to mount a new valve
guide from one side of camshaft.

62
Valve guide replacer: 1003102FA-9101

5. Valve guide oil seal

· Press in a new oil seal with a special tool.
Oil seal erector: 1003016FA-9101

4. Valve
· Apply oil to the outer surface of valve stem.

3. Valve spring
· Mount the valve spring on the upper spring
seat. The section with painting on the valve
spring shall be placed downwards (i.e. the
spring with less pitch placed downwards).

2. Valve cotter
· Use a spring compressor to press the valve
spring to a proper position.
· Mount the spring seat and valve cotter.
· Use a soft-faced hammer to slightly tap the
cotter head until it seats in place.
Valve spring compressor: 1003015FA-9101

1. Rocker assembly
Installation torque:55±5 N·m

63
2.3 Camshaft and tappet

Assembly sequence
1. Cylinder head assembly
2. Flywheel
3. Cylinder block liftback
4. Oil pan assembly
5. Oil pump assembly
6. Camshaft timing gear
6a. Camshaft timing pulley
7. Camshaft thrust plate
7a. Camshaft pulley central flange
8. Camshaft
9. Tappet

Reassembly sequence
Reassemble all parts in reverse
sequence.

Disassembly
1. Cylinder head assembly
2. Flywheel
3. Flywheel baffle
4. Oil pan assembly
5. Oil pump assembly
6. Camshaft timing gear
· Remove camshaft timing gear bolt(s)
from the camshaft.
Note
Fasten the camshaft to avoid turning.
· Pull out camshaft timing gear ② with a
universal puller ① .Universal puller:
1007017FA-9101
· Remove the thrust washer ③.

64
7. Camshaft thrust washer
8. Camshaft
9. Tappet

Inspection and repair

If excessive abrasion and damage is found during
checking, adjust, repair and replace parts in time.

1. Measure the camshaft thrust

clearance
· Measure the camshaft axial clearance with a
dial gauge.
This shall be done before disassembling the
camshaft gear.
If the camshaft axial clearance exceeds
prescribed limit, the thrust washer shall be
replaced.
Camshaft axial clearance mm
Nominal Limit
0.005-0.114 0.2

2. Camshaft journal outer diameter

· Use a micrometer to measure the outer
diameter of each camshaft journal in
direction ① and ② . If the measurement
value exceeds prescribed limit, the camshaft
shall be replaced.
Journal outer diameter mm
Nominal Limit
49.945—49.975 49.60

3. Cam height
· Use a micrometer to measure the cam height
a. If the measurement value is lower than the
prescribed value, the cam shall be replaced.
Cam height mm
Nominal Limit
42.02±0.05 41.65

65
4. Camshaft radial runout
· Put the camshaft on a V block.
· Measure the radial runout with a dial gauge.
If the measurement value exceeds prescribed
limit, the camshaft shall be replaced.
Radial runout mm
Nominal Limit
0.04 or less 0.10

5. Camshaft and camshaft bearing

clearance
· Measure the camshaft bearing inner
diameter with a dial gauge.
Camshaft bearing inner diameter mm
Nominal Limit
50.00—50.03 50.08

Camshaft bearing clearance mm

Nominal Limit
0.025—0.080 0.12

If the camshaft bearing inner diameter or the

journal clearance exceeds the prescribed values,
the camshaft bearing shall be replaced.

Camshaft bearing replacement

Camshaft bearing disassembly
1. Remove cylinder block stopper.
2. Disassemble the camshaft bearing
with a camshaft bearing replacer.
Camshaft bearing replacer:
1002107FA-9101

66
Camshaft bearing assembly
1. Align the oil hole on the bearing to the oil
hole on the cylinder block.
2. Mount the camshaft bearing with a camshaft
bearing replacer.
Camshaft bearing replacer: 1002107FA-9101

Tappet
Visually check whether there is any point
corrosion, crack and other abnormities on contact
surface between the camshaft and tappet. If so,
replace the tappet.
See left figure.
① Normal contact
② Crack
③ point corrosion
④ Abnormal contact
⑤ Abnormal contact
Note
The tappet has spherical surface.Never use an
oilstone or similar tools to grind the spherical
surface when you repair the tappet.If the
tappet is damaged, you must replace it with a
new one.

Tappet outer diameter

1. Measure the tappet outer diameter with a dial
gauge. If the measurement value exceeds
prescribed limit, the tappet shall be replaced.

Tappet outer diameter mm

Nominal Limit
12.72—12.90 12.70

67
2. Measure the upper tappet installation hole
inner diameter on the cylinder block and
calculate the clearance.
If the clearance exceeds the limit value,
replace the tappet and/or cylinder block.

Clearance between the tappet and tappet hole

mm
Nominal Limit
0.010-0.046 0.10

Reassembly
9. Tappet
1) Apply oil to the tappet ① and in the upper
tappet installation hole on the cylinder block.
2) Determine the tappet position according to
the identification made in disassembling (if
the tappet is newly used).
Note
The tappet shall be installed before
assembling the camshaft.

8. Camshaft
1) Apply oil to the camshaft and camshaft
bearing.
2) Install the camshaft to the cylinder block.
Be careful not to damage the camshaft bearing.

7. Camshaft thrust washer

Mount the thrust washer to the cylinder block and
tighten the thrust washer bolt (s) to specified
torque.
Thrust washer bolt torque : 25±5 N·m

68
6. Camshaft timing gear
1) Install camshaft timing gear to the camshaft.
The timing gear mark (“Y-Y”) shall face
outwards.
2) Tighten the timing gear bolt to the specified
torque.
Timing gear bolt torque 110±10 N·m

5. Oil pump assembly

· Apply some oil on the oil pipe O-ring and
mount it to the cylinder block O-ring groove.
· Install the oil pump assembly and oil outlet
pump to the cylinder block. Tighten the fixing
bolt(s) to specified torque.
25±5 N·m
· Tighten sleeve nut(s) to the following
specified torque:
30±5 N·m

4. Oil pan assembly

As shown in the figure, apply recommended silica
gel (Loctite 598) or equivalent in alignment on the
arc area of the fifth bearing cap, groove, the arc
area of timing gear casing and oil pan gasket.

· Mount the rear lip of seal washer into the

groove of the fifth bearing cap.
· Make sure the lip perfectly contacts with the
groove.
· Install the oil pan to the cylinder block.
· Tighten oil pan bolt(s) to the specified torque.

Oil pan bolt torque 23.5±3.5 N·m

69
3. Flywheel baffle
· Tighten the flywheel baffle fixing bolts to the
specified torque.
Flywheel baffle bolt torque 85±10N·m

2. Flywheel
· Apply some oil to fixing bolts.
· Screw down the flywheel bolts to the
specified torque in two steps by torque
tightening method.
Tighten them as the sequence number shown in
the figure.
Flywheel bolt torque N·m
Step 1 Step 2 Step 3
25 70 120±10

1. Cylinder head assembly

1) Assemble the valve seat
1. Carefully place the attachment ①(its outer
diameter is less than that of valve seat) on
the valve seat ②.
Note
Make the smooth side of attachment contact with
the valve seat.
2. Use a table press ③ to gradually press the
attachment until the valve seat seats in
place.

Note
Never apply excess compressive force on the
valve seat when you use a table press. Otherwise,
the valve seat may be damaged.
Measure the upper height of valve guide from the
upper surface of cylinder head.
Upper height of valve guide (H) (reference value):
13 mm

70
Note
If a valve guide has been disassembled,
you should replace the valve and valve
guide in pairs.
2) Lower spring seat
3) Valve stem oil seal
· Mount a new oil seal to the valve.
· Use a special tool to guide.
Oil seal erector: 1003016FA-9101
4) Valve

5) Valve spring
· Mount the valve spring on the upper spring
seat.
Caution
· The section with painting on the valve spring
shall be placed downwards.
· Supply compressed air from glow plug hole
to cylinder until the valve seats in place.
· Install the valve cotter with a special tool.
Valve spring compressor: 1003015FA-9101

6) Valve cotter
· Use a spring compressor to press the spring
in place.
· Mount the spring seat and valve cotter.
· Use a soft-faced hammer to tap the cotter
head until it seats in place.
Valve spring compressor: 1003015FA-9101

71
2.4. Rocker arm assembly

Disassembling sequence:
1.Rocker shaft assembly
2.Rocker shaft elastic retainer
3. Rocker arm
4. Rocker shaft support
5. Rocker arm
6. Rocker shaft spring
7. Rocker shaft
Reassembling sequence:
Reassemble all parts in reverse
sequence.

Disassembly
1. Rocker shaft assembly
2. Elastic retainer of rocker shaft
3. Rocker arm
4. Rocker shaft retainer
5. Rocker arm
6. Rocker shaft spring
7. Rocker shaft

Inspection and repair

If excessive abrasion and damage is found
during checking, adjust, repair and replace
parts in time.
Measure the outer diameter of rocker shaft at
its swinging position with a dial gauge.
Replace the rocker shaft if the diameter
exceeds prescribed limit.
mm.
Nominal Limit
18.98— 19.00 18.9

72
Oil film clearance
1. Measure the inner diameter of rocker shaft
hole with a vernier caliper or dial gauge.
Inner diameter of rocker shaft hole mm
Nominal Limit
19.010— 19.030 19.100
2. Measure the outer diameter of rocker shaft.If
the measured value exceeds prescribed limit,
replace rocker arm or rocker shaft.
Clearance between rocker arm and rocker
shaft mm
Nominal Limit
0.01— 0.05 0.10

3. Check the upper oil hole of rocker arm is

blocked.
Blow clean the oil hole of rocker shaft with
compressed air if necessary.

Rocker arm correction

Check there is abrasion or scratch with the
upper valve stem contact surface.
If there is slight abrasion or scratch of step
shape with the contact surface, polish it with
oil.
The rocker arm has to be replaced if this
abrasion or scratch is serious.

73
Radial runout of rocker shaft
1. Put the rocker shaft on a V block.
2. Measure the radial runout at middle part of
rocker shaft with a dial gauge.
If the radial runout is slight, correct this
runout with a table press.
If the radial runout of rocker shaft exceeds
prescribed limit, the rocker shaft has to be
replaced.
Radial runout of rocker shaft mm

Limit
0.2

Reassembly
7. Rocker shaft
 Apply a thin layer of oil to the rocker
shaft.
 The rocker shaft should be placed in
such a way that the bigger hole (ø4)
faces the engine forepart.
 Install the rocker shaft, rocker shaft
retainer and spring together.
6. Rocker shaft spring
5. Rocker arm
4. Rocker shaft retainer
3. Rocker arm
2. Elastic retainer of rocker shaft
1. Rocker shaft assembly
 Install the rocker shaft assembly on the
cylinder head.
 Tighten the flywheel baffle fixing bolts to
the specified torque.

74
2.5 Oil pump

Assembling sequence:
1. Flywheel
2. Rear plate of cylinder block
3. Oil pan assembly
4. Oil pump assembly
5. Oil pipe
6. Strainer
7. Pump cover
8. Driven gear and bush
9. Drive gear
10. Driven shaft
11. Pinion pin
12. Pinion
13. Drive shaft
14. Oil pump body
Reassembling sequence:
Reassemble all parts in reverse
sequence.

Disassembly
1． Flywheel
2. Flywheel baffle
3． Oil pan assembly

75
4． Oil pump assembly
5. Oil pipe
6. Strainer
7. Pump cover
8. Driven gear and bush
9. Drive gear
10. Driven shaft
11. Pinion pin
 File flat the tip of pinion stop pin.
 Knock out the pinion pin with a hammer
and bar.
 Remove the pinion.
12. Pinion
13. Drive shaft
14. Oil pump body

Inspection and repair

If excessive abrasion and damage is found during
checking, adjust, repair and replace parts in time.
Housing and gear
The oil pump assembly must be replaced if one of
the following conditions is found:
 The driven gear sleeve is worn or
damaged seriously.
 The upper gear teeth is worn or
damaged seriously.

Clearance between upper gear teeth and

inner housing wall
 Measure the clearance between upper gear
teeth and inner housing wall with a clearance
gauge.
 If the clearance between upper gear teeth
and inner housing wall exceeds prescribed
limit, either the gear or housing has to be
replaced.
Clearance between upper gear teeth and inner
housing wall
mm
Nominal Limit
0.14 0.20

76
Clearance between gear and cover
 Measure the clearance between gear
and cover with a clearance gauge.
 If the clearance between gear and cover
exceeds prescribed limit, the housing
must be replaced.
Clearance between gear and cover mm
Nominal Limit
0.06 0.15

Clearance between drive shaft and oil

pump body
 Use a micrometer to measure the
borehole diameter of drive shaft.
 Measure the inner diameter of pump
body with a dial gauge.
 If the Clearance between drive shaft and
oil pump body exceeds prescribed limit,
the oil pump assembly has to be
replaced.
Clearance between drive shaft and oil pump
body mm
Nominal Limit
0．04 0．20

Clearance between driven shaft and

bush
 Use a micrometer to measure the outer
diameter of driven shaft.
 Measure the inner diameter of bush with
a dial gauge.
 If the clearance between driven shaft
and bush exceeds prescribed limit, the
bush must be replaced.
Clearance between driven shaft and bush mm
Nominal Limit
0.05 0.15

Reassembly
14. Oil pump body
13. Drive shaft
12. Pinion

77
11. Pinion pin
 Install new drive shaft on the pump body.
 Install the pinion on the drive shaft.
 Drill a hole withφ5mm (0.20in) bore bit
for the pinion and drive shaft to pass
through.
 Insert the pinion pin into the hole.
Rivet the pin.
10. Driven shaft
9. Drive gear
8. Driven gear and bush

7. Pump cover
6. Strainer assembly
 Mount the strainer assembly and screw
down its fixing bolts.
20±5 N·m

5. Oil pipe
4． Oil pump assembly
 Apply oil containing molybdenum to the
oil pump driven gear and camshaft drive
gear.
 Tighten the oil pump fixing bolts to the
specified torque.
20±5 N·m

3． Oil pan assembly

 Apply recommended liquid sealant or
equivalents to the fifth bearing cap arch
section, groove and timing gear
chamber arch section shown in the
diagram.

78
 Mount the rear lip of seal washer into the
groove of the fifth bearing cap.
 Make sure that the lip is perfectly in
contact with the groove.
 Install the oil pan on the cylinder block.
 Tighten oil pan bolt(s) to the specified
torque.
Oil pan bolt torque: 23.5±3.5 N·m

2. Flywheel baffle
 Align the flywheel baffle with the anchor
pin of cylinder block, and tighten
flywheel baffle bolt(s) to the specified
torque: 85±10 N·m

1． Flywheel
 Apply some oil to fixing bolt.
 Screw down the flywheel bolts to the
specified torque in two steps by torque
tightening method.
Flywheel bolt torque N·m

Step Ⅰ Step Ⅱ Step Ⅲ

25 70 120±10

79
2.6. Crankshaft

Assembling sequence:
1. Cylinder head assembly and
gasket
2. Oil pan
3. Timing gear
3a. Timing belt and pulley
4. Front oil seal
5. Timing pulley chamber
6. Oil pump assembly
7. Piston cooling oil pipe
8. Piston and connecting rod
9. Flywheel
10. Rear plate of cylinder block
11. Rear oil seal of crankshaft
12. Main bearing cap
13. Crankshaft

Reassembling sequence:
Reassemble all parts in reverse
sequence.

Disassembly
1. Cylinder head assembly and gasket
2. Oil pan assembly
3. Timing gear
4. Timing gear chamber
5. Oil pump assembly
6. Piston cooling oil pipe

80
7. Piston and connecting rod
8. Flywheel
9. Flywheel baffle
10. Rear oil seal
 Push in the oil seal, install the special
tools according to the sequence shown in
the diagram to facilitate removing the oil
seal.
Rear oil seal remover: 1002430FA-9102
Note: Take care not to damage the flywheel
baffle and crankshaft sealing surface
during oil seal removal.
11. Main bearing cap
12. Crankshaft

Inspection and repair

If excessive abrasion or damage is found
during checking, adjust, repair and replace
parts in time.

1. Crankshaft
Thrust clearance
Install dial gauge according to the sequence
shown in the diagram and measure the thrust
clearance of crankshaft.
If the thrust clearance exceeds prescribed
limit, the thrust bearing shall be replaced in
pair.
Thrust clearance mm
Nominal Limit
0.040-0.201 0.30

2. Main bearing clearance

1) Remove the main bearing cap according to
the sequence shown in the diagram.
Place the removed main bearing cap
according to the sequence number of
cylinder.
2) Remove crankshaft. Dismantle main bearing.
3) Clean the upper and lower bearings and
main journal of crankshaft.
4) Check the bearing is damaged or
excessively worn.
If excessive abrasion or damage is found
during checking, the bearing has to be
replaced in pair.

81
5) Install the upper bearing and thrust washer
on their original positions. Carefully install the
crankshaft.
6) Mount the lower bearing to the bearing cap in
its original position.
7) Install plastic cord clearance gauge on the
main journal of crankshaft.
8) Install main bearing cap. Apply oil to the
threads and mating surfaces of bolts. Tighten
the bolt to the specified torque.
170±10 N·m

Note:
The crankshaft is not allowed to rotate.
9) Remove main bearing cap.
10) Measure the width of plastic cord clearance
gauge and determine the oil film clearance.
If the oil film clearance exceeds prescribed
limit, the main bearing and (or) crankshaft
has to be replaced in pair.
11) Remove the plastic cord clearance gauge off
bearing and crankshaft.
Dismantle crankshaft and bearing.
Oil film clearance mm(in)
Nominal Limit
0．031— 0．066 0．11

3. Radial runout
1) Carefully put the crankshaft on a V block.
Slowly rotate the crankshaft and measure the
radial runout.If the radial runout of crankshaft
exceeds prescribed limit, the crankshaft has
to be replaced.
Radial runout mm

Nominal Limit
0.05 or less 0．08

82
Measure the diameter of main journal and
crankpin and the uneven abrasion.
If the abrasion of crankshaft exceeds prescribed
limit, the crankshaft has to be replaced.
mm
Nominal Limit
Main journal
69.91— 69.932 69.910
diameter
Crankpin
52.91— 52.930 52.900
diameter
Uneven
0.05 or less 0.08
abrasion limit

Crankshaft inspection
Check the main journal of crankshaft and
crankpin surface are damaged or excessively
worn.
Check there is excessive abrasion or
damage on the mating surface of oil seal.
Check the oil hole is blocked.

The tested part has to be kept in Inspection on soft nitrogen treatment of

balance to prevent testing fluid
flowing.
No testing fluid is crankshaft
necessary around
the oil hole. 1. Thoroughly clean the crankshaft with a
Sliding surface of
crankpin or main
kind of organics. There must be no oil
journal stains on the tested surface.
About 10mm 2. Prepare some solution containing 5％
— 10 ％ ammonium cupric chloride
(dissolved in distilled water).
3. Apply the solution on the tested surface
with an injector.
Keep the tested surface in full level state
to prevent solution flowing.
Note:
The solution is not allowed to wash the oil
hole and area around.
Test
1. Wait for 30— 40 seconds.
If the color does not change after 30— 40
seconds, the crankshaft can be used.
If the color changes (the tested surface
becomes copper color), the crankshaft has to
be replaced.

83
2. Clean the crankshaft surface with steam
immediately after test is completed.
Note:
There is high corrosiveness with
ammonium cupric chloride solution.
Therefore, it is absolutely necessary to
clean the crankshaft surface immediately
after test is completed.
Crankshaft bearing selection
When assembling new crankshaft bearing or
replacing old bearing, see the selection table
below.
When selecting and installing new crankshaft
bearing, pay attention to the diameter size
mark of the upper journal hole and crankshaft
main journal 2.

Note:
Although there are oil grooves and holes
(cylinder block side) with all the upper
bearings of main journal and there are not oil
grooves and holes (bearing cap side) with all
the lower bearings, still pay attention to
identify them during assembly.

84
Main bearing hole diameter Crankshaft main journal
Main bearing Oil film
(mm) diameter (mm)
size mark clearance
Size mark Bore diameter Size mark Outer diameter
0.010
1 ＞69.926-69.932 Black（Φ2  0.006 ） 0.036-0.062
1 73.988-74.000
2 ＞69.920-69.926 0.014 0.034-0.060
Blue（Φ2  0.010 ）
3 69.914-69.920 0.040-0.066
1 ＞69.926-69.932 0.006 0.031-0.057
Green（Φ2  0.002 ）
2 ＞69.920-69.926 0.037-0.063
2 73.975-73.987
0.010
3 69.914-69.920 Black（Φ2  0.006 ） 0.035-0.061

Reassembly
13. Crankshaft
 Install the main bearing on the cylinder
block and main bearing cap.
 Make sure that their positions are
correct.
 Apply fresh oil to the upper and lower
main bearing surfaces.
 Carefully install the crankshaft.
 Apply oil to the thrust washer.
 Install the thrust washer on the third
main journal. Its oil groove must face the
crankshaft.

85
12. Main bearing cap
 Apply recommended liquid sealant or
other equivalents to the fifth crankshaft
bearing cap ① as shown in the drawing.
 Install arc gasket ② on the fifth bearing
cap. Put the arc gasket into the bearing
cap groove with fingers.

 Apply recommended liquid sealant or

other equivalents to the fifth crankshaft
bearing cap ③ as shown in the drawing.

 Apply recommended liquid sealant or

other equivalents to points ③ and ④ of
the fifth crankshaft bearing cap cylinder
block mating surface as shown in the
drawing.
Note:
Ensure that there in no oil stain on the
mating surface of bearing cap before
coating liquid sealant.
Make sure the liquid sealant do not block
cylinder thread hole and bearing.

 Install the bearing cap, and make sure

the arrow mark on its top points at
engine forepart.
 Apply oil to crankshaft bearing cap bolts.
 Tighten the crankshaft bearing cap bolts
step by step in several times according
to the sequence shown in the drawing
until specified torque is reached.
Nm
Step Ⅰ Step Ⅱ Step Ⅲ (final
(sealing (sealing torque)
torque) torque)
20 110 170

86
Note:
Manually rotate the crankshaft to check
whether it is flexible.

11. Rear oil seal of crankshaft

Install the oil seal on the cylinder block with
an oil seal erector.
Rear oil seal erector: 1002430FA-9101
Notes:
Clean the rust and chips off the press-in
portion of the oil seal.
Pay attention to the press-in direction of
the oil seal.
1) Connect the adaptors of special tools to
the rear end of the crankshaft with two
bolts.
2) Install the oil seal to the periphery of the
adaptors.
3) Insert the socket into the adaptor and
screw down the bolt (M12XL75L=70) until
the adaptor tip is in contact with the
socket.
4) Remove the adaptor and socket.
5) Check the oil seal installation depth and
flatness after it is installed.
Depth standard: 12.5±0.3mm
10. Flywheel baffle
Align the baffle with the upper anchor pin of
cylinder block.
Tighten the flywheel baffle bolts to the
specified torque: 85±10N·m
9. Flywheel
1) Thoroughly clean out the oil stains on the
crankshaft thread(s).
2) Install the flywheel on the crankshaft, and
then mount the washer(s).
3) Apply oil to flywheel bolt thread(s).
4) Align the flywheel with the anchor pin of
crankshaft.
5) Screw down the flywheel bolts to the
specified torque in two steps by torque
tightening method. Tightening sequence
is shown in the diagram.
Flywheel bolt torque N·m
Step Ⅰ Step Ⅱ Step Ⅲ (final
(sealing (sealing torque)
torque) torque)
25 70 120±10

87
8. Piston and connecting rod assembly
 Apply oil to cylinder hole, connecting rod
bearing, crankpin, piston ring and piston.
Check the position of piston ring
opening is correct.

 Encase piston/connecting rod assembly

into each cylinder with a piston ring
compressor.
The front mark must face the engine
forepart.
 The number on cap should be in pair
with the one on connecting rod. Align the
printing mark on connecting rod with the
one on cap.
 Apply oil to the threads and mating
surfaces of nuts.
 Screw down the connecting rod cap nuts
in two steps by torque tightening method
according to the following descriptions.
N·m
First step Second step
(pretightening) (tightening)
20 85±5
Check the crankshaft rotates freely after the
connecting rod nuts are tightened.

7. Piston cooling oil pipe

 Tighten bolt(s) and injection nozzle
plug(pressure limiting valve) to the
specified torque.
Bolt: 20±5 N·m
Injection nozzle plug
(pressure limiting valve): 30±5 N·m

88
6. Oil pump assembly
1) Prepare some solution containing 80％
oil and 20％ supramoly.
2) Apply a thin layer of the above solution
to the teeth of oil pump pinion.
3) Install the oil pump and tighten bolt(s) to
the specified torque.
25±5 N·m

Note:
Take care not to damage O-ring when
screwing down oil pipe bolt(s).
4) Tighten sleeve nut(s) to the specified
torque:
30±5 N·m

5. Timing pulley chamber

1) Install timing pulley chamber on the
cylinder block.

2) Use bolt(s) to tighten both timing pulley

chamber and timing pulley chamber
gasket(s) to the specified torque.
25±5 N·m

3) Cut off the gasket tip on the mating

surface (as shown in the diagram).

4. Front oil seal of crankshaft

Install the front oil seal of crankshaft on the
gear chamber cover assembly with a front oil
Front oil seal seal erector as shown in the diagram.
of crankshaft Front oil seal erector: 1002420FA-9101
Note:
Take care not the twist the front oil seal.

89
3． Timing gear
11) Crankshaft gear
① Install crankshaft gear
② Install crankshaft gear ② with crankshaft
gear erector ①.Crankshaft gear timing
mark (“K-X”) must face the outside.

10) Camshaft timing gear

① Install camshaft timing gear to the
camshaft with timing gear mark (“Y-Y”)
toward outside.
② Tighten camshaft timing gear bolt(s) to
the specified torque:
110±10 N·m

9) Idler gear
① Apply some oil to the idler gear and its
shaft.
The oil hole in idler gear shaft must face
upward.
② Idler gear setting marks “X” and “Y”
should face the engine forepart during
assembly.

③ Align idler gear setting mark “X” with

setting mark “X-X”of crankshaft timing
gear ①.
④ Align idler gear setting mark “Y” with
setting mark “Y-Y” of camshaft timing
gear ②.
⑤ Install thrust ring and bolt(s) on the
cylinder block.
Thrust ring oil hole must be toward
upward, while its chamfer shall face the
outside.
⑥ Tighten idler gear bolt(s) to the specified
torque.
25±5 N·m

90
8) Idler gear “B”and its shaft
① Apply some oil to the idler gear and its
shaft.
② Align idler gear setting marks “B”③ “Z”
with “A”④ “Z-Z”.
③ Tighten idler gear bolt(s) to the specified
torque.
110±10 N·m

7) Injection pump
① Install O-ring ① on injection pump
flange ②.
② Install the injection pump to the timing
gear chamber.
Align idler marks “B”③ “V-V”.

③ Temporarily tighten six injection pump

nuts ⑤.
The final screwing down of injection
pump nuts is conducted after the rear
support bolt(s) of injection pump is
tightened.

④ Install rear support ⑥ and rear support

bolt⑦ of injection pump on the cylinder
block.
⑤ Mount rear support bolt ⑧ to the
injection pump support ⑨.
Finally tighten rear support bolts ⑦ and
⑧ to the specified torque.
25±5 N·m

91
6) Timing gear injection pipe
① Install the oil pipe to the timing gear
chamber and idler gear “A”.
② Tighten oil pipe punching bolt ① and
bolt ② to the specified torque.
20±5 N·m

5) Timing gear chamber cover

① Align the timing gear chamber with
timing gear chamber anchor pin, then
install timing gear chamber cover.
⑥ Tighten gear chamber cover bolt to the
specified torque.
25±5 N·m

4) Crankshaft damper pulley

Screw down the crankshaft damper
pulley bolt(s) to the specified torque.
Note:
While screwing down the damper
pulley bolt(s), fix the flywheel gear to
prevent crankshaft rotating.
210±15 N·m

3) Cooling fan assembly

 Install the fan pulley and cooling fan
assembly to the water pump in turn and
tighten the bolt to the specified torque.
12.5±2.5N·m
2) Drive belts of the alternator and
power steering pump
 Mount drive belts of the alternator and
power steering pump and adjust the belt
tension.
 Press the belt center with 100N force.
Drive belt deflection 8～10 mm

92
1) Fan guard
 Install the fan guard and coolant storage
tank hose.
 Fill in coolant.

2． Oil pan assembly

 Apply recommended liquid sealant or
equivalents to the fifth bearing cap arch
section, groove and timing gear
chamber arch section shown in the
diagram.

 Mount the rear lip of seal washer into the

groove of the fifth bearing cap.
 Make sure the lip perfectly contacts with
the groove.
 Install the oil pan to the cylinder block.
 Tighten oil pan bolt(s) to the specified
torque.
Oil pan bolt torque: 23.5±3.5 N·m

1. Cylinder head

Cylinder head assembly

① Mount the anchor pin to the cylinder
block.
② Install cylinder head gasket with top
mark toward upside.
③ Clean the lower cylinder head surface
and upper cylinder block surface.
④ Mount the cylinder head carefully.
⑤ Apply oil to the threads and mating
surfaces of cylinder head bolts.
⑥ Tighten the cylinder head bolts to the
specified torque in three steps according
to the sequence shown in the diagram.

93
Cylinder head bolt torque N·m
Step Ⅰ Step Ⅱ Step Ⅲ
65 85 105±5

Push rod
 Apply oil to the push rod and insert it into
the cylinder head.

Rocker shaft assembly

① Loosen all adjusting screws.
② Install the rocker shaft so that the bigger
oil hole (Φ4) faces engine forepart.

③ Tighten the rocker shaft support bolt(s)

to the specified torque according to the
sequence shown in the diagram.
Rocker shaft support bolt torque
55±5 N·m

 Adjust the valve clearance.

94
2.7. Piston and connecting rod

Disassembly sequence
1. Cylinder head assembly
2. Oil pan assembly
3. Oil pump assembly
4. Piston cooling oil pipe
5. Connecting rod bearing cup
6. Piston and connecting rod
7. Piston ring
8. Piston ring retainer
9. Piston pin
10. Piston
11. Connecting rod
Reassembly sequence
Reassemble all parts in reverse sequence.

Disassembly
1. Cylinder head assembly
2. Oil pan assembly
3. Oil pump assembly
4. Piston cooling oil pipe
5. Connecting rod cap
6. Piston and connecting rod
 Scrape carbon deposits on upper
cylinder wall with a scraper before
disassembling the piston and connecting
rod.

95
7. Piston ring
 Remove the piston ring with a piston ring
expander.
 Place the removed piston ring as the
sequence number in the drawing.

8. Piston ring retainer

 Dismantle piston pin retainer with pliers.

9. Piston pin
Note:
Place parts removed from each cylinder.All
the parts have to be reassembled to the
original positions.
10. Piston

11. Connecting rod

Inspection and repair

Piston and piston ring
Piston
Carefully clean up carbon deposits on the
piston top and piston ring groove.
Notes:
Never use metal brush for cleaning the
piston.Otherwise it will damage the
piston.Visually inspect if there are any
cracks, scratches or other signs of
excessive abrasion on each piston.
If so, replace the piston.
Piston outer diameter
1. Measure the outer diameter of the piston
at the position of each piston group.
Position of each piston group:
Distance to the piston top is 73.9 mm

96
Outer diameter groups of 4DA1 series pistons
Mark G mm
Diameter mark Outer diameter
A 92.957～92.970
B 92.970～92.983
C 92.983～92.996

Front mark 4 DA1 series cylinder liner bore diameters

mm
Diameter mark Outer diameter
A 93．021～93．034
B 93．034～93．047
C 93．047～93．060

Measure the cylinder bore diameter (refer to

“Inspection of the cylinder block” in this
section). If the piston clearance does not
comply with the specified values, replace the
piston and/or cylinder liner.
Piston clearance mm
4DA1 Series 0.051～0.077

Piston ring
If during engine overhaul it is found that any part is
worn-out or damaged, you should replace it.
1. Piston ring opening measurement
 Install the piston ring into the cylinder liner.

97
 Push the piston ring with the piston into the
most narrow part of the cylinder liner bore in
such a way that it is vertical to the cylinder
wall.
4DA1 series piston ring opening gap mm
Piston ring 4DA1 4DA1-1 Limits
First gas ring 0.2～0.4 0.2～0.4 1.5
Second gas
Top mark (first ting) 0.2～0.4 0.6～0.85 1.5
(Second ring) ring
Oil ring 0.1～0.3 0.35～0.65 1.5

2. Measure the clearance between the piston

ring groove and piston ring with a clearance
gauge. If the clearance exceeds the specified
limits, you should replace the piston
4DA1 series piston ring end gap mm
Piston ring 4DA1 4DA1-1 Limits
First gas ring 0.09～0.125 0.078～0.139 0.15
Second gas 0.05～0.075 0.045～0.09
0.15
ring
Oil ring 0.03～0.07 0.03～0.07 0.15

Piston pin
Visually inspect if there are any cracks,
scratches or other signs of abrasion on the
piston pin and replace the piston pin if
necessary.
1. Measure the piston pin outer diameter with
a micrometer at three positions in two
directions.If the measurement values
exceed the specified limits, the piston pin
has to be replaced.
Piston pin outer diameter mm

Nominal Limits
4DA1 30.994～31.000 30.970
4DA1-1 33.994～34.000 33.970

98
2. Measure the inner diameter of the
connecting rod small end.If the clearance
between the connecting rod small end and
pin does not comply with the specified
values, you have to change the connecting
rod or bushing and pin.
mm
Nominal Limits
0.008～0.026 0.05

3. Insert the piston pin into the piston and

rotate it.If the pin rotates freely and is
compact with the piston, it means the
clearance is permissible.If there is any
clearance or the surface between them is
rough, measure the clearance.If the
clearance exceeds the specified values,
you have to replace the piston and piston
pin.
mm
Nominal Limits
4DA1 系列 0.002～0.016 0.04

Replacing the bushing

Disassembly: use suitable compression bar
and table press or hammer.
Assembly: use suitable compression bar and
table press
Notes:
The bushing should be aligned with the oil
hole on the connecting rod.
Grind the bushing bore with a pin hole
grinder before mounting new bushing.

99
Connecting rod
1. Check the centerline deviations of two
connecting rod holes with a connecting rod
aligner.
If the amount of inclination or twist exceeds the
specified limits, you have to replace the
connecting rod.
mm
Nominal Limits
Amount of inclination
0.08 or less 0.20
(Per l00m)
Twist
0.05 or less 0.15
(Per l00m)
2. Measure the axial clearance of the connecting
rod
Measure the connecting rod thrust clearance at
its big end with a clearance gauge.
If the clearance exceeds the specified limits,
you have to replace the connecting rod.
Axial clearance mm
Nominal Limit
0.175～0.290 0.350
3. Measure the oil film clearance between the
connecting rod and crankshaft:
1) Remove the connecting rod cap nut and the
cap.
Place the removed connecting rod
according to the cylinder sequence number
2) Clean the connecting rod bearings and
crankpin.
3) Inspect the connecting rod bearings
carefully.
Even if there is only one damaged or
severely worn-out bearing, all the bearings
have to be replaced.Reassemble the
bearings to their original positions.Place a
plastigage on the crankpin.
4) Reinstall the connecting rod cap to its
original position.
5) Screw down the connecting rod cap nut to
the specified torque in two steps via torque
tightening method according to the following
instructions.
N·m
First step Second step
(pretightening) (tightening)
4DA1 20 85
Series

Note:
Never rotate the crankshaft.

100
6) Remove the connecting rod cap
7) Measure the plastigage width and determine
the oil film clearance. If the oil film clearance
exceeds the prescribed limit, the connecting
rod bearings shall be replaced in pair.
8) Remove the plastigage from the bearings
and crankpin.
Clearance between the crankshaft main
journal and bearing mm
Nominal Limit
4DA1 Series 0.029— 0.066 0.100

Reassembly
11. Connecting rod
10. Piston
9. Piston pin
Apply oil to the piston pin and piston pin hole.
8. Piston ring retainer
Apply a thin layer of oil to the piston pin.
Manually press the piston pin into piston pin
hole.
Weigh each piston and connecting rod
assembly.
Select the piston and connecting rod
assembly in such a way that the assembly
weight difference varies within the specified
limits.
Weight variation 4DA1 Less than 10g
after combined 4DA1-1
Less than 8g
as an assembly

Note:
When replacing the piston/connecting rod
assembly, do not change the piston/piston
pin assembly.

101
 Mount the piston onto the connecting rod
in such a way that the piston front mark
Front mark and connecting rod mark should face the
same direction.

JAC mark

7. Piston ring
 Install the piston ring with a piston ring
expander.
The TOP mark should face upward
during gas ring erection.
 The position of the identification sign is
shown in the drawing.
TOP mark (first ting)
(Second ring)

 Mount the piston ring in following

sequence.
① Oil ring
 Oil ring with a spiral cup ring
② Second gas ring
③ First gas ring
 The TOP mark should face upward
during gas ring erection.

 First gas ring: TOP.

No 1 gas ring  Second gas ring: TOP.
 Apply some oil to all piston rings after
installing the rings.
No 2 gas ring Check whether all piston rings can
rotates freely.
 Install the bearings onto the connecting
Oil ring rod and its cap.
Apply fresh oil to the bearing surfaces.

102
6. Piston and connecting rod
 Apply oil to the cylinder hole, connecting
rod bearings and crankpin.
 Check whether the piston ring opening
position is correct.
 Install the piston/connecting rod
assembly into each cylinder with a piston
ring compressor.
 The front mark must be towards the
engine forepart.

5. Connecting rod bearing cap

 Screw down the connecting rod cap nut
in two steps via torque tightening method
according to the following instructions.
N·m
First step Second step
(pretightening) (tightening)
4DA1 Series 20 85

Check if the crankshaft rotates freely

after tightening the cap nut.

4. Piston cooling oil pipe

 Mount the piston cooling oil pipe to the
cylinder block.
 Screw down the oil pipe bolt and relief
valve to the specified torque.
Oil pipe bolt torque N·m
(1)M8×1.25 25

N·m
(2)M6×1.00 7.5
Oil-pressure adjusting valve torque N·m
(3)M16×1.5 30

Note:
Turn the crankshaft slowly; make sure the
piston and the oil injection pipe don’
t interfere
with each other.

103
3． Oil pump assembly
 Apply some oil on the oil pipe O-ring and
mount it to the cylinder block O-ring
groove.
 Install the oil pump assembly and oil
pump to the cylinder block and tighten
the fixing bolt(s) to the specified torque:25±5 N·m

Tighten sleeve nut(s) to the following

specified torque:30±5 N·m

2． Oil pan assembly

 Apply recommended liquid sealant or
equivalents to the fifth bearing cap arch
section, groove and timing gear chamber
arch section shown in the diagram.
 Mount the rear lip of seal washer into the
groove of the fifth bearing cap.

 Make sure that the lip is perfectly in

contact with the groove.
 Install the oil pan to the cylinder block.
 Tighten oil pan bolt(s) to the specified
torque
Oil pan bolt torque: 23.5±3.5 N·m

104
1. Cylinder head assembly
① Mount the anchor pin to the cylinder
block.
② Install cylinder head gasket with its top
mark toward upside.
③ Clean the lower cylinder head surface
and upper cylinder block surface.
④ Mount the cylinder head carefully.
⑤ Apply oil to the threads and mating
surfaces of cylinder head bolts.
⑥ Tighten the cylinder head bolts to the
specified torque in three steps according
to the sequence shown in the diagram.
Cylinder head bolt torque N·m
Step Ⅰ Step Ⅱ Step Ⅲ
65 85 105±5

Push rod
 Apply oil to the push rod and insert it into
the cylinder head.

Rocker shaft assembly

① Loosen all adjusting screws.
② Install the rocker shaft so that the bigger
oil hole (Φ4) faces engine forepart.

③ Tighten the rocker shaft support bolt(s) to

the specified torque according to the
sequence shown in the diagram.
Rocker shaft support bolt torque 55±5 N·m

 Adjust the valve clearance

105
2.8 Cylinder block

Disassembly sequence
1. Cylinder head assembly and gasket
2. Oil pan
3. Timing gear
4. Front oil seal
5. Timing pulley chamber
6. Oil pump assembly
7. Piston cooling oil pipe
8. Piston and connecting rod
9. Flywheel
10. Rear plate of cylinder block
11. Rear oil seal of crankshaft
12. Main bearing cap
13. Crankshaft
14. Tappet
15. Camshaft
16. Cylinder block

Reassembly sequence
Reassemble as the opposite order of
disassembly.

Disassembly
1. Cylinder head assembly and gasket

106
2. Oil pan assembly
3. Timing gear
4. Front oil seal
5. Timing pulley chamber
6. Oil pump assembly
7. Piston cooling oil pipe
8. Piston and connecting rod
9. Flywheel
10. Flywheel baffle
11. Rear oil seal of crankshaft
12. Main bearing cap
13. Crankshaft
14. Tappet
15. Camshaft
16. Cylinder block

Inspection and repair

If excessive abrasion and damage is found during
checking, adjust, repair and replace parts in time.

1. Remove the gasket(s) and any other attached

matters on the surface of cylinder block.
Be careful to prevent matters falling into the
cylinder block by accident.

Take care not to scratch the cylinder block.

2. Carefully remove the oil pump, rear oil seal

retainer and the seal on the oil pan assembly
surface.

3. Wipe the cylinder block clean.

Inspection of cylinder liner protrusion size

1. Put ruler ① at the top edge of cylinder liner

to be measured.
2. Measure the protrusion size of each cylinder
liner with clearance gauge ②.

The difference between any two adjacent

cylinders in cylinder liner protrusion height shall
not exceed 0.05mm.
Standard value mm
0～0.08

107
Flatness
1. Remove the dowel from cylinder block.
2. Install cylinder liner detacher on the cylinder
liner.
3. Check the base on the detacher shaft covers
the bottom edge of cylinder liner firmly.
4. Slowly rotate the detacher shaft hand wheel
anticlockwise to pull out the cylinder liner.

Detacher base of cylinder liner:

1002106FA-9102 (4DA1 Series)

Note: be careful not to damage the

upper surface of cylinder during
disassembling the cylinder liner.

5. Measure four edges and two diagonals of

cylinder block upper surface with ruler ①and
clearance gauge ②.
If measurement value exceeds the limit, the cylinder
block has to be replaced.

Measurement of cylinder liner bore

diameter
Measure the bore diameter of cylinder liner along
thrust direction ②-② and the axial direction ③
of crankshaft with inside dial indicator in the depth
of 20mm,90mm,160mm, and take the average
value of 6 sizes as group size.
If measurement value exceeds prescribed limit,
the cylinder liner has to be replaced.
Notes:
The inner surface of dry cylinder liner is
chromalized, so it is not allowed to reface or
perform honing.
If there are nicks or burns with the inner surface
of cylinder liner, the cylinder liner has to be
replaced.

108
Group selection of cylinder liner
Measure the inner diameter of cylinder block and
choose appropriate cylinder liner group.
Standard over-fitting mm
0.001～0.019

Too little over-fitting of cylinder liner will have

adverse effect on cooling efficiency of engine.
If the over-fitting of cylinder liner is too large, it will
be difficult for the cylinder liner to encase gas.
Note:
There are two ways to select cylinder
liner.
Method I
The surface of the cylinder block has been
marked during manufacturing to indicate the
correct size of cylinder liner.Cylinder liner groups
(1, 2, 3, 4, etc.) are written with permanent ink.
When there is doubt with cylinder liner marks,
select the cylinder liner properly with the method
below.

Method Ⅱ
Measurement of cylinder block bore diameter
1) Measure the diameter at measuring point (A)
Ⅰ -○
○ Ⅱ -○
Ⅰ 、○ Ⅲ -○
Ⅱ 、○ Ⅲ。

The measuring point is the position 20mm,

90mm, 160mm away from the cylinder block
surface.

109
2) Calculate the average value of 6 measured
sizes to determine appropriate cylinder liner
group.
3) Refer to the table below according to the
average value, and apply proper cylinder liner.

4DA1 Series mm

Cylinder Average value of

Outer diameter of
liner cylinder bore
cylinder liner
groups diameter

0 94.991～95.000 95.001～95.010

1 95.001～95.010 95.011～95.020

2 95.011～95.020 95.021～95.030

3 95.021～95.030 95.031～95.040

4 95.031～95.040 95.041～95.050

Cylinder liner installation

1. Install the cylinder liner with special tools.
1) Thoroughly clean the cylinder liner and hole
surface with new kerosene or diesel oil.
2) Dry the surface of cylinder liner hole with
compressed air.Cylinder liner erector
1002106FA-9101
Note:
Be sure to carefully remove all the
foreign matters from the cylinder liner
and cylinder hole before installation.

110
3) Insert cylinder liner ① into cylinder block ②
from the top of cylinder block.

4) Install cylinder liner erector ③ at the top of

cylinder liner.
The position of cylinder block shall ensure
that the erector center is directly under
desk-top pressing machine shaft ④.
Erector 1002106FA-9101
Note:
Check the cylinder liner is in vertical with desk-top
pressing machine and without swinging.

5) Apply detent force 500kg (4900N) to the

cylinder liner with desk-top pressing machine.
6) Apply 2500ka (1102.5lb/24500N) force to put
the cylinder liner in place completely.
7) After the cylinder liner is installed, measure
the protrusion size.
See “Inspection of cylinder liner protrusion
size”in this chapter.
Measure the inner diameter of cylinder liner
hole and choose appropriate piston group.

Reassembly
16. Cylinder block
15. Camshaft
· Coat oil on tappet and in the installation hole
of upper cylinder block tappet.
· Fix position according to the position mark
made during removal (if the tappet is reused).

111
· Coat oil on the camshaft and camshaft
bearing.
· Install the camshaft on the cylinder block.
Be careful not to damage the camshaft
bearing.

14. Tappet
13. Crankshaft
· Install the main bearing on the cylinder block
and main bearing cap.
· Ensure that their position is correct.
· Apply fresh oil to the upper and lower main
bearing surfaces.
· Carefully install the crankshaft.

· Apply oil to the thrust plate.

· Install the thrust plate at the third main journal
bearing.Its oil groove must face the
crankshaft.

12. Main bearing cap

· Apply recommended liquid sealant or other
equivalents to the fifth crankshaft bearing cap
① as shown in the drawing.
· Install arc gasket ② on the fifth bearing cap.
Put the arc gasket into the bearing cap groove
with fingers.
Note:
Ensure that there in no oil stain on the mating
surface of bearing cap before coating liquid
sealant.Make sure the liquid sealant do not
block cylinder thread hole and bearing.

112
· Apply recommended liquid sealant or other
equivalents to the fifth crankshaft bearing cap
③ as shown in the drawing

· Install the bearing cap, and make sure the

arrow mark on its top points at engine
forepart.
· Apply oil to crankshaft bearing cap bolts.

· Tighten the crankshaft bearing cap bolts step

by step in several times as the sequence
shown in the drawing until specified torque is
reached:
170±10 Nm

Note:
Manually rotate the crankshaft to check it is
flexible.

11. Rear oil seal of crankshaft

· Install the oil seal on the cylinder block with
an oil seal erector.
Rear oil seal erector: 1002430FA-9101
Notes:
Clean the rust and chips off the press-in
portion of the oil seal.
Pay attention to the press-in direction of the
oil seal.
1) Use two bolts to connect the adaptors of
special tools to the rear end of the
crankshaft.
2) Install the oil seal to the periphery of the
adaptors.

113
3) Insert the socket into the adaptor and screw
down the bolt until the adaptor tip is in contact
with the socket.
4) Remove the adaptor and socket.
5) Check the oil seal size after it is installed.
Standard value mm
12.5±0.3
10. Flywheel baffle
· Tighten the flywheel baffle fixing the bolt(s) to
the specified torque:
85±10N·m
9．Flywheel
· Apply oil to the fixing bolts.
· Screw down the flywheel bolts to the specified
torque in two steps via torque tightening
method.
Tighten them as the sequence number shown
in the drawing.

8．Piston and connecting rod

1) Press the piston pin into piston pin hole with
fingers.
Weigh each piston and connecting rod
assembly.Select the piston and connecting
rod assembly in such a way that the assembly
weight difference varies within the specified
limits.
Weight 4DA1 4DA1-1
variation
after
Less than
combined Less than 8g
10g
as an
assembly

2) Clamp the connecting rod by a vice.Be careful

not to damage the connecting rod.
3) Encase the piston pin retainer into piston with
pliers.

Note:
When changing the piston/connecting rod
assembly, do not change the piston/piston pin
assembly.

114
4) Install the piston onto the connecting
rod.Mark ① on the piston head and casting
symbol “F908”② on the connecting rod
should be toward the same direction.

5) Apply oil to the piston pin and piston pin hole.

Forcibly push the piston pin into piston with
fingers until it is in contact with piston pin
retainer.

6) Forcibly press the piston pin retainer into

piston retainer groove with fingers.
Check whether the connecting rod swings
freely on the piston pin.

7) Install the piston ring with piston ring

expansion lip.
The TOP mark on gas ring should be toward
upwards.
Identification sign is shown in the drawing.
N mark (top ring)
(the second ring)

115
8) Mount three piston rings with a piston ring
replacer.
Gas ring NO.1
Piston ring replacer:
Install the piston ring as the sequence
number shown in the drawing.
Gas ring NO.2 ① Oil ring
② The second gas ring
③ The first gas ring
Oil ring

Notes:
Make sure that the surface with marks is
toward the upward when gas ring is installed.
Encase the spiral cup ring into the oil ring, and make
sure that there is no clearance at any side of the
Cup ring
NO.2 gas ring
spiral cup ring before the oil ring is installed.

9) Apply some oil to the piston ring surface.

10) Check whether the piston ring turns freely in
Mark

NO.1 gas
the piston ring groove.
Oil ring ring 11) Place the piston ring opening as shown in the
drawing.
12) Carefully remove the oil stains or other foreign
matters from the back of connecting rod
bearing or the installation surface of
connecting rod bearing.
13) Apply some oil to the upper bearing surface.
Apply some oil to the cylinder wall.

116
14) Place the piston in such a way that the front
mark on the bearing cap must be toward the
engine forepart.
Encase the piston into engine block with
piston installation taper sleeve.
Piston installation taper sleeve:
1004001FA-9102
15) Push in the piston with a hammer handle until
the connecting rod touches the crankpin.
In addition, rotate the crankshaft until the
crankpin is at bottom dead center.
16) Place the bearing cap in such a way that its
front mark is toward the engine forepart.
17) Install connecting rod bearing cap.
Align the cylinder sequence mark on
connecting rod bearing cap with the one on
connecting rod.
18) Apply oil to the thread and mating surface of
each connecting rod bearing cap bolt.
19) Screw down the connecting rod bearing cap
bolt to the specified torque in two steps via
Front mark torque tightening method.
Torque of connecting rod bearing cap bolt N·m

First step Second step

(pre-tightening) (tightening)

4DA1
20 85
Series

Note:
Manually rotate the crankshaft to check
whether it is flexible.

7. Piston cooling oil pipe

6. Oil pump assembly
5. Timing pulley chamber
4. Front oil seal
3.Timing gear
2. Oil pan assembly
1. Cylinder head assembly and gasket

See “Crankshaft”in 2.6 for the reassembly of

“7 - 1”.

117
3.4 DA1 Series Engine

3.1 General

4DA1 Series
ωtype combustion chamber is adopted in 4DA1 Series engine, and this kind of design provides
outstanding economical efficiency of fuel within wide running range.
The cylinder head gasket is piled up with sheet steel.
Tighten the fixing bolts of such parts as cylinder head, connecting rod and flywheel with torque tightening
method.
Dry cylinder liner made of chromized steel has high durability.
The piston with automatic heat compensation is supported with cast steel, which is used to reduce the
noise resulted from heat expansion and cold engine.
The crankshaft by soft nitrogen treatment has long life.Because of its soft nitrogen treatment, the
crankshaft can not be refaced.
Both the crankshaft main bearing and connecting rod bearing are made of aluminum alloy.This kind of
bearing is particularly easy to be damaged when encountering foreign matters such as metal chips.
Therefore, it is very important to keep the oil hole and other associated surfaces clean and remove
foreign matters.
The crankshaft’s soft nitrogen treatment (nitrogen treatment) improves its intensity, and saves the step of
refacing crankpin and main journal.
4DA1-1 engine is equipped with fuel injection device for cooling piston in the fuel line, and the fuel is
injected toward piston from the fuel line of cylinder block via non-turn valve.
Be careful not to damage the oil nozzle when disassembling and assembling piston and connecting rod.
4DA1 Series is direct injection engine, and the fuel injector had five holes, which enables inlet air and
fuel injection to gain optimum mixing ration.

118
3.2 Right support of engine

Locking bolt

Disassembling sequence:
Alternator fixing bolt 1. Fan cowl
2. Fan belt
3. Support rubber

Independent suspension Assembling sequence

Dependent suspension As assembling, go on according to the
reverse sequence of disassembly.

Disassembly
Preparation:
· Remove the ground cables of battery.
1. Fan guard
· Remove the storage tank hose and fan
guard.
2. Fan belt
· Remove locking bolts of adjusting plate.
· Loosen the alternator fixing bolt and then
remove the fan pulley drive belt.

3. Support rubber
·Remove the two fixing nuts at the beam side.

119
· Remove the generator from the engine.
· Remove the support rubber nut from engine foot rest side.
· Lift the engine to remove the support rubber.

Assembly

3. Support rubber

· Lift the engine to install the support rubber.

· Tighten the fixing nut(s) to the specified torque.

Engine foot rest side N·m

Beam side N·m

Drive belt of air 40

compressor
Drive belt of 2．Fan pulley drive belt
power steering
oil pump
·Install the fan pulley drive belt.

·Press the middle part of fan pulley drive belt with 100N force to let

the belt go down for 8-10mm.

·Tighten the fixing nut(s) to the specified torque.

Generator fixing bolt N·m

37.5

1．Fan guard

·Install the fan guard and tighten the storage tank hose.

120
3.3 Left support of engine

Disassembling sequence:
1. Air-intake duct
2. Fan cowl
3. Support rubber

Assembling sequence
Independent suspension As assembling, go on according to
Dependent suspension the reverse sequence of
disassembly.

Disassembly

Preparation:
· Remove the ground cables of battery.
1. Air-intake duct
· Remove the air-intake duct.
2. Fan guard
· Remove the storage tank hose and fan guard.

3. Support rubber
· Remove the two fixing bolts at beam side.

121
· Remove the support from engine foot rest side.

· Remove the support rubber nut from engine foot rest side.

· Lift the engine to remove the support rubber.

Assembly
3. Support rubber

· Lift the engine to install the support rubber.

· Tighten the fixing nut(s) to the specified torque.

Engine foot rest side N·m

82

Beam side N·m

40

2．Fan guard

· Install the fan guard and tighten the storage tank hose.

1．Air-intake duct

· Install the air-intake duct.

· Connect the ground cables of battery.

122
3.4 Air-intake manifold

Disassembling sequence:
1.Vacuum hose
2. Air-intake duct
3. Crankcase vent hose
4. High pressure oil pipe
5. Oil scale guide
6. Air-intake manifold
Assembling sequence
As assembling, go on according to the
reverse sequence of disassembly.

Disassembly
Preparation:
· Remove the ground cables of battery.
· Discharge coolant completely.

1. Vacuum hose
2. Air-intake duct
3. Crankcase vent hose
4. High pressure oil pipe
· Unscrew high pressure oil pipe clip.
· Loosen the taper nut(s) at injection pump side.
· Loosen the taper nut(s) at injector side, remove the pipe and
put it aside.
5. Oil scale guide
· Remove the fixing bolt(s) and disassembly the oil scale guide.

123
6. Air-intake manifold

· Remove the fixing bolt(s) and nut(s) of manifold.

Assembly
6. Air-intake manifold

· Tighten the fixing bolt(s) and nut(s) to the specified torque.

Bolt and nut N·m

20

5. Oil scale guide

·Install the guide and tighten it together with the manifold.

4. High pressure oil pipe

· Connect the high pressure oil pipe and tighten the taper nut(s)
to the specified torque.

Taper nut torque N·m

30

· Install the clip of high pressure oil pipe at the original position.

3. Crankcase vent hose

2. Air-intake duct

1. Vacuum hose

· Connect the ground cables of battery.

· Add some coolant.

· Start the engine and check whether the coolant leaks.

124
3.5 Exhaust manifold

Disassembling sequence:
1. Front exhaust pipe nut
2. Front exhaust branch pipe bolt
3. Heat insulating plate
4. Exhaust branch pipe

Assembling sequence
As assembling, go on according to the
reverse sequence of disassembly.

Disassembly
Preparation:

· Remove the ground cables of battery.

1. Front exhaust pipe nut

· Remove the fixing nut(s) at exhaust manifold side.

2. Front exhaust pipe support bolt.

125
3. Heat insulating plate

4. Exhaust manifold
· Remove the bolt(s) and nut(s) of manifold, and then
dismount the manifold and gasket(s).

Assembly

4. Exhaust manifold
· Tighten the fixing bolt(s) and nut(s) to the specified
torque.

Manifold bolt torque N.m

30

3. Heat insulating plate

· Install the heat insulating plate and tighten the bolt(s) to
the specified torque.

Heat insulating plate bolt torque N.m

25

2. Front exhaust pipe support bolt

· Tighten the fixing bolt(s) to the specified torque.

Support bolt torque N.m

40

1. Front exhaust pipe nut

· Tighten the fixing nut(s) to the specified torque.

N.m

40

· Connect the ground cables of battery.

· Start the engine and check whether the coolant leaks.

126
3.6 Oil cooler

Disassembling sequence:
Type I
1. Water hose
2. Oil cooler fixing bolt
3. Oil cooler
Type II
1.Water hose
2. Oil filter element
3. Oil cooler fixing bolt
4. Oil cooler
Assembling sequence
As assembling, go on according to the
4D A1 Series reverse sequence of disassembly.

Disassembly
Preparation:

·Remove the ground cables of battery.

·Discharge the coolant completely.

·Place the wiping cloth at oil cooler 9 to prevent oil immersion.

1. Water hose

·Remove water inlet and outlet hoses.

2. Oil filter element

3. Fixing nut of oil cooler

4. Oil cooler
Inspection
Relief valve
1. Install an oil pressure gauge at the position where the oil line is
near oil filter.
2. Start the engine and check the opening pressure of the relief
valve.

Opening pressure of relief valve kg/cm 2

4.7

127
3. Oil cooler

Inspection of water passage leakage

1. Block one end of the oil cooler water passage.

2. Immerse the oil cooler into the water.

3. Add compressed air at the other end of the oil cooler water

passage.

(2kg/cm2(28.5pai/19.60kpa))，bubbles rising on the surface

indicates that there is leakage with the water passage.

Assembly
3. Oil cooler

· Install O ring onto the oil filter and place the oil cooler.

2. Fixing nut of oil cooler

Tighten the fixing nut(s) of oil cooler to the specified torque.
Oil cooler nut torque N.m

30

1. Water hose

· Connect the water hose.

· Connect the ground cables of battery.

· Start the engine and check whether the oil leaks.

128
Oil filter element

Disassembly
· Place a container under the oil filter to receive oil.

· Remove the oil filter element with a filter wrench.

· Filter wrench: 1010300FA-9101

Assembly
· Coat a thin layer of oil on the oil filer O ring.
· Screw new oil filter element into the filter until the sealing
surface in jointed with O ring.
· Tighten the oil filter with the filter wrench, and screw down
1 1
another 1 circles for I type, while screw down another 1
8 4
circles for II type.
· Start the engine and check whether the oil leaks from the oil
filter.

129
3.8 Cylinder head cover

Disassembling sequence:
1. Crankcase vent hose
2. Cylinder head cover

Assembling sequence
As assembling, go on according to
the reverse sequence of
disassembly.

Disassembly
Preparation:

·Remove the ground cables of battery.

1. Crankcase vent hose

·Dismantle crankcase vent hose from air-intake duct side.

2. Cylinder head cover

Assembly
2. Cylinder head cover

·Apply oil to the rocker arm and valve spring.

·Install the gasket(s) of cylinder head cover on the cylinder head

cover.
The gasket(s) must be flat and without damage.
·Tighten the cylinder head cover nut(s) to the specified torque.

N·m

13
1. Connect the crankcase vent hose.
·Connect the crankcase vent hose to the air-intake pipe.

·Connect the ground cables of battery.

130
3.9 Rocker shaft assembly

Disassembling sequence:
1. Crankcase vent hose
2. Cylinder head cover
3. Rocker shaft assembly
Assembling sequence
As assembling, go on according to the
reverse sequence of disassembly.

Disassembly
Preparation:

Remove the ground cables of battery.

1. Crankcase vent hose

2. Cylinder head cover

3. Rocker shaft assembly

Loosen the bolt(s) and nut(s) of rocker shaft support in sequence

and remove the rocker shaft assembly.

Assembly
3. Rocker shaft assembly

· Install the rocker shaft so that the bigger oil hole (Φ4) locates at

engine forepart.

· Align the fixing bolts with the holes on the rocker shaft, and

tighten them to the specified torque.

N．m

55

131
Valve clearance adjustment

① Rotate the crankshaft until TDC line of the crankshaft damper

pulley is aligned with timing pointer, and either the first cylinder

piston or the fourth cylinder piston is at the top dead center (TDC)

of compression stroke.

② Check the nuts of rocker shaft support are loose.

Tighten all the loose nuts of the rocker shaft support before

adjusting valve clearance.

Rocker shaft support nut torque N.m

55

③ Check the clearance between intake valve and exhaust valve

push rod for the first cylinder.If there is clearance between intake

valve and exhaust valve push rod for the first cylinder, the first

cylinder piston locates at the top dead center of compression

stroke.

If there is no clearance between intake valve and exhaust valve

push rod for the first cylinder, the fourth cylinder piston locates at

the top dead center of compression stroke.

Top dead center of the first

cylinder compression stroke
The piston of cylinder must locate at the top dead center of
compression stroke when the valve clearance of the first cylinder
or fourth cylinder is adjusted.

Valve clearance (cold state) mm

0.3-0.4

④ Loosen the adjustment screw(s) for each valve clearance shown

in the drawing.
⑤ Insert a clearance gauge with proper thickness between the
rocker arm and valve stem end.

132
Top dead center of the fourth
cylinder compression stroke

⑥ Rotate the adjustment screw(s) for valve clearance until a touch

of resistance is felt on the clearance gauge.

⑦ Tighten the locking nut(s) firmly.

⑧ Rotate the crankshaft for 360o.

⑨ Then align TDC line of crankshaft damper pulley with timing
pointer.

⑩ Adjust the clearance of other valves shown in the drawing.

2. Cylinder head cover

● Install the cylinder head cover and tighten the bolt(s) to the

specified torque.

N．m

13

1. Crankcase vent hose

· Connect the ground cables of battery.

133
3.10 Valve stem oil seal and valve spring

Disassembling sequence:
1. Cylinder head cover
2. Rocker shaft assembly
3. Valve spring
4. Valve stem oil seal

Assembling sequence
As assembling, go on according to
the reverse sequence of
disassembly.

Disassembly
Preparation:
· Remove the ground cables of battery.

1. Cylinder head cover

2. Rocker shaft assembly

· Loosen the bolt(s) and nut(s) of rocker shaft support in
sequence and remove the rocker shaft assembly.

3. Valve spring
· Compress the valve spring with a special tool and remove
the valve cotter.

Valve spring compressor: 1003015FA-9101

Caution:
· Place the removed valve springs as the cylinder number
sequence.

134
4. Valve stem oil seal

· Remove the valve stem oil seals with pliers.

Caution:
The valve stem oil seal that has been removed should not be used
again.

Assembly
4. Valve stem oil seal

· Install new valve stem oil seals on the valve guide with a

special tool.

Special tool: 1003016FA-9101

3. Valve spring

· Place upper valve spring retainer on the valve spring.

Caution:

· The colored part of valve spring should be downward.

· Add compressed air to the cylinder from glow plug and lift the

valve to set it in place.

· Install the valve cotter with special tool.

· Valve spring compressor: 1003015FA-9101

2. Rocker shaft assembly

· Install the rocker shaft so that the bigger oil hole (Φ4) locates at
engine forepart.
· Align the fixing bolts with the holes on the rocker shaft, and
tighten them to the specified torque.

N·m

55
· Valve clearance adjustment

135
Valve clearance adjustment
① Rotate the crankshaft until TDC line of the crankshaft damper

pulley is aligned with timing pointer, and either the first cylinder

piston or the fourth cylinder piston is at the top dead center (TDC)

of compression stroke.

② Check the nuts of rocker shaft support are loose.

Tighten all the loose nuts of the rocker shaft support before

adjusting valve clearance.

Rocker shaft support nut torque N.m

55

③ Check the clearance between intake valve and exhaust valve

push rod for the first cylinder.If there is clearance between intake
valve and exhaust valve push rod for the first cylinder, the first
cylinder piston locates at the top dead center of compression
stroke.
If there is no clearance between intake valve and exhaust valve
push rod for the first cylinder, the fourth cylinder piston locates at
the top dead center of compression stroke.

The piston of cylinder must locate at the top dead center of

compression stroke when the valve clearance of the first cylinder
Top dead center of the first cylinder or fourth cylinder is adjusted.
compression stroke
Valve clearance (cold state) mm

0.3-0．4
④ Loosen the adjustment screw(s) for each valve clearance shown
in the drawing.
⑤ Insert a clearance gauge with proper thickness between the
rocker arm and valve stem end.

136
⑥ Rotate the adjustment screw(s) for valve clearance until a touch

Top dead center of the fourth

of resistance is felt on the clearance gauge.
cylinder compression stroke ⑦ Tighten the locking nut(s) firmly.
⑧ Rotate the crankshaft for 360o.

⑨ Then align TDC line of crankshaft damper pulley with timing

pointer.
⑩ Adjust the clearance of other valves shown in the drawing.

1. Cylinder head cover

· Apply oil to the rocker arm and valve spring.

· Install the gasket(s) of cylinder head cover on the cylinder head

cover. The gasket(s) must be flat and without damage.

· Install the cylinder head cover and tighten the bolt(s) to the

specified torque.

Cylinder head cover bolt torque N·m

13

· Connect crankcase vent hose.

· Connect the ground cables of battery.

137
3.11 Timing gear

Disassembling sequence:
1. Fan cowl
2. Drive belt of power steering pump
3. Drive belt of alternator
4. Cooling fan assembly
5. Crankshaft damper pulley
6. Acoustic hood
7. Acoustic hood liner
8. Timing gear chamber cover
9. Oil pipe
10. Idler gear
11. Idler gear
12. Oil injection pipe
13. Timing gear of camshaft
14. Crankshaft gear
Assembling sequence
As assembling, go on according to the
reverse sequence of disassembly.

Disassembly
Preparation:
· Remove the ground cables of battery.
· Discharge the coolant completely.
1. Fan guard
2. Power steering pump drive belt
· Unscrew the bracket bolt(s) and adjusting bolt(s) for power
steering pump and remove the drive belt.
3. Alternator drive belt
· Unscrew the alternator bracket bolt(s) (lower part) and adjusting
plate locking bolt(s) and remove the drive belt.
4. Cooling fan assembly
· Unfasten tight nut(s), and dismount fan assembly, collar and fan
pulley.
5. Crankshaft damper pulley
6. Acoustic hood
7. Acoustic hood liner
8. Timing gear chamber cover

138
9. Oil pipe

10. Idler gear

1) Measure the timing gear play of camshaft and crankshaft before
disassembling the idler gear.
2) First measure the axial clearance for idler gear before
disassembling the idler gear.

Note:
Refer to the following items for details on gear clearance and
axial clearance measurement methods.

Timing gear clearance measurement

1) Install a dial gauge onto the timing gear to be tested. Fix the gear

to be examined and the gear connected to it.

2) Swing the gear to be checked left and right as much as possible.

Read out the dial gauge readings.

If the measured value exceeds prescribed limit, the timing gear has to

be replaced.

Timing gear clearance mm

Standard Limit

0.10--0.17 0.30

Axial clearance measurement of idler gear ”A”

Insert a clearance gauge between the idler gear and thrust ring to

measure the clearance and determine the axial clearance of idler

gear.

If the measured value exceeds prescribed limit, the thrust ring has to

be replaced.

Axial clearance of idler gear mm

Standard Limit

0.07 0.2

139
11. Idler gear

12. Injection pump

1) Remove six injection pump bracket bolts ① from timing gear
chamber.

2) Remove rear bracket bolt ② from injection pump bracket ③.

3) Remove rear bracket bolt④ and bracket⑤ of injection pump from
the cylinder block.
4) Draw out both the injection pump and injection pump timing gear
toward the engine backside.

Note:

Cover the hole in injection pump delivery valve body with a cover or

equivalents to prevent foreign matters falling into the valve.

13. Camshaft timing gear

1) Measure the axial clearance of camshaft with a dial gauge.

Measure the clearance before disassembling the camshaft gear.
If the axial clearance of camshaft exceeds prescribed limit, the
thrust washer has to be replaced.
Axial clearance of camshaft mm

Standard Limit

0.050--0.114 0.2

2) Remove camshaft timing gear bolt(s) from the camshaft.

Note:

Keep the camshaft fixed to prevent its rotating.

140
3) Pull out camshaft timing gear② with universal puller ①.
Universal puller: 1007011FA-9101
4) Remove thrust washer ③.

14. Crankshaft gear

Assembly
14. Crankshaft gear

1) Install crankshaft gear

2) Install crankshaft gear ② with crankshaft gear erector ①.·

Crankshaft timing gear mark (“X-X”) must face the outside.

Crankshaft gear erector: 1007011FA-9102
13. Camshaft timing gear

1) Install the thrust washer onto the cylinder block.

2) Tighten thrust washer bolt(s) to the specified torque.

N·m

25

3) Install camshaft timing gear to the camshaft.

The timing gear mark (“Y— Y”) has to face the outside.

4) Tighten the timing gear to the specified torque.

N·m

110

12. Injection pump

1) Install O-ring ① to injection pump flange ②.

2) Install injection pump to the timing gear chamber.

Align the mark “V-V”of idler gear “B”③ with the mark “V”of

injection pump timing gear ④.

141
3) Temporarily tighten six nuts ⑤ for injection pump.

The final screwing down of injection pump nuts is conducted after rear
bracket bolt(s) of the injection pump is (are) tightened.

4) Install rear bracket ⑥ of injection pump and rear bracket bolt

⑦ on the cylinder block.

5) Mount rear bracket bolt ⑧ to injection pump bracket ⑨.

Do not screw down those bolts.

Rear bracket bolt ⑦ and ⑦ will be tightened to the specified torque
after the injection pump nuts are tightened.
6) Tighten the injection pump nuts to the specified torque.

N·m

25

7) Screw down injection pump bracket bolt(s) to the specified torque.

N·m

25

11. Idler gear

1) Apply some oil to the idler gear and its shaft.

The oil hole in idler gear shaft must be toward upward.

2) Arrange idler gear marks “X”and “Y”so that they both face the

engine forepart.

142
3) Align idler gear mark “X”with the mark “X— X”of crankshaft

timing gear ①.

4) Align idler gear mark “Y”with the mark “Y— Y”of camshaft timing

gear ②.

5) Install the thrust washer and bolt(s) onto the cylinder block.
Thrust ring oil hole must be toward upward while its chamfer should
face the outside.
6) Tighten idler gear bolt(s) to the specified torque.

N·m

20

10. Idler gear

1) Apply some oil to the idler gear and its shaft.

2) Align mark “Z”of gear “B”③with mark “Z— Z”of idler gear “A”④.
3) Tighten idler gear bolt(s) to the specified torque.

N.m

110

9. Lubrication oil pipe

1) Install the lubrication oil pipe on the timing gear chamber and idler
gear “A”.
2) Tighten lubrication oil pipe punching bolt ① and bolt ② to the
specified torque.
Oil pipe punching bolt torque N·m

20

8. Timing gear chamber cover

1) Align timing gear chamber anchor pin with the timing gear
chamber, then install timing gear chamber cover.
2) Tighten gear chamber cover bolt(s) to the specified torque.

143
7. Acoustic hood liner

6. Acoustic hood

5. Crankshaft damper pulley

Screw down the crankshaft damper pulley bolt(s) to the specified
torque.

Note:
While screwing down the damper pulley, hold the flywheel ring gear to
prevent crankshaft rotating.

Pulley bolt torque N·m

210

4. Cooling fan assembly

· Install fan silicone oil clutch and cooling fan assembly (as this
sequence) on water pump, and tighten them to the specified
torque.

N·m

12.5

3. Alternator drive belt

Install alternator drive belt and adjust the belt tension.

Press the belt center with 100N force.
Drive belt deflection mm

8-10

· Tighten idler gear locking nut(s) to the specified torque.

N·m

25

144
2. Power steering pump drive belt

· Install power steering pump drive belt and adjust the belt
tension.

· Press the belt center with 100N force.

Drive belt deflection mm

8-10

· Tighten idler gear locking nut(s) to the specified torque.

N·m

25

1. Fan guard
· Install fan guard and storage tank hose.

· Add some coolant.

· Start the engine and check the coolant leaks.

