V80Service Manual 4 Chassis Right VI DP Y Y 02

Service Workbook
Chassis
2012Year
WARNING
Warning: To reduce the possibility of personal injury and property damage, the following
instructions must be observed:
All six service workbooks provided by SMCV are dedicated for professional technicians. Trying to
do service or repair work without appropriate trainings, tools or equipments may cause injury to
yourself or others. It can also result in vehicle damage or abnormal operation.
正 Correct service and repair work is essential to personal safety of service technicians, as
well as safe and reliable operation of vehicles. If any part needs to be replaced, use the same part
number or other part number(s) specified by SMCV only. Never use any replacement part which is not
approved by SMCV.
The repair instructions suggested and introduced in this workbook are beneficial for correct
service and repair. And sometimes special tools are required.
In this case, any use of the replacement parts, repair instructions or tools which are not
suggested or approved by SMCV should not be allowed until it is proved that this has no threat to
the personal safety or safe operation.
The technical parameters and maintenance instructions of power train provided in this workbook
are intended for all Datong PV, MPV and VAN models of model year - 2012 in general rather than any
particular vehicle model. For the specification of any particular vehicle, purchasers should consult
their SMCV Distributor or Dealer.
Throughout this workbook, WARNINGS and CAUTIONS are included which should be strictly observed
for reducing personal injuries at the service and repair work. Any incorrect service or repair will
cause damage to the vehicle, leaving hidden dangers. However, these WARNINGS and CAUTIONS are not
complete. And it is impossible for SMCV to give warnings for all potential dangers resulting from
violation of these instructions.

In order to avoid accidental airbag deployment and relevant potential injury, it is recommended
to service the airbag first when both the airbag and other systems need to be repaired.
No part of this publication may be reproduced, stored in a retrieval system or transmitted, in
any form, whether electronic or mechanical, or by photocopying, recording or other means without
prior permission in writing of SMCV.

Error and Advice Reporting
If any error is found in this service workbook, or any advice, you are encouraged to tell us.
You can send any advice via letter or fax to SMCV After Sales at
After Sales, SAIC Commercial Vehicle Co., Ltd
#2500, Jungong Road,
Shanghai City, China Postcode: 200438
The following information should be provided:
· Your name
·Authorized repair center
·Tel. and fax of the authorized repair center
·Model year and model
·VIN
·Description of your concern(s)
·Necessary relevant information (e.g. sample or marked page)
·Any applicable electronic information part identification number
SMCV will give relevant response in the following ways:
·Submitting your concern to relevant service engineer
·Consulting relevant service engineer
·Satisfying your concern within 10 working days.
Datong users are encouraged to send your concerns to SMCV Customer Support Center at: 400-081-2011.
Content
General Information ........................................................................................ 1-1
Introduction .......................................................................................................................... 1-1
General Precautions ............................................................................................................ 1-1
Front Suspension ............................................................................................ 2-1

Technical Data ..................................................................................................................... 2-1
Parameters ........................................................................................................................................................ 2-1
Torque................................................................................................................................................................ 2-1
Layout .................................................................................................................................. 2-2

Layout of front suspension................................................................................................................................. 2-2
Exploded diagram of front shock absorber ........................................................................................................ 2-3
Exploded diagram of front suspension............................................................................................................... 2-4
Fault diagnosis information and procedure .......................................................................... 2-5
SPECIAL TOOLS ................................................................................................................. 2-6
Repair instructions ............................................................................................................... 2-7

Replacing front strut and spring assembly......................................................................................................... 2-7
Replacing control arm ...................................................................................................................................... 2-10
Replacing front suspension anti-roll bar........................................................................................................... 2-15
Rear suspension ............................................................................................. 3-1

Technical Data .................................................................................................................... 3-1
Parameters ........................................................................................................................................................ 3-1
Torque................................................................................................................................................................ 3-1
Layout .................................................................................................................................. 3-2

Layout of rear suspension.................................................................................................................................. 3-2
Exploded diagram of rear suspension ............................................................................................................... 3-3
Exploded diagram of rear shock absorber assembly......................................................................................... 3-4
SPECIAL TOOLS ................................................................................................................. 3-5

Replacing rear shock absorber .......................................................................................................................... 3-6
Replacing rear steel leaf spring ......................................................................................................................... 3-7
Steering ........................................................................................................... 4-1

Technical Data ..................................................................................................................... 4-1
Content
Parameters......................................................................................................................................................... 4-1
Torque ................................................................................................................................................................ 4-2
Layout ................................................................................................................................... 4-3

Layout of steering unit and power-assisted steering unit .................................................................................. 4-3
Exploded diagram of steering column ................................................................................................................ 4-4
Exploded diagram of steering unit assembly...................................................................................................... 4-5
Exploded diagram of Steering unit ..................................................................................................................... 4-6
Fault diagnosis information and procedure........................................................................... 4-7
SPECIAL TOOLS.................................................................................................................. 4-7
Repair instructions ................................................................................................................ 4-8

Emptying the power-assisted steering ............................................................................................................... 4-8
hydraulic system................................................................................................................................................. 4-8
Track adjustment................................................................................................................................................ 4-8
Replacing the steering wheel ........................................................................................................................... 4-10
Replacing the steering column ......................................................................................................................... 4-13
Replacing the steering intermediate shaft ........................................................................................................ 4-16
Replacing the steering gaiter............................................................................................................................ 4-17
Replacing the steering unit............................................................................................................................... 4-19
Replacing the knuckle ball pin.......................................................................................................................... 4-22
Replacing the knuckle ...................................................................................................................................... 4-26
Replacing the combined switch........................................................................................................................ 4-31
Replacing the ignition switch assembly............................................................................................................ 4-33
Replacing the ignition switch locking barrel...................................................................................................... 4-35
Brakes ............................................................................................................. 5-1

Technical Data ...................................................................................................................... 5-1
Parameters......................................................................................................................................................... 5-1
Torque ................................................................................................................................................................ 5-2
Layout ................................................................................................................................... 5-3

Layout of brake system ...................................................................................................................................... 5-3
Exploded diagram of front brakes ...................................................................................................................... 5-4
Exploded diagram of rear brake caliper ............................................................................................................. 5-5
Exploded diagram of handbrake ........................................................................................................................ 5-6
Fault diagnosis information and procedure........................................................................... 5-7
Repair instructions ................................................................................................................ 5-8

Checking the front brake disc............................................................................................................................. 5-8
Checking the rear brake disc.............................................................................................................................. 5-9
Draining the brake system................................................................................................................................ 5-11
Adjusting the clearance between handbrake ................................................................................................... 5-13
and handbrake pad .......................................................................................................................................... 5-13
Content
Replacing the front brake pad.......................................................................................................................... 5-15
Replacing the rear brake pad........................................................................................................................... 5-19
Replacing the front brake disc ......................................................................................................................... 5-23
Replacing the rear brake disc .......................................................................................................................... 5-24
Replacing the rear brake shoe......................................................................................................................... 5-26
Replacing the brake master cylinder and......................................................................................................... 5-29
brake reservoir ................................................................................................................................................ 5-29
Replacing the servo assembly ......................................................................................................................... 5-30
Replacing the brake pedal assembly ............................................................................................................... 5-32
Replacing the brake pedal return spring：....................................................................................................... 5-33
Replacing the ABS regulator............................................................................................................................ 5-34
Wheel·Hub .................................................................................................... 6-1

Technical Data ..................................................................................................................... 6-1
Torque................................................................................................................................................................ 6-1
Layout .................................................................................................................................. 6-2

Exploded diagram of front hub........................................................................................................................... 6-2
SPECIAL TOOLS ................................................................................................................. 6-3

Replacing the front hub...................................................................................................................................... 6-4
Adjusting the rear hub........................................................................................................................................ 6-6
Replacing the rear hub....................................................................................................................................... 6-8
Replacing the wheel......................................................................................................................................... 6-11
Content
General Information
General Information
Introduction
WARNINGS and CAUTIONS are given throughout this Service Workbook in the following form:
Warning: Procedures which must be followed precisely to avoid the possibility of personal
injury.
CAUTION: This calls attention to procedures which must be followed to avoid damage to components
or methods which make a job easier to be performed.
References to the left or right hand side in this Service Workbook are made when viewing the
vehicle from the rear, unless instructed otherwise.
To reduce repetition, operations covered in this service workbook do not always include
reference to testing the vehicle after repair. It is essential that work is inspected and tested
after the assembly. And if necessary, road test can be performed to test the safety performance of
the vehicle.
The drawing number of the illustration inset lies in the left bottom of the figure.
The illustration insets in the repair instructions are laid out parallel to the described
contents; Parts pointed by a bold straight arrow are those to be removed or installed; parts
numbered with 1, 2, ... correspond to the descriptions of the same number; In illustrations, numbers
1, 2, etc. indicates the relevant parts in the text contents.
General Precautions
The suspension, steering and brakes are safety related; therefore all precautions stated in this
workbook must be strictly adhered to.
Please select appropriate wheels and tyre sizes/specifications originally from SMCV.
Replacements must always be recommended specification.
Correct tyre pressures are important, both for steering lightness and safety, and may be subject
to legal requirements. Always ensure to use pressure value recommended by the manufacturer.
When disconnecting the vehicle battery, always disconnect the earth return (negative) cable
firstly, and then the positive cable. For double batteries installation, disconnect both earth
return (negative) cables firstly, and then the positive cables. When connecting battery, connect the
positive cable(s) firstly, then the negative cable(s).
If any work involves the drive shafts or steering system, do not allow gaiters to become trapped
which could cause damage, splits, etc.
If any brake component has been disturbed or if the system has been bled, always check for a firm
brake pedal prior to road testing.
1-1
General Information
A range of springs are fitted to suit model specification. If renewing, always ensure the
correctly specified component is fitted.
Care must be taken when working underbonnet to avoid rotating pulleys and drive belts.
When carrying out service / repair work on a vehicle that has been driven recently, the fluid in
the power steering system and therefore the components containing the fluid will be hot.
When the engine is running, never hold the steering wheel on full lock for more than 30 seconds
in any one minute.
Before refilling fluid in the power steering system or operating any part in fluid system,
cleaning should be done to prevent dust from entering.
In vehicle test:
·"Do not release the handbrake before the steering lock has been disengaged.
·"Do not move or attempt to move the ignition key to the position 'LOCK' while on the move as
the vehicle cannot then be steered.
·"Free-wheeling with the engine switched off is dangerous as both power steering and brake
servo assistance are not available under this condition.
Do not work under the vehicle when supported only by a jack. Always use safety stands.
When supporting the vehicle with a jack, position it under a strengthen point if possible. Never
use the jack at center of rear axle tube; If necessary, position jack at the fitted position of "U"
bolt.
When renewing / refitting rubber bushed suspension components, the weight of the vehicle must be
on its road wheels before finally tightening the fixing nut(s) / bolt(s) to the correct torque.
When fitting wheels, it is important to tighten the wheel bolts in the correct sequence and to
the correct torque.
Before using special tools to fit oil seals, ensure there are no burrs on the tool diameters
which could damage the seal lip.
Some bolts in this vehicle use micro-encapsulation (patch-lock) for locking purposes. The
threads of these bolts should be cleaned and Loctite 270 applied before re-use.
Only oils approved by SMCV can be used.
Brake fluid precautions:
·"At all times use the recommended brake fluid.
·"Never leave brake fluid in unsealed containers. It absorbs moisture quickly and can be
dangerous if used in the braking system in this condition.
·"Fluid drained from a brake system or used for bleeding should be discarded.
1-2
General Information
·"The necessity for absolute cleanliness throughout cannot be over-emphasized.
Always wear safety glasses for eye protection. Always wear gloves when handling oil or grease.
Ensure the ignition switch is 'OFF', unless the procedure requires otherwise.
Always apply the handbrake when working on the vehicle, and place blocks against the front and
rear of the tyres to prevent movement.
Only run the engine in a well-ventilated area to avoid the danger of carbon monoxide poisoning.
To prevent burns, avoid contacting with hot parts such as the cooling and exhaust systems.
Do not eat or smoke while working on a vehicle.
To avoid injury, always remove rings, watches, loose jewellery, loose clothing etc. before
starting work on a vehicle.
If using compressed air to clean or dry components, ensure all precautions are taken to protect
yourself and other personnel in the area.
1-3
General Information
1-4
Front Suspension
Front Suspension
Technical Data
Parameters
Front suspension type Macphersan independent suspension
Torque
Application Torque value (Newton metres)
Front suspension anti roll bar to sub-frame bolt 50 ± 5

