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Vantage Hearth truckall Operation And Service Manual
Summary of truckall
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Vantage premium model: truckall ® & vango ® operation and service manual (2 nd edition) vantage vehicle international, inc..
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Foreword dear customer, thank you for your purchase and use of vantage vehicle international, inc. Vehicle. The purpose of this manual is to provide you some useful information and necessary technical data on operation, maintenance, trouble-shooting and service of vantage truckall & vango series. Si...
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1 contents contents chapter i. Whole vehicle…………………………………………………………………………………………………………………………1 section 1. General introduction……………………………………………………………………………………………………………1 section 2. Operation of vehicle……………………………………………………………………………………………………………7 section 3. Service and maintenance of vehicle………………………………………...
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2 contents chapter iv. Vehicle body………………………………………………………………………………………………………………………114 section 1. Front door and rear slide door…………………………………………………………………………………………………114 section 2. Rear door……………………………………………………………………………………………………………………128 section 3. Seats…………………………………………………………………………………………………………………………130 ...
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1 chapter i. Whole vehicle section 1. General introduction i. Vin and engine number location • vin location: ¾ vin located at front left of the instrument panel. • engine number location: ¾ engine number located on the right surface of the cylinder block. Operation and service manual on vantage truc...
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2 ii. Vehicle parameters vehicle model b900, x900 b1000, x1000, c1000 & p1000 type straight four 4-stroke water-cooled electronic fuel injection gasoline engine bore x stroke (mm x mm) 62×72 65.5×72 displacement (l) 0.890 0.995 compression ratio 8.7 8.8 rated power (kw) (r/min) 32/5200 35.5/5200 max...
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3 iii. Pparameters and structure description capacity parameters tire (general cross ply 165/70r13 (5.00-12ult) fuel tank: 37l rim(general cross ply) 5.00 × 13 (4.00b × 12) engine lubricating system: 3.5l tire pressure(general cross ply) cooling system: 4.0l front wheel 200kpa (21kpa) transmission: ...
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4 iv repair regulations fig. 1.1-3 sketch of jack used in back side chapter i. Whole vehicle operation and service manual on vantage truckall & vango series 1. When repairing electric parts, the joint of binding post of battery negative pole should be disconnected first, in order to avoid electric s...
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5 fig. 1.1-6 sketch of safe dais put in back side 4. When lift a vehicle with a lifting rack, guarantee that lifting arm does not contact to brake pipeline, fuel pipeline, bracket or any other parts. The lifting position of listing rack and listing arm on a vehicle is shown as fig. 1.1-7, fig. 1.1-8...
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6 section 2 operation of vehicle i. Operation description (i) key two key are provided for a vehicle (key with code anti-theft system sees chapter 6). Vehicle key has the following functions: 1. To control the power supply of vehicle electrical equipment. 2. To unlock and lock vehicle door lock. 3. ...
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7 1. Front seat (1) fixing 3.Rear door lock unlocking and locking outside vehicle is shown as fig. 1.2-5. Insert key into key hole, turn anticlockwise 90 ° , take out the key, then hold on outer handle manually, press lock cylinder with thumb and pull backward, rear door is opened; after the door is...
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10 (3) backrest regulation seat backrest is tilt able. When regulating, raise handle, select backrest angle, release the handle, the backrest is locked, see fig. 1.2-9. 2. Backseat the second row seat can tilt a certain degree forward, in order to be easy for passengers on the third row seat to get ...
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11 note: · seat belt is designed according to human body’s structure, so the user must use it on the requirement, the lower end position should not exceed abdomen, shoulder seat belt should sling over chest and shoulder. · seat belt should keep clean, to avoid oil, chemicals, particularly electrolyt...
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12 when fuel gauge pointer points at f, the fuel tank is full; when it points at e, the fuel tank is nearly empty, see fig. 1.2-17. 3. Water-temperature meter when ignition switch is on gear on, pointer can indicate the coolant temperature within engine. When the pointer fluctuates in c section, eng...
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13 if the engine starts the lamp is still bright or the lamp is lightened during running, showing the braking fluid in fuel tank is deficient, please fill it. If the braking fluid is filled out, the lamp is still bright, the braking system should be repaired, see fig. 1.2-19g. 11. (electronic fuel i...
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14 3.High/low beam switch of far-reaching lamp and near-field lamp put lamplight switch on gear 2 position. When the handle is on middle position, near-field lamp is bright; press the handle, to make the handle be in lower side position, far-reaching lamp is bright, see fig. 1.2-22. 4. Windshield wi...
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15 (xi) horn horn switch is on steering panel. Press any point on the button to make the horn sound, see fig. 1.2-25. Fig. 1.2-25 (xii) indoor lamp switch on gear is to turn on the light, off gear is to turn off the light. (xiii) warning lamp switch on the combination switch shell under steering whe...
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16 fig. 1.2-29 fig. 1.2-30 (xvii) sun screen when the vehicle runs in face of the sun, pull sun screen downwards to your requiring position to keep glaring sunlight out; after using it, push it to the original position, see fig. 1.2-32. Fig. 1.2-31 fig. 1.2-32 (xviii) ventilation unit there are 6 ve...
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17 2. A/c control panel the a/c unit of this vehicle has the functions of ventilation, heating and defogging, etc. (1) natural air ventilation set button 1 at the desired position, button 5 at the right side, and button 1 at the desired mode, then the ventilation shall be available when air indoors ...
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18 (xxi) pedal 1. Clutch pedal clutch pedal is used for controlling of power transferring from engine to transmission. Thread on the pedal, cut off power transfer, you can operate gear selection and gear shift; disengage the pedal, the power transfer shall be engaged. See ○ 1 in fig. 1.2-37. Note: w...
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19 12. Presence and absence of abnormal sound of engine and transmission system. 13. Driver tools and accessories are complete or not. (ii) new vehicle breaking-in the operating life, working reliability and using economical efficiency of a vehicle depend greatly on earlier operating conditions. Bef...
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20 section 3 service and maintenance of vehicle 1. Routine maintenance routine maintenance means daily maintenance before departure and after traveling, is the foundation of regular maintenance. Taking cleaning and observation as the key. Besides washing inside and outside body, cleaning glass, the ...
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21 mileage ( x1,000km ) 1 10 20 30 40 50 60 time interval: number of months or kilometers, whichever comes first number of month (month) breaking-in period 6 12 18 24 30 36 fan belt : degree of tightness, damage j · t j · t · g g j · t · g timing belt: degree of tightness, damage j · t · g j · t · g...
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22 iii. Service and maintenance items (i) engine 1. Water pump(fan) belt (1) check and adjustment 1) check the presence and absence of crack, break, distortion, abrasion and cleanliness of belt. Check belt tension force. Press the belt with thumb(about 10kg force), if it bends 6-9mm, show the tensio...
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23 2. Valve clearance (1) dismount valve cover. (2) check the valve clearance of air intake and exhaust, and adjust if necessary. Standard valve clearance: 0.13-0.18mm (when the engine is cool), 0.23-0.28mm (when the engine is hot). (3) install valve cover, and screw bolt to specified torque. 3. Eng...
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24 note: in order to prevent oil leakage, it is necessary to guarantee the engine oil cleaner screwed tightly, but it is not over tight. (4) after installing engine oil cleaner, start engine to check whether there is oil leakage. (5) replacement of engine oil before discharging engine oil, first che...