145
3.12 Cylinder head assembly and gasket

Disassembling sequence:
1. Upper radiator hose
2. Heater hose
3. Air compressor drive belt
4. Engine wire
5. Air-intake duct
6. High pressure oil pipe
7. Oil return hose
8. Crankcase vent hose
9. Glow plug wire
10. Oil scale guide
11. Oil cooler tube
12. Air compressor assembly
13. Vacuum modulator
14. Front exhaust hose
15. Bypass hose
16. Cylinder head cover
17. Rocker shaft
18. Push rod
19. Cylinder head assembly
20. Cylinder head gasket
Assembling sequence
As assembling, go on according
to the reverse sequence of
disassembly.

Disassembly
Preparation:

·Remove the ground cables of battery.

·Discharge the coolant in the radiator and engine completely.

1. Upper radiator hose

·Remove the upper radiator hose at engine side.

146
2. Heater hose

· Remove the heater hose from the heater pipe.

3. Air conditioning compressor drive belt

·Unscrew idler locking nut(s).

·Loosen adjusting bolt(s) and remove the drive belt.

4. Engine wire

Temperature ·Detach wire connector from upper thermostat cover component.

sensor
5. Air-intake duct

·Remove anchorage clip(s) and air-intake duct.

6. High pressure oil pipe

·Unscrew high pressure oil pipe anchorage clip(s).

·Loosen the taper nut(s) at injection pump side.

·Loosen the taper nut(s) at injection pump side and remove the

pipe.

Note:

Plug the holes in injector body and delivery valve body to prevent

foreign matters falling in.

7. Oil return hose

·Remove the oil return hose at oil return pipe side.

8. Crankcase vent hose

·Dismantle crankcase vent hose(s) from air-intake pipe.

9. Glow plug wire

10. Oil scale guide

·Remove oil scale guide out of the cylinder head.

147
11. Oil cooler tube
· Dismantle the fixing bolt(s) at rear side of cylinder head.

12. Air conditioning compressor assembly

· Remove the wire connector of clutch.

· Remove fixing bolt(s) of the air conditioning compressor and

temporarily bind the compressor to the frame side with wires.

13. Front exhaust pipe

· Remove exhaust pipe fixing bolt(s) out of the exhaust
manifolds.

· Remove exhaust pipe support bolt(s).

14. Bypass hose

15. Cylinder head cover

148
16. Rocker shaft
· Loosen rocker shaft support bolt(s) bit by bit as according to
the sequence shown in the diagram.

Note:
Disobedience will have unfavorable influence on the rocker shaft.

17. Push rod

18. Cylinder head assembly

· Loosen cylinder head bolt(s) bit by bit according to the
sequence shown in the diagram.

Note:

Disobedience will bring unfavorable influence to the lower

surface of cylinder head.

19. Cylinder head gasket

· Remove cylinder head gasket and anchor pin.

Assembly
19. Cylinder head gasket

Before assembling, carefully remove carbon deposits on piston top

and upper cylinder block surface and also clean the place where the
gasket is installed.

149
Note:

18. Cylinder head assembly

1) Install the anchor pin onto the cylinder block.

2) Install cylinder head gasket with top mark toward upside.

3) Clean the lower cylinder head surface and upper cylinder block
surface.

4) Mount cylinder head gently.

5) Apply oil to the threads and mating surfaces of cylinder head

bolts.

6) Tighten the cylinder head bolts to the specified torque in three

steps according to the sequence shown in the diagram.

Cylinder head bolt torque N·m

First step Second step Third step

65 85 105

17. Push rod

· Apply oil to the push rod and put the rod in cylinder head.

150
16. Rocker shaft assembly

1) Loosen all adjusting screws.

2) Install the rocker shaft so that the bigger oil hole (Φ4) faces
engine forepart.

3) Tighten the rocker shaft support bolt(s) to the specified torque

according to the sequence shown in the diagram.

Rocker shaft support bolt torque N.m

55

·Valve clearance adjustment

Valve clearance adjustment

① Rotate the crankshaft until zero scale line of the crankshaft
damper pulley is aligned with timing pointer, and either the first
cylinder piston or the fourth cylinder piston is at the top dead center
(TDC) of compression stroke.

② Check the nuts of rocker shaft support are loose.

Tighten all the loose nuts of the rocker shaft support before

adjusting valve clearance.

Rocker shaft support nut torque N.m

55

151
③ Check the clearance between intake valve and exhaust valve
push rod for the first cylinder.If there is clearance between intake
valve and exhaust valve push rod for the first cylinder, the first
cylinder piston locates at the top dead center of compression stroke.If
there is no clearance between intake valve and exhaust valve push
rod for the first cylinder, the fourth cylinder piston locates at the top
dead center of compression stroke.

The piston of cylinder must locate at the top dead center of compression
stroke when the valve clearance of the first cylinder or fourth cylinder is
adjusted.

Valve clearance (cold state) mm

0.3-0.4
Top dead center of the first
cylinder compression stroke ④ Loosen the adjustment screw(s) for each valve clearance shown
in the drawing.

⑤ Insert a clearance gauge with proper thickness between the

rocker arm and valve stem end.

⑥ Rotate the adjustment screw(s) for valve clearance until a touch

of resistance is felt on the clearance gauge.

⑦ Tighten the locking nut(s) firmly.

Top dead center of the fourth ⑧ Rotate the crankshaft for 360o.
cylinder compression stroke
⑨ Then align zero scale line of crankshaft damper pulley with timing
pointer.

⑩ Adjust the clearance of other valves shown in the drawing.

15. Cylinder head cover

·Apply oil to the rocker arm and valve spring.

·Install cylinder head cover gasket(s) of on the cylinder head cover.

·The gasket(s) must be flat and without damage.

·Tighten cylinder head cover nut(s) to the specified torque.

Cylinder head cover torque N.m

13

14. Bypass hose

152
13. Front exhaust pipe
· Connect the pipe with manifold and tighten bolt(s) and nut(s) to
the specified torque.

Manifold nut torque N·m

37

Pipe support bolt torque N·m

40

12. Air conditioning compressor assembly

· Install the fixing bolt(s) of air conditioning compressor and

screw down the bolt(s) to the specified torque.

Compressor bolt torque N.m

20

153
11. Oil cooler tube

· Install tube bolt(s) and tighten the bolt(s) to the specified

torque.

Tube nut torque N·m

25

10. Oil scale guide

9 Glow plug wire connector

8. Crankcase vent hose

7. Oil return hose

· Install oil return hose with new copper washer.

6. High pressure oil pipe

· Install taper nut(s) at injection pump side.

· Install taper nut(s) at injector side.

· Tighten taper nut(s) to the specified torque.

Taper nut torque N·m

30
· Assemble the anchorage clip(s) of pipe within specified torque.

5. Air-intake duct

154
4. Engine wire
Temperature
sensor ·Connect temperature sensor and thermometer component wire.

2. Air conditioning compressor drive belt

·Check drive belt is worn or damaged, and replace if necessary.

·Check the belt tension, and adjust if necessary.

·Check the tension of drive belt.

Air conditioning compressor and

power steering pump drive pulley
Alternator and fan pulley drive belt · Apply a force of 100N to the belt center and check the deflection
of each belt.

· Deflection standard value

mm
Alternator and fan
pulley drive belt
Sinkage

Alternator and fan pulley drive belt 8— 10

Air conditioning compressor drive belt

Power steering pump drive belt

Tension adjustment

Air
conditioning Idler pulley Power steering pump and air conditioning compressor drive belts.
compressor
Adjusting Adjusting bolt · Loosen power steering pump locking bolt and adjust belt tension
plate
Power steering pump pulley
with the adjusting bolt.
Fan pulley
Alternator
Cooling fan pulley belt
Alternator bolt Idler pulley

Crankshaft pulley · Loosen alternator bracket and locking bolt(s), and then adjust the
Adjusting bolt

belt tension with the adjusting bolt of regulator.

155
Torque standard value N.m

Alternator fixing bolt 40

Adjusting plate fixing bolt 25

Adjusting plate locking bolt 25

2. Heater hose
· Install the heater hose, and then tighten the anchorage clip(s)
firmly.

1．Upper radiator hose

·Connect the radiator hose, and then tighten the anchorage clip(s)
firmly.
· Add some coolant.
· Connect the ground cables of battery.
· Start the engine and check whether the coolant leaks.

156
3.13 Oil pan

Disassembling sequence:
1. Vacuum oil pump
2. Engine support bolt
3. Stiffener plate
4. Oil pan assembly
5. Oil pump assembly
Assembling sequence
As assembling, go on according to the
reverse sequence of disassembly.

Disassembly
Preparation:

· Remove the ground cables of battery.

· Lift the automobile.

· Discharge the coolant completely.

oil hose②
Note:

Install oil drain plug with new gasket.

N.m
oil hose①
80

1. Vacuum pump oil hose

· Remove oil hose ① out of the oil pan.

157
2. Engine support bolt

·Remove engine support bolts at both left an right sides.

3. Stiffener plate and rubber cushion

·Remove exhaust pipe bracket.

·Remove the stiffener plates out of oil pan (both left and right).

·Take out the rubber cushion.

4. Oil pan

·Lift the engine for about 50mm.

·Remove the oil pan from the cylinder block.

Assembly

4. Oil pan
·Apply recommended liquid sealant or equivalents to the fifth
bearing cap arch section, groove and timing gear chamber arch
section shown in the diagram.

158
·Install back lip portion of the gasket into the fifth groove.

·Make sure that the lip portion is compact with the groove.

·Install the oil pan on the cylinder block.

·Tighten oil pan bolt(s) to the specified torque.

Oil pan bolt torque N·m

23.5

3. Stiffener plate and rubber cushion

·Install rubber cushion.

·Install the stiffener plates at both left side and right side and

tighten bolts to the specified torque.

Engine block side N.m

37.5

Clutch housing side N.m

87

· Install exhaust pipe bracket.

2. Engine support bolt

· Install bracket bolts and tighten the bolts to the specified torque.

Bracket bolt torque N.m

40

· Install the oil hose on the oil pan.

1. Vacuum pump oil hose

·Add some oil.

·Connect the ground cables of battery.

·Start the engine and check whether the coolant leaks.

159
3.14 Oil pump assembly

Disassembling sequence:
1.Vacuum oil pump
2. Engine bracket bolt
3. Stiffener plate and rubber
cushion
4. Oil pan assembly
5. Oil pump assembly

Assembling sequence
As assembling, go on
according to the reverse
sequence of disassembly.

Disassembly
Preparation:

· Remove the ground cables of battery.

· Lift the automobile.

· Discharge the oil completely.

Oil hose ②
Note:

Install oil drain plug with new gasket.

Oil hose ①
N.m

80

1. Vacuum pump oil hose

· Remove oil hose ① out of the oil pan.

160
2. Engine support bolt

·Remove engine support bolts at both left an right sides.

3. Stiffener plate

· Remove exhaust pipe bracket.

· Remove the stiffener plates out of oil pan (both left and right).

4. Oil pan assembly

· Lift the engine for about 50mm.
· Remove the oil pan from the cylinder block.

5 Oil pump assembly

·Remove oil pump assembly from the cylinder block.

Assembly

·Prepare some solution containing 80％ oil and 20％ supramoly.

· Apply solution to the oil pump pinion teeth.

5．Oil pump assembly

· Apply some oil to the oil pipe O-ring and put it into the cylinder
block O-ring groove.

· Install the oil pump assembly with oil pipe to the cylinder block,
and tighten fixing bolts to the specified torque.

N.m

25

161
Tighten sleeve nut(s) to the specified torque.

N.m

30

4. Oil pan assembly

· Apply recommended liquid sealant or equivalents to the fifth
bearing cap arch section, groove and timing gear chamber arch
section shown in the diagram.

· Install back lip portion of the gasket into the fifth groove.

· Make sure that the lip portion is compact with the groove.

· Install the oil pan on the cylinder block.

· Tighten oil pan bolt(s) to the specified torque.

Oil pan bolt torque N·m

23.5

3. Stiffener plate
· Install the stiffener plate and tighten bolt(s) to the specified
torque.

Engine block side N.m

37.5

Clutch housing side N.m

87
· Install exhaust pipe bracket.

162
2. Engine support bolt

· Lay down the engine, and install bracket bolts and tighten the

bolts to the specified torque.

1. Vacuum pump oil hose

· Install the oil hose on the oil pan.

· Add some oil.

· Connect the ground cables of battery.

· Start the engine and check whether the oil leaks.

163
3.15 Piston, Piston ring and connecting rod

Disassembling sequence:
1. Cylinder head assembly
2. Oil pan assembly
3. Oil pump assembly
4. Connecting rod bearing cap
5. Piston and connecting rod
assembly

Assembling sequence
As assembling, go on according
to the reverse sequence of
disassembly.

Disassembly
Preparation:

·Remove the ground cables of battery.

·Discharge the coolant completely.

·Discharge the oil completely.

Note

· Install oil drain plug with new gasket.

N.m

80

1. Cylinder head assembly

1) Upper radiator hose

·Remove the upper heater hose at engine side.

2) Heater hose

164
· Remove the heater hose from the heater pipe.

3) Air conditioning compressor drive belt

· Unscrew idler locking nut(s).
· Loosen adjusting bolt(s) and remove the drive belt.

4) Engine wire
· Detach wire connector from upper thermostat cover
component.

5) Air-intake duct

·Remove anchorage clip(s) and air-intake duct.

6) High pressure oil pipe

·Unscrew high pressure oil pipe anchorage clip(s).

·Loosen the taper nut(s) at injection pump side.

·Unscrew taper nut(s) at fuel injector side and remove high

pressure oil pipe(s).

7) Oil return hose

·Remove the oil return hose at oil return pipe side.．

8) Crankcase vent hose

·Dismantle crankcase vent hose(s) from air-intake pipe.

9) Glow plug wire

10) Oil scale guide

·Remove oil scale guide out of the cylinder head.

11) Oil cooler tube

·Remove pipe bracket bolt(s) at rear side of cylinder head.

·Remove cooler tube from the cylinder head.

165
12) Air conditioning compressor assembly
·Remove the wire connector of clutch.
·Remove the wire connector of electromagnetic clutch.
·Remove fixing bolt(s) of the air conditioning compressor and
temporarily bind the compressor side with wires.

13) Vacuum modulator hose

·Remove vacuum modulator hose from the vacuum modulator.

14) Front exhaust pipe

·Remove exhaust pipe fixing bolt(s) from the exhaust manifold.

·Remove exhaust pipe support bolt(s).

15) Bypass hose

16) Cylinder head cover

17) Rocker shaft

·Loosen rocker shaft support bolt(s) bit by bit according to the

sequence shown in the diagram.

Note:
Disobedience will have unfavorable influence on the rocker
shaft.

18) Push rod

166
19) Cylinder head assembly
· Loosen cylinder head bolt(s) bit by bit according to the
sequence shown in the diagram.

Note:
Disobedience will bring unfavorable influence to the lower
surface of cylinder head.

20) Cylinder head gasket

· Remove cylinder head gasket and anchor pin.

Oil hose ②

2. Oil pan assembly

1) Vacuum pump oil hose

Oil hose ①
·Remove oil hose ① out of the oil pan.

2) Engine support bolt

·Remove engine support bolt(s).

3) Stiffener plate

·Remove exhaust pipe bracket.

·Remove stiffener plate.

167
4) Oil pan

·Lift the engine for about 50mm.

·Remove the oil pan from the cylinder block.

3. Oil pump assembly

·Remove the oil pump from the cylinder block.

4. Connecting rod bearing cap

· If it is intended to reassemble the lower bearing of connecting

rod, please attach a label to each bearing, and mark the

disassembling sequence of cylinder and its installation position.

168
5. Piston and connecting rod with upper bearing
1) Scrape carbon deposits on upper cylinder wall with a scraper
before disassembling the piston and connecting rod.

2) Move the piston to the top of cylinder head, push upward the
lower part of connecting rod with a hammer handle or
equivalents, then take out the piston and connecting rod.

3) If it is intended to reassemble the upper bearing of connecting

rod, please attach a label to each bearing, and mark the
disassembling sequence of cylinder and its installation position.

4) Clamp the connecting rod with a vice.

Take care not to damage the connecting rod.

Remove each piston ring with piston ring replacer.

Do not try to remove the piston ring with other tools other than

piston ring replacer.

Excessive tension of piston ring will reduce the elastic force of

piston ring.

169
5) Dismantle piston pin retainer with pliers.

6) Gently knock out the piston pin with hammer and bar copper.

If it is intended to reassemble piston and piston pin, please attach

a label to each piston and piston pin, and mark the disassembling
sequence of cylinder and its installation position.

Assembly
5. Piston and connecting rod with upper bearing
1) Try to push the piston pin into piston pin hole with your finger
pressure.

Weigh each piston and connecting rod assembly.

Select the piston and connecting rod set in such a way that the
weight difference of various assemblies is within the specified
limits.

Model Assembly mass difference (g)

4DA1 ≤10

4DA1-1 ≤8

2) Clamp the connecting rod with a vice.

Take care not to damage the connecting rod.

3) Encase piston pin retainer to the piston with pliers.

Note:

When replacing the piston/connecting rod assembly, do not

change the piston/piston pin assembly.

170
4) Install the piston onto the connecting rod.

Front mark ① on the piston head and connecting rod “F908”

casting symbol ⑦ should face the same direction.

5) Add oil to the piston and piston pin hole.

Push piston pin into the piston with your finger until it touches the
piston pin retainer.

6) Press the piston pin retainer into piston retainer groove with
fingers.

Check whether the connecting rod can freely swing on the piston
pin.

7) Install piston ring and piston packing ring.

The gas ring mark “JAC”should face upward.

Identification mark is shown in the drawing.

Mark (first ring)

(second ring)

171
8) Assemble three piston rings with a piston ring replacer.

The assembling sequence of piston ring is shown in the diagram.

① Oil ring

② Second gas ring

③ First gas ring

Note:
First gas ring Support
spring
opening Mount the gas rings with chamfer toward upward.

Install the spiral ring into oil ring groove and make sure that
there is no clearance at either side of the packing ring before
Oil ring Second gas ring the oil ring is installed.

9) Apply some oil to the piston ring surface.

10) Check whether the piston ring can turn freely in piston ring
groove.

11) The cutout position for placing piston ring is shown in the
drawing.

12) Carefully wipe off the foreign bodies on connecting rod bearing
back and bearing mating surface.

13) Apply some oil to the upper bearing surface.

Apply some oil to the cylinder wall.

172
14) The front mark on piston head must be toward the engine
forepart during installation.

Compress the piston ring with a piston ring compressor.

Piston ring compressor: 1004022FA-9101

15) Push in the piston with a hammer handle until the connecting
rod touches the crankpin.

In the meanwhile, rotate the crankshaft until the crankpin

reaches its bottom dead center.

4. Connecting rod bearing cap

1) The front mark on the bearing cap must be toward the engine
forepart during installation.

2) Install connecting rod bearing cap.

Align the cylinder sequence mark on connecting rod bearing cap

with the one on connecting rod.

3) Apply oil to the thread and mating surface of each connecting rod
Front mark bearing cap bolt.

4) Screw down connecting rod bearing cap bolt to the specified

torque in two steps via torque tightening method.

Connecting rod bearing cap bolt torque N·m

First step (sealing torque) Second step (final torque)

20 85

Note:

Manually rotate the crankshaft to check whether it is flexible.

173
3. Oil pump assembly
·Prepare some solution containing 80％ oil and 20％ supramoly.

·Apply solution to the oil pump pinion teeth.

·Apply some oil to the oil pipe O-ring and put it into the cylinder
block O-ring groove.

·Install the oil pump assembly with oil pipe on the cylinder block,
and tighten fixing bolts to the specified torque.

Oil pump bolt torque N·m

25

·Tighten sleeve nut(s) to the specified torque.

Sleeve nut torque N·m

30

Note:

Be careful not to damage O-ring when tightening the oil pipe

bolt(s).

2. Oil pan assembly

1) Apply recommended liquid sealant or equivalents to the fifth
bearing cap arch section, groove and timing gear chamber
arch section shown in the diagram.

174
2) Install back lip portion of the gasket into the fifth groove.

Make sure the lip portion is compact with the groove.

3) Install the oil pan to the cylinder block.

Tighten oil pan bolt(s) to the specified torque.

Oil pan bolt torque N·m

23.5

4) Install the stiffener plate and tighten bolt(s) to the specified

torque.

Engine block side

Stiffener plate bolt torque N.m

30

5) Install exhaust pipe bracket.

6) Install support rubber and tighten nut(s) to the specified torque.

Support rubber nut torque N.m

40

175
Oil hose ②
7) Mount vacuum pump oil hose ① to the oil pan.

1. Cylinder head assembly

Oil hose ①
Refer to “3.12 Cylinder head assembly and gasket”.

176
3.16 Camshaft and tappet

Disassembling sequence:
1. Transmission assembly and
clutch assembly
2. Engine assembly
3. Cylinder head assembly and
gasket
4. Timing gear
5. Oil pan
6. Oil pump
7. Camshaft and tappet
Assembling sequence
As assembling, go on according to
the reverse sequence of
disassembly.

Disassembly
Preparation:

·Remove the ground cables of battery.

·Discharge coolant completely.

·Discharge the oil completely.

Note:

Install oil drain plug with new gasket.

Oil drain plug torque N·m

80

177
1. Transmission assembly and clutch assembly

· Hoist the automobile and support it with a suitable and safe

bench.

1) Transmission
Setting mark ① Transmission

· Make a setting mark on the flange yoke and parking brake

drum.

· Disassemble the drive shaft on the flange yoke.

· Move aside the drive shaft and bind it on the frame so as to

facilitate maintenance work.

② Parking brake cable

· Move the connecting cover away.

· Dismantle connecting bolts.

· Remove anchorage clips and withdraw bracket cables.

Shift cable Anchorage clip

Pin

Select cable
③ Wire connector

Pin
· Detach the wire connectors of vehicle speed sensor, neutral

switch and backup light switch.

④ Shift and select cables

· Remove the shift and select cables at transmission side.

178
Elastic hose ⑤ Clutch slave cylinder

·Remove the clutch hose clips and clip bracket (only for vehicles

with right steering wheel).

Clutch pipe

·Disassemble the lower slave cylinder assembly together with

hoses, and bind them to the frame so as to facilitate

maintenance work.

⑥ Exhaust brake assembly

⑦ Front exhaust pipe

⑧ Transmission assembly

Note:
Sometimes the exhaust pipe bracket, gear control bracket and
anchorage clips are at mounting positions or directions.In
order to prevent this, please make correct mounting marks on
those parts.

·Use a transmission jack to jack up the transmission.

179
Caution:
In order to prevent transmission overturn, use chains or belts
to secure it to the jack.

Do not let the transmission hover over the clutch, or it will destroy
the clutch.

· Remove nuts securing the transmission bracket at beam side.

· Angles of the engine and transmission have to be adjusted so

that they can be easily disassembled.

· Use a jack or crane to jack up the rear part of engine.

Caution:

After jacking up the engine, place a wooden block under it to

protect the oil pan.

· Remove the transmission binding bolts.

· Draw out the transmission assembly backwards.

⑨ Bracket

2) Clutch
· Hoist the vehicle and support it with a suitable and safe bench.

Caution:

Make sure that no clutch fluid is left on the coating surface, or

wash it away immediately.

① Pressure plate assembly

② Driven plate assembly

· Use a guiding centralizer to prevent the driven plate assembly
falling freely.

· Mark the flywheel and pressure plate flange to ensure

alignment during installation.

· Loosen fixing bolts of the pressure plate assembly.

2. Engine assembly

1) Radiator assembly
· Remove the upper and lower hoses of the radiator.

· Remove storage tank hose.

· Remove the shock-absorbing rubber at both sides.

· Remove radiator support.

2) Air intake duct

180
3) Heater hose

4) Engine control cable

· Unscrew the locking nut(s) at the bracket and remove throttle

wire(s) from the injection pump control lever.

5) Glow plug wire

6) Fuel hose

· Remove fuel inlet hose and return hose.

7) Oil pressure switch wire

8) Air conditioning compressor assembly

· Unscrew idler locking nut(s).

· Loosen adjusting nut(s) and remove the drive belt.

· Remove the wire connector of electromagnetic clutch.

· Remove fixing bolt(s) of the air conditioning compressor and

temporarily bind the compressor to the frame with wires.

9) Power steering pump and bracket assembly (power steering

type)

· Unscrew idler locking nut(s).

· Loosen adjusting nut(s) and remove the drive belt.

· Remove pipe bracket fixing bolt(s) and anchorage clip (s).

Bracket
· Remove power steering pump fixing bolt(s) and temporarily

Locking nut
bind the pump to the frame with wires.

Anchorage
clip
Anchorage
clip

181
10) Modulator vacuum hose (exhaust brake type)

· Remove the vacuum hose at modulator side.

11) Vacuum pump hose (exhaust brake type)

· Remove the vacuum hose at both vacuum tank and

solenoid valve sides.

12) Front exhaust pipe

· Remove exhaust pipe fixing bolt(s) from the exhaust

manifold.

· Remove exhaust pipe support bolt(s).

· Remove fixing nut(s) from front exhaust pipe.

13) Support rubber

① If mounted at right side

· Remove the two fixing nuts at beam side.

② If mounted at the left side

· Remove the two fixing nuts at beam side.

182
14) Engine assembly

· Slowly hoist the engine with a crane.

· Lift the engine with its front part higher than rear part.

· While taking out the engine assembly, be careful to avoid

breaking any oil pipe, brake pipe, etc.

· Place the engine on an engine support.

3. Cylinder head assembly and gasket

1) High pressure oil pipe

· Unscrew high pressure oil pipe anchorage clip(s).

· Loosen the taper nut(s) at injection pump side.

· Unscrew taper nut(s) at fuel injector side and remove high

pressure oil pipe(s).

2) Oil return hose

· Remove the oil return hose at oil return pipe side.

3) Crankcase vent hose

· Dismantle crankcase vent hose(s) from air-intake duct.

4) Glow plug wire

5) Oil scale guide

· Remove oil scale guide out of the cylinder head.

183
6) Oil cooler tube

· Remove pipe bracket fixing bolt(s) at rear side of cylinder

head.

· Remove oil scale guide out of the cylinder head.

7) Bypass hose

8) Cylinder head cover

· Remove crankcase vent hose and cylinder head cover bolt(s).

9) Rocker shaft

· Loosen rocker shaft support bolt(s) bit by bit according to the

sequence shown in the diagram.

Note:

Disobedience will bring unfavorable influence to the rocker

shaft.

10) Push rod

11) Cylinder head assembly

· Loosen cylinder head bolt(s) bit by bit according to the
sequence shown in the diagram.

Note:
Disobedience will bring unfavorable influence to the lower
surface of cylinder head. 12) Cylinder head gasket

· Remove cylinder head gasket and anchor pin.

4. Timing gear

1) Cooling fan assembly

· Unfasten tight nut(s), and dismount the fan assembly and fan
pulley.

184
2) Crankshaft damper pulley

3) Acoustic hood

4) Acoustic hood liner

5) Timing gear chamber cover

6) Camshaft timing gear

① Measure the axial clearance of camshaft with a dial gauge.

Measure the clearance before disassemble the camshaft gear.

If the axial clearance of camshaft exceeds prescribed limit, the

thrust washer has to be replaced.

Axial clearance of camshaft mm

Standard Limit

0．050—0．114 0．2

② Remove camshaft timing gear bolt(s) from the camshaft.

Note:

Keep the camshaft fixed to prevent its rotating.

③ Pull out camshaft timing gear ② with a universal puller ①.

④ Remove the thrust washer ③.

5. Oil pan
· Remove vacuum pump oil hose ① out of the oil pan.

Oil hose ②

Oil hose ①

185
· Remove stiffener plate and rubber cushion from both sides of
the oil pan.

· Dismantle oil pan bolt(s) and remove the oil pan from the
cylinder block.

6．Oil pump assembly

· Remove oil pump assembly from the cylinder block.

7. Camshaft and tappet

· Remove the oil pan from the cylinder block.

· Be careful not to damage the camshaft bearing.

· Take out the tappet from the cylinder block.

186
Assembly
7. Camshaft and tappet
· Coat oil on the tappet and in the installation hole of cylinder
block tappet.

· Place the tappet according to the position mark made during

removing (if the tappet is intended to be reused).

Note:

The tappet must be installed before camshaft is assembled.

· Coat oil on the camshaft and camshaft bearing.

· Install the camshaft on the cylinder block.

Be careful not to damage the camshaft bearing.

6. Oil pump assembly

· Prepare some solution containing 80％ oil and 20％
supramoly.

· Apply enough solution to the oil pump pinion teeth.

· Apply some oil to the oil pipe O-ring and put it into the cylinder
block O-ring groove.

· Install the oil pump assembly with oil pipe on the cylinder block,
and tighten fixing bolts to the specified torque.

Oil pump bolt torque N·m

25

Tighten sleeve nut(s) to the specified torque.

Sleeve nut torque N·m

30

187
5．Oil pan
· Apply recommended liquid sealant or equivalents to the fifth
bearing cap arch section, groove and timing gear chamber arch
section shown in the diagram.

· Install back lip portion of the gasket into the fifth groove.

· Make sure that the lip portion is compact with the groove.

· Install the oil pan to the cylinder block.

· Tighten oil pan bolt(s) to the specified torque.

Oil pan bolt torque N·m

23.5

4. Timing gear

7) Camshaft timing gear

· Install the thrust washer onto the cylinder block and tighten
thrust washer bolt(s) to the specified torque.

N·m

25

· Install camshaft timing gear to the camshaft.

The timing gear mark (“Y— Y”) has to face the outside.

Align idler gear marks “B”“V-V”with injection pump timing gear

mark “V”.

Align idler gear marks “B”“Z”with idler gear marks “A”“Z-Z”.

Arrange idler gear setting marks “X”and “Y”so that they both face

the engine forepart.

Align idler gear mark “X”with crankshaft timing gear mark “X— X”.

188
Align idler gear mark “Y”with camshaft timing gear mark “Y— Y”.

· Tighten the timing gear to the specified torque.

Timing gear bolt torque N·m

110

6) Timing gear chamber cover

Align timing gear chamber anchor pin with the timing gear

chamber, then install timing gear chamber cover.

Tighten gear chamber cover bolt to the specified torque.

Gear chamber cover bolt torque N·m

25

5) Acoustic hood liner

6) Lower acoustic hood

7) Upper acoustic hood

2) Crankshaft damper pulley

Screw down the crankshaft damper pulley bolt(s) to the specified

torque.

Note:
While screwing down the damper pulley, hold the flywheel ring
gear to prevent crankshaft rotating.

Crankshaft pulley bolt torque N·m

210

1) Cooling fan assembly

·Install the fan pulley and cooling fan assembly (in this installation
order) on water pump, and tighten those parts to the specified
torque.

N·m

12.5

189
3. Cylinder head assembly and gasket
Refer to “3.12 Cylinder head assembly and gasket”.
2. Engine assembly

14) Engine assembly

· Hoist the engine support with a crane.

13) Support rubber

· Tighten fixing bolts to the specified torque after all of them
(left: 2, right: 2) have been inserted into their corresponding
holes.

Support rubber bolt torque N.m

40

12) Front exhaust pipe

· Connect exhaust pipe and tighten nut(s) to the specified
torque.

Exhaust pipe nut torque N·m

67
· Install exhaust pipe support bolts and tighten bolts and nuts
to the specified torque.

Support bolt and nut torque N·m

40

11) Vacuum pump hose

· Install the vacuum hose at both vacuum tank and solenoid
valve sides.

190
· Connect the vacuum hose to the modulator.

9) Power steering pump and bracket assembly (power steering

type)

· Install power steering pump and pipe bracket, then tighten

Bracket
bolts to the specified torque.
Locking nut
Pump bolt torque N·m

Anchorage 20
clip
Anchorage
clip Pipe bracket bolt torque N·m

20

Anchorage clip bolt torque N·m

10

· Install power steering pump drive belt and adjust the belt
tension.

· Check drive belt is worn or damaged, and replace if

Air conditioning compressor necessary.
drive belt and power steering
pump drive belt · Check the belt tension, and adjust if necessary.

· Press the central section of belt with a force of 100N and

check the deflection of each belt.

Alternator and fan · Deflection standard value

pulley drive belt

mm

Initial tension

Power steering pump drive belt 8—10

· Loosen power steering pump locking bolt(s) and adjust belt

tension with adjusting bolt.

10) Modulator vacuum hose

191
Power steering pump locking bolt torque

N·m

37.5

Idler locking nut torque

N·m

25

8) Air conditioning compressor assembly

· Install the fixing bolt(s) of air conditioning compressor and
screw down the bolt(s) to the specified torque.

Compressor fixing bolt torque N·m

20

· Connect the wire connector of electromagnetic clutch.

· Install air compressor drive belt and adjust the belt tension.

· Check drive belt is worn or damaged, and replace if

necessary.

· Check the belt tension, and adjust if necessary.

· Press the central section of belt with a force of 100N and

check the deflection of each belt.

· Deflection standard value

mm

Initial tension

Air conditioning compressor drive belt 8— 10

· Loosen rir conditioning compressor locking bolt(s) and adjust
belt tension with the adjusting bolt of adjuster.

Idler locking nut torque N·m

25

7) Oil pressure switch wire

· Connect oil pressure switch wire connector.

6) Fuel hose
· Connect fuel delivery hose and return hose, and then tighten
the anchorage clip(s) firmly.

192
5) Glow plug wire
· Install wire connector and tighten bolt(s) firmly.

4) Engine control cable

① Mount the control cable to engine control lever.

② Place the throttle lever at fully-off position and pull tight the

control cable along the arrow direction to prevent slackness.

③ Tighten the throttle cable bracket bolt(s).

3) Heater hose
· Connect the radiator hose, and then tighten the anchorage
clip(s) firmly.

2) Air intake duct

· Connect the air-intake duct, and then tighten the anchorage
clip(s) firmly.

1) Radiator assembly

① Install shock-absorbing rubber at both sides.

② Mount radiator support.

③ Connect the upper and lower hoses of the radiator.

④ Connect storage tank hose.

1. Transmission assembly and clutch assembly

2) Clutch

193
② Driven plate assembly
· Apply multifunctional supramoly grease to the splines of
driven plate hub.

· Mount the driven plate assembly with a guiding centralizer.

① Pressure plate assembly

· Screw down pressure plate fixing bolts in turn.

Pressure plate fixing bolt torque N·m

25

· Remove the guiding centralizer.

Note:
If a new pressure plate is installed, make sure to remove the
protection diaphragm spring cable after tightening the
pressure plate to the specified torque.

1) Transmission

⑨ Mounting bracket

Mounting bracket nut torque N·m

69

⑧ Transmission assembly
· Use a transmission jack to jack up the transmission.

Caution:
In order to prevent transmission overturn, use chains or belts
to secure it to the jack.

· Shift the transmission to high speed gear.

· Tilt the transmission in the same straight line with the engine.

· Rotate parking brake drum outputs to ease the clutch spline

engagement.

194
Clutch cover to flywheel casing bolt torque

N·m

M10：46

M12：91
· Hoist the engine and let the transmission enter the rear
transmission bracket.

Rear engine support nut and bolt torque

N·m

MlO：40

M12：69

⑦ Front exhaust pipe

Front exhaust pipe bolt torque N·m

37

⑥ Exhaust brake assembly

Exhaust brake bolt torque N·m

17

⑤ Clutch slave cylinder

Slave cylinder bolt torque N·m

20
· Adjust the slave cylinder before mounting return spring.

a) Unscrew the push rod locking nut.

b) Turn the adjusting nut until it is against the release fork.

c) Back off the adjusting nut by 1½ turns.(The free gap of
release fork is about 2mm).
d) Screw down the locking nut.

Push rod locking nut torque N·m

16

④ Shift and select cables

③ Wire connector

195
② Parking brake cable

① Drive shaft
· Align previously made marks.

Drive shaft nut torque N·m

66

· Connect the ground cables of battery.

· Add some coolant.

· Add some oil.

· Start the engine and check whether the coolant leaks.

196
3.17 Crankshaft front oil seal

Disassembly sequence
1. Fan cowl
2. Power steering pump drive belt
3. Alternator drive belt
4. Cooling fan assembly
5. Crankshaft damper pulley
6. Front oil seal
Assembly sequence
As assembling, go on according to the
reverse sequence of disassembly.

Disassembly
Preparation:

 Remove battery ground cables.

 Discharge coolant completely.

1. Fan guard

2. Power steering pump drive belt

 Unscrew bracket fixing bolt(s) and adjusting bolt(s) of the

power steering pump, then remove the drive belt.

3. Alternator drive belt

 Unscrew alternator bracket fixing bolt(s) and adjusting

plate locking bolt(s), then remove the drive belt.

4. Cooling fan assembly

 Unfasten tight nut(s), and dismount the fan assembly,

collar and fan pulley.

197
5. Crankshaft damper pulley

6. Front oil seal

 Tap around the oil seal with a plastic hammer and a

screwdriver, and take out the oil seal out of the gear
chamber cover.

Exercise care to avoid damaging the seal mating surface.

Assembly
6. Front oil seal

 Mount the oil seal ① onto the gear chamber cover ② with
an erector.

Oil seal erector: 1002420FA-9101

Pay attention to the seal mounting level ③ shown in the

diagram.

Mounting depth ③ = l mm

5. Crankshaft damper pulley

Screw down the crankshaft damper pulley bolt(s) to the

specified torque.

Note:

Pulley bolt torque N·m

210

4. Cooling fan assembly

 Install the fan pulley, spacer block and cooling fan

assembly (in this installing order) to a water pump, and
tighten those parts to the specified Tightening torque

N·m

12.5

3． Alternator drive belt

 Mount the alternator drive belt and adjust the belt tension.

 Refer to the “Drive belt adjustment”in this section.

198
2. Front oil seal

 Mount power steering pump drive belt and adjust the belt
tension.

 Refer to the “Drive belt adjustment”in this section.

1. Fan guard

 Install the fan guard and storage tank hose.

 Add in some coolant.

 Start the engine and check whether there is any leakage

of the coolant.

199
3.18 Crankshaft rear oil seal

Disassembly sequence
1. Transmission and clutch assembly
2. Flywheel
3. Rear oil seal
Assembly sequence
As assembling, go on according to the
reverse sequence of disassembly.

Disassembly
Preparation:

 Remove the battery ground cable.

1. Transmission and clutch assemblies

Hoist the car and support it with a suitable and

Setting mark
safe bench.

1) Transmission

① Transmission

Mark the parking brake drum and flange yoke

beforehand.

 Remove the flange yoke drive shaft.

 Put the bundled up drum and flange yoke

aside so as to facilitate maintenance work.

200
② Parking brake cable

 Detach the connecting hood.

 Remove connecting bolts.

 Dismantle anchorage clips and withdraw

bracket cables.

③ Wire connector

 Detach wire connectors of the vehicle

Shift cable Anchorage clips
speed sensor, neutral switch and back-up
Gear pin
light switch.

④ Shift and select cables

Select cable  Remove the shift and select cables on
Gear pin transmission side.

⑤ Clutch slave cylinder

Elastic hose
 Remove the clutch hose clips and clip
bracket

Clutch
hose

 Disassemble the slave cylinder assembly

with Elastic hoses, and bind it to the frame
so as to facilitate the maintenance work.

201
⑥ Exhaust brake assembly

⑦ front exhaust pipe

⑧ Transmission assembly

Notes:

Sometimes the exhaust pipe bracket /gear

control bracket and anchorage clips are in the
wrong mounting positions or directions.In order
to prevent this, please mark correct mounting
signs on those parts.

 Use a transmission jack to jack up the

transmission.

Caution:

In order to prevent transmission overturn, use

chains or belts to secure it to the jack.

Do not let the transmission hover over the

clutch, or it will destroy the clutch.

 Remove nuts securing the transmission

mounting bracket on the beam side.

 Angles of the engine and transmission

have to be adjusted so that they can be
easily disassembled.

 Use a jack or crane to jack up the engine

rear part.

Caution:

After jacked up the engine, place a wooden

block under it to protect the oil pan.

 Remove the transmission binding bolts.

 Draw the transmission assembly

backwards.

⑨ Mounting bracket

2) Clutch

 Hoist the car and support it with a suitable

and safe bench.

Caution:

Make sure no clutch fluid is left on the coating

surface, or wash it away immediately.
202
① Pressure plate assembly
② Driven plate assembly
 Use a guiding centralizer to prevent the
driven plate assembly dropping freely.
 Mark the flywheel and pressure plate
flange to ensure alignment during
installation.
 Loosen fixing bolts in the pressure plate
assembly.
2. Flywheel
3. Rear oil seal
 Push in the oil seal and mount special
tools according to the left diagram to
dismantle the oil seal.
 Rear oil seal detacher: 1002430FA-9101
Note:
Take care to avoid damaging the crankshaft and oil
seal pedestal while removing the oil seal.

Assembly
3. Rear oil seal
 Mount the oil seal to the cylinder block with
an oil seal erector.
Rear oil seal erector: 1002430FA-9102
Notes:
Clean the rust and chips off the press-in portion of
the oil seal.
Pay attention to the press-in direction.
1) Use two bolts to connect the adaptor of special
tools to the crankshaft rear end.
2) Install the oil seal to the periphery of the adaptor.
3) Insert the socket into the adaptor portion and
screw down it with a bolt (M12×1.75L=70) until the
adaptor tip is against the socket.
4) Remove the adaptor and socket.
5) Check the oil seal size after it is installed.

Standard value mm

12．2— 12．8

203
2. Flywheel
 Apply some oil to fixing bolts.
 By using of the torque tightening method,
screw down the flywheel bolts to the
specified torque in two steps according to
the left diagram.

Flywheel bolt torque N·m

Step Ⅰ Step Ⅱ Step Ⅲ

25 70 120

1. Transmission and clutch assemblies

2) Clutch
② Driven plate assembly
 Apply multifunctional supramoly grease to
the splines of driven plate hub.
 Mount the driven plate assembly with a
guiding centralizer.
Guiding centralizer:
1601100FA-9101

① Pressure plate assembly

Screw down pressure plate fixing bolts in turn.

Pressure plate fixing bolt torque N·m

25

 Remove the guiding centralizer.

Note:

If a new pressure plate is installed, make sure to

remove the protection diaphragm spring cable after
tightening the pressure plate to the specified torque.

1) Transmission

⑨ Bracket

Bracket nut torque N·m

69

204
⑧ Transmission assembly
 Use a transmission jack to jack up the
transmission.
Caution:
In order to prevent transmission overturn, use
chains or belts to secure it to the jack.
 Shift the transmission to high speed gear.
 Make the transmission tilt in the same
straight line with the engine.
 Rotate parking brake drum outputs to ease
the clutch spline engagement.
Clutch cover to
flywheel casing bolt torque N·m
M10：46
M12：91

 Hoist the engine and let the transmission

enter the rear transmission bracket.
Rear engine bracket nut
and bolt torque N·m
M10：40
M12：69

⑦ front exhaust pipe

Front exhaust pipe bolt torque N·m

37

⑥ Exhaust brake assembly

Exhaust brake bolt torque N·m

17

⑤ Clutch slave cylinder

Slave cylinder bolt torque N·m

19

205
 Adjust the slave cylinder before mounting
return spring.
a) Unscrew the push rod locking nut
b) Turn the adjusting nut until it is against
the release fork.
c) Back off the adjusting nut by 1½ turns.
(The free gap of release fork is about
2mm/0.lin).
d) Screw down the locking nut.
 Push rod locking nut torque N·m

16

④ Shift and select cables

③ Wire connector
② Parking brake cable
① Drive shaft
 Align previously made marks.
Drive shaft nut torque N·m

66

 Connect battery ground cables.

206
3.19 Crankshaft and main bearing

Disassembly sequence
1. Transmission and clutch
assemblies
2. Engine assembly
3. Cylinder head assembly and
gasket
4. Timing gear
5. Oil pan
6. Oil pump
7. Piston oil cooling pipe
8. Piston and connecting rod
assembly
9. Timing pulley chamber
10. Water pump assembly
11. Flywheel and flywheel baffle
12. Rear oil seal
13. Crankshaft and main bearing
Assembly sequence
As assembling, go on according
to the reverse sequence of
disassembly.

207
Disassembly
Preparation:
 Remove battery ground cables.
 Discharge the coolant in the radiator and
engine completely.
1. Transmission and clutch assemblies
 Hoist the car and support it with a suitable
and safe bench.
Setting mark 1) Transmission
① Transmission
 Mark the parking brake drum and flange
yoke beforehand.
 Remove the flange yoke drive shaft.
 Bind the removed drive shaft to the frame
so as to facilitate the maintenance work.

② Parking brake cable

 Detach the connecting hood.
 Remove connecting bolts.
 Dismantle anchorage clips and withdraw
bracket cables.

③ Wire connector
Shift cable Anchorage clips  Detach wire connectors of the vehicle
Gear pin speed sensor, neutral switch and back-up
light switch.
④ Shift and select cables
 Remove the shift and select cables on
transmission side.
Select cable

Gear pin

208
Elastic hose
⑤ Clutch slave cylinder
 Remove the clutch hose clips and clip
bracket (only for vehicles with right
steering wheel).

 Disassemble the slave cylinder assembly

with Elastic hoses, and bind it to the frame
so as to facilitate the maintenance work.

⑥ Exhaust brake assembly

⑦ front exhaust pipe

⑧ Transmission assembly
Notes:
Sometimes the exhaust pipe bracket, gear
control bracket and anchorage clips are in the
wrong mounting positions or directions. In order
to prevent this, please mark correct mounting
signs on those parts.
 Use a transmission jack to jack up the
transmission.
Caution:
In order to prevent transmission overturn, use
chains or belts to secure it to the jack.

209
Do not let the transmission hover over the
clutch, or it will destroy the clutch.
 Remove nuts securing the transmission
mounting bracket on the beam side.
 Angles of the engine and transmission
have to be adjusted so that they can be
easily disassembled.
 Use a jack or crane to jack up the engine
rear part.
Caution:
After jacked up the engine, place a wooden
block under it to protect the oil pan.
 Remove the transmission binding bolts.
 Draw the transmission assembly
backwards.
⑨ Mounting bracket
2) Clutch
 Hoist the car and support it with a suitable
and safe bench.
Caution:
Make sure no clutch fluid is left on the coating
surface, or wash it away immediately.
① Pressure plate assembly
② Driven plate assembly
 Use a guiding centralizer to prevent the
driven plate assembly dropping freely.

 Mark the flywheel and pressure plate

flange to ensure alignment during
installation.
 Loosen fixing bolts in the pressure plate
assembly.
2. Engine assembly
1) Radiator assembly
 Remove the upper and lower hoses of the
radiator.
 Remove storage tank hose.
 Remove the shock-absorbing rubber on
both sides.
 Remove radiator support.
2) Air intake duct

210
3) Heater hose
4) Engine control cable
 Unscrew the locking nut(s) at the bracket
and remove throttle wire(s) from the
injection pump control lever.
5) Glow plug wire
6) Fuel hose
 Remove fuel inlet hose and return hose.
7) Oil pressure switch wire
8) Air conditioning compressor assembly
 Unscrew idler locking nut(s)
 Loosen the adjusting nut(s) and remove
the drive belt.

 Remove the magnet clutch wire connector.

 Remove fixing bolt(s) of the air
conditioning compressor and bind the
compressor to the frame temporarily with
wires.

9) Power steering pump and bracket

assemblies (power steering type)
Bracket  Unscrew idler locking nut(s)
 Loosen the adjusting nut(s) and remove
Locking nut
the drive belt.
 Remove pipe bracket fixing bolt(s) and
anchorage clip (s).
Anchorage
clip  Remove power steering pump fixing bolt(s)
Anchorage and bind the pump to the frame
clip temporarily with wires.

211
10) Front exhaust pipe
 Remove exhaust pipe fixing bolt(s) of the
exhaust manifolds.
 Remove exhaust pipe support bolt(s).
 Remove front exhaust pipe fixing nut(s).

11) Support rubber

① If mounted on the right side
 Remove the two fixing nuts on beam side.
② If mounted on the left side
 Remove the two fixing nuts on beam side.

12) Engine assembly

 Slowly hoist the engine by a crane.
 Lift the engine with its front part higher
than rear part.
While taking out the engine assembly be
careful to avoid breaking any oil pipe, brake
pipe, etc.

3. Cylinder head assembly and gasket

1) High pressure oil pipe
 Unscrew high pressure oil pipe anchorage
clip(s).
 Remove taper nut(s) on the injection pump
side.
 Remove taper nut(s) on the fuel injector
side and high pressure oil pipe.

212
2) Oil return hose
 Remove oil return hose(s) of the injection
pump.
3) Crankcase vent hose(s)
 Dismantle crankcase vent hose(s) from the
air-intake duct.

4) Glow plug wire

5) Oil scale guide
 Remove oil scale guide out of the cylinder
head.

6) Oil cooler tube D

 Remove pipe bracket fixing bolt(s) on the
rear side of cylinder head.
 Remove cooler tube from the cylinder
head.

7 Bypass hose
8) Cylinder head cover
 Remove crankcase vent hose and cylinder
head cover bolt(s).

213
9) Rocker shaft
 Loosen rocker shaft support bolt(s) bit by
bit according to the sequence shown in the
diagram.
Note:
Disobedience will bring unfavorable influence
to the rocker shaft.
10) Push rod
11) Cylinder head assembly
 Loosen cylinder head bolt(s) bit by bit
according to the sequence shown in the
diagram.
Note:
Disobedience will bring unfavorable influence
to the cylinder head lower surface.
12 Cylinder head gasket
 Remove cylinder head gasket and anchor
pin.
4. Timing gear
1) Cooling fan assembly
 Unfasten tight nut(s), and dismount the fan
assembly and fan pulley.
2) Crankshaft damper pulley
3) Acoustic hood
4) Acoustic hood liner
5) Timing gear chamber cover
 Remove oil seal from the timing gear
chamber cover.
6) Oil pipe
7) Idler gear
 Measure camshaft and crankshaft timing
gear clearances before disassembling the
idler gear.
 Measure axial clearance for idler gear
before disassembling the idler gear.
Note:
Refer to the following items while measuring
gear clearance and axial clearance.

214
Timing gear clearance measurement
1) Install a dial gauge onto the timing gear to
be tested.
Fix the gear to be tested and the gear
connected to it.
2) Swing the gear to be tested left and right.
Read out the dial gauge readings.
If the measured value exceed prescribed limit,
the timing gear has to be replaced.
Timing gear clearance mm
Standard value Limit
0.10— — 0.17 0.30

Axial clearance measurement of idler gear ”A”

Measure the clearance between idler gear A
and thrust ring with a clearance gauge and
determine the idler gear axial clearance.
If the measured value exceeds prescribed limit,
the thrust ring has to be replaced.
Idler gear axial clearance mm
Standard value Limit
0.07 0.2

9) Idler gear
10) Injection pump
 Remove six injection pump bracket bolts①
from the timing gear chamber.
 Remove rear bracket bolt② from the
injection pump bracket③.
 Remove rear bracket bolt④ and bracket⑤
from the cylinder block.
 Drag both the injection pump and injection
pump timing gear out towards the engine
backside.
Note:
Cover the hole in injection pump delivery valve
body with a cover or equivalents to prevent
foreign bodies falling into the valve.

215
11) Camshaft timing gear
① Measure the camshaft axial clearance with
a dial gauge.
Measure the clearance before disassemble the
camshaft gear.
If the camshaft axial clearance exceeds
prescribed limit, the thrust washer has to be
replaced.
Camshaft axial clearance mm
Standard value Limit
0.050— — 0.114 0.2

② Remove camshaft timing gear bolt(s) from

the camshaft.
Note:
Protect the camshaft against rotating.
③ Pull out camshaft timing gear② with a
universal puller①.
Universal puller: 1007011FA-9101
④ Remove the thrust washer③.

12) Crankshaft gear

 Detach crankshaft gear② with crankshaft
gear detacher①.
Crankshaft timing gear detacher:
1007011FA-9101

5. Oil pan
 Remove the stiffener plate from both sides
of the oil pan.
 Remove the oil pan from the cylinder
block.

216
6. Oil pump
 Remove the oil pump from the cylinder
block.

7. Piston cooling oil pipe (4DA1-1) / hexagonal

head plug (4DA1)
 Remove the oil cooling pipe from the
cylinder block.

8. Piston and connecting rod assembly

 If it is intended to reassemble the lower
bearing of connecting rod, please attach a
label to each bearing, then mark the
cylinder disassembling sequence and its
installation position.

 Scrape carbon deposits on upper cylinder

wall with a scraper before disassembling
the piston and connecting rod.
Move the piston to cylinder head, push
upwards connecting rod underpart with a
hammer handle or equivalents, and then take
out the piston and connecting rod.

 If it is intended to reassemble the upper

bearing of connecting rod, please attach a
label to each bearing, then mark the
cylinder disassembling sequence and its
installation position.

217
9. Timing pulley chamber
10. Water pump assembly
11. Flywheel and flywheel baffle
 Install flywheel stopper.
 Loosen flywheel fixing bolt(s) and remove
the flywheel.
 Disassemble the flywheel baffle from
cylinder block.
12. Rear oil seal
 Push in the oil seal and mount special
tools according to the left diagram to
dismantle the oil seal.
Rear oil seal detacher: 1002430FA-9101
Note:
While disassembling, take care to avoid
damage the flywheel baffle and crankshaft
sealing surface.
13. Crankshaft and main bearing
1) Remove main bearing cap and thrust
plate.
2) Disassemble the crankshaft carefully.
3) Disassemble the upper crankshaft bearing.

Assembly
13. Crankshaft and main bearing
 The upper crankshaft bearing has an oil
hole and oil groove while the lower
bearing doesn’ t.
 Apply fresh oil to the upper and lower main
bearings.
 Make sure the main bearings are in the
correct positions.
 Wipe off foreign bodies on the bearings.
 Mount crankshaft main bearings to the
cylinder block and main bearing cap.
Note:
Do not apply oil to bearing backside and
cylinder bearing mating surface.
 Bearings should be installed in correct
positions.
 Apply fresh oil to the upper and lower main
bearings.

218
 Install the crankshaft carefully.
 Apply oil to the thrust plate.
 Mount the thrust plate to the third main
journal.
The oil groove on thrust plate must be facing
the crankshaft.

 Apply recommended liquid sealant or

equivalents to the fifth crankshaft bearing
cap as shown in the drawing.

 Apply recommended liquid sealant or

equivalents to the fifth crankshaft bearing
cap surface mating with cylinder block as
shown in the drawing.
Notes:
Before applying liquid sealant, make sure there
is no oil on the main bearing cap mating
surface.
Make sure the liquid sealant will not block
cylinder thread hole and bearings.
 While mounting bearing caps, arrow signs
on each bearing cap must point to the
engine forepart.
 Apply oil to crankshaft bearing cap bolts.
 Tighten the crankshaft bearing cap bolts to
the specified torque bit by bit as shown in
the drawing.
N·m
170
Note:
Manually rotate the crankshaft to check
whether it is flexible.

219
12. Crankshaft rear oil seal
Mount the oil seal to the cylinder block with an
oil seal erector.
Rear oil seal erector: 1002430FA-9102
Notes:
Clean the rust and chips off the press-in portion
of the oil seal.
Pay attention to the press-in direction.
1) Use two bolts to connect the adaptor of
special tools to the crankshaft rear end.
2) Install the oil seal to the periphery of the
adaptor.
3) Insert the socket into the adaptor portion
and screw down it with a bolt
(M12×1.75L-70) until the adaptor tip is
against the socket.
4) Remove the adaptor and socket.
5) Check the oil seal size after it is installed.
Standard value mm
12.2— — 12.8

11．Flywheel and cylinder block flywheel baffle

 Align the flywheel baffle with cylinder block
anchor pin(s).
 Tighten the flywheel baffle to the specified
torque.
Flywheel baffle bolt torque N·m
85

 Lock the crankshaft with hardwood so as

to prevent the flywheel rotating.
 Apply oil to flywheel bolt thread.
 Align the flywheel with crankshaft anchor
pin(s).
 By using of the torque tightening method,
screw down the flywheel bolts to the
specified torque in two steps according to
the diagram.
Flywheel bolt torque N·m
Step Ⅰ Step Ⅱ Step Ⅲ
25 70 120

220
10. Water pump
 Install a O-ring to water pump body.
 Install water pump and tighten the bolt(s)
to the specified torque.
Water pump bolt torque N·m
25

 Eliminate the gasket burrs.

9. Timing gear chamber
 Install the timing gear chamber to the
cylinder block. Exercise care to avoid
bending front oil seal.
 Tighten the timing gear chamber and its
gasket to the specified torque.
Timing gear chamber
Bolt torque N·m
25

8. Piston and connecting rod assembly

1) Try to manually push the piston pin into
piston pin hole.
Weigh each piston and connecting rod
assembly.
Select the piston and connecting rod set in a
way that different assembly weight differences
are in the specified limits.
Weight differences
while assembled
4DA1 10
4DA1-1 8

2) Clamp the connecting rod by a vice

Take care not to damage the connecting
rod.
3) Mount piston pin retainer to the piston with
pliers.
Note:
When replacing the piston / connecting rod
assembly, do not change the piston / piston pin
assembly.

221
4) Install the piston onto the connecting rod.
Mark ① on the piston head and connecting rod
“F908”casting symbol ② should point to the
same direction.

5) Add oil to the piston pin and piston pin

hole.
Manually push piston pin into the piston until it
is against the piston pin retainer.

6) Manually mount the piston pin retainer into

piston retainer groove.
Check whether the connecting rod can freely
swing on the piston pin.

7) Install piston ring and piston packing ring.

The gas ring mark JAC should face upwards.
Identification sign is shown in the drawing.

JAC mark (first ring)

(Second ring)
8) Mount three piston rings with a piston ring
erector.
The piston ring mounting sequence is shown in
the drawing.
① Oil ring
② Second gas ring
③ First gas ring
Note: When mounting gas rings the chamfer is
facing upwards.
Install the helical piston packing ring into oil ring
groove and make sure that the packing ring
and the oil ring are closely meshed.

222
First gas ring Coil-spring-loaded
opening
9) Apply some oil to the piston ring surface.
10) Check whether the piston ring can turn
freely in piston ring groove.
11) The cutout position for placing piston ring
is shown in the drawing.
Oil ring Second gas ring

12) Carefully wipe off the foreign bodies on

connecting rod bearing backside and
bearing seat joint faces.
13) Apply some oil to the upper bearing
surface.
Apply some oil to the cylinder wall.

14) While installing, the piston head mark must

be towards the engine forepart.
Compress the piston ring with a piston ring
compressor.
Piston ring compressor: 1004022FA-9101
15) Push in the piston with a hammer handle
until the connecting rod touches the
crankpin. In the meanwhile rotate the
crankshaft until the crankpin reaches its
bottom dead center.

16) While installing, the bearing cap upper

front mark must be towards the engine
forepart.
17) Install connecting rod bearing cap.
Align the cylinder sequence mark on
connecting rod bearing cap with the one on
connecting rod.
Front mark

223
18) Apply oil to each connecting rod bearing
cap bolt thread and bearing seat joint
faces.
19) Screw down connecting rod bearing cap
bolt to the specified torque in two steps by
utilizing the torque tightening method.
Connecting rod bearing cap bolt torque N·m
First step (sealing Second step (final
torque) torque)
20 85

Note:
Manually rotate the crankshaft to check
whether it is flexible.
7. Piston cooling oil pipe (4DA1-1) / hexagonal
head plug (4DA1)
 Mount the piston cooling oil pipe to the
cylinder block.
Screw down oil pipe bolt and check valve to the
specified torque.
4AD1-1 oil pipe bolt torque N·m
①M8X1．25 20
N·m
②M6X1．00 7.5
Oil pressure regulating valve torque
③M16X1．5 30
4DA1 hexagonal head plug moment
45
Note:
Turn the crankshaft slowly; make sure the piston
and the oil injection pipe don’ t interfere with each
other.
6. Oil pump assembly
 Prepare some solution containing 80％ oil
and 20％ supramoly.
 Apply enough solution to the oil pump
pinion teeth.
 Apply some oil to oil pipe O-ring and put it
into the cylinder block O-ring groove.
 Install the oil pump assembly with oil pipe
to the cylinder block, and tighten fixing
bolts to the specified torque.

224
Oil pump bolt torque N·m
25
 Tighten sleeve nut(s) to the specified torque.
Sleeve nut torque N·m
30
Note:
Be careful not to destroy the O-ring when tightening
the oil pipe bolt(s).

5. Oil pan assembly

 Apply recommended liquid sealant or
equivalents to the fifth bearing cap arch
section, groove and timing gear chamber
arch section.

 Install back lip portion of the gasket into

the fifth groove.
 Make sure the lip portion is compact with
the groove.
 Install the oil pan to the cylinder block.
 Tighten oil pan bolt(s) to the specified
torque.
Oil pan bolt torque N·m
23.5

225
4. Timing gear
12) Crankshaft gear
 Install crankshaft gear
 Install crankshaft gear② with crankshaft
gear erector①.
 Crankshaft timing gear mark (“X-X”)
should face outwards.
Crankshaft gear erector: 1007011FA-9102

11) Camshaft timing gear

 Install the thrust washer onto the cylinder
block.
 Tighten thrust washer bolt(s) to the
specified torque.
N·m
25

 Install camshaft timing gear to the

camshaft.
The timing gear mark (“Y— Y”) has to face
outwards.
 Tighten the timing gear to the specified
torque.
Timing gear bolt torque N·m
110

10) Injection pump

① Install O-ring ① to the injection pump
flange ②.
② Install the injection pump to the timing gear
chamber.
Align the mark “V-V”of idler gear “B”③ with the
mark “V”of injection pump timing gear ④.

③ Temporarily tighten Six injection pump nuts

⑤.
The final screwing down of injection pump nuts
is conducted after tightening the injection pump
rear bracket bolt(s).

226
④ Install injection pump rear bracket⑥ and
rear bracket bolt⑦ to the cylinder block.
⑤ Mount rear bracket bolt⑧ to the injection
pump bracket⑨.
Do not screw down those bolts.
Rear bracket bolt⑦ and ⑧ will be tightened to
the specified torque after tightening the
injection pump nuts.
⑥ Tighten the injection pump nuts to the
specified torque.
Injection pump nut torque N·m
30

⑦ Screw down injection pump bracket bolts

to the specified torque.
Pump bracket bolt torque N·m
25
9) Idler gear “B”and its shaft
① Apply some oil to the idler gear and its
shaft.
② Align mark “Z” of gear “B” ③with mark
“Z— Z”of idler gear “A”④.
 Tighten idler gear bolt(s) to the specified
torque.
Idler gear bolt torque N·m
110

8) Idler gear
① Apply some oil to the idler gear and its
shaft.
The oil hole in idler gear shaft must be facing
upwards.
② Arrange idler gear marks “X”and “Y”so
that they both face the engine forepart.
③ Align idler gear mark “X” with the mark
“X— X”of crankshaft timing gear①.
③ Align idler gear mark “Y” with the mark
“Y— Y”of crankshaft timing gear②.
⑤ Install the thrust ring and bolt to the
cylinder body passing through the idler
gear.
Thrust ring oil hole must be facing upwards
while its chamfer facing outwards.

227
⑥ Tighten idler gear bolt to the specified
torque.
Idler gear bolt torque N·m
25
7) Timing gear oil pipe
Install the oil pipe to timing gear chamber and
idler gear “A”.
Tighten oil pipe eyebolt① and bolt② to the
specified torque.
Oil pipe punching bolt torque N·m
20
6) Timing gear chamber cover
Align timing gear chamber anchor pin with the
timing gear chamber, then install timing gear
chamber cover.
Tighten gear chamber cover bolt to the
specified torque.
5) Acoustic hood liner
4) Acoustic hood
3) Upper acoustic hood
2) Crankshaft damper pulley
Screw down the crankshaft damper pulley
bolt(s) to the specified torque.
Note:
While screwing down the damper pulley, hold
the flywheel ring gear to prevent crankshaft
rotating.
Pulley bolt torque N·m
210
1) Cooling fan assembly
 Install the fan pulley, spacer block and
cooling fan assembly (in this installing
order) to a water pump, and tighten those
parts to the specified Tightening torque.
N·m
12.5

3. Cylinder head assembly

2. Engine assembly
1. Transmission and clutch assemblies
“3-1”is referred to the “3.16 shaft and tappet”
section.

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4 Engine cooling system
4.1 General

The engine cooling system is a pressure type

coolant forced circulation version.It has a
radiator cover and its differential pressure and
boiling point are 98 ～ 196kpa and 120℃
respectively.The system consists of a water
pump, thermostat, fan, radiator and other
components.Circulating coolant is used to cool
down the oil in oil filter and turbocharger.

Oscillating valve
Water pump
It is a vane centrifugal pump driven by V drive
belt.

Thermostat
The thermostat belongs to wax type with an
oscillating valve installed on the original valve. It
is installed on the thermostat body.

Radiator
It is a tube type radiator with corrugated fins. In
order to increase the boiling point, a cap with a
valve is installed on the cylinder head thermostat
body. This valve opens at the pressure
0.90— 1.20kg/cm2.

229
Mixing ratio (%)
Anti-freezer
 The relationship between mixing ratio
Freezing point (℃)

and freezing point

The freezing point temperature of engine
coolant changes with the ratio of anti-freezer
in water.
Correct mixing ratio can be determined
according to the graph. Do not add the
attached anti-rust agent or additive with
enhancing cooling ability to the cooling
system without approval of JAC Automotive
Co., Ltd.
 Mixing ratio calculation

Anti-freezer（L/qt）
Maxing ratio =
Anti-freezer（L/qt）+ water（L/qt）

Note: Anti-freezer + water = 10L

Total volume of the cooling system
E.g., total volume of the cooling system is
10L

Mixing Anti-freezer Water

ratio％
L(qt (En)／qt L(qt (En)／
(Ame)) qt(Ame))

0 0 (0) 10(8.80／10.57)

5 0.5(0.44／0.53) 9.5(8.36／10.04)

10 1.0(0.88／1.06) 9.0(7.92／9.51)

15 1.5(1.32／1.59) 8.5(7.48／8.98)

20 2.0(1.76／2.11) 8.0(7.04／8.45)

25 2.5(2.20／2.64) 7.5(6.60／7.93)

30 3.0(2.64／3.17) 7.0(6.16／7.40)

35 3.5(3.08／3.70) 6.5(5.72／6.87)

40 4.0(3.52／4.23) 6.0(5.28／6.34)

45 4.5(3.96／4.76) 5.5(4.84／5.81)

50 5.0(4.40／5.28) 5.0(4.40／5.28)

230
 Mixing ratio
Mixing ratio
Measure the specific gravity of engine cooling
system coolant in 0℃ to 50℃ temperatures with
a draft hydrometer, and then determine the
coolant mixing ration according to the graph.
Specific gravity

Coolant temperature (℃)

231
4.2 Water pump

Disassembly sequence
1. Fan cowl
2. Fan assembly
3. Power steering pump drive belt
4. Air conditioning compressor
drive belt
5. Alternator drive belt
6. Water pump assembly

Assembly sequence
As assembling, go on according to
the reverse sequence of
disassembly.

4.2.1 On-vehicle repair

Disassembly
Preparation:
 Remove battery ground cables.
 Discharge the coolant.

1. Fan cowl
 Remove storage tank hose and fan
cowl.
2. Fan assembly
 Unscrew the locking nut(s) and take out
the fan assembly.
3. Power steering pump drive belt
 Loosen idler locking nut(s) and
adjusting bolt(s), and then remove the
drive belt.

232
4. Air conditioning compressor
 Loosen ac compressor idler locking
nut(s) and adjusting bolt(s).
Dismount the drive belt.

Locking bolt
5. Alternator drive belt
 Unscrew alternator fixing bolt(s) and
adjusting plate locking bolt(s), then
remove the drive belt.

Assembly

6．Water pump assembly

 Detach the O-ring.
 Put the O-ring into the water pump
groove.
 Install water pump assembly and
tighten the bolt(s) to the specified
torque.
Water pump fixing bolt torque N·m
25

233
Air conditioning idler Inspection
compressor
Adjusting If during inspection it is found that the water
Adjusting bolt
plate pump is severely worn or damaged, repair the
Power steering pump
pulley water pump and replace the worn-out parts. The
whole water pump assembly has to be replaced
Fan pulley
in case of one of the following problems.
Alternator
 There is a crack on the water pump
Alternator bolt idler body.
 The coolant leaks from the water seal.
Crankshaft pulley
adjusting idler  The ball bearing is loose or produces
unusual noise.
 Water pump impeller cracked or
experienced corrosion.

5. Alternator drive belt

4. Air conditioning compressor drive belt
3. Power steering pump drive belt
 Install and adjust those drive belts.
Inspect whether the drive belts are
intact. Replace them if necessary.
Check the belt tension, if necessary
adjust the tension.
 Apply a force of 100N to those belts
and check the deflection of each belt.

Ac conditioning compressor and  Standard deflection

power steering pump drive belts
mm

Initial tension
Alternator drive belt 8— — 10
Air conditioning compressor
drive belt
Alternator and fan Power steering pump drive
drive belts
belt

234
Generator fixing bolt torque N·m
40
Adjusting plate fixing bolt torque N·m
25
Ac compressor idler locking nut torque N·m
27
Power steering pump idler
locking nut torque N·m
27

2． Fan assembly
 Fix the fan pulley and fan assembly
onto the water pump, and tighten them
to the specified torque.
Fan pulley nut torque N·m
12.5

1． Fan cowl
 Install the fan cowl and storage tank
hose.
 Connect battery ground cables.
 Fill in coolant.
 Start the engine and check whether
there is any leakage of the coolant.

235
4.2.2 Single-piece repair

Disassembly sequence
1. Set screw
2. Fan center flange
3. Water pump impeller
4. Water seal assembly
5. Oil striker
6. Bearing assembly
7. Water pump body

Reassembly sequence
As reassembling, go on
according to the reverse
sequence of disassembly.

Disassembly
1. Set screw
2. Fan center flange
 Push down the fan center flange with a
bench press and compression bar.

3. Water pump impeller

4. Water seal assembly
5. Oil striker
6. Bearing assembly
1) Heat up water pump body in hot water
(80-90℃／176-194℉).

236
2) Push down the water pump impeller,
water seal assembly and bearing
assembly with a bench press and
compression bar.
Note:
Do not attempt to disassemble the water
pump impeller with a hammer, or it will
destroy the impeller.
7. Water pump body

Inspection and repair

 If during inspection it is found that the
water pump is severely worn or
damaged, adjust and repair it and
replace the worn-out parts.
Bearing assembly
 Check if there is any noise, stuck and
other unusual phenomena in the
bearing assembly.

Reassembly
7. Water pump body
6. Bearing assembly
1. Set screw
1) Align bearing set screw(s) with water
pump body set screw(s).
Set screw
2) Press the bearing assembly into the
water pump body.
3) Fix the bearing with set screw(s).
5. Oil striker

4 Water seal assembly

1) Coating a thin layer of liquid sealant on
the water seal assembly outer edge.
2) Install the water seal assembly.

237
3. Water pump impeller
1) Install the water pump impeller with a
bench press.
2) Measure the distance between water
pump impeller protrusion and water
pump body end face. The water pump
impeller protrusion size has to be
ensured.
Impeller protrusion size (L) mm
24.6

2. Fan center flange

Measure the distance between fan fitting surface
and rear fan cover.
Fan center distance mm

Standard value
79．2— — 79.8

Notes:
1. Never disassemble and install the fan center
flange and water pump impeller for the
second time while mounting those units onto
the water pump shaft with a bench press.
Otherwise replace the whole water pump
assembly. Disassembling and installing
those units for the second time will lead to
the water pump broken during engine
operation with serious overheating.
2. If the force applied to fan center flange and
water pump impeller is less than 1960N
(200kg ／ 44lb), replace the water pump
assembly.
3. Do not use hammers or similar tools to
knock the bearing into water pump body, or
it will destroy the bearing.

238
4.3 Thermostat

Disassembly sequence
1．Switch wire bundle
2．Water outlet pipe
3．Gasket
4．Thermostat
Assembly sequence
As assembling, go on according to the
reverse sequence of disassembly.

Disassembly
Preparation:
 Remove battery ground cables.
 Drain off the coolant in the radiator and
generator .
1． Switch wire bundle
2． Water outlet pipe
Unscrew the fixing bolt(s). Remove both the
water outlet pipe and radiator hose.
3． Gasket
4． Thermostat

Inspection
Put the thermostat assembly into water.
Place a wooden block under the water container.
Do not heat up the thermostat directly.
Increase water temperature gradually with
continuous stirring so as to keep the water
temperature in the container be equalized.
Confirm the main valve opens at the specified
temperature.

239
Valve opening temperature ℃
82
Confirm the secondary valve fully opens at the
specified temperature.
Valve fully opening temperature ℃
95
If during inspection it is found that the thermostat
is severely worn or damaged, repair it and
replace the worn parts.

Assembly
4． Thermostat
3． Gasket
2． Water outlet pipe
 Connect water outlet pipe and tighten
the bolt(s) to the specified torque.
N·m
19

1． Switch wire bundle

 Install the switch wire bundle.
 Connect battery ground cables.
 Fill in coolant.
 Start the engine and check whether
there is any leakage of the coolant.