Anti-roll bar link to control arm nut 50 ± 5
Control arm to sub-frame bolt 240 ± 14
Rear controlling shock absorber bush retaining bolt 200 ± 10
Rear controlling shock absorber bush to sub-frame bolt 200 ± 10
Knuckle ball pin to knuckle screw 90 ± 9
Knuckle ball pin to control arm nut 180 ± 10
Front strut retaining nut 90 ± 9
Front shock absorber top supporting to carriage nut 50 ± 2.5
Front strut to knuckle bolt 180 ± 10
Sub-frame to carriage nut 240 ± 14
Track rod ball joint to knuckle nut 85 － 95
Road wheel bolt 180 ± 13
2-1
Front Suspension
Layout
Layout of front suspension
1 1
3 3
4 4
CS220000
1 Front strut and spring assembly 3 Anti roll bar link assembly
2 Front suspension anti roll bar 4 Control arm sub assembly
2-2
Front Suspension
Exploded diagram of front shock absorber
10
2 5
4
1
CS220002
1 Strut sub assembly 6 Bearing

2 Helical spring 7 Shock absorber support
3 Insulating gaiter front spring retaining ring 8 Front strut to knuckle bolt
4 Upper spring seat assembly 9 Retaining nut
5 Bump stop 10 Front shock absorber top supporting nut
2-3
Front Suspension
Exploded diagram of front suspension
2
3
1
8 9 5
7 14
13
12
11
10 15
6
CS220001
1 Front suspension anti roll bar 9 Front control arm to sub-frame nut
2 Front suspension anti roll bar clamp support 10 Control arm sub assembly
3 Front suspension anti roll bar bush 11 Control arm front bush shim
4 Front anti roll bar clamp support tosub-frame bolt 12 Rear controlling shock absorber bush assembly
5 Anti roll bar link assembly 13 Control arm rear bush shim
6 Front anti roll bar link nut 14 Front control arm allen bolt
7 Front control arm to sub-frame bolt 15 Rear control arm shock absorber bush to sub-
frame bolt
8 Front control arm to sub-frame washer
2-4
Front Suspension
Fault diagnosis information and

procedure
Fault Possible cause Solution
Noise from front suspension Front shock absorber attachment bolt is Tighten the bolt
loosen
Helical spring failed or broken Replace helical spring
Front wheel tyre worn Front wheel pressure is abnormal Adjust the tyre pressure
abnormally
Front wheel alignment toe out is incorrect Adjust the toe out
2-5
Front Suspension
SPECIAL TOOLS
Name Illustration
22mm hex wrench
C00017034-1
9mm stud flat wrench
C00017034-2
Ball joint remover
C00017036
Macpherson spring shock

absorber replacer 1
C00017035-1
Macpherson spring shock

absorber replacer 2
C00017035-2
2-6
Front Suspension
Repair instructions
Replacing front strut and spring assembly
Tools required: C00017034-1, C00017034-2,

C00017035-1, C00017035-2,
Removal
1 Lift the vehicle to a certain height with lifter, and
remove the tyre (see "Replacing wheel").
Warning: Do not work under a vehicle with only

jack as the support. Vehicle should be safely
supported.
2 On the carrier of strut, loosen the front brake

hose and disconnect the front ABS wheel speed
sensor harness.
CS223002
3 Remove the 4 bolts used for securing strut and
knuckle.
CS223003
2-7
Front Suspension
4 Remove the 3 bolts used for securing front shock

absorber support and vehicle body.
5 Remove the front strut and spring assembly.
CS223000
6 As shown in the figure, attach spring
compressors C00017035-1 and C00017035-2 to
the front shock absorber spring.
C00017035-1
Warning: Spring is compressed in assembly with
considerable force. Ensure you are familiar with C00017035-2
correct use of spring compressor before
attempting to dismantle front strut.
CS223001
7 Use C00017034-1, C00017034-2 and inner hex

wrench, to remove and discard the front strut top
retaining nut.
C00017034-2
Warning: Before removing the front strut top
retaining nut, ensure the spring compressor is C00017034-1
compressing the spring to clear supporting

pressure on the shock absorber.
8 Remove the front shock absorber support.
CAUTION: Ensure that the black coating on

spring is not damaged.
CS223014
9 Remove the front strut upper bearing, upper
spring seat assembly and insulating gaiter front
spring retaining ring.
10 Release the force of helical spring, loosen helical

spring from the spring compressor, and then
remove the helical spring and bump stop.
2-8
Front Suspension
nstallation
1 Check the front shock absorber bearing for any
crack or damage.
2 Check the front shock absorber gaiter and bump
stop for any deterioration or damage.
3 Attach the bump stop onto front strut.
4 Using spring compressor C00017035-1 and

C00017035-2, attach the helical spring onto front
strut.
5 Attach the insulating gaiter front spring retaining

ring, upper spring seat assembly and bearing
onto the front strut.
6 Confirm if fitted in the correct relative positions,

and attach the shock absorber support.
7 Attach the front strut top retaining nut.
8 Tighten the front strut top retaining nut with a

inner hex wrench, to a torque of 90 ± 9 N.m.
9 Loosen the spring compressor to release spring
force.
10 Clean the front shock absorber, spring assembly

and body joint.
11 Position the front shock absorber and spring

assembly to vehicle body, and tighten the nut to
a torque of 50 ± 2.5 N.m.
12 Attach the front shock absorber and spring
assembly to knuckle, fit the bolts and tighten the
nut to a torque of 180 ± 10 N.m.
13 Fasten the front brake hose to front strut carrier,
and connect the front wheel ABS speed sensor
harness.
14 Fit the wheel (see "Replacing wheel").
15 Lower the lifter to lay vehicle to the ground.
2-9
Front Suspension
Replacing control arm

Removal
1 Lift up the vehicle with lifter, to remove the wheel
(see "Replacing wheel").

supported.
2 Remove the 2 nuts connecting anti-roll bar link

with control arm.
CS223004
3 Remove the 4 screws attaching knuckle ball pin

to knuckle.
CS223005
2-10
Front Suspension
4 Remove the bolts and buts connecting control

arm with sub-frame.
CS223006
5 Remove the bolt securing rear control arm shock

absorber bush.
CS223007
2-11
Front Suspension
6 Remove the 2 bolts connecting rear control arm

shock absorber bush with sub-frame.
7 Loosen the nut for securing knuckle ball pin with

control arm, and remove the control arm.
CAUTION: Control arm is heavy.
CS223008
Installation
1 Attach the control arm to knuckle ball pin and

secure with a nut, tighten to a torque of 180 ±
10 Nm.
2 Position a new nut to joint of control arm and

sub-frame.
CS223009
3 Move the control arm up to position its bush into

the groove of sub-frame, and fasten with bolt
washer and nut.
CS223010
2-12
Front Suspension
4 Apply Loctite on the bolt thread, fit it with control

arm through control arm rear bush washer, rear
control arm shock absorber bush and control
arm front bush washer, and tighten the bolt to a
torque of 10 Nm,
CAUTION: Control arm front bush washer has 4 4

4
internal chamfer, which must be fitted correctly 4 2
with chamfer facing control arm shoulder. 5 3
3
5 Fit and pretighten the rear control arm shock
absorber bush to sub-frame with a bolt
CS223015
6 Attach the knuckle ball pin to knuckle with a
screw, and tighten to a torque of 90 ± 9 Nm.
CS223011
7 Attach the anti-roll bar link to control arm, fit a nut
and tighten to a torque of 50 ± 5Nm.
CS223004
CAUTION: The torque for fastening rear control
arm shock absorber bush with control arm is 10
Nm. Do not tighten completely in this step.
2-13
Front Suspension
8 Attach the rear control arm shock absorber bush

to sub-frame with a retaining bolt, and tighten it
to a torque of 200 ± 10Nm.
10 Lower the lifter to lay vehicle to the ground.
11 Drive vehicle backwards and forwards for a few

yards, and at the same time 'bounce' the front of
vehicle to settle the suspension.
12 Attach the control arm to sub-frame with a

retaining bolt, and tighten it to a torque of 240 ±
14Nm.
13 Attach the rear control arm shock absorber bush

to control arm bolt, and tighten to q torque of 200
± 10Nm.
2-14
Front Suspension
Replacing front suspension anti-roll bar

Removal

2 Loosen the 2 nuts securing anti-roll bar link from

the front suspension anti-roll bar with a wrench.
CS223013
3 Remove the 2 bolts used for securing front
suspension anti-roll bar clamp support to front
3
suspension anti-roll bar.
4
4 Remove the front suspension anti-roll bar, and
position the front anti-roll bar clamp support 5
correctly.
5 Remove the front anti-roll bar bush.

4
CS223016
Installation
CAUTION: There is a special coating on the front
suspension anti-roll bar bush, which cannot be
lubricated.
1 Fit the front suspension anti-roll bar bush.