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25 (4) screw discharge orifice cock, and install the hydraulic accumulator at the original position. Fill up coolant into radiator, and run engine at idle speed, until affirm that engine coolant pass through one large cycle at least, then stop running engine. After temperature drops, fill up the rad...
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26 (3) check whether distributor arm is broken, and electrode is abraded. (4) if you find the bad cases mentioned above, please repair or replace them if necessary. Note: if there is dust or dirt on the inside distributor, wipe up them with soft cloth. 3. Replacement of spark plug (1) dismount secon...
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27 (4) equip filter cartridge into air filter bowl. Note: after the vehicle runs in dusty area, check whether filter cartridge is full of dust, if it is, it must be cleaned. (5) cyclone duster dismount dust pocket from cyclone duster, and clear off the inside dust pocket, as shown in fig. 1.4-11. Du...
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28 for the check and regulation steps of idle and idle mixture, refer to operation manual on engine. (iv) exhaust pollution control system crankcase ventilation hose and connector check the presence and absence of leakage and break of crankcase ventilation hose. If there is any bad case, repair or r...
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29 2) under the condition that wheels and brake drum are dismounted, check whether brake drum and friction facing is over-abraded, whether brake wheel cylinder leaks oil. Replace relevant parts if necessary. 3. Brake line check check whether brake hose and oil pipe are clamped correctly, there are o...
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30 1) check whether front wheel bearing is abraded, caught or loose. 2) check whether rear wheel bearing is abraded, caught or loose. (3) wheel nut check whether wheel nut is screwed, and screw is screwed to the specified torque if necessary. See fig. 1.4-14. The screwing torque of wheel nut: 50-80 ...
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31 fig. 1.4-16 1. Transmission filler 2. Transmission oil if gear oil is deficient, fill the specified brand gear oil to the above-mentioned oil level. 4) dismount rear axle filler plug. The oil level can be checked from the filler, the method is the same as the above, gear is deficient, please fill...
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32 12. Suspension (1) check whether the presence and absence of abrasion and break of spring, if there is over abrasion and break case, the spring should be replaced. (2) check the tightness of bolt and nut, and screw them to the specified value if necessary. 13. Steering system (1) check the steeri...
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33 • check the engine and ensure smooth operation at different rpm • check the engine and ensure no abnormalities during operation 7. Body, wheel and power train check the body, wheels and power train, there shall be no abnormal noise, vibration and other conditions. 8. Instruments check the speedom...
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34 chapter ii. Engine note: the part of engine will mainly focus on service manual. The following will only illustrate the aspects not referred in the previous part. Section 1 carburetor engine accessories i. Oil supply system of carburetor engine (i) components of fuel supply system fuel supply sys...
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35 therefore changed resulting cut off of contact switch (2) and electrical current and disposal of wiring magnetism as well. The diaphragm and pull rod are pushed downward under the force of gravity and elasticity, so oil in the oil chamber can push the oil valve and flow out of the oil pipe, the u...
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36 oil pump specifications discharge pressure 24.5-24.3kpa pump capacity 1.3l/min (200r/min) pump diaphragm pump rod fig 2.1-4 (2) disassembly as indicated in fig. 2.1-5, the upper and lower joints shall be marked ① , to recognize the angle position of upper body ② and lower body ③ . Only if angle r...
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37 fig. 2.1-6 (4) assembly 1) put the pump diaphragm on the pump rod as indicated in fig. 2.1.-6, and then insert the pump stay into the pump rod. Swivel it 90 º at the same time of pushing the pump rod, and the pump diaphragm is attached to the pump rod ④ in this way. Note: when the pump diaphragm ...
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38 fig. 2.1-8 3. Dirt collector dirt collector is installed on the front of the air filter inlet, and the purpose is to filter the air which flows into the air filter. (1) operational principle with the running of the engine, the air is drawn into the first chamber of the dirt collector, and then fl...
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39 ( 2) daily cleaning clean dirt collecting cup monthly. As is shown in fig. 2.1-9, disassemble dirt collecting cup from the dirt collector, dump the dirt and reassemble it to the previous position. 4. Exhaust emission control device in order to prevent the petrol vapor from flowing into the air an...
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40 as the exhaust manifold of engine applies compound exhausting, the exhaust system can be divided into two parts, namely intake pipe and muffler welding assembly. The intake pipe cooperates with the engine to make compound exhausting, and combines the two pipes into one pipe. 2. Installation and f...
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41 engine control system immediately supply power to engine electric controller after the ignition switch turn to the position of “on” (do not start the engine). The electric controller then connects fuel pump relay and the power source is switched on. 300kpa pressure will be produced in the fuel pi...
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42 note: • as the demand for electric vehicle oil supply pressure is quite high, the rubber pipe and clip must be able to ensure the pressure of more than 300kpa. Therefore, the rubber pipe and clip cannot be substituted by ordinary part, otherwise the leakage will occur in the pipe. More seriously,...
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43 fig. 2.2-3 structure chart of exhaust system 1. Tri-effective catalytic converter welding assembly 2. Muffler welding assembly 3. Joint component (2) catalytic converter structure catalytic converter includes a piece of ceramics carrier wrapped by backing strap and inserted in a section of tube s...
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44 the injection order shall be grouped injection: cylinder 1 and 4 are grouped together, and cylinder 2 and 3 are grouped together. 1. Fuel pump (type: delphi25330569) as to the fuel pump and support assembly components, please refer to uaes system. (1) installation method electric fuel pump is sub...
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45 fig.2.2-5 structure chart of exhaust system 1.Tri-effective catalytic converter welding assembly 2. Muffler welding assembly 3. Joint component operation and service manual on vantage truckall & vango series chapter ii. Engine.
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46 chapter iii. Chassis section 1 clutch i. Introduction clutch in the vehicle is single, dry, diaphragm spring clutch. Diaphragm spring outer side is a whole body, inner rings have some center pointing release fingers. The friction pad of the clutch is installed on the transmission input shaft thro...
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47 ii. Disassembly the prerequisite for disassembling the clutch is that the transmission has been disassembled in the correct order. The disassembly procedure is as the following: ① disassemble the six bolts used to tighten the clutch, and then take the clutch pressure plate and clutch friction pad...
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48 v. Maintenance 1. Free stroke of clutch pedal ① press the clutch pedal, stop pressing when feels the clutch resistance and measure the distance (namely free stroke of clutch pedal). The free stroke of clutch pedal shall be 20-30mm. ② if the free stroke of clutch pedal is out of the specified rang...
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49 section 2 transmission i. Introduction the transmission is gear meshed type, and has five (four) driving gears, one reverse gear and is operated by flexible shaft. Fig.3.2-1 1. Gearlever 2. Speed selecting arm 3. Bracket base 4. Ball base 5. Lining 6. Speed selecting return spring 7. Gear shiftin...
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50 1) gearlever ① disassemble the front gearlever assembly. ② disassemble the shift flexible shaft from the gearlever. ③ disassemble the speed selecting arm. 2) shift flexible shaft and speed selecting flexible shaft ① disassemble the shift flexible shaft and the speed selecting flexible shaft from ...
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51 fig.3.2-2 1. The second spring 2. Reverse gear limit pawl 3. Gear lever 4. Washer 5. The first spring ③ insert the gear shifting handle axle into the gear shifting cover body until groove “a” on the axle aligns with pin hole “b” on the gear shifting cover body. The lever arm of fork arm and the a...