240
4.4. Radiator

Disassembly sequence
1．Storage tank hose
2．Radiator hose
3．Air-intake duct
4．Radiator support
5．Condenser
6．Rubber cushion
7．Radiator assembly
Assembly sequence
As assembling, go on according to
the reverse sequence of
disassembly.

Disassembly
Preparation:
 Remove battery ground cables.
 Loosen drain plug and discharge the
coolant.
1． Storage tank hose
 Remove the lower hose from the
radiator.
2． Radiator hose
 Remove the upper and lower hoses
from the engine.
3． Air-intake duct
4． Radiator support

241
5． Condenser
 Remove the condenser from the
radiator and bind it to the vehicle front
with wires temporarily.
6． Rubber cushion
 Remove the rubber cushions on both
bottom sides.
7． Radiator assembly
 Remove upwards the radiator assembly
with hose(s). Notes
Take care to avoid the fan blades
scratching the radiator core.
Inspection
Radiator cap
 Measure the pressure valve opening
pressure with a radiator cap tester.
If the opening pressure exceeds standard
values, replace the radiator cap.
Check opening pressure of the vacuum
valve installed in the radiator cap valve seat
center.
Valve opening pressure N·m
88．2— 117．6
If the vacuum valve can’ t move smoothly due to
rust or dust, clean or replace the radiator cap.
Radiator core
 Fin distortion will deteriorate the thermolysis
effect and cause the cooling system to be
overheated. Flatten the fin and take care to
avoid damaging the fin bottom part.
 Clean off the dust and other foreign bodies.
Wash the radiator
 Wash radiator inside and coolant passage
with water and neutral detergent. Clean the
scale and incrustant completely.

242
Check whether there is any coolant leakage.
 Feed the compressed air with pressure
of 196．9kPa (28．4psi) through the filler
neck into the radiator by a radiator cap
tester, then check if there is any
leakage in the cooling system.

Assembly
7． Radiator assembly
 Install the radiator.
6． Rubber cushion
 Mount the rubber cushions to the both
bottom sides of the radiator.
 Install the radiator assembly with
hose(s).Take care to avoid the fan
blades scratching the radiator core.
5． Condenser
4． Radiator support
3． Air-intake duct
 Connect the air-intake duct and fix the
clip(s).
2． Radiator hose
 Connect the inlet hose and outlet hose
to the engine.
 Connect battery ground cables.
 Fill in coolant.
 Fill in coolant until it goes up to the
radiator filler neck and MAX mark of the
storage tank.
1． Storage tank hose
 Start the engine and warm it up. Inspect
the coolant level.

Storage tank

243
4.5 Drive belt adjustment

Idler
Ac compressor Adjusting locking nut

Adjusting plate Adjusting bolt

Power steering pump

Fan pulley
Alternator

Alternator fixing bolt

Idler
Crankshaft pulley
Locking nut
Belt position Adjusting bolt

Crankshaft; alternator; fan

Crankshaft; ac compressor; power steering pump
Crankshaft; ac compressor; power steering pump

Crankshaft pulley

Inspection
Inspect whether the drive belts are intact.
Replace them if necessary. Check the belt
tension, if necessary adjust the tension.
 Check belt tension.
 Apply a force of 100N to those drive
belts and check the deflection of each
belt.
 Standard deflection

244
mm
Belt tension while
adjusting
Alternator and fan pulley
drive belts
Air conditioning
8— 10
compressor drive belt
Power steering pump drive
belt

ension adjustment
1． Fan pulley drive belt
 Loosen generator bracket locking bolt.
Adjust belt tension with adjusting bolts
on the adjusting plate. Tighten the bolt
to the specified torque.
Generator fixing bolt torque N·m
37.5
Adjusting plate fixing bolt torque N·m
25

2． Power steering pump and ac compressor

pulley belts
 Loosen power steering pump locking
nut and adjust belt tension with the
adjusting bolt.
Tighten locking nut to the specified torque.
Locking nut torque N·m
27

245
5 Fuel system

5.1 General
Remember the following points while working on Clean and inspect the O-ring. Replace them if
fuel supply system: necessary.
 While the fuel supply system is working Before repairing any part of the fuel supply
you should cut off battery ground system, relieve the pressure in pipes.
cables anytime except when carrying Before repairing the fuel supply system, please
out tests that need batteries. read the product manual and consult to repairing
 Always prepare dry chemical fire drawings.
extinguishers (class B) near the work A certain amount of fuel in the fuel tank flows
place. through water separator and fuel filter –filters off
 Replace all removed oil pipes and parts moistures and other foreign bodies in the fuel,
with same ones. and then goes through the injection pump
The fuel supply system consists of a fuel tank, plunger to the fuel injector in the best time, so the
water separator, fuel filter, injection pump and engine can work effectively.
fuel injector.

Fuel flowing schematic diagram

Solenoid valve of
cold-start unit

Fuel injector
Fuel cut-off
solenoid valve

Distributor type injection pump

Fuel filter Water separator

Fuel tank

246
Injection pump

Governor spring
Aneroid barometric compensator

Control lever
Control shaft lever Floating lever
Pull lever
From the oil filter
Fuel cut-off solenoid valve
Drive shaft

Plunger
Fuel feed pump
Gear flows to the fuel injector
Delivery valve
Driven plate Control sleeve
Automatically advanced supply injector Plunger spring

From the oil filter

Flows to the fuel injector

A distributor type injection pump is used.A This injection pump features a compact and
Reciprocating / Rotating plunger will deliver lighter structure, which works efficiently.
equal fuel to each fuel injector and this has no Aneroid barometric compensator can be used in
relationship with the cylinder number. vehicles operating in plateau areas and it can
The governor, automatically advanced supply regulate the mixing ratio of fuel air.
injector and fuel feed pump are all installed in the
injection pump case.

247
Fuel filter and water separator

Priming pump
Filter body assembly

Filter body
assembly

Housing

Water
Filter element discharging
level

Double filters Float

Lever
sensing unit

Water
drain plug

Besides the distributor type injection pump, a There is a float in the water separator.When the
filter and water separator is also used. float rises up to the specified level, a warning
The injection pump inside is lubricated with the light reminds the workers to discharge water in
flowing fuel.The fuel must be clean. Before the the water separator.
fuel flows into the injection pump, the fuel filter There is a membrane priming pump installed on
and water separator will filter off moistures and the top of the water separator.Use this pump
other foreign bodies in the fuel. when discharging water and air.

248
Fuel injector

Fuel injector body

Pressure adjusting shim

Injector pressure-adjusting spring

Pressure-adjusting spring seat

Fuel injector Gland nut

The fuel injector injects high-pressure fuel from The high-pressure fuel coming from the injection
the injection pump via an injector nozzle into the pump injects via into the combustion chamber
combustion chamber. the injector and injector nozzle.
4DA1 Series generators use hole-type fuel
injector.It has five nozzles.The fuel injector
consists of injector body and fuel injection nozzle
pairs assembly.

249
5.2 Fuel filter assembly

Disassembly sequence
1. Fuel filter cap
2. Fuel hose
3. Fuel filter assembly
Assembly sequence
As assembling, go on according to the
reverse sequence of disassembly.

Disassembly
Preparation:
 Remove battery ground cables.
1. Fuel filter cap
2. Fuel hose
 Remove the fuel hose connected to the
fuel filter body.
 Plug hose ends to pervert fuel
overflowing.
3. Fuel filter assembly
 Loosen the fixing bolt(s) on the fuel filter
bracket.

ASSEMBLY
3. Fuel filter assembly
 Assemble the fuel filter bracket and
screw down the fixing bolt(s).
2. Fuel hose
 Connect the fuel hose to the filter body.

250
1. Fuel filter cap
 Connect battery ground cables.
 Deliver fuel to the injection pump with a
priming pump, and then discharge the
air in the fuel supply system.

Fuel filter element

Disassembly
 Remove the filter element with a filter
wrench.
 Filter wrench: 1010300FA-9101

Assembly
 Clean the filter element installing
surface so that the element can be
installed securely.
 Coating a thin layer of fresh engine oil
on the new element O-ring.
 For discharging air, fill some fuel into
the new element.
 Screw on the new element until the filter
O-ring sticks to the seal surface
seamlessly. Exercise care to avoid fuel
flowing out.
 Further screw on the element by ⅓ - ⅔
turn with a filter wrench.
 Filter wrench: 1010300FA-9101

Air bleed
 Squeeze up the air inside fuel supply
system to the injection pump by starting
the priming pump.
 Loosen injection pump bleeder plug
and start the priming pump until the air
bleeds totally.

251
 Tighten the bleeder plug.
 Start the engine. If the engine can’
t start
within 10 seconds, repeat the above air
bleed operation.
 Make sure there is no fuel leakage and
tighten the priming pump cover.

Water drain
 When the water in oil-water separator
reaches the specified amount, the
warning light will give a signal. Here
drain water in the following steps.
 Connect a vinyl hose to the water drain
plug.
 Loosen the water drain plug.
 Start the priming pump for several times
to drain the water.
 Tighten the plug after draining the
water.
 Start the priming pump for several times
to check whether there is any fuel
leakage.
 Check whether the warning light has
gone out.

252
5.3 Fuel injector

Disassembly sequence
1. High pressure oil pipe
2. Return pipe
3. Fuel injector
Assembly sequence
As assembling, go on
according to the reverse
sequence of disassembly.

Disassembly
Preparation:
 Remove battery ground cables.
1. High pressure oil pipe
 Loosen high pressure oil pipe clamp.
 Loosen the taper nut(s) on the injection
pump side.
 Loosen the taper nut(s) on the fuel
injector side and put aside the high
pressure oil pipe after disconnecting it.
2. Return pipe
3. Fuel injector
Inspection
 Install the fuel injector on the injector
tester.
When the oil pressure is 185kg ／ cm2,
check if there is any oil leakage from the
head portion of the injector.
Replace them if there is any leakage.

253
Disassembly
1. Gland nut
2. Fuel injection nozzle pairs
1) Remove injector parts from the injector
body.
Attach a label to each injector part and the
injector body to ensure that they are
reassembled to the original positions.
Do not change the assembly of injector parts
and the injector body.
2) In order to prevent dust entering the
injector, put it in a tool pan full of clean
diesel oil.
3. Spacer
4. Pressure-adjusting spring seat
5. Pressure-adjusting spring
6. Pressure-adjusting shim
7. Injector body

254
Inspection and repair
If during inspection it is found that the injector is
severely worn or damaged, you have to adjust
and repair the injector and replace the worn-out
parts.
Inspection on fuel injection nozzle pairs
1. Remove the needle valve from the
needle valve body of oil nozzle.
2. Carefully wash the needle valve of oil
nozzle and the valve body in clean oil.
3. Check if the needle valve moves
smoothly in the needle valve body. If
this is not the case, repair the needle
valve and needle valve body.
Grinding procedure of fuel injection nozzle pairs
1. Grind the needle valve of oil nozzle ①
and needle valve body ② with chrome and
animal oil grinding paste.
Notes:
Do not apply excessive chrome and animal
oil grinding paste to the needle valve seat
joint faces. Too much paste will lead to the
severe abrasion of the needle valve and
valve cone.
2. Carefully wash the needle valve and the
valve body in clean oil after grinding.
Inspection on the needle valve body of oil nozzle
and the needle valve
Check if the needle valve body of oil nozzle and
needle valve are damaged and distorted.
If during inspection it is found that the needle
valve and valve body are damaged or distorted,
replace them.

Reassembly
7. Injector body
6. Pressure-adjusting shim
5. Pressure-adjusting spring
4. High pressure spring seat
3. Spacer

255
2. Fuel injection nozzle pairs
1. Gland nut
Tighten gland nut to the specified torque.
N·m
69

Injector adjustment
1) Install the fuel injector on the injector
tester.
2) Pressurize the injector tester to check if
the injector opens at the specified
pressure.
MPa
4DA1 19 — 20
4DA1-1 18.6 — 19.6

If the injector doesn’ t inject oil under the

specified pressure, adjust it with suitable
adjusting shim according to different pressure
classes.
Adjusting shim available mm
Thickness range 0.50— — 1.50
Grading thickness 0.025
Total no. of adjusting shims 40

Decrease or increase the thickness of adjusting

shims by one grade will increase or reduce the
injector opening pressure by 369.46kPa.
Warning:
The testing liquid in the injector is injected
under high pressure, so it may burn your
skin easily. During testing, your hands
should keep away from the injector tester.

256
Assembly
3. Fuel injector
1) Install the injector gasket ① and O-ring
② onto the injector body ③.
The O-ring should be placed in the injector
groove.
2) Fill engine oil into the injector body
nozzle on the cylinder head.
3) Install both the injector body and
injector pressure plate onto the cylinder
head and tighten to the specified
torque.
N·m
37

4) Tighten the injector body nut and shim

⑤ to the specified torque.
N·m
35

2. Return pipe
1. High pressure oil pipe

257
5.4 Injection pump assembly

Disassembly sequence
1. Fan assembly
2. Fan cowl
3. Power steering pump drive
belt
4. Air conditioning compressor
drive belt
5. Alternator drive belt
6. Soundproof cover
7. Soundproof cover gasket
8. Air-intake duct
9. Injection pump control wire
10. Fuel hose
11. Water hose of cold start
device
12. Oil pump wire harness
13. High pressure oil pipe
Assembly sequence
As assembling, go on according
to the reverse sequence of
disassembly.

Disassembly
Preparation:
 Remove battery ground cables.
 Discharge the coolant.
1． Fan assembly
 Remove the gland nut(s), fan assembly,
collar and fan pulley.
2． Fan cowl
3． Power steering pump drive belt
 Unscrew power steering pump fixing
bolt(s) and adjusting bolt(s), then
remove the drive belt.

258
4. Air conditioning compressor drive belt
 Loosen idler locking nut(s) and
adjusting bolt(s) of the air conditioning
compressor and then remove the drive belt.
5. Alternator drive belt
 Unscrew alternator fixing bolt(s)
(lower side) and adjusting plate locking
bolt(s), then remove the drive belt.
6. Soundproof cover
7. Soundproof cover gasket
8. Air-intake duct
9. Injection pump control wire
 Remove the control wire bracket bolt(s)
and control wire.
10. Fuel hose
 Disconnect fuel inlet hose and return
hose.
11. Water hose of cold start device (CSD)
 Disconnect the water hose from the
injection pump side.
12. Injection pump wire harness
 Dismount the speed sensor (with a
tachometer), solenoid valve of the cold start
Solenoid valve
device (CSD) and the fuel cut-off solenoid
speed
of the cold start valve.
sensor
device 13. High pressure oil pipe
Injection  Loosen high pressure oil pipe clamp.
pump  Remove the taper nut(s) on the
injection pump side.
 Remove taper nut(s) on the fuel injector
Fuel cut-off
solenoid valve side and high pressure oil pipe.
Caution:
 Plug the holes in injector body and
delivery valve body to prevent foreign
bodies falling in.
14. Injection pump assembly
 Loosen injection pump fixing nut(s).
 Unscrew the adjusting and locking bolts
in the injection pump rear bracket.
 Unscrew the generator side fixing
bolt(s). Take out the injection pump from the
engine backside.
Notes:
 Cove holes in injection pump delivery
valve body with a cap (or equivalents) to
prevent foreign bodies falling into the valve.

259
Assembly
14. Injection pump assembly
1. Mount inspection hole covers on the
camshaft timing gear side of the timing
gear chamber and the timing gear side
of the injection pump.
2. Turn the crankshaft clockwise and
check whether the Ⅱ℃ mark on the
crankshaft pulley is aligned with the
index. Place the piston of the first
cylinder on the top dead center of the
compression stroke.
3. Observe and check if the scale on the
timing gear mark “O”is aligned with the
hole index via the inspection hole on
crankshaft timing gear side.
4. Align the injection pump gear mark “O”
with the inspection hole index and
install the injection pump assembly.
 Screw on the injection pump fixing bolts
Camshaft gear Injection pump gear
and tighten them to the specified
torque.
Injection pump fixing bolt torque N·m
25

13. High pressure oil pipe

 Connect the high pressure oil pipes to
the injection pump side and fuel injector
side and screw down these pipes.
 Install the oil pipe fixing clips in the
original positions.
N·m
30

12. Injection pump wire harness

 Fix the injection pump wire harness and
connect it to the switch.

260
11. Water hose of cold start device
 Connect the water hose of cold start
device and tighten the fixing clip(s).

10. Fuel hose

Connect the fuel inlet hose and return hose.
 Connect the defuelling hose(s).
9. Injection pump control wire
1) Connect the control wire rope to the
engine control lever.
2) Place the throttle lever in fully cut-off
position and pull tight the control wire
towards the arrow direction to prevent it
being slack.
3) Tighten the throttle wire bracket bolt(s).
8. Air-intake duct
7. Soundproof cover gasket
6. Soundproof cover

5. Alternator drive belt

 Mount the alternator drive belt and
adjust the belt tension.
 Apply a force of 100N to the middle part
of the drive belt.

Ac compressor drive Drive belt deflection mm

belt
8— 10
Power
steering
 Screw on the fixing bolt and tighten it to
pump drive
belt the specified torque.

Alternator fan
pulley drive belt

261
Generator fixing bolt torque N·m
Drive belts of the ac compressor and
power steering pump 37.5

Adjusting plate fixing bolt torque N·m

25

4. Air conditioning compressor drive belt

Drive belts of the  Mount the ac compressor drive belt and
alternator and fan adjust the belt tension.
 Apply a force of 100N to the middle part
of the drive belt.力。
Drive belt deflection mm
8— 10

 Tighten the idler locking nut to the

specified torque.
N·m
27

3． Power steering pump drive belt

 Mount the power steering pump drive
belt and adjust the belt tension.
 Apply a force of 100N to the middle part
of the drive belt.力。
Drive belt deflection mm
8— 10

 Tighten the idler locking nut to the

specified torque.
N·m
27

262
2． Fan cowl
 Install the fan cowl and storage tank
hose.
1． Fan assembly
 Fix the fan pulley, collar and fan
assembly onto the water pump in
sequence, and tighten them to the
specified torque.
N·m
12.5

 Connect battery ground cables.

 Fill in coolant.

263
Fuel supply and timing adjustment
 Place the piston of the first cylinder on
the top dead center.
 Remove the top plug of the injection
pump distributor.
 Dismantle wax type cold start device
with screwdriver hand lever.
 Mount a dial indicator and pre-elevate
to 1 mm.
Measuring instrument: 1100300FA— 9101
 Place the top dead center mark on the
crankshaft damper pulley at a position
30°-45°to the index.
 Place the dial indicator at the “0”
position.
 Turn the crankshaft left and right slightly
and observe if the dial indicator is still at
the “0”position.
 Turn the crankshaft in normal direction
and read out the dial gauge readings in
the following cases.
4DA1 16°to the top dead center (before)
4DA1-1 12°to the top dead center (before)
Dial indicator readings mm
4DA1 1.60
4DA1-1 1.50
If the readings are improper, unscrew the
injection pump fixing nut and the bracket
adjusting bolt. Adjust the readings by changing
the injection pump mounting position. When the
dial gauge readings change to the specified
values, tighten the fixing nut and bolt to the
specified torques.
Injection pump fixing nut torque N·m
25
Adjusting Bolt torque N·m
25
 Tighten the top plug of the injection pump
distributor to the specified torque after
removing the measuring instrument.
N·m
35

264
Caution:
 While mounting the top plug of the
injection pump distributor, you should
use a new copper gasket.
 Connect the high pressure oil pressure.
 Fix the oil pipe clamp.
Carry out idle speed inspection and adjustment
1) Pull the parking brake lever and lock the
drive wheel (s).
2) Set the transmission gear to neutral shift.
3) Start the engine and operate it at idle
speed until the water temperature rises to
70°-80°.
4} Reverse the idle control knob. Remove
the control wire from the injection pump
control lever.
5) Install the engine tachometer.
6) Check the idle speed.
If the idle speed exceeds the specified limit,
correct it.
Specified value (r／min) = 700-800
1) Unscrew the locking nut of the idle speed
adjusting bolt.
2) Turn the idle speed adjusting bolt and
adjust the idle speed to the specified value.
3) Tighten the locking nut and adjusting bolt.
4) Check the control wire tension and pull
tight this wire if necessary.

265
5.5 Fuel system related parameters

Test conditions
Items Conditions
Model 4DA1 4DA1-1
Fuel injector
Injector type KBAL—P001 KBAL—P001
Fuel injection nozzle pairs DSLA153P009 DLLA153P034
Injector opening pressure (Mpa) 19 — 20 18.6 — 19.6
Size of high pressure oil pipe
Inner diameter 1.6
Outer diameter 6.5
Length 430
Feeding pressure (kPa) 19.61
Test fuel SAE standard test diesel oil (SAE967D)
ISO standard test diesel oil (ISO4113)
Test fuel temperature ℃ 48—52

266
5.6 Fuel tank

Frame

Disassembly sequence
1.Fuel evaporation hose
2. Fuel supply hose
3. Fuel return hose
4. Fuel level gauge connector
5. Clamp band
6. Fuel tank
Assembly sequence
As assembling, go on
according to the reverse
sequence of disassembly.

Disassembly
Preparation:
 Remove battery ground cables.
 Open the fuel filter cap
 Drain oil via the oil drain plug
 Tighten the oil drain plug to the
specified torque after draining the oil.
N·m
29
1. Fuel evaporation hose
2. Fuel supply hose
3. Fuel return hose
 Plug hose ends to pervert the fuel
flowing out.Fasten the hose to the
frame with plugged end upward.

267
4. Fuel lever gauge connector
 Remove the fuel lever gauge connector.
5. Clamp band
 Loosen the fixing nut of the fuel tank
clamp band. Draw out the clamp band
from one end of the frame.
6. Fuel tank
 Withdraw the fuel tank.
Note:
If it is impossible to withdraw the fuel tank,
remove the bracket and pull out the fuel tank
downwards.。

Assembly

6. Fuel tank
Note:
If the bracket is removed while pulling out
the fuel tank, mount it to the frame and
tighten it to the specified torque.
N·m
55

 While mounting the fuel tank to the

bracket, you have to place a piece of
cushion on the bracket.
5. Clamp band
 Tighten the clamp band nuts to the
specified torque.
N·m
12

4. Fuel lever gauge connector

 Connect the fuel lever gauge connector.
3. Fuel return hose
2. Fuel supply hose
 Insert the hose into the oil pipe with
insert depth above 25mm.
1. Fuel evaporation hose
 Feed fuel into the fuel tank.
 Connect battery ground cables.

268
5.7 Fuel lever gauge

Fuel evaporation
hose Frame

Disassembly sequence
1. Fuel lever gauge
connector
2. Fuel lever gauge
Assembly sequence
As assembling, go on
according to the reverse
sequence of disassembly.

Disassembly
Preparation:
 Remove battery ground cables.
1. Fuel lever gauge connector
 Remove the connector from the fuel
lever gauge.
2. Fuel lever gauge
 Unscrew the fuel lever gauge fixing bolt
(s) and remove the gauge.
Note:
 After removing the fuel lever gauge,
plug the tank port with cotton waste to
prevent dirt falling into the tank.

Assembly
2. Fuel lever gauge
1. Fuel lever gauge connector
 Connect the wire connector to the fuel
lever gauge

269
6 Starting system
6.1 General

The starting system consists of battery, starter motor, start switch, starting
relay, etc. These parts are connected according to the diagram.The diagram
shows the details of the starting circuit.
Starting relay

Starter motor

Start switch

Holding coil
Contact

“50”terminal post

“30”
terminal post
Magnetic switch
Pinion clutch Suction coil Battery

The starting system utilizes the gear reduction magnetic starter motor and its
shaft can be used as pinion shaft.When the start switch is switched on, the
magnetic switch contact closes causing the armature to rotate.Meanwhile,
Move the movable core by suction and push the pinion forward to engage with
the ring gear by a deflector rod.Then the ring gear starts to run and the engine
starts.When the engine is started and the start switch is switched off, the
movable core returns to the original position while the pinion runs out of the
ring gear, then the armature stops.When the engine speed is higher than the
pinion’s, the latter stays in idle state, so it can’
t drive the armature.
Note:
The starting circuit diagram is only for information and the overall circuit
diagram is prevail in specific cases.

270
6.2 Starting circuit

Starting system Starter

Battery Ignition Battery Accessories Ignition
Key position Key motor
B1 IG1 B2 ACC IG2
ST
Battery
Pulled
Lockup
out
Switch off
Accessories  
Inserted
Switch on     
Start     

Main switch Key switch

15A
engine
Generator ignition

Starter motor
Starting relay

Quick start element

Suction
Holding
coil
coil

Magnetic switch

Starter motor

271
6.3 Starter motor

Disassembly sequence
1. “50”terminal post
2. “30”terminal post
3. Ground cable terminal post
4. Starter motor assembly
5. Separator (4JB1, except cold area)
Assembly sequence
As assembly, go on according to the
reverse sequence of disassembly.

Disassembly
Preparation:
 Remove the ground cables of battery.
1. “50”terminal post
2. “30”terminal post
3. Ground cable terminal post
4. Starter motor assembly
5. Separator (except cold area)

Assembly
5. Separator (except cold area)
4. Starter motor assembly
 Tighten the fixing bolt(s) and nut(s) to
the specified torque.
Starter motor bolt and nut torque N·m
81
3. Ground cable terminal post
 Connect the ground cable terminal
post.
2. “50”terminal post
 Connect the wire connector.
1. “30”terminal post
 Connect the battery cable and start
switch wire terminal posts, and tighten
nuts to the specified torque.
Fixing nut torque N·m
9

272
Single-piece repair

Disassembly sequence
1. Lead
2. Through bolt
3. Yoke assembly
4. Yoke cover
5. Brush and brush-holder
6. Armature
7. Transmission case
8. Sprag clutch
9. Return spring
10. Steel ball
11. Idler pinion
12. Holder
13. Roller
14. Magnetic switch
Reassembly sequence
As reassembly, go on according to
the reverse sequence of
disassembly.

Disassembly
1. Lead
Remove the magnetic switch lead.

273
2. Through bolt
Unscrew the yoke through bolt.

3. Yoke assembly
Dismantle the magnetic switch yoke.
4. Yoke cover

5. Brush and brush-holder

Remove (pull out) the brush and
brush-holder from the armature with long
nose pliers.
6. Armature
7. Case

8. Sprag clutch
Remove the sprag clutch from the case

Brush Spring

274
9. Return spring
Remove the return spring from the magnetic
spring.

10. Steel ball

Dismantle the steel ball from the sprag
clutch.

11. Idler pinion

Remove the idler pinion from the case.

12. Holder
Remove the holder from the case.
13. Roller
14. Magnetic switch

275
Inspection and repair
If during inspection it is found that some
parts are worn-out, damaged or flawy,
remove or replace these parts.
Armature
Check the radial runout of the commutator. If
the runout exceeds the limits, replace the
commutator.
Radial runout mm
kW Standard value Limit
2.2
0.02 0.05
2.0

Check if the mica sheet is worn-out.

Insulator
The depth of mica sheet mm
Segment
kW Standard value Limit
2.2
Correct 0.7— 0.9 0.20
2.0

Incorrect Check the outer diameter of the commutator.

Outer diameter of the commutator mm
kW Standard value Limit
2.2
35.00 34.00
2.0

Short circuit test for the armature

Place the armature in the coil short circuit tester
to check if there is any short circuit in the
armature. Touch the armature core with a piece
of saw blade when rotating the armature slowly.
It will cause the saw blade to vibrate and stick to
the core if the armature is in short-circuit state. If
the saw blade vibrates and sticks to the core, you
have to replace the armature for it is
short-circuited.

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Earth test for the armature
Touch the segment and armature core with test
probes of the multimeter to check if the armature
is in open-circuit state. If the armature circuit is
closed, it means the armature has been earthed.
If this is the case, replace the armature.

Closed circuit test for the armature

Touch two segments with both test probes of the
multimeter. All test points should in closed-circuit
state. If there is any open circuit, replace the
armature.

Yoke
Earth test for the field winding
Touch the field winding wire or brush with one
test probe of the multimeter and the yoke outer
surface with another test probe to check if the
winding is in open-circuit state. If the multimeter
shows a closed circuit, it means the field winding
has been earthed and you have to replace the
yoke assembly.

Closed circuit test for the field winding

Touch the “C”terminal post wire with one test
probe and the brush with another test probe to
check if the field winding is in closed-circuit state.
If there is an open circuit, replace the yoke
assembly.

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Brush and brush-holder
Measure the brush length. If the worn-out
length exceeds the limit, replace the brush.
Brush length mm
kW Standard value Limit
2.2 14.5
10
2.0 16

Insulation test for the brush-holder

Check if the brush-holder is insulated with a
multimeter. Touch the brush-holder plate
with one test probe and the positive
brush-holder with another test probe. The
brush-holder should be in open-circuit state.

Sprag clutch
Check whether the pinion teeth are worn-out
or damaged and replace the pinion if so.
It should be smoothly to turn the pinion
clockwise.
But when the pinion is turned anti-clockwise,
it should be locked up.

Bearing
Check if the bearings are worn-out and
damaged. If there is any noise during
bearing operation, you have to replace the
bearings.

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Reassembly
Steel ball
As reassembly, go on according to the
reverse sequence of disassembly and pay
attention to the following items:
Roller
 magnetic switch
 Idler
Idler  Clutch assembly
 Case
1) Install the clutch assembly to the
M terminal
post magnetic switch.
2) Mount the idler and case.
Note:
Remember to mount the steel ball and
“50”terminal spring between the clutch and magnetic
post switch. Install the roller onto the idler
beforehand.
Magnetic switch
Temporarily mount a magnetic switch
between the clutch and case and carry out
Disconnected the following tests. The duration of each test
should not be longer than 3 to 5 seconds.
1. Test of pullout binding force
The negative terminal post of the battery is
connected to the magnetic body and M
terminal post. While the current is flowing
from the positive terminal post to the “50”
terminal post, the pinion should chatter.
2. Holding test
Remove the M terminal post wire. The
pinion remains chattering.

3. Return test
The negative battery terminal post is
connected to the “50” terminal post and
case. The positive battery terminal post is
connected to the M terminal post. At this
time the pinion should chatter. After the “50”
terminal post wire is removed, the pinion
should return to its original position
immediately.

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“30”terminal post 4. Current value
Complete the circuit according to the
diagram and measure the current value.
Standard value = 120A or lower
Notes:
You should use fully charged batteries.
Choose heavy gage wire for the
flowing-through high current.

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7 Intake/exhaust system
7.1 General

Engine intake/exhaust system mainly consists of air filter, intake pipe and

exhaust pipe. If it is a supercharged engine, the system also includes the

charger assembly. The installation and maintenance qualities may affect the

engine performance and this factor has become particularly remarkable in the

4DA1-1 type chargers.

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7.1 Air filter

Disassembly sequence
1. Filter cap wing nut
2. Filter cap
3. Filter element wing nut
4. Air filter element
Assembly sequence
As assembly, go on according to
the reverse sequence of
disassembly.

Disassembly
1. Filter cap wing nut
2. Filter cap
3. Filter element wing nut
4. Air filter element
Cleaning
 Clean the air filter inside.
 Clean the air filter cap.
Inspection
 Check if the air filter element is intact
and clear or with holes by light.
Cleaning method
Dust accumulated at the filter element
Manually turn the filter element and blow the
compressor air into the element in order to
blow off the dust.
Pressure of compressed air kPa
392— 490

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Caution:
In order to protect the filter element, do not
knock the element with other objects during
cleaning.
Filter element with carbon and dust accumulated
1. Prepare the filter cleaning liquid originally
provided by JAC and dilute it with water.

2. Immerse the filter element in the cleaning

liquid for 20 minutes.

3. Take the element out of the cleaning liquid

and flush it with running water.The water
pressure should not exceed 2.8kg ／ cm2
(274kPa／40psi).

4. Dry the filter element at a place with good

ventilation. Use a fan for quick drying.
Note:
Never use the compressed air or open fire for
quick drying or it will damage the filter element. It
will take two to three days to completely dry a
filter element. In this case, it would be better if a
standby element were available.

Assembly
4. Air filter element
3. Filter element wing nut
2. Filter cap
1. Filter cap wing nut

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7.2 Exhaust pipe and charger assembly

Disassembly
1. Loosen the binding bolt(s) of the charger
lubrication oil pipe with a wrench.

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2. Unscrew the charger exhaust pipe bolt with
a wrench and remove the charger exhaust
pipe.

3. Remove the exhaust pipe heat insulator.

4. Remove the charger and exhaust manifold

subassembly

5. Disassemble the charger assembly

Inspection
(1) Check the airtightness and tightening of the
connecting pipes between the air filter and
charger and between the charger and
engine intake/exhaust pipes.
(2) Check if the fuel inlet/return hoses of the
turbocharger are damaged or blocked and if
the connecting bolt on the connector is tight.
(3) Check of the oil quality and clean or replace
the oil.
(4) Check the air filter and clean or replace the
element periodically.
Notes
Seal ring (1) Protect the charger return pipe from being
Floating Compressor
Spiral case bearing housing bended or damaged.
(2) Make sure the fuel inlet/return hoses of the
Compressor charger are unblocked.
wheel
Thrust (3) Always check the airtightness of the
bearing
connecting pipes between the charger and
Turbine
Intermediate engine.
(4) The duration of idle state shouldn’ t be too
Bypass valve mechanism
+long

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(5) Make sure the crankcase oil pipes are
unblocked.
(6) Prevent the lower blow-by gas of the engine
to be too much
Faulty diagnosis:
The purpose of faulty diagnosis is to find out the
diesel fault and its reason, so as to clear the fault.
If the charger has been removed, you can’ t carry
out the faulty diagnosis. Never replace the
charger before finding out the fault and clear it.

Inspect and determine whether the charger is

damaged directly according to the follow
items:
A) If the charger rotor rotates smoothly.
B) Check if the compressor wheels are
damaged via the compressor inlet.
B) Check if the compressor wheels rub
with the case via the compressor inlet.

There are four main causes for charger

failure:
A) Foreign matters entering in
B) Lubrication oil impure or aging
C) Lack of lubrication oil
Compressor impeller damaged Compressor impeller damaged by D) Improper use and failure to maintain
by particles solid objects damaged

A)
①. Compressor side:
a. The seal for intake pipes is poor and the air
directly goes into the compressor impeller
Compressor impeller damaged Turbine impeller damaged by without filtering;
by dust particles
b. Replace the air filter without consulting to
the regulations or use poor quality filter
element;
c. Foreign matters enter the front intake pipes
during maintenance.
②. Turbine side:
a. Some parts in the diesel cylinder are
damaged.
b. Objects like bolts have fell into the exhaust
pipes while connecting the exhaust
manifold.
Any matters going into the manifold will break the
charger rotor balance, which will block the rotor
and break the pivot ultimately.

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B) Impure lubrication oil:
a. Replace the lubrication oil filter without
consulting to the regulations or use
poor quality filter element
b. The filter element has broken down or
the filter in the man diesel oil gallery
Comparison between the bearing
damaged by foreign matters and has been blocked.
new bearing
c. Replace the lubrication oil without
Foreign matters in the oil cause the
bearing to be damaged consulting to the regulations, and didn’t
clean the main diesel oil gallery before
replacing the oil.
d. Foreign matters have fell into the
lubrication oil pipe during charger
replacing or pre-fabrication.
e. The sealer or gasket fragments have
fell into the lubrication oil gallery.

Stripped
Stripped

C) Lubrication oil insufficient or aging:

a) Replace the lubrication oil without
consulting to the regulations or use
inferior oil;
b) The diesel stops abruptly after
heavy-load operation without idling;
Damage caused by foreign matters c) The engine starts without idling;
d) There is no pre-fabrication before
replacing the charger

Assembly
5. Install the charger assembly and tighten the
charger union nut (remember to replace the
gasket during charger installation)
Nut tighten torque Nm
25

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4. Install the charger and exhaust manifold
subassembly to the cylinder head
(remember to replace the exhaust pipe
gasket)
Bolt tighten torque Nm
30

3. Remove the exhaust pipe heat insulator.

Bolt tighten torque Nm
25

2. Connect the charger exhaust pipe and

tighten the connecting bolt
Bolt tighten torque Nm
25

1. Connect the charger lubrication oil pipe and

tighten the two punching bolts

Punching bolt II (M12) tighten torque Nm

41

Punching bolt I (M14) tighten torque Nm

55

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Replacement oil-gas separator
Due tothe improper maintenance, it will make the oil-gas separator filter blocked and the
crankcase vent system poorly work. Sometime it may even make crankcase vent system blocked.
It may make block the valve because of the dust bonding after the engine runs long time. This
leads to the pressure in the crankcase increase sharply, have the risk of engine runaway
Repair Procedure
Procedure:
1. Open the engine cover and remove the oil filler cap，
2. Remove the old oil-gas separator system:
3. Remove the oil-gas separator fixing bolts;
4. Loosen the oil-gas separator air intake hose 、 outlet hose 、oil return hose clamp. Take out
the oil-gas separator assemblies with intake hose and outlet hose.
5. Lifting the vehicle or parking the vehicle on the trench;
6. Unplug separator’s oil-return hoses, then quickly install the new one.
Attention：Must quickly install the new oil return hose assembly to avoid leaking too much oil.
7. Remove the oil-gas separator bracket .
Install the maintenance-free oil-gas separator system:
1. Pre-install the three-way intake hose, oil return one-way hose assembly, intake connecting
hose on the oil-gas separator.
2. Install the new oil-gas separator bracket and tighten fixed bolts with gasket. The gasket should
be placed between the bracket and intake hose(as the picture shown)
3. Fixing the above-mentioned assembly on the the bracket clamp(the intake hose should face
the engine side ).
4. Tighten the three-way intake hose with bolts.
5. Install the new intake hose assembly, outlet hose assembly and the oil return hose assembly.

Operating requirements:
1. Tighten torque of the bracket mounting bolts is 20-25N.m.
2. Tighten torque of the three-way intake hose mounting bolts is 10-25N.m.
3. Ensure the clamp installed in the right position, no loose, slip or interfere.
Checking and adjustment
1. Adjust the position of these hoses, in order to avoid excessive force
2. Check the oil level, add oil if it is necessary. Then put on the oil filler cap.
3. Start engine, check whether there is oil or air leakage etc.
New oil-gas separator system installation specifications
1. Pre-install oil-gas separator and related hoses
The pre-installation position of the separator, three-way pipe, intake connection hose assembly, oil
return one-way hose can refer to picture 1.
There is one way valve inside the one-way hose, the position can be seen at picture 2(you can feel
the one-way vale when you touch the hose).The function of one-way valve is to ensure one-way
flow. If reverse install the direction of the one-way hose by mistake, it will prevent oil returning.
You can use the blowing method to test the continuity of one-way hose(the white arrow show the
direction of airflow),blowing from the one-way valve side(separator end) to the other
side(three-way intake hose end), if it is through, OK.
2.Other hoses installation specifications
2.Other
There are many types hoses involved in exchange process , the detailed position can refer to
picture 3.

Three-way
intake oil-gas
hose separator
intake
connection
hose
Oil return
one-way
hose
picture1 assembly
Items: N125

Transmission System Service Manual

No. N 125-NAM - PV - DP - G9-18

Version: 1.0
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Edition:
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Proof:

Revision:

Standardization:

Countersignature:

Approval:

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Clutch

1. Overview ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... …….3

2. Main data and specification…………………………………………………………5

3. Clutch assembly check and repair ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 5

4. Clutch control device check and repair ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ........10

5. Clutch master cylinder check and repair ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... . 14

6. Clutch wheel cylinder check and repair ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 16

7. Fault diagnosis………………………………………………………………………...22
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1. Review
Clutch Assembly

Clutch Pressure Plate Clutch Driven Disc Assemblies

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Clutch Master Cylinder

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Clutch wheel Cylinder

Clutch Circuit Diagram

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1、Clutch wheel cylinder assembly 2、Clutch hose assembly 3、Clutch buffer valve assembly 4、Clutch pipe assembly Ⅰ

5、Clutch pipe assembly Ⅱ 6、Clutch master cylinder assembly 7、Clutch brake pedal assembly 8、clutch master cylinder oil inlet hose

9、oil reservoir assembly

W5000 series mini-truck uses single-chip dry diaphragm spring clutch. This includes clutch pressure plate and

clutch driven disc. Clutch driven disc is equipped with corrugated gaskets to offer a buffer to driven disc when the clutch

is engaged. Shock absorber is installed onto the drive hub to relieve the Engine and Drive Train vibration. Diaphragm

spring from clutch pressure plate provides with contact pressure. Diaphragm spring tip offers the effect of separation.

Clutch separation mechanism includes split bearings, split sleeves, split rocker arms, and so on. Split bearings are

roller bearing to reduce friction. Inside of split sleeve needs grease lubrication for that it glides on gearbox input shaft

when clutch is separated or engaged. Split Sleeve of some types of vehicles is equipped with grease tube. Split bearings

are lubricated bearings which do not require additional lubrication.

Clutch control device adopts hydraulic remote control, including the oil reservoir, the oil hose, and clutch pedal,
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clutch master cylinder, hydraulic hard way, buffer valve, hoses, and clutch wheel cylinder. The master cylinder is

controlled by the clutch pedal, and the hydraulic oil pushes the rod of clutch wheel cylinder to push forward the rocker to

disengage the clutch.

2. Main data and specification

Types of clutch Single-chip dry diaphragm spring clutch

Driven disc diameter Ф250mm

Clutch master cylinder
Ф15.87mm
diameter
Clutch wheel cylinder
Ф 20.64 mm
diameter
Clutch pedal stroke 155 mm ～165mm

Clutch pedal free stoke 5mm～15mm

3. Clutch assembly inspection and repair

Disassembling
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Disassembly Order

1、Transmission assembly 2、Clutch mounting bolt assembly 3、Clutch pressure plate assembly 4、Clutch driven

disc assembly 5、Engine assembly

Disassembling steps (in order)

Jack up the car and prop up it.

1． Remove the transmission. (Reference to the operation of the transmission in the manual )

2． Pressure plate assembly

3. Driven plate assembly

Use a guide shaft to prevent the free falling of driven disc assembly.

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Mark on the flywheel and pressure plate so as to make them aligned when reassembled.

Note: Make sure the brake fluid is wiped off immediately so as not to flow to the paint surface.

Inspection and repair.

If in the course of the inspection, excessive wear, damage, or other failures are found, necessary

actions should be made to adjust 、repair or replace the appropriate parts.

Pressure plate assembly

Visually inspect if there are wear-and-tear, hot cracks and bending

deformation on the pressure plate. If there is an excessive worn, bent or dark hot crack,

replace the disk. (Pressure plate deformation - measure the pressure plate friction surface

flatness, change the pressure plate assembly if the limit is exceed. Operation limit: 0.3

mm)
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Pressure plate assembly

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Visually inspect if there are wear-and-tear, hot cracks, bending deformation

and other damage on the pressure plate. Clutch pressure plate assembly with

excessive wear, cracks and other damage must be replaced.

Measurement Clutch installation contact pressure

Metal blocks
1) Upside down clutch pressure plate

2) Put a metal block of which the thickness is 7.4 MM (8) on

the pressure plate.

3) Push down the tray until the distance "B" reaches 0

mm

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4) Record the pressure numerical reading.

Standard pressure: 6100 N ~6700 N

Diaphragm spring separation height

1) Put a metal block of which the thickness is 7.4 MM (8) below

the pressure plate.

2) Push down the tray until the distance "B" reaches 0 mm.

Two ways can be adopted:

a: Press down from the top of the tray .

b: Tighten the mounting bolts.

3) Measure from the base panel to disengagement end.

Standard Height: 40 mm± 1mm

Driven plate assembly

Visually check if torsion spring is loose, soft or broken. If one

of the situations is detected, drive plate assembly should be

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replaced.
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Visually check friction surface if there are cracks, grease or

over-burned. If one of the situations is detected, drive plate

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assembly should be cleared or replaced Check if the driven disc

assembly can move smoothly on the transmission shaft splines.

Driven plate deformation

Insert pilot shaft into the splined hub. Keep the pilot shaft

Straight, fix a scale onto the driven disc outer annulus, and then slowly turn the

driven disc assembly to read out the scale readings. If the measured value

exceeds the limit, the driven disc assembly should be replaced. Limit value

≤1.0mm.

Clean the inner of splined hub

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Install the driven disk to transmission shaft splines; mount on the outer circle of the driven disk with a surface

measurement meter; slowly turn the driven disk, measure the changes of outer circle ; if the measured value exceeds

the limit, you should replace driven disc assembly; driven disc splined hub wear limit ≤1.0mm.

The rivet head depth of the driven disc

Measure the distance between the rivet head and the friction

surface with a depth gauge measurements. Both sides should be

measured.

If the measured value is less than the limit value, the driven

disc assembly should be replaced.

The driven disc rivet head depth limit is 0.2 mm.

Warning: release bearing is filled with the lubricant so do not clean it in any solvent, in case

that the lubricant is dissolved. Note if no problem occurs, do not disassemble split sleeve. Visually
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check if the spring is broken or soft. If it is, parts must be replaced.
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Re-installation
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Orders of re-installation

1、engine assembly 2、clutch driven disc assembly 3、clutch pressure plate assembly 4、clutch mounting bolt

assembly 5、transmission assembly

Steps of re-installation

1、 Driven plate assembly

Daub molybdenum disulfide in the inner of the driven

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disc splined hub; install the driven disc assembly with a guide shaft.

2、Pressure plate assembly

Press and tighten the mounting bolts in numerical sequence. Mount bolts by 2 steps: step1, the pre-tensioner (10 - 19)
N.M, in the shape of a star: step 2, (17 - 26) N.M, in the shape of a star; mark the bolts to make sure they are tightened.
Warning: after tighten the mounting bolts; remove the protective steel wire of the film leaf-spring

4. Clutch control device inspection and repair

Disassembling

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Disassembly Order
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1、clutch wheel cylinder assembly 2、clutch hose assembly 3、clutch buffer valve assembly 4、clutch steel tube

assembly I

5、clutch steel tube assembly II 6、clutch master cylinder assembly 7、 clutch brake pedal body assembly

8、clutch master cylinder inlet hose 9、oil reservoir assembly

Disassembling procedures of the clutch control device

Drain the brake fluid in clutch hydraulic line.

Note: Do not keep the fluid retention on the paint surface; wipe it off immediately if any.

1、clutch wheel cylinder assembly

2、clutch hose assembly

3、clutch buffer valve assembly

4、clutch steel tube assembly I

5、clutch steel tube assembly II

6、clutch master cylinder assembly

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7、clutch brake pedal body assembly

8、clutch master cylinder inlet hose

9、oil reservoir assembly

Inspection and repair

If in the course of the inspection, excessive wear, damage, or other failures are found, necessary actions should be

made to adjust, repair or replace the appropriate parts.Pressure plate assembly

Re-installation

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Orders of re-installation
1、oil reservoir assembly 2、clutch master cylinder inlet hose 3、clutch brake pedal body assembly 4、clutch master

cylinder assembly

5、clutch steel tube assembly I 6、clutch steel tube assembly II 7、clutch buffer valve assembly

8、clutch hose assembly 9、clutch hose assembly

The clutch pedal assembling

a) Pre-installation spot inspection: check the number of all parts and see if there is any defect in the
pedal, slide back and forth the pedal to see if there is abnormal sound. Remove the master cylinder seal
plug; check the pump body and parts for cracks, scratches. Make sure the joint of pumps is clean and
clear of objects. Make sure the steel tube and inlet hose are mounted with a dust plug.
b) Install the main pump inlet hose: First, mount 1 (Q673B155) onto two ends of the inlet hose, and fit
the right end of inlet hose 2 (1607110W5000) right-side into 4 (1605010W5000) the oil hole. And then
lock it tightly with 1 (QB673155).

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c) Install the main pump: fix the pump with 3(Q1460830) onto the pedal, the torque is (23 ~ 28) N·m.
Connect 4 (1605010W5000) and 8 (1635010W5000) with pedal pivot shaft, and lock it with pivot shaft
lock.

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d) Installation of pipeline stationary barrier and oil pipe: level the connector of 7 (1607120W5000) at
the pump outlet threaded hole, pre-tension it first, and mount the onto the tube and fix them with
the pipeline stationary barrier. Then tighten the connector with power（16～20）N·m.

Brake pipe clamp

The clutch circuit assembling

a) The spot inspection before pre-installation: check the clutch pipe, hose, and valve, pump surface for
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dust plug、scratches, burrs and cracks. Make sure the joint and the connectors are clean and clear of
objects.
b) Buffer valve installation: fix the buffer valve 12 (1607600W5000) on the vehicle chassis through 11
(Q1420616). Tightening torque: (6～10) N·m

c) The clutch tube and hose installation: connect the clutch steel tube 10 (1607010 W5000) with brake
hose clips, align the front connector of steel tube with brake 3-way bracket threaded holes to tighten
them with torque (16 to 20) N·m. Align the other end of steel pipe and the center of valve threaded
holes, and tighten them in same way. Pad the top and bottom of the clutch hose with copper backings
17 (3506016R001), then fix the hose 13 (1607020W5000) to valve body with piercing bolt 16
(1607013W5000), and the tighten torque is (20 to 25) N·m.
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d) The clutch wheel cylinder assembling

Fix the sub-pump 15(1609010W5000) with two bolts 14 (Q1421030) onto the transmission, and
tighten it with torque (20 to 30) N·m. Let piercing bolt 16 (1607013W5000) go through the central
hole of hose 13(1607020W5000), and pad the top and bottom of the hose with copper backings 17
(3506016 R001), then fix it onto the clutch wheel cylinder 15 (1609010W5000) with tighten torque
(20 to 25) N·m.

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After the above assembly, the clutch control mechanism needs
Nuts clearance 1—2 mm
adjustments

Clutch pedal height and stroke

1. Loosen the clutch master cylinder push rod and lock the nuts.

2. Rotate rod to adjust the pedal.

Clutch pedal height: 155 - 165 mm

Clutch pedal stroke: 155 - 165 mm

Idle stroke 15-25mm

Stroke 3. Clutch master cylinder push rod lock nut torque 1.3N·m.

4. Re-install meters and adjust clutch pedal free stroke

Loosen the clutch switch or pedal spacing bolt. Adjust clutch switch or pedal spacing bolt to offer free

stroke of clutch pedal.

Clutch pipeline deflating

Follow the steps below

1. Strain the parking brake.

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2. Pour the brake fluid into the oil reservoir, to the

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maximum level. See if there is brake fluid in the oil reservoir

during the deflating.

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3. Remove bleed screw rubber cap from the clutch

booster, connect the cap with a plastic pipe to bleed screw, and insert the other end of the plastic tube

into a transparent container of brake fluid. Step on the clutch pedal after press it down several times,.

4. Keep the pedals down then loosen the bleed screw to let out the air, and then tighten the bleed screw.

5. Repeat the above steps until the air has been completely expelled. Add the brake fluid to the mark

"MAX” in the oil reservoir after deflating.

7. Fault diagnosis
Clutch dragging (gear grinding sounds when shifting)

Inspect the hydraulic circuit

Normal Hydraulic circuit failure Fluid leakage Air in the circuit

Replace Repair or replace

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Check the master cylinder and wheel cylinder

Normal Abnormal

Check free clearance Repair or replace

Normal Excessive clearance

Check the clutch disk Adjustment

Normal Disk warped

Check diaphragm spring Replace clutch disk

Normal Diaphragm spring force weakened or pointer tip worn Diaphragm spring clip fault

Replace pressure plate assembly Replace pressure plate assembly

Check shaft splines

Normal Inflexible sliding

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Clean, repair, coat grease

Check pilot bearing

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Pilot bearing is worn or damaged

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Replace pilot bearing

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Clutch skidding

Check the master cylinder and wheel cylinder

Normal Abnormal

Check the clutch pedal Repair or replace

Normal Hold the clutch pedal down

Adjust the clutch switch settings

Check the clutch pedal and pump free clearance

Normal No clearance

Check clutch disk Adjust

Friction surface hardened Clutch disk worn Oil or grease on the disk
Normal

Repair or replace clutch disk assembly Replace clutch disk assembly Replace clutch disk assembly
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Check diaphragm spring

Normal Diaphragm spring force weakened

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Replace pressure plate assembly

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Check pressure plate and flywheel

Flywheel warped Pressure plate warped

Repair or replace Repair or replace pressure plate assembly

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Clutch vibration (the body will vibrate when the clutch is partially engaged)

Check clutch disk

Poor contact of clutch friction disc Clutch disk warped or worn Clutch disk surface harden

Replace clutch disk assembly Replace clutch disk assembly Repair or replace

No oil on clutch disk surface Clutch disk damping spring Clutch disk loosen rivet
or no grease weakened or broken
Normal
Replace clutch disk assembly Replace clutch disk assembly Replace clutch disk assembly

Check pressure plate and flywheel

Pressure plate warped or worn Flywheel warped or worn

Normal Repair or replace Repair or replace

Check diaphragm spring

Normal Diaphragm spring force weakened

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Replace pressure plate assembly
A

Check the engine mount or rubber pad

Engine support loosen Rubber deterioration

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Tighten Replace the rubber pad assembly

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Clutch noise (check to see if clutch noises when it is engaged and disengaged thus to determine the reason for this
noise.

Check the release fork or the rod

Abormal

Normal repair or replace

Check the clutch pedal

Clutch disc cracks or damping Vibration damper spring weaken Rivet head out
spring housing cracked or broken
Normal
Replace clutch disk assembly Replace clutch disk assembly Replace clutch disk assembly

Check release bearing

C
Normal Release bearings poor lubrication Release bearing worn

Replace release bearing Replace release bearing

A

Check pilot bearing

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Pilot bearing worn

Replace pilot bearing

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Transmission Assembly Device
1. Repair and Maintenance Data ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .19

2. Instructions for Use ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ..21

3. Transmission Structure ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 22

4.Transmission Disassembling ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 23

5. Wearing Parts Catalog ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .... 30

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1、Repair and Maintenance Data
1. Technical parameters
Type 5-gear overspeed

Control mode Long-distance control

Rated input torque 240 N·M.

Center distance 79mm

Assembly mass About 41 kg

First gear (1st) 4.271

Second gear (2nd) 2.283

Third gear (3rd) 1.414

Gear ratio

Forth gear (4th) 1.000

Fifth gear (5th) 0.813

Reverse (Rev) 3.814

C

South of the Yangtze River 85 W/90 GL - 4

A

Lubricant oil North of the Yangtze River 85 W/90 GL - 4

mode Cold region 80 W/90 GL - 4
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Bitter region 75 W GL - 4

Lubricant amount Approximately 2.5 L

2. Meaning of Transmission Name

L C 5 T 8 0
Center distance (mm)
Tape synchronizer

5 drive gears
The manufacturer logo: 6 gears

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3. Transmission identification location:

The ex-factory date, serial number and identification of the transmission are pasted on its side.

4. Repair and Maintenance Data:

Unit: mm
Operating
Items Standard Remarks
limit
Gear head and striker gap 0.213～-0.422 0.6
Shaft rail and housing clearance 0.05～-0.11 0.4
1/2 gear, 5/R gear fork shaft locking ball Compressed
33. 6
spring pressure to 16.2 mm
3 / 4 gear gear fork shaft locking ball Compressed
51.6
spring pressure to 16.2 mm
Shift fork and synchronizer gear shift fork
0.1～-0.4 1.0
slot clearance
Gear wheel side clearance 0.05～-0.12 0.30
Ball bearing axial runout 0.50

Reverse gear shaft axial clearance 0.20～-0.35 0.50

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Jackshaft axial clearance 0.04～-0.07

The first
A

0.20～-0.33 0.45
(1st)
The second
0.20～-0.33 0.45
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(2nd)
The third
Axial clearance of each 0.20～-0.33 0.45
(3rd)
shaft of the second shaft
The fifth
0.20～-0.33 0.45
(5th)
The
Reverse 0.20～-0.33 0.45
(Rev)

gear spline and gear hub spline clearance 0.033～-0.116

Clearance of the simultaneous ring and

1.4～-2.2 0.5
each gear clearance

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5. Tightening torque

Items Torque
Connecting bolts of transmission and engine 43-55N·m
Clutch release cable bracket bolts 20～-27 N·m
Exhaust shaft bracket bolts 20～-27 N·m
Front cover bolts of the first shaft 10～12 N·m
Clutch wheel cylinder bolt 30～42 N·m
Release fork ball bearing 30～42 N·m
The second shaft lock nut 250～270 N·m
The middle shaft lock nut 160～190 N·m
Reverse shaft lock nut 20～60 N·m
Reverse shaft screw 15～22 N·m
Eccentric pin nut 30～42 N·m
Oil drain plug 35～45 N·m
Refueling plug 30～35 N·m
The bed bolt 8～10 N·m
Odometer shaft sleeve bolt 3～5 N·m
Reversing light switch assembly 30 N·m
The chassis body mounting bolt 10～12 N·m
Starter installation bolts 43～55 N·m
Ball lock plug 10～12 N·m
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2. Instructions for Use
A

1. Each gear of LC5T80 transmission is equipped with a synchronizer. To reduce the wear of gear wheel and

synchronizer, and avoid gear broken, make sure to shift moderately so as that synchronize and gear wheel can
J

successfully engaged and disengaged. Car can only be switched from forward gear to reverse gear or from reverse gear

to forward gear when it is stopped.

2. Particular attention should be given to: the 5th gear of the transmission is overdrive. To avoid any damage to gear

wheel caused by excessive speed, the 5th gear can only be adopted by 3 terms: with no overload, under good road

conditions and speed reaches 50 km/h or more. At the 5th gear, in a case that the vehicle speed drops below 50 km/h, a

lower gear should be adopted. If keep no change, the 5th gear is easy to be broken.

3. The transmission can use 85W/90 GL - 4 gear oil, and change the oil after 6000 km. After draining the oil , keep the

car at reverse gear , jack up the rear axle , fill in with kerosene, keep the transmission gear rotate 2 ~3 minutes, then drain

the dirty oil and fill in clean gear oil.

4. It is forbidden to shut off It is not allowed to shut off the engine, the engine when the car is coasting on the downhill.

It is also forbidden to start the engine by inertia of this coasting when the engine is stopped, so as not to damage the

gear.

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3、The Transmission Structure

1/2gear
3/4gear synchronizer R/5gear
synchronizer assembly synchronizer
assembly assembly
First shaft 3rd gear 2nd gear 1st gear
Main reverse 5th gear
gear

Middle
Middle
C
Intermediate Reverse gear 5th gear
reverse
shaft
gear
A
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4、The Transmission Disassembly (Disassembly)

1、Dismantling

 Key points for disassembly :

1) Put the start switch in the position "OFF” before remove the transmission assembly from the vehicle. Pad the
wheels with a wedge to ensure that the vehicle will not slip.
2) Unscrew the oil drain plug to drain all the gear oil from the transmission box.
3) Remove (loosen) drive shaft, manipulate stringing, wire, clutch parts, etc. .
4) Demount the transmission assembly from the engine flywheel housing. Prop the transmission from the bottom
with a jack so as to avoid a sudden fall, and then demount the transmission assembly from the engine flywheel
housing.

2、Disassembly

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Quanti
No. Code Name Remark
ty
H - 1702211 - 79 -
1 Oil seal (selecting, shifting shaft) 2
00
H - 1702215 - 79 -
2 O-ring seal 1
00
3 H-1702214-79-00 Gear selection adjustment pin 1

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H - 1702216 - 79 -
4 Flat washer 1
00
5 Q341B12 Nut 1
H - 1701519 - 79 -
6 Washer (oil filler plug) 1
00
H - 1701518 - 79 -
7 Refueling plug 1
00
H - 1702213 - 79 -
8 Needle roller bearings (shifting shaft) 2
00
H - 1702240 - 79 -
9 Push rod assembly 1
00
H - 1702410 - 79 -
10 Director plate fitting unit 1
00
H - 1702230 - 79 -
11 Grip ring - 2 2
00
H - 1702225 - 79 -
12 Selecting shaft resistance arm assembly 1
00
H - 1702223 - 79 -
13 Setting bolt spring 1
00
H - 1702224 - 79 -
14 Torsion Spring 1
00
H - 1702222 - 79 -
15 flat pad (Selecting shaft ) 2
00
C
H - 1702218 - 79 -
16 Selecting shaft assembly 1
22
H - 1702229 - 79 -
A

17 Grip ring - 1 1
00
H - 1702239 - 79 -
18 Grooved pin 1
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00
H - 1702310 - 79 -
19 Shifting shaft assembly 1
22
20 Q 5280532 Elastic cylindrical pin ( 2
H - 1702124 - 79 -
21 Bolt (ball nut) 3
00
H - 1702122 - 79 -
22 Ball-lock spring - 2 1
00
23 7.9375 - GB 308 Steel ball 3
H - 1702121 - 79 -
24 Ball-lock spring - 1 2
00
H - 1702212 - 79 -
25 Blank cap 2
00
H - 1701611 - 79 -
26 Bolt and elastic pad assembly (base plate) 12
00
H - 1701513 - 79 -
27 Magnet 1
00

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H - 1701516 - 79 -
28 Washer (drain plug) 1
00
H - 1701515 - 79 -
29 Oil drain plug assembly 1
00
H - 1701517 - 79 -
30 Gasket (base plate) 1
00
H - 1701510 - 79 -
31 Base plate assembly 1
00
H - 1701110 - 79 -
32 The first axle shaft assembly 1
61
H - 1701001 - 61 -
33 The front box 1
02
H - 1602240 - 79 -
34 Dust shield 1
00
H - 1701114 - 79 -
35 The first axle shaft bearing 1
00
H - 1701113 - 79 -
36 The first axle shaft washer 1
00
H - 1701116 - 79 -
37 Snap ring 1
00
H - 1601311 - 79 -
38 Oil seal (1st axle) 1
00
H - 1601310 - 79 -
C
39 The first axle front cover 1
61
40 1602050 1 Z A Release bearing 1
H - 1602200 - 61 -
A

41 Release fork assembly 1

00
H - 1701612 - 79 -
42 Bolt and elastic pad assembly 6
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00
H - 1602230 - 79 -
43 Ball fulcrum bearing 1
61

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Quanti
No. Code Name Remark
ty
H - 1701614 - 79 -
1 Bolt and flat pad assembly 6
00
C
H - 1702118 - 79 -
2 1/2 gear fork 1
00
3 Q5280526 Spring pin 6
A

H - 1702119 - 79 -
4 1 / 2 gear striker 1
00
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H - 1702123 - 79 -
5 Interlock pin 2
00
H - 1702117 - 79 -
6 1/2 gear fork shaft 1
00
H - 1702111 - 79 -
7 R/5 gear fork shaft 1
00
H - 1702112 - 79 -
8 R/5 gear fork 1
00
H - 1702113 - 79 -
9 R/5 gear striker 1
00
H - 1701330 - 79 -
10 Oil seal (rear box) 1
00
H - 1702114 - 79 -
11 3/4 gear fork shaft 1
00
H - 1702116 - 79 -
12 3 / 4 gear striker 1
00
H - 1701650 - 79 -
13 Bracket assembly 1
00

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H - 1702115 - 79 -
14 3/4 gear fork 1
00
H - 1701630 - 79 -
15 Null line 1
00
H - 1702125 - 79 -
16 Reversing light switch assembly 1
00
H - 1701642 - 79 -
17 Wire clamps - 2 1
00
H - 1701641 - 79 -
18 Wire clamps - 1 1
00
H - 1701613 - 79 -
19 Bolt and flat pad assembly 2
00
20 7.9375 - GB 308 Steel ball 1
H - 1701360 - 79 -
21 Locating pin 2
00
H - 1701350 - 79 -
22 Oil sump 1
00
H - 1701620 - 79 -
23 Stud bolt 4
00
H - 1701340 - 79 -
24 Vent plug 1
00
H - 1701002 - 79 -
25 Rear box 1
00
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H - 1701311 - 79 -
26 Speedometer driven gear 1
00
H - 1701313 - 79 -
A

27 Oil seal (guide bushing) 1

00
H - 1701312 - 79 -
28 O-ring (guide bushing) 1
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00
H - 1701310 - 79 -
29 Guide bushing 1
00
30 Q 1860616 Screw bolt 1
31 Q 5280316 Spring pin 1
H - 1701380 - 79 -
32 Shield 1
00
H - 1702216 - 79 -
33 Flat washer 1
00

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No. Code Name Quantity Remark
H - 1701211 - 79 -
1 Needle roller bearings (2nd axle head 1
00
H - 1701225 - 79 -
2 3/4, R/5 gear synchronization rings 4
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00
H - 1701226 - 79 -
3 Snap ring (3/ 4 gear ) 1
00
A

H - 1701223 - 79 -
4 3 / 4 gear spring 4
00
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H - 1701222 - 79 -
5 3 / 4 gear hub 1
00
H - 1701224 - 79 -
6 3 / 4 gear slider 6
00
H - 1701221 - 79 -
7 3/4, R/5 gear sleeve 1
00
H - 1701230 - 79 -
8 The drive shaft third gear assembly 1
00
H - 1701233 - 79 - Needle roller bearings (drive shaft third and
9 2
00 fifth gears)
H - 1701210 - 79 -
10 The second shaft 1
00
H - 1701243 - 79 -
11 Needle roller bearings (drive shaft second gear) 1
00
12 H-1701240-79-51 Drive shaft second gear assembly 1
H - 1701256 - 79 -
13 Inner ring 2
00
H - 1701255 - 79 -
14 Dual-cone ring 2
00
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H - 1701257 - 79 -
15 Outer ring 2
00
H - 1701252 - 79 -
16 1 / 2 gear hub 1
00
H - 1701254 - 79 -
17 1 / 2 gear spring 3
00
H - 1701251 - 79 -
18 1/2 gear sleeve 1
00
H - 1701253 - 79 -
19 1 / 2 gear slider 3
00
H - 1701262 - 79 -
20 Drive shaft first gear bushing 1
00
H - 1701263 - 79 -
21 needle roller bearings (drive shaft first gear) 1
00
H - 1701260 - 79 -
22 Drive shaft first gear assembly
51
H - 1701264 - 79 -
23 Dual row angular contact ball bearings 1
00
H - 1701425 - 79 -
24 Pressure plate 1
00
25 Q 2580820 The 6-point take-countersunk head screws 9
H - 1701274 - 79 -
26 Main reversing sleeve 1
00
C
H - 1701270 - 79 -
27 Main reversing gear assembly 1
00
H - 1701281 - 79 -
A

28 R/5 gear hub 1

00
H - 1701293 - 79 -
29 Drive shaft fifth gear sleeve 1
J

00
H - 1701273 - 79 -
30 Needle roller bearings (Main reversing gear) 1
00
H - 1701290 - 79 -
31 Drive shaft fifth gear assembly 1
00
H - 1701294 - 79 -
32 Thrust washer 1
00
33 4.7625 - GB 308 Steel ball 2
H - 1701295 - 79 -
34 The second shaft nut 1
00
H - 1701296 - 79 -
35 Snap ring 2
00
H - 1701297 - 79 -
36 The second shaft rear bearing 1
00
H - 1701298 - 79 -
37 Snap ring (speedometer driven gear ) 2
00
H - 1701299 - 79 -
38 Speedometer driven gear 1
00

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H - 1701410 - 79 -
39 Intermediate shaft front sleeve 1
00
H - 1701411 - 79 -
40 Tapered roller bearing 1
00
H - 1701412 - 79 -
41 Intermediate shaft 1
51
H - 1701413 - 79 -
42 Tapered roller bearing 1
00
H - 1701414 - 79 -
43 Washer adjustment (intermediate shaft) 1
00
H - 1701415 - 79 -
44 Intermediate shaft rear sleeve 1
00
H - 1701416 - 79 -
45 Intermediate shaft reversing gear 1
00
H - 1701417 - 79 -
46 Intermediate shaft fifth gear 1
00
47 6305C3Z2 Ball bearing 1
H - 1701419 - 79 -
48 Nut (intermediate shaft) 1
00
H - 1701420 - 79 -
49 Reverse gear shaft 1
00
H - 1701421 - 79 -
50 Needle roller bearings (reverse gear) 2
00
C
H - 1701422 - 79 -
51 Reverse gear 1
00
H - 1701423 - 79 -
A

52 Thrust washer (reverse gear) 1

00
H - 1701424 - 79 -
53 Nuts (reverse shaft) 1
J

00

 Installation

1、 Install the transmission onto the vehicle with a jack or ropes. Note to adjust the first shaft so that its splines can be
engaged with the clutch friction disc splines.
2、 Install in its original position the drive shaft, lever, wire drawing, clutch components, and so on.

5. Wearing Parts Catalog

No. Code Name Materials Quantity Remarks

H - 1701419 - 79 -
1 Nut (intermediate shaft) 1
00
H - 1701295 - 79 -
2 The second shaft nut 1
00

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H - 1701424 - 79 -
3 Nuts (reverse shaft) 1
00
H - 1601311 - 79 -
4 Oil seal (1st axle) 1
00
H - 1702211 - 79 - Oil seal (selecting, shifting
5 2
00 shaft)
H - 1701330 - 79 -
6 Oil seal (rear box) 1
00
H - 1701312 - 79 -
7 O-ring (guide bushing) Nitrile rubber 1
00

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Selecting and Shifting Control Device

1. Overview
The transmission of this model is equipped in a short distance from the driver, it adopts the remote control mode,

the transmission operation system adopts mechanical mode, and the transmission mode between the transmission device

and shift operation system is cable transmission.

1
4
2
24
22 3
23
5
6 7

7 10 8
18 19 20
10
22
21 9
C

10
A

17 11
14
16
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12 13 12
15

(1) handle body （2）decorative ring （3）dust cover hoop （4）hoop （5）transmission lever shield（6）

stroke adjustment block (7) lock pin (8) hexagon headed bolt、spring washer and flat washer assemblies（9）

Shifting operation base assembly （10）spring shim （11）rubber pad（12）fixed pipe clamp assembly （13）

hexagon head bolt and single coil spring lock washer assemblies (14) gear selecting cable (15)hexagon head

bolt and single coil spring lock washer assemblies （16）gear changing cable bracket（17）small flat washer

（18）gear changing cable pad （19）hexagon flange nuts （20）pipe clamp（￠12） （21）gear changing

cable assembly （22）bonnet（23）Cross recessed big cup-head tapping screw（24）dustproof cover seat

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2. Specification
Number of gears 5 forward gear, 1 reverse gear
Operating mechanism
mechanical type
form
Transmissions type cable transmission

3. Disassembly and re-installation

Disassembly

1
2
C
4
3
5
A

+
6
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Disassembly Order
（1） handle body（2）transmission lever shield （3）dustproof cover seat （4）Shifting operation base assembly

（5）rubber pad （6）fixed pipe clamp assembly （7）gear changing cable assembly （8）gear selecting cable （9）

gear changing cable bracket

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Preparations
Before installation clean the gear changing cable to

avoid greasy dirt and mud, pull the parking brake

control handle to the braking position.

Important operations - disassembly

1、Dust cover seat

(1) Open the 4 plug covers of the set screw, and then

remove the four mounting screws in order,

then remove dust cover.

C
A

2、Gear changing cable

(1) Split gear shifting cable assembly and gear
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changing operation seat assembly

(2) Remove the lock pin and stroke adjustment

block to split gear shifting cable assembly.

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(5) Remove 4 mounting bolts and 2 spring washers

of the gear changing operation seat, remove the

operation seat.

(6) Remove the 2 mounting bolts of fixed flexible

shaft.
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(4) Unscrew the lever body, and then remove trim

ring and the transmission lever cap.

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(7) Remove the screw bolts fixed on the gear

changing fixing bracket of the transmission box,

the fixed flexible shaft and 2 lock pins, remove

flexible shaft.

(8) Disassemble 2 spring washers, set bolts of fixing

clip assembly, split soft shaft.

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Inspection and repair

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In the course of the inspection, if excessive wear or

damage is found, it is necessary to repair or replace

parts.

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Visual check
Visually check to find the damage or failure and replace

them.

No. Items Tightening torque (N·m)

(8) Hexagon bolt, spring washers and flat washer assembly 11.6
(Q146BB0830F62)
(13) Hexagon bolt and spring washers assembly 6.8
(Q1420616F71)
(19) Hexagon flange nuts (Q 32008 F62) 10.5

Re-installation
C

The order of re-installation is opposite to the disassembly order

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Transmission System Service Manual N 125-NAM - PV - DP - G 9 - 18

Drive shaft
1. Overview ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ……….... 2

2. Technical parameters……………………………………………………………………2

3. Disassembling and re-installation…………………………………..... ... ... ... ... ... .....2

4. Re-installation . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... …5

5. Fault diagnosis and maintenance ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 6
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Transmission System Service Manual N 125-NAM - PV - DP - G 9 - 18

1. Overview

Drive shaft consists of the shaft tube, telescopic sleeve and knuckle. Telescopic sleeve can automatically adjust the

distance change between the transmission and drive axle. Knuckle is to ensure two axles angle change of the

transmission output shaft and the drive axle input shaft, and the conformal speed drive of these 2 axles.