2 Position the front anti-roll bar, secure the front
suspension anti-roll bar clamp support with a
bolt, and tighten it to a torque of 50 ± 5N.m.
3 Align the front anti-roll bar link with the front
suspension anti-roll bar, fit the nut and tighten
with a wrench, with a torque of 50 ± 5N.m.
5 Lower vehicle to the ground on lifter.
2-15
Front Suspension
2-16
Rear suspension
Rear suspension
Technical Data
Parameters
Rear suspension style Longitudinal leaf spring dependent suspension
Steel leaf spring Level 2 few-leaf-spring
Span of leaf spring 1450mm
Torque
Rear steel leaf spring front carrier attaching nut 200 ± 20

Rear steel leaf spring attaching nut 200 ± 20
Rear steel leaf spring "U" nut 90 ± 9
Rear shock absorber to rear axle bolt 120 ± 9
Rear shock absorber to body bolt 90 ± 9
Rear suspension bump stop retaining bolt 48 ± 7
3-1
Rear suspension
Layout
Layout of rear suspension
1 2
4
5
6
7
CS220000
1 Rear steel leaf spring assembly 6 Rear spring upper cover

2 Rear shock absorber assembly 7 Rear axle assembly
3 Rear steel leaf spring bump stop 8 Rear shock absorber to rear axle bolt
4 Rear suspension bump stop bolt 9 Rear steel leaf spring U bolt to rear axle nut
5 Rear steel leaf spring U bolt
3-2
Rear suspension
Exploded diagram of rear suspension
11
10 7
8 8
3
7 3
6 9
5
13
1
12
2
4
CS220001
1 Rear steel leaf spring assembly 8 Rear steel leaf spring U bolt
2 Rear steel leaf spring eye rear bush 9 Rear steel leaf spring upper cover
3 Rear steel leaf spring eye front bush 10 Rear suspension bump stop attaching bolt
4 Rear steel leaf spring shackle assembly 11 Rear steel leaf spring bump stop
5 Rear steel leaf spring shackle bush 12 Rear steel leaf spring U bolt to rear axle nut
6 Steel leaf spring shackle cover 13 Rear steel leaf spring front attaching bolt
7 Rear steel leaf spring shackle nut
3-3
Rear suspension
Exploded diagram of rear shock absorber assembly
3 3 4
2
6 5
CS220002
1 Rear suspension shock absorber assembly 5 Rear suspension shock absorber to rear axle
bolt
2 Rear suspension shock absorber to body bolt
6 Rear suspension shock absorber to rear axle
3 Rear suspension shock absorber to body washer
washer
4 Rear suspension shock absorber to body nut
3-4
Rear suspension

procedure
Noise from rear suspension Rear shock absorber leaking oil Replace the rear shock absorber
or damaged
Rear hubs bearing damaged Replace the bearing
Rear suspension fastening bolt loose Tighten the bolt
Rear wheel sway Rear wheel unbalanced Balance the rear wheel
Excessive rear hubs clearance Adjust the hubs bearing clearance
Rear hubs bearing damaged Replace the bearing
Rear wheel tyre pressure is abnormal Adjust the tyre pressure
Rear shock absorber failed Replace the rear shock absorber
Steel leaf spring has Excessive clearance of steel leaf spring Replace the steel leaf spring
abnormal knock noise, and bush and shackle carrier
vibration is increased
Steel leaf spring deformed due to fatigue, Replace the steel leaf spring
with camber reduced
SPECIAL TOOLS
Name Illustration
Rubber bush replacer

C00017038
3-5
Rear suspension
Repair instructions
Replacing rear shock absorber
Tools required: C00017038
Removal

2 Loosen and remove the bolt connecting rear

shock absorber with body (1) and rear axle
connecting bolt (2) with a special tool. 1
3 Remove rear suspension shock absorber

assembly.
2
CS223005
Installation
1 Perform several complete travels to the
replacement rear suspension shock absorber.
2 Fit the bolt connecting shock absorber with body

and rear axle, and tighten it with a torque of 90
± 9Nm,120 ± 9Nm.
3-6
Rear suspension
Replacing rear steel leaf spring
Removal
1 Lift the vehicle to a certain height with a lifter.
2 Disconnect the rear ABS speed sensor harness.
3 Using a socket wrench, remove the front bolt

connecting rear steel leaf spring with body fixing
rear steel leaf spring. 3
4 Remove the 2 nuts fixing rear steel leaf shackle, 5 6

bush and shackle cover. 4 4
6
4 5
5 Loosen the 4 nuts fitting at the "U" bolts for
connecting rear steel leaf spring with rear axle, 5
3
remove the rear spring cover, and then release
the rear steel leaf spring. 5
6
6 Check the rear steel leaf spring eye bush for any 4
worn. If necessary, remove the rear steel leaf
spring eye front/rear bush with a copper bar and CS223003
tool C00017038 respectively.
Installation
1 Fit the steel leaf spring eye bush with

tool C00017038.
2 Determine fitted position for rear steel leaf spring
shackle (1), then for rear steel leaf spring front 1 2
carrier (2).
CS223004
3-7
Rear suspension
3 When fitting rear steel leaf spring shackle (1),

bush (2) and shackle cover (3), ensure the bush
is fitted in the direction shown in figure.
2
1
2
CS223000
4 Fit and pretighten the "U" bolt and nut

connecting rear steel leaf spring with rear axle.
5 Fit and pretighten the rear steel leaf spring

shackle, bush, shackle cover and nut.
6 Fit and pretighten the front connecting bolt and

nut of rear steel leaf spring.
7 Tighten the above fixings to torque of:
-"U" bolt and nut90 ± 9 Nm

-Shackle nut200 ± 20Nm
-Front carrier nut200 ± 20 Nm
3-8
Steering
Steering
Technical Data
Parameters
Steering column structure style Mechanically fixed
Steering wheel diameter 387mm
Wheel Alignment Data
Front:
Wheel Camber 0.5 ± 1° (-0.5°～ 1.5°)
the difference between Left and right (-0.5°～ 0.3°)
Kingpin Castor 0.6 ± 0.9° (-0.3°～ 1.5°)
the difference between Left and right (-0.3°～ 0.3°)
Wheel Toe Smgle toe -0.11°～ 0.02°
generd toe -0.22°～ 0.04°
the absolute dispersion between Left and right ≤ 0.05
Kingpin Inclination 10 ± 2.5° (7.5°～ 12.5°)
Rear:
Wheel camber 0°
Wheel toe 0°
Rear-wheel thrust angle 0°± 0.25°
Power-assisted steering
Steering unit type Hydraulic pinion and rack
Maximum rack force 13572N
Flow 7L/min
Steering torque 6N/M
Steering travel 168mm
Maximum operating pressure 108
4-1
Steering
Torque
Anti-roll bar link to control arm nut 50 ± 5

Front brake caliper to knuckle bolt 107 ± 10
Drive shaft hubs nut： ① 100 ± 10 ② 300 ± 30 ③ 450 ± 16

Steering column carrier to body nut 23 ± 3
Steering column carrier to body screw 18 － 22
Track rod ball joint to knuckle nut 85 － 95
Steering unit to sub-frame bolt 180 ± 10
Steering wheel to steering column nut 30 － 35
Steering intermediate shaft to steering unit bolt 23 ± 2
Steering column to steering intermediate shaft bolt 23 ± 2
Strut to knuckle bolt 180 ± 10
Knuckle ball pin to knuckle dowel 90 ± 9
Knuckle ball pin to control arm nut 180 ± 10
Sub-frame to body nut 240 ± 14
Wheel bolt 180 ± 13
Steering hose assembly to steering gear joint 29 － 35
Steering hose assembly to steering pump joint 21 － 35
Steering hose assemblies joint 34 － 50
Combined switch to ignition switch securing self-tapping 1.5 ± 0.5
screw
4-2
Steering
Layout
Layout of steering unit and power-assisted steering unit
8
1
9
2
4
CS210000
1 Steering wheel 6 Steering fluid reservoir assembly

2 Steering column assembly 7 Power-assisted steering oil pipe assembly
3 Steering intermediate shaft 8 Fluid reservoir to steering pump oil pickup hose
4 Steering unit assembly 9 Steering oil pump
5 Steering oil pipe assembly
4-3
Steering
Exploded diagram of steering column
4 2
6
CS210001
1 Steering column assembly 4 Steering column to steering intermediate shaft

bolt
2 Steering column carrier to body nut
5 Steering intermediate shaft
3 Steering column carrier to body screw
6 Steering intermediate shaft to steering unit bolt
4-4
Steering
Exploded diagram of steering unit assembly
5 3
6
4
CS210002
1 Steering unit assembly 4 Gaiter assembly

2 Steering track rod inner ball joint 5 Steering track rod outer ball joint
3 Retaining nut 6 Track rod ball joint to knuckle nut
4-5
Steering
Exploded diagram of Steering unit
2 4
3
5
8
9
9
CS210003
1 Front suspension anti roll bar clamp support 6 Steering unit mounting plate
2 Front suspension anti roll bar rubber bush 7 Steering unit mounting plate
3 Front suspension anti roll bar 8 Front suspension sub-frame assembly
4 Anti roll bar link assembly 9 Steering unit fitting bolt
5 Steering unit assembly
4-6
Steering

procedure
Steering heavy Insufficient wheel tyre pressure Adjust the tyre pressure
Hydraulic steering system pipe blocked Replace the hydraulic pipe
Swing when low speed Excessive hubs clearance Adjust pre-tension force for bearing
Excessive toe out Adjust the toe out
Swing during high speed Inconsistent rigidity of helical springs Replace the helical spring
Knuckle bent Replace the knuckle
Different numbers of bolts in front tyre Make numbers of tyre bolts the same
Drive shaft unbalanced Calibrate to clear fault, or replace
Abnormal worn of tyre Knuckle bent and deformed Replace the knuckle
Rear hub bearing too loose or tight Adjust the hub bearing
Insufficient tyre pressure, different pressure Adjust the tyre pressure

for right and left wheels
SPECIAL TOOLS
Name Illustration
Ball joint separator
C00017036
Ball joint remover
C00017039
4-7
Steering
Repair instructions
Emptying the power-assisted steering
hydraulic system
1 Clear the area around power-assisted steering

reservoir filler and the surface of level scale.
2 Remove the reservoir cap from power-assisted

steering reservoir, and fill in steering oil to the
level between MIN and MAX marks of oil dipstick.
CAUTION:Do not let the steering wheel remain at

the lock point for over 10 seconds.
3 Start the engine, run it in idle speed for 1 minute,
and then stop the engine.
MAX
4 Top up the power-assisted steering reservoir, MIN
start the engine and fully turn the steering wheel

from left lock to right lock, circularly repeat this
for 3 times, and then stop the engine.
CS213019
CAUTION:Do not let the steering wheel remain at
the lock point for over 10 seconds.
5 Check the steering reservoir for any air bubble. If
so, wait until no any air bubble, then fill in the
reservoir to a level between MIN and MAX
marks.
6 Replace the power-assisted steering reservoir

filler cap.
Track adjustment
1 Adjust the track by changing the length of track

rod at any end of steering unit.
2 The 2 steering track rod are built with the same
length in factory. If the track is incorrect, it is
necessary to adjust the steering track rods to a
same length.
CAUTION: If adjustment is only made at one side,

vehicle operation will be affected and excessive
tyre wear will occur.
3 Check and adjust the track.
a Wheels must be straight-ahead.

b In this position, steering wheel should not be off
centre. If so, track rods must be adjusted to the same CS213032
length.
c Drive the vehicle forwards a few yards, then
check the track.
4-8
Steering
d If adjustment is required, loosen the retaining

nut, and adjust the 2 track rods to a same length.
CAUTION:When adjusting, turning a hexagon
surface of retaining nut is approximately equal to
wheel adjustment of 0.1 degree.
e Adjust the track to toe out (see Technical Data).
f After adjustment, turn steering on full lock in both
directions, and then tighten the retaining nut at both
sides of track rods to a torque of 53-72N.m.
4 After adjustment, turn steering on full lock in both
directions and check that road wheels cannot
foul suspension components.
4-9
Steering
Replacing the steering wheel

Removal
1 Disconnect the negative cable of battery.