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52 2) speed operating flexible lever and speed operating lever assemble according to the reverse order of disassembly. 3) washer and lining the washer and lining must be installed on the correct position, and lubrication grease shall be coated on the positions indicated below. Fig.3.2-4 1. Speed shi...
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53 5. Maintenance adjustment of flexible shaft note: • each lubricating part listed in fig.3.2-4 must be checked before adjustment to ensure adequate lubrication and there exists no wearing on the lining and other components. Maintenance shall be made based on particular conditions. • speed shifting...
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54 iii. Transmission (five gear type) 1. Introduction 995 cc models series micro vehicle adopts two types of transmissions: five gear type transmission is installed on 456 series engine and four gear type transmission is installed on 462 series engine. Four gear type transmission has four driving ge...
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55 fig.3.2-7b operation and service manual on vantage truckall & vango series chapter iii. Chassis deceleration drive gear high gear shifting fork the third gear the second gear ： low gear shifting fork the first gear reverse driving gear reverse gear shifting fork the fifth gear driving gear the se...
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56 2. Each gear ration of transmission the first gear 3.652 the second gear 1.947 the third gear 1.432 the fourth gear 1.000 the fifth gear 0.795 reverse gear 3.466 3. Disassembly 1) disassemble the negative pole (-) and the positive pole (+) tie wire from the battery binding post. 2) disassemble th...
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57 58 ⑥ disassemble the thrust washer and the reverse gear lining from the second axle. Note: the cylindrical roller may be fallen during the process of disassembly. Do not miss the cylindrical roller. What’s more, the ball bearing cannot disassemble simultaneously together with the above-mentioned ...
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58 clearance between gearing ring and tooth standard operation limit low gear, direct gear 1.0-1.4mm 0.5mm five gear 1.21-1.6mm 0.5mm fig.3.2-9 8) chamfered edge tooth of synchronizing ring (outer tooth) and outer ring (inner ring) the synchronizing ring and commutating ring has three grooves respec...
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59 standard operation limit slide block groove width of synchronizer ring 10.1mm 10.4mm 10) sizing spring of declutch shift shaft if the problem of “gear slides out of mesh” occurs, measure the free length of spring. If the free length is less than the operation limit, the spring must be replaced. S...
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60 then use the hydraulic press machine to install the first gear lining and the two linings on the second gear are the same. ② install the first gear needle bearing, collar ring, synchronizer ring, the first gear, cylindrical roller and washer to the second gear. Insert the cylindrical roller into ...
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61 ④ install the first axle and the second axle to the lower cover body. ⑤ sealant shall be coated evenly on the matching surface of the lower cover body. ⑥ insert the three gear shifting fork into the three grooves of the outer rings of the second axle respectively and install the upper cover body ...
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62 fig.3.2-12 tightening torque specification chapter iii. Chassis operation and service manual on vantage truckall & vango series.
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63 fig.3.2-13a 1. The first axle assembly 2. Needle bearing 3. The first axle bearing 4. C type lock ring 5. Collar ring 6. Oil seal 7. The second axle 8. Cylindrical roller 9. Thrust washer 10. The first gear 11. Lining 12. Needle bearing 13. The second gear 14. Needle bearing 15. The third gear 16...
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64 fig.3.2-13b iii. Transmission (four gear type) chapter iii. Chassis operation and service manual on vantage truckall & vango series under drive gear high gear shifting fork the third gear the second gear the first gear high gear shifting fork low gear shifting fork reverse driven gear reverse mid...
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65 note: please refer to the content of five gear type transmission for the unmentioned aspects. 1. As to the introduction, please refer to fig.3.2-13a and fig.3.2-13b. 2. Each gear ration of transmission the first gear 3.429 the second gear 2.109 the third gear 1.379 the fourth gear 1.000 reverse g...
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66 ⑤ press the reverse gear lining. Prevent the cylindrical rollers installed based on the step ④ fall out during operation. ⑥ install the reverse gear bearing, the reverse gear and the reverse gear commutating ring/outer ring. To ensure the correct installation order, the lower diameter and longer ...
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67 section 3 driving axle i. Introduction the driving axle in the vehicle is single section, open type and coreless dual universal joints structure. The front end is connected to the transmission output through driving axle splines, the rear end is connected to the real axle cardinal tooth flange th...
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68 ii. Disassembly 1. Lift the vehicle. 2. Disassemble the driving axle bolt and nut. 3. Pull the driving axle. If the vehicle is lifted horizontally, and the oil height of the transmission oil satisfies the corresponding specification, the transmission oil shall be firstly drained. Then pull the dr...
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69 ii. Disassembly 1) release parking brake lever. 2) lift the vehicle and disassemble the real wheel. 3) disassemble the oil draining bolt, and drain the gear oil completely from the rear axle. 4) pull the brake drum out by using m8 bolt. 5) rotate the sizing spring pin and pull the sizing spring o...
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70 computation expression: h=c-a-b a=85+ δ in the formula: c means the actual assembly distance of master retarder housing a means the actual assembly distance of driving conical gear b means the actual assembly distance of driven conical gear rear bearing (30306/p06) δ means the difference value be...
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71 fig.3.4-3 rotate the left and right side adjuster and change the axial position of the driven conical gear and thus adjust the flank clearance of the driving and driven conical gear. The back and forth of the left side and right side adjusters must be equal in order to not alter the adjusted bear...
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72 7. Tighten the differential bearing cover bolt by applying the tightening torque of 50-60n · m after adjusting the gear meshing mark. Install the adjuster locking piece and take down the driving gear conical gear flange. Lubricating grease shall be evenly coated between the mouth and assistant mo...
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73 11) connect the parking brake pulling arm to the parking brake cross bracing wire and install the brake shoe on it. 12) in order to maximize the clearance between parking brake shoe and parking brake drum, put the screw into the self adjusting meshing position of brake clearance and push the gear...
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74 assembly data of rear axle tightening torque unit: n · m items specification standard value pretension load of driving conical gear bearing (excludes oil seal resistance moment) 30305/p6 30306/p6 0.3-0.7 pretension load of differential bearing 6027-z/p6 0.3-0.7 flank tooth clearance of driving an...
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75 section 5 suspension system i. Introduction front suspension: slide column oscillating arm type independent suspension, coil spring and being installed with antis-way bar. Bilateral hydraulic solid bowl type retarder. Please refer to fig.3.5-1. Rear suspension: lengthwise sub elliptical leaf spri...
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76 (3) disassemble the rear nut of stabilizing pull rod. (4) disassemble the stabilizing pull rod. Examination (1) replace the stabilizing pull rod if there exists damage or deformation on it. (2) replace the cushion pad if there exists damage, wearing or deterioration on it. Assembly: assemble acco...
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77 (2) put the coil spring on the spring bottom base of the retarder and match its end and the ladder part of the spring bottom base. (3) install the piston rod cushion cover to the piston rod. Pay attention to its direction and do not reverse install it. (4) pull the piston rod upward as possible, ...
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78 3. Cantilever disassembly (1) support the vehicle and disassemble the wheels. (2) disassemble the antisway bar nut, washer and lining from the cantilever. (3) disassemble the stabilizing pull rod rear end nut from the cantilever. (4) disassemble the cotter pin of oversize ball pin and hexagon slo...
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79 4. Antis-way bar disassembly (1) support the vehicle and hang up the front suspension. (2) disassemble the left and right wheels. (3) disassemble the antis-way bar. Examination: examine whether there exist damage or deformation on the antis-way bar and cushion cover. And replace it based on parti...