Drive shaft, automotive drive train passes in the important parts, and its role is to the transmission, drive axle,

engine power is transmitted to the wheel, the cars drive.

C
A

N 125 drive shaft assembly

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2. Technical parameters

Bearing fixed mode Outer spring clasp

External diameter of universal joint pin (mm) 29 Φ

Shaft Tube Size (mm) Φ76×2.5

Flange bolt size (mm) M10

Flange pitch size (mm) Φ 90

The largest residual unbalance value（g·cm/r/min） No more than 30 /3200

Distance between universal joint pins (mm) 813

3. Drive device disassembly

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Transmission System Service Manual N 125-NAM - PV - DP - G 9 - 18

3.1. Drive device disassembly

7
6
5
4
8

4
3
2
1
Disassembly Order

1. Type 1 hexagon nut 2. Spring washer 3. Hexagon flange bolts 4.hexagon bolts - close pitched tube 5. Spring washer

6. Flat washer 7. Shaft protection framework 8. Drive shaft assembly

C

Drive shaft device disassembly steps

A

1 Remove the drive shaft assembly mounting bolts,

J

nuts and spring washers

2 Take out the drive shaft assembly ;

3 Remove drive shaft protection rack mounting bolts

and spring washers;

4 Remove the shaft protection rack. It is not necessary

to remove the protection rack if it has no distortion or

damage.

Note: The shaft requires a good balance of

performance so when disassembling it please mark the

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Transmission System Service Manual N 125-NAM - PV - DP - G 9 - 18

knuckle (so you can refer to these markers during re-installation).

3.2. The joint fork, universal joint disassembly

Disassembly Order
C
1. Flange york 2. Universal joint bearing shield ring g 3. Needle bearing 4.Field axle
A

The joint fork, universal joint disassembly

steps
J

(1) Spring shield ring

Remove the spring shield ring of the transmission shaft

with a nipper plier

(2) Needle roller bearings

Use a brass rod to gently tap the flange fork

shoulder, remove the cross shaft and needle bearings.

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Transmission System Service Manual N 125-NAM - PV - DP - G 9 - 18

Cross shaft Visual check

Needle roller bearings
Check the following parts for wear, damage and other
Flange fork
Link fork anomalies.

4. Re-installation

The order of re-installation is opposite to that of removal.

Please refer to the torque table for tightening torque

during reassembly.

1 2
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A
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Torque Reference Table (N·m)

No. Item
1 Drive shaft protection rack mounting bolts
2 Hexagon flange bolt

5. Fault diagnosis and maintenancee

5.1. Fault diagnosis

cross axle pin diameter

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Transmission System Service Manual N 125-NAM - PV - DP - G 9 - 18

1) Cross shaft pin diameter (mm)

If wear or damage is found, it is necessary to repair or

replace the parts. (4) Check the balance solder for sealing off.

Size Limit
29 29.13 Frequently check the balance pad to ensure the

dynamic balance of the transmission shaft.

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(2) Spline side clearance (mm)

Standard Limit
0.1 0.3

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Transmission System Service Manual N 125-NAM - PV - DP - G 9 - 18

（4）Abnormal sounds

Damage, wear, distortions, and the lost of the balance of drive shaft parts may cause abnormal sounds and vibration

when the vehicle is running, which even results in damage of relevant parts. If the vehicle sounds when starting or

accelerating, and shows the looseness, it is probably the loose of drive axle gear or that of drive shaft parts. The loose

probably locates in the universal joint cross shaft or the steel bowl and flange yoke, and spline shaft and spline sleeve of

the telescopic sleeve. The space between cross shaft diameter and bearing should not exceed 0.13 MM, backlash between

telescopic spline shaft and spline sleeve should not exceed 0.3 mm. Parts should be repaired or replaced if the limit is

over.

If chassis has a humming sound, and the higher the speed is, the louder the sound shows. This is typically caused by

the looseness between the universal joint and the bearings, or by the wear of the intermediate bearing of the transmission

shaft, or by the loose hanging bracket, or by the wrong position of the hanging bracket.

(5) Vibration
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The noise increases with the speed, and it is accompanied by a shaking, this is generally caused by the imbalance of

drive shaft. This vibration in the cab can be felt obviously. The largest remaining imbalance of the drive shaft dynamic
A

balance is not bigger than 30/3200 （ g·cm/r/min ）. Invalidation of the drive shaft dynamic balance will result in the

damage of relevant parts, of which the most common is the clutch housing cracks.
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Ways to Check:

Stuff up the front wheels with stow-wood, and jack up the drive axle from one side; start the engine, engage a high

speed to check the vibration of the drive shaft. If with the decrease of the speed the vibration is even significant, this

indicates that the drive is bent or flange is skew. It is often the axle tube that is bending, and this is mainly caused by

overload.

Replace drive shaft assembly, balance check should be carried out after the alignment, and the unbalanced volume

should be up to the required standard. The technical conditions of the universal joint and the transmission shaft also call

for detailed inspection. Undesirable installation may lead to looseness, vibration and damage of the cross shaft and roller,

which will also cause imbalance of the drive shaft.

5.2. Drive shaft maintenance

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To extend its service life, it should be noted.

1. Do not start a car in high gear.

2. Do not suddenly lift clutch pedal.

3. Do not overload or over speed.

4. Frequently check the drive shaft.

5. Frequently check the tightness of the drive shaft hanging bracket, check the connection of each parts for the looseness,

and check if the spindle is deformed.

6. Often add grease to the universal joint bearings. In summer, No.3 lithium grease should be filled in while in winter

No.2 lithium grease.

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Rear axle assembly

1. Overview ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 2

2. Rear axle structure parameters... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. 2

3. Disassembly, inspection and repair of rear axle assembly………………………………3

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1. Overview
The car is of unitary drive axle, axle housing adopts punch forming, the solder is of welding fabrication; the master
reducer box is casted formation, and to be connected by dual-head stud, nut and axle housing; rear axle assembly is
connected with rear brake.

2. Rear axle structure parameters

Heavy spring
1 Brake drum 2 Axle shaft bolt 3 4 Half-shaft
washers ¢ 10
Wheel hub outer oil
5 6 Bolt M5×12 7 Spring washer ￠5 8 Spring pad ￠5
seal
Wheel hub nut
9 10 Rear wheel lock nut 11 Bearing LM 102949 12 Wheel Hub
locking tab
Wheel hub outer oil Brake connecting bolt Brake connecting
13 14 Wheel nut 15 16
seal (short) bolt (long)
Brake assembly Rear axle housing
17 18 Copper washer 19 Refueling plug 20
(left) assembly
21 Brake lock nut 22 Flange lock nut 23 Washer 24 Flange
Pre-tightening
25 Dust shield 26 Oil seal 27 Bearing M88043 28
washers
Mounting distance
29 Spacer 30 Bearing HM89249 31 32 Driving bevel gear
adjusting washer
33 Reduction shell 34 Screw bolt 35 Driven bevel gear 36 Bearing 17887
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37 Thrust washer 38 Half-shaft gear 39 Differential Housing 40 Planetary Gear
41 Spherical washer 42 Planetary gear shaft 43 Pin 44 Bearing seat
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45 Bearing cap bolts 46 spring washer 47 Adjusting nuts 48 Locking tab

Spring washer ￠ Heavy spring
49 50 Bolt M8×16 51 Nut 52
5 washers ¢ 10
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Ventilator plug Brake assembly

53 Special bolt (long) 54 Special bolt (short) 55 56
assembly (right)

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Rear axle sealant and adhesive

Item Prescriptive sealant and adhesive

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Rear axle housing assembly and the main gear
YT598 silicone sealant.
assembly mounting panel
A

Driven gear cap screws Anaerobic Adhesive GY - 340

Half-shaft and wheel hub faying surface YT598 silicone sealant

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Axle housing and reduction shell connecting

Anaerobic Adhesive GY - 340
bolts straight thread

Wheel hub bearing and hub cavity NO. 2 the base grease

Main gear oil seal YT598 silicone sealant

Rear axle wearing parts list

Item Quantity

Main gear oil seal 1

Rear wheel hub inner oil seal 2

Rear wheel hub outer oil seal 2

Rear wheel hub inner bearing 32010 X 2

Rear wheel hub outer bearing LM 102949/LM 2

102910

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Active gear large bearings HM 89249/HM 1

89210

Active gear small bearings M 88043/M 88010 1

Differential Bearing 17887 /17831 2

Main bolt torque list
Bolt (nut) name Tightening torque (N.m)
Flange lock nut 200～300

Bearing cap bolts 90～110

Bolt-driven gear 140～160

Main reduction and axle housing cap screws 60～75

Locking tab 4～8

Rear brake bottom plate nut 65～80

Half-shaft cap screw 50～65

Wheel hub inner nut

Lock washer hexagon head bolt 4～8

Refueling plug 130 to 150 after gear oil refilling
Oil drain plug 130～150
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3. Rear axle disassembly, inspection and repair
Rear axle disassembly
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1. Pad the wheels with wooden wedges.

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2. Release the lug nuts of the outer side wheel.

3. Jack up the rear axle.

4. Remove drain plug and drain the gear oil.

Remove brake drum

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Remove half shaft

1. Release half-shaft cap screw

2. Remove half-shaft. If it is hard to remove the half shaft,

knock the shaft flange with a brass hammer until half

shaft is loosened.

Note: Lay the silicone sealant on the joint surface of half

shaft and the wheel hub when you assemble them.

Remove wheel hub outer oil seal

Remove the hub outer seal with a screwdriver

Disassemble wheel hub

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1. Remove wheel hub lock tab.

2. Remove wheel hub lock nut.

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Caution:

Remove adjusting nut with wheel hub bearing adjust

lever

Remove wheel hub assembly

Note: Remove wheel hub with rear wheel hub expander

Remove the inner oil seal from wheel hub assembly

Remove the outer ring of the inner and outer bearings

Disassemble axle housing, main reduction gear.

1. Drain lubrication oil of main reduction gear.

2. Disassemble the connection of drive shaft and the main
reduction gear.
3. Remove main reduction gear assembly with a jack.
4. Remove the tube, steel pipe and wire harness.
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5. Remove brake assembly.
6. Disassemble rear axle
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Prop up the axle housing with a jack.

Remove U bolt and backing plates, put down the jack

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then pull out the axle housing.

Disassemble main reduction gear assembly

1. Before disassembling, measure and record the gear

clearance between driving and driven gears;

Note：Check the mesh between gears after adjustment.

2. Remove locking plate

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3. Mark the bearing cover and housing

Caution:

Remove the bearing cap and the reduction gear then place

them separately by match number so as to avoid wrongly

assembly.

4. Loosen the bearing cap bolts, remove the nut with

differential wrench.

5. Remove the bearing cap and screws;

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6. Remove the differential assembly;

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Disassemble the differential assembly

1. Remove driven bevel gear;

a. remove 10 screws and 5 lock plate.

b. tap the driven gear with a plastic hammer to separate it

from differential housing

2. Before disassembling, measure and record the side gear

clearance of planetary gear;

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3. Get out planetary gear shaft

4. Remove the planetary gear and spherical washer and

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half-shaft gears and thrust washers;

5. Remove the differential bearings from the differential

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housing;

Driving gear disassembly

1. Inspect flange section run-out and port run-out

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2. Measure the driving bevel gear pretightening force

3. Remove the main gear flange nuts;

4. Take off the flange assemblies, pressure out the main

gear assembly
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5. Remove adjusting washer and bearing sleeve;

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6. Remove the bearing from the driving gear,

7. Remove oil seal from the main reduction housing

8. Take out the bearing outer ring from the reduction

housing

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Rear axle service parameters table

Items Value
Gear clearance between
0.10～0.20
driving and driven gears
Planetary gear and half-shaft
0.12～0.20
gear clearance
Driving gear pre-tightening
18N ~25N
force
Rear axle gear oil GL-5 85W/90
Friction disks and brake drum
0.3～0.5mm
clearance

Maintenance
Item Abrasion limit Remarks
standards
Rear axle steel spring seat positioning holes
wear
The left and right half shaft bushing outer
-
bearing journal radial run-out
Half shaft central undressed surface -
Wheel hub and axle flange faying surface face
-
run-out
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Driven gear tooth contact status Causes Adjustment methods:

A. circular tooth contact area
adjustment
B. backlash in circular tooth
adjustment
Driving gear is too far to
driven gear.
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inclined to the top 1. Depart driven gear from
driving gear.
A

2. Move driving gear towards driven gear

to get proper backlash in circular tooth.
(add shim)
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Driving gear is too close to

driven gear.

inclined to the bottom 1. Move driven gear towards

driving gear.
2. Depart driving gear from driven gear to
get proper backlash in circular
tooth.( remove shim)

Driven gear is too close to

driving gear.

inclined to the inner ring 1. Depart driven gear from

driving gear.
2. Depart driving gear from driven gear to
get proper backlash in circular
tooth.( remove shim)
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Driven gear is too far to

driving gear.

inclined to the outer ring 1. Move driven gear towards

driving gear.
2. Move driving gear towards driven gear
to get proper backlash in circular tooth.
(add shim)

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Wheel cover unit

1. Overview ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ................. 2

2.Technical parameters…………………………………………………………………….2

3.Disassembly……………………………………………………………………………...2

4.Re-installation…………………………………………………………………………....3

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1. Overview

Wheel cover unit is the decorative covers installed on the wheel rims which make the car even more pleasing. And it

prevents corrosions and scratches to wheel rims and wheel nuts from block liquid, dust, and debris.

2. Technical parameters
A

Front wheel mounting

surface diameter 183mm
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Rear wheel mounting

surface diameter 159mm

3. Disassembly

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Wheel cover unit disassembly

Level the cover with a screw driver then remove it.

Duiring disassembly, do not tear the wheel hub cover or wheel rim. Do not level too hard to breakdown the

wheel cover.

Inspection

Clean the wheels, the rims and wheel covers

surface, clear the dirt and keep the wheels, rims and

wheel covers clean and dry.

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If the bayonet turns loose, then the trim cove

A

will be easily drop off, especially under high-speed. The

drop of it is dangerous for cars and pedestrians. Repair or

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replace the wheel cover.

Keep the wheel cover and the rim at the same position,

and then gently push it in. If it is hard to match, point

the wheel cover at the location of rim gap valve, then

press the wheel cover in with with a screwdriver.

Notes for re-installation

(1) Fix the wheel covers on the wheels to ensure the security. Wheel cover is fixed with stainless steel wire snap ring and
the clip on the wheel rims; check the accepted products by removal stress test to ensure the security. Pay attention to the
wheel cover assembly during replacement. If the bayonet is loose then check if the spring tension is normal.
Clean the wheels and wheel covers clear the dirt and keep the wheels and covers clean and dry.
(3) If it is hard to install, do not slap with too much force in case the covers are destroyed. If the installation is failed, it is
recommended to turn to professionals.

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Spare tire lifter device

1. Overview ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ………..1

2.Technical parameters……………………………………………………………………..1

3.Disassembly……………………………………………………………………………...1

4. Re-installation . ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 4
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4. Overview

Because automobile spare tire is high from the ground and very heavy, manual removal will be quite difficult, a spare tire

lifter is necessary to raise or lower the spare tire so as to change tires. Generally, there are steel -wire -rope and chain

spare wheel lifters. N125 adopts chain spare tire lifter.

5. Disassembly
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Spare tire lifter disassembly

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Disassembly Order

1. Cotter pin 2. Pin roll 3.hexagon headed bolts and spring washer assembly 4. Handle mounting bracket 5. Spare tire

lifter locks 6. Handle 7. Handle rubber base 8. Hexagon flange bolt 9. Spare tire lifter assembly 10. Hexagon headed

bolts - fine 11. Spare tire lifter right beam 12. Spare tire lifter left beam

Spare Tire lifter device disassembly steps

(1). Open the spare tire lifter lock, and shake the spare

tire off.

(2). Remove the spare tire.

(3). Disconnect cotter pin with a nipper plier, remove pin

rolls.
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A

(4). Disassemble the handle mounting bracket bolts and

handle mounting bracket, take off handle rubber base.

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1. Pin roll
2. Spare tire lifter assembly
3. Handle
4. Chain
5. Bolts, etc.

(5). Remove spare tire lifter assembly mounting bolts and

its left and right beam mounting bolts.

Visually inspect the parts on the left side to

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ensure there is no damage, wear. To check if there is

corrosion and rust on spare tire lifter chains, if mounting

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bolts of parts are in good condition, etc.

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6. Re-installation

The order of re-installation is opposite to that of removal. Please refer to the torque table for tightening torque during

reassembly.

3
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Tightening torque (N·m)

Rema
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No. Item Torque

rks
① Spare tire lifter assembly mounting bolts 41～51
Spare tire lifter left and right beams mounting
② 41～51
bolts
③ Spare tire lifter handle mounting bracket bolts 7～9

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Wheels
1. Overview ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... …..1

2. Wheel specification ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ….2

3. Wheel inspection and repair ………………………………………………………3

4. Wheel installation torque ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 5

5. Fault diagnosis.……………………………………………………………………..5

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1. Overview
The car adopts two types of tires, front wheel is a single tire （195/70R15LT）, and rear wheel is single side dual tire

(155R13LT). There are two spare tires (one front tire and the other rear tire), the spare tire beam and tray are fixed in

rear rack by the spare tire lifter. Front and rear wheel nuts can be employed universally; specifications are M14×1.5 and

are left-hand threads.

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Front wheel Rear wheel
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Wheel nut

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2. Front and rear wheels specifications

Front wheel Rear Wheel

Tire type 195/70R15LT-6PR 155R13LT-8PR

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Rim specifications 5.5J×15 4 J×13

Standard inflation 350 kPa 450 kPa

Wheel nut M14×1.5，Left-wing

3. Wheel inspection and repair

1) Front wheels disassembly

Pull up the handbrake to stop the vehicle. Loosen the 5

nuts of the front wheel, back the sub-frame with a jack to let

the front wheels off the ground. Then remove the 5 nuts of

front wheels and take off the front wheels.

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Visually check the front wheels

① Check the front wheel rim for deformation and

surface cracks, and replace the front wheels if necessary.

② Check if the front tire pressure is adequate, if not

please inflate tires.

③ Check the front tires for the wear limit, if the wear

marker is reached then replace the front wheels.

Wear marker■

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3）Front wheel installation

Align the wheel mounting bolts on front wheel rims to

install the front wheels, then screw in 5 nuts successively,

pre-tension then tighten them.

4）Rear wheel disassembly

Engage a gear and block front wheels with bits of wood,

loosen the 5 wheel nuts on one side, and then prop up the leaf

spring with a jack to keep the rear wheels off the ground, then

remove these 5 nuts and take off rear wheels.

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5）Visually check the rear wheels

① Check the rear wheel rims for deformation and

surface cracks, and replace the rear wheels if necessary.

② Check if the rear tire pressure is adequate, if not

please inflate tires.

③ Check the rear tires for the wear limit, if the wear

marker is reached then replace the rear wheels.

Wear marker

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6) Rear wheels installation

Align the wheel mounting bolts on rear wheel rims to

install the front wheels, then screw in 5 nuts successively,

pre-tension then tighten them.

Note: Aim the inside rear tire valve stem to mounting

holes of the outside rear tire rims.

7) Spare tire disassembly

Open the spare tire lifter lock, cover the driver's tool on

the spare tire rocker lever, rotate counter-clockwise to remove

the spare tire.

8) Spare tire disassembly

Order of installation is opposite to that of disassembly, the

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rear tires are on the above and front tires down.
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Driver’s tool

4. Wheel installation torque

Front wheel nuts torque：180～220N·m

Rear wheel nuts torque：180～230N·m

5. Wheel fault diagnosis

1) Wheel abnormal wear

Possible causes: ① Tires didn't take dynamic balance test；

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② Problem occurs to front four-wheel alignment parameters adjustment, or suspension system parts are

deformed.

2） Under-inflation of tires

Possible causes: ① Valve stem encounters sealing leakage.

② Tires are broken.

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Service Manual N125-NAM-PV-DP-G9-19

Engine suspension
1. Overview…………………………………………………………....………………………………….………2
2. Engine suspension specification…………………………………………………………………..……………2
3. Engine suspension removal, re-installation………………………………………………………..……………3
4. Engine suspension fault handling……………………………………………………………………….………4

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Service Manual N125-NAM-PV-DP-G9-19

1. Review

Powertrain is central vertical with 3-point rubber suspension. There are fasteners including suspension beam

assembly, transmission hanging assembly, etc.

2. Engine suspension specification

2
1

3 3

4 4

5 5
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8 9
7

10
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No. Part Number Name Quantity Remarks

A

1 1001010W5000 suspension beam assembly 1

2 Q33010F62 All-metal hexagonal flange locking nut 4
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3 Q401B12F62 Flat washer 4

4 Q40312F62 spring washer 4
5 Q151C1230TF62 Hexagon bolt-closely-pitched 4

6 Q146B1030F62 Hexagon bolt, spring washers and flat washer assembly 4

7 1001020W5000 Transmission hanging assembly 1

8 Q33110F62_1.25 All-metal hexagonal flange locking nut 4
9 Q33112F62_1.25 All-metal hexagonal flange locking nut 2
10 1001691U1510 Rear Suspension bolts 2

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3. Engine suspension removal, re-installation

Removal suspension beam assembly

(1)Remove 2 hexagon bolts, spring washers, flat

washer assembly and hexagon flange locking nut on

left side of engine suspension

(2)Remove 2 hexagon bolts, spring washers, flat

washer assembly and hexagon flange locking nut on

right side of engine suspension

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(3)Remove 2 rear suspension bolts and hexagon

flange locking nut

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Caution:
Before remove powertrain fixing components, make

sure the related harness connected to power are

disconnected; After removing fasteners, should use

professional lifter or suspension devices shift the

power assembly to secure site.

(4) Remove 4 hexagon bolts, spring washer and flat

washer connecting suspension beam, remove the

suspension beam assembly

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Transmission hanging assembly removal

Remove four hexagon flange locking nuts connecting

the transmission hanging assembly and remove the

transmission hanging assembly.

Re-installation
Re-installation is in the opposite direction of removal.

Fasteners re-installation torque summary

No. Description Torque values (N * Remarks

m)
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1 Hexagon bolts and hexagon flange locking nuts on both sides

41～51
of engine suspension
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2 Rear suspension connecting bolts and hexagon flange locking

73～89
nuts
Connecting suspension beam assembly and hexagon screws of
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3 73～89
car frame
4 Hexagon flange locking nuts connecting the transmission
41～51
hanging assembly

4. Engine suspension fault handling

(1) When removing the engine suspension device, check if there is obvious mechanical damage on each

component, must be replaced if there is any damage.

(2) While removing or re-installation engine suspension, pay attention to prevent water, Corrosive solvents

into parts, otherwise, it will influence life of parts.

(3) If there is engine or power vibration and sounds while using vehicle, check if there are any desoldering

or rubber cracking on suspension beam assembly and transmission hanging assembly, prepare corresponding

replacement or dealing with to dismiss problem.

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Speed drive device

1. Instruction of speed drive device………………………………………………2

2. Specifications and related parameters………………………………………… 2

3. Removal and re-installation of speed drive device……………………………3

4. Cautions of speed drive device………………………………………..………5

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1. Instruction of speed drive device

Speed drive device is composed by accelerator pedal, pedal bracket, accelerator cable, etc., accelerator
pedal bracket connects with body floor and front panel, accelerator pedal is fixed to the accelerator pedal
bracket, one end of accelerator cable is connected with accelerator pedal, and the other end to the engine throttle
arm.

2. Specifications and related

No. part no. Name Quantity Remarks

1 1108020W5000 Accelerator pedal bracket assembly 1
2 Q32006F62 Hexagonal flange nut 3
3 1108010W5000 Accelerator pedal assembly 1
4 Q146B0616F71 Hexagon bolt, spring washer and flat 4
washer assembly
5 1108030W5000 Accelerator cable assembly 1
6 1108035W5000 ribbon I 3
7 1108036W5000 ribbon II 1
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Device explosion drawing

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3. Removal and re-installation of speed drive device

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Accelerator pedal bracket removal

1. Remove 4 screws off accelerator pedal bracket
from the body floor and front mold.

2. Remove 3 nuts connecting accelerator pedal

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bracket and accelerator pedal to remove the throttle

pedal
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Accelerator cable removal

1. Loosen the screw connecting the cable and pedal
to separate buckle of pedal and cable

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2. Twist the steel wire rope, making it parallel with

gaps, to pull out steel cable terminal in the direction
of arrow

3. In the engine side, repeat steps 1 and 2, loosen

the nut, separate the stringing and buckle, and then
rotate the steel wire rope paralleled with gaps, push
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out steel wire rope connector
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4. Remove the ribbon and washer connecting

stringing and car body to remove the throttle
stringing.

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Re-installation of the speed drive system

The order of re-installation is opposite to the disassembly order. When fastening throttle cable, direction

must be same as original, do not circle, and ribbon must be blocked in the original hole. Tightening torque is in

the following table:

Part Number Name The torque (N • M)

Q32006F62 Hexagonal flange nut 7.5～10.5
Q146B0616F71 Hexagon bolt, spring washer and flat 8～11
washer assembly

4. Caution of speed drive device

Check if the rubber guard of throttle cable is in place, being badly sealed could lead to excessive matter and
dust, now it is necessary to replace throttle cable with a new one, then it may cause pedal force too much or
does not return to original, which influences road safety.
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Fuel System
1. Instruction of Fuel System……………………………………………………….

2. Specifications and related parameters……………………………………………

3. Fuel System Removal and re-installation ………………………………………....

4. Cautions of Fuel System…………………………………………………………

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1. Instruction of Fuel System

Fuel system is composed by oil filling pipe, fuel tank, fuel supply and return pipes, fuel filter, fuel tank is
in HDPE plastic parts, with a fuel sensor inside, and is fixed by a steel band clamps to the frame. Fuel pipe is
composed by rubber pipe and steel pipe, closely connected by steel band clamps, inlet pipe and the return pipe
is fixed by plastic tube and tube clip to the frame, and connected with the engine inlet port, return port
individually. Fuel filter is installed with a hand pump in upper side, drainage lower side and with electrical
heating.

3. Specifications and related parameters

Parts List
No. part no. Name Quantit Remarks
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1 BTH126A Steel belt type Ring Clamp 8
2 1104060W5000 The inlet hose components IV 1
3 1104016W5000 Oil return Hose III 1
4 BTH111A Steel belt type Ring Clamp 6
5 Q146B0616F71 Hexagon bolt, spring washer and flat washer 3
assembly
6 1104030W5000 The pipe clip assembly I 1
7 1104032W5000 pipe clip I 3
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8 1104019W5000 oil return steel pipe II 1
9 1104040W5000 Hose assemblyⅡ 1
10 1104015W5000 Oil return Hose II 1
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11 1104018W5000 Oil return steel pipe I 1

12 1104014W5000 Oil return Hose I 1
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13 1101120W5000 Oil pump bracket with sensor assembly 1

14 1104011W5000 Oil inlet hose I 1
15 1104017W5000 The oil inlet steel pipe I 1
16 1104012W5000 Oil inlet hose II 1
17 1104020W5000 The oil inlet steel pipe II 1
18 1104013W5000 Oil inlet hose II 1
19 1105010W5000 Diesel oil Filter 1
20 1105030W5000 Diesel oil Filter bracket assembly 1
21 Q40310F61 spring washer 2
22 Q151C1030F61 Hexagon bolt-closely-pitched 2
23 Q33008F62 All-metal hexagonal flange locking nut 2
24 1101030W5000 Fuel tank vent tube assembly 1
25 BTH202A Steel belt type Ring Clamp 2
26 1101100W5000 Fuel Tank Assembly 1
27 Q1840820F61 Hexagonal flange screw 2
28 1103020W5000 oil filler cap assembly 1
29 1101010W5000 oil filler pipe assembly 1

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30 1101031W5000 Oil filler hose 1

31 Q67570 A type transmission hose strap 2
32 1101070W5000 Fuel tank clamp I assembly 1
33 1101080W5000 Fuel tank clamp II assembly 1
34 Q401B10F62 Flat washer 4
35 Q40310F62 spring washer 4
36 Q151C1035F62 Hexagon bolt-closely-pitched 4

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Fuel System explosion drawing

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3. Fuel System Removal and re-installation

1. Remove 2 screws connecting oil filler tube and

car body.

2. Remove steel band clamps in the connection of

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fuel tank and and its ventilation hose
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3. Remove the strap connecting the oil fuel hose and

the fuel tank, then remove the fuel filler tube
assembly.

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Remove the oil filler components

1. Remove two steel clamps connecting the steel

pipe and hose near fuel tank

2. Remove two screws connecting the fuel tank

clamp and car frame out of fuel tank
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3. Remove two screws connecting the fuel tank

clamp and car frame out of fuel tank, take off 2
fuel tank clamp and fuel tank.
Note: After removing screws here, remove drive
Remove fuel tank shaft Protection Architecture first, then remove
fuel tank.

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2. Remove two screws connecting the Fuel Filter

and its bracket to remove the fuel filter.

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Fuel pipe removal

1. Remove steel clamps connecting fuel pipe and
engine in cabin floor to separate the oil inlet/return
line and engine.

Fuel Filter removal

1. Remove two band clamps connecting hose of fuel
filter, separating the filter and hose

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3. Remove bolts connecting the other pipe clamp

assembly and the car frame to separate fuel pipe and
the car frame.

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2. Remove bolts connecting pipe clamp assembly

and car frame.

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3. Fuel System re-installation

The order of re-installation is opposite to the disassembly order. After re-installation, make sure the Fuel

Supply System Pipe is sealed, drain air from oil pipe after filling oil to fuel system. Fastener torque refer to the

following table:

Part Number Name The torque (N • M)

Q146B0616F71 Hexagon bolt, spring washer and flat 9～11
washer assembly
Q151C1030F61 Hexagon bolt-closely-pitched 41～51
Q1840820F61 Hexagonal flange screw 21～25
Q67570 A type transmission hose strap 6～10
Q151C1035F62 Hexagon bolt-closely-pitched 41～51
Q33008F62 All-metal hexagonal flange locking 21～25
nut
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4. Cautions of Fuel System
When removing fuel system, check if there is obvious mechanical or electrical damage on each component,
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must be replaced if there is any damage.

Water and debris should be prevented from entering while fuel system removal or re-installation;
When removing be ready to deal with fuel spillage timely, complying with fuel handling procedures.
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Otherwise it may cause burn and may lead to personal injury.

When removing or re-installing, it's prohibited to smoke or carry any type of tobacco or kindling.

Intake system

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1. Instruction of intake System…………………………………….……………….2

2. Specification and related parameters…………………………………….………2

3. Removal and re-installation of intake system……………………………………4

4. Cautions of intake system………………………………………….….…………9

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1. Instruction of intake System

The air intake system is composed by air intake, air filter, inter cooler, and pipes connecting those
components, and the air intake is in front of car body to intake enough air, the air filter is in right front of car
frame, easy to remove and clean filter element. Engine is equipped with turbo system, so there is inter cooler in
intake system Outlet pipe of air intake is equipped with resonant cavity, reducing intake noise.

2. Specifications and related parameters

Parts List
1. Intake system (from intake passage to turbo intake part)

No. part no. Name Quantit Remarks

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1 1109200W5000 Intake passage assembly 1
2 1109100W5000 air filter assembly 1
3 1109901W5000 Intake protection cover 1
4 1109050W5000 resonant cavity assembly 1
5 1109401W5000 Air filter outlet hose 1
6 1109402W5000 Supercharger air inflow rigid tube 1
7 1109403W5000 Supercharger air inflow hose 1
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8 Q402B06F62 Big washer 6
9 Q1420635F62 Hexagon bolt and spring washer assembly 6
10 Q67590 A type transmission hose strap 3
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11 Q402B08F62 Big washer 2

12 Q1420835F62 Hexagon bolt and spring washer assembly 2
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13 Q1420620F62 Hexagon bolt and spring washer assembly 4

14 Q402B06F62 Big washer 4
15 Q67580 A type transmission hose strap 2
16 Q67570 A type transmission hose strap 1

Intake system (from intake passage to turbo intake)

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2. The air intake system (Turbocharger outlet to the engine air intake)
Quantit
No. part no. Name Remarks
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1 1109300W5000 Inter cooler assembly 1
2 1109405W5000 Inter cooler air inflow hose 1
3 1109520W5000 The inter cooler air intake steel tube assembly 1
4 1109404W5000 Supercharger outlet hose 1
5 1109406W5000 Inter cooler outlet hose 1
6 1109540W5000 Inter cooler outlet steel tube assembly 1
7 1109407W5000 Engine air intake hose 1
8 1109550W5000 Engine air intake steel tube assembly 1
Hexagon nut and tapered elastic washer
9 Q32208F61 2
combination.
10 Q1420835F61 Hexagon bolt and spring washer assembly 2
11 Q402B08F61 Big washer 2
12 RQ67765 T-clamp 3
13 RQ67760 T-clamp 5
14 Q402B08F62 Big washer 2
15 Q1420835F62 Hexagon bolt and spring washer assembly 2
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16 Q1840816F62 Hexagonal flange screw 2
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The air intake system explosion drawing (Turbocharger outlet to the engine air intake)

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3. Removal and re-installation of intake system

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Intake passage removal

1. Remove 3 screws connecting the air intake and
front body mold
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2. Remove the clamp connecting air intake passage

Intake protection cover removal and air filter to remove the air intake passage
1. Remove 4 screws from air intake shield in the
bottom of front frame, 2 of which are connected to
front bumper, the other 2 screws are connected to
the body front mold, now remove the air intake
shield.

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Remove air intake

1. Remove the clamp connecting air filter and its
outlet hose to separate them.

2. Remove 2 screws connecting supercharger intake

rigid tube and car body.
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3. Remove two hoses' clamps connected to engine

turbocharger. You can remove the tube from air
filter to turbocharger.

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4. Remove two screws connecting the inter cooler

air intake steel pipe and the frame

5. Remove two clamps connecting the air inlet and

outlet hose, then remove tube from turbocharger to
inter cooler.
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6. Remove two screws connecting the inter cooler

air outlet steel pipe and the frame

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7. Remove two nuts connecting engine and its air

intake steel pipe, then remove the tube from inter
cooler to engine

Remove air filter

1. Remove 3 screws connecting the air filter and
frame to remove the air filter
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2. Air filter disassemble is showed in the figure.

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Remove the inter cooler

1. Remove 2 nuts and 2 screws connecting inter

cooler and frame to remove the inter cooler.

Re-installation of intake system

The order of re-installation is opposite to the disassembly order. Fix inter cooler, air filter, then fix the rigid

tube, and finally install the hose. Hose must be installed firmly when re-installing hose: insertion depth arrives

to the tube mark. The tube and hose must also be aligned with the arrow mark.
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Tightening torque is in the following table:

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The tube mark Arrow mark

Part Number Name The torque (N • M)

Q1420635F62 Hexagon bolt and spring washer 8.5～9.5
assembly
Q67590 A type transmission hose strap 3
Q1420620F62 Hexagon bolt and spring washer 8.5～9.5
assembly
Q67580 A type transmission hose strap 3

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Q67570 A type transmission hose strap 3

Hexagon nut and tapered elastic 21～25
Q32208F61
washer combination.
Hexagon bolt and spring washer 21～25
Q1420835F61
assembly

RQ67765 T-clamp 5.5～7.5

RQ67760 T-clamp 5.5～7.5

Hexagon bolt and spring washer 21～25
Q1420835F62
assembly

Q1840816F62 Hexagonal flange screw 21～25

4. Cautions of intake system

1. Air filter element has little dust, vehicles travels first 3000Km to deal with, then clean every 5000 km. after
13000 km replace new filter element; Reduce the maintenance mileage under harsh environments or heavy dust
environment, refer to automobile maintenance manual for more details.
2. Seal of pipe: test if tube clamp is tight enough or not, and watch with eyes if the insertion depth is up to
requirement or not: hoses are required be insert to the tube mark.
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Exhaust system
1. Instruction of exhaust system …………………………………………………...2

2. Specification and related parameters …………………………………………... 2

3. Removal and re-installation of intake system……………………………………3

4. Cautions of exhaust system………………………………………………………5

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1. Instruction of exhaust system

Exhaust system includes: front exhaust pipe, muffler, muffler hanging, exhaust tail pipe, exhaust tube
brackets, rubber hanging, and so on.

2. Specifications and related parameters

Parts List

No. part no. Name Quantity Remarks

The front exhaust tube
1 1203010W5000 1
assembly
2 1201100W5000 Muffler assembly 1
3 1203020W5000 Exhaust tail pipe assembly 1
4 1201200W5000 muffler hanging assembly 1
5 1203071W5000 Exhaust pipe rubber hanging 2
6 Q32310F61 Hexagonal flange nut 4
7 28764-28020 sealing pad 2
8 1203072W5000 The muffler rubber hanging 2
9 Q401B08 Flat washer 1
10 Q40308 spring washer 1
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11 Q150B0830 Hexagon head bolt 1
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Exhaust system explosion drawing

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3. Removal and re-installation of exhaust system

Remove front exhaust tube

(1) Remove two screws connecting engine exhaust

manifold and front exhaust pipe

(2) Remove rubber hanging from hooks and remove

front exhaust tube

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Remove muffler assembly

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(1) Use ratchet wrench to remove 2 nuts connecting

the muffler and front exhaust pipe.

(2) Remove rubber hanging from hooks and remove

muffler assembly

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Remove exhaust tail pipe

(1) Use ratchet wrench to remove 2 nuts connecting

the muffler and exhaust tail pipe.

(2) Remove rubber hanging from hooks and remove

exhaust tail tube

Re-installation of exhaust system

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Place the front exhaust pipe and the muffler and exhaust tail pipe to the correct location of frame, and then tighten the

nut, tighten all nuts for some laps, tightening torque is in the table below.
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Part Number Name Tightening torque (N·m)

Q32310F61 Hexagonal flange nut 45～55

5. Cautions of exhaust system

There are some easily damaged parts in exhaust system, such as seals, rubber hanging, bellows, and so on. These

parts need to be checked regularly. Change damaged parts timely.

Exhaust system leaks, please check if the seal pad of exhaust system flanged connection is damaged, if welding of

corrugated pipe and exhaust pipe snaps.

Exhaust System jitters abnormally, please check the muffler rubber hanging, front exhaust pipe rubber hanging, exhaust

tail pipe rubber hanging is abnormally worn or not. If it is worn, replace timely. See more in explosion drawing. Part 2,

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part 5 and part 11 are rubber hanging, which are easy to be worn, leading to severe vibration, should be replaced timely.

Sealing gasket should be installed between front exhaust pipe and the muffler, between muffler and exhaust tail pipe,

part 4 and part 8 is seal. Pay attention that seal gasket needs to be replaced each time after removing exhaust

system. .

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III. Cooling system

1. Review
Cooling system is comprised of radiator, cooling fan, compensation tank, etc., which are general components of

cooling system. Its function is to maintain engine at normal temperature while working ensuring its working

environment is relatively stable.

1 1 1
1

1 8
1 1
5 1
7
6
2 9 1
1

3 8
4 1
1
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(1) cross self tapping screw (2) Liquid storage pot cover (3) hexagon screws, spring washer, big washer (4)

Plastic fastening belts (5) Liquid storage pot cap assembly (6) hose assemblies (7) plastic buckle I (8) hexagon

screws, spring washers, big washers (9)radiator (10) radiator mounted with hose (11) hexagon head with cross

bolts, spring washer, flat washer

(12) steel-Flex hoops I (13) steel-Flex hoops II (14) radiator outlet pipe (15) radiator inlet pipe (16) steel-Flex

hoops III (17) the wind hood (18) Tank Cover Assembly

2. Specification
Radiator wind shield
Φ474mm
diameter
radiator stripe number 60
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Service Manual N125-NAM-PV-DP-G9-19

radiator radiating area 15.4 m2

Water Tank Cover
1.1 KPa
pressure
Radiator, water outlet
Φ36mm
diameter.

3. Disassembling and re-installation

Disassemble

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1 7

6
2
3 4

5
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Disassembling Order
(1) Liquid storage pot cover (2) Liquid storage pot cap assembly (3) Liquid storage pot hose Assembly (4) radiator
assembly (5) radiator mounted with soft pads below (6) radiator outlet pipe (7) wind hood (8) radiator inlet pipe (9)
water tank cover assembly

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(2) Remove four self-tapping screws fixing liquid

storage pot and remove its shield.

2. Liquid storage pot hose assembly

Remove four hose clamps fixing hose assembly

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3. Radiator assembly

Preparations
Before disassembling, clean the cooling system to
avoid greasy dirt and mud, pull the parking brake
control handle to the braking position, remove cab
and open its front hood.

Important operations - disassembly

1. Liquid storage pot cover assembly

(1) Remove the mounting bolts above and below the
the expansion tank with ratchet wrench.

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(1) Loosen flexible strap with slip-joint pliers,

remove the outlet pipe from the engine outlet, and
then remove inlet with the same method.

(2) Remove 2 mounting bolts off radiator assembly

and remove the radiator. C

(4) Remove 5 cross bolts fixing the wind hood,

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(3) A Loosen flexible strap with slip-joint pliers and remove the wind hood.
remove inlet and outlet.
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Inspection and repair

In the course of the inspection, if excessive wear or
damage is found, it is necessary to repair or replace
parts.

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replace them.

Visual check
Visually check to find the damage or failure and

Re-installation
No. Item Tightening torque (N·m)
(3) Hexagon 9-11
bolt-closely-pitched( Q151C0616F61)
(8) Hexagon 21-25
bolt-closely-pitched( Q151C0835F61)
(11) Hexagon cross bolts ( Q174B0616F61) 3.6

The order of re-installation is opposite to the disassembly order

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Project: N125

Brake System Service Manual

Number: W5000-NAM-PV-DP-G9-16

Version: 1.0
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Compilation:
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Proofread:

Review:

Standardization:

Countersignature:

Approval:

ANHUI JIANGHUAI AUTOMOBILE CO., LTD.

Year Month Day

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Foreword

《 The Light Cargo Truck Service Manual-HFC1036K 》 describes the

precautions that you must pay attention to, when testing HFC1036K Series

models, doing maintenance,repairing, as well as disassembling and assembling

the parts. Meanwhile, it introduces the basic judgment methods and solutions to

some of the common problems for the vehicles.

All the information involved in the Service Manual should take the latest

data and the latest status of the vehicle when it is published, as a reference.
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However, with the advances in technology, the product updates, and other

reasons, all the content in the Service Manual might change.Our company
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reserve the rights to change this manual without prior notice.Thanks for your
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understanding.

《 The Light Cargo Truck Service Manual-HFC1036K 》 is projected by Anhui Jianghuai

Automobile Co., Ltd, and complied by Commercial Vehicle Research Institute.

The right of interpretation for all the provisions in the Service Manual shall be

vested in Anhui Jianghuai Automobile Co., Ltd.

Anhui Jianghuai Automobile Co., Ltd.

March, 2014

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Contents

Brake and Operation System

1. Overview ………………………………………………………………………1

2. Main Data and Specification of Front and Rear

Brake ……………………………………………1

3. Brake System Inspection and

Maintenance……………………………………………………3

4. Fault Handling for Brake

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System ………………………………………………………13
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1. Overview
The truck adopts a II-dual-circuit hydraulic brake system, the front brake is a hollow disc brake, the rear

brake is a bi-directional drum brake, the vacuum booster is a non-cross-cutting, double-diaphragm structure. The

brake master cylinder structure is a single center valve. It equipped with LSPV (loading sensing pressure

proportioning valve)--an adjustable Brake Force Distribution. The front brake includes brake caliper, brake discs,

fender, etc., rear brake includes brake drum, brake plate, brake shoes, paddle, the parking brake pulling plate.

The park brake is manual control mechanical ratchet cable type, acting on the rear brake.

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Front brake device Rear brake device

2. The main data and specifications of front and rear brakes

Front brake Rear brake

Type Disk brake Type Drum brake

Brake disc 274 Brake drum 220

diameter(mm) diameter(mm)

Brake disc 26 Brake drum idth 67

thickness(mm) (mm)
Brake wheel cylinder 2×46 Brake wheel cylinder 17.46

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diameter(mm) diameter(mm)

Friction disks, 0.3～0.5 Clearance between 0.3～0.5

clearance (mm) friction blades(mm)

Friction blades 11 Friction blades 4.7

thickness (mm) thickness (mm)

Brake pedal free 3～8

stroke(mm)

3. Brake system inspection and maintenance

Front brake disassembly:

1) Brake caliper disassembly:

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① disassemble the two bolts installed on the steering
knuckle, and remove the brake caliper.
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② Remove the friction blades from the brake caliper,

and check the thickness of it.

Standard thickness: 11mm；

Wear limit thickness: 2mm

2) Brake disc disassemble:

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① disassemble the five nuts on the brake disc in

sequence, and take out the brake disc.

② Visual inspection: Check that if there is any

uneven abrasion, crack or serious damage on the surface of

the brake disc. If so, replace it.

③ Runout Check: Use dial indicator to check runout;

Runout limit: 0.05 MM (can be measured in the inside

edge, 10mm to the brake, if runout exceeds the set value,

replace it or carry out the necessary process.

④ Thickness Check: Use dial indicator to check the

brake discs' thickness. If thickness is less than wear limit,

replace brake discs.

Standard thickness: 26 mm; wear limit: 24 mm.

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3) Fender disassembly:
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① Disassemble three mounting screws which are

installed on the steering, and remove the fender

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② Visual inspection: Check the fender whether there

had been a serious distortion, and if so, please replace it

Front brake installation:

The install order of the front brake is in reverse with the disassembly order.

Brake caliper mounting bolt tightening torque: 140～180N·m

Brake discs mounting nut tightening torque: 45～52N·m

Front Brake running-in procedure:

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Repair or replace brake discs 、 if there appears brake pedal soft when running in a short distance, please

replace friction plates, and please operate as the following steps to run-in the joint surface between brake plates

and discs.

Note: Before running in, if the braking effect is not so good, please control the speed. Only under the

security road and traffic conditions, this step can be performed, it is necessary to pay attention to safety.

1) Drive the car on a straight road.

2) Control the brake pedal, to make the vehicle brake in 3～5 seconds.

3) After driving a car for a certain distance, park the car for 3 minutes to cool the brake system.

4) Repeat the steps 1～3, until the friction plates and brake discs fully run-in.

Rear brake disassembly:

1) Brake drum disassembly:

① Brake drum and rear wheels use the mounting nuts

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in common, and remove the rear wheels firstly before

disassembling the brake drum, then remove the brake

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drum.
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② Check the inner diameter of brake drum: because

when the worn or abrasive lead to the size increase,

please change the brake drum, or adopts the friction

plates whose size has been increased.

Standard ID (inner diameter): 220

Wear Limit: 221.5

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2) Rear brake assembly and disassembly:

① Disassemble four nuts installed on the rear axle

flange, then remove the rear brake.

②Visual inspection: Check the pump inside the brake

whether exists leaks or damage.If so, replace the entire rear

brake assembly; check the brake plate assembly whether

deformed or cracked.If so, replace the entire rear brake

assembly; check if the other parts existing any unusual

deformation and wear. If so, replace the parts.

3) Brake shoes disassembly

① Remove the two back springs respectively, then

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release the springs.

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②Disassemble the two pressure spring seat

③Disassemble the clearance adjustment assembly and

the drop-down spring

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④ disassemble the guide plate and return spring of the

brake foot, and then you can remove the brake leading and

sub-foot.

⑤ Check the friction plates for abnormal wear, if the

abnormal wear exists, please replace brake shoes and

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friction plates assembly.

Friction plates thickness: 4.7mm

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Limit thickness: 1mm

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Rear brake installation:

The installation order of rear brake assembly and parts reverse with the disassembly order

Rear brake assembly mounting nuts tightening torque: 25～30N·m

Note: ①When installing the rear brake assembly nuts tighten them according to the diagonal order.

② When installing brake drum, please adjust clearance between it and the friction plates, the

clearance is 0.3～0.5mm.

Brake Line device disassembly

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1) Brake lines diagram

1. Oil reservoir jug 2. Vacuum booster with brake master cylinder 3. Single pass connector 4. Cross 5. Front

brake wheel cylinder 6. Vacuum Cylinder 7. Vacuum pump 8. LSPV( loading sensing pressure
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proportioning valve) 9. T-Cock 10. Rear brake wheel cylinder

2) Oil reservoir jug disassembly and inspection

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The following picture shows the location of the oil

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reservoir jug on the vehicle.

(The brake fluid can only use liquid brake fluid and

must be in consistent with 1703 DOT value, the

corresponding GB 10830 JG4）

① Disconnect two hoses connected with the oil

reservoir jug, and remove the two mounting

screws of the oil reservoir jug, then take out the

oil reservoir jug.

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② Vehicle check: Check the height of the brake fluid

level, to confirm if brake fluid level in the oil reservoir

jug is within the specified range (between MIN and

MAX).

If the level is too low, please check whether the oil

reservoir jug and brake system existing leak.

3) Disassembly of vacuum booster with brake

master cylinder
① Disconnect the tube and hose connecting with the

brake master cylinder.

② Disassemble the locking pin and washers from the

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brake pedal.
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③ Remove the four mounting nuts installed on the

brake clutch pedal, and remove the vacuum booster with

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brake master cylinder.

4)Brake pedal disassembly and inspection

①Brake pedal and clutch pedal integrated in the brake

clutch pedal assembly,

the pedal repair need to replace the entire brake clutch

pedal assembly. Assembly remove refer to the disassembly

method of brake clutch pedal assembly.

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② Check non-slip rubber foot pads of brake pedal for

excessive wear or damage, and if so, please replace

non-slip rubber feet.

5) Disassembly of LSPV (loading sensing

pressure proportioning valve)
① Disconnect three tubes connected with LSPV, then

remove

② a nut connecting with the rear axle bracket, and

then remove the two bolts fixed on the frame.

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Brake Lines device installation

The installed order of all parts and components is in reverse order of removal.

Vacuum booster with brake master cylinder mounting torque: 24～30N·m

LSPV mounting torque: 20～25N·m

The brake pipe connector torque: 16～20N·m

Brake lines disassembly and installation precautions

1) All brake lines can not be excessively bent, twisted and stretched.

2) Confirm that all brake lines will not be interfered with other parts when the vehicle is stationary or

steering.

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3) Brake lines are the important security components, if finding that brake fluid leak, please tighten the fixed

device. If you find damaged parts, please replace the new applicable components.

4) When you disconnect brake lines, please seal the connector end to avoid dust and dirt.

5) Refill the brake fluid (brake fluid model DOT 3/DOT4) after disassembling and installing, and then bleed

air.

Brake Lines air emissions methods and steps

1) Continuously depress the brake pedal, and set up the pressure within the brake system.

2) After reinsert the air hose (hose connected to the recycling containers, so as to avoid the brake fluid

flowing out pollute other parts), depress the pedals and hold it, not release.Open the exhaust bolts on the caliper or

brake cylinder, and close the exhaust bolts, after the brake fluid which containing air bubbles is no longer flowing

out from the exhaust vent.

3) Repeat the above two steps until the brake fluid overflow from the exhaust hoses does not contain air
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bubbles.

4) Note: This is only possible when the engine is started, you can operate the exhaust work for the system.
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The parking brake device disassembly

1) The parking brake device breakdown drawing

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1. parking handle 2. front drawbench 3. park connector 4. left drawbench 5. left park drawing-bracket 6. right
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park drawing-bracket 7. right drawbench
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2) Parking handles disassembly

Firstly, to remove the retaining nut and adjusting nut
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of the front drawbench at the end of the handle, loosen the

front drawbench, and then disassemble the handle

mounting bolts and nuts, lastly remove handle.

3) Parking drawbench disassembly

① In accordance with the installation point of the

drawbench, disassemble the mounting bolts or screws in

sequence.

②Vehicle check: Check the parking brake drawbench

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fot distortion, or worn, cracked, if it has, replace it.

4) Parking connector disassembly

1 Remove the connectors of the three drawbenches,

release the spring, and then remove the lockpin, and

remove the two pin rolls, finally remove the parking

connector assembly.

The parking brake device installation

The installation order of the parking brake is in reverse to the disassembly order.
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Parking handle mounting bolts torque: 23 N•m～27 N•m

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Parking handle mounting nuts torque: 23 N•m～27 N•m

Note: When checking the brake system, the vehicle should be placed on level ground, and use the corner
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blocks to fix wheels.

Parking brake device adjustment

1)When the parking handle is in a put-down state, and having installed the repair/replacement parts, please

adjust the right parking drawbench length to ensure the installation status.

2) After debugging is completed, pull the parking handle with 210N power whose direction is vertical to the
Le
handle.adjust the front parking drawbench, to lock the handle on 5 - 7 gears, and then use the two ends left-turn

and right-turn muts to lock them.

5. Brake system fault handing

Service braking system troubleshooting:

Common troubleshooting table

Fault phenomenon Possible cause Solution

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Left and right tire under-inflation Adjustment

Front wheel adjustment is not correct Adjustment

When braking,the Brake shoes poor contact Adjustment

vehicle ran off Brake Shoe surface is with grease or oil Replacement

Incorrect installation brake cylinder Adjustment

Self-regulating bodies have faulty Adjustment

Brake fluid is less or polluted Supplement or

replace

Air in the brake system Bleed the system

Insufficient braking Brake vacuum booster has faulty Replacement

force Brake shoes poor contact Adjustment

Brake Shoe surface is with grease or oil Replacement

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Brake Shoes dragging leads to the brake rotating parts Adjustment

overheating
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Pedal stroke Air in the brake system Bleed the system

increases(pedal to the
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Brake fluid leaks Adjustment

floor distance Self-regulating bodies have faulty Adjustment

reduction)

The parking brake is not fully liberalized Release

The parking brake is maladjusted

Brake pedal return spring wears Replacement

Brake retard Brake master pump no-return valve or piston return Replacement

springs have defective

Clearance between push rods and brake master cylinder Adjustment

is too small

The parking brake Rear brake shoes are damaged Replacement

function is not Rear brake shoe surface is with grease or oil Replacement

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enough The parking brake handle stroke is too large Adjustment

Self-regulating bodies have faulty Adjustment

Parts troubleshooting:

Brake shoes:

Fault problems Possible reasons Handling method

The middle part 1. The inner cavity of brake drum is deformed. 2. Repair or replace

of brake foots Brake Plate damage. 3. Brake shoes bent. 4. Brake as needed.

poor contact shoes pin or bushes are worn. 5. The bearing of wheel

hub is loose.

Within a brake, 1. The installation of brake shoes is imbalance Repair or replace

inside foots wear 2. Brake shoes pin or bushes are worn. as needed.

is uneven
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The wear amount 1. Brake plate is deformed. Repair or replace

of the ends of the 2. Brake shoes pin or bushes are worn. as needed.
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brake shoes is
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large.

The surface of 1. The surface of brake linings is polluted by the Repair or replace

brake linings is lubricating oil. 2. During the maintenance process, the as needed.

glazing. model of the brake linings is incorrect.

The surface of 1. The friction surface of brake drum is uneven. 2. Repair or replace

brake linings has There are foreign materials in the brake drum. as needed.

scratches.

Edge wear of 1. The width of break linings is not correct. 2. The Repair or replace

brake linings bearing of wheel hub is loose. 3. Brake shoes bent. as needed.

Brake drum:

Fault Possible reasons Handling method

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problems

Part of brake 1. Brake drum is out-of-round. 2. The installation Repair or replace as

drum is at of brake drum is in different heart. needed.

high 3. The bearing of wheel hub is loose.

temperature

The whole 1. The friction material on brake linings or brake Repair or replace as

brake drum is drum deteriorated. needed.

at high 2. Brake overburden. 3. Drive overburden, wheel

temperature hub bearing is at high temperature.

The brake 1. The friction material on brake linings or brake Repair or replace as

drum has drum deteriorated. needed.

scratches 2. Brake overburden. 3. There are foreign matters

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among brake lining or brake drum.

Brake drum 1. Drive overburden 2. The friction material on Repair or replace as

A

cracks brake linings or brake drum deteriorated. 3. Brake needed.

overburden.
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Park system troubleshooting

1) Trouble lamp is lit or not lit.

①check to see if the trouble lamp is damaged in its performance

②check to see if there is loose between the trouble lamp and the screw connection of the toothed plate

Maintenance:

If the above situations exist, replace or reinstall the trouble lamp.

2) The braking force is not enough or fails:

①check to see if the drawbench plate is connected with the brake drawbench

②check to see if the locknut for sliding

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③check to see if the current braking distance and the braking distance that the vehicles required is the same

Maintenance:

①The first case: please connect the drawbench plate and brake drawbench.

②The second case: please replace the locknut.

③The third case: please adjust the distance of the locknut.

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Maintenance Manual
N125-NAM-PV-DP-G9-17

Project N125

Transmission System Maintenance Manual

No. N 125-NAM - PV - DP -
Version:1.0
G 9 - 18

Edited by:

Proofread by:
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Reviewed by:
Standardized
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by:
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Countersigned
by:

Approved by:

Anhui Jianghuai Automobile Co., Ltd.

Year Month Day

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Maintenance Manual
N125-NAM-PV-DP-G9-17

steering system
1.Overview ………………………………………………………………………

2.Main data and

specification ……………………………………………………………

3.decomposition, assembly, inspection,

reassembly …………………………………………………

4.Malfunction

diagnosing ……………………………………………………………………

4.Frequent Malfunction elimination

method …………………………………………………………
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Maintenance Manual
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1.Overview
Automobile power steering system is made up of steering device, power steering pipe line

device. steering device is the executive module of hydraulic power steering system; steering

device is made up of steering wheel assembly, steering column assembly, steering shaft&driving

universal joint, steering column under shield, commutator assembly, commutator transmission

shaft, steering device with tie rod assembly and so on.

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steering device

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power steering pipe line device is made up of steering pump, power steering oil reservoir

assembly, oil pump inlet oil pipe assembly, oil pump outlet oil pipe assembly, powering steering

oil inlet pipe assembly and so on. steering oil pimp, with engine together, is to provide hydraulic

power source to system; steering oiler has fuctions of storage, cooling and filtering the oil.

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power steering pipe line device

2.Main data and specification

steering wheel diameter (mm) 390

steering turns 3.19

cylinder diameter 50mm

working oil pressure ≥8.85Mpa

working conditions temperature -40℃ ~135℃

Pump rated flow 7.5L/min

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3.decomposition, inspection, assembly

decomposition

1
2

7
5

10

8
9
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steering device
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①horn button ②steering wheel nut and spring washer ③steering wheel ④steering column assembly

⑤steering shaft&driving universal joint ⑥strapping tape ⑦steering column under shield
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⑧commutator assembly ⑨commutator transmission shaft ⑩steering device with tie rod assembly

4
3

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Maintenance Manual
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power steering pipe line device

①power steering pump ②power steering oil reservoir ③oil pump outlet oil pipe ④oil pump inlet

oil pipe ⑤powering steering oil inlet pipe

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disassembly and reassembly
A

steering wheel
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1.pull out the horn button

2.Remove steering wheel mounting nut with

sleeve and ratchet spanner, remove steering

wheel mounting spring washer

3.Remove steering wheel

combination switch involucrum

1.Remove combination switch under involucrum

2.Remove steering column under shield cover

assembly

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Maintenance Manual
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steering column assembly, steering

shaft&driving universal joint,

steering column under shield

1.Remove strapping tape with needle-nose

pliers

2.Remove under universal joint connecting bolt

3.Remove 4 upper universal joint connecting

bolts in turns.

4.Remove steering column

5.Remove middle, left, right bolts of steering

column under mounting shield in turns

5.Remove steering column under universal joint

mounting bolt

6.Remove steering column under mounting body

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assembly

7.Remove steering column under mounting body

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assembly.
steering column assembly
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1.Remove steering shield strapping tape.

2.Remove 4 mounting bolts of steering column

with cocket wrench.

3.pull apart steering shield involucrum,

remove connecting bolt between steering column

and under shaft with sleeve

4.Remove steering column

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Maintenance Manual
N125-NAM-PV-DP-G9-17
of device.

Steering column under shield +

steering shaft&driving universal

joint

1.Remove connecting bolt between steering

shaft&driving universal joint and commutator

assembly.

2.Remove 3 fixing bolts of steering column

2
under shield(on the floor) 1

3.Remove steering column under shield and

steering shaft&driving universal joint

together. Disassemble steering column under

shield+steering shaft&driving universal joint

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4.Remove 3 connecting screw of steering column

under shield assembly, remove steering shield

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body in turns

5.Mark with marker pen on steering

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shaft&driving universal joint, disengage

assembly limit sleeve ， disassemble and

separate assembly upper&under semi-axis

6.Take out dustproof rubber sleeve , mounting

seat and gland of steering column under shield

assembly

Attention:
Disassembly steering shaft&driving universal

joint upper&under semi-axis and dustproof

sleeve, mark the position, aim at the position

when reassemble, in order to ensure stability

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Maintenance Manual
N125-NAM-PV-DP-G9-17

2
1

commutator assembly, commutator

transmission shaft
3

1.Remove connecting bolt between steering

transmission shaft and steering device

2.Remove fixing nut between commutator and

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frame, fixing bolt 1, fixing bolt 2, fixing

A

bolt 3.

3.Take out commutator and commutator

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transmission shaft

commutator assembly

Remove 3 assembling bolts and nuts, take out

steering assembly.

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commutator transmission shaft

Remove 2 assembling bolts in turns, take out

commutator transmission shaft

steering device with tie rod assembly

1.Remove splitpin and hex slotted nut of

left&right steering joint, take out steering

tie rod ball and spigot.

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2.Disconnect steering pipe line

A

3.Remove 4 assembling bolts from sub-frame in

turns, take out mounting frame, rubber

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mounting liner and steering device with tie rod

assembly parts.

power steering oil reservoir

1.Remove steering kettle front&rear

mounting bolt

2.Take out power steering oil reservoir

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Maintenance Manual
N125-NAM-PV-DP-G9-17

power steering oiler tie-in

Remove hose clamps， remove oil pipe and oil

return line pipe（connect with power steering

oiler）

pipe clamp bolt

1.Remove the 2 bolts of pipe clamp beside power

steering oiler.
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2.Remove the pipe clamp bolt of sub-frame with

ratchet spanner

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Maintenance Manual
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3.Remove the pipe clamp bolt beside power

steering

4.Remove the bolt connecting frame pipe clamp

of high-pressure oil tube

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5.Remove the bolt of oil return line pipe clamp

as shown in the picture

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Maintenance Manual
N125-NAM-PV-DP-G9-17
6.Remove the pipe clamp bolt of oil return line

pipe connecting frame

power steering oil pump tie-in

1.Remove high-pressure oil tube with

open spanner, remove high-pressure oil tube

tie-in (connect with power steering oil pump)

2.Remove hose clamps, remove inlet oil pipe

(connect with inlet oil pipe)

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Steering device

1.bracket bushing assembly: remove

bracket and bushing in turns.

2.outer ball joint assembly: screw hex nut with

spanner, and then remove the outer ball joint.

3.gear shield and clamps: remove hex nut and

fixing gear shield clamps & monaural stepless,

withdraw from gear shield.

4.inner ball assembly: fix gear flat square,

screw inner ball joint assembly with spanner,

and remove inner ball joint assembly.

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Maintenance Manual
N125-NAM-PV-DP-G9-17
5.adjusting mechanism: remove adjusting plug 8.gear assembly: draw out gear plunger

screw, spring, gear fulcrum bearing, plug assembly.

cover and so on. 9.left&right pipe line assembly: remove

6.Valve assembly and accessories:screw bolt left&right pipe line assembly.

and remove Valve assembly.

7.Limiting sleeve assembly: screw limting

sleeve assembly with auxiliary tool.

inspection and maintenance

If there is any wear and tear or error state after inspection, it shall need some necessary

proofread or parts replacement.

reassembly

reassembly sequence is on the contrary to disassembly sequence.

Quanti

Project ty Tightening torque （N.m）

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Steering wheel fixing nut 1 35～40

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steering column mounting nut 2 18～22

steering column mounting bolt 2 18～25

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connecting bolt between steering column and

under shaft 1 25～30

connecting bolt between under shaft and

power steering device 1 25～30

power steering device fixing bolt 4 90～110

connecting nut between steering tie rod end

and steering joint 2 50～60

oil pipe and bolt of fixing bracket 9 9～11

oiler bracket fixing bolt 3 18～22

oiler bracket fixing bolt 4 18～23

oiler bracket fixing bolt 5 18～24

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Maintenance Manual
N125-NAM-PV-DP-G9-17
power steering pump bracket mounting bolt

Q14010100 1 50～60

power steering pump bracket mounting bolt

Q1461060 1 50～60

power steering pump bracket connecting bolt

3406742U2010 1 20～25

power steering pump bracket connecting bolt 1 22～30

power steering pump and high-pressure oil

tube connecting piercing bolt 1 57～63

4.Malfunction diagnosing：
frequent malfunction diagnosing sheet
malfuncti malfunction malfunction reason malfunction

on phenomenon elimination

exchange power
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power steering power steering pump oil seal
steering pump oil
pump oil leak damage
seal
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oil leak
oil leak of oil pipe high temperature
exchange oiler and
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pipe line and ageing, faulty union and so

oil pipe
oiler on

exchange power
power steering pump oil seal
steering pump oil
power steering damage
damage seal
pump damage
power steering pump shell exchange power

damage steering pump

The system spool valves obstruction

remove spool valves,
pressure is low open-close
grinding and
hairpin power steering spool valves obstruction
cleaning to make it
pump flow open-close, spring lose
slide freely
inadequately efficacy

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Maintenance Manual
N125-NAM-PV-DP-G9-17
Check the safty
spool valves obstruction
steering valve/pressure
open-close and parts of
device has no relief valve,
steering pump wear and tear
pressure exchange oil and
severely.
steering pump.

Check the safty

valve/pressure
internal
power steering device relief valve,
pressure
internal pressure relief exchange oil and
relief
power steering
power steering
device.
device
oil seal inside of the power exchange oil seal or

steering device lose power steering

efficacy device
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open the steering limitator adjust steering

too early limitator

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steering system
power steering suction air
exhaust
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pump abnormal
driving medium inside of the exchange power
sound
power steering pump damages steering pump

This problem can only

be solved from

noise The oil pipe expand the noise optimizing power

noise inside of of steering pump and liquid steering matching

oil pipe/power which is not absorbed in oil aspect. Exchanging

steering oiler pipe, thus lead to too much any part alone

noise in system. couldn't find the

solution, only if

adding resonant tube

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Maintenance Manual
N125-NAM-PV-DP-G9-17
inside of oil pipe.

oil level of power steering

add oli
oiler is too low

suction air eliminate air

steering column or steering

linkage obstruction adjust linkage

open-close

clean and exchange

Filter pf power steering
power steering oiler
oiler block up
and steering oil

Check the output

operating pressure
the
Left and right of hydraulic
direction
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direction are pressure pump with
of
both piezometer, check
A

sedimenta
a little heavy out whether the pump
tion
is damaged; Further
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power steering pump damage

inspections of

hydraulic pressure

oil filter and pipe

should be made if the

pressure or flow of

power steering is not

enough.

Check out if the

power steering device is not
power steering
good
device is damaged

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Maintenance Manual
N125-NAM-PV-DP-G9-17
Check out if the triangle

belt skids or is too lose;

inspection and
Check anastomosis of gear
adjustment of parts
transmission if the gear

transmits.

check and repair of

There is air in system
leak/exhaust air

inner pressure of power

system is a little low, fuel

delivery of power steering

pump is not enough; driving

belt is lax and skids.

overflow valve Check, adjust and

quick steering
misalignment; pressure repair the entire
with idling
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tubing will be deformed too steering system
speed is quite
much under the influence of
heavy
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high pressure oil, which

will lead to pressure

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hysteresis and air entering

hydraulic system.

exchange power

internal of power steering steering pump and

pump wear and tear clean the entire

steering device

Exhaust air, check

power power steering
There is air in the steering out if there is leak
steering liquid
system. of oil and then solve
liquid is produces
the problem.
abnormal emulsion foam
There is liquid leakage in Check power steering

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Maintenance Manual
N125-NAM-PV-DP-G9-17
steering system. oiler and pour oil

into oiler

steering round ball joint adjust front wheel

loosen or front wheel positioning,

improper positioning steering round ball

steering gear connection

pour steering liquid
twist and deform or wear and
and exhaust air
tear too much

tightness of gear inside of adjust or repair

automobile power steering device lose tightness of power

deflecti
deflection balance steering device gear
on driving
driving check and adjust the

returnability of steering connecting parts of

wheel is not good, steering steering system

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wheel shakes or hacking according to

regulations
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Project: N125 Meng Cheng Pickup Project with Standard II
（2.8L）
Repair Manual
Numb N125-NAM-PV-ZB-G
er: 9-2

Version: 1.0
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Compilation:

Proofread:
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Review:
Standardizat
ion:
Countersign
ature:

Approval:

ANHUI JIANGHUAI AUTOMOBILE CO., LTD.

Year Month Day

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Front Suspension Device
1. Overview ……………………………………………………………3

2. Repair Notes…………………………………………………4

3. Maintenance data and

Specifications………………………………………………5

4. Disassembly and

Re-installation ………………………………………………………5

5. Troubleshooting…………………………………………………………8
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Front Suspension Device
1. Overview
Suspension, transmit all the force and torque acting on among the wheel and the frame, or the body,

moreover it can ease the impact load that the rough ground pass on to the frame or the body,to attenuate the

vibration that caused by the carrying system, in order to ensure the vehicle normal driving.

The front suspension adopts double arm type independent suspension with unequal length, including

sway bar assembly, flexible elements with torsion rod spring; shock attenuation device is a two-way

bidirectional-cylinder-hydraulic shock absorber.

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Serial
Number Name Quantity
number
Hexagonal head bolt, spring washer and
1 Q146B0825TF62 4
flat washer assembly
2 2906014W5000 Front sway bar mounting bracket 2

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3 2906013W5000 Front sway bar bushing installation 2
4 2906010W5000 Front sway bar assembly 1
5 2909010W5000 Front push-rod assembly 2
6 Q151B1260TF61 Hexagonal head bolt-fine tooth 2
Front sway bar connecting rod
7 2906020W5000 2
assembly
The lower-right suspension arm
8 2904400W5000 1
assembly
9 13141-1600F61 Slotted nut 4
Serial
Number Name Quantity
number
10 Q5004028 Cotter pin 4
11 Q151B1455TF61 Hexagonal head bolt-fine tooth 4
The upper right suspension arm
12 2904600W5000 1
assembly
13 2905010W5000 Front shock absorber assembly 2
14 Q151B12100TF61 Hexagonal head bolt-fine tooth 4
15 Q40312F61 Spring washer 4
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16 Q341B12T13F61 1 type hexagon nut-fine tooth 4
17 2902020W5000 Right torsion bar spring assembly 1
18 2902030W5000 Adjusting rod assembly 2
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19 Q40314F61 Spring washer 4

20 Q341B14T13F61 1 type hexagon nut-fine tooth 4
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21 Q341B12T13F61 1 type hexagon nut-fine tooth 2

22 Q40312F61 Spring washer 2
23 Q40312F62 Spring washer 4
24 Q341B12T13F62 1 type hexagon nut-fine tooth 4
25 2904320W5000 Adjusting bolt components 2
26 Q33010F61 All-metal 6-point flange lock nut 2
27 Q1851240TF62_1.25 Hexagonal flange bolts 4
28 2901070W5000 Front buffer block assembly 2
29 2904331W5000 Adjusting pad 2
30 Q40316F61 Spring washer 2
31 Q361B16T13F61 2 type hexagon nut-fine tooth 2
32 2901081W5000 The front upper buffer block 2
33 2902010W5000 Left torsion bar spring assembly 1
34 2904500W5000 The left upper suspension arm assembly 1
35 2904300W5000 The left lower suspension arm assembly 1

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2. Maintenance Notes
■When install the suspension or rubber bushings, the final tightening must be operated on the condition that the

tires landing and no-load.

■After finishing repairing the suspension components, be sure to check wheel alignment.

■The oil will shorten rubber bushing's life.

■Be sure to wipe clean the overflowing oil

■The no-load conditions mean that the fuel, engine coolants and lubricants are normally filled. Besides, spare tires,

jack, tools and foot pad should be placed in the specified location.

■The lock nut can not be reused. When replacing, before tightening lock nut, do not wipe off the rust-preventive

oil of the lock nut.

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3. Maintenance Data and Specifications
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Table of technical specifications

Project Parameters and specifications

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Double wishbone torsion bar independent

Front Suspension forms
suspension

Type Bidirectional cylinder-type shock absorber

Stroke 184.5mm
Shoc
Stret
k 1371N (piston speed 0.3m/s)
Dam ch
absorber
ping force Com
454N (piston speed 0.3m/s)
pression

Torsion Color mark:

Torsion bar spring
stiffness37.7N.m/° White/Yellow circular mark

Whe Toe-in (front) 1～3mm

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el Wheel camber
0.4°±0.5°
alignment angle

Kingpin

inclination angle pin 15.3°±0.5°

pitch

kingpin caster
2.67°±0.5°
angle

Scrub Radius 3±2mm

1) Disassembly

① Disassemble the preloaded nut and adjusting nut,

then remove right-hand torsion bar spring adjusting

components;

②Disassemble the front connecting nuts of the torsion

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bar, and remove the torsion bar spring assembly.