Warning: SRS ECU capacitors must be allowed to
discharge for at least 10 minutes after battery
disconnection (and any auxiliary power supply
which may be connected to vehicle) before
starting to remove the airbag.
2 Ensure the wheels are straight-ahead.
3 Remove the driver's air bag in steering wheel

(see "Replacing the driver's air bag").
4 Disconnect the horn harness.
5 Temporarily mark the fitting positions of steering

wheel and steering column.
CS213016
6 Remove the retaining nut of steering wheel and

steering column.
CS213018
CAUTION:Do not damage the clock spring under

steering wheel.
4-10
Steering
7 Remove the steering wheel assembly.
8 For continuous operation, please remove the

upper and lower steering column cowls, (see
"Replacing the upper and lower steering column
cowls"). It is recommended to fix the lock spring
with tape or other similar item, to prevent it from
turning.
CS213025
4-11
Steering
Installation
1 Remove the masking tape (if used).
2 If the clock spring is not located in the central

position, then required to be adjusted.
CAUTION:Do not use force on the clock spring as

it is fragile.
3 Adjust the clock spring:
a Turn the clock spring to fully locked position.

b Carefully wind outer casing clockwise, then
count number of turns required to turn it in the
opposite direction.
c Find centrally fitting position by turning back by

half the number of turns just counted, and align it with
the mark on manufacturer's label.
4 Fit the upper and lower steering column cowls
(see "Replacing the upper and lower steering
column cowls").
5 Thread airbag and horn harness through the

large hole at top. When positioning clock spring,
the clock spring pin can be fixed in the hole at 6
o'clock (arrowed). When fitting the steering
wheel, it should be aligned with temporary mark
made during steering wheel removal.
CS213017
4-12
Steering
6 Align steering wheel and steering column marks,

fit the steering wheel onto steering column with a
nut, and tighten it to torque of 30 - 35Nm.
7 Connect the horn harness.
8 Install the driver's airbag (see "Replacing the

driver's airbag").
9 Connect the positive cable of battery.
10 Check operation of the SRS warning light.
CS213018
Replacing the steering column

Removal
Warning: SRS ECU capacitors must be allowed to
discharge for at least 10 minutes after battery
disconnection (and any auxiliary power supply
which may be connected to vehicle) before
starting to remove the airbag.
2 Remove the steering wheel. (see "Replacing the

steering wheel")
3 Remove the upper and lower steering column

cowls. (see "Replacing the upper and lower
steering column cowls")
4 Fix the lock spring with tape or other similar item

to prevent it from turning, as shown in figure.
5 Remove the clock spring. (see "Replacing the

clock spring")
6 Remove the ignition switch.(see "Replacing the

ignition switch")
4-13
Steering
7 Remove the steering column to steering

intermediate shaft top clamp bolt.
CS213013
8 Loosen and remove the steering column carrier

to body retaining nut (1) and steering column
carrier to body securing screw (2).
2
CS213026
Installation
1 Fit and pretighten the 2 steering column carrier

to body retaining nuts (1) and 2 steering column
carrier to body securing screws (2).
2 Fix the steering column carrier nut, and tighten it 2
to torque of 23 ± 3Nm. Fix the steering column
carrier screw, and tighten it to torque of 18 - 22 1
Nm.
CS213026
4-14
Steering
3 Fit the steering column onto the splined end of

steering intermediate shaft with a bolt, and
tighten it to a torque of 23 ± 2Nm.
4 Fit the ignition switch ("Replacing the ignition
switch").
5 Fit the clock spring (see "Replacing the clock

spring"), and remove masking tape (if used).
6 If the clock spring is not located in the central

position, then required to be adjusted (see
"Adjusting the clock spring").
CAUTION:Do not use force on the clock spring as CS213013

it is fragile. Special care should be taken when
turning the clock spring, especially at the full lock
position. Otherwise, clock spring may be
damaged.
7 Fit the upper and lower steering column cowls
(see "Replacing the upper and lower steering
column cowls").
8 Fit the steering wheel (see "Replacing the

steering wheel").
9 Install the driver's airbag (see "Replacing the

driver's airbag").。
CS213024
4-15
Steering
Replacing the steering intermediate shaft
Removal：
1 Make the wheels to be straight-ahead.
2 Remove the clamp bolt for fixing steering

intermediate shaft and steering column.

supported.
CS213013
4 Remove the clamp bolt fixing lower end of

steering intermediate shaft (threaded through the
floor hole) and steering splines. 6
6 Slide up the steering intermediate shaft within 4

steering column, until clear of steering column
splines.
7 Remove the steering intermediate shaft.
CS213027
4-16
Steering
Installation
1 Fixing the splined end of steering intermediate

shaft with steering column with a bolt, and
tighten it to a torque of 23 ± 2N.m.
2 Thread the other end of steering intermediate
shaft through the floor hole, and engage the
steering intermediate shaft rubber bush into floor
gap.

supported.
4 Connect the steering splines with lower end of
steering intermediate shaft (threaded through the
floor hole). Fix with a bolt and tighten it to a
torque of 23 ± 2N.m.
Replacing the steering gaiter

Removal

supported.
2 Remove the track rod ball joint to knuckle nut,
and use the tool C00017036 to separate track
rod ball joint.
C00017036
CS213002
4-17
Steering
3 Loosen the steering track rod retaining nut with a

wrench.
CS213010
4 Temporarily mark the track rod and retaining nut,

for later fitting.
CS213011
5 Remove the gaiter securing clip, to separate the

gaiter.
CS213012
4-18
Steering
Installation
1 Lubricate the rack and ball joint, and turn the
rack to be straight-ahead.
2 Apply lubrication grease inside the end of new
gaiter before fitting it. Ensure the gaiter is fully
located in rack housing and groove of steering
track rod, and fix it with a new clip.
3 Fit the steering track rod retaining nut to the

temporarily marked position.
4 Fit the retaining nut into steering track rod.
5 Fix the track rod ball joint into knuckle with a nut,
and tighten it to a torque of 85-95 Nm.
6 Fit the wheel. (see "Replacing the wheel")
7 Lower vehicle to the ground.
8 Track should be accurately checked, and

adjusted if necessary. (see "Adjusting track")
Replacing the steering unit

Removal
CAUTION:Please block the pipe opening when
disconnecting hydraulic pipe, to prevent dust
from entering.

2 Lift the vehicle to a certain height with a lifter,
then remove the wheel. (see "Replacing the
wheel")
CAUTION:Do not work under a vehicle with only

supported.
3 Position the steering wheel to be straight-ahead.
4 Remove the steering intermediate shaft (see

"Replacing the steering intermediate shaft").
5 Remove the front suspension anti roll bar (see

"Replacing the front suspension anti roll bar").
4-19
Steering
6 Remove the track rod ball joint to knuckle nut,

and use the tool C00017036 to separate track
rod ball joint.
7 Locate an appropriate drain tray under the

steering unit, and disconnect the hydraulic pipe
to steering unit. Ensure to block the hydraulic
pipe opening to avoid dust from entering.
C00017036
CS213002
8 Remove the 4 bolts and nuts fixing steering unit

and sub-frame, and remove the steering unit
mounting plate.
9 Remove the steering unit assembly from sub-

frame.
CS213023
4-20
Steering
Installation
1 Ensure the steering rack is fixed at the central
position.
a Turn the steering wheel to the full lock position.
b Accurately count number of turns to move to opposite
full lock.
c Turn back by half that number of turns, which is the

steering rack central position.
d Temporarily mark the pinion and rack housing.
2 Check if marks on pinion and rack housing are

aligned, and steering wheel is located to be
straight-ahead.
3 Fit the support plate under steering unit carrier,

and fix with a bolt.
4 Fit the steering unit assembly and sub-frame,

and fix with a bolt tightened to a torque of 180 ±
10 Nm.
5 Reconnect the hydraulic pipe on steering unit,

and ensure that connection is clean. CS213014
6 Fit the steering intermediate shaft (see
"Replacing the steering intermediate shaft").
7 Position the front suspension anti roll bar, and fix

the front suspension anti roll bar clamp support
with a bolt tightened to a torque of 50 ± 5Nm.
8 Align the anti-roll bar link with the front
suspension anti-roll bar, fit the nut and tighten
with a wrench to a torque of 50 ± 5Nm.
9 Fit the steering track rod ball joint to knuckle,
and tighten the nut to a torque of 85-95 Nm.
10 Fit the wheel (see "Replacing wheel")
11 .Lower vehicle to the ground on a lifter.
12 Empty the power-assisted steering hydraulic

system (see "Emptying the power-assisted
steering hydraulic system").
13 Check the toe out track, and adjust if necessary

(see "Adjusting the toe out track").
4-21
Steering
Replacing the knuckle ball pin

Removal
1 Remove the wheel trim cover.
CS213034
2 Turn the the hub nut release, remove locking nut

.
and the washer from the driving axle hub and

discard the nut.
When removing the locking nut, note the following:
a. To remove the locking nut in the groove, insert a screw

driver or similar tools under its thin edge. Do not apply
excessive force or damage the driving axle thread;
b. Check if the feather edge of the locking nut has

reached beyond the radius of M20 thread. In case part of
the edge is still in the groove, smooth the cocking up part
CS213033
with sharp-nose pliers, so as to avoid damaging driving
axle thread;
c. With the locker on the locking nut off, use a socket

wrench to loosen the nut. Do not apply excessive force.
Should any abnormality happen, stop and identify the
source before moving on;
d. After the locking nut is removed, check the semiaxis

mandrel thread for burr and other defects, and remove
any with a threading die M30 × 1.5.
4-22
Steering

4 Separate and remove the control arm and anti

roll bar link connecting nut.
5 Remove the knuckle ball pin nut, and use the

tool C00017039 to separate knuckle ball joint.
C00017039
CS213001
4-23
Steering
6 Remove the screw for fixing knuckle ball pin on

knuckle.
CAUTION: Do not damage the knuckle gaiter in

operation.
CS213003
7 Use a pry bar to pull control arm down and

release arm from knuckle. Pull knuckle assembly
outwards, to enable knuckle ball pin to be
removed.
8 Remove the knuckle ball pin.
CS213029
Installation
1 Fit the control arm onto knuckle ball pin, and

pretighten the nut.
2 Use a pry bar to pull control arm down, to locate

the knuckle in knuckle ball pin fitting position.
3 Fix the 4 screws connecting knuckle ball pin with

knuckle, with a torque of 90 ± 9Nm.
CS213021
4-24
Steering
4 Fix the knuckle ball pin and control arm nut, with
a torque of 180 ± 10Nm.
5 Fit the hub washer and new retaining nut, and
tighten as the following 3 steps: Fit the wheel
and lower lift to ground.
a Pretighten to a torque of100 ± 10Nm.