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80 leaf spring the side must be aligned for each leaf spring chapter iii. Chassis operation and service manual on vantage truckall & vango series front rear spring upper chair spring upper chair 25-35n · m center bolt and nut nut bolt body center 40-70n · m leaf spring front bush when pressing sprin...
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81 section 6 steering system i. Introduction steering system consists of rack and pinion system and corresponding steering echelon form assembly. Rack and pinion is composed of gear shaft, pinion and the housings which enclose the two above mentioned components. Gear shaft support is on the deep gro...
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82 please refer to fig.3.6-2 to see the steering gear assembly. 1. Steering gear assembly 2. Steering gear housing assembly and lining assembly 3. Gear shaft assembly 4. Elastic collar used for holes 5. Collar ring 6. Steering gear oil seal assembly 7. Plunger assembly 8. Pressure spring 9. Locking ...
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83 5. Steering cross pull rod 1) support the vehicle and disassemble the wheels. 2) disassemble the cotter pin and steering cross pull rod groove type nut from the steering knuckle. Disassemble the steering cross pull rod ball pin assembly. 3) mark the position of steering cross pull rod locking nut...
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84 9) lubricating grease shall be slightly coated on the sliding part which the plunger against the pinion, sealant shall be coated on the adjusting bolt. Then screw the locking nut to its maximum value and rotate it 0-90º and examine the rotating torque of the gear shaft and the smoothness of the w...
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85 iv. Assembly 1. Steering gear assembly 1) set the front wheels (left and right) at the right front driving position. 2) rotate the gear shaft to adjust the length of the pinion to reach the indicated value in fig.3.6-7, set the steering pinion at the straight driving position. Fig.3.6-8 3) then i...
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86 5) connect the steering longitudinal pull rod to the steering boom and screw the groove type nut within specified torque range. Please refer to fig.3.6-9. 6) screw the gear shaft connector bolt to the specified torque. Please refer to fig.3.6-10. 7) install the upper wheels and screw the wheel nu...
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87 3) fix the steering bearing frame, and screw the bolt to the specified torque. Please refer to fig.3.6-14. Note: the nut on the universal joint boom must be tightened after tightening the gear shaft frame fixing bolt. 4) install the dust proof cover. 5) install the unit switch. 6) connect the lea...
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88 7. Steering gear dust proof cover note: each time to make regular maintenance and service or lift the vehicle due to certain reason, visually examine whether there exists damage or breakage on the dust proof cover. 1) lift the vehicle. 2) examine whether there exist breakage on the dust proof cov...
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89 fig.3.6-16 checks shall be done before adjusting the front wheel localization to ensure the precision of the front wheel localization adjustment: 1) check all the tires to see the suitableness of charged pressure and whether the wearing condition of the tire surfaces is the same. 2) check whether...
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90 6. Turing angle inner side 34 o ±3 o turning angle outer side 28 o ±3 o check the toe-in and turning angle by applying special apparatus after replacing the steering cross pull rod, steering cross pull rod ball pin and master steering arm. The front wheels shall be ensured to be on the condition ...
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91 section 7 brake system i. Introduction the vehicle applies dual pipe hydraulic brake system, front wheel disc brake, rear wheel drum brake (brake clearance is self adjustable). The brake has brake proportional valve. The operation system has vacuum booster. Parking brake applies to the rear wheel...
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92 ii. Front wheel disc brake (i) disassembly 1. Brake pad 1) loosen the front wheel nut, then support the vehicle by using a lifting jack. 2) support the vehicle on the safety board. Disassemble the hub nut, and take the front wheel down. 3) screw (one) clamp bolt down. 4) disassemble the clamp. No...
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93 (iii) notes for assembly reassemble the front wheel brake according to the reverse order of disassembly, pay attention to the following notes: · each components shall be washed and cleaned by using the brake fluid of the same type number with the fluid in the oil cylinder before assembly/ · do no...
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94 tightening torque fasteners n · m 1. Fastening brake disc and hub bolt 60-70 2. Fastening dust proof cover and steering knuckle bolt 18-25 3. Front brake hose connector bolt 20-30 4. Fastening brake tongs bolt 70-100 5. Clamp pin bolt (clamp side) 30-38 6. Clamp pin bolt (clamp bracket side) 50-6...
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95 check whether the brake drum is clean, measure the inner diameter of the brake drum and examine the wearing of the brake surface. Item standard operation limit inner diameter of brake drum 220mm 222mm once the brake drum is disassembled, it shall be completely cleaned and be examined to see wheth...
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96 fig.3.7-6 2) assemble each component according to the reverse order of disassembly. Note: do not damage dust proof cover of brake wheel cylinder when installs brake shoe. 3) press the brake shoe sizing spring down to the installation position and rotate the sizing spring to complete installation....
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97 fig.3.7-8 clearance adjustment: insert the screwdriver into the adjusting hole of the brake drum, rotate the adjusting screw until the clearance between the brake shoe and brake drum becomes zero and then rotate the adjusting screw 3 to 6 teeth in the reverse direction. (please refer to fig.3.7-9...
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98 fig.3.7-10 10) disassemble the instrument assembly. 11) disassemble the vacuum brake hose (i) from the vacuum pipe assembly (i) on the ground floor side. 12) disassemble the two oil cylinder rubber pipes from the brake master cylinder. 13) disassemble the two brake pipes from the brake master cyl...
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99 (iii) examine the components 1. Examine the internal components of brake master cylinder examine whether there exists wearing or corrosion on the disassembled components. Replace it based on particular need. Check whether there exists scores or corrosion on the inner wall of the brake master cyli...
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100 6) connect the vacuum brake hose (i) to the vacuum brake hose (ii), and clamp them tightly. 7) ensure that each component connected to the vacuum booster master cylinder assembly is tightly fixed. 8) the components which are taken down to disassemble the pedal support must be reassembled or reco...
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101 vi. Vacuum booster (i) disassembly 1) disassemble the vacuum booster from the body by applying the same method of disassembling brake master cylinder. 2) disassemble the brake master cylinder from vacuum booster. 3) disassemble the vacuum hose (i) from the vacuum booster. (fig.3.7-16) 4) disasse...
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102 chapter iii. Chassis operation and service manual on vantage truckall & vango series 1. Brake master cylinder 2. Piston fig.3.7-18 1. Vacuum booster 2. Master cylinder push rod fig.3.7-19 special tool i special tool ii special tool i special tool ii clearance between special tool and piston rod ...
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103 (iii) note for assembly (1) as is indicated in fig.3.7-21, check the distance between the fork pin hole and vacuum booster front end which shall be within 106.5-107.5mm. Screw the nut to the specified torque. (2) under the condition that the seal pad frame has been installed to the assistant cha...
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104 fig.3.7-24 1. Vacuum booster 2. Vacuum pipe connector 3. Vacuum hose 4. Collar clamp vii. Brake pipe (a) disassemble and assembly 1) clean the dirt and foreign particles on the joint of hose end and hard tube, and disassemble the brake hose and hard tube. 2) assemble the brake hose and hard tube...
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105 viii. Maintenance and service 1. Leakage of brake fluid examine the brake oil cylinder for liquid level. If the liquid level in the brake oil cylinder is slightly decreased, it shows that the decreasing is due to normal wearing of friction pad. If the liquid level is abnormally decreased, it ind...