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2) Installation

①Installation is as the reverse order of disassembly.

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1 ．② The preloaded nut tightening torque of

torsion bar spring :（34-50）N·m

2 ．The front connecting nut tightening torque of

torsion bar spring:（110～130）N·m

4. Break-down and Replacement

4.1 Disassembly and installation of

left/right-torsion bar spring assembly

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frame, as well as the spring washer components;

②Disassemble the retaining pin that connected the

upper suspension arm assembly with the steering

knuckle, as well as mounting nut

2) Installation

①Installation is as the reverse order of disassembly.

② The tightening torque of the bolts that connected

the upper suspension arm assembly with the frame:

（120～160）N·m

③The tightening torque of the nuts that connected the

upper suspension arm assembly with the steering

knuckle: （110～130）N·m
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4.3 Disassembly and installation of front

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sway bar assembly

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1) Disassembly

① Disassemble the retaining nuts that connected the

front sway bar assembly with the connecting rod of

the stabilizer, and then remove the connecting rod's

rubber cover as well as the rubber bushings;

② Disassemble the mounting brackets fixed bolts of

4.2 Disassembly and installation of the the front sway bar, and remove the stabilizer's

mounting bracket as well as the stabilizer's mounting

upper suspension arm:
bushings;
1) Disassembly
③ Remove the front sway bar assembly, and remove
①Disassemble the nuts that used to connect the bolts
the stabilizer's connecting rod assembly.
between the upper suspension arm assemblies with
2) Installation
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①Installation is as the reverse order of disassembly.

1 ②Front sway bar mounting bracket mounting bolt

torque:（32～39）N·m

4.4 Disassembly and installation of the

front shock absorber assembly

1) Disassembly

①Disassemble the nuts that used to connect the bolts

between the front shock absorber assembly and the

frame, as well as the spring washer components;

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② Disassemble the nuts that connected the front

shocker absorber with the frame;

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③Remove the shock absorber assembly

3) Installation
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①Installation is as the reverse order of disassembly.

1 ②The tightening torque of the nuts that used to

connect the bolts between the front shocker

absorber assembly with the down suspension arm

assembly:（70～95）N·m

2 ③The tightening torque of the nuts that connected

the front shocker absorber assembly with the

frame:（46～56）N·m

4.5 Disassembly and installation of the

left/right front push-rod assembly

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1) Disassembly

① Disassemble the connected nuts between the front

push-rod assemblies with frame, as well as the spring

washer components;

②Disassemble the nuts that used to connect the bolts

between the front push-rod assembly and the down

suspension arm, as well as the spring washer 4.6 Disassembly and installation of the
components;
down suspension arm assembly
③Remove the front push-rod assembly
1) Disassembly
2) Installation
① Disassemble the connected nuts that used to
①Installation is as the reverse order of disassembly.
connect the fixed adjusting bolt between the down
②The tightening torque of the nuts that connected the
suspension arm assembly and the subframe, as well as
front push-rod assembly with the frame: （140～190）
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the spring washer components;
N·m
② Disassemble the retaining lockpin that connected
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③The tightening torque of the nuts that connected the

the down suspension arm assembly with the steering
front push-rod assembly with the down suspension
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knuckle, as well as mounting nut

arm: （110～130）N·m
③Remove the down suspension arm

2) Installation

① Installation is as the reverse order of

disassembly.

② The tightening torque of the bolts that

connected the down suspension arm assembly

with the sub-frame:（240～300）N·m

③The tightening torque of the mounting nuts that

connected the down suspension arm assembly

with the steering knuckle: （110～130）N·m

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5. Fault Diagnosis
Fault phenomenon Possible cause for fault Solutions

Front wheel improperly positioned Adjustment

Turning exceed the ball joint of the Replacement

Hard steering down suspension arm

Tire pressure is too low Inflation

No power steering Repair or replace

Front wheel improperly positioned Adjustment

The shock absorber are defective Replacement

Horizontal stabilizer damaged Replacement

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Mal-return
Torsion rod spring is broken Replacement

The bushings of the down suspension Replacement

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arm abnormal wear

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Front wheel improperly positioned Adjustment

Tire abnormal wear Tire pressure is too low or too high Adjust the air pressure

The shock absorber are defective Replacement

Front wheel improperly positioned Adjustment

The steering resistance of the down Replacement

Vehicles off-tracking suspension arm's ball joint is not enough

Bushings of the down suspension arm Replacement

loose or abnormally wear

Front wheel improperly positioned Adjustment

Vehicles unilateral
The steering resistance of the down Replacement
off-tracking
suspension arm's ball joint is not enough

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The down suspension arm bent Replacement

Torsion rod spring is broken Replacement

Front wheel improperly positioned Adjustment

The steering resistance of the down Replacement

suspension arm's ball joint is not enough

Bushings of the down suspension arm Replacement

Steering wheel wobble
loose or abnormally wear

The shock absorber are defective Replacement

Horizontal stabilizer damaged Replacement

Torsion rod spring is broken Replacement

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The Sub-frame Device

1. Overview ………………………………………………………………3
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2. Disassembly and

Re-installation……………………………………………………4

3. Maintenance data and

Specifications………………………………………………4

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The Sub-frame Device

2. Overview
Sub-frame welded assembly adopts separated punch, welding is the assembly method, the group

weldments consist of sub-frame body, sub-frame connection panel, steering engine bracket,and etc.

Sub-frame body is welded by an upper and down pieces, forming a "口" shape closed section, with a good

geometrical shape and reliable structural strength.

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Serial
Number Name Usage
number
1 Q151B1435TF61 Hexagonal head bolt-fine tooth 4
2 Q40314F61 Spring washer 4
3 Q341B14T13F61 1 type hexagon nut-fine tooth 4
4 2810010W5060 Sub-frame welded assembly 1

2. Disassembly and Re-installation

1) Disassembly

① respectively disassemble the sub-frame weldments

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assembly, and the frame's left and right two mounting

bolts, nuts and spring washer components.

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② Remove the sub-frame weldment assembly.

2) Installation
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Installation is as the reverse order of disassembly.

① the tightening torque the mounting nuts that used

to connect the sub-frame weldment assembly and

2.1 Disassembly and installation of sub-frame weld frame: （120～160）N·m.

assembly

3. Maintenance data and Specifications

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Serial
Size description Size/mm
number
1 Installation surface height L1 151
2 Nut to body center distance L2 120
3 Nut center distance L3 102
4 The sub-frame width L4 311
5 The frame height L5 1004
6 Distance between mounting holes L6 730
Center distance between mounting holes
7 292
L7
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Center distance between mounting holes
8 215
Main size L8
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parameters 9 Strip hole width L9 15

10 Strip hole height L10 17
11 Distance between hole centres L11 344
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12 Distance between hole centres L12 120.5

13 The sub-frame thickness L13 194
14 Strip hole center distance L14 697
15 Strip hole height L15 30
16 Strip hole width L16 16
17 Weld angle θ 115
18 Mounting hole diameter D1 15
19 Mounting hole diameter D2 8
20 Internal thread M1 12

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Rear Suspension Device

1. Overview ………………………………………………………3

2. Specifications………………………………………………………4

3. Disassembly and Re-installation……………………………………4

4. Troubleshooting……………………………………7
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1. Overview
Rear Suspension adopts steel spring non-independent suspension, and vertical steel spring assembly consists
of three main springs and 2 sub-springs; the shock absorber device adopts bidirectional cylinder-type hydraulic
shock absorbers.

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8
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1 6

2
3 4 5

(1) the leaf spring pin (2). spring washers (3).1 type hexagon nut-fine tooth(4).rear u-bolt and nut (5).1 type

hexagon nut, flat washer, spring washer (6). the buffer block assembly (7). rear leaf spring assembly (8). rubber

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bushing Ⅱ (9). the rear-spring shell lug assembly (10). rubber bushing I (11). spring washers (12). 1 type

hexagon nut (13).rear u-bolts (14). rear shock absorber assembly

2. Specifications
Suspension type Non-independent suspension
Spring type less-plate leaf spring
the number of spring five pieces
The shock absorber
184.5mm
stroke

Warning: Please make sure that tighten the rear u-bolt and nut as specified torque value, because it relates to

the working life of the rear leaf spring assembly.

3. Disassembly and Re-installation

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Disassembly
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2
5
4
3
1

Disassembly order
(1). rear shock absorber assembly (2). the rear-spring shell lug assembly (3). rear spring fixed pin (4). rear

u-bolts (5). rear leaf spring assembly (6). the buffer block assembly

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Preparations
Before disassembling, clean the rear suspension

system, ensures that no silt and oil sludge. Please pull

the parking brake handle grip to the brake position,

then prop the front wheels up, use the jack to support

rear axle, and then use the security bracket to prop Important job - disassembly

rear end of the frame up. 1、The rear shock absorber assembly
Use jack to jack-up the rear axle. Disassemble the rear
shock absorber assembly
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2、The rear-spring shell lug pin

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(1) Disassemble the fixed nuts of the rear-spring shell

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lug.

(2) Remove the leaf spring back-end of the ear pin

assembly.

(3) Disassemble the rubber bushing I、II.

3、The rear-spring fixed pin

(1) Disassemble the fixed pins and bolts of the

rear-spring.

(2) Remove the rear spring pin.

(3) Slowly put down jack to let the rear axle land

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smoothly. At that time, the rear leaf spring
assembly in Free State.

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4、Rear u-bolt
After disassembling the rear u-bolts, please separate
the leaf spring rear buffer block and rear axle.

5、Rear buffer block

Remove the rear buffer blocks

6、Leaf spring

Remove leaf spring.

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Check and maintenance
In the course of the inspection, if you detect any
Leaf spring assembly
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U-bolt abnormal wear or damage, please make the necessary

U-bolt and nut
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repair or replacement of parts

The rear spring lug pins rubber

bushing

The rear spring fixed pin

Visual inspection
Please make visual inspection of the parts, if there is

damage or failure, please replace them

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Re-installation

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2
3
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Re-installation order
(1) the rear leaf spring assembly; (2) the u-bolts; (3) rear spring fixed pin; (4) rear spring shell lug assembly;

(5) rear shock absorber assembly

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Serial number Project Tightening torque （N·m）

(4) U-bolt and nut 126～154
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(3) Hexagon flange nuts 190～260

（Q341B16T13F62）
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(5) Hexagon flange nuts 78～96

（Q341B14T13F62）
(12) Hexagon flange nuts 73～89
（Q341B12T13F62）

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The rear leaf spring assembly

When fitting, the spring eye side of the leaf spring
should be forward, and shall not be installed
backwards.

The rear buffer block rear u-bolts

(1) Park the vehicle on a horizontal flat surface, please

install the rear buffer block and rear u-bolt at the

corresponding location on the leaf spring.

(2) Use jack to jack-up the rear axle, aligned with rear

axle hole and the rear u-bolts.

(3) Install the rear u-bolts, tighten the nuts.

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The rear spring fixed pin

(1) Use jack to jack-up the rear axle, align the rear

spring eye hole with the hole location of rear

spring fixed bracket, then install the rear spring

pin.

(2) Install the fixed pin and fixed bolts of the rear

spring pin, and tighten the nut.

Important job - Assembly

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The rear spring lug pin

(1) Put into the rubber bushings I、II, please align the

rear spring eye holes with the hole location of the

rear spring lug, then put rear spring lug pins in.

(2) Install the fixed bolts of the rear spring lug, and

tighten the nut.

The rear shock absorber assembly

Tighten the fixed nuts of the rear shock absorber
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Warning: Please make sure that the rear u-bolt nut

tightened as specified torque value, because it relates

to the working life of the rear leaf spring assembly.

4、Trouble Diagnosis

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Rear suspension assembly

Body tilt

Check the

Norm Rust Spring elasticity is

Clean Repla

Check lug pins and

Norm Worn or

Check the steel plate

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Norm Bolts loose Break

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Tight
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Check the

Bushings are worn

Norm Repla Check the fixed

Norm Dam

Repla

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Ground clearance is

Check the load

Steel spring

Check steel

Norma Breakag

Replac
Check

Norma Worn or

Replac
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Inspect bushing
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Norma Deterioration

Replac
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Lubricating

Norma Insufficient Lubrication

Add Remove any excess

Check whether the

Norma Loose Broken or

Tighten Replac

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Spring break

Load

Check lug pin and fixed

Norma Check whether bolt Worn or

Norma Replac

Check U-bolt

Norma Check bolt and nut Dama

Norma Replac

Check the shock absorbers

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Norma Oil Bushi Brack Dama

Replac Worn Break Replac

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Replac Replac

Check the

Norma Worn or

Replac

Check the center bolt

Norma Loose Dama

Tighte Replac

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The body

Road test

Noise has a Noise does not have a

Replace

Check the tires for

Norma Abnorm

Adjust or

Check suspension
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Norma Dama
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Replac
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Check suspension system's

Norma Loose or

Tighten or

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Engine fender device

1. Overview………………………………………………………………2

2. Disassembly and

Re-installation………………………………………………………3

3. Maintenance data and

Specifications…………………………………………………3

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Engine fender device

1.Overview
Engine fender device can reduce noise, as well as prevent silt and sedimentation flying to the

transmission; this device is connected to the frame through three fixed points

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3
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Serial
Number Name Usage
number
1 2802011W5000 Engine left fender 1
2 2802011W5000 Engine right fender 1
3 Q402B08F62 Big washer 6
4 Q1420825F62 hexagon bolt and spring washer components 6

2. Disassembly and Re-installation

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2.1 Engine Left/Right Fender disassembly and ② Remove the engine left/right fender.

installation: 2) Installation

1) Disassembly Installation is as the reverse order of disassembly.

① respectively disassemble three mounting bolts and ① Mounting bolt torque that connect the engine

big washer on the engine left/right fender and on the fender and frame: （18～23）N·m.

left and right side of the frame.

3. Maintenance data and Specifications

paramete The height of
rs 2 751.6
the fender L2
Fender
3 67.2
thickness L3
Distance
between
4 21.4
mounting holes
L4
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Distance
between
5 234.5
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mounting holes
L5
Distance
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between
6 20.4
mounting holes
L6
Distance
between
7 406
mounting holes
L7
Mounting Hole
8 23.9
spacing L8
Mounting hole
2.1. Engine left fender 9 9
diameter D1
The Serial Size/m
main numb Size description m
size er
and Fender width
1 283
main L1
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2.2. Engine right fender
Serial Size/m
numb Size description m
er
The height of
1 891
the fender L1
Fender width
2 300
L2
Fender
3 81
thickness L3
The Distance
main between
4 399
size mounting holes
and L4
main Distance
paramete between
5 409
rs mounting holes
L5
Install distance
6 44
L6
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Install distance
7 40
L7
Install distance
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8 36
L8
Mounting hole
9 10
diameter D1
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Wheel hub device

1.

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Overview……………………………………………………………………………3

2. The Main Data and Specifications of Wheel

Hub ……………………………………………………3

3. Disassembly and

Re-installation ……………………………………………………………………3

4. Maintenance and

Troubleshooting ………………………………………………………………8

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1. Overview

Wheel hub bearing is one of the key parts for a vehicle , with the development of automotive technology,

the using condition of the wheels hub bearings is much more rigor, and its life is one of the most important

factors that has a direct impact to the car life and its reliability.

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N125 model front wheel hub structure

2. The Main Data and Specifications of the Wheel Hub Device

The bolt circle diameter of the wheel

φ120mm
hub.
Distance between the mounting surface
170mm
and the center line of wheel hub
Center hole diameter of wheel hub φ50mm
The usage of the front wheel hub's one
（10-15）g
side bearing grease

3. Disassembly and Re-installation

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(1) Disassembly between tire and wheel hub

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3 4
2
1

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Disassembly order

①.wheel covers ②.wheel nut ③. wheels ④.slotted nut of the steering tie rod ⑤.slotted nut of the upper

suspension arm ⑥. slotted nut of the down suspension arm ⑦.wheel hub device and front brake disc assembly
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The main disassembly steps of wheel hub device:

Pull up the parking brake and pop-up the front axle.

（1）. Disassemble the wheel covers;

（2）Use a tire wrench to disassemble the wheel nuts;

（3）Disassemble the wheel.

（4）Disassemble cotter pin of the steering tie rod, and disassemble the hexagonal nuts of the steering tie rod.

Same actions to disassemble the hexagonal slotted nuts of the upper suspension arm and the hexagonal slotted

nuts of the down suspension arm. Remove the wheel hub device and front brake device.

1. The fender.
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2. Wheel hub bolt.
3. Steering knuckle slot.
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4. Brake discs.
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Inspection and Maintenance

Visually inspect the left lists of parts whether existing damage, wear, or expired.

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(2) The disassembly of wheel hub

13

7
6
5
4
3
2
1

16
15
14
12
11
10
9
8
Disassembly order

1. sealing cover 2. cotter pin 3. wheel hub lock nut 4. wheel hub gasket 5. outer bearing assembly 6. spring washer
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7. 1 type hexagon nut-fine tooth 8.hexagon head bolt-fine tooth 9. Wheel hub bolts 10. Front wheel hub 11. inner

bearing assembly 12. oil seal of wheel hub 13. brake discs 14.cross recess pan head screw spring washers and flat
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washers assembly 15. fender 16. steering knuckle

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Be careful not to damage the hub seal cover.

Remove the lock cotter pin, and disassemble the

hexagon slotted nut. Take out wheel hub gasket

The main disassembly steps of wheel

hub
（1）Disassemble the sealed cover of the wheel hub.

Use screwdriver to pry off the hub seal.

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N125-NAM-PDP-GH-G9-15
and outer bearing assembly.

(2) Disassemble the brake disc

When remove the brake disc and place it,

taking care to avoid brake disk surface is worn or

scratched.

(3) Disassemble the front wheel hub.

If there is no pressure equipment, do not

attempt to disassemble the hub bolts.

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(4) Disassemble the fender

Use a screwdriver to remove the fender.

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Inspection and Maintenance

When the hub shaft damage is found, if it has

cracks, pits, or ablation, please replaced it.

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Service manual
N125-NAM-PDP-GH-G9-15

1. Wheel hub gasket Visually inspect the left lists of parts whether
2. Outer bearing assembly
existing damage, wear, or expired.
3. Inner bearing assembly
4. Front wheel hub, and so on.

(3) Re-installation of wheel hub device

Re-installation is in reverse order of disassembly. When re-installing, the tighten torque should refer to tighten

torque table.

6
5
4
3
2
1 7
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A
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Tightening torque table（N·m）

Serial
Torque
numbe Name Note
（N.m）
r
① Wheel nuts 180～230
② The wheel hub lock nut
③ 1 type hexagon nut-fine tooth 45～52
Cross recess pan head screw spring washers and
④
flat washers’ assembly.
⑤ slotted nut of the upper suspension arm 110～130
⑥ 1 type hexagon slotted nut-fine tooth 110～130
⑦ slotted nut of the down suspension arm 110～130

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Service manual
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(1) The refill oil model: Fox grease LX-EP 2

Installation Notes:

Add grease as shown in the picture

Inner bearings （3-5）g

Outer Bearing （2-3）g

Within the hub cover （5-7）g

(2) Before installing the thrust bearing, please smear

appropriate grease.

Please do not install the wrong direction.

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Housi
Upper
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(3) Tighten the hub fixed nut, as soon as there exists a

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noticeable drag and friction on the bearing, please

Down immediately slowly loosen the nut until align it with

the nearest cotter pin holes, and then insert a new

cotter pin.

Note: In no case, you cannot reverse and

loose the nut of a quarter circles. Otherwise, this will

cause the hub bearings loose, and lead to the early

wear.

4. Maintenance and Troubleshooting

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Service manual
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(1) In order to maximize the safety and reliability, it is recommended that no matter how long the vehicle age is;

please constantly check the wheel hub bearing - pay attention to whether there are early warning signals for wear:

including the grinding noise in any turns or the suspension combination wheel when turning the deceleration.

When replacing the brake system, check the bearings and replace the oil seal.

(2) If you hear the hub bearing area making a noise, first of all, it is important to find where the noise occurred.

There are many possible noise of moving parts, it is also possible that some moving parts has contacted with

non-moving parts. If it is confirmed that the noise is in the bearing, the bearing may be damaged and needs to be

replaced.

(3) Because the both sides’ bearings of front wheel hub work in the similar conditions, so even if only one of the

bearing is broken, it is recommended that replace them in pairs.

(4) Wheel hub bearing is more sensitive, and in any case, need to be adopting the right way and the right tools.

The storage and transportation, as well as the installation of bearings, the bearing parts cannot be damaged.

(5) Installing the bearing should be in a clean and tidy environment, small particles enter into the bearing will also

reduce the bearing's life. When replace the bearing, maintaining a clean environment is very important. Do not
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allow the hammer taping on the bearings; do not let the bearing fall on the floor (or a similar improper handling).

Before installing, you should check the status of the relevant parts, even if it is the tiny wear, it can also cause
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poor fit, and result to the early expiration of the bearing.

(6) For the wheel hub bearing units, do not attempt to disassemble the hub bearings, or adjust the seal ring of the
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wheel hub unit, otherwise the seal ring will be damaged and cause water or dust entering. Even the orbit of the

seal ring and the inner ring will be damaged, causing the bearing permanently disabled.

(7) Many bearings are sealed; such bearings do not need to load the grease in its entire life cycle. Other non-sealed

bearings such as double row tapered roller bearing, when installing it, you should add the grease lubrication.

The Tools and Accessories

1.

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Service manual
N125-NAM-PDP-GH-G9-15

Overview ………………………………………………………………………………

44

2. Technical

Parameters…………………………………………………………………………44

3.

Disassemble ……………………………………………………………………………

…45

4.

Re-installation…………………………………………………………………………

……46

5.
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Maintenance ……………………………………………………………………………
A

…54
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Service manual
N125-NAM-PDP-GH-G9-15

The Tools and Accessories

1. Overview

The tools of N125 and accessories including tool box assembly, jack, combined socket, rim pry bar and

dual-purpose screwdriver, and etc. The tool box is in the left behind of the cargo box, fixed on the vehicle chassis.

Jack and accessories are in the cab.

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A

2. Technical Parameters
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2 ton hydraulic jack 1

Jack fixed bolt assembly 1 M8X1.25
Triangle warning signs and
package. 1
Combined socket 1
Socket I 1
Socket II 1
Socket III 1
Dual-purpose screwdriver 1
Tool Bag 1
Rim pry bar 1
Outer packing carton 1
Jack support base assembly 1
The tool box assembly 1
Hexagonal flange bolt 4 M10X1.25

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3. Disassembly

3.1. Disassembly of the tool box assembly

2
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Disassembly Order
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1. Hexagonal flange bolt 2. Tool box assembly

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The disassembly steps of tool box

Open the tool box latch, after opening the tool box

cover, use a socket remove the fixed bolts of the tool

box.

The tool box assembly

Tool box fixed bolt
Visual Check
Check the tool box assembly for corrosion, wear,

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N125-NAM-PDP-GH-G9-15
damage, deformation, and other abnormal conditions.

3.2 Disassembly of jack assembly

2
5

4
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Disassembly order
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1. Jack fixed bolt assembly 2.two ton hydraulic jack 3.hexagonal head bolt and spring washer components 4. big

washer 5.jack support

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The disassembly steps of tool box

(1) Unscrew the fixed bolt assembly of jack, and take

out the jack.

(2) Dissemble the fixed bolt of the jack support, then

you can remove the jack support.

Visual Check

Check the jack whether it is good, or has the oil

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leakage phenomenon

4. Re-installation

Re-installation is in reverse order of disassembly. when re-installing, the tighten torque should refer to the

tighten torque table.

3
C
A

Reference torque table（N·m）

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Serial number Name Torque Notes

1 Tool box fixed bolt 18～24
The fixed bolts of the jack
2 support 18～24
3 Jack fixed bolt assembly Tighten

5. Maintenance

(1) When prying open, it requires smooth and steady, after prying heavy objects open at a later time, please check

that there is no abnormality. If no, please continue to jack it. You cannot arbitrarily lengthen long handle or

operate excessively.

(2) Do not overload over-height. When socket appears red line, it indicates that you have reached the specified

height, you should stop jacking it.

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N125-NAM-PDP-GH-G9-15
(3) When using the hydraulic jack, pay attention to the joint between the sealing part and the pipe joint, but must

ensure that it is safe and reliable.

(4) Hydraulic jack does not apply to acid, alkali or corrosive gases situations.

(5) When using the combined the socket to tighten the bolts and nuts, do not overexert, or exert impact torque.

When the tighten resistance continuously increase, you should slow down the rotation speed for fear of damaging

thread. When the torque is too large, please do not reload the sleeve on the handle of the torque wrench, or use a

hammer to trash. Do not continue to spin when reaching the preset torque, if continuing to spin, it will make the

torque exceeds a preset value greatly, in addition to cause serious damage to the wrench; it will also damage the

bolts and nuts.

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A
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Reproduction is prohibited

Project: N 125

Vehicle System Maintenance Manual

No. W 5000 - NAM - PV - CS -

G 9 - 22

Version: 1.0
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Edited by:
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Proofread by:

Reviewed by:
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Standardized
by:
Countersigned
by:

Approved by:

Anhui Jianghuai Automobile Co.,Ltd.

Year Month Day

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Vehicle System
1.Front supporting device of

cabin ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1

2. Engine cover

device... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 3

3. Driver seat cover

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device... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 6
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4. Container
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device... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 8

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Reproduction is prohibited
1 Cabin supporting device

6
1
7

4
5
2
3

Disassembly Assembly

Disassembly sequence (remove the 2 safety hooks first, Assembly sequence (install the 4 sets of cushions first,
then remove the 4 sets of cushions) then install the 2 safety hooks)
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1、hex bolt、spring washer and plain washer assemblies ▲7、the supporting upper cushion assembly
▲2、safety hook assembly in the cabin ▲6、hex head flange bolts
3、1-type non-metallic insert hex lock nuts 5、cushion fixing bolt with bracket assembly
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▲4、the supporting lower cushion assembly ▲4、the supporting lower cushion assembly
5、cushion fixing bolt with bracket assembly 3、1-type non-metallic insert hex lock nuts
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▲6、hex head flange bolts ▲2、safety hook assembly in the cabin

▲7、the supporting upper cushion assembly 1、hex bolt、spring washer and plain washer assemblies

Important process — Disassembly

1. safety hook assembly in the cabin

 loosen hex bolt、spring washer and plain washer
assemblies.
 separate safety hook assembly in the cabin from the
cabin assemnbly.
 disassemble the other cabin safety hook assembly in
the same way.

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2. the supporting lower cushion assembly
 disassemble the 1-type non-metallic insert hex lock nuts、supporting lower
cushion assembly and cushion fixing bolt with bracket assembly.
 disassemble the other supporting lower cushion assemblies and cushion
Unauthorized fixing bolt with bracket assemblies.
Reproduction is prohibited
 remove the cabin assembly at last.

3.the supporting upper cushion assembly

 disassemble the two hex head flange bolts, and then remove the
supporting upper cushion assembly.
 disassemble the other three supporting upper cushion assemblies
in the same way.

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Important process — Assembly
A

1.the supporting upper cushion assembly

 put the supporting upper cushion assembly in the frame
installation position, aim at the hole, insert the hex
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head flange bolts into hole first, screw the neck; screw
the other bolt, and then tighten the two bolts in turns.
assemble the other three supporting upper cushion
assemblies in the same way.

Torque（N·m） 43－50

2. the supporting lower cushion assembly

 put the cabin assembly on the upper cushion assembly, aim at
the hole, insert the cushion fixing bolt with bracket assembly
into cushion installation hole, string rhe lower cushion
assemblies on the cushion fixing bolt with bracket assembly,
screw the neck of 1-type non-metallic insert hex lock nut; and
then install the other three cushion fixing bolt with bracket
assembly in the same way, screw the three 1-type non-metallic
insert hex lock nuts; tighten them in turns at last.

Torque（N·m） 41-51

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2. safety hook assembly in the cabin
 hitch the limiting rod on the safety hook assembly, and
then rotate to be fitted on the mounting surface, aim
the installation hole-top of cabin safety hook at the
Unauthorized vehicle body mounting point.
Reproduction is prohibited

 screw the neck of hex bolt、spring washer and plain

washer assemblies, and then screw the other three
fastening pieces from top to bottom, at last fasten the
four fastening pieces from top to bottom.

Torque（N·m） 17-28

 assemble the other cabin safety hook assembly in the

same way.

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A

2 Engine cover device

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2
4
3

Assembly
Disassembly

Disassembly sequence Assembly sequence

1、hex bolt, spring washer and plain washer assemblies ▲2、engine cover assembly
（Q1460820F62） ▲1、hex bolt, spring washer and plain
washer assemblies（Q1460820F62）
2、engine cover assembly

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Reproduction is prohibited
3、hex bolt, spring washer and plain washer assemblies 4、engine cover hasp assembly
(Q1460620F62) ▲3、hex bolt, spring washer and plain washer
assemblies (Q1460620F62)
▲4、engine cover hasp assembly
5、engine cover strap assembly ▲5、engine cover strap assembly

Important process — Disassembly

1. engine cover assembly：

 rotate the opening handle of engine cover hasp, to separate
engine cover hasp lock buckle from right locking hooks.
rotate the opening handle of engine cover hasp
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 disassemble the four hex bolts, spring washer and plain washer
assemblies as the shown part on the left picture（Q1460820F62）,
A

remove the engine cover assembly.

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2. engine cover hasp assembly：

 rotate the opening handle of engine cover hasp, to separate
engine cover hasp lock buckle from right locking hooks.

rotate the opening handle of engine cover hasp

 disassemble the two hex bolts, spring washer and plain

washer assemblies as the shown part on the left picture
（Q1460620F62）, remove the engine cover hasp assembly.
 disassemble the other engine cover hasp assembly in the same
way.

3. engine cover strap assembly ：

 open the engine cover strap assembly mounting box,
disassemble cross recessed pan head screw、spring washer and
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plain washer assemblies, remove the engine cover strap
assembly.
Unauthorized
Reproduction is prohibited

Important process — Assembly

1. engine cover assembly

 aim the left mounting hole of engine cover assembly, as shown
on the left picture, at the vehicle body mounting point. screw
them with hex bolts, spring washer and plain washer
assemblies （Q1460820F62).
 screw the hex bolts, spring washer and plain washer
assemblies (Q1460820F62) from left to right as shown on the
left picture.
 tighten the four standard parts from left to right in turns.

Torque （N·m） 17－28

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2. engine cover hasp assembly

A

 screw up the engine cover hasp of engine cover hasp

assembly on the locking hasp.
 aim the top mounting hole of engine cover hasp assembly, as
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shown on the left picture, at the vehicle body mounting point.

screw them with hex bolts, spring washer and plain washer
assemblies （Q1460620F62).
 screw the underpart mounting point with hex bolts, spring
washer and plain washer assemblies (Q1460620F62) as shown
on the left picture.
 tighten the two standard parts from top to bottom in turns.
 install the other engine cover hasp assembly in the same way.

Torque （N·m） 15－20

3. engine cover strap assembly

 open engine cover strap mounting box, insert cross recess head
screw, spring washer and plain washer assemblies into vehicle
body mounting point, fasten them, and then close engine cover
strap mounting box.

Torque （N·m） 15－20

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3 Driver seat cover device

1
2

3
4

Disassembly Assembly
C

Disassembly sequence Assembly sequence

A

1、hex nut and taper flexible washer assemblies ▲4、Driver seat cover assembly
▲2、access panel assembly 3、hex bolts, spring washer and plain washer
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assemblies
3、hex bolts, spring washer and plain washer assemblies ▲2、access panel assembly
▲4、Driver seat cover assembly 1、hex nut and taper flexible washer assemblies

Important process — Disassembly

1. access panel assembly

 push driver seat to the front position before disassembly, open
the carpet at the same time.
 disassemble the three hex nuts and taper flexible washer
assemblies as shown on the left picture.
 remove access panel assembly.

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Reproduction is prohibited

2. Driver seat cover assembly

 disassemble driver seats and access panel assembly, open
the carpet and engine cover assembly at the same time.
 disaeemble the eight hex bolts, spring washer and plain
washer assemblies as shown in the left picture.
 remove driver seat cover assembly.

Important process — Assembly

1. Driver seat cover assembly

 put the driver seat cover assembly on the back floor
assembly, aim at the hole, screw 1 and 2 mounting point
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1 with hex bolts, spring washer and plain washer
assemblies in turns, screw the other mounting points,
tighten the 8 mounting points in turns.
A

Torque （N·m） 17－28

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2. access panel assembly

 hitch the 3 mounting points of overhaul cover plate
assembly on rear floor assembly projection welding bolt;
srcew them with hex nuts and taper spring washer
assemblies, and then tighten them in turns.

Torque （N·m） 15－20

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4 Container device

1 2 3 4 5 6 7 8

Disassembly Assembly

Disassembly sequence Assembly sequence

disassemble the hex head flange nuts from 1 to 8 in turns assemble the hex head flange nuts from 1 to 8 in turns
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Important process — Assembly

A

Container device
aim the container fixing bracket at the container pedestal on
frame, screw them with the hex head flange nuts
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Torque （N·m） 90－95

4.1 rear wheel left/right mudguard assembly

1
2

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Disassembly Assembly

Disassembly sequence Assembly sequence

1、disassemble 2 front hex head flange bolts 3、tighten 4 under hex head flange bolts
2、disassemble 2 rear hex head flange bolts 2、tighten 2 rear hex head flange bolts
3、disassemble 4 under hex head flange bolts 2、tighten 2 front and rear hex head flange bolts

Important process — Assembly

rear wheel left/right mudguard assembly

 put the rear wheel left/right mudguard on the container
assembly, aim at the hole, screw 3、2、1 mounting point
withhex head flange bolts in turns, screw the three
mounting points in turns.
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Torque （N·m） 6－10
A
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4 .2container front panel assembly

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2 1

Disassembly Assembly

Disassembly sequence Assembly sequence

1、disassemble four hex head flange nuts（symmetrical 8 in total） 4、assemble 8 hex bolts, spring washer
and plain washer assemblies.
2、disassemble four hex head flange bolts（symmetrical 8 in total） 3、assemble 8 metallic hex head flange
locking nuts
3、disassemble 8 metallic hex head flange locking nuts 2、assemble four hex head flange bolts
（symmetrical 8 in total）
4、disassemble 8 hex bolts, spring washer and plain washer assemblies 1、assemble four hex head flange nuts
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（symmetrical 8 in total）
A

Important process — Disassembly

disassemble the container device from frame before disassembling container front panel assembly.
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Important process — Assembly

container front panel assembly

 insert container front panel assembly from top into
container floor assembly, aim at the hole; insert 8 hex bolts,
spring washer and plain washer assemblies into the place
between container front panel assembly and container floor
first, and then tighten the 8 metallic hex head flange
locking nuts, install 8 hex head flange bolts and hex head
flange nuts at left&right side.

Torque （N·m） 35－45

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Reproduction is prohibited
4 .3container left/right panel assembly

1
2

Disassembly Assembly
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Disassembly sequence Assembly sequence

1、disassemble 7 1-type non-metallic insert hex lock nuts 2、assemble 7 hinge bolts
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2、disassemble 7 hinge bolts 1、tighten 7 1-type non-metallic insert hex lock

nuts
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Important process — Assembly

container left/right panel assembly

 put container panel assembly on container left/right panel
assembly, aim at the hole; insert the 7 hinge bolts into the
place between container left/right panel assembly and
left/right panel hinge bracket, and tighten 7 1-type
non-metallic insert hex lock nuts.

Torque （N·m） 4.5－5.0

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Reproduction is prohibited
4 .4 container rear panel assembly

2 1 4 3

Assembly
Disassembly

Disassembly sequence Assembly sequence

1、disassemble one 1-type non-metallic insert hex lock nut 4、assemble one hinge bolt.
（symmetrical 2 in total）
2、disassemble one rear hinge bolt（symmetrical 2 in total） 3、assemble one 1-type non-metallic insert hex
lock nut.
3、disassemble one 1-type non-metallic insert hex lock nut 2、assemble one rear hinge bolt（symmetrical
2 in total）
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4、disassemble one hinge bolt 1、assemble one 1-type non-metallic insert hex
lock nut（symmetrical 2 in total）
Important process — Disassembly
A

open left/right locking assembly and left/right rear locking bolt assembly before disassembling container rear
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panel assembly，and then disassemble container rear panel.

Important process — Assembly

container rear panel assembly

 put container rear panel assembly on container floor
assembly, aim at the hole; assemble middle hinge bolt and
1-type non-metallic insert hex lock nuts first, and assemble
left/right rear hinge bolt and 1-type non-metallic insert hex
lock nut

Torque （N·m） 4.5－5.0

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Service manual N125-NAM-PV-CS-G9-23

Project: N 125

Service manual of interior system

No. N125-NAM-PV-CS-G9-23

Version: 1.0
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edit:
A

proofread:

check:
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standardization:

countersign:

permit:

Anhui Jianghuai Automobile Co., Ltd.

March 18, 2014

打印人：20122642 部门：客户服务部
1
Service manual N125-NAM-PV-CS-G9-23

Contents
1. Dashboard replacement……………………………………………… 2
2. Tubular girder Replacement ... ... ... ... ... ... ... ... ... …………… ... ... 6
3. Hand Brake cover replacement ... ... ... ... ... ... ...... ... ... ................ ...7
4. Seat replacement……………………………………………………… 8
5. Foot Rest replacement ... ... ... ... ... ... ... ... ... ... ... ... ... ... .... ... ... ... 11
6. Sun visor replacement……………………………………………… 12
7. The inner handle replacement ... ... ... ... ... ... ... ... ... ... ... ... ... .... 13
8. Top interior replacement ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. ... 14
9. Carpet replacement……………………………………………… 15
10. Heat insulator mat replacement…………………………………16
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11. The replacement of door interior trimming panel…………………17
12. Side wall interior panel replacement ... ... ... ... ... ... ... ... ...... ... 18
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13. Rear mold trim panel replacement ... ... ... ... ... ... ... ... ... ... ... 20
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14. Floor mound layer replacement ... ... ... ... ... ... ... ... .... ... ... ........ 21
15. Safety belt replacement ... ... ... ... ... ... ... ... ... ... . ... ... ... ... ... ... ... 22

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2
Service manual N125-NAM-PV-CS-G9-23
1. Dashboard replacement

1.1 Instrument Panel Removal

1.1.1 Remove 1 screw on side panel of instrument panel○

2 , pull out the lower trim panel of instrument panel○
1;

1 2

1. Lower trim panel assembly of instrument panel （5306500W5000）

2. Cross self-tapping screws and flat washer combination (Q 220 4816 B F 38)
1.1.2 Remove bottom of upper and lower Package and 2 screws on top○
1 , pull out the lower package○
2 and then the
upper package○
3.
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A

3
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1 2

1. Cross self-tapping screws and flat washer combination (Q B 220 4816 F 38)
2. Combination switch lower package assembly (5306720 W5000)
3. Combination switch upper package assembly（5306701W5000）

1.1.3 Remove two screws on lower instrument panel cover○

1 , remove the Instrument cover ○
2 and the shift switch,

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3
Service manual N125-NAM-PV-CS-G9-23
pre-warning switch, air conditioning knob plug-in;

1 2

1. Cross self-tapping screws and flat washer combination（Q220B4816F38）

2. Instrument cover assembly（5306200W5000）
1.1 .4 pull out the glove box○
1;

1
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1. Glove box assembly (5306400W5000)

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1.1.5 Remove the glove box cover ○

4 , Remove 2 glove box plug cover ○
2 , and then remove 5 screws on Lower
Glove Box○
3 , pull off the glove box body○
1;

1. Glove box body assembly （ 5303100W5000 ） 2. Glove box Installation Plug cover
（5303401W5000）
3. Cross self tapping screws and flat washer combination （Q220B4816F38）
4. Glove box assembly (5303200 W5000)
1.1.6 Pull out the steering column lower shield cover○
1;
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Service manual N125-NAM-PV-CS-G9-23

1. Steering Column lower shield cover (5306801 W5000)

1.1.7 Pry out left/right side cover with straight screw○
1 /○
2;

1
C 2

1. The left side cover assembly (5306610 W5000) 2. The right side cover assembly (5306620 W5000)
A

1.1.8 Remove instrument panel, radio, wire harness, and then remove 2 nuts connecting dashboard and beam ○
1 , 12
screws○
2 , and 2 screws linking the steering column○ 3 ○
2 , and remove the Dashboard assembly 3.
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1. 6-point hex flange nut (Q32006 F62)

2. Hexagon bolt, spring washers and flat washer combination（Q1460620F62）
3. Dashboard body assembly (5306100 W5000)

1.1.9 Remove the left/right air inlet from the Instrument Panel Body○
1 /○
2.

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Service manual N125-NAM-PV-CS-G9-23

1
2

1. Air inlet assembly (left) (5306110 W5000) 2. Air inlet assembly (right) (5306120 W5000)
1.1.10 Remove the steering column rubber pads ○
2 from instrument hood ○
1 , remove 8 screws ○
4 and take off the
control panel○
3 , remove the left/right center air inlet○
6 /○
5.

1
C
2
6
A

5
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3 4

1. Instrument hood (5306201W5000) 2. Steering Column rubber pad (5306202W5000) 3. The control panel
(5306301 W5000)
4. Cross self tapping screws and flat washers combination （Q220B4213F71） 5. Central air inlet assembly (right)
(5306320 W5000)
6. Central air inlet assembly (left) （530631W5000）

1.2 instrument panel installation

1.2.1 Pe-install the steering column rubber pad, the control panel, and the left/right central air inlet to instrument
panel (such as pre-installed in 1.1.10) in the reversed order of removal.
1.2.2 Pre-install left/right side air inlet to dashboard (as described in 1.1.9), in the reverse order of removal.
1.2.3 Finish the installation in the reversed order of removal as described in 1.1.1 to 1.1 8.

2. Tubular girder replacement

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Service manual N125-NAM-PV-CS-G9-23
2.1 tubular girder removal

2.1.1 Remove 12 screws from the tubular girder and the front floor, tubular girder and the clutch pedal,tubular
girder and its front connection panel, tubular girder and left/right side mold○
1○2○
3 , Remove the tubular girder
welding assembly; 4

3
2

1. Hexagon bolt/spring washers/flat washer assembly (QF 146082062)

2. Hexagon bolt/spring washers/flat washer assembly （Q1460825F62）
3. Hexagon bolt/spring washers/flat washer assembly （Q146B0616F71）
4. Instrument framework device (5307001W5000)

2.1.2 Remove 4 screws from front connecting panel of tubular girder and clutch pedal○
1 , remove the front

connecting panel of tubular girder○

2;
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1
2
A
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1. Hexagon bolt/spring washers/flat washer assembly (Q1460820F62）

2. Front connecting panel of tubular girder on instrument（5307201W5000）

2.2 The tubular girder Installation

Installation in the reversed order of removal steps.

3. Hand Brake cover Replacement

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Service manual N125-NAM-PV-CS-G9-23
3.1 The hand brake cover removal

1
3

1, the hand brake cover assembly (5108100 W5000) 2, Hexagon flange bolts (Q
1840616) 3, the hand brake cover plug cover (5108201 W5000)

6.1.1 Remove two hand brake cover plug cover○

3;

6.1.2 Remove two Hexagon flange bolts○

2;
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6.1.3 Take off hand brake cover○

1.
A

3.2 The hand brake cover installation

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Installation in the reversed order of removal steps.

4. Seat replacement

4.1 driving seat removal

4.1.1 Adjust the seat to the backmost location, remove the driver's seat assembly and 2 bolts fixing the driver's
seat mounting bracket and the driver's seat upper cover④.
4.1.2 Adjust the seat to the formost location, remove 1 nut⑤/1 screw④ fixing driver's seat assembly and the
driver's seat mounting bracket and the driver's seat upper cover, remove driver's seat assembly.

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Service manual N125-NAM-PV-CS-G9-23

1, the driver seat assembly (6800100 W5000) 2, driver seat cover upper plate (5121131 W
5000) 3, the driver's seat mounting bracket (5100831W5000)
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A

1
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2
3

1, the driver seat assembly (6800100 W5000) 2, driver seat cover upper plate (5121131W5000)
3, the driver seat mounting bracket (5100831 W 5000) 4, hexagon bolt, flexible washers, flat washer

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4
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Service manual N125-NAM-PV-CS-G9-23

1, the driver seat assembly (6800100 W5000) 2, driver seat cover upper plate (5121131W5000)
4.2 3, the driver seat mounting bracket (5100831 W 5000) 4, hexagon bolt, flexible washers, flat washer
assembly（11254-08203） 5, Hexagon nuts（Q32008F31）

driving seat installation

4.2.1 Installation in the opposite order of removal. To tightening bolts and nuts, have to settle the torque which is

16-20N·m.

4.3 co-driving seat removal

4.3.1 Remove the lower trim panel of seat cushion ③ , remove 2 self-tapping screws ② of angle-adjustment
cover with cross screwdriver, remove the angle-adjustment cover;
4.3.2 Remove 2 hexagon bolts fixed on engine cover besides angle-adjustment cover of co-driver seat④;
4.3.3 Remove 2 hexagon bolts fixed on engine cover besides angle-adjustment cover of backrest④;
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A
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2 4
4
3
1, angle-adjustment cover（7200150W5000） 2, cross self-tapping screws and big washer
assembly (Q221B4295F38A)
4
.3.4 Remove 2 split washer fixed to central mounting bracket in the middle of co-driver's seat backrest and small
backrest⑤;
4.3.5 Remove double seat cushion⑩ and small backrest⑥;
4.3.6 Remove double seat cushion⑨ along with the engine cover, remove 4 split washer fixed to cushion and
engine cover⑦;
4.3.7 Remove double seat cushion⑨;

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Service manual N125-NAM-PV-CS-G9-23

10

6
5 7 8 9

5, The opening ring (Q 43,690) 6, Double seat small back (7200120 W5000)
7, Hexagon flange nut（Q32008F31） 8, Engine Cover Assembly (5107120W5000)
9, Double seat cushion （ 7200130W5000 ） 10, double seat large backrest

4.4 co-driver

seat installation
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4.4.1 Installation in the opposite order of removal. To tightening bolts and nuts, have to settle the torque which is
16-20N·m.
A

5. Foot Rest replacement

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5.1. Foot Rest replacement

4
2

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Service manual N125-NAM-PV-CS-G9-23
1. Foot rest pedal (8206102W5000) 2.foot rest pedal mounting bracket
assembly(8206100W5000) 3.Hexagon bolt/spring washers/flat washer
assembly （Q1460825F62）

5.1.1 Remove 2 cross screws first○

4;
5.1.2 Remove 2 foot rest○
1;
5.1.3 And then remove 2 Hexagon screws, spring washers and flat washer combination○
3 , now remove the foot rest
pedal mounting bracket assembly○
2.

5.2. Foot Rest installation

Installation in the reversed order of removal steps.

6. Sun visor replacement

6.1. Sun visor removal

1 5
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3
A

4
2
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1. The left sun visor (8201100 W 5000) 2. Cross screws screws, spring washers and flat washers combination

Assembly （Q2360616）

3. Sun visor mounting foundation assembly (8204300 W5000) 4. Cross half-sunken head Self Tapping Screws -
C type assembly （Q2764816）
5. The right sun visor (8201200 W5000) 6. A hole-type embedded plastic nut（14910-05000）

6.1.1 Remove fixing screws of sun visor○

2;

6.1.2 Pull out sun visor axle tube from mounting hook;

6.1.3 Take off sun visor○

1 /○
5;

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Service manual N125-NAM-PV-CS-G9-23
6.1.4 Remove fixing screws of sun visor mounting foundation○
4 , and take it off○
3.

6.2 Sun visor installation

Installation in the reversed order of removal steps.

7. Inner handle replacement

7.1 inner armrest removal

7.1.1 Turn over the dome armrest assembly○

1 , pry off the cover, remove two fixing screws○
5 and remove the dome
armrest assembly.
7.1.2 Pry off the boarding armrest installation cover○
3 , and remove two mounting bolts of boarding armrest○
4 and
remove armrest○
2.

1
C

2
A
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1. Top armrest (5702700 U1510) 2. Log car armrest (8215101 W5000) 3. Log car armrest install plug cover
(8215102 W5000)
4. Cross screws, spring washers and flat washer combination (Q 2360625) 5. Oil filler tightening bolts (1101011 U
1010 )

7.2. Inner handle installation

Installation in the opposite order of removal.

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Service manual N125-NAM-PV-CS-G9-23
Caution:
■ Top armrest assembly installation requires finishing installation of top interior.

8. The Top interior replacement

8.1. The Top interior removal

8.1.1 Before removing top interior, first remove the right A pillar lower cover ③ , and then remove the top light

harness connector;

8.1.2 Then remove the side trim panel③⑥, top light④, sun visor②, top armrest⑤;

8.1.3 Remove the installation buckle on right side of ceiling①;

8.1.4 Remove the 3 installation buckles on the back of ceiling①;

8.1.5 Pull the ceiling out of car from metal plate of front windshield (or from front door holes).

Caution:
■wearing gloves to protect your hands;
■To remove the installation buckle, hold the ceiling to prevent ceiling deformations with a hand;
■The top interior is supposed to be removed after removal of top light, sun visor, pillar board and the car
armrest assembly;
C
A
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1 5

1, expansion buckle （5702300W5000） 2, sun visor (8204001 W5000)

3, A pillar upper cover (5402101 W 5000) 4, the front dome light assembly (4104200 U
1510)

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Service manual N125-NAM-PV-CS-G9-23
8.2 The Top interior installation

Installation in the opposite order of removal.

Caution:
■Must ensure that surface of top interior is clean before removal and installation of top interior;
■The top interior installation must starts from rear 3 mounting points, first install the middle mounting point,
and then the left one, and finally the right one.After which, install side buckles.

9. Carpet replacement

9.1 carpet removal

9.1.1 Remove the foot rest assembly⑥, then remove the side mold assembly;
9.1.2 Remove the co-driver seat cushion along with the engine cover, remove four hexagonal flange nuts with
which fix the seat cushion to the engine cover, remove the co-driver seat, and finally the remove double seat
left decoration assembly⑩, double seat left buckle decor Pad Assembly⑨ and double seat right buckle
decor Pad Assembly⑦ from double seat upholstery pad buckle one by one;
9.1.3 Remove 4 expansion buckles② from the lower trim assembly① on rear mold from left to right with buckle
C
opener,remove lower trim assembly from rear mold①;
9.1.4 Remove 3 buckles ⑧ from front carpet ③ from left to right with buckle opener, remove the front carpet
Assembly③;
A

9.1.5 Finally remove 2 carpet buckles④ from wheel package decoration⑤ from left to right with buckle opener,
remove wheel package decoration assembly⑤.
J

10 9 8 7

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Service manual N125-NAM-PV-CS-G9-23

1, rear mold lower trim decor assembly (5109600 W5000) 2, expansion buckle (86590 - 28000)3, Former
carpet assembly (5109100 W5000)
4, carpet staples (5109013E0) 5, wheel package decoration assembly (5109300W5000) 6, footrest assembly
(8206102W5000)
7, double seat right buckle decor pad assembly (5109500W5000) 8, buckle (5702011U8010)

Caution:
■Before removing the carpet, must ensure the carpet coverings are cleared(door adhesive tape, rear trim
panel assembly, side mold assembly, driver seat assembly, co-driver seat assembly, dust hood, hand brake
cover,driver's tool and accessories, Engine Cover and safety belt device);

9.2 carpet installation

Installation in the opposite order of removal.

Caution:
Carpet installation must ensure that it fits for the floor surface

10. Heat insulator replacement

10.1. Heat insulator removal

C

10.1.1 Remove 7 Plastic nuts○

3 , and remove engine cover rear heat insulator○
2 one by one;
A

10.1.2 Remove 4 insulator mounting tab○

1 , Remove the rear floor heat insulator○
4;
10.1.3 Make metal clip into straight with pincer pliers and remove right insulator○
5 , Engine Cover Left
insulator○
7 , the driver seat cover insulator○
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6 from engine cover.

2
4

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Service manual N125-NAM-PV-CS-G9-23

1. Engine Cover insulation pad fixing card（81126-37010） 2. Engine Cover rear insulator（5110106W5000） 3.
Plastic nut (5102101 U1010) 4. Rear Floor insulator (5110101 W5000) 5. Engine cover right insulator (5110103
W5000) 6. The driver seat cover insulator (5110105 W5000) 7. Engine cover left insulator (5110104 W5000)

10.2. Heat insulator installation

C
Installation in the opposite order of removal.

11. Replacement of door interior trimming panel:

A

11.1 Removal of door interior trimming panel

J

8
2

7
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Service manual N125-NAM-PV-CS-G9-23

1, left front door assembly (6101100 W 5000) 2, Grommet screw (6102410 U 8050)
3, screw cover (6102411 U 8050) 4, left front door cover assembly (6102100 W5000)
5, cross self-tapping screws and flat washers combination （Q220B4816F38） 6, left front door cover installation
cover (6102301W5000)
7, left front door switch panel assembly (6102500 W5000) 8, left front door inside handle assembly (6105140 W5000)
9, left triangular trimming panel assembly (6102700 W5000)

Order of removal:
11.1.1 Pry a breach from the left triangular trimming panel assembly upper side and pull it out from top to down, not
too hard to prevent damage of left high speaker assembly, remove connector of left high speaker assembly;
remove connector of left high speaker on left triangle trimming panel assembly⑨;
11.1.2 Remove 1 screw of left front door inside handle assembly, and take the handle off⑧;
11.1.3 Pry the left front door cover installation cover⑥, remove 1 screw⑤;
11.1.4 Pry off left front door switch panel assembly and the window regulator switch combination, unplug the
window regulator switch connector, Remove the left front door switch panel assembly⑦ and the window
regulator combination;
11.1.5 Remove 3 screw cover③，remove 3 grommet screws②, then remove 2 screws⑤;
11.1.6. Pry off left front door cover assembly from the brench of the bottom, remove the left front door cover
assembly④.
C
11.2 Installation of door interior trimming panel
A

Installation in the opposite order of removal.

J

12. Side mold cover replacement

1 7

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Service manual N125-NAM-PV-CS-G9-23

10

1, left side upper cover (5402500 W5000) 2, safety belt assembly (5810001 W5000)
3, left side lower cover (5402700 W5000) 4, Floor cover device (5102001 W5000)
5, Left pillar A lower cover (5402300 W 5000) 6, left A pillar upper cover (5402100
W5000)
7, the log car armrest (8215101 W5000) 8, right A lower cover (5402400 W5000)
C

12.1 side cover

A

removal
J

12.1.1 Remove log car armrest⑦, pull off fixing buckle, then remove the left and right A pillar trimming panel⑥;

12.1.2 Remove the floor stripe④, remove foot pedal, pull off fixing buckle, then remove the left pillar A cover⑤

and left and right side cover③;

12.1.3 Remove 2 plastic nuts of right A pillar⑨,pull off fixing buckle, then remove the right A pillar lower cover⑧

12.2.4 Remove the safety belt mounting point②, remove engine cover strips of right upper cover⑩, pull off fixing

buckle, remove left and right upper cover ①.

12.2 side cover installation

Installation in the opposite order of removal.

13. Replacement of rear mold interior trimming panel

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Service manual N125-NAM-PV-CS-G9-23
13.1 removal of rear mold cover

13.1.1 Remove rear mold cover③ along with 6 metal buckles② off rear mold beam⑥;

1 6 5

2 3

4
C

1, right side upper cover (5402601 W5000) 2, metal buckle (5402503 W5000)
A

3, The rear mold cover (5615001 W 5000) 4, Rear mold lower trimming carpet assembly
(5109600 W 5000)
5, Left side upper cover (5402501 W5000) 6, rear mold beam (5600201 W5000)
J

13.2 installation of rear mold cover

Install 6 metal buckles② on rear mold cover③, install rear mold trim panel assembly directly to rear beam⑥.
Caution:
Install rear mold lower decor carpet assembly④ and side mold upper cover, then install rear mold cover③.

14. Floor strips replacement

14.1 Floor strips removal

14.1.1 Remove press 4 floor strips installation cover no.1 ⑧ and no.2 (left) ⑨ off left floor strips⑥ from front
to rear;
14.1.2 Remove 5 cross self tapping screws and flat washer combination⑦ with cross screwdriver off left floor
strips⑥ from front to rear;

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Service manual N125-NAM-PV-CS-G9-23
14.1.3 Remove left floor strips⑥.

8 7 6 5 3

4 2

9
1

1, Left side lower cover(5402701W5000) 2,The Former carpet assembly (5109100 W5000) 3,door seal system (6107001
W5000) 4, floor strip expansion clip (5101012 E 0) 5,left A pillar lower cover(5402301W5000) 6,left floor
C
strip(5102101W5000)
7, cross self-tapping screws and flat washers combination （ Q2204816 ） 8, floor strip installation cover no.1
A

(5102105W5000)
9, Floor strip installation cover no. 2 (left) (5102103W5000)
J

Caution:
Removal method of right floor strip and that of left is the same.

14.2 carpet installation

Installation in the opposite order of removal.

Caution:

Before installation of carpet strip, must ensure that floor strip expansion buckle④ installed above the floor, and

carpets, door seal system③, side lower cover and floor harness must be assembled.

15. Safety belt

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Service manual N125-NAM-PV-CS-G9-23
Disassemble and Assemble

Seat device

C
A
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Order of removal ordr of installation

5, driver's safety belt latch assembly 1, 3-point safety belt assembly
4, middle safety belt assembly 2, 3-point safety belt assembly
3, middle safety belt latch assembly 3, middle safety belt latch assembly
2, passenger safety belt latch assembly 4, middle safety belt assembly
1, 3-point safety belt assembly 2, Driver safety belt latch assembly

Important operation - assembly

1, 3-point safety belt assembly
Mount the safety belt fixing components to B
column.
Pay attention to installation direction of the
safety belt fixing components.
Torque (N·m) 15-40

Portion
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Service manual N125-NAM-PV-CS-G9-23

forward forward

Crimping

Portion Portion Portion

forward
C
A
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Portion Portion

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Unauthorized
Copy is prohibited

Project: N125

Door System Service Manual

No. W5000-NAM-PV-CS-G9-24

Version: 1.0

Edition:

Proof:

Revision:
C
Standardization:

Countersignature:
A

Approval:
J

Anhui Jianghuai Automobile Co., Ltd.

Day Month Year

DS-1
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Door System Service Manual W5000-NAM-PV-CS-G9-24

Door system
1. Door ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 1
2. Door hinge assembly and stopper assembly.... .... .... .... .... .... .... ....7
3. Front grille ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... .. ... ... ... ...10

C
A
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1, Door Door exploded view

12

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Door System Service Manual W5000-NAM-PV-CS-G9-24

10 11
2 3 4 5 6 7 8 9
C
A
J

1, LF door lock and lock assembly 2, LF door outside handle assembly 3, LF door inside handle lever 4, LF door inside
handle assembly 5, LF door assembly 6, LF door lower hinge assembly 7, Front door stopper assembly 8, LF door glass
regulator assembly
9, LF door dust proof sealing strip assembly 10, LF door sealing trip assembly 11, LF door frame sealing strip
assembly 12, LF door groove assembly 13, LF door inner water sealing strip assembly 14, LF door glass assembly 15,
LF door vertical slot assembly 16, LF door outside water sealing strip assembly

1, Front door window regulator and glass assembly

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Door System Service Manual W5000-NAM-PV-CS-G9-24

2, Left front door locking device

1
2
3

4 5

Remo Install

Removal Order Installation order

1. M screws 5. LF door inner handle lever
2. LF door lock body and lock assembly 4. LF door outside handle assembly
3. Hexagon bolt, spring washer and pain washer assembly 3. Hexagon bolt, spring washer and pain washer assembly
C
4. LF door outside handle assembly 2. LF door lock body and lock assembly
5. LF door inner handle lever 1. M screws
A

Important process - Removal

J

1. Loosen M screws
2. Remove LF door lock body and lock assembly
3. Loosen Hexagon bolt, spring washer and pain
washer assembly
4. Remove LF door outside handle assembly
5. Remove rod fixing clip
6. Remove LF door inner handle lever

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Door System Service Manual W5000-NAM-PV-CS-G9-24

Important process
1. LF door outside handle assembly
 Place the outside handle on the installation point, making sure the hole
aims at the middle point. First, insert the hexagon flange bolt into the
round hole, and pre-tighten it. Then, pre-tighten the other bolt; tighten
the other two bolts in turn.

Torque (N.m) 9±2

2. Place the LF door lock and lock assembly on the installation point,
making sure the hole aims at the middle point. First, insert the M screw into
the round hole, and pre-tighten it. Then, pre-tighten the other two screws in
turn.
3. Insert the door lock lever firmly into the outside handle assembly
respectively, rotate the sleeve to tense it, and snap into the slot of the fixing
bayonet, connecting to the door inner trim panel.

3. Left front door vertical slot assembly and left- front door groove

assembly
1
C
2
A
J

5
4

Disassemble Install

Disassembly Order Installation order

1. Cross head Self-tapping screws and washers 5. Left front door groove assembly
combination. 4. Left front door vertical slot assembly
2. Left front door outside water proof rubber trip 3. Hexagon flange nut
3. Hexagon flange nut 2. Left front door outside water proof rubber trip
4. Left front door vertical slot assembly 1. Cross head Self-tapping screws and washers combination.
5. Left front door groove assembly

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Door System Service Manual W5000-NAM-PV-CS-G9-24

Important process - Removal

A
Left front door outside water proof rubber trip
1、 Remove cross head Self-tapping screws and washers
combination.
2、 Remove left front door outside water proof rubber trip
assembly
Left front door vertical slot assembly
1、 Remove hexagonal flange nut
2、 Remove left front door vertical slot assembly
Left front door groove assembly
1. In the figure, A point is the starting point, and remove
the left front door groove assembly

Important process - Assemble

A
C
Left front door outside water proof rubber trip
1. Clamp the outside rubber trip to the mounting holes of the
outside board.
A

2、 Tap the end of rubber trip from the rear edge of the door
to the front, according the rubber trip with the edge of the
door, and use shims and self-tapping screws to secure the
J

rubber strip.
Left front door vertical slot assembly
1、 Place the vertical slot into the mounting hole,
2、 pre-tighten hexagon flange nuts, and then tighten the
others sequentially
Left front door groove assembly
1. In the figure, A point is the starting point, and insert the left
front door groove assembly into the slot of the window frames.

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Door System Service Manual W5000-NAM-PV-CS-G9-24

4. Door stopper assembly and hinge assembly (car body)

2 1
Disassemble Install

Disassembly Order Installation order

1. Hexagon bolt, spring washer and flat washer 2. Hexagon bolt, spring washer and flat washer
assembly assembly
2. Hexagon bolt, spring washer and flat washer 1. Hexagon bolt, spring washer and flat washer
assembly assembly
C

Important process - Removal

A

Door stopper assembly

J

1. Open the door to the maximum degree, and remove the bolts
of door stopper from the car body.

Door hinge assembly

1. Open the door to the maximum degree, and remove the bolts
of door stopper from the car body.

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Door System Service Manual W5000-NAM-PV-CS-G9-24

Important process - Assemble

Door hinge assembly

1. By installation of the bolt(8.8 level), the door upper hinge
assembly is fixed on the side body and make sure that there is a
certain tightening torque.
2. By installation of the bolt(8.8 level), the door lower hinge
assembly is fixed on the side body and make sure that there is a
certain tightening torque.
Torque N·m 33±3
Door stopper assembly
1. By installation of the bolt, the door stopper assemblyis fixed on
the side body and make sure that there is a certain tightening torque.
Torque N·m 23±2

5. Door stopper assembly and hinge assembly (car body side)

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1

2
A

3
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5
6

Install
Disassemble

Disassembly Order Installation order

1. Hexagon bolt, spring washer and flat washer 6. LF door lower hinge assembly
assembly 5. Hexagon bolt, spring washer and flat washer
2. LF door upper hinge assembly assembly
3. Hexagon flange nut 4. Front door stopper assembly
4. Front door stopper assembly 3. Hexagon flange nut
5. Hexagon bolt, spring washer and flat washer 2. LF door upper hinge assembly
assembly 1. Hexagon bolt, spring washer and flat washer
6. LF door lower hinge assembly assembly

Important process - Removal

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Door System Service Manual W5000-NAM-PV-CS-G9-24

Door hinge assembly

1. Remove door upper hinge mounting bolts (door side).
2. Remove the door upper hinge.
3. Remove door lower hinge mounting bolts (door side).
4. Remove the door lower hinge.
Door stopper assembly
1. Remove door stopper mounting bolts (door side).
2. Remove door stopper assembly

Important process - Assemble

Door hinge assembly

Install the door hinge assembly on the door through the hinge mounting
bolts, and make sure that there is a certain tightening torque.

Torque N·m 23±3

Install the door stopper assembly on the door through the mounting nuts,
and make sure that there is a certain tightening torque.
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Torque N·m 7～11
A

Torque N·m 23±3

6. Door seal system
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1
2 3 Installation order
Disassembly Order 1. LF door sealing strip assembly
Disassembly
1. LF door sealingOrder
strip assembly 2. LF door anti-dust rubber strip
1. LF
2. LF door door sealing
anti-dust stripstrip
rubber assembly
assembly assembly
3. LF door frame sealing strip assembly strip
2. LF door anti-dust rubber
3. LF door frame sealing strip assembly
assembly

Important process - Removal

A B
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Door System Service Manual W5000-NAM-PV-CS-G9-24

Door seal system

1、 Remove the fastening nail at A point, remove the trip
buckles clockwise, and remove LF door sealing trip.
2、 B point is the starting point, remove door frame sealing trip
clockwise.
3. Remove the anti-dust sealing strip buckles in turn, and
remove the anti-dust sealing strip.

Important process - Assemble

A B

Door seal system

1、 First, fix the fastening nail at A point, install the rubber
strip clockwise.
2、 B point is the starting point, install door frame sealing
trip clockwise.
3. Install the anti-dust sealing strip buckles in turn.
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A
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3. Front grille

Front grille breakdown drawing

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Door System Service Manual W5000-NAM-PV-CS-G9-24

1 2

3 4 5 6

Order of removal:
1. Unlock handle assembly of front grille lock
2. Unlock cable assembly of front grille lock
3. Front grille lock assembly
4. Trunk cover buffer block
5. Front grille hinge device
6. Front grille assembly
7. Front grille sealing trip
C

4. Front grille lock assembly, unlock handle assembly and unlock cable assembly
A

5
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4
1

2 3

Disassemble Install

Removal Order Installation order

1-Hexagon bolt, spring washer and plain 5. Unlock cable assembly of front grille lock
washer unit 4. Front grille lock assembly
2. Unlock handle assembly of front grille 3. Hexagon bolt, spring washer and plain
lock washer unit
1-Hexagon bolt, spring washer and plain 2. Unlock handle assembly of front grille
washer unit lock
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4. Front grille lock assembly 1-Hexagon bolt, spring washer and plain
5. Unlock cable assembly of front grille lock washer unit
Door System Service Manual W5000-NAM-PV-CS-G9-24

Important process - Removal

1、 Remove the hexagon bolt, spring washer and

plain washer unit of the front grille lock
assembly, and remove the front grille lock
assembly.
2、 Remove the hexagon bolt, spring washer and
plain washer unit of the front grille unlock
handle assembly, and remove the front grille

Important process - Assemble

1.Connect the end of front grille unlock cable assembly close to the
buckle to the unlock handle, and then install the unlock handle
assembly to mounting holes of the side body lower door column
trim board with torque wrench, making sure that there is a certain
tightening torque.
C
Torque (N·m) 10±1
2. Make the cable assembly pass through the rubber sleeve of the
front wall assembly, and fix it on the metal plate by the use of
A

ribbon buckle.
3. Connect one side of the cable to the lock assembly, and install the
J

front grille lock assembly to the mounting holes of front wall outside
board lower part with torque wrench, making sure that there is a
certain tightening torque.
Torque (N·m) 10±1

5. Front grille lock sealing strip and buffer block

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2
Door System Service Manual W5000-NAM-PV-CS-G9-24

Instal
Disassemble

Removal Order Installation order

1. Trunk cover buffer block 2. Front grille sealing trip
2. Front grille sealing trip 1. Trunk cover buffer block

Important process - Removal

1. Screw and remove the trunk cover buffer block by hands

counterclockwise.
2. Remove the front grille sealing strip from the front wall
outside board directly.
C
A

Important process - Assemble

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1. Screw the trunk cover buffer to the bottom clockwise,

and then rotate it outward for three circles. If front grille
is hard to be locked or cannot be locked when it is closed,
please screw inward with reasonable strength.
2. Stick the sealing strip to the front wall outside board
lower part.

5. Front grille hinge device (front grille side)

1
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3
4
5 6

Removal Order Installation order

1. Hexagon bolt 6. Hexagon bolt, spring washer and plain
2. Front grille left hinge assembly washer unit
3. Hexagon bolt, spring washer and 5. Front grille right hinge assembly
plain washer unit 4. Hexagon bolt
4. Hexagon bolt 3. Hexagon bolt, spring washer and plain
5. Front grille right hinge assembly washer unit
6. Hexagon bolt, spring washer and 2. Front grille left hinge assembly
plain washer unit 1. Hexagon bolt

Important process - Removal

Front grille hinge device

1、 Remove the hexagon bolt of left and right hinges.
C
Torque (N·m) 24±2
2. Remove the front grille assembly
3. Remove hexagon bolt, spring washer and plain washer unit of left
A

and right hinges.

Torque (N·m) 10±1
J

4. Remove left and right hinge assembly.

Important process - Assemble

Front grille hinge device

1、 Connect the front grille hinge device with the front grille
assembly through hexagon flange bolts, and make sure
that there is a certain tightening torque.

Torque (N·m) 10±1

2、 Connect the front grille hinge device with the front grille
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washer unit, and make sure that there is a certain

tightening torque.
Door System Service Manual W5000-NAM-PV-CS-G9-24

C
A
J

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Project: N 125

Service manual of exterior system

No. N125-NAM-PV-CS-G9-25
Version:1.0

edit:
C
proofread:

check:
A

standardization:

countersign:
J

permit:

Anhui Jianghuai Automobile Co., Ltd.

Year month date

Table of Contents
TOC

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1. JAC Icon Replacement

1.1 JAC icon removal

1.1.1 JAC icon is Sticked directly to front grille with glue, so just pull off in X direction when removing;

1.2 JAC icon installation

1.2.1 Clean the JAC icon metal mounting surface with a clean cloth.
1.2.2 Uncover Double-sided adhesive paper on the back of J, A, C 3 icons, and then on the back of J, A, C 3 icons,
aiming at the cylindrical alignment sheet metal holes, insert and pressure, making the double-sided adhesive
tape and metal plate is fully Adhesive;
Caution:
■JAC icon can be installed on the front grille.
2. Front mold trim panel replacement

2.1 front mold trim panel removal

C

2.1.1 First using the cross opener pry off 6 cross screws① on the front trim panel ②, and then pull off front light
A

decorations following direction

X;
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1、Cross screws and flat washer Assembly (Q220B4213F71) , 2、Front grille

assembly (Front engine cover) (8402010W5000) 3、front mold decoration trip

Caution:
■Before removing the front light decorations, it is recommended that the front grille assembly (Front Door) to be
removed first.

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2.2 front mold trim strip mounting

2.2.1 Stick non-woven fabrics, sponge, and non-woven cloth - pillars mat to the front trim panel
2.2.2 The Front trim panel 2 main positioning post and auxiliary positioning pin alignment sheet metal master the
hole and Secondary positioning holes, snap the trim 3.
2.2.3 Install the cross screws and flat washer assembly ① to the front trim panel mounting hole through metal
plate mounting holes, pre-tight;
2 2.4 Adjust the front trim panel so that the metal clearance is within the standard;
2.2.5 Finally, using cross opener to tighten 6 cross screws① at torque of 3-4N•m;
Caution:
The installation of front trim panel goes before installation of the front grille.

3. Replacement of outside rear view mirror

3.1 Outside mirror removal

3.1.1 Remove the connector of harness assembly on the left front door of outside rear mirror;
C
3.1.2 Screw off the 3 bolts on outside rear view mirror, remove the outer mirror assembly;
A
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1 、 the left outside mirror assembly (8202100W5000) 2 、 left front door harness
assembly (4012100W5020) 3、hexagon bolt, spring washer and flat washer combination

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3.2 Outside mirror installation

Installation in the opposite order of removal.

Caution:
■During installation of outside Mirror, must ensure that all components of outside mirror are assembled well in
advance,insert 3 mounting points of outside mirror to the corresponding metal mounting holes and tighten the
bolts.