b Turn the drive shaft back and forth for 10 times,
fit the hub bearing into position, and tighten to a
torque of 300 ± 30Nm.
c Turn the drive shaft back and forth again, and
tighten to a torque of 450 ± 16Nm.
CS213004
6 Stake the left drive shaft retaining nut, and make
it trapped into half axle groove.
7 Fit the wheel trim cover.
8 Fit the wheel (see "Replacing the wheel").
4-25
Steering
Replacing the knuckle

Removal
1 Remove the wheel trim cover.
CS213034
2 Turn the the hub nut release, remove locking nut

.
and the washer from the driving axle hub and

discard the nut.

excessive force or damage the driving axle thread;

CS213033
with sharp-nose pliers, so as to avoid damaging driving
axle thread;

d. After the locking nut is removed, check the semiaxis

4-26
Steering


supported.
4 Separate and remove the control arm and anti

roll bar link connecting nut.
5 Loosen the front brake hose from strut carrier,

and disconnect the front ABS speed sensor.
CS213020
4-27
Steering
6 Loosen the bolt attaching front brake caliper to

knuckle, remove front brake caliper and hang it
to avoid damaging front brake hose.
CS213022
7 Remove the 1 bolt attaching brake disc to front

hubs.
CS213006
8 Remove the nut connecting steering track rod

ball joint with knuckle, and use C00017036 to
separate steering track rod ball joint.
9 Loosen and separate the nut attaching control

arm to anti roll bar link.
C00017036
CS213000
4-28
Steering
10 Remove the 4 screws attaching knuckle ball pin

to knuckle.
CS213009
11 Pull control arm down to clear knuckle ball pin

from knuckle.
CS213007
12 Pull the knuckle outwards to separate from its

drive shaft.
CAUTION:After removing, the drive shaft must be

supported to avoid damaging gaiter, knuckle, etc.
CS213030
4-29
Steering
13 Remove the 4 screws attaching knuckle to strut,

to remove the knuckle.
CS213008
Installation
1 Fit the knuckle to strut with a bolt, and tighten it
to torque of 180 ± 10Nm.
2 Position the knuckle over drive shaft, pull control

arm down, push knuckle inwards to locate it on
knuckle ball pin, fit knuckle ball pin screw and
tighten it to a torque of 90 ± 9Nm.
CAUTION:Be careful to avoid damaging hub oil
seal.
3 Fit the nut connecting anti roll bar link with
control arm, and tighten it to a torque of 50 ±
5Nm.
CS213009
4 Fit the nut attaching track rod ball joint to

knuckle, and tighten it to q torque of 95 - 116Nm.
5 Fit the bolt attaching brake disc to front hubs.
CS213035
4-30
Steering
6 Fit the brake caliper onto knuckle with a torque of

107 ± 10Nm.
7 Attach the front brake hose onto front strut
carrier.
8 Fit the hub washer and retaining nut, and tighten

them in the following 3 steps. Firstly, fit the
wheels and lower the lifter to lay vehicle to the
ground.
a Pretighten to a torque of 100 ± 10Nm.
b Turn the drive shaft back and forth for 10 times, fit
C00017036
the hub bearing into position, and tighten to a torque of
300 ± 30Nm. CS213002
CS213020
c Turn the drive shaft back and forth again, and tighten
to a torque of 450 ± 16Nm.Stake the left drive shaft
retaining nut, and make it trapped into half axle groove.
drive shaft retaining nut, and make it trapped into

half axle groove.
Replacing the combined switch

Warning: Before any operations on SRS system, it is
mandatory to read through all of related information.
Warning: Ensure to remove the ignition key from
ignition switch. Before any operations on SRS system,
it is mandatory to disconnect vehicle battery and wait
for 10 seconds.
CAUTION:Before disconnecting any part of
steering system, please ensure wheels are
straight ahead and steering wheel will not rotate.
If rotation of steering wheel is not limited,
Removal
1 Disconnect the two poles of battery, with
negative first.
2 Remove the driver's airbag assembly. (see
"Replacing the driver's airbag")
3 Remove the steering wheel assembly. (see

"Replacing the steering wheel assembly")

cowls. See "Replacing the upper and lower
steering column cowls assembly".
5 Remove the clock spring. (see "Replacing the

clock spring")
4-31
Steering
6 Remove the 3 self-tapping screws attaching

combined switch to ignition switch.
7 Disconnect the 4 connectors from combined

switch.
8 Remove the combined switch from steering

column.
9 Press and pull back the clips at both sides of

light-switch lever assembly.
10 Remove the light-switch lever assembly.
11 Press and pull back the clips at both sides of

wiper/washer-switch lever assembly. CS723009
12 Remove the wiper/washer-switch lever

assembly.
Installation
1 Attach the wiper/washer-switch lever assembly
onto combined switch.
2 Attach the combined switch onto steering
column, and connect the connectors.
3 Attach the combined switch onto ignition switch,

and tighten with retaining screws to a torque of
1.5 ± 0.5Nm.
4 Fit the clock spring.
5 Fit the upper and lower steering column cowls.
6 Fit the steering wheel assembly.
7 Fit the driver's airbag assembly.
8 Connect the two poles of battery, and connect

earth terminal finally.
9 Execute system inspection, to check functions of

light-switch lever assembly, wiper/washer-switch
lever assembly and steering wheel control.
4-32
Steering
Replacing the ignition switch assembly

Removal
negative first.
2 Remove the driver's airbag assembly. (see
"Replacing the driver's airbag")
3 Remove the steering wheel assembly. (see

"Replacing the steering wheel assembly")

steering column cowls assembly")
5 Remove the clock spring (see "Replacing the

clock spring").
6 Remove the combined switch (see "Replacing

the combined switch").
7 Disconnect the immobiliser coil connector.
CS723010
8 Remove the immobiliser coil fixing screw.
9 Disconnect the 2 ignition switch connectors.
10 Locate a tool such as chisel on the fractured

surface of broken immobiliser bolt. Hit it with a
hammer, to make the broken immobiliser bolt
rotate anti-clockwise. Remove the 2 broken
immobiliser bolts.
11 Remove the ignition switch cap, and then the

ignition switch.
CS723011
4-33
Steering
12 Insert the ignition key, and turn it to ACC

position.
13 Press the position 1 with a hard screwdriver, pry

the position 2 upwards with a flat screwdriver, 1
and then remove the ignition switch locking
barrel.
CS723012
Installation
1 Insert the key into ignition switch locking
barrel,and turn it to ACC position
2 Fit the ignition switch locking barrel and capinto
positions.
3 Tighten the immobiliser bolts to broken.
4 Connect the 2 ignition switch connectors.
5 Fit the immobiliser coil.
6 Connect the immobiliser coil connector.
7 Fit the combined switch.
9 Fit the steering wheel assembly.
10 Fit the driver's airbag assembly.
4-34
Steering
Replacing the ignition switch locking barrel

Removal
negative first.
steering column cowls assembly")
3 Disconnect the immobiliser coil connector.
4 Remove the immobiliser coil fixing screw, and

then remove the coil.
CS723010
5 Insert the ignition key, and turn it to ACC

position.
6 Press the position 1 with a hard screwdriver, pry

the position 2 upwards with a flat screwdriver, 1
and then remove the ignition switch locking
barrel.
CS723012
Installation
1 Insert the key into ignition switch locking barrel,
and turn it to ACC position.
2 Fit the ignition switch locking barrel into position.
3 Fit the immobiliser coil.
4 Connect the immobiliser coil connector.
4-35
Steering
4-36
Brakes
Brakes
Technical Data
Parameters
Type
·Front Disc brake
·Rear Disc brake
Diameter of brake caliper piston:：

·Front 2 x 48 mm
·Rear 1 x 48 mm
Diameter of brake disc:：

·Front 294 mm
·Rear 304 mm
Min. thickness of front brake disc

·New (nominal size) 24mm
·Fixing limit 22mm
Min. thickness of rear brake disc

·New (nominal size) 16mm
·Fixing limit 14mm
Min. thickness of rear brake disc/Max. diameter of inner

bore 16mm 190mm
·New (nominal size) 14mm 191mm
··Fixing limit
Min. thickness of brake lining material
·Front brake disc (with self-adhesive shim) 9 mm (only 2 mm for friction piece material)
·Rear brake disc (with self-adhesive shim) 7.6 mm (only 2 mm for friction piece material)
·Rear brake shoe (with self-adhesive shim) 4 mm (only 2 mm for friction piece material)
Handbrake: Manually operated, mechanically, forces passed to rear

disc-middle drum handbrake via cables
Anti-lock braking system Normally configured with ABS
ABS wheel speed sensor 75 Ω (static)

Brake pipe type X pipes layout
Brake master cylinder Tandem double chambers independent master cylinder
Vacuum servo With double diaphragm vacuum servo (with BA feature)
5-1
Brakes
Torque
Bleed screw 9 － 15
Front brake disc and front hub screw 10 ± 2
Rear brake disc and rear hub screw 8±2
Rear brake caliper to rear axle bolt 100 ± 10
Front brake caliper to knuckle bolt 107 ± 10
Handbrake to rear axle bolt 65 ± 5
Joint of braking pipes 15 ± 2
Braking hose to braking pipe joint 15 ± 2
5-2
Brakes
Layout
Layout of brake system
4 5 2
2
3
1
CS240001
1 Front caliper 4 Servo assembly

2 Rear caliper 5 Brake pedal assembly
3 ABS regulator
5-3
Brakes
Exploded diagram of front brakes
1
2
3
4
12
13 5
3
11
10
9
8
CS240002
1 Pin shaft bolt 8 Piston gaiter
2 Brake caliper 9 Rectangle seal
3 Pin gaiter 10 Piston
4 Guide pin 11 Setting pin
5 Guide pin bush 12 Bleed screw
6 Front brake pad 13 Bleed screw head
7 Support
5-4
Brakes
Exploded diagram of rear brake caliper
1
3 5
15
4
6
7 9
14 8
10
13 11
12
CS240000
1 Guide pin 9 Guide pin gaiter

2 Setting pin 10 Support
3 Bleed screw head 11 Guide pin bush
4 Bleed screw 12 Brake slipper snap spring
5 Brake caliper 13 Brake slipper
6 Rectangle seal 14 Mud flap
7 Piston 15 Bolt
8 Piston gaiter
5-5
Brakes
Exploded diagram of handbrake
4
3
6
2
7
1
8
12 9
10
11
13
CS240003
1 Brake shoe assembly 8 Clearance adjuster mechanism