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106 2) when the stop lamp switch is disassembled, please correctly assemble it according to the specifications in “adjust the stop lamp switch”. 5. Adjust the stop lamp switch when installs switch, firstly pull the brake pedal upward. Adjust the switch position to make the clearance between screw en...
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107 e) parking brake handle has been pulled several times by the force of 20kg. ③ the brake drum shall not have “dragging” condition after loosening the adjusting nut to adjust the stroke as is indicated in fig.3.7-28. 3) examine the parking brake pulling wire examine the damage on the brake pulling...
Page 110
108 fig.3.7-30 a) during the exhaust operation, the brake fluid shall be filled in and the oil cylinder shall be kept in the condition of half full. B) disassemble the exhaust screw protective cap. Connect the ethylene rubber pipe to the exhaust screw of brake wheel cylinder and insert the other end...
Page 111
109 b) start the engine as pressing the pedal. If the pedal stroke is slightly increased, it shows its function is normal. While if the pedal stroke do not change, it shows its function is abnormal. ③ examine air tightness with load a) press the brake pedal when the engine is running. And turn off t...
Page 112
110 iii. Charge the tire charging pressure for each model has been seriously and carefully calculated to get better riding comfort, operational reliability and to facilitate steering, best reduce the wearing to tire and prolong the durability of tire. Check the charging pressure when the tire is on ...
Page 113
111 v. Disassemble the wheels 1. Loosen the nut for about half a round. 2. Support the vehicle. 3. Disassemble the wheels. Note: · do not use heating method during disassembly of wheels. Otherwise, the life span of the wheels will be reduced and the wheel bearing will be damaged. · install the wheel...
Page 114
112 4. Screw the steering knuckle nut to the specified torque. Lock it by using cotter pin. 5. Screw the caliper nut to the specified torque. 6. Press the brake pedal and keep pressing, screw the brake pedal bolt to the specified torque. (please refer to fig.3.8-3.) 7. Install the dust proof cover. ...
Page 115
113 x. Assemble and adjust the front hub part of drum brakes 1. Disassemble the wheel hub and bearing (1) support the vehicle and disassemble the vehicle. (2) disassemble the dust proof cover (do not deform the dust proof cover) and o rubber seal ring. (3) disassemble the steering knuckle cotter pin...
Page 116
114 chapter iv vehicle body section 1 front door and rear sliding door the main assembly parts included in front door refer to fig. 4.1-1 i. Front door glass and front door glass regulator (i) disassembly disassemble front door glass and front door glass regulator according to the following sequence...
Page 117
115 fig. 4.1-2 fig. 4.1-3 4) front door inner panel . 5) front door seal membrane. 6) front door inner weather strip. The method is to wind down front door glass completely, then use a screwdriver wrapped with tape to pry inner and outer weather strips open, see fig. 4.1-3. 7) fixing screw for front...
Page 118
116 fig. 4.1-5 1. Front door glass fig. 4.1-6 1. Fixing screws for front door glass regulator (ii) inspection 1. Check whether front door glass regulator gear is abraded or damaged. 2. Check whether front door glass regulator spring is loose. (iii) assemble front door glass and front door glass regu...
Page 119
117 fig. 4.1-8 1. Glass bearer 2. Glass bearer rubber gibs 2) when assembling glass on glass bearer rubber gibs, daub soap water on glass bearer rubber gibs, and use rubber hammer to rivet slightly glass. The position of glass fixed on glass bearer sees fig. 4.1-8. 3) if it is difficult to wind up a...
Page 120
118 4) use adhesive agent to adhibit front door seal membrane on door inner panel tightly, see fig. 4.1-11. 5) assemble glass regulator handle, to make an angle of 45 º with vertical plane when the glass is closed fully, as shown in fig. 4.1-12. Fig. 4.1-11 1. Front door seal membrane 2. Adhesive ag...
Page 121
119 fig. 4.1-13 1. Front door outer handle assembly 2. Front door lock cylinder assembly 3. Front door inner handle assembly 4. Front door lock body assembly 5. Front door lock ring assembly 6. Fixing frame for front door glass guide rail. Operation and service manual on vantage truckall & vango ser...
Page 122
120 fig. 4.1-14 1. Outer handle assembly 2. Lock connection rod mechanism assembly 3. Inner handle assembly 4. Lock body assembly 5. Lock ring assembly fig. 4.1-15 1. Common screwdriver(disconnect door opening control slide rod) chapter iv vehicle body operation and service manual on vantage truckal...
Page 123
121 (iv) installation install front door lock and rear side slide door lock in the reverse sequence of disassembling .Pay attention to the following when installing. 1. Outer handle dragrod when installing outer handle drgrod 1 on door outside handle (outer handle), turn regulating nut 3 to make dis...
Page 124
122 fig. 4.1-18 1. Inside opening lever 2. Front door inner handle lever 3. Outside opening lever 4. Front door lock ring assembly b: 0-2mm 3. Door lock dragrod sheath use dragrod sheath 1 to fix firmly door lock dragrod according to the description in fig. 4.1-19. 4. Rear side slide door inner hand...
Page 125
123 fig. 4.1-21 lock ring regulation 1 . Lock ring assembly 2. Door lock regulating plate 3. Door 4. Front 5. Body (b-post) d: front door:12.7-14.7mm rear door:14.6-16.6mm 5. Lock ring regulation in order to make lock ring position rightly in front and rear directions, add regulating plates between ...
Page 126
124 iii. Front door front door joints vehicle body through the upper and lower hinges. In order to open the door easily, it is necessary to pour lubricating oil on the upper and lower hinge axes, see fig. 4.1-23. Fig. 4.1-24 1. Front door hinge 2. Bolt 3. Front door seal membrane 4. Front door hinge...
Page 127
125 fig. 4.1-26 1. Cloth 2. Wood block (ii) installation install front door in the reverse sequence of disassembling. Pay attention the following when installing. 1) if weather strip has been aged, water leakage may occur. If possible, replace it. 2) after finishing installation, regulate front door...
Page 128
126 fig. 4.1-27 1. Rear side slide door 2. Rear side slide lower roller arm 3. Rer slide door slide hinge 4. Rer side slide door upper roller arm 5. Rer side slide door slide rail 6. Rear end penal of rear slide door slide rail 7. Rer side slide door stop frame (block) a.B.C.D are all the positions ...
Page 129
127 fig. 4.1-29 1. Stop block 2. Door front end surface 3. Body surface 4. Lower roller arm fig. 4.1-30 1. Vehicle body(rear side ) 2. Vehicle body (front side) 3. Door rer end 4. Door front end 5. Slide hinge 3) dismount slide door inner handle, slide door inner trim board and slide hinge hole seal...
Page 130
128 4) regulate rer side slide stop block and screw the screw. See fig. 4.1-31. 5) lock ring position regulation refers to the above description. Fig. 4.1-31 1. Rear slide door stop block section 2 rear door main assembling parts included in rear door see fig. 4.2-1. Fig. 4.2-1 1. Rear door glass 2....
Page 131
129 i. Rear door support bar note: z because support bar cylinder is full of gas, it shall not be disassembled. Z if dismounted rear door support bar is rejected, not use again, it is necessary to wrap it with an ethane plastic bag according to the description of fig. 4.2-2. Then use a 2-3-mm borer ...
Page 132
130 iii. Disassembly rear door may be disassembled in the following sequence: 1) rear door support bar assembly. 2) rear door hinge. Iv. Installation install rer door in the reverse sequence of disassembly. V. Rear door regulation 1) unscrew rear door hinge bolt, regulate rear door along front, rear...