4. Front bumper replacement

4.1 Front bumper removel

4.1.1 First, screw off 2 screws connecting the front bumper and the left/right side mounting plate;
4.1.2 Remove 2 bolts and 4 xpansion card buckle connecting front bumper and anti-collision beam;
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A
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1, 6 hexagon head screws, spring washers and flat washers combination (Q1460620F62)
2, expansion card buckle (5522101 U 2152) 3, front bumper assembly (2803100W5000)

4.1 .3 Pull out the front bumper in X direction;

4.1.4 Take off 4 bolts in connection of front bumper collision frame assembly and the Left/Right Front Floor supporting
carling, and remove the front bumper collision frame assembly;

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1、hexagon head screws, spring washers and flat washer combination (Q1460620F62)
2、Front bumper collision frame assembly (2803200W5000)
C
A

Caution:
■Before removing front bumper, disconnect the front fog light connector.
J

4.2 Front bumper installation

Installation is the reversed order of removal.

Caution:
Before front bumper installation, must ensure that all parts of front bumper are installed in advance.

5. Replacement of inside rear view mirror

5.1 The inside rear view mirror removal

5.1.1 using cross opener to screw off the screws, take off the inside rear view mirror from bottom to the top;

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1 、 The inside rear view mirror assembly (8201100W5000) 2 、 Front Windshield

A

(5206001W5000)
3、the inside rear view mirror (8210901U1512)
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5.2 The inside rear view mirror installation

Installation is the reversed order of removal；

6. Foot Pedal replacement

6.1 foot pedal removal

6.1.1 Remove left/right foot pedal directly in Z direction;

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1、left foot pedal assembly (8405100W5000) 2、left mounting outer plate assembly
A

6.2
J

installation of foot pedal

Place the foot pedal buckle on the footrest into the metal mounting holes;

7. Front wing panel replacement

7.1 Front wing panel removal

7.1.1 Break off cable clamp, remove the left/right engine fender Rubber;
7.1.2 Remove the Left/Right Front Fender bolts and then remove expansion card buckle, then remove the Left/Right
Front Fender;
7.1.3 Remove the Left/Right Rear Fender bolts and screws, and then remove expansion card buckle, and finally remove
the Left/Right Rear Fender. Torque of self-tapping screws and bolts are (5-6)N.M and (9-11)N M;

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8
1
2

4
7
5

6
C
1. Engine fender rubber buckle （8403304LE010） 2. Left engine fender rubber (8403103 W5000)
3. Hexagonal head bolt, spring washers and flat washers combination （ Q1460620F62 ） 4. Large washer
A

（Q402B06F62）. 5. Cross head screws and flat washers combination （Q220B4816F71 ） 6. Left Rear Fender
（8403102W5000）
7. Expansion Card buckle (86590 - 28000) 8. Left Front Fender (8403101 W5000)
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7.2 Front wing panel installation

Installation is in reverse order of removal, torque of self-tapping screws and bolts are (5-6)N.M and (9-1)N.M;

8、Front mold side panel replacement

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8.1 Front mold side panel removal

Important job - Removing

a. Using a wrench and cross opener, respectively,
remove the 2, 3 bolts and 1, 4 screws;
b. Pull The front mold side panel down directly;
Do not damage the body painting.

C
A

8.2 Front mold side Panel Installation

J

Important job - Assembly

● As showed in the picture, install self-tapping screws and
bolts in the order of 1, 2, 3, 4, pre-tension;
● Adjust the interval between front mold mask and front
mold panel/the doors, living up to the standard-setting;
● As showed in the picture, install self-tapping screws and
bolts in the order of 1, 2, 3, 4 with torque of (5-6)N·m and
(9-11)N·M;

9、Rear mold fender replacement

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1. Rear mold hood

9.1 Rear mold fender removal

C
Important job - Removing
● Use the wrench to remove the fixing bolts in the order
A

of I, II, III, IV, V, VI, VII VIII, and then remove the rear
mounting mold fender;
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9.2 Rear mold fender installation

Important job - Assembly

● Install the Rear mold fender, aiming locating hole A at
corresponding hole on metal, installation in advance;
● Install the rest of installation hole as the order of I, II,
III, IV, V, VI, VII VIII, penetrate and tighten screws
with torque of 9-11N·M, and finally tighten the hole.；

10、The front windshield replacement

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1. Front windshield 2. Front windshield adhesive tape

10.1 The front windshield removal

Important job - Removing

c. From the flange and each corner of car body, tear off
the seal.
d. Put copper wire of φ0.5mm through glass cement on
C
top of A-pillar, both one people in and out of
window drag, separating glass and metal plate, and
slowly push out the glass to remove it.
A

Do not damage glass surface.

10.2 The front Window Installation

J

Important job - Assembly

1) Clean the installation metal face with a clean cloth with
glass cleaner, cool down 1 - 2 minutes;
2) Brush the glue evenly to the car window surface;
3) Put the window on the location with glass glue, and clean
the black frame area of glass with glass cleaner;
4) Install the Window adhesive assembly along the glass
edge, ensuring it is well adhesive; when temperature is low,
put the adhesive assembly into the oven to heat; Otherwise,
it is too hard to stick;

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5) Paint the glue in the certain area evenly and get dry;
6) Paint the glass glue to the sticking area along the
adhesive tape with glue guns; width: 7 to 9 MM, high: 10 -
14 MM, Triangle glass glue outer edge cover the inner
edge.
7) after the glue, put the front windshield to the body metal
pedal borders, limited post align to pedal limited hole, tie
with bandage to prevent it getting off, and put it in still for
more than 12 hours, during which time avoid flip cab.
aquaseal One-component
polyurethane glass paint

11、Rear window replacement

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1. Rear windshield 2. Rear windshield adhesive tape

11.1 Rear window assembly removal

Important job - Removing

1. In the cab, take body metal flange off

the wind window adhesive strip, and firmly
push the windshield outside;

2. Along with length of adhesive tape

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11.2 Rear Window Installation

Seal
Important job - Assembly

1. The glass trademark is placed in the lower left,

adjust the glass center to the seal lower connection.

2. Put rope with width ofФ 5 - 6 mm

Rope
through the edge. Rotate rope one lap, then make it
doublication with lower center of the glass.
Seal
3. Adjust Glass in the center of the window, press

the glass from outside, then drag the rope from inner side,
instal the rear windshield adhesive tape to car body
Center
flange.

4. Tap the adhesive tape with a rubber hammer,

Left Right Connection making the body flange fully connect the seal.
C

Note: Do not distort glue, nor make it off rear

Push
windshield, otherwise there will be water
A

leakage.
J

Pull

Rubber Winshield
hammer
Seal

Car flange

12. The front combination light and light bulb replacement

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12.1 The front combination lamp removal

1. Remove the front bumper (refer to FRONT

BUMPER).

2. Open the front cover, using a 10# wrench remove

the headlight front mounting bolts （M6X15）.
C
A
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3. Open the door, between door and side panels, using

8 #socket wrench remove the rear mounting bolts
of front headlight （2XM6X10）.

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4. Unplug connector, take off front headlight.

12.2 The headlight bulb removal

Before removing low and high beam headlights, turn signal lights, position light bulb, it is necessary to remove the
headlights from car. And then put aside high/low Beam rubber cover, replace low and high beam light bulb, position light
bulb. Counter-clockwise twist the turn signal bulb socket to replace it.

12.3 The headlight installation

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Installation is the reversed order of removal.
A

13. Side turn signal lights and light bulb replacement

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13.1 Side turn signal lamps and Bulb Removal

1. Using a straight screwdriver gently pry off the turn

signal, take out the side turn signal lights from the
door.

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2. Disconnect the turn signal connector, and then
remove turn signal lights. Counter-clockwise twist the
bulb socket to remove the side turn signal light bulb.

13.2 Side turn signal lights installation

Installation is the reversed order of removal.

Replacement of the front fog lamp bulb

C
14.1 FRONT FOG LIGHTS AND Bulb Removal
A

1. Lying under front bumper, you can see the fog light
installation point and plug-ins. Disconnect front fog
light connector.
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2. Remove 4 screws with cross screwdriver and
remove the front fog lights.
Counter-clockwise Twist the bulb socket and remove the
front fog light bulb.

14.2 Front fog lamp installation

Installation is the reversed order of removal.

15. Top light and light bulb replacement

15.1 Remove top lamp and Bulb

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1. Pry off the top light transparent masks with straight

A

screwdriver, and then remove the top light bulb

with hand.
J

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2. Open glasses box, remove two upper fixing screws
with cross screwdriver.

3. Pry off top light in front of glasses box with slotted

screwdriver, and take the top light from the ceiling.
C
A

4. Remove the top light connector, take the dome light

J

off.

15.2 dome light installation

Installation is the reversed order of removal.

16. Replacement of the door lamp bulb

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16.1 Door Light Bulb Removal

1. Remove door cover unit (refer to door cover unit).

2. Disconnect Door Light connector and remove the

door cover unit.
C
A

3. Remove the door lamp connector, and make it

away from the door panels. Counter-clockwise
J

Twist the bulb socket, you can remove the door

light bulb for replacement.

16.2 Door light bulb installation

Installation is the reversed order of removal.

17. Replacement or license plate light and its bulb.

17.1 License Plate Lamp and Bulb Removal

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1. Disconnect license lamp connector.

2. Remove 2 mounting screws of License Plate

Lamp with cross screwdriver.

3. Take off license plate light. License Plate Lamp

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assembly needs to be replaced before light bulb
replacement .
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17.2 License Plate Lamp installation

Installation is the reversed order of removal.

18. Combination rear lamp and light bulb replacement

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18.1 combination rear light and bulb removal

1. Disconnect the rear combination lamp connector.

2. Remove rear combination light nut (2XM 8) with a

13# socket wrench.

C
A

3. Remove combination rear lamp.

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4. Use a flathead screwdriver to pry the combination

rear lamp cover, and then counter-clockwise twist the
bulb off.

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18.2 combination rear light installation

Installation is the reversed order of removal.

19. Lamp diagnostic and testing

19.1 position lights, license plate light does not work

steps Operating Yes No

Turn the Light Switch to position light. Check if the small light
1 To step 2 To step 3
relay pin 87 has output voltage?
2 Check if the fuse F 55, F 56 are normal.
3 Check if the fuse of SB 11 is normal. To step 4
4 Check if the small light relay pin 85 is low voltage? To step 5 To step 7
5 Check if light switch pin 1 is low voltage? To step 6 To step 8
6 Check if light switch is functioning properly?
7 Check if the small light relay pin 85 wire to BCM is normal?
8 Check if light switch pin 1 wire to BCM is normal? To step 9
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9 Check if BCM is functioning properly?
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19.2 The front dome light does not work

steps Measures Yes No

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1 Check if the top light bulb has voltage? To step 2 To step 4

2 Check if the top light bulb filament is fusing? To step 5 To step 3
3 Check if light switch is functioning properly? To step 7 To step 8
4 Check if the fuse of F51 is fusing? To step 6 To step 2
5 Replace the bulb.
6 Replace the fuse.
7 Check ground wiring harness connection
8 Replace the top light.

19.3 High/Low Beam Lights do not work

Steps Measures Yes No

1 Turn the ignition switch ON, check if fuse F32 has 12V voltage? To step 3 To step 2
2 Replace the fuse.
3 Check the headlight relay pin 86 is 12V? To step 4 To step 9
4 Lighting switch 2 Pin connector is low voltage? To step 6 To step 5
5 Light switch is functioning properly? To step 8 To step 7
6 Replace the headlight relay
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7 Replace Light Switch.
8 Check Light Switch 2 pin grounding harness failure.
9 Check if fuse F32 to headlight relay 86 pin wiring harness has
malfunction.

19.4 Only High Beam Lights do not work

steps Measures Yes No

Check if Light Switch 5 Pin Plug-in High Beam wires has 12 V
1 To step 2 To step 4
voltage?
2 Check Light Switch High Beam function To step 6 To step 3
3 Replace Light Switch.
Check if the high beam light 1 Pin Plug-in to light switch pin 5
4 To step 6 To step 7
wire is conducted.
5 Replace the bulb.
6 Exclude the malfunction of wire and switch.
7 Troubleshooting

19.5 Only low beam lights do not work

C
steps Measures Yes No
1 Check if Light Switch connector low beam wires has 12 V voltage? To step 2 To step 3
2 Replace Light Switch.
A

Check low beam light connector and wiring harness connector is

3 To step 4 To step 5
well contacted.
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4 Replace the bulb.

5 Exclude the Faulty contact.

Diagnostic procedures of front fog light:

steps Measures Yes No

Turn the front fog light switch to "Fog Lights" position, turn on the To step 7 To step 2
1
front fog lights, check if the instrument indicator works
2 Check if the fuse #39 is intact? To step 4 To step 3
3 Replace the damaged fuse. To step 4
Remove the front fog light relay to measure voltage of relay socket, To step 6 To step 5
4
the voltage is normal?
According to the schematic check INSTRUMENT PANEL
5 WIRING HARNESS and front fog light switch wiring is
functioning properly? If necessary, should be repaired.
6 Replace the relay, fog lights are functioning properly? To step 7
Check Fog Light connector, ensuring that the voltage and ground is To step 8
7
no problem.

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According to schematic check harness between relay and light
8
switch.

19.7 Diagnostic procedures of rear fpg light:

steps Measures Yes No

Turn the rear fog light switch to the "Fog Lights" position, turn on To step 7 To step 2
1
the rear fog lights, check if the instrument indicator works?
2 Check if the fuse #38 is intact? To step 4 To step 3
3 Replace the damaged fuse. To step 4
Remove the rear fog light relay to measure voltage of relay socket, To step 6 To step 5
4
the voltage is normal?
According to the schematic check INSTRUMENT PANEL
5 WIRING HARNESS and front fog light switch wiring is
functioning properly? If necessary, should be repaired.
6 Replace the relay, fog lights are functioning properly? To step 7
Check Fog Light connector, ensuring that the voltage and ground is To step 8 To step 9
7
no problem.
According to the schematic check harness from the relay to the fog
8
light.
According to the schematic check harness from the relay and light
C
9
switch to BCM.
A

19.8 Diagnostic procedures of braking light:

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steps Measures Yes No

1 Check if the fuse is in intact? To step 3 To step 2
2 Replace the fuse, is it still broken? To step 5 To step 3
3 Measure voltage of the Fuse is normal? To step 5 To step 4
4 Please check the engine wiring harness.
5 Separate brake switch connector and check the brake switch, making
sure the brake switch is not a problem, measure if the voltage is To step 7 To step 6
normal.
6 Check the instrument panel harness from brake switch to the fuse.
7 Check the connector between engine and the rear body harness and To step 8
make sure it is not a problem.
8 Check the body harness from connector to the brake lights. To step 9
9 Check the braking light and harness which connects to its harness. To step 10
10 Please check the rear body Harness locations, making sure it is well
connected to ground.

19.9 Diagnostic procedures of backup light:

steps Measures Yes No

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1 Check if the fuse is intact? To step 3 To step 2
2 Replace the damaged fuse, is the backup light normal? To step 3
3 Check the the connector between engine and cab harness,
To step 4 To step 10
measuring if voltage is normal?
4 Please check the connector between engine and body harness,
To step 5 To step 10
measuring if voltage is normal?
5 Separate reversing light switch connector, measure if connector
To step 6 To step 10
voltage is normal?
6 Please check the instrument panel harness from fuse to the
To step 7 To step 10
reversing light switch.
7 Check the body harness from reverse light switch connector to
To step 8 To step 10
body harness, making sure that it is not a problem.
8 Check the rear combination light and connector leading to its
To step 9 To step 10
harness.
9 Check the body harness location, making sure that it is well
connected to ground.
10 Exclude that the wiring harness is faulty
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Items N125

Service manual of electrical system

Number: W5000-NAM-PV-DQ-G9-15

Version:1.0

edit:
Proofread
:
check:
standardi
C
zation:
countersig
n:
A

permit:
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Anhui Jianghuai Automobile Co., Ltd.

Year month date

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N125 Combination instrument
Function Description

Component Diagram of Combination Instrument

Combination instrument indicates following functions:

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1.Speedometer: Pointer of speed meter rotates upon frequency signal from speed sensor to indicate speed of vehicle. It is

considered as 0 when speed is less than 2（Km/h）

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2. Tachometer: Pointer of speedometer moves upon revolution speed signal from engine to indicate rpm of engine.
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3. Water-thermometer: Pointer of water-thermometer rotates upon Resistance signal from water temperature sensor of

engine to indicate temperature of engine coolant.

4. Fuel Gauge: Pointer of fuel gauge rotates upon resistance value signal from fuel sensor to indicate the remaining oil

of fuel tank.

5. LCD display: Mileage accrual, subtotal mileage.

6. Relevant parameters of combination instrument

Items Descriptions
Color Black
Table licensing technology 3D
Dial Scale line/digital White, find more details in the effect design
Red Zone red, find more details in the effect design
Dial white (with blue halo)
Pointer Red
back lighting
LCD White on Black
The chipset type stepping motor great force VID 2905
Speedometer signal source (ON) Vehicle Speed Sensor
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Speed units Km/h

The Maximum Scale (Km/h) 160
The Minimum Scale (Km/h) 10
KM/H Symbol back lighting
The chipset type Stepping motor
signal source (ON) Generator
tachometer The maximum speed scale 6000
minimum scale 500
Red Zone 4000～6000
X1000R/min Symbol back lighting
The chipset type Stepping motor
Water
signal source (ON) water temperature sensor
temperature
Scope 50 °C ~120 °C (C ~H)
gauge Red Zone 115 °C ~120 °C
Remarks 85 °C ~105 °C remain at 1/2 scale
The chipset type Stepping motor

Fuel gauge signal source (ON) Fuel sensor

Scope E～F
Red Zone E ~ 1/8
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Total number of miles (ON) 0~999999 Km

LCD display: Mileage subtotal (ON) 0~999.9 Km

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Fuel Consumption Information (ON) Average and instantaneous fuel consumption L/100 Km
Left Turn (B + or
high voltage Green
ON)
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right turn (B + or
high voltage Green
ON)

High Beam (ON) low voltage Blue

high voltage
Rear fog lamp(ON) Yellow

Front fog lamp(ON) high voltage Green

Open door (B + or
low voltage Red
ON)
charge and discharge Need to provide 200
low voltage Red
instructions (ON) mA excitation
High or
ABS failure (ON) In reserve Yellow
suspended
Alarm Driver’s safety
low voltage Red
belt(ON)
indicator
Engine blow down
low voltage Reserved Yellow
symbols in dial system failure (ON)

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Airbag failure
low voltage Reserved red
indicator(ON)
Water temperature
Resistance
high/low coolant instrument drive red
values
(ON)
Resistance
Low fuel level (ON) instrument drive Yellow
values
Oil pressure alarm
low voltage red
(ON)
engine failure
low voltage Reserved Yellow EPC
indication (ON)

The hand brake, the

Brake Failure (B + or
brake fluid level is low,
ON) low voltage red
the Brake Pressure ia
Low

Engine anti-theft
indicator low voltage Reserved Yellow
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(B + or ON)
Daytime running
high voltage Green
lights (ON)
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Cruise Indicator
high voltage Reserved Green
(ON)
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preheat Indicator
low voltage Yellow
(ON)
Water separator
high voltage red
(ON)

Combination meter terminal description

Combination meter terminal description (currently N125 only uses a connector: AMP 966658 - 1 (green)

AMP 966658-1(green)CON_A
A1 oil and water separation A17 oil pressure-
A2 empty A18 door open-
A3 empty A19 ignition electric+
A4 right turn + A20 rotation signal frequency
A5 left turn + A21 speed signal frequency
A6 charge-discharge A22 telecommunication
A7 small lamp+ A23 speed output frequency
A8 empty A24 fuel ground-
A9 empty A25 fuel signal resistance of value
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A10 empty A26 water temperature signal resistance value

A11 rear fog lamp+ A27 safety belt
A12 high beam lamp- A28 braking-
A13 front fog lamp+ A29 parking braking-
A14 preheat A30 empty
A15 empty A31 battery +
A16 DRL A32 battery ground-

Actual speed Speed instruction range

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Speedometer and odometer

Test:
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① Adjust tire pressure to the specified value.

② Put vehicle on speed test stand.

③ Make sure that parking brake functions properly.

④ Fix vehicle onto to prevent lateral moving.

⑤ Fasten rear end of vehicle with chain or steel cable to prevent longitudinal moving of vehicle.

⑥ Check if it's in the correct indication range of speedometer.

Speedometer Indication Range is showed in the below table:

Caution:

■Never operate clutch or change speed suddenly during test.

■Confirm the speed of change:

Tachometer
Inspection of tachometer

Compare readings in tachometer above mentioned and that onboard with different engine speed. Make sure that difference
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is within the standard limitation.

Tachometer Indication Range is showed in the below table:

Actual speed Allowed mistake range

Water temperature gauge

1. Water Temperature table Description

Lower than C – lower temperature zone

Engine temperature indication will be in this zone during warming up of engine. In this temperature range, the engine
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should not run in high speed or under high load.

Between C and red zone – It shows temperature range in normal operation with normal rpm.
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The pointer will go beyond this zone when engine runs with heavy duty in hot environment. The vehicle can operate
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normally before coolant temperature indicator lit up. In case this indicator is lit up, stop engine and check cooling system.

Above the Red Zone - hot zone

A pointer in this red zone indicates overheated engine. Stop vehicle safely and turn off engine immediately. Check for

cause of overheating after engine cools down.

Descriptions:

The auxiliary headlight in front cool air inlet under front bumper effects cooling air circulation, which results in

poor cooling effect of engine. If engine runs with heavy duty under high ambient temperature, it will be easily

overheated. Front spoiler also directs cooling air. The engine will be overheating if it is damaged or broken resulting

from compact.

2. Inspection of Water Temperature Gauge

Measuring the information sent from water temperature sensor.

Speedometer Indication Range and Resistance values Comparing Table

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Scale Resistance(Ω) Check point Actual temperature(℃)

Fuel gauge
Floater moves along with change of fuel level, corresponding to the sliding contact with pole of floater to change

resistance of thick-film resistor. Minimum resistance of thick-film resistor corresponds when fuel tank is full, the pointer of

fuel gauge indicates maximum fuel quantity in position F. Otherwise, in case fuel tank emptied, the maximum resistance

results in that the pointer of fuel gauge indicates minimum fuel quantity in position E.

1. Inspection methods
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1) Inspect fuel gauge operation

There is about 10 L fuel remaining in fuel tank when pointer is in position E. The pointer will go out of position F when
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vehicle runs a while after the fuel tank is topped up. Fill quantity may be less than capacity on label because of fuel remaining

when refill the fuel tank.

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2.Simply procedure for fuel gauge inspection

Disconnect the connector of Fuel

Use a special tool to connect test lights

Replace Fuel gauge sensor
(12 V - 3.4 V) to connector of wiring.

Normal

Turn on the test lights when ignition Norm

FUEL GAUGE pointer swings.
switch is ON position.

Abnormal

Repair electrical wiring.

Change fuel gauge.

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Repair electrical wiring

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3. Inspection of fuel gauge sensor component

Remove sensor component from fuel tank before inspection.

4. Resistance of fuel gauge sensors component

1) With floater of fuel gauge sensor assembly at position F (highest) and E (lowest), verify if resistance values between

terminals of sensors is within the standard values.

Comparing Table of Sensor Resistance and Reading on Fuel Gauge is below:

Scale Resistance(Ω) Check point（Ω）

Warning point C
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2) Check if resistance values varies smoothly with floater moving between position F and E.
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Combination instrument replacement

1) Removal procedure:

① Remove negative (-) of battery.

② Adjust the steering wheel to the bottom position

③ Remove 2 screws in the instrument panel cover

④ pry off the Instrument panel cover from the IP Board completely

⑤ Take instrument panel cover away to expose the screws on instrument cluster

⑥Remove screws on combination instrument.

⑦Unplug connectors and remove combination instrument assembly.

2) Installation Steps: installation is the reverse order of

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removal

Fault diagnosis
Fault Diagnostic Table of Combination Instrument
No. Major Fault Cause elimination methods
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(1) circuit is not
Malfunction of the (1) Check battery and ground, if battery is
connected
1 whole combination 12V and connected.
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instrument (2) Exchange instruments

(2) Damaged wiring
(1) circuit is not
(1) Check for connectivity of relevant
Indicator light connected
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circuit and connector

2 and/or spotlight (2) (2) False
(2) Check if there is level signal
can’t be lit up controlling signal
(3) Exchange instruments
(3) Damaged wiring
False indication or
(1) System failure
malfunction of (1) Check if relevant frequency signal is
3 instruments; normal
(2) Damaged wiring of
malfunction of (2) Exchange instruments
instrument
odometer LED
Absence of strokes Damaged wiring of
4 Exchange instruments
on odometer LED instrument

Audio System
Layout of Components
Layout of radio and tape player:

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1- Radio and tape player.

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High pitch Woofer
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Woofer
High pitch

Description for host terminals

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Diagram of Terminal 16

Description Table of Terminal 16

Terminal No. Function Terminal No. Function

A1 Null B1 ILL (illuminator) (+)
A2 Rear left speaker (+) B2 Rear right speaker (-)
A3 Front left speaker (+) B3 Front right speaker (-)
A4 Rear right speaker (+) B4 Null
Front right speaker B5 Null
A5
(+)
A6 ILL (illuminator) (-) B6 Front left speaker (-)
A7 ACC B7 Rear left speaker (-)
Memory power B8 Ground
A8
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Sound supply system
replacement
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1. Audio unit
1) Remove procedure:
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① Using flat screwdriver, pry off instrument panel.

② remove the screws.

③ Pull audio unit forward and unplug electric connector to remove audio unit assembly.

2）Installation is in the reverse order of removal. Verify normal function of audio unit.
2. Antenna replacement
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1) Remove procedure:
① disconnect the connector between side trim panel under A pillar and antenna

② From A pillar, pull out the rod antenna.

2) Installation procedure:
Installation is in the reversed order of removal.

Replacement of woofer
1. Removal procedure:
1) Remove the door internal trim panel.
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2) Disconnect on the connector on woofer.

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3) Remove the screws on woofer.

4) Remove the woofer.

2. Installation procedure:
Installation is in the reversed order of removal.

Replacement of Loudspeaker
1. Removal procedure
1) Cut in border of loudspeakers with a flat screwdriver.
Pry off the loudspeaker.

Note:
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■Don’t touch glass to avoid damage.

2) Unplug connector on rear side of loudspeaker.

Remove loudspeaker.

2. Installation procedure
Installation is in the reversed order of removal.

Fault diagnosis
Any minor mistaking operation may cause a problem to be detected. Confirm failure according to
table below at first.
Fault Diagnosis Table of Audio System
Symptoms Cause Solution
Replace by using a new fuse in the
1. Burn battery fuse
same size.
Cannot be started 2. Poor contact between
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power supply plug and unit Try to plug again or replace the plug.
socket
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Improperly connected
Intermittent sound Inspect wiring
power supply
1. Volume knob is on
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Adjust the volume to a moderate level

No sound from speaker Minimum position.
2. incorrect connection Inspect wire and connection
antenna socket and antenna Check the antenna socket and the
cables connects abnormally antenna cables are connected properly
auto-preset does not work
To manually adjust or move to
properly
Radio signal is weak another place with less obstruction to
search
unrecognized formats of Please refer to manuals to check file
file format
cannot play USB
Storage Device Is Not
Check if properly connected
Connected.

WW Wiper and Washer System

Front wiper
Installation Position

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There is white lines on glass, corresponding to the initial installation

3. Removal

1.Remove the front wiper plug cover (A) and nut (B), remove the front wiper arm and wiper blades.
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A

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2.Unscrew the nut and remove the front wiper arm and wiper blades (A).

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3.If necessary remove wiper blades, pull wiper blade adapter cap; Remove wiper blades through wiper blades Adapter Cap

with the U-hook on wiper arm.

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4.Remove the ring and then remove instrumentation.

5.Connect Wiper Motor connector from wiper motor and linkage assembly.

6.Remove 8 bolts, remove the windshield wiper motor and linkage assembly (A).

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Note: Before removing wiper motor and connecting rod assemblies, make sure the rod stops at the automatic stop position

(with power on, turn off the wiper switch, Wiper System natural stop position is automatically stopped position).

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Installation
1.Install the wiper motor and linkage assembly, connect Wiper Motor connector. Mounting Screw torque is 9 ± 2N·m .

2.Install the Ventilation cover.

3.Install front windshield wiper arms and blades.

Caution:

■ You must run the windshield wiper motor, making sure wiper motor is at the initial position.

■ There is white anchor point under glass in black edge, install the arm and the blade which should be right on the

white point.

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There is white lines on glass, corresponding to the initial installation

■ The nut tightening torque is 24 ± 2N. m.

Check
Speed operation check
1.Split Wiper Motor connector.
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NO . 53 53a 53b 31b 31

definition Low Power High off-positi Groundin
speed supply Speed on g

2. 53 and 53b terminal connected to the battery ( +) and No. 31 terminal to battery ( - ).
3. As showed in the below table, check if the engine is normal.

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53 53a 53b 31b 31

Location

Terminal

OFF

LO

HI
Caution:
■ In general, sources of pollution are the insects, tree sap and hot wax processing from using some commercial vehicle

wash liquid. If wiper blades do not work properly, clean doors and windows and wiper blades with good cleaning

liquid or a mild detergent, then clean thoroughly with clean water.

Check wiper automatic stop

1.Use the control lever to operate motors in low speed.

2.Disconnect motor cable connector 31b terminal, making the motor stops anywhere except OFF.
3.Connect 31b and 53 terminals.
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4.Connect battery ( +) and negative ( -) terminals to no. 53a terminal and no. 31 terminal separately.
5.Verify if the motor stops in OFF position.
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31 31b 53 53a
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Cleaning the motor

Check

1.Attach washing motor to the water tank and fill the water tank with water.

2. Connect the battery ( +) and ( -) to number 2 and number 1 terminal separately, check that if the motor is working

properly, if washing motor is running, and if the nozzle spray.

3. Change washer motor if any abnormal.

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Note: before adding water to the reservoir, check if the filter has any impurity or pollution.

Clean filter according to needs.

NO . 1 2
definition Negative pole Power supply

Removal:
1.Disconnect negative terminal of battery.

2.Remove front bumper cover.

3.Remove washing water (A), separate washing motor connector (B).

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A

A B
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4.Remove washing motor.

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5.Remove 2 bolts (A), and one nut (B), remove washer fluid jug (C).

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A C

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Caution:

■ While repairing washing pump, be careful not to damage the seal of washer pump.

■ Before adding washing pump reservoir, do not operate the washing pump. Incorrect operation may cause premature

pump failure.

Installation
1.Install washing liquid pot.
2.Connect washing motor and washing hose.
3.Install washing motor
4.Install front and rear washing system nozzles.
5.Install the front bumper cover.
Note: Before installing the washing motor, check if there are impurity or pollution, and if necessary, clean filter and washing

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motor.

HORN
ELECTRIC HORN
Installation Position

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A

ELECT

ELECTR
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Check
1. Remove the front bumper. Refer to "Front bumper replacement"
2. Disconnect the horn connector.

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1
2

3. Connect the horn terminal no.1 with the battery positive, terminal no. 2 with the battery negative,
horn should beep.
4. If the horn doesn’t beep, it should be replaced.
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Replace
1) Remove procedure:
A

① Open the hood and remove the front bumper, refer to "the front bumper replacement".
② Remove the fixing bolts of horn.
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③ Disconnect the connector of horn.

④ remove the horn assembly.
2) Installation procedure:
① Install the horn assembly.

■Tightening torque: 9±1 N·m

② Connect the connectors of horn assembly.
③ Cover up the engine hood

CIGAR Lighter
Installation Position

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A
C
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Schematic Diagram of Cigar Lighter

Fault diagnosis
1) Inspection of Cigar Lighter System
Abnormal
steps Measures Normal result
result
Lighter will jump to edge of socket
Push lighter into socket till click Cigarette lighter
1 when negative pole is connected to
sound does not work
electric power.
Cigarette lighter
2 Cigarette lighter lights
off
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2) Cigarette lighter does not work

step
Measures Yes No
s
Check the fuses
1 To step 4 To step 2
if the fuse is burned off
Connect a testing lamp on both sides of lighter.
2 To step 5 To step 3
Is the testing lamp on?
3 Cigarette lighter light on? To step 6 To step 7
to the "System
4 Replace the fuse -
Check"
to the "System
5 Replace cigar lighter -
Check"
to the "System
6 Replace cigar lighter -
Check"
to the "System
7 Repair poor contact -
Check"

Alarm light switch

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Installation Position
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Warning light switch terminals description

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Schematic

Terminal

Gear

Turning Back Turning

Back Right Left
Pin definition signal lamp signal
lamp lamp lamp
input positive output
ground

Removal:
Using flat screwdriver pry off instrument panel cover, refer to "removal methods of instrument
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1

panel cover"
A

2 Press connector with hands and force out the plug-ins.

3 Pry off alarm light switch with a flat screwdriver.
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Installation
1 The warning light switch is mounted to the instrument cover.
2 Connect the plug-in to the alarm light switch terminals.
3 install the instrument hood to instrument, refer to the "instrument hood installation method"
A/C Switch
Installation Position

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A/C switch plug-in terminal descriptions

Schematic

Remarks
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Function indicator
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Background indicator

Removal:
1 Using flat screwdriver pry off instrument panel cover, refer to "removal methods of instrument
panel cover"
2 Press connector with hands and force out the plug-ins (yellow).
3 Remove the switch mounting bracket with cross screwdriver,
4 Pry off A/C switch with a flat screwdriver.
Installation
1 Install the A/C switch to switch bracket.
2 Install the mounting bracket to instrument hood with cross screwdriver,
3 Connect the plug-in to connect to A/C switch terminals.
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4 Install the instrument hood to instrument, refer to the "instrument
hood installation method"

7. Internal & external Circulation Switch

Installation Position

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Internal and external Circulation switch plug-in terminal descriptions

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Schematic

Remarks

Function indicator

Background indicator

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Removal:
1 Using flat screwdriver pry off instrument panel cover, refer to "removal methods of instrument
panel cover"
2 press connector with hands and force out the plug-ins(blue),
3 Remove the switch mounting bracket with cross screwdriver,
4 Use a flat-blade screwdriver to pry off the inner and outer loop switch.
Installation
1 Install the Internal and external loop switch to switch bracket,
2 Install the mounting bracket to instrument hood with cross screwdriver,
3 Connect the plug-in to internal and external loop switch terminals.
4 Install the instrument hood to instrument, refer to the "instrument hood installation method"
Rearview Mirror Heating Switch
Installation Position
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A
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Rearview mirror heating switch plug-in terminal descriptions

Schematic

Remarks

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Function indicator
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Removal:

1 Using flat screwdriver pry off instrument panel cover, refer to "removal methods of instrument
panel cover"
2 Press connector with hands and force out the plug-ins(red),
3 Remove the switch mounting bracket with cross screwdriver,
4 Use a flat-blade screwdriver to pry off the mirror heat switch.
Installation
1 Install the mirror heat switch to switch bracket.
2 Install the mounting bracket to instrument hood with cross screwdriver,
3 Connect the plug-in to the mirror heat switch terminal.
4 Install the instrument hood to instrument, refer to the "instrument hood installation method"
Warm-up switch
Installation Position
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Warm-up switch plug-in terminal descriptions

Schematic
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Remarks

Background
indicator

Removal:
1 Remove the fuse box cover to check the cover plate.
2 Hold the warm-up switch card with hand, and remove the warm-up switch from the Instrument
body,
3 Press connector with hands and force out the plug-ins.
Installation
Connect the plug-in to warm-up switch terminals,
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2 Install the warm-up switch to Instrument body.

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Electric adjustment headlight switch

Installation Position
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Electric adjustment headlight switch plug-in terminal descriptions

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Schematic

Schematic
+12V power supply
Small lamp

Light adjust
Right switch
Left
generator Generator

Ground Light adjusting switch

Removal:
1 Remove the fuse box cover to check the cover plate with hand.
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2 Hold down the headlight switch card to bosses with hand, and
remove the headlight switch from the Instrument body,
3 Press connector with hands and force out the plug-ins.
Installation
1 Connect the plug-in to electric adjustment headlight switch terminal.
2 Install the electric adjustment headlight switch to the instrument body.

Combination Switch
Installation Position

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Wiper switch
Combination
light switch

Combination LIGHT SWITCH plug-in terminal descriptions

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Schematic

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Combination Wiper Switch connector terminal description

Wiper docking sheath

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Schematic

Removal:
A

1 Remove the steering wheel (refer to the "steering wheel removal method")
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2 Remove the package below the steering wheel (refer to the "package Removal Method")
3 Press connector with hands and, and firmly pull out the combination light connector and the
combination wiper connector.
4 Press and hold light switch and connection of combination wiper switch and Steering Column
with left and right hand separately at the same time, making the combined switch off steering
column, and take out the combination switch.

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Installation Boss Boss

A

1 Push the combination switch along the guide slot to Steering Column card slot. ,
2 Install the combination light switch plug-in and the combination wiper switch plug-in to
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combination switch separately.

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Project:

Electrical System Maintenance Manual

NO.

Version:
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A
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ANHUI JIANGHUAI AUTOMOBILE CO.,LTD.

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Applicable models: JAC small commercial truck products
Table of Contents
Page
Picture stories Description 1

1 Schematic 9
Distribution system 9
Start System 16
Charging System 17
Electric horn 18
Cigarette Lighter 19
Engine preheating 20
Diesel filter heating 21
Lighting 22
BCM........................................................................................................................................................................ 32
Combination of instruments 35
Window Control 38
Air-conditioning system 40
Diagnostic System 43
Power Mirrors 44
Wiper and washing 45
2.BCM.......................................................................................................................................................................... 50
2.1 Installation Location 50
2.2 Features 51
2.3 System Architecture 51
C
2.4 Description 52
2.5 Pin Assignment 57
2.6 Removing BCM 58
A

2.7 Installation BCM 60

2.8 Basic parameters 61
3 vehicle harness layout 62
3.1 cab harness 62
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3.2 engine wiring harness 63

3.3 chassis harness 64
3.4 left door harness 65
3.5 right door wiring harness 66
3.6 dome light harness 67

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3.7 Power Harness 68
3.8 Harness Layout Considerations 69
4 Battery 73
4.1 Installation position 73
4.2 Precautions 74
4.3 Maintenance 75
4.4 Fault Diagnosis and Testing 77
4.5 Removing the battery 81
4.6 Installing the battery 82
5 air-conditioned 84
5.1 Precautions 84
5.2 Diagnosis and Testing 87
5.2.1 works 87
5.2.2 Description 89 air distribution system
5.2.3 Leak Test 91
5.2.4 conditioning system performance testing 92
5.2.5 Recovery of refrigerant 96
5.2.6 Air Conditioning System Performance Table 98
5.2.7 Performance Diagnostics 99
5.3 Removing and installing air conditioning 112
5.3.1 Removing the well-being of the host unit 112
5.3.2 Removing HVAC 114
5.3.3 Removing the blower assembly 115
5.3.4 Removing the condenser fan assembly 117
5.3.5 Removing the compressor assembly 119
5.3.6 Installation of the compressor assembly 121
5.3.7 Removing the air conditioning controller assembly 123
C
5.3.8 Removing the expansion valve 125
5.4 Basic parameters of 129 air-conditioned
A
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Picture stories Description
Every system begin with its circuit. Diagram shows the path of each component of the entire work. For
example, the electrical load of the power supply
And negative grounding, wire connectors location and the composition of the associated circuit fuses,
switches and so on. To diagnose and troubleshoot, we must first fully understand the circuit.

A-3
Power Distribution System-3
Harness 线束图-配电系统
Diagram - Power Distribution System
配电系统-3

E17 车架保险盒
Frame Fuse Box

PE2
SB09 SB10 SB11 SB12 SB14
15R

120A 80A 40A 50A 40A

Power Supply Harness

电源线束
Internal Connection Point

P2
3.0Bl
Storage

3.0W
+

Battery 内连接点 Fuse Box Internal

蓄电池 Connection Point
X1 保险盒
-

内连接点

011

3.0R
30R
30B

G-1 A-5

预热继电器
Preheating Relay E44驾驶
E44 Cab Fuse Box

室保险盒
X2 3.0W 010
G04 C-1 A-4

Storage 蓄电池负极搭铁
Battery Cathode F19 F20 启动继电器
Start-Up Relay E34点火开关、
E34 Ignition Switch Main Relay

Ground 10A 10A 主继电器

3.0W

C
0.85Bl
0.5R

001
C-1
A

009 008 007

P3 P3起动机电源
Starter Power
C-1 I-1 A-5
Supply
启动加浓 E11制
Start-Up Enrichment Relay E11 Braking Switch M44驾驶
M44 Cab Fuse Box
继电器 动开关 室保险盒
J

PE3
SB01 SB03 SB08
15W

30A 30A 30A

2.0W

F18
002 10A
3.0W

D-1
2.0R

2.0Y

0.85R

P9P9发电机B+
Generator B+

003 004 005 006

H-1 N-1 N-3 N-3

柴虑加热
Diesel Filter Heating Relay 鼓风机
Fan Relay 冷凝器风Fan
Condenser 压缩机
Compressor
继电器 继电器 Relay 扇继电器 继电器
Relay

PE3
PE3
PE2 X2X2车架搭铁端子
Frame Ground Terminal
X1
X1蓄电池负极端子
Storage
Battery Cathode Frame
车
PE2
Frame P2蓄电池正极端子
P2 Storage Battery Positive Terminal
Terminal Fuse
Box
车
Fuse
Box
架
Terminal
架
Terminal

保 保
险 险
盒 盒
端 端
子 子

Schematic example

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Harness layout
Description The main wiring harness, wire connectors harness mounting location and major
routes. The layout of the circuit wiring harness repair easier.

C
A

Harness layout example

ID Name
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E1 diesel filter water level sensor

E2 Diesel filter heater
E3 Ground G
E4 Ground 8
E5 condenser fan
E6 sub woofer
E7 vacuum tube switch
E8 tweeter
E9 Ground 11
E10 pick wiper motor
E11 then brake switch
E12 connection clutch switch
E13 pressure switches
E14 connected glow plugs
E15 connection idle poppet
E16 start-stop device
E17 fuse box frame
EM1 take a cab harness
EM2 take a cab harness
EM3 take a cab harness

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This manual uses the following notation appliances, electrical symbols and abbreviated names.

Schematic representation on

Diode
Compone
nt Solid line indicates components are fully visible Diode indicates that the electrical current can be only
flowing according to the direction shown by the arrow

Permissible current of the protective loop circuit

Fuse and Fusible wire

Dash line indicates components are partially visible

ON-indicates there is electricity

Fuse
box
Brake lamp
switch (when
depressing
the brake The component name is located at the top-right
pedal, the
corner Indicates short end connected with fuse
switch
closed)
Fuse serial number

The function instruction of the component is Permissible current of the protective loop
behind the component name circuit

Constant Electricity

Engine compartment relay box

Connector

plug

Connector serial number

Fusible sheet B30A
socket
C
Terminal serial number in the connector

Indicates the connector connected with

component straight
A

Interrupter
Indicates connection with
component through wire
Interrupter can be reused, when the current is overloaded,
J

interrupter will be disconnected due to suffering from heat,

some interrupter can be automatically reset when it
becomes cooling, some will be reset by hand.

Indicates the bolt terminal of the component

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ON-indicates there is electricity
The wave line indicates that the circuit is interrupted
actually it is connecting
Fuse
box

Wire color: a red line exists on the surface of yellow

color

Circuits in the two diagrams are interlinked, the

arrow indicates the current direction, you can find
“A” in the marked position

Connection point
The arrow wire points to another circuit

Connection point serial

number
Circuit name The interrupted wire indicates that it displays
a partial of the circuit, refer to schematic
diagram of the component that displays the
circuit
The connection point is characterized by
dot, and the accurate position of these
connection points is different in terms of
different vehicle
C
A

Ground
connection
J

The different selection of the circuit is indicated by the

selective brace of the following diagram This symbol indicates that the
wire end is connected with
vehicle body metal

Manual transmission Automatic transmission

This kind of grounding identification (one point

and three-way) indicates that component case
is connected with vehicle body metal

The dash line indicates that both the red wire

SHIELD WIRE
and yellow and blue wire are on the E35
connector

Indicates that wire is wrapped by

shielding layer to prevent radio
disturbance, shielding connection is
always ground connection

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CONNECTOR
ON/OFF
This kind of switch moves together,
the dash line expresses that the
switches connected by mechanical
Indicates multiple power lines
device connection

RELAY INDICATOR
Indicates that seat belt warning
lamp is connected with other
This relay expresses that there is no indicator lamp in the combination
current in the coil, when current passes instrument
through the connector, the relay will be
switched Indicator light

Safety belt warning lamp

When the indicator lamp is

Normally open contact lighted, the symbol will display
in the coil,
Normally
contact h
closed
C
A

Wire line color description

Line color Code Line color Code
J

Black B Orange O
Blue L Pink P
Brown Br Red R
Green G Purple V
Gray Gr Yellow Y
Light Green Lg White W

Code identifying wire connectors

Wire harness connector identification code by the identification number and location identification
code consisting of wire connectors. Example:

E 10

Said wire connector main number (serial number)

Said harness position code (engine harness)

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Note
Between wire harness connectors are represented by the following code. Example:

M R 01
Said wire connector main number (serial number)

After wiring harness

Main Harness

Relay Identification
Relay identification code by the abbreviation of the relay and the main number (serial number)
components. Example:
R/L 18

Said relay primary number (serial number)

C

Said abbreviation relay

A
J

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Electrical circuit diagram symbols on
Electrical symbol Symbol description Symbol description

Generate electrical current through chemica

reaction Generate heat through electrical
current
Supplement electrical current to the circuit
directly

Electrical heating
Storage battery

Connect vehicle body ground point through harness, make the Generate heat through electrical current which also can be used
electrical current connect with the negative electrode of battery as vehicle power supply
form circuit

Harness ground point Cigarette lighter

Electricity distribution to external electrical appliances

within rated voltage

If electrical current exceeds the rated current, fusible wire will be

melted and cracked, accordingly the electrical current will be cut off.

Warning: when replacing the delay fuse, the current should be

within the rated current
Delay fuse Vehicle power supply

Make a sound through

electrical current
C
Chip fuse
Chip fuse
Delay fuse
Horn

When the current passes through lamp filament, it wil

generate light and emit heat
A

Lighting
J

Loudspeaker

Mainly used for cascading circuit, protect the electric device within
the limit of rated voltage Allow or prevent current passing through by way of opening o
closing the circuit

Resistance

Switch

Turn electrical energy into mechanical energy

Diode, only permits the current to pass through in one
direction

Motor
Diode

Absorb and release gas or liquid through motor When the current passes through, luminous diode will emit light

When diode emitting light, it will not generate heat, which is differen
from common bulb

Pum Luminous
p diode

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Electrical symbol Symbol description Electrical symbol Symbol description

Sensor Resistance value changes with temperature Used for cooling the engine

(Thermistor type) Fan

Sensor Resistance value changes with component position

Internal connection of The above diagram means that circuit C-D interna
loop circuit connection with circuit A-B
Sliding resistance type

Generates magnetic force through coil, sucks & shuts relay contactor, and makes the electrical curren
pass through

No electrical current through the coil electrical current through the coil

No electrical current electrical

current
Normally open relay

Generates magnetic force through coil, sucks & shuts relay contactor, and makes the electrical current pas
through

No electrical current through the coil electrical current through the coil
C
No electrical current
No electrical current

Normally closed relay

A
J

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1
S h i
A-1
线束图-配电系统

Power Distribution
配电系统-1 System-1 Harness Diagram - Power Distribution System

M44驾驶室保险盒
M44 Cab fuse box

Daytime Running Lamp 备 SB15

日行车继电器
Relay(Optional)
前雾灯继电器 后雾灯继电器 Spare
Front Frog Lamp Relay Rear Frog Lamp Relay
用
Fuse
30A
（选装）
保
险
电动门窗 备 备 F57 10A
Power Window Relay 大灯继电器 喇叭继电器 小灯继电器
Lamplet Relay Spare Spare
Headlamp Relay Horn Relay
继电器
Fuse
用 用
Fuse

保 保 F55 F56
险 险 10A 10A

鼓风机 F50 F51 F52 F53

Fan Relay 主继电器 闪光器 15A 10A 10A 15A
继电器 Main Relay Flashlight

F44 F45 F46 F47

10A 10A 10A 10A

D
F26 F27 F28 F29 F30 F31 F32 F33 F34 F36 F37 F38 F39 F40
10A 10A 20A 10A 10A 10A 10A 15A 10A 10A 10A 10A 15A 15A
C
A
J

D 二极管
F26 启动控制 F40 喇叭
F27 预热控制 F44 大灯调节、车身控制器
F28 刮水、洗涤 F45 熄火电磁阀
F29 左前照灯 F46 组合仪表
F30 右前照灯 F47 转向灯、倒车灯
F31 柴虑加热、主继电器控制 F50 自动门锁
F32 BCM、空调模式、大灯、鼓风机控制 F51 门灯、顶灯
F33 点烟器 F52 后视镜除霜
F34 收放机、电动后视镜 F53 危险报警灯
F36 压缩机、冷凝风扇控制 F55 左位置灯、牌照灯
F37 日间行车灯（选装） F56 右位置灯
F38 后雾灯 F57 组合仪表、收放机、空调控制器、BCM常电
F39 前雾灯 SB15 电动车窗

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A-2 线束图-配电系统
Harness Diagram - Power Distribution
Power Distribution
配电系统-2System System

E17车架保险盒
E17 Frame fuse box

ALT B+ 5 1
SB01 30A SB11 40A
EP
SB09 120A SB12 50A
8 4
F18 10A
SB03 30A
F19 15A
SB10 80A 22 12
SB14 40A F20 10A
11 1
010
R3.0 EF

Start-Up Relay
起动继电器 柴虑加热
Diesel Filter
冷凝器
Condenser Relay
预热继电器
Preheating Relay Heating Relay
继电器 继电器
C
SB08 30A

1GL
启动加浓 压缩机
A

Start-Up Enrichment
Relay Compressor 保险夹
Safety Clip
继电器 继电器
Relay
2GL
J

SB01 Diesel
柴虑加热 Filter Heating
鼓风机
SB03 Fan
冷凝器
SB08 Condenser
灯光
SB11 Lamplight
常电 Electricity
SB12 Constant
SB14 Ignition
点火开关、起动机Switch、Starter

压缩机
F18 Compressor
启动加浓
F19 Start-Up Enrichment

制动灯
F20 Braking Light

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A-3 Harness线束图-配电系统
Diagram - Power Distribution
Power Distribution System-3 S t
配电系统-3

E17 车架保险盒
Frame fuse box

PE2
SB09 SB10 SB11 SB12 SB14
15R

120A 80A 40A 50A 40A

Power Supply Harness Internal
Connection Point

P2 电源线束
Bat

3.0Bl

3.0W
+

内连接点
ter
蓄电池 Fuse Box
Connection Point
Internal

X1
y 保险盒
-

内连接点

011

3.0R
30R
30B

G-1 A-5
E44 Cab Fuse Box
Preheating Relay
预热继电器 E44驾驶
室保险盒
X2 3.0W 010
G04 C-1 A-4
E34 Ignition Switch Main Relay
Storage蓄电池负极搭铁
Battery Cathode F19 F20 启动继电器 E34点火开关、
Start-Up Relay

Ground
10A 10A 3.0W 主继电器
0.85Bl
0.5R

001
C-1
C
009 008 007
P3 Starter Power
P3起动机电源
Supply C-1 I-1 A-5
启动加浓
Start-Up Enrichment Relay E11 Braking Switch
E11制 M44驾驶
M44 Cab Fuse Box

继电器 动开关 室保险盒

A

PE3
SB01 SB03 SB08
15W

30A 30A 30A

J

2.0W

F18
002 10A
3.0W

D-1
2.0R

2.0Y

0.85R

P9 Generator B+
P9发电机B+

003 004 005 006

H-1 N-1 N-3 N-3
Condenser Fan Compressor
Diesel Filter Heating Relay
柴虑加热 鼓风机
Fan Relay
Relay 冷凝器风 压缩机
Relay
继电器 继电器 扇继电器 继电器

PE3

X1 Storage
Battery Cathode PE3
Frame
PE2 X2
PE2 Frame Ground Terminal
X2车架搭铁端子
P2 Storage Battery Positive Terminal
X1蓄电池负极端子
Terminal
Fuse
车
Box
Frame
P2蓄电池正极端子
Terminal 车
Fuse
Box
Terminal
架 架
保 保
险 险
盒 盒
端 端
子 子

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A-4 线束图-配电系统
Harness Diagram - Power Distribution System
Power Distribution System-4
配电系统-4
SB14 40A
EM3 3.0R
A-3 010
3

3.0R 驾驶室线束
Cab Harness Internal Connection Point

内连接点
0.5Bl

3.0Bl
F31
3.0R

3.0R
10A
M34
钥匙开关
端子 5 6 4 3 1 2
Terminal
Key Switch

0.5Bl
档位 B1 ACC IG1 ST B2 IG2 1 2

3.0R
点
Ignition
Gear

火
Switch
拔出钥匙
LOCK Plug out Key

开 插入钥匙
Plug in Key

关 F32 86 30 主
ACC Main Relay
10A 继

0.5Bl
ON
电
START
器
M34 M33 85 87
0.5RW
0.5Gr
3.0Br
3.0W
3.0Y

0.5B

3.0G
F26 045 6 M3
10A G16
B-1
M9转
C
M9 Adapter 1
接器1

024 025 026 027

A

F33 F34 C-1 K-3 K-3 H-1

15A 10A
E12离合
E12 Clutch Switch
M29 BCM2 M29 BCM2 柴虑加热 Diesel Filter Heating

器开关 继电器 Relay

驾驶室线束
Cab Harness Internal Connection Point
J

内连接点

F44 F45 F46 F47 F27 F28 F29 F30

10A 10A 10A 10A 10A 20A 10A 10A
0.85Gr

0.5BlW
1.25Gr

0.5Gr

0.5RB

0.5RW

0.85W

0.85R
1.25W
0.5W

0.5R

012 013 014 015 016 017 018 019 020 021 022
F-1 R-1 P-1 J-9 C-1 L-1 J-2 G-1 Q-1 J-8 J-8
M28
M28 Cigarette Lighter M23 D8电
D8 Power M37
M37 E16熄
E16 Flameout M35 M6危
M6 Hazard 预 刮 M42 M19
M23 Radio M35 Preheating M42Left M19Right
点 收 动后
Rearview
Mirror
大灯
Headlamp
Control Switch 火电
Solenoid Valve
组
Combination Warning
险报 热
Relay
Wiper
水、 左
Headlamp 右
Headlamp
Washer
烟 放 视镜 调节 磁阀 合
Instrument Switch
警开 继 洗 前 前
器 机 开关 仪 关 电 涤 照 照
表 器 灯 灯

M34点火开-1关接口 M33
M33点火开-2关接口
Ignition Switch Interface-2
M34 Ignition Switch Interface-1 EM3发动机线束与 EM3 Engine Harness and Cab Harness Interface
M3搭铁点16接口
M3 Ground Point 16 Interface
驾驶室线束接口
M44驾驶室保险盒
M44 Cab Fuse Box Fuse Cutout Refer to
A-1 熔断器见A-1 3 2 1 1 2
1 2 3 4
1 2 3 4
6 5 4 3 4 5 6 7 8

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A-5 Harness Diagram - Power Distribution
线束图-配电系统
Power Distribution System-5
S t
配电系统-5

SB11 40A SB12 50A

A-3 A-3

011 007

1 EM3 2 EM3
3.0Bl

3.0W
M44 Cab Fuse Box
M44驾驶室保险盒

Cab Harness Internal Connection

驾驶室线束
Point
Cab Harness Internal Connection
内连接点
驾驶室线束
Point
内连接点
3.0Bl

3.0Bl

3.0W

3.0W

SB15
30A
C

F37 F38 F39 F40 F57 F50 F51 F52 F53

A

10A 10A 15A 15A 10A 15A 10A 10A 15A

J
0.5RBl

0.85Br
1.25Y

0.85R

0.85R

0.5RW

0.5Bl

0.85W
1.25W
3.0W

0.5R

031 032 033 034 035 023 036 037 038 039 040 130
M-2 J-4 J-3 J-3 E-1 J-5 B-1 K-2 B-1 K-2 J-2 K-2
Rear Frog
Power Daytime Front
电动
Window 日间
Running 后雾
Lamp
Relay
前雾
Frog 喇
Horn Relay Position
位置 LampM9 Adapter 1
M9 Automatic
自
Door Lock
M9 Adapter 1 M2
M9 M2后 M6危
Rearview MirrorM6 Hazard
M2 Automatic Door Lock Relay
M2自
Relay Anti-Frog Relay Warning Switch
车窗
Relay Lamp Relay
行车 灯继 灯继
Lamp 叭 灯继 转 动 转 视镜 险报 动门
Relay
继电 灯继 电器 电器 继 电器 接 门 接 除霜 警开 锁继
器 电器 电 器1 锁 器1 继电 电器
关
器 器

EM3 Engine Harness and Cab Harness

EM3发动机线束与驾驶室线束接口
Interface
M44 Cab Fuse Box Refer to A-1
M44驾驶室保险盒见A-1
1 2

3 4

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B-1
Harness Diagram
线束图-配电系统- Power Distribution
Adapter-1
转接器-1 S t

M7 Interior and Exterior

M7内外循
Circulation Switch
M36预热
M36 Preheating Switch
M14空调模M5后视镜
M14 Air Conditioner Mode Controller M5 Rearview Mirror Heating Switch

环开关 开关 式控制器 加热开关

N-2 G-1 N-2 P-1

060 061 062 063

M35
M35 Right Rear Position M19
M19 Right Front

D7主
D7 Main Power Window Switch M37 M37 Headlamp
Control Switch
M6 Switch
组
Combination
M27 M23
M23 Radio M4
M4 A/C Switch 右
Lamp License Plate
Lamp 右
Position Lamp

合 A/C
M6 Hazard Warning M27 Cigarette

电动 大灯 危险
Switch
点
Lighter 收 后牌 前
车窗 调节 报警 仪 烟 音 开 位照 位
开关 开关 开关 表 器 机 关 灯灯 灯 F56
10A
M-1 J-9 J-2 L-3 F-1 R-1 N-1 J-5 J-5 J-5
051 052 053 054 055 056 057 058 059
103

0.85GR
0.3GR

0.3GR
0.3GR

0.3GR

0.3GR

0.3GR

0.3GR

0.3GR

0.3GR

0.3GR

0.3GR
0.5GR

0.5GR
M9

1 2 3 4 5 6 7 8 9 10
C
M9转接器1
M9 Adapter 1

11 12 13 14 15 16 17 18 19 20
A

M9
0.5RW

0.5RW

0.5RW

0.5RW

0.85R

0.85R
0.5R

0.5R

0.5R
0.5RW

0.5RW

038 036
042 043 044 045 046 047 048 049
A-5 J-6 J-6 J-7 A-4 K-1 L-1 N-2 R-1 A-5
F51 F57
10A D10
D10 Left Door Lamp D2
D2 Right Door T1 M33
M33 Ignition Switch M8 BCM1 M35
M35
Combination M14
M14 Air
M23
M23 Radio
10A
T1Front Dome Lamp
左 Lamp
右 前 点 组
Instrument
空调
Conditioner
Mode
收
门 门 顶 火 合 Controller
模式 音
灯 灯 灯 开 仪 控制 机
关 表 器

041

O-1
M43诊断接口
M43 Diagnosis Interface

M9M9转接器1接口
Adapter 1 Interface

1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20

打印人：20122642 部门：客户服务部
B-2 线束图-配电系统
Harness Diagram - Power Distribution System
Adapter-2
转接器-2

M35
M35 Combination Instrument
M2 Center
Relay
M2中
Control
Lamp
组
控车 合
灯继 仪
电器 表
K-2
L-3

090 091

M42 Left
High
M31
M31
Lamplight
Beam M35
Combination
M6 Hazard
F4 Left Rear
F4
Steering Lamp M42
M42 Left Front D2
D2 Left Side
Steering
Switch
灯 M19 Right
High
M35
Instrument
Warning
Switch 左
Steering Lamp
左 Lamp 左 M31
M31 Lamplight Switch

光 M42 M19
Beam 组 M6 后 前 侧 灯
开 左 右 合 危险 转 转 转 光
关 远 远 仪 报警 向 向 向 开
光 光 表 开关 灯 灯 灯 关
J-8 J-8 J-8 L-2 J-2 J-2 J-2 J-2 J-2
081 086 087 088
082 083 084 085 089
0.85GW

0.85GW
0.85Y

0.85Y

0.5GW

0.5GW

0.5GW

0.5GW

0.5GW
1.25Y

0.5Y

M11

1 2 3 4 5 6 7 8 9 10
C
M11 Adapter-2
M11转接器2

11 12 13 14 15 16 17 18 19 20
A

M11
0.85Or

0.85Or
1.25Or

0.85GBl

0.85GBl
0.5Or

0.5GBl

0.5GBl

0.5GBl

0.5GBl

0.5GBl
J

073 074 075 076 080

072 077 078 079
J-8 J-8 J-9 J-2 J-2 J-2 J-2 J-2
J-8
M42
M42 Left Low Beam
M19
M19 Right Low Beam
M37M37 M6
M6 Hazard Warning Switch M31
M31 Lamplight Switch

M31
Headlamp
大灯 F4
F4Right
M19 D5
D5 Right Side
灯
M31 Lamplight Switch
左 右 Control Switch 危险 Rear
M19 Right
Front Steering
Steering Lamp
右
灯 近 近 调节 报警 右
Steering Lamp右 光
光
Lamp
后 前 侧 开
光 光 开关 开关 转
开 转 转 关
关 向 向 向
灯 灯 灯

070
071
K-2
L-3
M2 Center ControlM2中
Lamp Relay
M35M35 Combination
控车 Instrument
灯继 组
电器 合
仪
表

M11 Adapter 2 Interface

M11转接器2接口

1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20

打印人：20122642 部门：客户服务部
C-1
Harness 线束图-启动系统
Diagram - Starting System
启动系统-1
Starting System-1

F26
10A
A-4 F19 F45
10A 10A
SB14 FrameSB14车架
Fuse Box D-1
保险盒 A-3
024
A-3 0.5G
009 101

7 EM1
0.5G

0.5R
0.5W
Clutch
合
Switch
器 启
Start-Up
开 86 30 动
Enrichment
关 加
Relay
0.5W

浓
继
电
85 87 器
P2蓄电池+
0.5W

0.5Bl

0.5Gr
P2 Storage Battery +

A-3
30 86 起
Start-Up Relay
001 动
继

0.5RW
IG1
4 PE IG1
Power
电 电
器 E16
C
87 1
85
起
Start-Up
动
Enrichment
2.0R

Pump
加
浓
A

2 E16
泵
1 PE 熄
30R

Flameout
P11 Solenoid
火
Valve
2.0R

起动 电
J

Start-Up Enrichment Sensor

加浓 磁
传感 阀
P3 P7 器

起 M
Starter
动 E3
机 G09

E16启停装置接口
E16 Start-Stop Device Interface P7起动机电磁开关接口 P11启动加浓传感器接口
P7 Starter Solenoid Switch Interface P11 Start-Up Enrichment Sensor Interface

1 2 1 1

PE电源线束与发动机线束接口
PE Power Supply Harness and Engine Harness Interface P3电源线束起动机端子
P3 Power Supply Harness Starter Terminal
EM1发动机线束与驾驶室线束接口
EM1 Engine Harness and Cab Harness Interface

1 2 3 4 5 6 7 8 9 10 11 4 3 2 1
12 13 14 15 16 17 18 19 20 21 22 8 7 6 5

打印人：20122642 部门：客户服务部
A-2 线束图-配电系统
Harness Diagram - Power Distribution
Power Distribution
配电系统-2System System

E17车架保险盒
E17 Frame fuse box

ALT B+ 5 1
SB01 30A SB11 40A
EP
SB09 120A SB12 50A
8 4
F18 10A
SB03 30A
F19 15A
SB10 80A 22 12
SB14 40A F20 10A
11 1
010
R3.0 EF

Start-Up Relay
起动继电器 柴虑加热
Diesel Filter
冷凝器
Condenser Relay
预热继电器
Preheating Relay Heating Relay
继电器 继电器
C
SB08 30A

1GL
启动加浓 压缩机
A

Start-Up Enrichment
Relay Compressor 保险夹
Safety Clip
继电器 继电器
Relay
2GL
J

SB01 Diesel
柴虑加热 Filter Heating
鼓风机
SB03 Fan
冷凝器
SB08 Condenser
灯光
SB11 Lamplight
常电 Electricity
SB12 Constant
SB14 Ignition
点火开关、起动机Switch、Starter

压缩机
F18 Compressor
启动加浓
F19 Start-Up Enrichment

制动灯
F20 Braking Light

打印人：20122642 部门：客户服务部
A-3 Harness线束图-配电系统
Diagram - Power Distribution
Power Distribution System-3 S t
配电系统-3

E17 车架保险盒
Frame fuse box

PE2
SB09 SB10 SB11 SB12 SB14
15R

120A 80A 40A 50A 40A

Power Supply Harness Internal
Connection Point

P2 电源线束
Bat

3.0Bl

3.0W
+

内连接点
ter
蓄电池 Fuse Box
Connection Point
Internal

X1
y 保险盒
-

内连接点

011

3.0R
30R
30B

G-1 A-5
E44 Cab Fuse Box
Preheating Relay
预热继电器 E44驾驶
室保险盒
X2 3.0W 010
G04 C-1 A-4
E34 Ignition Switch Main Relay
Storage蓄电池负极搭铁
Battery Cathode F19 F20 启动继电器 E34点火开关、
Start-Up Relay

Ground
10A 10A 3.0W 主继电器
0.85Bl
0.5R

001
C-1
C
009 008 007
P3 Starter Power
P3起动机电源
Supply C-1 I-1 A-5
启动加浓
Start-Up Enrichment Relay E11 Braking Switch
E11制 M44驾驶
M44 Cab Fuse Box

继电器 动开关 室保险盒

A

PE3
SB01 SB03 SB08
15W

30A 30A 30A

J

2.0W

F18
002 10A
3.0W

D-1
2.0R

2.0Y

0.85R

P9 Generator B+
P9发电机B+

003 004 005 006

H-1 N-1 N-3 N-3
Condenser Fan Compressor
Diesel Filter Heating Relay
柴虑加热 鼓风机
Fan Relay
Relay 冷凝器风 压缩机
Relay
继电器 继电器 扇继电器 继电器

PE3

X1 Storage
Battery Cathode PE3
Frame
PE2 X2
PE2 Frame Ground Terminal
X2车架搭铁端子
P2 Storage Battery Positive Terminal
X1蓄电池负极端子
Terminal
Fuse
车
Box
Frame
P2蓄电池正极端子
Terminal 车
Fuse
Box
Terminal
架 架
保 保
险 险
盒 盒
端 端
子 子

打印人：20122642 部门：客户服务部
A-4 线束图-配电系统
Harness Diagram - Power Distribution System
Power Distribution System-4
配电系统-4
SB14 40A
EM3 3.0R
A-3 010
3

3.0R 驾驶室线束
Cab Harness Internal Connection Point

内连接点
0.5Bl

3.0Bl
F31
3.0R

3.0R
10A
M34
钥匙开关
端子 5 6 4 3 1 2
Terminal
Key Switch

0.5Bl
档位 B1 ACC IG1 ST B2 IG2 1 2

3.0R
点
Ignition
Gear

火
Switch
拔出钥匙
LOCK Plug out Key

开 插入钥匙
Plug in Key

关 F32 86 30 主
ACC Main Relay
10A 继

0.5Bl
ON
电
START
器
M34 M33 85 87
0.5RW
0.5Gr
3.0Br
3.0W
3.0Y

0.5B

3.0G
F26 045 6 M3
10A G16
B-1
M9转
C
M9 Adapter 1
接器1

024 025 026 027

A

F33 F34 C-1 K-3 K-3 H-1

15A 10A
E12离合
E12 Clutch Switch
M29 BCM2 M29 BCM2 柴虑加热 Diesel Filter Heating

器开关 继电器 Relay

驾驶室线束
Cab Harness Internal Connection Point
J

内连接点

F44 F45 F46 F47 F27 F28 F29 F30

10A 10A 10A 10A 10A 20A 10A 10A
0.85Gr

0.5BlW
1.25Gr

0.5Gr

0.5RB

0.5RW

0.85W

0.85R
1.25W
0.5W

0.5R

012 013 014 015 016 017 018 019 020 021 022
F-1 R-1 P-1 J-9 C-1 L-1 J-2 G-1 Q-1 J-8 J-8
M28
M28 Cigarette Lighter M23 D8电
D8 Power M37
M37 E16熄
E16 Flameout M35 M6危
M6 Hazard 预 刮 M42 M19
M23 Radio M35 Preheating M42Left M19Right
点 收 动后
Rearview
Mirror
大灯
Headlamp
Control Switch 火电
Solenoid Valve
组
Combination Warning
险报 热
Relay
Wiper
水、
Washer
左
Headlamp 右
Headlamp
烟 放 视镜 调节 磁阀 合
Instrument Switch
警开 继 洗 前 前
器 机 开关 仪 关 电 涤 照 照
表 器 灯 灯

M34点火开-1关接口 M33
M33点火开-2关接口
Ignition Switch Interface-2
M34 Ignition Switch Interface-1 EM3发动机线束与 EM3 Engine Harness and Cab Harness Interface
M3搭铁点16接口
M3 Ground Point 16 Interface
驾驶室线束接口
M44驾驶室保险盒
M44 Cab Fuse Box Fuse Cutout Refer to
A-1 熔断器见A-1 3 2 1 1 2
1 2 3 4
1 2 3 4
6 5 4 3 4 5 6 7 8

打印人：20122642 部门：客户服务部
A-5 Harness Diagram - Power Distribution
线束图-配电系统
Power Distribution System-5
S t
配电系统-5

SB11 40A SB12 50A

A-3 A-3

011 007

1 EM3 2 EM3
3.0Bl

3.0W
M44 Cab Fuse Box
M44驾驶室保险盒

Cab Harness Internal Connection

驾驶室线束
Point
Cab Harness Internal Connection
内连接点
驾驶室线束
Point
内连接点
3.0Bl

3.0Bl

3.0W

3.0W

SB15
30A
C

F37 F38 F39 F40 F57 F50 F51 F52 F53

A

10A 10A 15A 15A 10A 15A 10A 10A 15A

J
0.5RBl

0.85Br
1.25Y

0.85R

0.85R

0.5RW

0.5Bl

0.85W
1.25W
3.0W

0.5R

031 032 033 034 035 023 036 037 038 039 040 130
M-2 J-4 J-3 J-3 E-1 J-5 B-1 K-2 B-1 K-2 J-2 K-2
Rear Frog
Power Daytime Front
电动
Window 日间
Running 后雾
Lamp
Relay
前雾
Frog 喇
Horn Relay Position
位置 LampM9 Adapter 1
M9 Automatic
自
Door Lock
M9 Adapter 1 M2
M9 M2后 M6危
Rearview MirrorM6 Hazard
M2 Automatic Door Lock Relay
M2自
Relay Anti-Frog Relay Warning Switch
车窗
Relay Lamp Relay
行车 灯继 灯继
Lamp 叭 灯继 转 动 转 视镜 险报 动门
Relay
继电 灯继 电器 电器 继 电器 接 门 接 除霜 警开 锁继
器 电器 电 器1 锁 器1 继电 电器
关
器 器

EM3 Engine Harness and Cab Harness

EM3发动机线束与驾驶室线束接口
Interface
M44 Cab Fuse Box Refer to A-1
M44驾驶室保险盒见A-1
1 2

3 4

打印人：20122642 部门：客户服务部
B-1
Harness Diagram
线束图-配电系统- Power Distribution
Adapter-1
转接器-1 S t

M7 Interior and Exterior

M7内外循
Circulation Switch
M36预热
M36 Preheating Switch
M14空调模M5后视镜
M14 Air Conditioner Mode Controller M5 Rearview Mirror Heating Switch

环开关 开关 式控制器 加热开关

N-2 G-1 N-2 P-1

060 061 062 063

M35
M35 Right Rear Position M19
M19 Right Front

D7主
D7 Main Power Window Switch M37 M37 Headlamp
Control Switch
M6 Switch
组
Combination
M27 M23
M23 Radio M4
M4 A/C Switch 右
Lamp License Plate
Lamp 右
Position Lamp

合 A/C
M6 Hazard Warning M27 Cigarette

电动 大灯 危险
Switch
点
Lighter 收 后牌 前
车窗 调节 报警 仪 烟 音 开 位照 位
开关 开关 开关 表 器 机 关 灯灯 灯 F56
10A
M-1 J-9 J-2 L-3 F-1 R-1 N-1 J-5 J-5 J-5
051 052 053 054 055 056 057 058 059
103