2 Brake back plate 9 Compression spring rod
3 Thrust plate return spring 10 Compression spring
4 Upper end return spring 11 Compression spring seat
5 Plate 12 Peep hole rubber plug
6 Parking thrust plate 13 Lower end return spring
7 Brake shoe with draw arm assembly
5-6
Brakes

procedure
Brake caliper cannot be Piston is stuck Adjust or replace the piston

released
Guide pin is stuck Adjust or replace the guide pin
Brake caliper is fitted Refit it correctly as instructed

incorrectly
Brake is delayed Piston return incorrectly Replace the piston
Guide pin bush is worn Replace the guide pin bush
Brake pedal is hard to be Piston is stuck due to rust in Repair or replace the brake caliper
applied caliper cylinder hole
Guide pin is stuck due to rust Repair or replace the brake caliper
in carrier and guide hole
Insufficient parking force Excessive clearance between Adjust the clearance adjuster mechanism
brake shoe and brake drum
Brake shoe is oily or hardened Replace the brake shoe
Parking is hard to be Insufficient clearance between Adjust the clearance adjuster mechanism
released brake shoe and brake drum
Return spring is broken, or its Replace the return spring

force is reduced
Insufficient brake, Excessive worn of friction Replace the friction piece

braking distance is too piece
long
Hardened friction piece Repair or replace the friction piece
surface
Water into brake disc, or Drain the brake disc or clean the surface of friction piece
friction piece is oily
Vehicle is off tracking or Left and right brake discs have Adjust the left and right brake discs to have the same
side slipping when different clearances with clearances with friction pieces
braking friction pieces
Inconsistent pressures of left Adjust the tyre pressure or replace the tyre
and right tyres, or worn
unevenly
Malfunction of brake wheel Adjust or replace the brake wheel cylinder

cylinder
Left and right friction pieces Replace the friction pieces

are worn unevenly
5-7
Brakes
Repair instructions
Checking the front brake disc
supported.
2 Remove the wheel (see "Replacing the wheel").
3 Remove the 2 bolts fixing front brake calipers

onto knuckle, remove front brake caliper
assembly and put it aside.
CAUTION: Do not hang the brake caliper on brake

hose.
4 Using abrasive paper, clear any slight rusts,
scratches and ruts on working surface of brake
disc. If there is any serious worn, scratch or
crackle on working surface, lathe work should be
carried out on the brake disc or even replace
with a new one.
CS213022
5 Using an outside micrometer, measure thickness
on at least 4 points in central touching position of
brake disc and friction piece. The measuring
points are located at 10mm inwards of brake disc
edge. Thickness of brake disc should be at least
22mm, and thickness variation within the same
radius circle should not be more than 0.01mm. If
this limit is exceeded, front brake disc must be
replaced.
CAUTION: Brake discs must be changed as a

pair.
CS243022
6 Attach micrometer inside the front hub via the

seat.
7 Fix micrometer head at 5mm away from front

brake disc edge.
8 Zero micrometer and rotate the wheel for one

round, to measure variation of front brake disc.
The variation of front brake disc should not be
more than 0.10 mm.
CS243023
5-8
Brakes
9 If the variation of front brake disc exceeds its

limit:
a Remove the screw fixing front brake disc onto

hub, and then remove front brake disc.
b Ensure the junction surface of front brake disc
and front hub flange is clean.
c Fit the front brake disc onto front hub, fix the
screw and torque it to 10 ± 2N.m.
d Check variation of brake disc again as instructed
above.
e If still exceeds, replace brake disc or hub.
10 Remove micrometer and seat from inside of front
hub.
11 Fit the front brake caliper onto knuckle, fix the

bolt and torque it to107 ± 10Nm.
13 Apply the brake pedal for several times, to adjust

front brake pad.
Checking the rear brake disc

supported.
2 Remove the wheel (see "Replacing wheel").
3 Remove the 2 bolts fixing rear brake calipers

onto rear axle, remove rear brake caliper
assembly and put it aside.
CAUTION:Do not hang the brake caliper on brake

hose.
CS243029
4 Using abrasive paper, clear any slight rusts,
scratches and ruts on working surface of brake
disc. If there is any serious worn, scratch or
crackle on working surface, lathe work should be
carried out on the brake disc or even replace
with a new one.
5-9
Brakes
5 Using an outside micrometer, measure thickness

on at least 4 points in central touching position of
brake disc and friction piece. The measuring
points are located at 10mm inwards of brake disc
edge. Thickness of brake disc should be at least
14mm, and thickness variation within the same
radius circle should not be more than 0.01mm. If
this limit is exceeded, rear brake disc must be
replaced.
CAUTION:Brake discs must be changed as a pair.
CS243022
6 Attach micrometer inside the rear hub via the
seat.
7 Fix micrometer head at about 5mm away from

brake disc edge.
8 Zero micrometer and rotate the wheel for one

round, to measure variation of rear brake disc.
The variation of rear brake disc should not be
more than 0.10 mm.
9 If the variation of rear brake disc exceeds its

limit:
a Remove the screw fixing rear brake disc onto CS243023

rear hub, and then remove rear brake disc.
b Ensure the junction surface of rear brake disc
and rear hub flange is clean.
c Fit the rear brake disc onto rear hub, fix the
screw and torque it to 8 ± 2N.m.
d Check variation of rear brake disc again as
instructed above.
e If the variation still exceeds its specification,
replace rear brake disc or rear hub.
10 Remove micrometer and seat from inside of rear
hub.
11 Fit the rear brake caliper onto rear axle, fix the
bolt and torque it to 100 ± 10Nm.
13 Apply the brake pedal for several times, to adjust

rear brake pad.
5-10
Brakes
Draining the brake system
Below is the method for draining the entire system.

However, if the primary or secondary loop is an isolated
loop, only the loop required drained should be operated.
Hydraulic system is allowed to be drained only
whenbrake pipe or brake hose is disconnected and there
is only slight oil loss.
Warning: Do not allow brake fluid to contact eyes

or skin.
CAUTION: Never reuse brake fluid drained from

brake system.
排空
1 Top up the brake reservoir to the mark of MAX.
CAUTION:During draining process, ensure level
of new brake fluid is between the "MIN" and
"MAX" marks.
3 Remove the bleed screw cap at rear right brake

caliper (for left drive models), and fit the hose
onto bleed screw. Immerse the free end of hose
into a container filled with new brake fluid.
4 Apply the brake pedal for several times, and then

with stable pressure. CS243025
5 Loosen the bleed screw to separate brake fluid
from air, and let the pedal return without any
external force.
6 Apply the brake pedal to its max. travel under

stable pressure, and let it return without any
external force. Repeat this procedure for several
times, until air-free brake fluid flow into the
container. Keep the brake pedal at its max.
travel, then tighten the bleed screw to a torque of
9-15Nm.
7 Remove the hose from bleed screw, and fit the

bleed screw cap.
8 Repeated draining procedure for brake caliper:
·LHD model: Rear right: Front left: Rear left: Front

right
·RHD model: Rear left: front right: Rear right: Front
left
Warning: If draining is not clear, braking
efficiency would be significantly reduced
5-11
Brakes
10 Top up the brake reservoir with brake fluid to the

MAX mark.
11 Apply brake and check for any leakage.
12 Road test the vehicle. When applying brake,

check if the free travel of brake pedal is within
10mm.
5-12
Brakes
Adjusting the clearance between handbrake

and handbrake pad
1 Clip the wheel and release handbrake.

2 Start engine.
3 Operate the handbrake for 4 - 6 times, to ensure

correctly adjusting handbrake.
CAUTION:If adjuster is disturbed, handbrake

must be operated for 20 times.
4 Stop engine.
5 Lift vehicle in a lifter, to make wheels free.

supported.
6 Check if both rear wheels can be rotated:
When applying force of about 196N to fully lock

handbrake (generally 4-7 gears) and release handbrake,
rear wheels should rotate freely. Otherwise, it is
necessary to adjust clearance between handbrake shoe
and brake drum, and then adjust handbrake front cable

length.
7 Adjust the cable length with welded nut in

adjuster.
8 Adjust flange retaining nut by rotating adjuster

flange nut until 2 rear wheels are locked, then
tightening and fixing the cable. Torque to: 6-
12Nm.
8
CS243027
5-13
Brakes
9 If handbrake pad is worn and need to adjust

clearance, use screwdriver or similar tool to
rotate clearance adjusting ratchet in direction
shown. Rotating one gear can reduce clearance
for 0.156mm. Brake shoe will be widened in
arrowed direction.
10 Release handbrake, and check if 2 rear wheels

can rotate freely.
11 Release handbrake completely, and handbrake

light should turn off. It will be on if pull
handbrake.
CS243034
5-14
Brakes
Replacing the front brake pad

Warning: Brake pads should be replaced in pair
of bearings, otherwise the braking efficiency
would be reduced.
Removal
supported.
3 Put a container under the knuckle to collect

overfilled fluid.
4 Release the front brake hose on strut carrier.
CAUTION: Brake pads should be replaced in pair

would be reduced.
5 Loosen and remove the bolt connecting front

brake hose (1) with brake caliper (2).
CS243028
6 Remove the brake caliper to knuckle retaining

bolt, to release brake caliper.
CS213022
5-15
Brakes
7 Remove the brake slipper from brake caliper.
CS243013
8 Loosen the fitting bolt for securing guide pin.
9 Separate caliper from carrier. 8 10

9
9
10 Remove guide pin, setting pin, pin gaiter anpin
rubber bush.d 7
CS243021
11 Fill in pressurized gas from caliper oil inlet, and

push out the piston.
CS243001
5-16
Brakes
12 Pry the gaiter with a screwdriver.
13 Lever out the rectangle seal with a needlenose

tool
CS243016
Installation
1 Clean the brake parts.
Warning: Do not clean brake parts with
pressurized gas, to avoid inhaling friction
material which is poisonous.
2 Before fitting rectangle seal, clean it with water-

free alcohol and apply special lubrication grease
evenly. Fitted seal should not be distorted.
3 Press piston directly into caliper cylinder hole.
4 Press the gaiter into gaiter hole completely.
5 When fitting guide pin and setting pin, pay

attention to the direction of guide pin. It should
be opposite to brake caliper oil inlet.
6 Fit brake pads, and notice the differences of

theirleft and right parts as well as inner and outer
parts.
7 When fitting snap spring, make protrusion end of

carrier to match with protrusion end of brake
pad.
8 Apply ST271 glue on threads of pin fitting bolt,

and tighten it to a torque of30-35N.m.
CS243012
9 Clear all stains from brake disc edge.
10 Fit a front brake caliper to knuckle retaining bolt,

and tighten it to a torque of 107 ± 10Nm.
11 Connect front brake hose to front brake caliper
housing, fix with a bolt torqued to25 ± 2Nm.
12 Attach the front brake hose to strut carrier.
13 Drain the brake system (see "Draining the brake

system")
5-17
Brakes

.
5-18
Brakes
Replacing the rear brake pad

would be reduced.
Removal

supported.
3 Put a container under the rear axle brake disc

tocollect overfilled fluid.
CAUTION: When disconnecting and removing

brake pipe, please ensure the area around
connection is clean. Block the opening to prevent
contaminants from entering.
4 Loosen and remove the rear brake hose (1) to

rear brake caliper (2) retaining bolt, to separate
rear brake caliper from rear brake hose.
2
CS243026
5 Remove the rear brake caliper to rear axle

retaining bolt, to release rear brake caliper.
CS243029
5-19
Brakes
6 Remove the brake pad from rear brake caliper.
CS243015
7 Loosen and remove setting pin ① ,guide pin ②

and separat caliper ③ from carrier ④ . 4
8 Remove guide pin gaiter from carrier,and
remove guide pin bush from guide pin.
2 1
3
CS243031
9 Remove snap spring from carrier.
CS243007
5-20
Brakes
10 Fill in pressurized gas from caliper oil inlet, and

push out the piston.
11 Pry piston gaiter with a screwdriver.
12 Lever out the rectangle seal with a needlenose

tool.
CS243006
Installation
1 Clean the brake parts.
pressurized gas, to avoid inhaling friction
2 Before fitting rectangle seal, clean it with water-
free alcohol and apply special lubrication grease
evenly. Fitted rectangle seal must be flattened,
and should not be distorted.
3 Fit and press piston directly into caliper

cylinderhole.
4 Press the gaiter into gaiter hole completely.
5 Apply special lubrication grease on guide pin

bush and guide pin gaither surface, and then fit
them onto guide pin and carrier.
6 Fit snap spring pad and brake pad, and notice

the differences of their left and right parts as well
as inner and outer parts. Also pay attention to
fitting direction of snap spring pad.
7 Fit guide pin onto caliper, and torque it to 35-40