Page 133
131 note: z keep the seat surface clean, to avoid strong acid substance to spatter on the seat surface. Z smoker must note not to throw away dog-end on the seats. Fig. 4.3-1 fig. 4.3-2 fig. 4.3-3 operation and service manual on vantage truckall & vango series chapter iv vehicle body.
Page 134
132 section 4 instrument cluster i. General instrument cluster structure as shown in fig. 4.4-1(taking hard plastic board as an example) fig. 4.4-1 1. Instrument cluster body 2. Cross-recessed flat-round-head screw 3. Gasket 4.Glove box 5. Glove box lock 6. Glove box lock spring bolt 7. Cross-recess...
Page 135
133 ii. All parts disassembly (as shown in fig. 4.4-1) 1. Instrument cluster body 1 is installed on vehicle body with cross-recessed flat-round-head tapping screw 2, after dismounting screw, the instrument cluster body can be disassembled. 2. Instrument decoration cover 14 is installed on instrument...
Page 136
134 2. Installation fig. 4.5-2 windshield installation 1. Windshield glass 2. Windshield outer decorative moulding 3. Windshield inner decorative moulding 4. Adhesive glue as shown in fig. 4.5-2, first install the inner decorative moulding of front windshield glass on front windshield, then install ...
Page 137
135 2. Installation as shown in fig. 4.5-2, first install the inner decorative moulding of rear windshield glass on rear door window, then adhibit rear door glass installed with the outer decorative moulding of rear door glass and daubed with adhesive glue on rer door window. Note: ● daub glue evenl...
Page 138
136 section 6 bumper i. Front bumper front bumper is composed of front bumper bracket a, front bumper bracket b and front bumper assembly, as shown in fig. 4.6-1. Two front fog lights are installed on the right and left of bumper lower part respectively. Fig. 4.6-1 1. Front bumper assembly 2. Front ...
Page 139
137 the front bumper assembly method is as shown in fig. 4.6-1, screw out the nuts on front bumper bracket a and the screws, the front bumper is dismounted. When installing it, screw the above-mentioned nuts and screws. Ii. Rear bumper when disassembling rear bumper, as shown in fig. 4…..6-2, screw ...
Page 140
138 chapter Ⅴ air-conditioner system the function of vehicle air-conditioner system is to make air mass, temperature and humidity in the vehicle be regulated, meet the requirement of occupants for air comfort degree maximally. In order to meet this requirement, 995 cc models vehicle air-conditioner ...
Page 141
139 iii. Disassembly 1. Speed control resistor speed control resistor is installed on the driver side of heater shell. (1) disconnect defrost pipe on heater shell driver side, see fig. 5.1-2. Fig. 5.1-2 (2) disconnect wiring harness connector, see fig. 5.1-3. Fig. 5.1-3 1. Wiring harness connector 2...
Page 142
140 (3) dismount screws (3 pieces). (4) dismount motor and fan impeller. Fig. 5.1-4 1. Siring harness connector 2. Screw 3. Motor iv. Inspection and repair 1. Speed control resistor this resistor lies on heater shell driver side. Check the presence and absence of crack and damage, if necessary, repl...
Page 143
141 section 2 cooling system i. Refrigeration system composition the refrigeration system installed on both 995 cc engine models and common type mini-cars with electronic fuel injection engine and non-electronic fuel injection engine is different in the composition and control. The user should ident...
Page 144
142 refrigeration system is composed of compressor, condenser, stock solution drying bottle, evaporator, connection pipes and electric appliance control. The refrigeration system of 995 cc models adopts environmental protection type refrigerant (r134a). 1. Compressor assembly compressor is installed...
Page 145
143 fig. 5.2-3 magnetic clutch table 5.2-2 technical parameters of clutch name technical parameters rated work voltage 12v min. Engaging voltage 7.5v rated power 42w transmission torque 19.6n · m max. Continuous rotation speed 7800r/min pulley o type, outer diameter 118mm weight 1.4kg 2. Condenser a...
Page 146
144 3. Stock solution drying bottle is installed under right front seat of the body. Stock solution drying bottle has three functions: the first is to stock the refrigerant liquid cooled by condenser; the second is to absorb dryly the refrigerant water in the system, to prevent expansion valve from ...
Page 147
145 fig. 5.2-6 main evaporator fig. 5.2-7 auxiliary evaporator 5. Refrigeration pipe all assembly of refrigeration system is connected through refrigeration pipe. The induction pipe and outlet elbow of compressor and the induction pipe and outlet elbow of 995 cc models mini-car all adopt hose connec...
Page 148
146 after this kind of fog-like gas and liquid mixture enter into evaporator to evaporate and absorb inside heat, it besoms low temperature and low pressure gas, which is sucked into compressor to carry out another circulation. In this way, evaporator continually absorb inside heat, condenser contin...
Page 149
147 995 cc models mini-car with non-electronic fuel injection engine adopts air conditioner amplifier to carry out center control, (the automatic control of air conditioner of 995 cc models with electronic fuel injection engine is realized by the computer.). The amplifier has totally 7 links of sign...
Page 150
148 unit: acceleration switch signal is negative logical signal, low level o shows having acceleration signal. When amplifier receives acceleration switch signal, close vacuum magnetic valve and cut off magnetic clutch automatically, and open vacuum magnetic valve 9.2 seconds later, then engage comp...
Page 151
149 iv. Maintenance and inspection of air conditioning system 1. Current maintenance of air conditioning system current maintenance is routine checking, if any problems are found out, eliminate them in time. Items of current maintenance are as follows: outage check a. Check whether there is sludge a...
Page 152
150 fig. 5.2-12 observing refrigerant amount through sight glass of stock solution dryer appropriate although there are a few bubbles, they float up and down along with engine running inadequate see that bubbles flow no see that fog-like substance flow chapter Ⅴ air-conditioner system operation and ...
Page 153
151 place air volume switch on max. Gear, temperature switch on the min. Temperature position(max cool), open the door, to make engine operate at 2000r/min for 15-20min, then detect the pressure in high and low pressure sides with high and low pressure gage. The pressure in low pressure side should ...
Page 154
152 table 5.2-10 adaptor tightening torque joint aluminium pipe size and nut size locking torque n • m(kgf • cm) nut ф 8 tubing 1/2 ″ tubing 5/8 ″ tubing 12-15(120-150) 20-25(200-250) 30-35(300-350) strap m6 screw (stock solution drying bottle, etc) 4.0-7.0(40-70) (2) check items and check points th...
Page 155
153 table 5.2-11 check items and check points of air conditioning system no. Check items check points check positions check methods 6 check the temperature on high pressure and low pressure sides 1. The temperature of compressor high pressure side outlet, condenser, stock solution dryer, expansion v...
Page 156
154 (3) inspection with compound pressure gage the judgment on air conditioning system operation state with compound pressure gage(manifold pressure gage) sees table 5.2-12 table 5.2-12 judgment on air conditioning system operation state with compound pressure gage measured value of compound pressur...
Page 157
155 chapter vi electric of vehicle note: for ignition system please refer to “use and service manual for engine.” section 1 power supply system for 995 cc models series, nominal voltage of electrical system is 12v unanimously, single wire system is adopted and the negative pole is earthed. The volta...
Page 158
156 1. Sulfuration of pole plate sulfuration of pole plate refers to a layer of thick, hard recrystalisation of plumbum sulfate formed on pole plate. Mini hole of pole plate sulfated is blocked, therefore, it is hard for electrolyte to filter into the inner layer of pole plate, thus reducing the qua...