0.85GR
0.3GR

0.3GR
0.3GR

0.3GR

0.3GR

0.3GR

0.3GR

0.3GR

0.3GR

0.3GR

0.3GR
0.5GR

0.5GR
M9

1 2 3 4 5 6 7 8 9 10
C
M9转接器1
M9 Adapter 1

11 12 13 14 15 16 17 18 19 20
A

M9
0.5RW

0.5RW

0.5RW

0.5RW

0.85R

0.85R
0.5R

0.5R

0.5R
0.5RW

0.5RW

038 036
042 043 044 045 046 047 048 049
A-5 J-6 J-6 J-7 A-4 K-1 L-1 N-2 R-1 A-5
F51 F57
10A D10
D10 Left Door Lamp D2
D2 Right Door T1 M33
M33 Ignition Switch M8 BCM1 M35
M35
Combination M14
M14 Air
M23
M23 Radio
10A
T1Front Dome Lamp
左 Lamp
右 前 点 组
Instrument
空调
Conditioner
Mode
收
门 门 顶 火 合 Controller
模式 音
灯 灯 灯 开 仪 控制 机
关 表 器

041

O-1
M43诊断接口
M43 Diagnosis Interface

M9M9转接器1接口
Adapter 1 Interface

1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20

打印人：20122642 部门：客户服务部
B-2 线束图-配电系统
Harness Diagram - Power Distribution System
Adapter-2
转接器-2

M35
M35 Combination Instrument
M2 Center
Relay
M2中
Control
Lamp
组
控车 合
灯继 仪
电器 表
K-2
L-3

090 091

M42 Left
High
M31
M31
Lamplight
Beam M35
Combination
M6 Hazard
F4 Left Rear
F4
Steering Lamp M42
M42 Left Front D2
D2 Left Side
Steering
Switch
灯 M19 Right
High
M35
Instrument
Warning
Switch 左
Steering Lamp
左 Lamp 左 M31
M31 Lamplight Switch

光 M42 M19
Beam 组 M6 后 前 侧 灯
开 左 右 合 危险 转 转 转 光
关 远 远 仪 报警 向 向 向 开
光 光 表 开关 灯 灯 灯 关
J-8 J-8 J-8 L-2 J-2 J-2 J-2 J-2 J-2
081 086 087 088
082 083 084 085 089
0.85GW

0.85GW
0.85Y

0.85Y

0.5GW

0.5GW

0.5GW

0.5GW

0.5GW
1.25Y

0.5Y

M11

1 2 3 4 5 6 7 8 9 10
C
M11 Adapter-2
M11转接器2

11 12 13 14 15 16 17 18 19 20
A

M11
0.85Or

0.85Or
1.25Or

0.85GBl

0.85GBl
0.5Or

0.5GBl

0.5GBl

0.5GBl

0.5GBl

0.5GBl
J

073 074 075 076 080

072 077 078 079
J-8 J-8 J-9 J-2 J-2 J-2 J-2 J-2
J-8
M42
M42 Left Low Beam
M19
M19 Right Low Beam
M37M37 M6
M6 Hazard Warning Switch M31
M31 Lamplight Switch

M31
Headlamp
大灯 F4
F4Right
M19 D5
D5 Right Side
灯
M31 Lamplight Switch
左 右 Control Switch 危险 Rear
M19 Right
Front Steering
Steering Lamp
右
灯 近 近 调节 报警 右
Steering Lamp右 光
光
Lamp
后 前 侧 开
光 光 开关 开关 转
开 转 转 关
关 向 向 向
灯 灯 灯

070
071
K-2
L-3
M2 Center ControlM2中
Lamp Relay
M35M35 Combination
控车 Instrument
灯继 组
电器 合
仪
表

M11 Adapter 2 Interface

M11转接器2接口

1 2 3 4 5 6 7 8 9 10
11 12 13 14 15 16 17 18 19 20

打印人：20122642 部门：客户服务部
C-1
Harness 线束图-启动系统
Diagram - Starting System
启动系统-1
Starting System-1

F26
10A
A-4 F19 F45
10A 10A
SB14 FrameSB14车架
Fuse Box D-1
保险盒 A-3
024
A-3 0.5G
009 101

7 EM1
0.5G

0.5R
0.5W
Clutch
合
Switch
器 启
Start-Up
开 86 30 动
Enrichment
关 加
Relay
0.5W

浓
继
电
85 87 器
P2蓄电池+
0.5W

0.5Bl

0.5Gr
P2 Storage Battery +

A-3
30 86 起
Start-Up Relay
001 动
继

0.5RW
IG1
4 PE IG1
Power
电 电
器 E16
C
87 1
85
起
Start-Up
动
Enrichment
2.0R

Pump
加
浓
A

2 E16
泵
1 PE 熄
30R

Flameout
P11 Solenoid
火
Valve
2.0R

起动 电
J

Start-Up Enrichment Sensor

加浓 磁
传感 阀
P3 P7 器

起 M
Starter
动 E3
机 G09

E16启停装置接口
E16 Start-Stop Device Interface P7起动机电磁开关接口 P11启动加浓传感器接口
P7 Starter Solenoid Switch Interface P11 Start-Up Enrichment Sensor Interface

1 2 1 1

PE电源线束与发动机线束接口
PE Power Supply Harness and Engine Harness Interface P3电源线束起动机端子
P3 Power Supply Harness Starter Terminal
EM1发动机线束与驾驶室线束接口
EM1 Engine Harness and Cab Harness Interface

1 2 3 4 5 6 7 8 9 10 11 4 3 2 1
12 13 14 15 16 17 18 19 20 21 22 8 7 6 5

打印人：20122642 部门：客户服务部
J-3
Harness线束图-灯光照明
Diagram-Lamplight
Lamplight Illume-Front/Rear Frog Lamp
灯光照明-前、后雾灯 Illume

F55
10A
F39 J-5 F38
15A 10A
A-5 029 A-5

034

0.5GY
033
0.5GY

0.5GY
1.25Y

0.5R
Front
Frog 前 30 86 Rear 后
30 86
Lamp Frog
Relay雾 Lamp雾
灯 Relay
灯
继 继
电 87 85 电 87 85
器
1.25GOr

器
0.5Bl

0.5Bl

0.5YB
D1
C 0.5Bl

0.5Bl

驾驶室线束
Cab Harness Internal
Connection Point
内连接点
0.5Or

Cab Harness Internal Cab Harness Internal

Connection Point
驾驶室线束 Connection
驾驶室线束 Point
内连接点 内连接点 14 ME2
0.5Bl
0.85GOr

0.85GOr

A
0.5Or

0.5Or
0.5GOr

20 EF
Left Right
0.5Bl

Front Front 030

J

Frog Frog
K-1
左 M41 右 2 M17
Lamp Lamp
前2 前
117 雾 雾 064 105 118 4 F4 M8 BCM1
L-3 灯1 灯1 K-3 J-8 L-3 后
Rear
Frog
M31Combinatio 雾
Lamp
M35仪表 M29 BCM2 M31组合
Switch 2 M35仪表
0.85B

0.85B

M35 M35
Instrument
n
Instrument 6 灯
开关2
0.85B

底盘线束
Chassis Harness Internal Connection
Point
内连接点
2 M3 4 M16
1.25B

G16 G12
F5
G01

F4 Left Rear Combination Lamp M41/M17 Left Right Front EM2 Engine Harness and Cab Harness Interface EF Engine Harness and
F4左后组合灯接口
Interface M41/M17左右
Combination lampF6 Ground Terminal
M3/M16 Ground Point 16/12 Interface EM2发动机线束与驾驶室线束接口
Chassis Harness Interface

前组合灯接口 F5搭铁端子 M3/M16搭铁点16/12接口 EF发动机线束与底盘线束接口

interface

3 2 1 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11
2 1
6 5 4 5 6 7 8 12 13 14 15 16 17 18 19 20 21 22

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J-4 Harness Diagram-Lamplight Illume
线束图-灯光照明

Lamplight Illume-Daytime Running Lamp

灯光照明-日间行车灯

F37
10A
A-5

032

0.5RBl
0.5RBl

86 0.5RBl 30 日间
Daytime Running
行车Relay
Lamp

灯继
85 87 电器
0.5RY

0.5GW
C
0.5BlW

0.5BlW

0.5BlW
A

左
J

Left
2 M40
Right
Daytime
右 2 M18
065 日
Daytime Running
日 119
Running Lamp

K-1 Lamp 间 间 L-3

行 1 行 1
M8 BCM1 车 车 M35仪表
M35 Instrument
灯 灯
0.5B

0.5B

3 M3 2 M16
G16 G12

M40/M18左右日间行车灯接口
M40/M18 Left Right Daytime Running Lamp Interface
M3/M16搭铁点16/12接口
M3/M16 Ground Point 16/12 Interface

1 2 3 4
2 1
5 6 7 8

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J-5 Harness Diagram – Lamplight Illume
线束图-灯光照明
Lamplight Illume-Position Lamp 、 License Plate
Lamp 灯光照明-位置灯、牌照灯

SB11 M9 Adapter1
40A M9转接器1
A-5 B-1

023 059

0.5GR
2.0Bl
3.0Bl
Right
Front
3
Position
M19
Lamp右
前
30 86 小
Lamplet
Relay 位
灯
灯 7
继
电

0.5B
87 85 器 Cab Harness
M9 Adapter1 Internal Connection
0.5YR

M9转接器1 Point
3.0R

驾驶室线束
B-1 内连接点

0.85B
058
0.5GY

F55
10A
F56 2 M16
2 0.5GY 10A 0.5GR
G12
0.5GY

0.85GR

ME2
0.5GY

C
12 ME2
0.5GY

14 EF
0.5GR

029 103 066

A
0.5GY

J-3 B-1 K-1

Frog Lamp Relay
雾灯继电器 M9转接器1
M9 Adapter1
M8 BCM1 14 EF
0.5GR 0.5GR
J

Left
Left Rear F4
Position 1 Front3 M42
Position
Lamp 左 左
Lamp
0.5GR

0.5GR

后 前
位 位
灯6 灯 5 2 F2 2 F3 1 F1
Right
右
License Left 左 Right右
Plate License Rear
0.5B

牌 Plate牌 后
0.85B

Position
Lamp
照 照 位
Chassis
底盘线束 Harness
驾驶室线束
Cab Harness Internal Connection Point 灯 1 灯 1 灯 6
Internal Connection
0.85B
0.85B 0.5B
0.5B

内连接点
Point 内连接点
1.25B

0.85B

F5 2 M3
G01 G16 F5
G01

F3/F2 Left Right License Plate Lamp Interface EM2 Engine Harness and Cab Harness Interface EF Engine Harness and Chassis M3/M16 Ground Point 16/12 Interface
M42/M19 Left Right Front Combination Lamp Interface
F3/F2左右牌照灯接口M42/M19左右前组合灯接口 EM2发动机线束与驾驶室线束接口
Harness Interface
M3/M16搭铁点16/12接口
EF发动机线束与底盘线束接口
10 9 8 7 6 1 2 3 4
1 2 1 2 3 4 5 6 7 8 9 10 11
5 4 3 2 1 5 6 7 8
12 13 14 15 16 17 18 19 20 21 22

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J-6 线束图-灯光照明
Harness Diagram – Lamplight Illume
Lamplight Illume-Door Lamp
灯光照明-门灯

M9转接器1
M9 Adapter1 M9转接器1
M9 Adapter1

B-1 B-1

042 043

0.5RW

0.5RW
MD1 11 MD2 11
0.5RW

0.5RW
D2
左 1 D10 右 1
M29 BCM2 Left Door Lamp Right Door Lamp M8 BCM1
门 门
K-3 灯 2 灯 2 K-1
067 068
0.5BrB

0.5Br

19 MD1 MD2 19
C
0.5BrB

0.5BrB

0.5Br

0.5Br

驾驶室线束
A

Cab Harness Internal Connection

Point内连接点
0.5BrB

0.5Br
J

左 1 M1 右
M20 1 Right
Left
Door车 0.3G 0.3G 车
Door
Signal Signal
门
Switch 2 2 门
Switch
信 信
0.3G

号 号
开 开
关 关

069

L-2
M35仪表
M35 Instrument

MD1左、MD2右车门线
MD1 Left 、 MD2 Right Door Harness and Cab Harness
束与驾驶室线束接口
Interface
D10/D2左右门灯接口
D10/D2 Left Right Door Lamp Interface M1/M20左右门信号开关接口
M1/M20 Left Right Door Signal Switch Interface

1 2 3 4 5 6 7
8 9
1 2
10 11 12 13 14 15 16
1 2
17 18
1920 21 22 23 24 25

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J-7 Harness Diagram –Lamplight
线束图-灯光照明
Illume
Lamplight Illume-Dome Lamp
灯光照明-顶灯

M9 Adapter 1
M9转接器1
B-1

044

0.5RW
6 MT
0.5RW

Front Dome Lamp

前顶灯
T1
2

OFF
ON OFF ON
DOOR
C
1 4
T1
0.5B

A 0.5G

1 5 MT
0.5G
0.5B

3 M16
G12

125
K-1

M8 BCM1

MT Cab Harness and Dome Harness Interface

MT驾驶室线束与顶棚线束接口 T1 Front Dome Lamp Interface
T1前顶灯接口

6 5 4 3 2 1
4 3 2 1

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J-8 Harness
线束图-灯光照明 Diagram-Lamplight
Lamplight Illume-Left/Right Dipped Headlight，Left/Right High-Beam Headlight
Illume
灯光照明-左右近、远光灯

F29
10A
F32 A-4
10A
K-2 021
M29 BCM2M29 BCM2 M8 BCM1

0.85W
104
K-3 K-3 K-1
Left
Left
126 127 128 Dipped
左
High-Beam 6 左
5 M3 Headlight
Headligh
t
远 近
0.5WR

1.25B G16
光 光
1 2

0.85Or
M42

0.85Y
86 87 大
Headlamp
Relay
灯
继

0.85Or
电

0.5Or
85 30
器
1.25Bl
0.5V

0.5R

0.5Y

0.5Y

M11转接器2
M11 Adapter 2 107
082 073
B-2 B-2 B-2 B-2 J-9

081 072 M42左电机

M42 Left Motor
M11转接器2
M11 Adapter 2
C
前雾灯
Front Frog lampJ-3 105 F30
Relay 继电器
10A
1.25Or
0.5Or

1.25Y

A-4
A

M31
022
端子 10 11 12 1 2 3 4 5 6 7 8 9
Terminal
0.85R

灯光 OFF
开关 小灯
Lamplight Switch
J

Lamplet

大灯
6
Headlamp
Lamplight
灯 Right Right
右
Switch 变光 近光 Lower Beam
High-Beam 右
Dipped
远
Dimmer
光 开关 远光
Switch
High Beam
Headlight Headlight
近
开 超车 光 光
1 2
Passing

关 左转
M19
Turn Left
0.85Y

0.85Or

右转 Turn Right

前雾灯 Front Frog lamp

后雾灯 Rear Frog Lamp

0.85Or

M31
0.5Or
1.25B 1.25B
0.5B

驾驶室线束
Cab Harness Internal
内连接点Point
Connection
106
083 074
8 M3 B-2 B-2 J-9
G16 M11转接器2 M19右电机
M11 Adapter 2 M19 Right Motor

M31组合开关2接口
M31 Combination Switch 2 Interface M42/M19左右前组合灯接口
M42/M19 Left/Right Front Combination Switch Interface M3搭铁点16接口
M3 Ground Point 16 Interface

10 11 12
10 9 8 7 6 1 2 3 4
9 8 7 6 5 4 3 2 1 5 4 3 2 1 5 6 7 8

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J-9 线束图-灯光照明
Harness Diagram-Lamplight
灯光照明-灯光调节
Lamplight Illume-Lighting Regulation
Illume

F44 M9 Adapter
M29 BCM2 10A M9转接器1
A-4 B-1
K-3
108 015 052

0.5RB
驾驶室线束
Cab Harness Internal Connection Point
内连接点
0.5RB

0.5Lg
0.5RB
0.3GR
0.5W
0.5RB

0.5Lg

0.5RB

0.5W

C
M37
4 9 4 9 5 4 1 3
左
Left
右 大灯调节开关
Headlamp Control Switch
Right
M Motor
电 M 电 2 6
A

Motor

机 机
0.5Or

0.5B

5 M42 5 M19
0.5Or

0.5Or
J

7 M10
G15

107 106 075

J-8 J-8 B-2
M42左近光灯 M19右近光灯 M11转接器2
M42 Left Low Beam Lamp M19 Right Low Beam Lamp M11 Adapter 2

M37大灯调节开关接口 M10M10搭铁点15接口
Ground Point 15 Interface M42/M19M42/M19左右前组合灯接口
Left/Right Front Combination Lamp
M37 Headlamp Control Switch Interface
Interface
1 2 2 3
1 4 10 9 8 7 6
3 4 5 6 5 6 7 8
5 4 3 2 1

打印人：20122642 部门：客户服务部
K-1
Harness Diagram-BCM
线束图-BCM系统
BCM System-1 System
BCM系统-1

M9转 日间行车 M31组合

Daytime Running Lamp Relay M31 Combination Switch 2
后雾灯 电动车窗
Power Window Relay
M9 Adapter
接器1 1 灯继电器 小灯继电器Rear Frog
Relay 继电器
Lamp
继电器
开关2 Lamplet Relay

B-1 J-4 J-8 J-5 J-3 M-2

046 065 128 066 030 121

日
Daytime
间
Running Rear 电
Lamp
行
Relay 后
Frog
Lamp
Power
动
Window
车 小
Lamplet
雾
Relay Relay
车
灯 大 灯
Relay 灯 窗
0.5RY

0.5YR

0.5GR
Constant Headlamp
灯 继

0.5YB
继 继
0.5R

继
0.5Y

常
Electricity Switch

电 电 开 电 电 电
器 关 器 器 器

A10 A18 A16 A17 A6 A15

BCM
C
A22 A24 A19 A2
M8

右
Right
车 车
A

Door
0.5BlG

前
0.85B

Speed Front
0.5G
0.5Br

门
Switch
Signal
速
Signal 顶
Dome
开 信 Lamp
关 灯
号
信
号
J

110 125
068
J-6 L-1 J-7
T1前
M20右车门 M35组合
M35 Combination Instrument
T1 Front Dome Lamp
顶灯
M20 Right Door Signal Switch
信号开关 仪表

6 M10
G15

M29(灰）BCM-2接口
M29(Gray) BCM-2 Interface M10 M10搭铁点15接口
Ground Point 15
Interface

9 8 6 5 4 3 2 1
7
1 2 3 4
18 17 16 15 14 13 12 11 10
22 21 20 19 5 6 7 8
24 23

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K-2
线束图-BCM系统
BCM System-2
Harness Diagram – BCM System
BCM系统-2

BCM
B14 A12 A21 A13 A9 B5
M29 M8 M29
F50 F52

0.5GBlR
15A

0.5GW
10A
A-5 A-5

037 039
0.85R

0.5Bl
0.5OrB

0.5YW

0.5GY
0.5W

自动门锁继电器
Automatic Door Lock Relay
M2
8 3 14 10

86 87a 87 86 87a 87 85 30 86 30

30 30 86 87 85 87
85 85
7 1 6 9 4 13 11 5 12
0.5GBl

M2
0.85W
0.85G

0.5GW
0.85B

0.5R
C
0.85Gr

3 M3
G15
A

130
20 1 2 MD2 070 090 092
MD1 2 1
B-2 B-2 A-5 P-1
0.85Gr

0.85Gr
0.85G

0.85G

M11转接器2 F53
J

M11 Adapter 2 M5电动Rearview

10A M5 Power
后视镜
Mirror

1 2 5 4
4 M M 2
D9 3 5 1 3 D1
左前闭 右前闭
锁器
Left Front Dead Lock Right Front Dead Lock
锁器
0.5B

0.5B

20 MD2

18 MD1 18 MD2
1.25B
2.0B

1 M3 5 M16
G16 G12

MD1左、MD2右车门线
M8(白）BCM-1/M29(灰）BCM-2接口
M8(White) BCM-1/M29(Gray) BCM-2 Interface 束与驾驶室线束接口
MD1 Left、MD2 Right Door Harness and Cab Harness Interface

M2闭锁控制器接口
M2 Dead Lock Controller Interface

1 2 3 4 5 6 7
9 8 7 6 5 4 3 2 1 8 9
5 4 3 2 1
10 11 12 13 14 1516 12 11 10 9
18 17 16 15 14 13 12 11 10
17 18 14 13 8 7 6
24 23 22 21 20 19 19 20 21 22 23 2425

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K-3
线束图-BCM系统
Harness Diagram – BCM System
BCM系统-3
BCM System-3

P8 Generator Controller
M33点火 F44
M33 Ignition Switch 2 M31组合 M31组合 M31组合 M43诊断
M31 Combination Switch 2M31 Combination Switch 2
M31 Combination Switch 2
M43 Diagnosis Interface
P8发电机
开关2 10A 开关2 开关2 开关2 接口 调节器
A-4 J-9 J-3 J-8 J-8 O-1 D-1
114
025 108 064 127 126 093

0.5P
7 EP

0.5P
Front Rear
Frog Frog
钥
Key Lamp
前 后
Lamp Learning 14 ME1
匙
Insertion Switch
雾 Switch
雾
Code
学
Switch
插 小
Lamplet 0.5GrY Input
发
0.5Gr

0.5RB

0.5Or

IG1
IG1 灯 灯 灯 码 Generator
0.5R

0.5V

0.5P
Switch
入 Power
开 开 输 电
开 电 开 机
关 关 关 入
关
M29
B11 B18 B8 B15 B6 B17 B23

BCM
C
B1 B7 B9
M29
A 0.5WR

IG2
IG2 Power

驾驶室线束
0.5BrB

Cab Harness Internal Connection

0.5Y

Point
内连接点
0.5WR

0.5WR
0.5WR

067 131
J-6 P-1
M1左
M1 Left Door Signal Switch M5后 026
M5 Rearview Mirror
车门 视镜
Heating Switch 104 124
信号 加热 A-4
开关 J-8 N-1
开关
F32
10A M44大灯
M44 Headlamp Relay
M14空调模
M14 Air Conditioner Mode Controller

继电器 式控制器

M29(灰）BCM-2接口
M29(Gray) BCM-2 Interface
PE电源线束与发动机线束接口
PE Power Supply Harness and Engine Harness Interface
EM1(白色)发动机线束与驾驶室线束接口
EM1(White) Engine Harness and Cab Harness Interface

9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10 4 3 2 1 1 2 3 4 5 6 7 8 9 10 11
24 23 22 21 20 19 8 7 6 5 12 13 14 15 16 17 18 19 20 21 22

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C
A
J

打印人：20122642 部门：客户服务部
L-1 线束图-组合仪表
Harness Diagram - Combine Instrument
组合仪表-1
Combination Instrumemt-1 System

F46
F47 P8发电机
P8 Generator M9转接器1
M9 Adapter 1 10A
111 J-1 10A
D-1 B-1 A-4

0.5R
3 2 028 047 017
里程表
0.5BlB

Odometer Sensor
传感器

0.5V
1
M43 Diagnosis Interface
F8 M43诊 M8 BCM1
0.5B

断接口
1 EF 底盘线束 K-1 5 EP
O-1
0.5BlB

Chassis Harness Internal Connection

内连接点
Point

0.5V
110

0.5R

0.5W
1.25B

109
12 EM1 F5 5 EM1

0.5BlG
0.5BlB

0.5VG Constant

0.5V
G01 常 IG1
Electricity

电 M35
A21 A22 A23 A20 A31 A19 IG1
LCD:里程
LCD: Sub-total Mileage Rotation
车
Speed
累计小计 车
Speed
Speed
Signal 转 电源电路
速
Signal 数
Data 速
Output 速
Power Supply Circuit

信 Line
据 输 信 燃油
Fuel Warning Water水温 Temperature

蜂
Warning

号 线 出 号 报警 报警 Buzzer
鸣
CPU控制单元 器
CPU Control Unit

水 燃 燃
Water
温 油
Fuel Fuel
油
C
Temperatur Signal Signal
信 步进电机驱动器 仪
e Signal
信 信
Ground
Stepper Motor Driver Instrument

号 号 表
Ground

号
地 地
燃油表 转速表
Fuel
Tachometer
车速表
Speedomete 水温表 Water Temperature
Gauge r
A24 A25
Gauge

A26 A29 A32

A

M35
0.5LgB

0.5BlR
0.5Gr

0.5GB

0.5B

EM1 1 11 EM1 2 EM1

J
0.5Gr

0.5Gr
0.5Gr

M24
驻车
Parking Brake Switch
制动 M26
EP 2 9 EF 10 EF 开关 G17
0.5Gr

0.5Gr

0.5Gr

P10 １
水
Water Fuel油２ F6
温
Temperature
Sensor 量
Volume
Sensor
传 传
感 感
器 器１
PE电源线束与发动机线束接口
PE Power Supply Harness and Engine Harness Interface

M26搭铁点17端子
F8里程表传感器接口M26 Ground Point 17 Terminal
F8 Odometer Sensor Interface

4 3 2 1
8 7 6 5 1 2 3
F6燃油液位传感器接口
F6 Fuel Level Sensor Interface
EM1发动机线束与驾驶室线束接口
EM1 Engine Harness and Cab Harness Interface EF Engine Harness and Chassis Harness
Interface
EF发动机线束与底盘线束接口 M24/P10 Parking Brake Switch/Water Temperature
M24/P10驻车制动开
Sensor Interface 1 2
关/水温传感器接口
1 2 3 4 5 6 7 8 9 10 11
M35组合仪表接口
M35 Combination Instrument Interface
12 13 14 15 16 17 18 19 20 21 22
1 1718 1920 2122 2324 2526 2728 293031 32
1 2 3 4 5 6 7 8 9 1011 1213 14 1516

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L-2 线束图-组合仪表
Harness Diagram - Combing Instrument
Combination Instrument-2 System
组合仪表-2

IG1
Constant

常
Electricity

Door 门
Unlocked

Indicator 安
Seat
Charging
充
High
beam 远 Oil 机
Braking
制
Malfunction
Indication
Lamp
未 全
Belt 预
Preheat
电 光
Indication Pressure
油 动
关 带 热 指 指 压 故
指 示 示 力 障
示
灯

A18 A27 A14 A6 A12 A17 A28

0.5GBr

0.5Or
M35
0.3Br

0.5P

0.5Y

0.5Y
0.3G

C
EM1 3
069 113
0.5Or

0.5Or
112 084
0.5Y

J-6 G-1 D-1 B-2

A

左右车门
Left/Right Door Signal Switch
M36预 P8发电机 M11转
M36 Preheating Switch P8 Generator ControllerM11 Adapter 2

信号开关 热开关 调节器接口接器2 Interface

Braking
制
Liquid
EP 3 4 EM1 动 2 M38
Level
Switch

安
M25 １Seat 液
J

全
Belt 位
Switch
带 开１
0.5Or

开 关
0.5Y

2关
0.5B
0.5B

E7
Oil机
Pressure
真
Vacuum
Cylinder
油
Switch P4 空
Switch

压 筒 6 M3
M26 力 开
开 关 G16
G17
关

M26搭铁点17端子
M26 Ground Point 17 Terminal E7 Vacuum Cylinder Switch Interface
E7真空桶开关接口
M38制动液位开关接口
M38 Braking Liquid Level Switch Interface
P4机油压力开关接口
P4 Oil Pressure Switch Interface

EM1 Engine Harness and Cab Harness Interface PE电源线束与

PE Power Supply Harness and Engine Harness Interface 1 2 1
EM1发动机线束与驾驶室线束接口 发动机线束接口
M35组合仪表接口
M35 Combination Instrument Interface

1 2 3 4 5 6 7 8 9 10 11 4 3 2 1 1718 1920 2122 23242526 2728 2930 3132

12 13 14 15 16 17 18 19 20 21 22 8 7 6 5 1 2 3 4 5 6 7 8 9 10 11 1213 14 1516

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L-3 Harness Diagram - Combine Instrument System
线束图-组合仪表
Combination Instrument-3
组合仪表-3

F47
10A
J-1
Daytime Running
Front Frog Lamp Lamp Relay
116
Relay
M9 Adapter1 M11 Adapter M11 Adapter Rear 后雾灯
Frog Lamp 前雾灯 日间行车
M9转接器1 M11转接器2 M11转接器 2 Relay 继电器 继电器 灯继电器

0.5R
B-1 B-2 B-2 J-3 J-3 J-4

117
054 091 071 118 119
3
油水分离
Oil Water Separator Sensor

2
器传感器

0.5Lg
1
E1

0.5B
15 EM1
0.5GBl

0.5GOr

0.5BlW
0.3GR

0.5GW

0.5Bl

0.5Lg
M35
A7 A5 A4 A11 A13 A16 A1
E3
G09
C

Rear
Lamplet
Left
左
Steering
Right
右
Steerin Frog 后 Front
Indication前
Frog
日
Daytime
Running 油
Oil Water
小 间 Separatio
A

转
g
转 雾
Indication
雾 Lamp
n 水
灯 向 向 灯 灯 行 分
指 指 车 离
示 示 灯
J

Cathode

负极

E3 Ground 9 Terminal
EM1 Engine Harness and Cab Harness Interface E1 Diesel Filter Water Level Sensor E3搭铁9端子
EM1发动机线束与驾驶室线束接口 E1柴虑水位传感器接口
Interface

M35 Combination Instrument Interface

1 2 3 4 5 6 7 8 9 10 11 M35组合仪表接口
1 2 3
12 13 14 15 16 17 18 19 20 21 22 1718 1920 21222324 2526 2728 2930 3132
1 2 3 4 5 6 7 8 9 10111213 14 15 16

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J-5
线束图-灯光照明
Harness Diagram – Lamplight Illume
Lamplight Illume-Position Lamp、License Plate Lamp
灯光照明-位置灯、牌照灯

SB11 M9 Adapter 1
40A M9转接器1
A-5 B-1

023 059

0.5GR
2.0Bl
3.0Bl
3 M19
右
Right Front Position
Lamp
前
30 86 小
Lamplet
Relay 位
灯
灯 7
继
电

0.5B
87 85 器
M9 Adapter 1
0.5YR

M9转接器1
3.0R

驾驶室线束
Cab Harness Internal Connection Point

B-1 内连接点

0.85B
058
0.5GY

F55
10A
F56 2 M16
2 0.5GY 10A 0.5GR
G12
0.5GY

0.85GR

ME2
0.5GY

C
12 ME2
0.5GY

14 EF
0.5GR

029 103 066

A
0.5GY

J-3 B-1 K-1

Frog Lamp Relay
雾灯继电器 M9 Adapter 1
M9转接器1 M8 BCM1 14 EF
0.5GR 0.5GR
J

1 F4 3 M42
Left Rear
Lamp
左
Position
左
Right Front Position
Lamp
0.5GR

0.5GR

后 前
位 位
灯6 灯 5 2 F2 2 F3 1 F1
Right

Plate
右
License 左
Left License
Plate Lamp
右
Right Rear
Position
0.5B

牌 牌 Lamp 后
0.85B

Lamp

照 照 位
Chassis Harness Internal
底盘线束
Connection Point
Cab Harness Internal
驾驶室线束
Point
Connection 灯 1 灯 1 灯 6
0.85B
0.85B 0.5B
0.5B

内连接点 内连接点
1.25B

0.85B

F5 2 M3
G01 G16 F5
G01

EM2 Engine Harness and Cab Harness Interface EF Engine Harness and
M3/M16 Ground Point 16/12 Interface
F3/F2左右牌照灯接口M42/M19左右前组合灯接口
F3/F2 Left Right License Plate Lamp Interface M42/M19 Left Right Front Combination Lamp Interface
EM2发动机线束与驾驶室线束接口
Chassis Harness Interface
M3/M16搭铁点16/12接口
EF发动机线束与底盘线束接口
10 9 8 7 6 1 2 3 4
1 2 1 2 3 4 5 6 7 8 9 10 11
5 4 3 2 1 5 6 7 8
12 13 14 15 16 17 18 19 20 21 22

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J-6 线束图-灯光照明
Harness Diagram-Lamplight Illume
灯光照明-门灯
Lamplight Illume-Door Lamp

M9转接器1
M9 Adapter 1 M9转接器1
M9 Adapter 1

B-1 B-1

042 043

0.5RW

0.5RW
MD1 11 MD2 11
0.5RW

0.5RW
D2
左 1 D10 右 1
M29 BCM2 Left Door Lamp Right Door Lamp M8 BCM1
门 门
K-3 灯 2 灯 2 K-1
067 068
0.5BrB

0.5Br

19 MD1 MD2 19
C
0.5BrB

0.5BrB

0.5Br

0.5Br

Cab Harness Internal Connection

驾驶室线束
A

Point
内连接点
0.5BrB

0.5Br
J

左 1 M1 右 Door
M20 1 Right
Left Door Signal
车
Signal
0.3G 0.3G 车
Switch
Switch
门 2 2 门
信 信
0.3G

号 号
开 开
关 关

069

L-2
M35仪表
M35 Instrument

MD1左、MD2右车门线
MD1 Left 、 MD2 Right Door Harness and Cab Harness
束与驾驶室线束接口
Interface
D10/D2左右门灯接口
D10/D2 Left Right Door Lamp Interface M1/M20左右门信号开关接口
M1/M20 Left Right Door Signal Switch Interface

1 2 3 4 5 6 7
8 9
1 2
10 11 12 13 14 15 16
1 2
17 18
19 20 21 22 23 24 25

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Harness Diagram-Lamplight Illume
J-7 线束图-灯光照明
Lamplight Illume-Dome Lamp
灯光照明-顶灯

M9 Adapter 1
M9转接器1
B-1

044

0.5RW
6 MT
0.5RW

Front Dome Lamp

前顶灯
T1
2

OFF
ON OFF ON
DOOR
C
1 4
T1
0.5B

A 0.5G

1 5 MT
0.5G
0.5B

3 M16
G12

125
K-1

M8 BCM1

MT Cab Harness and Dome Harness Interface

MT驾驶室线束与顶棚线束接口 T1 Front Dome Lamp Interface
T1前顶灯接口

6 5 4 3 2 1
4 3 2 1

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K-2
线束图-BCM系统
Harness Diagram – BCM System
BCM系统-2

BCM
B14 A12 A21 A13 A9 B5
M29 M8 M29
F50 F52

0.5GBlR
15A

0.5GW
10A
A-5 A-5

037 039
0.85R

0.5Bl
0.5OrB

0.5YW

0.5GY
0.5W

自动门锁继电器
M2
8 3 14 10

86 87a 87 86 87a 87 85 30 86 30

30 30 86 87 85 87
85 85
7 1 6 9 4 13 11 5 12
0.5GBl

M2
0.85W
0.85G

0.5GW
0.85B

0.5R
C
0.85Gr

3 M3
G15
A

130
20 1 2 MD2 070 090 092
MD1 2 1
B-2 B-2 A-5 P-1
0.85Gr

0.85Gr
0.85G

0.85G

M11转接器2 F53
J

10A M5电动
后视镜
1 2 5 4
4 M M 2
D9 3 5 1 3 D1
左前闭 右前闭
锁器 锁器
0.5B

0.5B

20 MD2

18 MD1 18 MD2
1.25B
2.0B

1 M3 5 M16
G16 G12

MD1左、MD2右车门线
M8(白）BCM-1/M29(灰）BCM-2接口 束与驾驶室线束接口 M2闭锁控制器接口
1 2 3 4 5 6 7
9 8 7 6 5 4 3 2 1 8 9
5 4 3 2 1
10 11 12 13 14 1516 12 11 10 9
18 17 16 15 14 13 12 11 10
17 18 14 13 8 7 6
24 23 22 21 20 19 19 20 21 22 23 2425

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K-3
线束图-BCM系统
Harness Diagram – BCM System
BCM系统-3
BCM System-3

P8 Generator Controller
M33点火 F44
M33 Ignition Switch 2 M31组合 M31组合 M31组合 M43诊断
M31 Combination Switch 2M31 Combination Switch 2
M31 Combination Switch 2
M43 Diagnosis Interface
P8发电机
开关2 10A 开关2 开关2 开关2 接口 调节器
A-4 J-9 J-3 J-8 J-8 O-1 D-1
114
025 108 064 127 126 093

0.5P
7 EP

0.5P
Front Rear
Frog Frog
钥
Key Lamp
前 后
Lamp Learning 14 ME1
匙
Insertion Switch
雾 Switch
雾
Code
学
Switch
插 小
Lamplet 0.5GrY Input
发
0.5Gr

0.5RB

0.5Or

IG1
IG1 灯 灯 灯 码 Generator
0.5R

0.5V

0.5P
Switch
入 Power
开 开 输 电
开 电 开 机
关 关 关 入
关
M29
B11 B18 B8 B15 B6 B17 B23

BCM
C
B1 B7 B9
M29
A 0.5WR

IG2
IG2 Power

驾驶室线束
0.5BrB

Cab Harness Internal Connection

0.5Y

Point
内连接点
0.5WR

0.5WR
0.5WR

067 131
J-6 P-1
M1左
M1 Left Door Signal Switch M5后 026
M5 Rearview Mirror
车门 视镜
Heating Switch 104 124
信号 加热 A-4
开关 J-8 N-1
开关
F32
10A M44大灯
M44 Headlamp Relay
M14空调模
M14 Air Conditioner Mode Controller

继电器 式控制器

M29(灰）BCM-2接口
M29(Gray) BCM-2 Interface
PE电源线束与发动机线束接口
PE Power Supply Harness and Engine Harness Interface
EM1(白色)发动机线束与驾驶室线束接口
EM1(White) Engine Harness and Cab Harness Interface

9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10 4 3 2 1 1 2 3 4 5 6 7 8 9 10 11
24 23 22 21 20 19 8 7 6 5 12 13 14 15 16 17 18 19 20 21 22

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L-1 线束图-组合仪表
Harness Diagram - Combine Instrument
组合仪表-1
Combination Instrumemt-1 System

F46
F47 P8发电机
P8 Generator M9转接器1
M9 Adapter 1 10A
111 J-1 10A
D-1 B-1 A-4

0.5R
3 2 028 047 017
里程表
0.5BlB

Odometer Sensor
传感器

0.5V
1
M43 Diagnosis Interface
F8 M43诊 M8 BCM1
0.5B

断接口
1 EF 底盘线束 K-1 5 EP
O-1
0.5BlB

Chassis Harness Internal Connection

内连接点
Point

0.5V
110

0.5R

0.5W
1.25B

109
12 EM1 F5 5 EM1

0.5BlG
0.5BlB

0.5VG Constant

0.5V
G01 常 IG1
Electricity

电 M35
A21 A22 A23 A20 A31 A19 IG1
LCD:里程
LCD: Sub-total Mileage Rotation
车
Speed
累计小计 车
Speed
Speed
Signal 转 电源电路
速
Signal 数
Data 速
Output 速
Power Supply Circuit

信 Line
据 输 信 燃油
Fuel Warning Water水温 Temperature

蜂
Warning

号 线 出 号 报警 报警 Buzzer
鸣
CPU控制单元 器
CPU Control Unit

水 燃 燃
Water
温 油
Fuel Fuel
油
C
Temperatur Signal Signal
信 步进电机驱动器 仪
信
e Signal
信
Ground
Stepper Motor Driver Instrument

号 号 表
Ground

号
地 地
燃油表 转速表
Fuel
Tachometer
车速表
Speedomete 水温表 Water Temperature
Gauge r
A24 A25
Gauge

A26 A29 A32

A

M35
0.5LgB

0.5BlR
0.5Gr

0.5GB

0.5B

EM1 1 11 EM1 2 EM1

J
0.5Gr

0.5Gr
0.5Gr

M24
驻车
Parking Brake Switch
制动 M26
EP 2 9 EF 10 EF 开关 G17
0.5Gr

0.5Gr

0.5Gr

P10 １
水
Water Fuel油２ F6
温
Temperature
Sensor 量
Volume
Sensor
传 传
感 感
器 器１
PE电源线束与发动机线束接口
PE Power Supply Harness and Engine Harness Interface

M26搭铁点17端子
F8里程表传感器接口M26 Ground Point 17 Terminal
F8 Odometer Sensor Interface

4 3 2 1
8 7 6 5 1 2 3
F6燃油液位传感器接口
F6 Fuel Level Sensor Interface
EM1发动机线束与驾驶室线束接口
EM1 Engine Harness and Cab Harness Interface EF Engine Harness and Chassis Harness
Interface
EF发动机线束与底盘线束接口 M24/P10 Parking Brake Switch/Water Temperature
M24/P10驻车制动开
Sensor Interface 1 2
关/水温传感器接口
1 2 3 4 5 6 7 8 9 10 11
M35组合仪表接口
M35 Combination Instrument Interface
12 13 14 15 16 17 18 19 20 21 22
1 1718 1920 2122 2324 2526 2728 293031 32
1 2 3 4 5 6 7 8 9 1011 1213 14 1516

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L-2 线束图-组合仪表
Harness Diagram - Combing Instrument
Combination Instrument-2 System
组合仪表-2

IG1
Constant

常
Electricity

Door 门
Unlocked

Indicator 安
Seat
Charging
充
High
beam 远 Oil 机
Braking
制
Malfunction
Indication
Lamp
未 全
Belt 预
Preheat
电 光
Indication Pressure
油 动
关 带 热 指 指 压 故
指 示 示 力 障
示
灯

A18 A27 A14 A6 A12 A17 A28

0.5GBr

0.5Or
M35
0.3Br

0.5P

0.5Y

0.5Y
0.3G

C
EM1 3
069 113
0.5Or

0.5Or
112 084
0.5Y

J-6 G-1 D-1 B-2

A

左右车门
Left/Right Door Signal Switch
M36预 P8发电机 M11转
M36 Preheating Switch P8 Generator ControllerM11 Adapter 2

信号开关 热开关 调节器接口接器2 Interface

Braking
制
Liquid
EP 3 4 EM1 动 2 M38
Level
Switch

安
M25 １Seat 液
J

全
Belt 位
Switch
带 开１
0.5Or

开 关
0.5Y

2关
0.5B
0.5B

E7
Oil机
Pressure
真
Vacuum
Cylinder
油
Switch P4 空
Switch

压 筒 6 M3
M26 力 开
开 关 G16
G17
关

M26搭铁点17端子
M26 Ground Point 17 Terminal E7 Vacuum Cylinder Switch Interface
E7真空桶开关接口
M38制动液位开关接口
M38 Braking Liquid Level Switch Interface
P4机油压力开关接口
P4 Oil Pressure Switch Interface

EM1 Engine Harness and Cab Harness Interface PE电源线束与

PE Power Supply Harness and Engine Harness Interface 1 2 1
EM1发动机线束与驾驶室线束接口 发动机线束接口
M35组合仪表接口
M35 Combination Instrument Interface

1 2 3 4 5 6 7 8 9 10 11 4 3 2 1 1718 1920 2122 23242526 2728 2930 3132

12 13 14 15 16 17 18 19 20 21 22 8 7 6 5 1 2 3 4 5 6 7 8 9 10 11 1213 14 1516

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L-3 Harness Diagram - Combine Instrument System
线束图-组合仪表
Combination Instrument-3
组合仪表-3

F47
10A
J-1
Daytime Running
Front Frog Lamp Lamp Relay
116
Relay
M9 Adapter1 M11 Adapter M11 Adapter Rear 后雾灯
Frog Lamp 前雾灯 日间行车
M9转接器1 M11转接器2 M11转接器 2 Relay 继电器 继电器 灯继电器

0.5R
B-1 B-2 B-2 J-3 J-3 J-4

117
054 091 071 118 119
3
油水分离
Oil Water Separator Sensor

2
器传感器

0.5Lg
1
E1

0.5B
15 EM1
0.5GBl

0.5GOr

0.5BlW
0.3GR

0.5GW

0.5Bl

0.5Lg
M35
A7 A5 A4 A11 A13 A16 A1
E3
G09
C

Rear
Lamplet
Left
左
Steering
Right
右
Steerin Frog 后 Front
Indication前
Frog
日
Daytime
Running 油
Oil Water
小 间 Separatio
A

转
g
转 雾
Indication
雾 Lamp
n 水
灯 向 向 灯 灯 行 分
指 指 车 离
示 示 灯
J

Cathode

负极

E3 Ground 9 Terminal
EM1 Engine Harness and Cab Harness Interface E1 Diesel Filter Water Level Sensor E3搭铁9端子
EM1发动机线束与驾驶室线束接口 E1柴虑水位传感器接口
Interface

M35 Combination Instrument Interface

1 2 3 4 5 6 7 8 9 10 11 M35组合仪表接口
1 2 3
12 13 14 15 16 17 18 19 20 21 22 1718 1920 21222324 2526 2728 2930 3132
1 2 3 4 5 6 7 8 9 10111213 14 15 16

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J-5
线束图-灯光照明
Harness Diagram – Lamplight Illume
Lamplight Illume-Position Lamp、License Plate Lamp
灯光照明-位置灯、牌照灯

SB11 M9 Adapter 1
40A M9转接器1
A-5 B-1

023 059

0.5GR
2.0Bl
3.0Bl
3 M19
右
Right Front Position
Lamp
前
30 86 小
Lamplet
Relay 位
灯
灯 7
继
电

0.5B
87 85 器
M9 Adapter 1
0.5YR

M9转接器1
3.0R

驾驶室线束
Cab Harness Internal Connection Point

B-1 内连接点

0.85B
058
0.5GY

F55
10A
F56 2 M16
2 0.5GY 10A 0.5GR
G12
0.5GY

0.85GR

ME2
0.5GY

C
12 ME2
0.5GY

14 EF
0.5GR

029 103 066

A
0.5GY

J-3 B-1 K-1

Frog Lamp Relay
雾灯继电器 M9 Adapter 1
M9转接器1 M8 BCM1 14 EF
0.5GR 0.5GR
J

1 F4 3 M42
Left Rear
Lamp
左
Position
左
Right Front Position
Lamp
0.5GR

0.5GR

后 前
位 位
灯6 灯 5 2 F2 2 F3 1 F1
Right

Plate
右
License 左
Left License
Plate Lamp
右
Right Rear
Position
0.5B

牌 牌 Lamp 后
0.85B

Lamp

照 照 位
Chassis Harness Internal
底盘线束
Connection Point
Cab Harness Internal
驾驶室线束
Point
Connection 灯 1 灯 1 灯 6
0.85B
0.85B 0.5B
0.5B

内连接点 内连接点
1.25B

0.85B

F5 2 M3
G01 G16 F5
G01

EM2 Engine Harness and Cab Harness Interface EF Engine Harness and
M3/M16 Ground Point 16/12 Interface
F3/F2左右牌照灯接口M42/M19左右前组合灯接口
F3/F2 Left Right License Plate Lamp Interface M42/M19 Left Right Front Combination Lamp Interface
EM2发动机线束与驾驶室线束接口
Chassis Harness Interface
M3/M16搭铁点16/12接口
EF发动机线束与底盘线束接口
10 9 8 7 6 1 2 3 4
1 2 1 2 3 4 5 6 7 8 9 10 11
5 4 3 2 1 5 6 7 8
12 13 14 15 16 17 18 19 20 21 22

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J-6 线束图-灯光照明
Harness Diagram-Lamplight Illume
灯光照明-门灯
Lamplight Illume-Door Lamp

M9转接器1
M9 Adapter 1 M9转接器1
M9 Adapter 1

B-1 B-1

042 043

0.5RW

0.5RW
MD1 11 MD2 11
0.5RW

0.5RW
D2
左 1 D10 右 1
M29 BCM2 Left Door Lamp Right Door Lamp M8 BCM1
门 门
K-3 灯 2 灯 2 K-1
067 068
0.5BrB

0.5Br

19 MD1 MD2 19
C
0.5BrB

0.5BrB

0.5Br

0.5Br

Cab Harness Internal Connection

驾驶室线束
A

Point
内连接点
0.5BrB

0.5Br
J

左 1 M1 右 Door
M20 1 Right
Left Door Signal
车
Signal
0.3G 0.3G 车
Switch
Switch
门 2 2 门
信 信
0.3G

号 号
开 开
关 关

069

L-2
M35仪表
M35 Instrument

MD1左、MD2右车门线
MD1 Left 、 MD2 Right Door Harness and Cab Harness
束与驾驶室线束接口
Interface
D10/D2左右门灯接口
D10/D2 Left Right Door Lamp Interface M1/M20左右门信号开关接口
M1/M20 Left Right Door Signal Switch Interface

1 2 3 4 5 6 7
8 9
1 2
10 11 12 13 14 15 16
1 2
17 18
19 20 21 22 23 24 25

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Harness Diagram-Lamplight Illume
J-7 线束图-灯光照明
Lamplight Illume-Dome Lamp
灯光照明-顶灯

M9 Adapter 1
M9转接器1
B-1

044

0.5RW
6 MT
0.5RW

Front Dome Lamp

前顶灯
T1
2

OFF
ON OFF ON
DOOR
C
1 4
T1
0.5B

A 0.5G

1 5 MT
0.5G
0.5B

3 M16
G12

125
K-1

M8 BCM1

MT Cab Harness and Dome Harness Interface

MT驾驶室线束与顶棚线束接口 T1 Front Dome Lamp Interface
T1前顶灯接口

6 5 4 3 2 1
4 3 2 1

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C
A
J

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J-8 Harness
线束图-灯光照明 Diagram-Lamplight
Lamplight Illume-Left/Right Dipped Headlight，Left/Right High-Beam Headlight
Illume
灯光照明-左右近、远光灯

F29
10A
F32 A-4
10A
K-2 021
M29 BCM2M29 BCM2 M8 BCM1

0.85W
104
K-3 K-3 K-1
Left
Left
126 127 128 Dipped
左
High-Beam 6 左
5 M3 Headlight
Headligh
t
远 近
0.5WR

1.25B G16
光 光
1 2

0.85Or
M42

0.85Y
86 87 大
Headlamp
Relay
灯
继

0.85Or
电

0.5Or
85 30
器
1.25Bl
0.5V

0.5R

0.5Y

0.5Y

M11转接器2
M11 Adapter 2 107
082 073
B-2 B-2 B-2 B-2 J-9

081 072 M42左电机

M42 Left Motor
M11转接器2
M11 Adapter 2
C
前雾灯
Front Frog lampJ-3 105 F30
Relay
继电器
10A
1.25Or
0.5Or

1.25Y

A-4
A

M31
022
端子 10 11 12 1 2 3 4 5 6 7 8 9
0.85R

Terminal
灯光 OFF
开关 小灯
Lamplight Switch
J

Lamplet

大灯
6
Headlamp
Lamplight
灯 Right 右 Right
Switch 变光 近光 Lower Beam
High-Beam 右
Dipped
远
Dimmer
光 开关 远光
Switch
High Beam
Headlight 近
Headlight
开 超车 光 光
1 2
Passing

关 左转
M19
Turn Left
0.85Y

0.85Or

右转 Turn Right

前雾灯 Front Frog lamp

后雾灯 Rear Frog Lamp

0.85Or

M31
0.5Or
1.25B 1.25B
0.5B

驾驶室线束
Cab Harness Internal
内连接点Point
Connection
106
083 074
8 M3 B-2 B-2 J-9
G16 M11转接器2 M19右电机
M11 Adapter 2 M19 Right Motor

M31组合开关2接口
M31 Combination Switch 2 Interface M42/M19左右前组合灯接口
M42/M19 Left/Right Front Combination Switch Interface M3搭铁点16接口
M3 Ground Point 16 Interface

10 11 12
10 9 8 7 6 1 2 3 4
9 8 7 6 5 4 3 2 1 5 4 3 2 1 5 6 7 8

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J-9 线束图-灯光照明
Harness Diagram-Lamplight
灯光照明-灯光调节
Lamplight Illume-Lighting Regulation
Illume

F44 M9 Adapter
M29 BCM2 10A M9转接器1
A-4 B-1
K-3
108 015 052

0.5RB
驾驶室线束
Cab Harness Internal Connection Point
内连接点
0.5RB

0.5Lg
0.5RB
0.3GR
0.5W
0.5RB

0.5Lg

0.5RB

0.5W

C
M37
4 9 Front Frog lamp
4 9 5 4 1 3
左
Left
右 大灯调节开关
Headlamp Control Switch
Right
M Motor
电 M 电 2 6
A

Motor

机 机
0.5Or

0.5B

5 M42 5 M19
0.5Or

0.5Or
J

7 M10
G15

107 106 075

J-8 J-8 B-2
M42左近光灯 M19右近光灯 M11转接器2
M42 Left Low Beam Lamp M19 Right Low Beam Lamp M11 Adapter 2

M37大灯调节开关接口 M10M10搭铁点15接口
Ground Point 15 Interface M42/M19M42/M19左右前组合灯接口
Left/Right Front Combination Lamp
M37 Headlamp Control Switch Interface
Interface
1 2 1 2 3 4 10 9 8 7 6
3 4 5 6 5 6 7 8
5 4 3 2 1

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K-1
Harness Diagram-BCM
线束图-BCM系统
BCM System-1 System
BCM系统-1

M9转 日间行车 M31组合

Daytime Running Lamp Relay M31 Combination Switch 2
后雾灯 电动车窗
Power Window Relay
M9 Adapter
接器1 1 灯继电器 开关2 小灯继电器Rear Frog
Relay 继电器
Lamplet Relay
Lamp
继电器
B-1 J-4 J-8 J-5 J-3 M-2

046 065 128 066 030 121

日
Daytime
间
Running Rear 电
Lamp
行
Relay 后
Frog
Lamp
Power
动
Window
车 小
Lamplet
雾
Relay Relay
车
灯 大 灯
Relay 灯 窗
0.5RY

0.5YR

0.5GR
Constant Headlamp
灯 继

0.5YB
继 继
0.5R

继
0.5Y

常
Electricity Switch

电 电 开 电 电 电
器 关 器 器 器

A10 A18 A16 A17 A6 A15

BCM
C
A22 A24 A19 A2
M8

右
Right
车 车
A

Door
0.5BlG

前
0.85B

Speed Front
0.5G
0.5Br

门
Switch
Signal
速
Signal 顶
Dome
开 信 Lamp
关 灯
号
信
号
J

110 125
068
J-6 L-1 J-7
T1前
M20右车门 M35组合
M35 Combination Instrument
T1 Front Dome Lamp
顶灯
M20 Right Door Signal Switch
信号开关 仪表

6 M10
G15

M29(灰）BCM-2接口
M29(Gray) BCM-2 Interface M10 M10搭铁点15接口
Ground Point 15
Interface

9 8 7 6 5 4 3 2 1
1 2 3 4
18 17 16 15 14 13 12 11 10
23 22 21 20 19 5 6 7 8
24

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K-2
Harness
线束图-BCM系统Diagram-BCM
System
BCM系统-2
BCM System-2

BCM
B14 A12 A21 A13 A9 B5
M29 M8 M29
F50 F52

0.5GBlR
15A

0.5GW
10A
A-5 A-5

037 039
0.85R

0.5Bl
0.5OrB

0.5YW

0.5GY
0.5W

自动门锁继电器
Automatic Door Lock Relay
M2
8 3 14 10

86 87a 87 86 87a 87 85 30 86 30

30 30 86 87 85 87
85 85
7 1 6 9 4 13 11 5 12
0.5GBl

M2
0.85W
0.85G

0.5GW
0.85B

0.5R
C
0.85Gr

3 M3
G15
A

130
20 1 2 MD2 070 090 092
MD1 2 1
B-2 B-2 A-5 P-1
0.85Gr

0.85Gr
0.85G

0.85G

M11转接器2 F53
J

M11 Adapter2
10A M5电动
M5 Power Rearview Mirror
后视镜
1 2 5 4
4 2
M M
D9 3 5 D1
1 3
左前闭 右前闭
Left Front Dead Lock Right Front Dead Lock
锁器 锁器
0.5B

0.5B

20 MD2

18 MD1 18 MD2
1.25B
2.0B

1 M3 5 M16
G16 G12

MD1左、MD2右车门线
M8(白）BCM-1/M29(灰）BCM-2接口
M8(White) BCM-1/M29(Gray) BCM-2 Interface
MD1 Left、MD2 Right Door Harness and Cab Harness Interface
束与驾驶室线束接口 M2闭锁控制器接口
M2 Dead Lock Controller Interface

1 2 3 4 5 6 7
9 8 76 5 4 3 2 1 8 9
5 4 3 2 1
10 11 12 13 14 1516 12 11 10 9
18 17 16 15 14 13 12 11 10
17 18 14 13 8 7 6
24 23 22 21 20 19 19 20 21 22 23 2425

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K-3
Harness
线束图-BCM系统Diagram-BCM
BCM系统-3
BCM System-3
System

M33 Ignition Switch 2 P8 Generator Controller

M33点火 F44 M31组合 M31组合 M31组合 M43诊断
M31 Combination Switch 2M31 Combination Switch 2
M31 Combination Switch 2
M43 Diagnosis Interface
P8发电机
开关2 10A 开关2 开关2 开关2 接口 调节器
A-4 J-9 J-3 J-8 J-8 O-1 D-1
114
025 108 064 127 126 093

0.5P
7 EP

0.5P
Front Rear
Frog Frog
钥
Key Lamp
前 后
Lamp Learning 14 ME1
匙
Insertion Switch
雾 Switch
雾
Code
学
Switch
插 小
Lamplet 0.5GrY Input
发
0.5Gr

0.5RB

0.5Or

IG1
IG1 灯 灯 灯 码 Generator
0.5R

0.5V

0.5P
Switch
入 Power
开 开 输 电
开 电 开 机
关 关 关 入
关
M29
B11 B18 B8 B15 B6 B17 B23

BCM
C
B1 B7 B9
M29
A 0.5WR

IG2
IG2 Power

驾驶室线束
0.5BrB

Cab Harness Internal Connection

0.5Y

Point
内连接点
0.5WR

0.5WR
0.5WR

067 131
J-6 P-1
M1左
M1 Left Door Signal Switch M5后 026
M5 Rearview Mirror
车门 视镜
Heating Switch 104 124
信号 加热 A-4 J-8 N-1
开关 开关
F32
10A M44 Headlamp Relay
M44大灯 M14空调模
M14 Air Conditioner Mode Controller

继电器 式控制器

M29(灰）BCM-2接口
M29(Gray) BCM-2 Interface
PE电源线束与发动机线束接口
PE Power Supply Harness and Engine Harness Interface
EM1(白色)发动机线束与驾驶室线束接口
EM1(White) Engine Harness and Cab Harness Interface

9 8 7 6 5 4 3 2 1
18 17 16 15 14 13 12 11 10 4 3 2 1 1 2 3 4 5 6 7 8 9 10 11
24 23 22 21 20 19 8 7 6 5 12 13 14 15 16 17 18 19 20 21 22

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L-1 线束图-组合仪表
Harness Diagram-Combination Instrument
组合仪表-1
Combination Instrumemt-1

F46
F47 P8发电机
P8 Generator M9转接器1
M9 Adapter 1 10A
111 J-1 10A
D-1 B-1 A-4

0.5R
3 2 028 047 017
里程表
0.5BlB

Odometer Sensor
传感器

0.5V
1
M43 Diagnosis Interface
F8 M43诊 M8 BCM1
0.5B

断接口
1 EF 底盘线束 K-1 5 EP
O-1
0.5BlB

Chassis Harness Internal Connection

内连接点
Point

0.5V
110

0.5R

0.5W
1.25B

109
12 EM1 F5 5 EM1

0.5BlG
0.5BlB

0.5VG Constant

0.5V
G01 常 IG1
Electricity

电 M35
A21 A22 A23 A20 A31 A19 IG1
LCD:里程
LCD: Sub-total Mileage Rotation
车
Speed
累计小计 车Speed
Speed
Signal 转 电源电路
速
Signal 数
Data 速Output 速
Power Supply Circuit

信 Line
据 输 信 燃油
Fuel Warning Water水温 Temperature

蜂
Warning

号 线 出 号 报警 报警 Buzzer
鸣
CPU控制单元 器
CPU Control Unit

水 燃 燃
Water
温 油
Fuel Fuel
油
C
Temperatur Signal Signal
信 步进电机驱动器 仪
e Signal
信 信
Ground
Stepper Motor Driver Instrument

号 号 表
Ground

号
地 地
燃油表
Fuel 转速表
Tachometer
车速表
Speedomete 水温表 Water Temperature
Gauge r
A25
Gauge

A26 A24 A29 A32

A

M35
0.5LgB

0.5BlR
0.5Gr

0.5GB

0.5B

EM1 1 11 EM1 2 EM1

J
0.5Gr

0.5Gr
0.5Gr

M24
驻车
Parking Brake Switch
制动 M26
EP 2 9 EF 10 EF 开关 G17
0.5Gr

0.5Gr

0.5Gr

P10 １
水
Water Fuel油２ F6
温
Temperature
Sensor 量
Volume
Sensor
传 传
感 感
器 器１
PE电源线束与发动机线束接口
PE Power Supply Harness and Engine Harness Interface

M26搭铁点17端子
F8里程表传感器接口
F8 Odometer Sensor Interface
M26 Ground Point 17 Terminal

4 3 2 1
8 7 6 5 1 2 3
F6燃油液位传感器接口
F6 Fuel Level Sensor Interface
EM1发动机线束与驾驶室线束接口
EM1 Engine Harness and Cab Harness Interface EF Engine Harness and Chassis Harness
Interface
EF发动机线束与底盘线束接口 M24/P10 Parking Brake Switch/Water Temperature
M24/P10驻车制动开
Sensor Interface 1 2
关/水温传感器接口
1 2 3 4 5 6 7 8 9 10 11
M35组合仪表接口
M35 Combination Instrument Interface
12 13 14 15 16 17 18 19 20 21 22
1 17181920 2122 2324 2526 2728 293031 32
1 2 3 4 5 6 7 8 9 1011 1213 14 1516

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L-2 Harness线束图-组合仪表
Diagram-Combination
Combination Instrument-2
Instrument
组合仪表-2

IG1
Constant

常
Electricity

Door 门
Unlocked

Indicator 安
Seat
Charging
充
High
beam 远 Oil 机
Braking
制
Malfunction
Indication
Lamp
未 全
Belt 预
Preheat
电
Indication
光 Pressure
油 动
关 带 热 指 指 压 故
指 示 示 力 障
示
灯

A18 A27 A14 A6 A12 A17 A28

0.5GBr

0.5Or
M35
0.3Br

0.5P

0.5Y

0.5Y
0.3G

C
EM1 3
069 113
0.5Or

0.5Or
112 084
0.5Y

J-6 G-1 D-1 B-2

A

左右车门
Left/Right Door Signal Switch
M36预 P8发电机 M11转
M36 Preheating Switch P8 Generator ControllerM11 Adapter 2

信号开关 热开关 调节器接口接器2 Interface

Braking
制
Liquid

EP 3 4 EM1 动 2 M38
Level
Switch

安
M25 １Seat 液
J

全
Belt 位
Switch
带 开１
0.5Or

开 关
0.5Y

2关
0.5B
0.5B

E7
Oil
机
Pressure
真
Vacuum
Cylinder
油
Switch P4 空
Switch

压 筒 6 M3
M26 力 开
开 关 G16
G17
关

M26搭铁点17端子
M26 Ground Point 17 Terminal E7 Vacuum Cylinder Switch Interface
E7真空桶开关接口
M38制动液位开关接口
M38 Braking Liquid Level Switch Interface
P4机油压力开关接口
P4 Oil Pressure Switch Interface

EM1 Engine Harness and Cab Harness Interface PE电源线束与

PE Power Supply Harness and Engine Harness Interface 1 2 1
EM1发动机线束与驾驶室线束接口 发动机线束接口
M35组合仪表接口
M35 Combination Instrument Interface

1 2 3 4 5 6 7 8 9 10 11 4 3 2 1 1718 1920 2122 23242526 2728 2930 3132

12 13 14 15 16 17 18 19 20 21 22 8 7 6 5 1 2 3 4 5 6 7 8 9 10 11 1213 14 1516

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L-3 Harness Diagram-Combination
线束图-组合仪表 Instrument
Combination Instrument-3
组合仪表-3

F47
10A
J-1
Daytime Running
Front Frog Lamp Lamp Relay
116
Relay
M9 Adapter1 M11 Adapter M11 Adapter Rear 后雾灯
Frog Lamp 前雾灯 日间行车
M9转接器1 M11转接器2 M11转接器 2 Relay 继电器 继电器 灯继电器

0.5R
B-1 B-2 B-2 J-3 J-3 J-4

118 117
054 091 071 119
3
油水分离
Oil Water Separator Sensor

2
器传感器

0.5Lg
1
E1

0.5B
15 EM1
0.5GBl

0.5GOr

0.5BlW
0.3GR

0.5GW

0.5Bl

0.5Lg
M35
A7 A5 A4 A11 A13 A16 A1
E3
G09
C

Rear
Lamplet
Left
左
Steering
Right
右
Steerin Frog 后 Front
Indication前
Frog
日
Daytime
Running 油
Oil Water
小 间 Separatio
A

转
g
转 雾
Indication
雾 Lamp
n 水
灯 向 向 灯 灯 行 分
指 指 车 离
示 示 灯
J

Cathode

负极

E3 Ground 9 Terminal
EM1 Engine Harness and Cab Harness Interface E1 Diesel Filter Water Level Sensor E3搭铁9端子
EM1发动机线束与驾驶室线束接口 E1柴虑水位传感器接口
Interface

M35 Combination Instrument Interface

1 2 3 4 5 6 7 8 9 10 11 M35组合仪表接口
1 2 3
12 13 14 15 16 17 18 19 20 21 22 1718 1920 21222324 2526 2728 2930 3132
1 2 3 4 5 6 7 8 9 10111213 14 15 16

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M-1
Harness Diagram-Window
线束图-车窗控制
Window Control-1
车窗控制-1 Control

电动车窗
PowerWindow M9 Adapter 1
继电器
Relay M9转接器1
M-2 B-1

120 051

0.5GR
2.0R

Main Power Window Switch

主电动车窗开关
6 1 D7

主按钮
Main Button 副按钮
Deputy Button 小灯
Lamplet
Terminal
端子
6 2 3 7 6 4 5 7 7 1
功能
Function B+ U1 D1 E B+ U2 D2 E E TA
上升
Up

OFF
下降
Down
C
2 3 4 5 7 D7
2.0Bl
2.0P

2.0Y

2.0G

2.0B
A

1 2
M
D5 18 MD1
J

左前玻璃
Left Front Window Elevating Motor
升降电机
122 123
2.0B

M-2 M-2

D3副电动车窗开关
D3 Deputy
Power Window
Switch

1 M3
G16

D7主电动车窗开关接口
D7 Main Power Window Switch Interface
M3搭铁点16接口
M3 Ground Point 16 Interface D5左升降电机接口
D5 Left Elevating Motor Interface
MD1左车门线束与驾驶室线束接口
MD1 Left Door Harness and Cab Harness Interface

1 2 3 4 5 6 7
3 2 1 3 8 9
1 2 4
1 2 1011 12 13 14 15 16
7 6 5 4 5 6 7 8 17 18
1920 21 22 23 24 25

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M-2 线束图-车窗控制
Harness Diagram-Window
车窗控制-2
Window Control-2
Control
SB15
30A
A-5

D7 Main Power Window Switch MB BCM1

031
D7主电动车窗开关M8 BCM1

3.0W
M-1 M-1 K-1
123 122 121

1.25W

3.0W
电
86 30 动Power
Window
车
2.0Y
2.0G

Relay
窗
继
85 87 电
MD1 9 8 器
0.5GR

3.0R
2.0Y

驾驶室线束
2.0G

内连接点
Cab Harness Internal Connection
2.0R

2.0R
Point

MD2

8 17 MD2
C
MD2 17 MD1
2.0R
2.0G

2.0Y

2.0R

9
D3
A

副
Deputy
Power
Window 端子 Terminal
1 3 4 5 7
电
Switch

功能 MD D2 MU U2 B+
Function

动
上升
J

车 Up
120
窗 OFF
M-1
开
关 下降 Down D7主电动
D7 Main Power Window Switch
车窗开关
D3
2.0Bl

2.0P

2 1
M
D6
右前玻璃
Right Front Power Window Elevating Motor
升降电机

D3 Deputy Power Window Switch Interface MD1左、MD2右车门线束与驾驶室线束接口

MD1 Left、MD2 Right Door Harness and Cab Harness Interface
D3副电动车窗开关接口 D6 Elevating Motor Interface
D6右升降电机接口

1 2 3 4 5 6 7
3 2 1 8 9
1 2 10 11 12 13 14 1516
7 6 5 4
17 18
1920 21 22 23 24 25

打印人：20122642 部门：客户服务部
N-1 线束图-空气调节系统
Harness Diagram-Air-Conditioning
空气调节系统-1
Air-Conditioning System System

SB03 F32
30A 10A
A-3 K-3

004 124 M9转接器1

M9 Adapter 1

B-1
3.0Y

0.5WR
F36 057
EM3 3 10A

0.5GR

0.5R
0.5WR
3.0Y

M4
鼓 端子 5 4 6 3 1 2
Fan 功能 Terminal
30 86 风 Function
A/C
Relay 小灯
机 Lamplet 开

2.0W
继 OFF Switch
关
电 ON
87 85 器

0.5YR
0.3B
3.0W

0.3B
0.5P

0.3B
0.5WR

鼓 端子 3 IG2
Fan 2 1 6 5 4 3 M10
风 功能
Terminal
Speed Functio
Control
OFF n

机
Switch
1 G15
1
C
调 Air Conditioner Module Controller E13压力
2 空调模式控制器 E13 Pressure
速 开关
Switch
3 17 18
开 4 N-3
关 M14
M15 129
2.0BrBl
1.25R

A
2.0Y

3.0G
3.0B

0.3P

0.3W

M+ M-
M13
G13
J

M22
8 12 7 13 4 3 9 15
3.0W

4 3 2 1 Evaporator
蒸发器温
14 M Temperature Sensor
M
度传感器
鼓风机 内外循环电机
Internal and External Circulation Motor
Fan
Speed调速电阻Regulation
Resistance 10
0.5B

M14空调控制器接口
M14 Air Conditioner Controller Interface
7 M16
G12
10 9 8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11

M13搭铁点13端子
M13 Ground Point 13 Terminal M4 AC Switch Interface
M22M22HAVC线束接口
HAVC Harness Interface

M10/M16 Ground Point 15/20 Interface

M10/M16搭铁点15/12接口 M4 AC开关接口
4 3 2 1
8 7
M15鼓风机调速接口
M15 Fan Speed Control Interface
5 1
10 9 6 5
1 2 3 4 6 4 2 3 14 13
3 2 1
5 6 7 8 16 15 12 11
6 5 4

打印人：20122642 部门：客户服务部
N-2 Harness Diagram- Air
线束图-空气调节系统 Conditioning
System
Air Conditioning System-2
空气调节系统-2

M9 Adapter 1
M9转接器1
B-1

060

0.3GR
M9 Adapter 1 M9 Adapter 1
Internal
内 Termina M9转接器1 M9转接器1
功能 端子 5
and Function l
1 6 3 2 4
外
External
B-1 B-1
Circulation Lamplet

Switch循 小灯
环 OFF 048 062
开 ON
关
M7
0.3BlR
0.3YW

0.3GY

0.3GR
0.3B
0.3G

0.5R
Constant
Electricity

M10 1 常
G15 电

M14
10 20 9 12 2 11
Air Conditioner
空调模式控制器 Mode Controller
C
5 6 7 4 8 13 15 5 4 3 6 2
M14 M45
GND PBR +5V M+ M- +5V PBR - M+ M-
0.3GrOr

0.3GrY
A
0.3GrG
0.3GrR

0.3GrB
0.3Or
0.3GB

0.3Br
0.3PB

0.5B

0.5B
0.3Y

M22
J

5 2 1 6 11
1 6 M16
M46
G12 G12
3 4 5 1 2
M
M

Warm and Cool Wind Actuator

冷暖风执行器
Mode Actuator
MODE执行器

M14空调控制器接口
M14 Air Conditioner Controller Interface

10 9 8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14 13 12 11

M22 HAVC Harness Interface

M22 HAVC线束接口 M10/M16 Ground Point 15/12 Interface
M45冷暖模式开关接口
M45 Cool and Warm Mode Switch Interface

M10/M16搭铁点15/12接口 M7 Internal and External Circulation Switch Interface

M7内外循环开关接口
4 3 2 1 5 4 3 2 1
8 7 M46 Cool and Warm Execution Unit
10 9 6 5 1 2 3 4 5 1 M46冷暖风执行单元接口
Interface

14 13 6 4 2 3 1 5
5 6 7 8
16 15 12 11 2 4 3

打印人：20122642 部门：客户服务部
N-3 线束图-空气调节系统
Harness Diagram- Air Conditioning System

空气调节系统-3
Air Conditioning System-3

F18 SB08
10A 30A
A-3 A-3

006 005

0.5Br

3.0W
0.85R
0.85BlR

压 冷
Compresso
缩 86 30 86 30 Condense
凝 r Relay
r Relay
2 机 器
继 继
HI 压 电 85 87 85 87 电
Pressure
Switch
力 器 器
0.85Br

3.0R
0.5B

0.5B

开
LO
C
关
1
E13
冷
0.85Br
0.5YB

2 Condense
A
0.5B

r Motor
凝
M 器
0.85Br

怠 Idle Speed
1 速
Lift Solenoid 电
18 EM2
Valve
E5 1 机
提
J

升
0.5YB

2 6 EP E3
E15 电
3.0B

E4 Ground Terminal
磁 G09
0.85B

0.85Br

阀
129 E4

N-1 E3 G08
P12
M22 HVAC线束
M22 HVAC Harness G09 压缩
Compressor Electromagnetic
机电
Clutch

磁离
合器

PE电源线束与
PE Power Supply Harness and Engine Harness
EM2 Engine Harness and Cab Harness Interface
EM2发动机线束与驾驶室线束接口
Interface
发动机线束接口 E4搭铁端子
E4 Ground Terminal
E3搭铁端子
E3 Ground Terminal

4 3 2 1 1 2 3 4 5 6 7 8 9 10 11

8 7 6 5 12 13 14 15 16 17 18 19 20 21 22

打印人：20122642 部门：客户服务部
O-1
Harness Diagram-Diagnosis
线束图-诊断系统
Diagnosis
诊断系统-1 System-1 System

M9 Adapter 1 M29 BCM2

M9转接器1
B-1 K-3
093
041

0.5GrY
0.5RW

M43

16 10

5 4 1

M43
C
0.5VG
0.5B

A 0.5B

109
J

L-1
M35 Combination
M35组合仪表 Instrument

7 M3
G16

M43 Diagnostic Interface M35 Ground Point 16 Interface

M43诊断接口 M3搭铁点16接口

16 15 14 13 12 11 10 9 1 2 3 4
8 7 6 5 4 3 2 1 5 6 7 8

打印人：20122642 部门：客户服务部
P-1 Harness Diagram-Power
线路图-电动后视镜 Rearview
Mirror
Power Rearview Mirror-1
电动后视镜-1

F34 10A
M9 Adapter 1 MD1
M29 BCM2 M9转接器1 A-4 014

0.5Gr
22
K-3 B-1
Power Rearview Mirror Switch

电动后视镜开关 7
131 063
Left
上
Up

mirror
下
0.3GR

Down
0.3Y

左镜 OFF
Rearview
后
Heating 左
Left

Switch
视
1 3 2 6 5 端子 Terminal
Function 右
Right

功能 镜
OFF 加 Right
上 Up

mirror

热 下
Down

ON
开 右镜 OFF
关
M5
Left
左
右
Right
0.5B

0.3B
0.5R

12 10 9 8 11 1 D8-左 D8-Left
0.5WBl

0.5Br
0.5P
0.5W

0.5Y
0.5B

Left Door Harness Interna

Cab Harness Internal Connection Point 左门线束Connection Point

驾驶室线束 内连接点
2 内连接点
0.5Y
G15M10
C
0.5R

6 7 5 MD1
驾驶室线束
0.5R

Cab Harness Internal Connection Point

0.5Y

内连接点
MD1 4
A

4 6 7 5
0.5R

MD2 0.5B
0.5R

0.5Y

0.5R

0.5Y

D8-Right

D4-左
D4-Left
D8-右
J

092 7 2 3 4 7 2 3 4
Left
下
Down
左
Left
左 下
Down

K-2
M2 Automatic Door Lock Relay
M2自动门锁继电器 M M M M Left Door Harness Interna
Connection Point

上Up
右Right 右
Right
上Up 左门线束
内连接点
6 6
1.25B 1.25B 0.5B

2.0B

Left Exterior Rearview mirror

左外后视镜 右外后视镜
Right Exterior Rearview mirror
0.5B

18 MD1
2.0B

18 MD2

1 M3
5 M16
G16
G12

MD1左、MD2右车门线
MD1 Left、MD2 Right Door Harness and Cab Harness Interface
D4左、D8右电
D4 Left、D8 Right Power Rearview Mirror Interface
D8左门线束电动
D8 Left Door Harness Power Mirror Switch Interface
M5电动外后视镜
M5 Power Exterior Rearview mirror Heating Switch Interface

束与驾驶室线束接口 动后视镜接口 后视镜开关接口 加热开关接口

1 2 3 4 5 6 7
8 9 5 1
1 2 3 4 6 5 4 3 2 1
1011 12 13 14 15 16
17 18 5 6 7 8 12 11 10 9 8 7 6 4 2 3
19 20 21 22 23 24 25

打印人：20122642 部门：客户服务部
Q-1 Harness Diagram-Wiper
线路图-刮水和洗涤 and
Scrubber
Wiper 刮水器、洗涤器-1
and Scrubber-1

F28 20A
A-4

020

1.25W
Cab Harness Internal Connection Point
驾驶室线束内连接点
1.25W 1.25W

1.25W
Front Wiper Switch
前雨刮开关
8

Terminal
端子 4
Function
7 8 INT1 INT2 B
功能 5 9
MIST
OFF
INT
LO
HI
上抬喷水
Water Spray When Lifting the Wiper
C
INT UNIT
A

4 5 9 7 6
1.25Bl

1.25GR

1.25R
1.25G

M10

10 11 9 22 EM1
J 1.25GR

1.25R
1.25G

Front
Scrubber 前 2
Motor
洗
涤 M
电 1 LO 4 E10
M39
机 HI 3
Front Wiper Motor
1 前刮水器电机
M 2

5
1.25B

1.25B

4 M3 E9
G16 G11

EM1 Engine Harness and Cab Harness Interface

M30 Front Wiper、Scrubber Switch Interface M39 Scrubber Motor Interface E10 Wiper Motor Interface
M30前雨刮、洗涤开关接口 EM1发动机线束与驾驶室线束接口 M39洗涤器电机接口 E10刮水器电机接口

1 2 3 4 5 6 7 8 9 10 11 1 2 3
1 2 3 4 5 6 7 8 9 10 1 2
12 13 14 15 16 17 18 19 20 21 22 4 5

打印人：20122642 部门：客户服务部
R-1
线路图-刮水和洗涤
Harness Diagram-Wiper and
Scrubber
音响系统-1
Audio System-1

M9 Adapter 1
M9 Adapter 1
F34 10A M9转接器1 M9转接器1
A-4 B-1 B-1

013 056 049

Antenna
天线

0.85R
0.5Gr

0.5GR

M23
7(ACC) 9(小灯)
(Lamplet)
8(B+)

收音机
Radio

3 14 4 11 6 16
0.5BlB
0.5BlW

0.5G

0.85B
0.5W

0.5B 驾驶室线束
Cab Harness Internal Connection point
内连接点
C

15 16 MD1 15 16 MD2
M12
A

G14
J

Left Door Harness Internal Right Door Harness Internal

左门线束
Connection Point 右门线束
Connection Point

内连接点 内连接点
0.5BlB

0.5BlB
0.5BlW

0.5BlW

0.5G

0.5G
0.5W

0.5W

1 2 D6 1 2 D3 1 2 D7
1 2 D4
＋ － ＋ － ＋ －
＋ －

左前低音扬声器 左前高音扬声器 右前高音扬声器

Left Front Woofer Left Front Tweeter 右前低音扬声器 Right Front Tweeter
Right Front Woofer

M23收放机接口 MD1左、MD2右车门线束与驾驶室线束接口
MD1 Left、MD2 Right Door Harness and Cab Harness Interface D6D6左、D4右车门线束
Left、D4 Right Door Harness Woofer Interface D3D3左、D7右车门线束
Left 、 D7 Right Door Harness Woofer
M23 Radio Interface
低音扬声器接口 低音扬声器接口
Interface

1 2 3 4 5 6 7
7 6 5 4 3 2 1 8 9
10 11 12 13 14 15 16 1 2
8 9 10 11 12 13 14 15 16 17 18 1 2
1920 21 22 23 24 25

打印人：20122642 部门：客户服务部
C
A
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打印人：20122642 部门：客户服务部
Mengcheng minitruck BCM used to control most electric system of vehicle. Electric facilities controlled by
BCM are: indoor top light,anti-theft alarming bell,safety belt warning, electric window, rear foglight, rear defrost,
small light, hazard warning light, fastener system.
BCM will control according to the following facilities: driving seat door, passenger seat door, driving
seat door fastener, passenger seat door fastener, speeding signal, rear foglight, front foglight, small
light switch, headlight switch, rear defrost switch, keyhole, ignition switch.