Nm.
8 Fit mud flap onto caliper with a bolt torqued to5-

10Nm.
9 Clear all stains from brake disc edge.
10 Fit the rear brake caliper to rear axle retaining

bolt, and tighten it to a torque of 100 ± 10Nm.
11 Connect rear brake hose to rear brake caliper
housing, fix with a bolt torqued to 25 ± 2Nm.
12 Drain the brake system (see "Draining the
brakesystem").
5-21
Brakes
5-22
Brakes
Replacing the front brake disc
Warning: Brake discs must be changed as a pair.
Removal

supported.
3 Release the front brake hose on strut carrier.
4 Remove the knuckle to front brake caliper

retaining bolt.
CAUTION:Do not hang the brake caliper on brake

hose.
CS213022
5 Remove the bolt attaching front brake disc to

front hub.
6 Remove the front brake disc assembly.
CS243014
5-23
Brakes
Installation
1 Ensure the junction surface of front brake disc

and front hub is clean.
2 Fit the front brake disc onto front hub with a
screwtorqued to 10 ± 2Nm.
3 Check variation of front brake disc (see
"Checking the front brake disc").
4 Check brake pad, and replace it if necessary.
5 Fit the front brake caliper onto knuckle, fix the

6 Fix the front brake hose onto strut carrier.
8 Lower vehicle to the ground on lifter. CS243014
Replacing the rear brake disc

would be reduced.
Removal

supported.
2 Remove the wheel. (see "Replacing the wheel")
3 Remove the bolt fixing rear axle and rear

brakecaliper.
CS243029
5-24
Brakes
4 Remove the bolt attaching rear brake disc to rear

hub.
5 Remove the rear brake disc assembly.
CS243030
Installation
1 Ensure the junction surface of rear brake disc
and rear hub is clean.
2 Fit the rear brake disc onto rear hub with a screw
torqued to 8 ± 2Nm.
3 Check variation of rear brake disc (see
"Checking the rear brake disc").
4 Check brake pad, and replace it if necessary.
5 Fit the rear brake caliper onto rear axle, fix the
5-25
Brakes
Replacing the rear brake shoe

Removal
1 Remove the rear brake disc (see "Replacing the

rear brake disc").
2 Remove the bolt fixing rear axle and handbrake.
3 Rotate the compression spring seat, to remove

compression spring and compression spring rod.
CS243032
4 Remove the 2 upper return springs with a steel

needle.
CS243017
5 Remove the plate ① and parking thrust plate ② ,

and then remove brake shoe assembly.
CS243018
5-26
Brakes
6 Remove the clearance adjuster mechanism (1)

and lower return spring (2) from brake shoe 2
assembly.
CS243019
Installation
1 Clean backplate and all components to be
refitted.
pressurised gas, to avoid inhaling friction
2 Check clearance adjuster mechanism for any
wornor damage, and replace it if necessary.
3 Apply correct quantity of 3# lithium lubrication

grease on threads of clearance adjuster
mechanism, and then fit it.
4 On the protrusion surface of backplate, apply

correct quantity of heat-resisting lubrication
grease on junction area of brake shoe, clearance
adjuster mechanism and supporting pin. Grease
must be applied evenly.
5 Fit the thrust plate between 2 brake shoe

assemblies, and then fit the 2 upper return
springs. Note: Fit the spring at left, and then
right. After fitting, the left spring is at below while
right spring is on top.
6 After fitting, check outer diameter with a slide

caliper. After fitting it into brake disc and when
rotating brake disc, all parts will not interfere with
brake disc and brake disc is not stuck.
7 Left and right parts of handbrake are different but

symmetrical. Do not fit them incorrectly,
especially for left and right of clearance adjuster
mechanism. Draw arm should not be fitted
reversely。
8 Fit the handbrake onto rear axle, and fix with a
bolt torqued to 65 ± 5Nm.
5-27
Brakes
9 Fit the rear brake disc (see "Replacing the rear

brake disc").
5-28
Brakes
Replacing the brake master cylinder and

brake reservoir
Removal
1 Put a cloth under brake reservoir to

absorboverfilled fluid.
3 Disconnect brake reservoir level electrical

connection.
4 Disconnect brake pipes at master cylinder and

cap all pipes and ports to prevent fluid loss or dirt
ingress.
5 Remove the bolt fixing brake reservoir to

brakemaster cylinder.
6 Loosen the reservoir assembly from brake

master cylinder. 6
7 Loosen the 2 brake pipes from brake master
cylinder.
7
8 Remove and discard the 2 nuts fixing brake
5
master cylinder and brake servo, then remove
the brake master cylinder.
CAUTION:Before disconnecting and removing

8
reservoir, ensure central area around connection CS243003
is clear, including connection itself. Block the
opening to prevent contaminants from entering.
Installation
1 Fit the brake master cylinder onto vacuum servo,
and fix with a new nut torqued to 25 ± 4N.m.
2 Clean the brake pipe connector.
3 Fit the brake pipe onto brake master cylinder,

and torque it to 16 ± 2 Nm.
4 Fit the brake reservoir onto brake master
cylinder, and fix it with a connecting bolt torqued
to 3.5 ± 1Nm.
5 Connect brake level electrical connector.
6 Fill in reservoir with specified new brake fluid.
7 Bleed the brake caliper (see "Bleeding the

brake").
9 Road test vehicle.
5-29
Brakes
Replacing the servo assembly
1 Remove the brake master cylinder and brake

reservoir (see "Replacing the brake master
cylinder and brake reservoir").
2 Loosen the vacuum pipe from servo.
CS243031
3 Remove the pin shaft (1), washer (2) and spring

pin (3) used for fixing servo push rod onto brake
pedal.
1 2 3
CS243035
4 Remove the 4 nuts fixing servo and brake

servostiffening plate onto body.
CS243032
5-30
Brakes
5 Remove and discard servo liner.
CS243033
Installation
1 Clean the junction surface of vacuum servo and
body.
2 Fit a new vacuum servo liner onto vacuum servo.
3 Position the vacuum servo on body, fix nut and

tightenit to a torque of 18.5 ± 1.5NM.
4 Connect the vacuum servo push rod to brake

pedal with spring pin, washer and pin shaft.
5 Connect the vacuum pipe to vacuum servo.
6 Fit the brake master cylinder and brake reservoir

(see "Replacing the brake master cylinder and
brake reservoir").
5-31
Brakes
Replacing the brake pedal assembly

Removal

2 Remove the pin shaft, flat washer and spring pin
used for fixing vacuum servo push rod to brake
pedal.
2
3 Disconnect the clutch switch harness.
6 2
4 Disconnect the brake light switch harness.
5 Respectively remove the 9 nuts fixing brake 5

5
pedal to brake servo and brake servo stiffening
plate. 2 5
6 Remove the brake pedal assembly.
CS243008
Installation
1 Respectively fit the brake pedal onto brake servo
and brake servo stiffening plate. Fit the nuts with
socket, and tighten it to torque of 18.5 ± 1.5Nm.
2 Connect the clutch switch harness.
3 Connect the brake light switch harness.
4 Fix the vacuum servo push rod onto brake pedal

with pin shaft, flat washer and spring pin.
5 Ensure that brake light and brake pedal operate

correctly when brake pedal is released.。
CAUTION:After fitting, brake pedal is 160-165mm

over the floor, and its free travel is within 10mm;
Clutch pedal is 145-150mm over the floor, and its
free travel is 9mm. When brake pedal is applied,
the brake light should be on.
5-32
Brakes
Replacing the brake pedal return spring：
Removal
1 Remove the brake pedal (see "Replacing the

brake pedal").
2 Loosen and remove the bolts and nuts used for
fixing clutch pedal, brake pedal and return
spring.
3 Remove the return spring.
CS243024
Installation
1 Thread return spring and brake pedal through

bolts.
2 The long end of return spring is located on
pedalarm.
3 The short end of return spring is fixed on 3

carrierwith a screwdriver.
4 Fix the return spring with bolt and nut torqued 2

to25-35Nm.
5 Fit the brake pedal (see "Replacing the brake

pedal").
CS243010
5-33
Brakes
Replacing the ABS regulator

Removal
2 Put a cloth under ABS regulator to absorb
overfilled fluid.
CAUTION:Brake fluid may damage surface of

painting. Accidently overfilled brake fluid
shouldbe wiped rapidly, and that area should be
cleaned.
3 Disconnect the ABS regulator harness.
4 Remove the 2 brake pipes from ABS regulator.
CAUTION:Before disconnecting and removing 4

brake pipes, ensure central area around pipes
and connections are clean. Block the opening to
prevent contaminants from entering.
5 Notice the position of ABS regulator oil outlet for 5
using in fitting, and then disconnect the brake
pipe oil outlet pipe from top of ABS regulator.
CS243020
6 Remove the ABS regulator from its lower carrier.
7 Remove the ABS damping pad stuck on ABS

regulator carrier.
6
8 Remove the bolt fixing ABS regulator carrier to
body, and then remove the lower ABS regulator
carrier. 7
8
8
8
CS243005
5-34
Brakes
Installation
1 Fit the ABS regulator carrier onto body, and fix it
with 3 bolts torqued to 16 ± 2Nm.
2 Snap the ABS damping pad into fitting hole of
ABS carrier.
3 Snap the lower end of ABS regulator into ABS

damping pad, with its side snapped into ABS
regulator carrier.
4 Clean the brake pipe connector.
5 Connect oil inlet and outlet to ABS regulator, and

ensure each pipe is connected to its
corresponding head. Tighten the brake pipe joint
to a torque of 16 ± 2Nm.
6 Refill in brake fluid, and then drain air.
7 Connect the ABS regulator harness.
8 Drain the ABS regulator. For detailed method,

see instructions for SMCV diagnostic apparatus.
9 Drain the brake system (see "Draining the brake

system").
5-35
Brakes
5-36
Wheel·Hub
Wheel·Hub
Technical Data
Torque

Spare wheel bracket to body bolt 50 ± 5
6-1
Wheel·Hub
Layout
Exploded diagram of front hub
4
2
3
CS233015
1 Knuckle 4 Front hub assembly