Page 159
157 (iii) parameters model jf132 jf138 jf158 jfz162-2 jfz162-1 normal working voltage 12v max output current 35a 50a polarity negative pole earthed. Built of regulator built-out built-in effective diameter of pulley φ 65mm φ 58mm φ 58.5mm idle rotation speed 1200r/min adjustable voltage 13.8—14.8v 1...
Page 160
158 (iv) trouble shooting note: ● never mix up the polarity of terminal ig and terminal l. ● prevent short-circuit from being formed between terminal ig and terminal l. ● never connect terminal i to terminal e with any lead. 1. Engine noise for alternator with loose driving belt, loose fixing bolt, ...
Page 161
159 1. Disassembling (1) disassemble the negative connection wire of battery. (2) disassemble the connection wire of alternator. (3) disassemble alternator driving belt regulation bolt, and alternator fixing blot. (4) disassemble the alternator. 2. Knocking down (see figure 6.1-4) (1) for convenient...
Page 162
160 (2) disassemble the casing bolts from the alternator. See figure 6.1-6. Marks figure 6.1-5 1. Front casing 2. Rear casing figure 6.1-6 (3) insert a stick into between stator core and front casing, to separate the front and rear casings of the alternator. See figure 6.1-7. Figure 6.1-7 1. Rear ca...
Page 163
161 while using a vice, put a piece of clean cloth between the rotor and chop in order not to damage the rotor. Figure 6.1-8 1. Pulley nut 2. Rotor 3. Cloth 4. Vice (5) disassemble the rotor from the front casing and separation ring. (6) when disassembling the front bearing, the bearing guard screw ...
Page 164
162 figure 6.1-11 1. Screw 2. Battery terminal screw (9) use a searing iron of big power (over 180w) to separate the weld from the regulator to the rectifier assembly. Disassemble the stator lead. See figure 6.1-12. Figure 6.1-12 (10) to disassemble the brush, first disassemble the brush support cov...
Page 165
163 figure 6.1-15 1. Brush 3. Checking (1) check the fan belt for looseness and soundness. (2) check the rotor. Use an ohmmeter to check each slip ring of rotor for conductivity. In case of not conducting, the rotor should be replaced. Use an ohmmeter to check the conductivity between the slip ring ...
Page 166
164 use the same method and steps as above to check the conductivity between each lead of three groups of diode. Conductivity should only exist in one direction. (6) check the capacitor. Measure the capacitance with a capacitance meter. The standard capacitance value is 0.5 mf. Replace the capacitor...
Page 167
165 for fuse box cover of 797cc model series carburetor vehicle, see figure 6.1-17. For fuse box cover of 995 cc model series electronic injection vehicle, see figure 6.1-18. Figure 6.1-17 fuse box cover of carburetor vehicle headlamp warning lamp horn brake interior lamp fog lamp electronic injecto...
Page 168
166 section 2 starting system i. Circuit of starting system the starting system consists of battery, starting motor, ignition switch and related electrical wires. See figure 6.2-1 for circuit diagram. Ii. Starting motor figure 6.2-1 1. Core 2. Detention coil 3. Traction coil 4. Electromagnetic switc...
Page 169
167 (i) see figure 6.2-2 for structure. Figure 6.2-2 1. Casing cover of driving mechanism 2. Driving mechanism lining 3. Casing of driving mechanism 4. Armature ring 5. Armature stopping ring 6. Overspeed clutch 7. Pinion driving lever 8. Switch cover 9. Brush switch 10. Rectifier end casing 11. Bru...
Page 170
168 (ii) parameters model qd1226 qd121a output power 12v 0.8kw rotation direction counterclockwise viewed from pinion side brush length 19 ≥ l ≥ 12mm number of teeth of pinion 8 features of idling when u=11v, i ＜ 50a, n ＞ 5000r/min features of loading when u=9.5v and m=6.86n·m, i ＜ 270a and n ＞ 1200...
Page 171
169 standard limit inspection of collector non-roundness under 0.05 mm 0.4 mm figure 6.2-4 (3) check the outer surface of collector for wearing. If the outer diameter is under the limit value, replace the armature. Standard limit outer diameter of collector 28 mm 27 mm (4) inspect the depth of mica ...
Page 172
170 3. Check the brush. Measure the length of every brush to check whether the brush is worn. If the measured length is under the limit value, the brush must be replaced. Standard limit brush length 16 mm 10.5 mm 4. Check the brush support and spring. (1) check the brush for movement conditions insi...
Page 173
171 battery disassemble the magnetic field coil lead from the binding post m before the inspection. Figure 6.2-8 figure 6.2-9 3. Coil return: disassemble the negative lead from the electromagnetic switch casing, and at this time check if core has retracted inwardly. If the core does not retract, the...
Page 174
172 figure 6.3-1 antitheft controller (2) reading and writing coil the reading and writing coil is a hollow one slipped on the ignition key cylinder. It is connected to the socket of antitheft controller through wire. Controlled by the antitheft controller, this coil can generate a high-frequency el...
Page 175
173 3. Definition of antitheft controller socket and terminal (see figure 6.3-5.) b a b1 … b8 a1 … a3 b1 led indicator lamp a1 positive pole of reading and writing coil b2 ground a2 vacant b3 ignition switch input a3 reading and writing coil ground b4 positive pole of battery b5 diagnosis interface ...
Page 176
174 iii. Key imitating process an antitheft controller has two statuses—non-imitated status and imitated status. It is in non-imitated status at delivery, having not imitated the code key or matches with the electronic injector controller, so in this case any code key can start the engine. After key...
Page 177
175 1. Insert the red key, turn on the ignition switch, and turn it off within 2 seconds. 2. Remove the red key and insert the black one. Turn on the ignition switch within 10 seconds and turn it off again within 2 seconds. 3. Now it flashes at 10 hz to indicate that the antitheft controller is in t...
Page 178
176 trouble code led always on the antitheft controller and electronic injector controller do not match. Led on for 2 seconds common status: the code key is recognized by the antitheft unit, and the engine can be started. Led flashing for 30 seconds at 0.5hz trouble in electronic injector controller...
Page 179
177 regulator transistor type, with built-in alternator starter output capacity: 0.8kw flicker relay 140w headlamp relay rated current: 25a horn rrated current: 4a radio and tape player fm, am, stereo, auto reverse fm, am, stereo, manual reverse fm, am, manual reverse am, manual reverse speaker 5w, ...
Page 180
178 iv. Headlamp relay for wiring position and internal principle, see figure 6.4-3. Figure 6.4-3 v. Windshield power wiper and washer (i) power wiper 1. Structure the power wiper mainly consists of motor 1, driver (linkage) 2 and blade 3. See figure 6.4-4. Figure 6.4-4 power wiper 1. Motor 2. Linka...
Page 181
179 2. Operation of wiper figure 6.4-5 the wiper switch is of rotation type, located on the lower right of the steering wheel i.E. The right handle of the combination switch has this function. There are four positions (see figure 6.4-5). When it is positioned at off, the wiper does not work, and at ...
Page 182
180 2. Washing fluid in summer add proper quantity of rust preventive and detergent into 205ppm water. In winter proper quantity of methanol or glycol should also be added. Ingredient of mixture proportion application glycol 50% temperature volumetric thickness rust preventive and detergent 2% rust ...