C
A
J

2.1 BCM installation location

BCM is installed to beam bracket right under steering wheel.

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打印人：20122642 部门：客户服务部
1. Left side blowing switch 10. Rear view mirror defrost switch 19. Right defrost vent
2. Preheat switch 11. Shriner 20. Glove box
3. Electric adjustment headlight switch 12.Hazard warning lamp switch 21. Font defrost
vent
4. Fuse cover 13. AC switch 22. Central venting
5. Horn switch 14. Wind speed switch 23. Wiper washing
switch
6. Steering wheel 15. Mode switch 24. Light switch
7. A/C switch 16. Glove box 25.left defrost vent
8. Storage box 17. Right venting switch 26. Left venting
9. Inner and outer cycle switch 18. Right venting

2.2 BCM functions introduction

Mengcheng minitruck BCM defines the following functions:
A. indoor light control
C
B. small light control
C. Rear fog lamp control
D. DRL control
A

E. electric power window control

F. Central Lock Control
G. Automatic lock control
H. Collision unlock
J

I. remote lock and unlock

J. rear view mirror heat control (optional equipment)
K. remote key identical code

2.3 system structure

Structural Diagram:

80

打印人：20122642 部门：客户服务部
1. BCM is electric control module for centralized control car;
2. Body electric control includes mainly speeding input/ collision signal input
Switching value input/ remote receiving control and indoor electric control output;
3. All parts in electric control are connected by indoor harness;

4. BCM judges all kinds of inputs and give certain orders to electric equipment.
C
A
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打印人：20122642 部门：客户服务部
2.4 BCM functions introduction
1、 Indoor light control:
door light is in DOOR position:
1 Ignition switch is not in ON position,
indoor lamp lights up if any door opens,
indoor lamp will last for 30s before going
out when all doors close. Press remote
lock within 30s, indoor light will go out
immediately.
2 Ignition switch is in ON position, indoor
lamp lights up if any door opens, indoor
lamp will go out immediately when all
doors close.
3 Ignition key is not inserted, all doors
closed, press remote unlock, indoor lamp
light up for 30s before going out. Press
remote lock within 30s, indoor light will
go out immediately.
4 Ignition key is not inserted, any door
opens indoor lamp will lamp up, press
remote lock, indoor lamp will not go out
5 Indoor lamp will be on during the time of
door opens, indoor lamp will go out if the
time is more than 15min, time of indoor
C
lamp going out is 5.5±0.5s.
2. Small light control
1 Start small light:
A

Ignition switch is on any position, small

light will be on if its switch input is
effective.
J

2 Small light goes out:

·The light switch turns to “OFF” from
“ON”.
·Key is taken out with the driver-sided
door opened, small lamp will go out; if
the key is inserted now, small lamp
lights up.

82

打印人：20122642 部门：客户服务部
3、 Rear fog lamp control
1 Starting condition
When Ignition switch is ON, small
lamp/headlight and front fog light switch are
all opened, rear fog lamp turns on.
2 Closing condition
·Small lamp switch is off
·Rear fog lamp switch is off
·Ignition switch is turned to any other
location except ON

C
A
J

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打印人：20122642 部门：客户服务部
BCM functions introduction
4、 DRL control
1 Starting condition:
Turn on IGN, electric generator L is
effective, low beam(reserved) switch is
closed, headlight switch is closed, DRL
lights up;
2 Closing condition:
Turn off IGN, electric generator L is
ineffective, low beam (reserved) switch
is open, headlight switch is open, DRL
goes out.

5、 Electric power window control

Used to control electric power window power
supply
1 When ignition switch is in ON position,
electric power window could be opened
2 Within 30s after ignition switch ON-OFF, it
could turn on if no front door opens, and
could close if any front door opens or it is
out of 30s.
C
A
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84

打印人：20122642 部门：客户服务部
6、 Central Lock
① Turn left/right front door switch when
driver or passenger door is closed, all
doors could lock and unlock.
② When key is not inserted, lock and
unlock could be implemented no matter
door is open or closed
3 When key is inserted, any one of front
doors is open
·Press once central lock, output unlock
commander once,
·Keep pressing lock of opening door,
output unlocking commander 3 times
continuously after outputting it once,
·Keep pressing lock of closing door,
output unlocking commander once
·Keep pressing lock of opening door,
loose during outputting unlocking
commander, and then never output
unlocking commander.
When key is inserted, front doors are
open
·Press once central lock, output unlock
commander once
C
·Keep pressing lock of opening door,
output unlocking commander 3 times
continuously after outputting it once.
A
J

BCM functions introduction

7、Automatic lock.
Automatic lock function: when speed
reaches to the set value n (defaulted value is
40km/h, speed=frequency/2), if locking
electric motor is unlock, driver door is closed,
BCM will be locked to doors automatically,
and then left front door opens, lock after
(1±0.3)s, continue to lock if left front door is
unlocked; if it is still unlocked after 3 times,
stop locking. When speed decreases to
40km/h, automatic lock is restored.

85

打印人：20122642 部门：客户服务部
8、 H. Collision unlock
1 40ms after collision happens, and safety
airbag output collision signal, fastener
will carry out the commander of 5
seconds' time, then all doors are
unlocked. Do not implement any locking
action, until get out of collision status.
2 When ignition is in ON position, collision
input signal is effective, BCM will shield
automatic locking function/ central
locking function and RKE locking
function, door will stay in unlocking
status, indoor lamp (DOOR position) will
be on all the time, hazard warning lamp
(left and right turning lamp) twinkles with
0.5s on and 0.5s off, until ignition switch
changes ON-OFF-ON position; BCM will
restore to normal function when out of
C collision status.
A
J

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打印人：20122642 部门：客户服务部
BCM functions introduction
9. remote lock and unlock
① Remote unlock
· With all doors locked, doors will be
unlocked if BCM receives effective
remote unlocking signal, and implement
the definite action, left and right turning
light goes out after twinkling 2 times
with 0.5s on and 0.5s off.
·With all doors unlocked, BCM unlock if
receives effective unlocking signal, and
turning lights continue to implement the
definite action.
· There is no door open or key inserting
signal within 30s after pressing remote
lock, BCM will implement locking
commander once again and lock all
doors.
3 Remote lock
· With all doors unlocked, BCM receives
effective locking signal and lock all
doors if they are closed, all turning lights
twinkle once with 0.5s on and 0.5s off.
If BCM receives unlocking commander
C
during twinkling, then twinkling lights
turn to unlock twinkling process;
· If any door is not closed, lock electric
motor, and turning lights do not twinkle.
A

When all doors closed, implement

actions once again, left/right turning light
twinkle once with 0.5s on and 0.5s off.
J

· If all doors are closed, lock remotely, lock

electric motor, but the lock is still
unlocked, turning lights do not twinkle.
When all locks are locked, implement
actions once again, left/right turning light
twinkle once with 0.5s on and 0.5s off.
· When doors are locked, BCM receives
effective locking signal and lock,
left/right turning lights twinkle once with
0.5s on and 0.5s off at the same time.

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打印人：20122642 部门：客户服务部
BCM functions introduction
10、 Rear view mirror heat control.
Electric generator L receives rear defrost
switch inputting signal, than rear defrost
starts to heat and cut off automatically 20
min later. During which, press defrost
switch or electric generator L ineffective,
than heat stops.

11、 Remote key identical code

Unplug ignition key, connect special identical
code equipment and reserved identical code,
making controller into identical code status,
now turning lamps light on; If turning lamps
will go out after twinkling 3 times if they
C
receive effective remote signal within 10s,
meaning one key identical code successful.
Each can only study one key, each controller
A

can also study one key at most, the first key

will be erased if one second key studies
successfully. If there is no key studying
within 10s, turning lamps go out and
J

studying status stops.

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打印人：20122642 部门：客户服务部
2.5 Stitch definition

Connector Working
Port name Input/output Initial status Remark
number status
A1 reserve Output High voltage Low voltage
High
A2 Interior lights Output voltage(hang in Low voltage reserve
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the air)
A3 reserve Output High voltage Low voltage
A4 reserve Output High voltage Low voltage
A

A5 reserve Output High voltage Low voltage

A6 Rear fog lamp relay Output High voltage Low voltage
A7 / Output hang in the air Low voltage
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A8 reserve Output High voltage Low voltage

Rear view mirror
A9
heat relay
A10 B+
A11 reserve Output High voltage Low voltage
Low
hang in the
A12 Fastener relay Input voltage(door
air(door closed)
open)
A13 Turning lamps relay Output High voltage Low voltage
A14 reserve Output High voltage Low voltage reserve
A15 Power window relay Output High voltage Low voltage
A16 Headlight switch Input High voltage Low voltage
A17 Small light relay Input hang in the air Low voltage
A18 DRL relay Output High voltage Low voltage
A19 Ground
A20 reserve Output High voltage Low voltage
A21 Unlocking relay Output High voltage Low voltage
passenger seat
A22 Input High voltage Low voltage
door switch
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Right rear door
A23 Input High voltage Low voltage
switch

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BCM snitch definition (continuous)
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Re
Connector
Port name Input/output Initial status Working status mar
number
k
A24 Speed signal Input hang in the air Pulse
Driver seat door
B1 Input hang in the air Low voltage
switch
B2 reserve Input hang in the air Low voltage
B3 reserve Output hang in the air Low voltage
Left rear door lock
B4 Input hang in the air Low voltage
switch
Passenger seat door
B5 Input hang in the air Low voltage
lock switch
B6 Rear fog lamp switch Input hang in the air Low voltage
B7 Rear defrost switch Input hang in the air Low voltage
B8 Front fog lamp switch Input hang in the air Low voltage
B9 IG2 Input hang in the air High voltage
B10 reserve Input hang in the air Low voltage
Key inserted into
B11 Input hang in the air High voltage
switch
B12 reserve Input hang in the air Low voltage
B13 Left rear door switch Input hang in the air Low voltage
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Driver seat door lock
B14 Input hang in the air Low voltage
switch
Hang in the Low
B15 Small light switch Input
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air(locked) voltage(unlocked)
B16 reserve Input hang in the air Low voltage
B17 Identical code input Input hang in the air Pulse
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B18 IG1 Input hang in the air High voltage

B19 reserve Input hang in the air Low voltage
B20 reserve Input High voltage Low voltage
B21 Collision signal Input hang in the air Low voltage
B22 reserve Input Analog signal
B23 Generator L Input hang in the air High voltage
B24 Outside antenna

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2.6 Remove BCM
1. Disconnect the battery harness.

2. Car controller is under dashboard which is

right lower the steering wheel, fixed to beam,
removed with socket spanner from bottom to up.

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3. Remove controller fixing nut(M6) with socket
spanner of 10#, bolt torque: 7N·m～9N·m.
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4. Disconnect BCM connector.

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2.7 Install BCM
1. Remove controller fixing nut(M6) with socket
spanner of 10#, bolt torque: 7N·m～9N·m.

2. Insert BCM connector.

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3. Install battery harness.

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2.8 Basic parameter

Electric parameter Require

Voltage DC12V
Working voltage range DC9V～DC16V
Static current ≤5mA
Insulated resistance 100MΩ (DC500V tramegger)
Remote control transmission frequency 433.92MHz±100KHz
Receiving frequency of car controller 433.92MHz±100KHz
Distance of remote control no dead zone within 20m
Operation temperature -40ºC～+80ºC
Storage temperature -40ºC～+85ºC

3. Car harness layout

3.1 Cabin harness:
Label name label name
M1 receiving left door signal switch M29 receive BCM-2
M2 fastener controller M30 combination switch
assembly-1
M3 Iron spot16 M31 combination switch assembly-2
M4 receive AC switch M32 receive horn switch
M5 receive electric rear view mirror heat switch M33 receive ignition switch-2
M6 receive hazard warning switch M34 receive ignition switch-1
M7 receive inside and outside circulation switch M35 receive dashboard 1
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M8 receive BCM-1 M36 receive preheat switch
M9 adaptor 1 M37 receive electric adjustment
switch
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M10 iron spot 15 M38 receive braking fluid pot

M11 adaptor 2 M39 receive washing pot
M12 iron spot 14 M41 receive left front fog lamp
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M13 iron spot 13 M42 receive left combination lamp

M14 AC controller M44 cabin crisper
M15 air blower speed control switch MD1 receive left door harness
M16 iron spot 16 MD2 receive right door harness
M17 receive front right fog lamp MT receive roof lamp harness
M19 receive right combination lamp ME1 receive engine assembly
harness1
M20 receive right door signal switch ME2 receive engine assembly
harness2
M22 receive HVAC harness ME3 receive engine assembly
harness3
M23 receive radio-cassette player
M24 receive handbrake switch
M25 receive safety belt switch
M26 receive iron spot 17
M27 receive cigarette lighter1
M28 receive cigarette lighter2

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3.2 Engine Harness
Label name
E1 diesel filter water level sensor
E2 diesel filter heater
E3 iron G
E4 iron 8
E5 condenser fan
E6 bass horn
E7 Vacuum tube switch
E8 Loudspeaker
E9 iron 11
E10 receive wiper motor
E11 receive braking switch
E12 receive clutch switch
E13 Pressure switch
E14 receive preheat stopper
E15 receive idle lifting valve
E16 Start and Stop
E17 car frame crisper
EM1 Cabin harness 1
EM2 Cabin harness 2
EM3 Cabin harness 3
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3.3 chassis harness
Label name
F1 right combination rear lights
F2 right license plate lamp
F3 left license plate lamp
F4 left combination rear lights
F5 iron
F6 fuel liquid level sensor
F7 reversing switch
F8 receive odometer sensor
FE receive car frame crisper

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3.4 Left door harness
Label name
DM1 receive dashboard harness (left)
D2 left turning light
D3 left loudspeaker.
D4 Power Rear View Mirror
D5 lifting motor
D6 left bass loudspeaker
D7 left power window switch
D8 Power rear view mirror switch
D9 left fastener
D10 left door light

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3.5 right door harness
Label name
D1 right fastener
D2 right door light
DM2 receive cabin harness
D3 assistant power window switch
D4 right bass loudspeaker
D5 right turning light
D6 lifting motor
D7 right loudspeaker
D8 Power Rear View Mirror

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3.6 roof light harness

Label name
T1 receive front top light
TM receive cabin harness

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3.7 Power supply harness

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Label name
P2 Plus-n-Minus battery clamp
P3 starter +
P4 engine oil pressure sensor
P7 starter electric magnetic switch
P8 electric generator adjustment
P9 Generator+
P10 water temperature sensor
P11 start thickening sensor
P12 compressor
PE1 receive car frame crisper connector1
PE2 receive car frame crisper（B+）
PE3 receive car frame crisper（ALT）
negative harness instruction of battery
Label name
X1 battery negative pole
X2 car frame iron

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C
3.8 harness layout precautions
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Removal of harness connector:

Please cut off connector with two hands
all the time. Pulling out connector with
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one hand will lead to breakdown of wire

connection
Note: Press down locking plate on both
sides, pull out plug to cut off again.

Connection of harness connector:

Hold both sides of connector firmly,
making sure snitch matches the snitch
hole, and both sides aligns, until crisp
buckle sound.

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Check of harness connector:
Check continuity of connector with
circuit tester. Insert testing needle in
the side of guiding line

Do not insert testing needle to the

beginning side of connector

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Removal of guide line of connector:
1. Insert thin stick to crust of connector
A

2. Press agnail (in the direction of

guide line of connector), and drag
guide line of connector.
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Insert of snitch of guide line:

1. Check if agnail of snitch is open
completely.
2. Insert snitch from guide line of
connector, press snitch until agnail
buckles tightly.
3. Drag guide line slightly, restore
snitch.

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Harness layout precautions:
Protect harness with cover or cannula,
avoiding direct touch with sharp edge or
surface;

There should be enough interval between

harness and bracket, and protect harness
with ethylene cannula and clip to avoid
direct touch;

Harness between engine and chassis

should be long enough, avoiding
damaging harness because of all kinds
of vibration.

Fuse:
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Fuse is the most common protective way in
electric circuit. Fuse will be blown down
when there is overcurrent flowing through,
A

preventing strong current damage other

parts of circuit.
Check and solve the problem that caused
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overcurrent before replacing fuse.

Current value of replaced fuse should be
4. Battery
Minitruck uses maintenance-free battery. Its character is: Consumption of electrolyte is very small,
no need to refill distilled water during its lifetime. It also has character of
shock-proof/high-temperature-proof/small volume/tiny self-discharge, etc. Lifetime is usually twice of
common battery.

4.1 Battery installation location

Battery is right below the cargo tank

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4.2 Battery precautions
Warning: Battery must be placed where children can't touch to prevent damage to human body.

Warning: In general, battery will produce explosive gas, which may harm human if handled
wrongly. It may harm human if not following related instructions.

Warning: Do not let frame/spark or lighting objects close to battery. When positive and
negative poles of battery is shorted connected by metal (eg. metal tools/ metal lines/metal
parts, etc.), battery will be short circuited, electric arc will be produced to melt poles, the
melted lead alloy will splash and cause burning due to heat.

Warning: There is sulfuric acid in battery, keep it away from skin/ eyes or clothes. Protect your eyes when working
close to battery, prevent acid fluid splashed out. When acid fluid touch skin or eyes, must wash with clean water
for at least 15min, and go to see doctor immediately. Go to hospital immediately when swallow acid
fluid by mistake. Otherwise, it may harm human.

Battery has poisonous substance. Used battery is harmful for health and environment. Used
battery is not allowed to be disposed as household garbage. Use legal disposal facility
specially for car garbage.

Protection: Wear protective glasses and gloves. Protect face and eyes when close to battery or charging,
keep good ventilation.

Note: Do not charge dead battery only with generator, which needs at least 8 hours to be fully charged if there is no
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extra duty in charging system.
Warning: Start charger only after connecting battery and charger. Otherwise, it may harm human.
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Warning: Remove battery only after shut off charger.

Otherwise, it may harm human.
Warning: Avoid charging on car.
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Warning: Must follow manufacturer's instructions when using charging facility. Otherwise, it may
harm human.
Urgent disposal: Use clyburn spanner or other tools when burning, disconnect metal conductor
outside battery, do not touch with bare hands and put off fire with extinguish material.
Precaution: Avoid direct short circuit of both poles of battery when operate with metal tools.

4.3. Battery maintenance

1. Battery status indicator (electric eye):
Green: Battery is fully charged, could start car.
Black: Battery is not fully charged, need to be charged.
White: Disposed battery, need to be replaced.

2. Auxiliary charge of battery

When car is not started, many problems may cause battery couldn't be used or leakage: on-board electric
equipment are used too long or badly used, electric leakage and do not drive for long time, or generator charging
problems. Battery needs to charge outside of vehicle if electric eye is black or couldn't start vehicle.

 Exterior check before charging:

Battery whose crust break down or has acid leakage can't be charged, replace it after checking.
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Battery whose newel post break down can't be charged, replace it after checking.
Battery whose electric eyes are black can't be charged, replace it.
Clear newel post before recharging battery, erasing oxide skin on the surface.

 Precautions when charging:

Wear safety glasses.
Keep ventilation when charging at normal temperature.
Smoking is forbidden when charging to avoid kindling.
Connect positive line first after charging; Disconnect negative line when removing lines before charging.

 Battery refill charge:

Clear newel post and connect charging loop.
Positive pole of charger is connected to positive pole of battery, negative pole of charger is connected to
negative pole of battery. Do not charge battery which is series connection (24V).
Choose charger which has constant voltage of 16V (less than 16.2V, otherwise water will be electrolysed
and electric eye goes to white, battery is scraped), current-limiting of 25A to charge battery until its
electric eye is green. Green electric eye means it is fully charged.
Follow the following rules if there is no constant voltage to charge:

1. Choose current with 1/8～1/10 that of rated current, voltage should reach but no more than 16V at the end
of charging (otherwise, electric eye will still be black when fully charged, but do not influence normal use).
Monitor the voltage per hour by human when can't guarantee voltage lower than 16V, otherwise it will
influence battery's lifetime or invalidation due to overvoltage charging.
2. Check color of electric eye after charging. If it is green, then it is fully charged. If it is black, check
charging line is connected firmly or not, connecting point is clean or not, voltage reaches 16V or not, check
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voltage after placing 24 hours, recharge.
3. If electric eye is white, maybe there is bubble in electric eye, slight shake may drive away bubble. Replace
battery if it is still white after shaking (meaning electrolyte is wasted).
There may be failure of charging at initial period for battery lower than 11V. Vitriolic acid is close to water
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for battery which has severe electric leakage, inner resistance is very big. Now, reduce charging current or
replace with charger with high-power, vitriolic acid is increasing along with charging, charging current of
battery can restore to normal gradually.
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If there is mass acid spraying from gas vent when charging battery, should stop charging and check for
reasons.
Stop charging if battery temperature is over 45° when charging, until it decreases to normal temperature,
reduce charging current to half, and continue to charge.
Check electric eye per hour during recharging. If it is green, then it is fully charged, stop charging.
Recharging is finished and is qualified. Put grease on newel post to prevent galvanic corrosion.

3. Correct use of battery

 Discharging time of large current should not be too long, otherwise polar plate will be deformed due to heat,
which may cause short circuit or active material loss, Starting vehicle should be within 5s, interval between
start time should be more than 10～15s;
 It should also be within 5s when check capacity with High rate discharger;
 Battery is in charging status when car is driving; but, regulator regulates wrongly, low power supply ability,
frequent start consumes too much electric, or short circuit, ect., may cause severe electric leakage of battery,
should recharge battery.
 Recharge should be done: using battery for 3 months, capacity is less than 50%, poor start, gloomy light,
abnormal horn sound, etc. At the same time, battery with different voltage should not be charged together.
New and old battery should not be mixed together.
 Check output voltage after battery is put on vehicle, adjust it within 13.8 ～ 14.8V, suggested voltage is
14.4V. Adjustment can be done within this range, battery may be over charged if vehicle is used too often,
now lower the voltage; otherwise, increase voltage. Make it high in winter and low in summer, to prevent
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over charged.
 Disconnect negative terminal with vehicle if car is restored for long time. Charge every 3 months if there is
no electric leakage to avoid over self-discharge and severe sulfation. Recharge according to voltage if there
is electric leakage at the beginning of storage, usually recharge is needed when voltage is lower than 12.6V.
 Discharge current should not be bigger than biggest battery of manufacturer, usually it is 4～5C20 (4～5
times of battery capacity), short-circuit method is not allowed to test electric.

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4.4 Malfunction diagnosis and test of battery.
Malfunctions Bad phenomenon Analysis of problems Disposing measures
Low electric ① voltage is around 12V ① Vehicle adjustment sets low ① replace adjuster
quantity ② density is lower value. ② charge out of
3 ② electricity consumption is vehicle
1.220g/cm
more than charging quantity ③ trouble shoot
③ poor start, gloomy ③ too many starts, short driving generator or harness
light 、 weak horn distance malfunction
sound ④ Generating electric is not ④ clear corrosion on
④ capacity test is in enough or harness malfunction newel post
yellow zone ⑤ newel post is corroded or
connected weakly
over charged ① Permanent reddish ① Vehicle adjustment sets high ① Adjust or replace
yellow inside of battery value. adjuster
crust (working bolt) ② current is big and time is long ② Charge according to
② Clapboard is when charging protocols
carbonized or softening ③ Working bolt is not open ③ Slight overcharge,
③ Electrolyte is when charging charge again after
reddish-brown and thick washing with water
④ positive active
material is like mud and
get off
Over ① voltage is below 10V ① Use when battery is not fully ① Replace circuit
discharged ② Density（proportion） charged adjuster
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3 ② Battery is used for long time, ② Guarantee quality
1.100g/cm vehicle generates insufficient when charge out of
③ electrolyte is pale electric vehicle
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and thick ③ Vehicle harness short circuit ③ Eliminate circuitry

④ Forget to shut off battery malfunction
switch ④ Turn off switch when
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⑤ Impure electrolyte battery parked

causes self-discharge ⑤ Replace new battery
short circuit ① voltage is below 10V ① Lead leakage or foreign ① dissection analysis
② No voltage in failure matter falls into battery when ② Replace new battery
zone assembling
② No proportion in ② Polar plate bends over when
failure zone assembling
④ There is smoke and ③ Burrs at the foot of plate
bubble when discharging group
⑤ No reaction from ④ Hole or crack in clapboard
failure zone when ⑤ Man-made damage
charging
Circuit ① Voltage is not stable ① Welding of newel post is bad ① Repair
disconnectio ② Discharge to zero ② Bus-bar fault ② Replace new battery
n and test voltage is ③ Cross-wall welding is open
below 10V ④ Middle column is broken off
③ Current can’t be
inputted or there is
sound when charging
Improper ① Electrolyte has ① Electrolyte is impure ① Replace new battery
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adding fluid abnormal taste ② Electrolyte proportion is high ② Adjust density and
② Density（proportion） ③ Density is not enough recharge electric
1.300g/cm
3 ④ Add pure water by mistake ③ Adjust charging with
3
above 1.400g/cm acid after
3 replacing electrolyte
② density is 1.100g/cm
after adding fluid
around
④ Color is slight white
Polar plate ① Quantity is low when ① Charging is insufficient and ① over charge method
sulfation discharging time is long at the beginning of ② Charge repeatedly
② Voltage decreases charging ③ Water treatment
rapidly when discharging ② Fluid back-out time is long, ④ Replace new battery
③ Bubble produces recharge is not timely
early when charging ③ Fluid is insufficient and polar
④ Voltage increases group is exposed for long
rapidly and high when time
charging
⑤ Surface of polar plate ④ Density of electrolyte is high
has white particle or ⑤ Temperature of electrolyte is
hickie high
⑥ Electrolyte is impure
The ① Low voltage ① Crack on crust of battery ① Repair and replace
electrolyte ② Electrolyte flows ② Vibration when moving crust
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cross zones when connected grids ③ Vibration when vehicle is ② Replace new battery
incline moving
③ Boiling when ④ Ignite causing inner
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discharging explosion
⑤ Heat is not sealed tightly
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Diagnosis and test
1. Malfunction diagnosis of battery.
Excessive ① There is too much ① Vehicle circuit adjustment ① Clean sedimen with
loss of active sediment at the bottom sets high value. water and charge to
material of the battery ② current is big and time is long use
② The battery capacity when charging ② Replace new battery
is low ③ Discharging quantity is huge
③ Single grid and and time is long
working bolt have ④ Temperature is high for long
permanent time after vehicle is driving long
reddish-brown ⑤ Making polar plate is not
④ Electrolyte is reddish qualified
brown
⑤ Electrolyte is reddish
and polar plate active
substances go off in
mud, clapboard is in
softening state,
negative polar plate
active material is
softening and expands
⑥ go off in block-form
Install anti ① Go back one grid is Manufacturing quality ① Replace new battery
polar 8V ② Remove and install
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② Go back two grids is again
4V
③ Go back all over -12V
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Charge anti ① Voltage value is

① Continuous mistake of ① Discharge the
polar negative positive/negative pole when battery of anti polars
② Color is opposite of charging ② First, charge small
positive/negative newel current, charge
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post normally after all

③ Polar plate color is grids react
opposite ② Replace new battery
if severe
Battery ① Ignition of newel post ① Improper installation ① Install firmly
cracks ② Damage of positive ② Old and thin harness ② Replace harness
harness ③ Malfunction operation of ③ trouble shoot
③ There is hole or crack generator generator malfunction
on crust/cover ④ outer spark intervenes ④ Keep battery away
⑤ Welding is weak on newel from heat center
post ⑤ Keep vent
⑥ Bus-bar fault unblocked often
⑦ Plate falls down ⑥ Replace new battery
④ Middle column is broken off
⑨ Polar plate is broken down
Quantity id ① poor start ① Connection is poor or ① Check circuit
low at initial ② Voltage value is low harness malfunction carefully
status ③ slow reaction ② Out of deposit period ② Recharge
③ Positive polar plate is
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passivated
④ Negative polar plate is
oxidized
⑤ Clapboard is slightly
penetrated

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Diagnosis and test
Malfunction diagnosis of battery
1. Appearance check
Check contents Cause Disposing measures
① Outer crust of battery is damaged Replacement
Damage
② Improper installation
① Harness connector of newel pole is loose Replacement
Burning damage
② Outside short circuit
① Inner short circuit Replacement
Crust ② Fluid level of electrolyte is too low,
Crack
causing inside spark
③ Gas vent is blocked
① over charge Replacement
Deformation ② Charge with excessive current
③ Gas vent is blocked
① Plastic crust is damaged with external Replacement
force hit
There is acid leakage of battery ② Battery is put upside down or too
inclined
③ Heat seal is not tight
① Outside short circuit Replacement
Newel pole is fused badly ② Connection is poor
Welding is bad
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2. Voltage check
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over 12.5V, electric eye is Normal Burden experiment

green
Within 12.4 ～ 11V, electric Charge is not enough Recharge
eye is black
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Voltage
① Over discharge (electric eye is black) Replacement
② Short circuit (electric eye is mostly
Around or lower than 10.5V
green)
③ Circuit is broken down

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diagnostic and test
Battery Failure judgment
Charging system Fault Diagnosis
Symptoms Fault diagnosis Fault handling

While ignition Switch is in

"ON" position, charging
indicator light is off ① Lamp failure. ① Install new bulb

② Generator or battery ② Clean and tighten the battery or generator

connector is loose or cable, smearedwith acid proofing grease.

oxidized, the ground Check ground connector, need to clean and
connection is poor. tighten when necessary

③ Voltage adjuster, rotor or ③ Eliminate open circuit

brush circuit failure

④ Install new ignition switch

④Ignition switch failure
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When the engine is running, the

charging light does not
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correctly die out ① Drive belts are loose ① Re-tension drive belt
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② Generator connector is loose ② Clean and tighten splice

or oxidized, the ground

connection is poor.
③ Check the electric brush connections,

③ Electric brush must not

clean/release brushes if necessary, replace
new voltage regulator or replace alternator
connect with the rotor ring,
stuck, worn, damaged, oil
contamination in conduction
direction. Bearings, slip rings
are worn and the voltage
regulator or rectifier
assembly failure

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Low battery

① Drive belts are loose ① Re-tension drive belt

② Welding spot defective on ② Replace new voltage regulator or replace

the alternator connector alternator when necessary

③ Connection between ③ Clean and tighten splice

pressure regulator and

alternator housing is poor.
Excessive charging

① Voltage regulator failure ① Replace new voltage regulator or replace

alternator when necessary

There is noise when running

① Bearing is worn ① Install new alternator

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② Pulley slack ② Tighten pulley to specified torque. If shaft

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is damaged, replace alternator

③ Belt is worn
③ Install new belt

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4.5 Remove the battery.
1. Remove pressing plate of battery.

① loosen nuts on the battery pressing plate

② Remove pressing plate of battery

2. Loosen the mounting bolts on negative pole of

battery.
Remove the battery negative wire.

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3. Remove the battery positive wire.

① Open sheath on positive pole of battery upward

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② Loosen the mounting bolts on positive pole of

battery.

③ Remove battery positive wire

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4. Pull the battery from the vehicle.

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4.6 Removal and installation:
Install battery

Warning: In general, the battery will produce explosive gas, which may result in personal injury if handled
carelessly. Therefore do not allow flames, sparks or flame to get close to the battery. If you do not follow
the instructions, it may cause personal injury.

Protection: Wear safety glasses and gloves. Protect face and eyes when charging or working close to the
battery, and keep good ventilation.

Warning: The battery contains sulfuric acid components, must be avoided from the skin, eyes or clothing.
When working close to the battery, protect properly your eyes from acid solution spilling out. Once the
acid fluid contacts the skin or eyes, immediately rinse it with clean water for at least 15 minutes and go to
hospital immediately. If swallow the acid solution by accident, go to hospital immediately. Otherwise it may cause
personal injury.

Caution: make sure all electric systems are closed before connecting battery iron wire, which could avoid
damage to electric system.

The battery tilt do not exceed 40 degrees.

Do not put the battery upside down or lateral.

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Do not install battery which has leakage problem.
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Check if there is any screw or nut in tray which is used to move battery to prevent the battery from secondary
damage.
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Order of connecting the battery: Connect battery positive cable first and then the negative battery cable.

Note: if the service needs to remove the battery, you should use this procedure to remove the battery.

Before installation, check eyes, making sure they are green.

Do not install the battery with black eye to car.

When installation, do not tap or twist on end post.

When Installing the battery, ensure that all electrical accessories are in the "OFF" position.

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4.6 Install battery

1. Put the battery smoothly on the battery plate.

2. Install battery positive line.

① Install battery positive line.

② Tighten the mounting bolts on positive pole of

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battery, torque（6-8）N.m
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③ Install battery positive sheath

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3. Install battery negative line.

Tighten the mounting bolts on negative pole of battery,
torque（6-8）N.m

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4 Install battery pressing plate.
① Install battery pressing plate.
3 Tighten the nuts by pressing plate

5. Air conditioning
description and operation
5.1 Precautions:
1. It is required to use gloves and goggles so as to
avoid chilblain, blindness, and other effects on skin
during skin contact, as the freezing point of
refrigerant is low but the volatility is strong.

2. If refrigerant beam into the eye or contact skin:

Rinse with clean water, and need treatment by
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ophthalmology or dermatology. It is not allowed to

rub eye with hand or handkerchief.
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3. Operating refrigerant, places need to be

easy-to-ventilation.
Vast discharge of refrigerant at enclosed place may
lead to oxygen deficiency.

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4. It is not allowed for moisture, dust, and other
extraneous substances to be present in the
surrounding environment during operating
refrigerant, these substances may be harmful to the
air conditioning system when they flow inside,
so it is necessary to be noted.

5. Refrigerant should be R-134a.

It may cause adverse impact on the system parts if
other refrigerants are used.

6. R-134a refrigerant and R-12 refrigerant are

incompatible, so blending is not allowed even in a
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very little quantity.

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7. It is not allowed for pyrophorus or ignitable

materials to be present around the vehicle, during
operations related to refrigerant, and special
attention shall be paid, as explosion may be
aroused when refrigerant tank is exposed to heat
source, so needs to be noted.

Away from inflammable

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8. R134a container is in high-pressure state, and it is
absolutely not allowed to be placed under
high-temperature environment.
Moreover it is required to check whether or not
the temperature of storage environment is below

52℃.

Caution High Temperature

9. Dust covers are generally used on air conditioning

parts in order to prevent the inflow of sewage, dust,
and water content. Dust covers shall be removed
before operation and sealed after operation.
moisture

dust
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10. Air-condition must be smeared frozen oil at O-ring
when re-installing,
especially the bolt connecting part shall be
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manually installed, then installed by two wrenches.

Connect nuts and bolts at the same time of pushing
pipeline gently, when assembly flange connecting
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part.

Hands first, then tools

11. When the air-conditioner is installed, apply torque

above regulation to assembly or O-ring is stuck,
refrigerating fluid will leak, so must operate
according to regulations.

Install according to regulated torque

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12. It is not allowed for hose to be twisted.

Do not curve the tube

5.2 Diagnostic and test

5.2.1 Working Principle
1. Low-pressure gaseous refrigerant coming from the
evaporator turn into high-pressure hot gas when
flowing through compressor, turn into a
high-pressure and low-temperature liquid through
the condenser radiating tube, and then
Dehumidifier and buffer through reservoir dryer,
and then flow to expansion valve at stable
pressure and quantity, finally flow to the evaporator
through throttle and pressure. refrigerant will
evaporate in a low voltage environment, absorbing
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considerable heat.
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2. Cooling system high pressure side.

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3. Cooling system low pressure side.

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4. Compression process.

5. Condensation process.

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6. Cut off flow expansion process.
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7. Process of evaporation.

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Diagnostic and test
5.2.2 Air distribution system description
1. Mixed flow.
Outside air through the following exits:
 Dashboard exit
 Floor outlet

2. Ventilation.
Outside air through the dashboard exit.
Compressor does not work.
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A
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3. Heater.
Most air flow through Defroster Duct through floor
exit.

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4. Cooling.
Compressor works, air passes through the evaporator
core, and blow out from the instrument panel outlets.

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Diagnostic and test
5.2.3 Leak Test
1. The tools you need.
R-134a air-conditioning system tracer dye with 24
boxes.
Universal 12 V leak inspection light.
Fluorescent Dye remover.
Air condition dye injector tool components.
Replace dye cell.
Electronic Leak Detection.
Spray bottle fitted with soap water.

2. Fluorescent leak detector.

Important note: Be sure to use dark glasses with
UV lamp, since these can deepen color of colouring
agent.
Fluorescent Dye helps to identify leakage place in
air-conditioning system.
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3. Electronic Leak Detection.

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Important Note: To test with continuous path,

ensuring that you do not miss any possible leak. If
there is a leak for all parts of test System.
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4. Soap water.
Fill a bottle with 50% water and 50% detergent.
Run air-conditioning system and spray soap water
to the connectors and components.
If the leak is obvious, there will be bubble in
solution.
This is a a good way to detect leak in hoses and
splice.

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Diagnostic and test
5.2.4 Air Conditioning System Performance Test
1. Should test vehicles in direct sunlight.

2. Do not test vehicles with condenser airflow

obstruction, for example, against
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3. Set air blower motor at the highest speed.

A
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4. Air outside circulation mode.

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5. Set cooling temperature to maximum. Turn the
knob indicator points to the far left

6. Dashboard air-out place when you open to the

front. The
Put thermometer into central air-out place
approximately 50 mm deep.
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7. Test is performed when idling.

8. two front windows are closed.

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A
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9. Connect the precise pressure gauge to

air-conditioning system.

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10. Test humidity (RH%) exactly,
when humidity(RH%) changes, pressure and
temperature of air outlet will change accordingly.
See "air-conditioning system performance" in this
section.

11. Turn off the engine, compare the reading with the
data in " air-conditioning system performance
table" .
Air-conditioning system at normal operation
Best should not be too large difference.

Normal

Need to be repaired
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Diagnostic and test
5.2.5 Recycling refrigerant
1. Park the vehicle in a well-ventilated area.

2. Connect refrigerant recovery machine.

3. Open refrigerant recovery machine, select

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refrigerant recovery procedure on the control panel.
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4. Turn on manual valves on high-side and low-side

of the device.

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5. Refrigerant will begin recycle refrigerant and oil
from air conditioning system. Refrigerant Recycled
to the storage tank, lube flows to the reservoir
which could be assembled.

6. Refrigerant recycling machine will drain all

refrigerant from air conditioning system, which
will be vacuum partly with pressure of about 34
KPa (10 Inches of Mercury).

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7. Once it is partly vacuum, it is recommended that
you close refrigerant recovery machine
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Close the above two manual valves and record the

pressure reading. If 2 minutes later, vaccum reading
rises to positive pressure,
this indicates that the refrigerant
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(after boiling) is still remaining in filtering the fluid

in the dryer,
In this case, continue recycling program until
pressure is not increasing obviously.

8. Check the oil reservoir and record recovery

quantity,
Because it needs to fill same amount of fluid to
air-conditioning system later.

Diagnostic and test

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5.2.6 Air Conditioning System Performance Test
Pounds/Square Pounds/Square
°C °F kPa °C °F kPa
Inch Inch
Definition: The table lists the pressure of refrigerant 134A at different temperatures. For example, at 26.6 °C (80
°F) room temperature, refrigerant tank pressure reaches 595.6 KPa (86.4 pounds/square inch). If refrigerant is
heated to 51.6 °C (125F), the pressure will rise to 1278.8 KPa (185.5 pounds/square inch). Also can check
reversibly, finding the boiling point of refrigerant 134A under different pressure. For example, boiling point of
refrigerant 134A is 0°C (32°F) under pressure of 188.2 kpa（27.3 pounds/square inch）
15.5 60 392.3 56.9
-23.3 -10 12.4 1.8 18.3 65 438.2 63.6
-20.5 -5 27.0 3.9 21.1 70 487.3 70.7
-17.7 0 43.2 6.3 23.8 75 539.7 78.3
15.0 5 60.8 8.8 26.6 80 595.6 86.4
-12.2 10 80.1 11.6 29.4 85 655.1 95.0
9.4 15 101.3 14.7 32.2 90 718.5 104.2
-6.6 20 124.3 18.0 35.0 95 785.6 113.9
-3.8 25 149.4 21.7 37.7 100 856.9 124.3
-1.1 30 176.6 25.6 40.5 105 932.3 135.2
0.0 32 188.2 27.3 43.3 110 1012.1 146.8
1.6 35 206.2 29.9 46.1 115 1096.4 159.0
4.4 40 238.0 34.5 48.8 120 1185.2 171.9
7.2 45 272.5 39.5 51.6 125 1278.8 185.5
10.0 50 309.5 44.9 54.4 130 1377.3 199.8
12.7 55 349.4 50.7 60.0 140 1589.6 230.5
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Diagnostic and test
5.2.7 Air Conditioning System Performance diagnostic
1. warm wind performance diagnostic.
steps operation Yes No
Implement this diagnostic according to "symptom" or
1 To step 2 -
indication from diagnostic machine?
① Start the engine.
2 ② Let engine work idling. To step 3 To step 9
Whether engine arrives to normal working temperature?
① Let engine work idling.
② Choose"（floor wind）"mode.
③ Choose min rotating speed of blast blower.
3 ④ Choose the warmest temperature setting. To step 7 To step 4
⑤ Touch to feel temperature of inlet and outlet hose of
heating core.
Is heating inlet hose warmer than outlet hose?
① Put thermometer at central outlet.
② Fix thermometer to heating hose at the exit of heating core.
③ Choose max rotating speed of blast blower.
④ Choose the warmest temperature setting.
4 ⑤ Write down the temperatures of follwoing locations： To step 5 To step 6
central dashboard vent.
Heating hose at the exit of heating core.
⑥ Compare 2 temperatures recorded.
Are 2 temperatures reading close?
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① Check if the following parts have leakage and repair：
Front hood panel.
Inner revolving door.
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5 Warm air, ventilation, and air-conditioning system To step 10 -

module housing.
② Make necessary repair.
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Is the repair completed?

① Check the temperature door operation.
6 ② Make necessary repair. To step 10 -
Is the repair completed?
① Turn off the engine.
② Reverse wash heating core.
③ Start the engine.
④ Choose"（floor wind）"mode.
7 ⑤ Choose min rotating speed of blast blower. To step 8 To step 10
⑥ Choose the warmest temperature setting.
⑦ Touch to feel temperature of inlet and outlet hose of
heating core.
Is heating inlet hose warmer than outlet hose?
Replace heater core.
8 To step 10 -
Is the repair completed?
Repair the problem of engine temperature being too low.
9 To step 10 -
Is the repair completed?
Run the system to verify repair effect.
10 System Normal To step 2
The problem has been find and fixed?

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Diagnostic and test
Air Conditioning System Performance diagnostic
2. Defrost is not sufficient.
steps operation Yes No
Implement this diagnostic according to "symptom" or
1 To step 2 -
indication from diagnostic machine?
① Start the engine.
② Select the "DEFROST (Defrost) mode.
2 To step 3 To step 10
③ Choose max rotating speed of blast blower.
Is there sufficient air flowing from defroster outlets?
Measure engine operating temperature.
3 To step 4 To step 8
Does the engine has reached normal operating temperature?
① Choose min rotating speed of blast blower.
② Select the maximum temperature setting.
4 ③ Touch to feel temperature of inlet and outlet hose of To step 11 To step 5
heating core.
Is heating inlet hose warmer than outlet hose?
Test compressor of air conditioning operation situation.
5 To step 7 To step 6
Does air conditioning compressor work?
Replace A/C compressor.
6 To step 14 -
Is the repair completed?
Perform air conditioning system testing.
7 To step 9 To step 12
Air-conditioning system is working up to code?
Repair the problem of engine temperature being too low.
8 To step 14 -
Is the repair completed?
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Inspect if the inner recirculation door is working properly.
9 To step 14 To step 13
Is inner revolving door working normally?
Repair problem of wind.
10 To step 14 -
Is the repair completed?
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Repair Heater failure.

11 To step 14 -
Is the repair completed?
Repair the air conditioning problem.
12 To step 14 -
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Is the repair completed?

Repair problem on the inner revolving door.
13 To step 14 -
Is the repair completed?
Run the system to verify repair effect.
14 System Normal To step 2
The problem has been found and fixed?

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Diagnostic and test
Air Conditioning System Performance diagnostic
3. Blower Motor noise diagnostic.
steps operation Yes No
Implement this diagnostic according to "symptom" or
1 To step 2 -
indication from diagnostic machine?
Check if there is debris at the air inlet grille.
2 To step 8 To step 3
If there is debris present?
1. Sit in the car.
2. Close the doors and windows.
3.Turn off the engine, turn the ignition switch on "ON"
position.
3 To step 4 To step 11
4. In all speeds and modes run the blower motor, in order to
determine when and where is the noise.

Is noise clear when blower is running?

Touch the blower housing, check if the Blower motor vibrates
4 running in all speeds. To step 6 To step 5
If there is excessive vibration?
Listen to the voice of the blower motor in all volving speed.
5 To step 9 To step 11
Is the blower motor making squeaking or chirping noise?
1. Remove blower motor.
2. Check if there is foreign matter in the Blower Motor
impeller.
6 To step 8 To step 7
3. Check if there is foreign matter in the Blower Motor.
Is there any foreign matter found in the blower motor or its
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impeller ?
Check if there is following situation in the blower motor:
Impeller cracks.
7 impeller fixing components are loose. To step 9 To step 10
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Impeller is not positioned correctly.

Do you find any of these problems?
Clear foreign objects.
8 To step 10 -
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Is the operation completed?

Replace blower Motor.
9 To step 11 -
Is the repair completed?
Install blower Motor.
10 To step 11 -
Is the operation completed?
Run the system to verify repair effect.
11 System Normal To step 2
The problem has been found and fixed?

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Diagnostic and test
Air Conditioning System Performance diagnostic
4. Refrigeration System noise diagnostic.
steps operation Yes No
Implement this diagnostic according to "AC system symptom"
1 To step 2 -
or indication from diagnostic machine?
Inspect if there is any failure on the accessory drive belt and
2 To step 3 -
belt tensioner, if necessary, solve the problem.
Run the engine and check if the compressor is noisy:
3 To step 5 To step 4
If the noise continues for 30 seconds or more?
The fluid clicking
noise is normal.
Turn off the system
in a high ambient
Allow engine to run for several minutes.
temperature for
Stop 1 minutes.
4 To step 6 long time, and then
Start the engine again.
temperature falls
If is there noise detected using this procedure?
after a whole night,
this situation will
happen.

Test if the system refrigerant quantity is too low.

5 To step 7 To step 8
Is system refrigerant enough?
Check if the thermal expansion valve is stuck at close or open
Replace expansion
6 position. To step 7
valve
Thermal expansion valve is stuck at open position?
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Check if the compressor bolts and/or Air Conditioning Circuit Tighten the screws
7 disturbs the body parts. and/or reset the To step 8
Are there mounting bolts loose. circuit
① Recycle refrigerant and replace the compressor.
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System check is
8 ② Refill system. complete
To step 1
Is the air pressure within the specified range.
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Diagnostic and test
Air Conditioning System Performance diagnostic
5. Air-conditioning system performer noise diagnostics.
steps operation Yes No
Implement this diagnostic according to "symptom" or
1 To step 2 -
indication from diagnostic machine?
① Start the engine.
② Complete all of the following settings:
Blower Motor revolving speed
Warm air, ventilation, and air-conditioning system
module
Temperature control settings
2 To step 6 To step 3
③ Determine the type of noise：
Scraping, twanging
Ticks/clicks, chirping sound or crunching sound
Wind/squeaking sound
When you select the mode or temperature settings, scraping or
POP is obvious.
When the blower motor speed is reduced, is tick/click,chirping,
3 chirping, scratches sound reducing? To step 6 To step 4

Is wind/squeaking noise obvious at all modes, but not under all

4 temperature settings? To step 6 To step 5

Is wind/whining noise obvious only in the defrost or floor wind

5 To step 6 To step 6
mode?
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Remove the dashboard tray.
① Check door is in proper operation.
6 To step 9 To step 7
② Check if the duct is blocked or there is foreign material.
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Is there any above problem detected?

Check the mode, temperature door and seal are warped or
7 cracked. To step 10 To step 8
Are wind doors in normal state?
J

Replace the doors and/or seal.

8 To step 10 -
Is the repair completed?
Clear obstructions or debris.
9 To step 10 -
Is the operation completed?
Install the dashboard tray.
10 To step 11 -
Is the operation completed?
Run the system to verify repair effect.
11 System Normal To step 2
The problem has been found and fixed?

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Diagnostic and test
Air Conditioning System Performance diagnostic
6. Odor diagnosis.
Steps operation Yes No
Implement this diagnostic according to "symptom" or
1 To step 2 -
indication from diagnostic machine?
① Sit in the car.
② Close all doors and windows.
③ Start the engine.
④ Let the engine run idling at normal operating temperature.
2 To step 3 To step 8
⑤ Choose max rotating speed of blast blower.
⑥ Choose the coldest temperature setting.
⑦ Run in all blower speeds, modes, and temperatures to
determine which kind of odor(mildew, coolant smell, oil).
Check if there is debris at the warm air, ventilation, and Air
Conditioning System Module Assembly filter and the air inlet
3 To step 4 To step 5
grille.
If there is debris present?
Remove all debris.
4 To step 15 -
Is the operation completed?
Check if the carpet is wet.
5 To step 6 To step 14
Carpet is wet.
Check to see if the following conditions exist:
The front windshield has water leakage
Warm air, ventilation, and air-conditioning system module
6 To step 7 To step 14
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draining pipe blocked.
Door Seal all around leak
Is there leakage?
If necessary, repair leaks.
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7 To step 15 -
Is the repair completed?
8 Whether the odor is coolant smell? To step 9 To step 12
Checking if there is leakage in cooling system.
9 To step 10 To step 12
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Is there leakage?
Check if coolant leaks or there is film on the front windshield
10 in the car. To step 11 To step 15
Is problem present?
Replace heater core.
11 To step 15 -
Is the repair completed?
12 whether the odor has oil smell? To step 13 To step 15
① Inspect if the engine leaks.
13 ② Repair oil leaks. To step 15 -
Is the repair completed?
Odor may be caused by mildew on evaporator, heating core,
14 ventilation and AC system module assembly. To step 15 -
Is the operation completed?
Run the system to verify repair effect.
15 System Normal To step 2
The problem has been found and fixed?

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Diagnostic and test
Air Conditioning System Performance diagnostic
7. Blower motor doesn't work.
steps operation Yes No
① Turn off the engine, turn the ignition switch on "ON"
position.
1 ② Put the blower motor switch in each revolving speed Go to the "failure 8". To step 2
position.
The blower motor works at any speed position?
① Turn ignition switch to “OFF” position.
② Cut off blower motor.
③ Connect a test lamp between blower motor supply voltage
circuit and its control circuit.
2 ④ Turn off the engine, turn the ignition switch on "ON" To step 9 To step 3
position.
⑤ Put the blower motor switch in each revolving speed
position.
Is test lamp at on any speed?
Test if blower motor supply voltage circuit is open or
3 resistance is excessive. To step 15 To step 4
The problem has been found and fixed?
Test if blower motor circuit is open or resistance is excessive.
4 To step 15 To step 5
The problem has been found and fixed?
① Turn ignition switch to “OFF” position.
② Connect blower motor.
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③ Warm air, ventilation, and air-conditioning system control
module.
5 ④ Turn off the engine, turn the ignition switch on "ON" To step 10 To step 6
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position.
⑤ Put the blower motor switch in each revolving speed
position.
The blower motor works at any speed position?
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Check that the serial data encoding or failure.

6 To step 7 To step 8
Is there problem detected?
Test the line.
7 To step 15 To step 8
The problem has been found and fixed?
Test if blower motor switch control circuit is open or resistance
8 is excessive. To step 15 To step 11
The problem has been found and fixed?
Check if connection is good on blower motor.
9 To step 15 To step 12
The problem has been found and fixed?
Check connection is good on warm air, ventilation, and
10 air-conditioning system control module. To step 15 To step 13
The problem has been found and fixed?
Check if audio-visual entertainment system is poorly
11 connected. To step 15 To step 14
The problem has been found and fixed?
Replace blower Motor.
12 To step 15
Is the replacement completed?
Replace warm air, ventilation, and air-conditioning system
13 control module. To step 15
Is the replacement completed?
Replace blower switch.
14 To step 15
Is the replacement completed?
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Run the system to verify repair effect.
15 System Normal To step 1
If the fault has been corrected?

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Diagnostic and test
Air Conditioning System Performance diagnostic
8. Blower Motor diagnostic.
Steps Operation Yes No
① Turn off the engine, turn the ignition switch on "ON"
position.
1 ② Put the blower motor switch in each revolving speed To step 3 To step 2
position.
The blower speed position works?
Check if the Blower motor fuse is blown. Replace the fuse with
2 To step 3
Is fuse is blown? same current.
Check power supply of blower motor.
3 Although there is a voltage, but the blower motor does not
run?
① Run blower motor in all speeds, and run once at the
position of integrated radio control blower control.
4 To step 8 To step 5
② There should be 20 blowers with effective revolving speed.
If all the blowers revolving speeds are effective?
① Insert 2 pin connectors in the back direction on blower
motor.
② Control Blower using the integrated radio, from the lowest
5 speed, run once in 20 fan revolving positions. To step 8 To step 6
③ Compare the voltage to the voltage in the drawing, see the
"1.2 1 2 sensor resistance values table" in "automatic warm air,
ventilation, and air conditioning system".
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Voltage is close to that showed in the drawing?
Connect fault diagnosis. Switch to composite test, switch data.
Use fault diagnosis to enlarge/ decrease soft buttons. choose Implement integrated
6 all 20 fan revolving speeds radio test of blower To step 7
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switch.
if all speeds are effective?
Replace warm air, ventilation, and air-conditioning system
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7 control module. To step 8

The problem has been found and fixed?
Run the system to verify repair effect.
8 System Normal To step 1
If the fault has been corrected?

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Diagnostic and test
Air Conditioning System Performance diagnostic
9. Air conditioning system cooling effect is poor.
Steps Operation Yes No
Check the running situation of air mix doors to make sure it is
1 not plugged or broken. Replace the server To step 2
Air mixing door is cracked or blocked?
① Turn off the engine, turn the ignition switch on "ON"
position.
Go to the "failure
2 ② Put the blower motor switch in each revolving speed To step 3
7".
position.
The blower motor works at any speed position?
Go to the "failure
3 The blower motor is running in the appropriate speed? To step 4
8".
Go to the "Air
① Start the engine. circulation
② Set the mode switch to face wind position. troubleshooting"
③ Turn the inner circulation switch to "ON (connected)" of "Automatic
position. warm wind,
4 ④ Observe inner revolving door. To step 5 ventilation and AC
⑤ Turn the inner circulation switch to "OFF (closed)" system".
position.
The inner circulation door is from the inner cycle position to
exhaust position?

① Start the engine.

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② Use troubleshooting scanner to clears all diagnostic
trouble codes stored in the warm wind, ventilation, and
air-conditioning system.
Replace
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5 To step 6
compressor
③ Place the left air temperature switch to the coldest position.
④ Set the mode switch to double wind position.
⑤ Put the blower motor switch in the highest speed position.
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Does air conditioning compressor work?

Perform air conditioning system testing.
6 To step 9 To step 7
The problem has been found and fixed?
Install a thermometer near the air temperature sensor inside the
7 car. To step 9 To step 8
Thermometer temperature is within 3°C (5°F)?
Check if the suction air pipe leaks or is blocked.
8 To step 9 -
The problem has been found and fixed?
Run the system to verify repair effect.
9 System Normal To step 1
If the fault has been corrected?

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Diagnostic and test
Air Conditioning System Performance diagnostic
10. Not enough warm air diagnostic.
Steps Operation Yes No
Check the running situation of air mix doors to make sure it is
1 not plugged or broken. Replace the server To step 2
Air mixing door is cracked or blocked?
Put the blower motor switch in each revolving speed position. Go to the "failure
2 To step 3
The blower motor works at any speed position? 7".
Go to the "failure
3 The blower motor is running in the appropriate speed? To step 4
8".
Go to the "Air
① Start the engine. circulation
② Set the mode switch to face wind position. troubleshooting"
③ Turn the inner circulation switch to "ON (connected)" of "Automatic
position. warm wind,
4 ④ Observe inner revolving door. To step 5 ventilation and AC
⑤ Turn the inner circulation switch to "OFF (closed)" system".
position.
The inner circulation door is from the inner cycle position to
exhaust position?
Turn the temperature switch to "OFF (closed)" position.
5 To step 6 To step 9
If a car is too cold with warm wind or defrost?
① Start the engine.
② Turn Off warm air, ventilation, and air conditioning control
6 Replace compressor To step 8
C
system.
Does air conditioning compressor work?
Check cooling system to see if the following conditions exist:
A

Coolant level is too low.

Accessory drive belt is loose or worn.
Radiator hose or heater hose leak.
7 To step 10 To step 8
Radiator hose or heater hose twist.
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Radiator cap pressure seal is missing.

Radiator cap leaks.
The problem has been found and fixed?
① Set the mode switch to face wind position.
② Turn off the engine, turn the ignition switch on "ON"
position.
③ Put the blower motor switch in fastest revolving speed
8 position. To step 10 To step 9
④ Cover sensor inlet with 5cm (2inch) piece of square paper,
check if there is air flow through the air temperature sensor
inside the car.
If the paper stays in original place?
Check if the suction air pipe leaks or is blocked.
9 To step 10 -
The problem has been found and fixed?
Run the system to verify repair effect.
10 System Normal To step 2
If the fault has been corrected?

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Diagnostic and test
Air Conditioning System Performance diagnostic
11. Poor wind coming out.
Steps Operation Yes No
① Start the engine.
1 ② Set the mode switch to OFF position. To step 2 To step 2
Check if blower motor stops working？
① Set the mode switch to ventilation position.
② Put the blower motor switch in each revolving speed Go to the "failure
2 To step 4
position. 7".
The blower motor works at any speed position?
Go to the "failure
3 The blower motor is running in the appropriate speed? To step 4
8".
Check if the mode door is damaged or clogged
4 Replace mode door To step 5
Mode door is damaged or clogged
Run the system to verify repair effect.
5 System Normal To step 1
If the fault has been corrected?

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Diagnostic and test
Air Conditioning System Performance diagnostic
12. Inner and out circulation fault diagnosis.
Steps Operation Yes No
① Turn off the engine, turn the ignition switch on "ON"
position.
② Put the blower motor switch in fastest revolving speed
position.
③ Set the mode switch to double wind position.
1 To step 2 To step 2
④ Turn the inner circulation switch to aeration position.
⑤ Turn the inner circulation switch to inner circulation
position.
When inner circulation switch is on inner circulation position,
do you hear sound of air flow changes?
① Turn the inner circulation switch to aeration position.
② Observe the drive shaft of inner circulation actuator.
2 ③ Turn the inner circulation switch to inner circulation To step 3 To step 3
position.
Does the drive shaft of inner circulation actuator rotate?
① Observe the drive shaft of inner circulation actuator.
3 ② Use the troubleshooting scanner, instruct the execution of To step 11 To step 4
inner circulation go to the recycling location and ventilation.
Does the drive shaft of inner circulation actuator rotate?
① Turn ignition switch to “OFF” position.
② Disconnect the execution of inner circulation actuator.
C
③ Turn off the engine, turn the ignition switch on "ON"
4 position. To step 5 To step 12
④ Use test light connected to good iron, detecting the ignition
A

3 voltage circuit of the execution of inner circulation.

Test lamp is on?
① Connect a test lamp between the inner circulation
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execution door control A circuit and the ignition 3 voltage

circuit.
5 To step 6 To step 7
② Use the troubleshooting scanner, instruct the execution of
inner circulation go to the recycling location and ventilation.
Test lamp is on at any instruction?
① Connect a test lamp between the inner circulation
execution door control B circuit and the ignition 3 voltage
circuit.
6 To step 9 To step 8
② Use the troubleshooting scanner, instruct the execution of
inner circulation go to the recycling location and ventilation.
Test lamp is on at any instruction?
Test whether the control circuit of inner circulation execution
is open, excessive resistance, short to ground or the voltage
7 To step 15 To step 11
short circuit.
The problem has been found and fixed?
Test whether the control circuit B of inner circulation
execution is open, excessive resistance, short to ground or the
8 To step 15 To step 11
voltage short circuit.
The problem has been found and fixed?

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Diagnostic and test
Air Conditioning System Performance diagnostic
13. Inner and out circulation fault diagnosis.
Steps Operation Yes No
Inspect if following situation exist in inner revolving door and
the execution:
Circulation actuator malposition.
linkages broken or stuck.
Inner revolving door broken or stuck.
9 To step 15 To step 10
There are obstructions influence Recirculation Door' all
activities.
Inner revolving door seal is missing.
Inner revolving door seal malposition.
The problem has been found and fixed?
Inspect the harness connector of inner circulation execution is
10 well connected or not. To step 15 To step 13
The problem has been found and fixed?
Check harness connection is good on warm air, ventilation,
11 and air-conditioning system control module. To step 15 To step 14
The problem has been found and fixed?
Repair the ignition voltage circuit of inner circulation
12 execution. To step 15 -
Is the repair completed?
Replace the execution of inner circulation actuator.
13 To step 15 -
Is the replacement completed?
Replace warm air, ventilation, and air-conditioning system
C
14 control module. To step 15 -
Is the replacement completed?
Run the system to verify repair effect.
15 System Normal To step 2
If the fault has been corrected?
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5.3 Removal and installation
5.3.1 Remove heating and cooling host unit assembly
1. Recycle refrigerant.

2. Disconnect battery negative (-).

3. Remove dashboard.
A
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4. Remove the fastening bolts of expansion valve.

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Removal and installation:
Remove heating and cooling host unit assembly
5. Remove fixing screws of heating and cooling host
unit assembly.

6. Disconnect plug, remove heating and cooling host

unit assembly
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A
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Removal and installation:
5.3 .2 Remove evaporator assembly
1. Remove screws and snaps connecting heating and
cooling host unit upper and lower shell and upper
shell.

C2. Remove temperature Sensor.

A
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3. Remove evaporator assembly.

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Removal and installation
5.3.3 Remove blower assembly
1. Remove the lower cover plate assembly of A/C.

2. Disconnect battery negative (-).

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3. Disconnect connector between heating and cooling
host unit harness assembly and blower assembly.
A
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4. Remove blower assembly.

C
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Removal and installation
5.3 .4 remove condenser with fan assembly
1. Recycle refrigerant.

2. Disconnect battery negative (-).

C
A

3. Drive the truck to the trench.

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4. Disconnected lines in the trench.

5. Remove the bolts connecting condenser and water

tank.
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A

6. Unplug connector, remove condenser.

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Removal and installation
5.3.5 Remove and install of Compressor Assembly
1. Recycle refrigerant.

2. Disconnect battery negative (-).

3. Disconnect air conditioning clutch switch harness.

A
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4. Unscrew the pipe mounting bolts, and then

disengage the high and low pressure connecting
pipe.

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5. Release the tensioner fixing nuts, then loosen the
tensioner adjusting bolts, remove the compressor
drive belt.

6. Remove the compressor mounting bolts.

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A
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7. Remove compressor.

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Removal and installation
5.3.6 Install compressor assembly
1. Re-inject the compressor oil into the compressor
and tighten oil filling screws.

2. install the compressor to car as the opposite order

of removal, compressor mounting bolt torque
19-28N.m.
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A

3. Adjust the belt tension degree after installation.

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4. Imposed 98 N force to belt middle position
vertically: belt deformation: 8 MM～11 MM (span
200 MM ～ 300 mm)

5. Add refrigerant again, check if the lines leak.

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Removal and installation
5.3.7 Remove A/C control assembly.
1. Disconnect battery negative (-).

2. Remove the controller between controller and

heating and cooling host unit.

C
A
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3. Remove the control panel assembly, disconnect air

conditioning controller connector.

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4. Remove the controller mounting screws.

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5. Remove air conditioning controller.
A
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Removal and installation
5.3.8 Remove expansion valve assembly.
1. Recycle refrigerant.

2. Disconnect battery negative (-).

3. Remove expansion valve mounting bolts

A

connecting refrigerant lines with expansion valve

assembly and heating and cooling host unit.
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4. Remove connection of compressor suction tube
assembly, compressor air tube assembly with
refrigerant lines with expansion valve assembly.

5. Remove the mounting of refrigerant lines with

expansion valve assembly at the bottom of cab.

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A

6. Remove the mounting of refrigerant lines with

expansion valve assembly at the front of cab.
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7. Disconnect the connector bewteen engine harness
assembly and the pressure switch.

8. Remove mounting bolts between expansion valve

C assembly and refrigerant lines.
A
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9. Install the expansion valve assembly as the

opposite order of removal.

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10. Add refrigerant again, check if the lines leak.

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5.4 Air conditioning basic parameters

Name Item Parameters

Type: 10 cylinder swashplate compressors
displacement: ML/R 147 ML/R
A/C compressor: Lubricating oil mark: PAG
Lubricating oil Capacity: G 140±20g
Electromagnetic Clutch: Diameter of 127mm double-V disc

Heater assembly.
Heating unit: Type: All aluminum welding heater
power: 5500W

AC Blower
Blower: working voltage: DC（12 V)
working currency: 15.6 A

AC Evaporator
Cascading
Cooling unit: Type:
evaporator
Evaporator power: ＞6000 W

Condenser
C
Assembly
Condenser Aluminum parallel
Type:
streaming
power: 12000 W
A

Reservoir tank Model number and capacity 121 ML R134a

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refrigerant: Model and charge R134a, 480 g

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