2 Front hub bearing 5 Knuckle ball pin
3 Circlip for holes
6-2
Wheel·Hub

procedure
Tyre worn at single side Pressure too high Adjust the tyre pressure
Front wheel is off tracking Inconsistent pressure of 2 front wheels Adjust the tyre pressure
The 2 front wheel tyres are worn, causes Replace the tyres
adhesion with road is reduced
Anti roll bar rubber bush is damaged, or Replacing the rubber bush or retaining bolt
retaining bolt is loose
Front shock absorber is damaged or Replace the front shock absorber

deformed
Wheel is swinging Bearing is loose Adjust the bearing
SPECIAL TOOLS
Name Illustration
Rear wheel bearing fitting

tool
C00017037
Universal drive handle
C00017045
6-3
Wheel·Hub
Repair instructions
Replacing the front hub
Removal
1 Remove the knuckle assembly (see "Replacing

the knuckle assembly").
2 Squeeze out the front hub.
CS233000
3 Remove circlip for hole from knuckle with circlip

pliers.
4 Squeeze out the front hub bearing.
CAUTION: When moving bearing out, be careful

to avoid burrs on knuckle inner surface.
CS621026
6-4
Wheel·Hub
Installation
1 Before assembly, check all parts for damage,
impurities and corrosion etc.
2 Press front hub bearing into the knuckle with
max. bearing press-fitting force of 60KN. Ensure
bearing race match knuckle inner bore shoulder.
CAUTION: Brown rubber oil seal face towards the

hub surface and silver metal sealing face towards
the inner side. Two side are silver metal sealing,
fit no direction
3 Put circlip for hole into the knuckle notches with
circlip pliers to secure the bearing.
4 Position one end of bearing inner race to fit front

hub with no bearing damaged.
5 Fit the knuckle assembly (see "Replacing the

knuckle assembly").
6-5
Wheel·Hub
Adjusting the rear hub
1 Raise the vehicle on a lift.

supported.
2 Remove the dust shield, turn the locker on the
locking nut. Remove the locking nut and washer
from rear axle hub and discard.

excessive force or damage the rear axle mandrel thread;

with sharp-nose pliers, so as to avoid damaging rear axle
mandrel thread;

d. After the locking nut is removed, check the rear axle

6-6
Wheel·Hub
3 Adjust the rear hub as below:
a Fit new hub nuts pre-tightened with a torque of

80N.m then loosen hub nut.
10±1Nm
b Turn the hub 3~5 turns back and forth to tighten
locknut.Torque:10 ± 1N.m
CS233010
c Hit one side of locknut to press into retaining
groove.
4 Fit the gaiter.
5 Lower vehicle to the ground.
CS233014
6-7
Wheel·Hub
Replacing the rear hub
Tools required: C00017037, C00017045

Removal
Removal
Warning:Do not work under a vehicle with only

supported.
3 Remove the rear brake caliper (see "Replacing

the rear brake caliper").
4 Remove the brake disc (see "Replacing the

brake disc").
5 Remove the gaiter.
6 Turn the locker on the locking nut. Remove the

locking nut and washer from rear axle hub and
discard.

excessive force or damage the rear axle mandrel thread;

with sharp-nose pliers, so as to avoid damaging rear axle
mandrel thread;

d. After the locking nut is removed, check the rear axle

6-8
Wheel·Hub
7 Remove the seal with a screwdriver and discard

it, then remove inner bearing.
CS233005
8 Hit bearing race with a tool, and then remove it.
CS233006
6-9
Wheel·Hub
Installation
1 Clean and check components, and replace if

necessary.
C00017045
2 Install bearing race with tool COOO17037 and
C00017045 with max.Pressing force of 30000N
for two bearing outer rings.
C00017037
CS233007
3 Grease filling capacity for inner bearing is 11-

13g,outer bearing 7-9g and hub cavity 50 ±
2g.Tap the locking nut into locking groove with
torque detection no more than 1.5N.m If
conforming, evenly apply grease between outer-
bearing and lock washer external surface in the
same height with washer.
Recommend grease: FUCHS brand, RENOLIT LX-

EP2. If using other grease, it must meet the
requirement of ISO standard brand:L-XCEEB 2
CS233009
4 Use tool C00017045 to fit the new seal (with seal

lip inwards).
CAUTION: After 24 hours of fitting, check to see if C00017045
offset of bearing seal end and rear hub end is not

more than 0.4mm.
5 Fit the hub and bearing into rear axle core.
6 Adjust the rear hub (see "Adjusting the rear

hub").
7 Fit the brake disc (see "Replacing the brake

disc").
CS233008
8 Fit the rear brake caliper (see "Replacing the
rear brake caliper").
6-10
Wheel·Hub
Replacing the wheel

Warning: Do not lubricate hubs and wheels using
lubricants with silicone oil. Before removing
wheels, ensure to clean wheel area. Before fitting,
use 50% of lubricants and 50% of water to
thoroughly lubricate this area.
Warning: Please use tyre changer to remove
tyres. Do not remove tyres only with hand tools
or tyre pry bar, otherwise rims or hubs may be
damaged.
Removal
2 Remove the wheel rim cover with a screwdriver.
3 Remove the 5 wheel bolts with socket tool

provided with vehicle.
4 Remove the wheel.
5 Remove and discard balancing blocks from

wheel.
6 Bleed out the tyre, remove it, and then remove

valve cap or tyre pressure monitor sensor.
CAUTION: Do not put the hub plate facing down

to avoid scratching it.
Installation
CAUTION: Using scrape or steel wire, remove
accumulated corrosives on wheel fitting surface
and brake disc fitting surface before fitting them.
When fitting wheels, incorrect junction of metal
fitting surface with metal may cause loose of
wheel bolts. This may make wheels fall off during
driving and result in vehicle out of control, and
may cause personal injury.
1 Fit the wheel valve cap or tyre pressure monitor

sensor with special tools on the hub, and
lubricate the valve cap fitted with sensor. When
fitting, align the bar code side with the hub, and
ensure valve cap is completely mated and
sealed with the hub.
6-11
Wheel·Hub
2 Fit the tyre with a tyre changer, and inflate it until

the rim is in position. Ensure the locating rings at
outside of tyre bead are located around the hub
flange at both sides of wheel. This locating
method can ensure correct positioning of tyre
bead. See User Manual and tyre label f
pressure.
3 Check the seal of valve cap with soapsuds, and

refit if necessary.
CAUTION: Do not damage the tyre when fitting,

especially the shoulder.
6-12
Wheel·Hub
4 When fitting steel wheel, the "Mark 1" on tyre

should be facing outside and symmetrical in core
10
with "Mark 2" on wheel. The offset should not be Badge1
more than 10°.
Badge2
CS233013
5 After fitting each wheel, dynamic balance tests

should be carried out at both sides.
6 When fitting balancing blocks, note that
a.The allowed unbalance at single side of steel wheel is

less than 10g, no more than one balancing block is
allowed at single side. The sum of both sides can not be
more than 120g.
b.The allowed unbalance at single side of alloy wheel is
less than 10g, maximum 80g of balancing block can be
used at single side. The sum of both sides can not be
more than 160g.
7 After dynamic balance tests on wheel, determine
the weight of balancing blocks and fit them onto
the wheel.
8 Fit the wheel, and use a socket wrench to tighten

the wheel bolt for 2 or 3 times to a torque of180
± 13N.m.The sequence of tightening bolts is
shown in the figure.(from 1 to 5)
4
1
2
3
5
CS233012
Warning: If there is oil leaked on wheel and brake
disc vertical plane, may make wheels loose
during driving which will result in vehicle out of
control and cause personal injury. Heating
method cannot be used to loose any
overtightened wheel. Otherwise, the life of wheel,
6-13
Wheel·Hub
wheel bolts, hubs and bearing assembly will be

reduced. All of the wheel bolts should be
tightened to correct torque in order, to avoid
distorting wheel and brake disc.
6-14

V80Service Manual 4 Chassis Right VI DP Y Y 02

Загружено:

Сведения о документе

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

V80Service Manual 4 Chassis Right VI DP Y Y 02

Загружено:

Авторское право:

Доступные форматы

Service Workbook

instructions must be observed:

yourself or others. It can also result in vehicle damage or abnormal operation.

service and repair. And sometimes special tools are required.

the personal safety or safe operation.

their SMCV Distributor or Dealer.

violation of these instructions.

No part of this publication may be reproduced, stored in a retrieval system or transmitted, in

prior permission in writing of SMCV.

After Sales, SAIC Commercial Vehicle Co., Ltd

#2500, Jungong Road,

Shanghai City, China Postcode: 200438

The following information should be provided:

·Authorized repair center

·Tel. and fax of the authorized repair center

·Model year and model

·Description of your concern(s)

·Necessary relevant information (e.g. sample or marked page)

·Any applicable electronic information part identification number

SMCV will give relevant response in the following ways:

·Submitting your concern to relevant service engineer

·Consulting relevant service engineer

·Satisfying your concern within 10 working days.

General Precautions ............................................................................................................ 1-1

Front Suspension ............................................................................................ 2-1

Layout .................................................................................................................................. 2-2

Fault diagnosis information and procedure .......................................................................... 2-5

SPECIAL TOOLS ................................................................................................................. 2-6

Repair instructions ............................................................................................................... 2-7

Rear suspension ............................................................................................. 3-1

Layout .................................................................................................................................. 3-2

Fault diagnosis information and procedure .......................................................................... 3-5

SPECIAL TOOLS ................................................................................................................. 3-5

Repair instructions ............................................................................................................... 3-6

Steering ........................................................................................................... 4-1

Layout ................................................................................................................................... 4-3

Fault diagnosis information and procedure........................................................................... 4-7

SPECIAL TOOLS.................................................................................................................. 4-7

Repair instructions ................................................................................................................ 4-8

Brakes ............................................................................................................. 5-1

Layout ................................................................................................................................... 5-3

Fault diagnosis information and procedure........................................................................... 5-7

Repair instructions ................................................................................................................ 5-8

Wheel·Hub .................................................................................................... 6-1

Layout .................................................................................................................................. 6-2

Fault diagnosis information and procedure .......................................................................... 6-3

SPECIAL TOOLS ................................................................................................................. 6-3

Repair instructions ............................................................................................................... 6-4

Only oils approved by SMCV can be used.

Brake fluid precautions:

·"At all times use the recommended brake fluid.

·"The necessity for absolute cleanliness throughout cannot be over-emphasized.

Do not eat or smoke while working on a vehicle.

Front suspension type Macphersan independent suspension

Application Torque value (Newton metres)

Front suspension anti roll bar to sub-frame bolt 50 ± 5

Exploded diagram of front shock absorber

1 Strut sub assembly 6 Bearing

Exploded diagram of front suspension

Fault diagnosis information and

Fault Possible cause Solution

Helical spring failed or broken Replace helical spring

22mm hex wrench