Vantage TruckALL, VanGO Service Manual

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Operation and Service Manual

VANTAGE TruckALL & VanGO Series

(3rd Edition)

VANTAGE VEHICLE GROUP

FOREWORD

Dear Customer,

Thank you for your purchase and use of Vantage Vehicle Group vehicle.

The purpose of this manual is to provide you some useful information and necessary technical data on operation, maintenance, trouble-shooting and service of Vantage TruckALL & VanGO series. Since the automobile vehicles made by our plant are mounted with different engine models, and each type of engine is provided with special-purpose manual on service, this manual only gives a general description on engine. Therefore, the operation manual of engine will prevail in case of any inconsistency with the operation manual of engine.

Your valuable comments on our products are warmly welcome. We will always carry out improvement to perfect the Vantage TruckALL & VanGO series.

Vantage Vehicle Group

ght

Vehicle Type

Engine Type

Engin e Pow er

Manufacturer’s Product Number

Date of Production

Mini-Passenger Car Series

Va nG O P a ss e ng er Va n S e ri es

Note

The nameplate is mounted on the right central column inside the cabin, as shown in the above picture.

China First Automobile Group Corporatio

umber of

Passen

ers

Total

Wei

Content of Nameplate

ameplate

Position of Nameplate

Overall Height 1830

Overall Width 1475

Rear Tread 1200

Front Tre ad 1205

Wheelbase 2040

Overall Length 3902

Contents

Chapter I. Whole vehicle…………………………………………………………………………………………………………………………1

Section 1. General introduction……………………………………………………………………………………………………………1

Section 2. Operation of vehicle……………………………………………………………………………………………………………7

Section 3. Service and maintenance of vehicle……………………………………………………………………………………………20

Chapter II. Engine ……………………………………………………………………………………………………………………………….34

Section 1. Accessories to engine with carburetor…………………………………………………………………………………………34

Section 2. Accessories to electronic fuel injection type engine series……………………………………………………………………40

Chapter III. Chassis……………………………………………………………………………………………………………………………46

Section 1. Clutch…………………………………………………………………………………………………………………………46

Section 2. Transmission……………………………………………………………………………………………………………………49

Section 3. Drive-shaft………………………………………………………………………………………………………………………67

Section 4. Rear axle………………………………………………………………………………………………………………………68

Section 5. Suspension system………………………………………………………………………………………………………………75

Section 6. Steering system…………………………………………………………………………………………………………………81

Section 7. Braking system…………………………………………………………………………………………………………………91

Section 8. Tire and wheel…………………………………………………………………………………………………………………109

Contents

Chapter IV. Vehicle body………………………………………………………………………………………………………………………114

Section 1. Front door and rear slide door…………………………………………………………………………………………………114

Section 2. Rear door……………………………………………………………………………………………………………………128

Section 3. Seats…………………………………………………………………………………………………………………………130

Section 4. Instrument panel………………………………………………………………………………………………………………132

Section 5. Front windshield, rear windshield and side window…………………………………………………………………………133

Section 6. Bumper………………………………………………………………………………………………………………………136

Chapter V. A/C system…………………………………………………………………………………………………………………………138

Section 1. Heating system………………………………………………………………………………………………………………138

Section 2. Cooling system………………………………………………………………………………………………………………141

Chapter VI. Vehicle electrical equipment………………………………………………………………………………………………………155

Section 1. Power supply system…………………………………………………………………………………………………………155

Section 2. Igniting system………………………………………………………………………………………………………………166

Section 3. Electronic fuel injection code anti-theft system………………………………………………………………………………171

Section 4. Electrical equipment and its accessories………………………………………………………………………………………176

Appendixes………………………………………………………………………………………………………………………………………184

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Chapter I. Whole Vehicle

Section 1. General Introduction

I. VIN and engine number location

Fig. 1-1 VIN location

a—VIN located at front left of the instrument panel

b—VIN located at the surface of wheel cover under the driver’s seat

Chapter I. Whole Vehicle

Fig. 1-2 Engine number location

Engine number located on the right surface of the

cylinder block under the carburetor

Chapter I. Whole Vehicle

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

II. Vehicle parameters

Vehicle type VANGO TRUCKALL

Rated passengers 6-8 persons 2 persons

Equipment weight 895kg 865kg Rated load age —————— 545kg

Weight

parameters

Size

parameters

Performance

parameters

Total weight 1410kg

Axle-load

distributio

External size

Axle base 1940mm

Front suspension 844mm

Rear suspension 712mm

Min. Lift-off clearance 156mm Angel of approach 26.1 ° Angel of d epart ure 31.7 ° Max. Steering a ngle of front inside wheel 37 °