Page 183
181 figure 6.4-8 (ii) rear window washer (1) for structure of rear window washer, see figure 6.4-9. Figure 6.4-9 1. Washer tank 2. Rear washer motor 3. Nozzle 4. Connection water pipe 5. Front washer motor note: the rear washer and the front washer have the common tank which is respectively controll...
Page 184
182 (iii) test and service of defroster wire of rear window defroster is very thin and small, so try to use soft cloth when cleaning the rear window glass. If the frost cannot be removed, examine and repair it according to the following possible reasons: (1) the defroster fuse blows. (2) the defrost...
Page 185
183 3. Failure check of power window regulator failure cause remedy one piece of glass can only move to one of the directions. There is perhaps an open circuit in the control wire between sub-switch and main switch. Repair one piece of glass can move to neither direction. (1) failure in motor. (2) b...
Page 186
184 fault reasons remedy start does not run. 1. Fuse is loose or blown. Repair or replace 2. Contact in ignition switch is not good or short. Repair or replace 3. Battery is exhausted. Charge or replace 4. Starter magnetic switch is out of work. Replace 5. Battery binding post connector is loose. Cl...
Page 187
185 continued fault reasons remedy difficult. Start fault of inside engine 1. Cylinder ring 2. Valve clearance is not proper 3. Valve spring has deficient elasticity or break 4. Intake manifold loosen, air is sucked into cylinder. 5. Piston, piston ring or cylinder is abraded. 6. Timing belt fractur...
Page 188
186 continued fault reasons remedy deficient power 2. Gasoline pump is damaged. 3. Gasoline filter is fouled. 4. Choke mechanism is damaged. 5. Float level is maladjusted. 6. Fuel pipe line is fouled. 7. Fuel tank outlet is fouled. 8. The connection within fuel system is loose. 9. Inspect according ...
Page 189
187 continued fault reasons remedy engine rotation speed is not steady. Fuel system fault 1. Gasoline filter is fouled. 2. Gasoline pipe line is kinked. 3. Gasoline pump is faulty. 4. Air intake manifold or carburetor gasket has leakage. 5. Float level is maladjusted. 6. Inspect according to fault c...
Page 190
188 continued fault reasons remedy idle is not steady 4. Air intake manifold, carburetor or cylinder gasket leak. 5. Float level is maladjusted. 6. Choke mechanism is damaged. 7. Fuel cut off magnetic valve to occur fault. 8. Inspect according to fault code(vehicle with electronic fuel injection eng...
Page 191
189 continued fault reasons remedy engine is over hot ignition system fault 1. Ignition timing is improper. 2. The calorific value of spark plug is improper. 3. Inspect according to fault code(vehicle with electronic fuel injection engine) fuel system fault 1. Float level set too low. 2. Carburetor ...
Page 192
190 continued fault reasons remedy the abnormal noise of engine note: before checking noise, guarantee the following points: z ignition timing has been adjusted well. Z spark plug conforms to the specification z fuel conforms to specification crank shaft makes noise 1. Bearing is abraded, causing ga...
Page 193
191 continued fault reasons remedy high fuel consumption 4. Carburetor air nozzle is dirtied or fouled. 5. Air cleaner core is fouled. 6. Inspect according to fault code(vehicle with electronic fuel injection engine) inside engine fault 1. Compression pressure is deficient. 2. Valve joint is not goo...
Page 194
192 continued ii. Carburetor fault reasons remedy gasoline overflow from carburetor 1. Float valve is dirtied or abraded. 2. Float level set is too high. 3. Float is broken, and with some fuel. 4. Gasket is broken. 5. Float chamber fastening bolt is loose. Clean or replace adjust replace replace scr...
Page 195
193 continued fault reasons remedy clutch action is retarded. 1. Clutch pedal free travel is improper. 2. Diaphragm spring elasticity is deficient or diaphragm spring end is abraded. 3. Transmission input shaft spline is abraded or damaged. 4. Transmission input shaft bearing is abraded or damaged. ...
Page 196
194 continued fault reasons remedy gear can not de-mesh. 1. Synchronizer spring has deficient elasticity or is damaged. 2. Inner ring groove of synchronizer ring is abraded. 3. Synchronizer ring is seized on friction conical surface. 4. Gearshift shifting fork shaft or gearshift shifting fork distor...
Page 197
195 continued vii. Driving shaft fault reasons remedy oscillation or emitting noise 1. The gear of universal joint spider is abraded or broken. 2. Driving shaft distorts. 3. Driving shaft imbalance exceeds standard. 4. Driving shaft bolt is loose. Replace replace adjust or replace screw down noise w...
Page 198
196 continued fault reasons remedy brake pedal free travel is over big. 1. Braking fluid within braking oil tank is deficient. 2. There is air in braking pipe line. 3. The braking system of rear wheel is not adjusted well (automatic regulation mechanism is faulty.) 4. Brake shoe distorts. 5. Brake s...
Page 199
197 continued fault reasons remedy steering wheel shakes 1. Tire inflation pressure is improper. 2. Front wheel pendulates. 3. The difference of tire diameter of left and right wheels is too big. 4. Wheel hub nut is loose. 5. Wheel bearing is abraded or damaged. 6. The small ball pin of steering hor...
Page 200
198 fault reasons remedy emitting noise when steering 1. Steering gear bolt or nut is loose. 2. Wheel bearing is abraded or damaged. 3. Steering gear is maladjusted. 4. Steering shaft connection is abraded. 5. The ball pins of steering horizontal or longitudinal pull rods are abraded. Screw down rep...
Page 201
199 x. Starter fault reasons remedy starter runs, but small gear and tooth ring do not mesh. 1. The small gear of starter clutch is abraded. 2. Spline is damaged. 3. Bush is abraded. 4. Tooth ring wheel tooth is abraded. Replace replace replace replace starter does not rotate or rotation speed is to...
Page 202
200 fault reasons remedy battery discharge is over fast. 1. Water pump belt is loose or broken. 2. Battery wiring is loose or pope connector is eroded. 3. Battery electrolyte acidity is over strong, or electrolyte level is too low. 4. Battery pole end plate is damaged. 5. Electrical load is over big...
Page 203
201 xiii. Fuel gage fault reasons remedy wrong indication of instrument 1. Connector contact is not good. 2. Sensor contactor is burned or bimetal components distort. 3. Float movement is irregular. 4. Sensor or fuel gage ground is not good. Repair replace repair or replace repair no indication 1. I...
Page 204
202 xvi. Engine oil pressure warning lamp fault reasons remedy warning light is not bright when ignition switch is put in the on position (engine is not started), warning light is not bright). 1. Fuse is blown. 2. Lamp is damaged. 3. Circuit is cut off. 4. Engine oil pressure sensor is damaged. Repl...
Page 205
203 xix. Turn indicator light fault reasons remedy left and right indicator lights both are not bright, or do not flash. 1. Fuse is blown. 2. Connector is loose. 3. Flasher is faulty. 4. The rated power of used lamp is lower than specific value. Replace repair repair or replace replace flash frequen...
Page 206
204 tool set no. Content 1 tool bag 2 open-ended spanner 8 × 10 3 open-ended spanner 12 × 14 4 open-ended spanner 13 × 16 5 dual-purpose screwdriver 6 screwdriver handle 7 slip joint pliers 8 socket wrench for spark plug 9 shank—spark plug socket wrench 10 square-head spanner 11 wheel spanner 12 jac...