Front

position

Max. speed.+ 110km/h Max. climbing capacity ≥29% Fuel consumption ≤6L/100km

Min. turn diameter 9m

Discha rged

pollutant

Front axle 480kg 475kg No load

Rear axle 415kg 390kg

Front axle 642kg

Full load

Rear axle 768kg

Length 3496mm

Width 1445mm

height 1841mm

Front wheel 1215mm Wheelbase

Rear wheel 1210mm

Kingpin i nclination angle 11°30′ Kingpin caster angle 5 ° Front wheel camber angle 1 °

Toe-in 2-5mm

CO 2.72g/km

HC+NOx 0.97g/km

Chapter I. Whole Vehicle

III. Main parameters and structure description

Parameters of engine assy. with transmission

Ararrangement

Cylinder bore X travel mm

Discharge

Compression ratio

Rated Horse Power Max. torque N·m/r pm

Supply mode

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

I-4, water cooled, 4-stroke, overhead camshaft EFI gas engine Carburetor

65.5×78 65.5×72 62×72

1.051 0.97 0.87

9.0 8.8 8.7

55 45 40

83/3000-3500 74/3000-3500 66/3000-3500

Multipoint closed loop electronic control fuel injection system -

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Chapter I. Whole Vehicle

Capacity parameters Tire (general cross ply 165/70R13 (5.00-12ULT) Fuel tank: 37L Rim(general cross ply) 5.00×13 (4.00B×12) Engine lubricating system: 3.5L Tire pressure(general cross

ply) Cooling system: 4.0L Front wheel 200kPa (21kPa) Transmission: 1.3L Rear wheel and spare wheel) 230kPa (260kPa) Rear axle: 1.3L Steering gear Steering gear: 0.6L Type Gear rack type Structural description Braking system Drive-shaft Running braking system Type

Rear axle Brake Front brake Disk, floating braking tongs (selecting drum brake) Rear brake Drum, clearance regulated automatically Type Single stage speed reduction,

Final drive ratio 5.125 Arrangement

Axle housing type Pressing, welding and integral Vehicle body Bearing and full metal enclosed body, 5 doors(2 front

Half axle type

Differential type

Suspension

Front suspension

Rear suspension Longitudinal semi-ellipse plate spring,

Single joint, open type, hollow, double universal joint

gear final drive

Semi-floating

Planetary taper gear

Strut swing-arm independent suspension, coil spring, equipped with stabilizer bar, bi-directional hydraulic tube absorber

bi-directional hydraulic tube absorber

arrangement Bi-pipe hydraulic braking, with braking force

Braking system

distribution valve, equipped with vacuum booster

Stay control, act on two rear wheel

doors, 2 slide doors and 1 back door), three-point seat belt, panoramic camber windshield

Chapter I. Whole Vehicle

IV Repair regulations

1. When repairing electric parts, the joint of binding post of battery

negative pole should be disconnected first, in order to avoid electric

shock or short; the step is to unscrew the nut on negative pole slice

end, to separate ground wire and binding post.

2. When jacking up the front end or back end with lifting jack, be sure

first to aim the lifting jack at the central position of front suspension

or rear axle housing, then to bear a vehicle, see Fig. 1.1-3, Fig. 1.1-4.

3. When repairing a vehicle after its front end or back end, be sure to

put a safe dais under carriage to bear the body firmly, see Fig. 1.1-5,

Fig. 1.1-6.

Note: When putting safe dais under carriage, prevent the safe dais

from bumping or contact the parts of carriage (such as fuel pipe).

Triangle bolster should be put under the front and back sides of left

and right wheels that are not jacked up, to prevent a vehicle from

moving forward and backward

Fig. 1.1-3 Sketch of jack used in back side

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Fig. 1.1-4 Sketch of jack used in front side

Fig. 1.1-5 Sketch of safe bench placed in front side

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Chapter I. Whole Vehicle

Fig. 1.1-6 sketch of safe dais put in back side

4. When lift a vehicle with a lifting rack, guarantee that lifting arm does not contact to brake pipeline, fuel pipeline, bracket or any other parts. The lifting position of listing rack and listing arm on a vehicle is shown as Fig. 1.1-7, Fig. 1.1-8. When the vehicle raises four wheels separating from the ground, try to drive the body from two sides, after it is confirmed that the vehicle may not drop, the reparation begins. After the vehicle is raised, the lifting rack should be locked.

Fig. 1.1-7 Front end bearing position

5. When repairing, disassembled parts must be placed a complete

set after a complete set or in order with pallet, tray or bulkhead,

to avoid in a mess or in wrong position.

6. Each bolt must be installed in original position. The bolts or

nuts with specified screw-down moment should be screwed

down with torsion spanner instead of yourself feeling.

7. The dismantled oil seal, sealing gasket and “O” hoop in

disassembling had better be scrapped, new ones shall be replaced

Fig. 1.1-8 Back end Bearing position

when reassembling.

8. When repairing, refer to this manual as much as possible, and

operate according to the description.

Chapter I. Whole Vehicle

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Section 2 Operation of vehicle

I. Operation description

(I) Key

Two key are provided for a vehicle (Key with code anti-theft system

sees Chapter 6).

Vehicle key has the following functions:

1. To control the power supply of vehicle electrical equipment.

2. To unlock and lock vehicle door lock.

3. To unlock and lock fuel tank cap

(II) Door lock and door window

a) Front door lock

Unlocking and locking outside a vehicle, as shown in Fig. 1.2-2.

Turning key clockwise can unlock left front door lock, turning key

anticlockwise can unlock right front door lock, vice versa, lock the

door lock.

Unlocking and locking inside a vehicle, as shown in Fig. 1.2-2. Lift

inner lock button, pull inner handle, vehicle door is unlocked; shut

vehicle door, press inner lock button, vehicle door is locked.

Note: When vehicle is running, inner lock button must be pressed, to

avoid accidentally pulling inner handle to open the vehicle door.

The door can be locked outside vehicle without key. First, open

vehicle door, press inner lock button, then lift the handle outside the

door, the door is locked, as shown in Fig. 1.2-3. But outer handle

should be pulled once, to affirm if the door is locked really or not .

Fig. 1.2-1 Fig. 1.2-2

Fig. 1.2-3

2. Middle door lock

When unlocking outside vehicle, pull backward outer handle, vehicle

door is opened.

Unlocking and locking inside vehicle, as shown in Fig. 1.2-4. Lift

inner lock button, pull backward handle, slide door is opened. Pull

forward inner handle to close vehicle door, press inner lock button,

vehicle door is locked.

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

3.Rear door lock

Fig. 1.2-4 Fig. 1.2-5

Unlocking and locking outside vehicle is shown as Fig. 1.2-5. Insert key into key hole, turn anticlockwise 90°, take out the key, then

hold on outer handle manually, press lock cylinder with thumb and

pull backward, rear door is opened; after the door is closed, insert key into key hole, turn clockwise 90°, rear door is locked.

4. Rising and falling of front vehicle door

Turn clockwise the lifting crank of right front door glass, right side

glass rises; turn anticlockwise the lifting crank of left front door glass,

left side glass rises, vice versa glass falls.

5. Side door window

If you want to open push side window, push the button to make the

window reach the locking position. If you open push-pull side window,

press button, at the same time, pull backward handle, up to the

expected position.

(III) Seat and body

Chapter I. Whole Vehicle

1. Front seat

(1) Fixing

Hang two lock hoop in seat front end on projective latch hook, press the handle up to lock-up, in this way the seat can be fixed, as shown in Fig. 1.2-6, Fig. 1.2-7.

Front seat and backrest is monolithic, so when repairing engine, the

seat should be tilted. Pull back shackle, raise backrest angle modifier

to make the backrest reach the most pitching position, tilt backward,

then the seat can be operated.

Fig. 1.2-7

(2) Regulating back and forth

There is a control handle under the seat, lifting the handle upward can

regulate the seat back and forth, see Fig. 1.2-8.

Note: When driving, do not regulate seat to prevent danger.

Chapter I. Whole Vehicle

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

(3) Backrest regulation

Seat backrest is tilt able. When regulating, raise handle, select

backrest angle, release the handle, the backrest is locked, see fig.

1.2-9.

2. Backseat

The second row seat can tilt a certain degree forward, in order to be

easy for passengers on the third row seat to get on and get out, which

is shown as fig. 1.2-10, the regulation of backrest degree is the same

as the front seat.

When the third row seat needs to regulate, raise handle, make the backrest forward level, then tilt entire seat 90°。

Fig. 1.2-7

Fig. 1.2-10

3. Body CA1010, and CA1010A Mini-Cargo Car Series with single row seat, The body is full metal rear body. Body safety frame is fixed on cab rear wall board, the body can be opened in three sides. Body panels are connected with self-locking catch and staple, with quick disassembling and assembly type. Pulling handle outward can make staple and catch separate to open the body; buckle staple and catch together, push handle, the body is closed and locked. (IV) Fuel tank cap The Oil filler of fuel tank is on the right side of vehicle. Inserting key and turning anticlockwise can lock wicket, vice versa open, see Fig.

1.2-11. After opening the wicket, turning anticlockwise fuel tank cap can open it, when turning clockwise and hearing “ka ka” sound, the fuel tank cap has been locked reliably. (V) Seat belt This vehicle uses automatic crimping seat belt. When fastening seat belt, insert the tongue into the buckle, until you hear a click, it is locked. Press the red button on the buckle, the seat belt can be unfastened.

Fig. 1.2-11 Fig. 1.2-12

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Note:

·Seat belt is designed according to human body’s structure, so the user must use it on the requirement, the lower end position should not exceed abdomen, shoulder seat belt should sling over chest and shoulder.

·Seat belt should keep clean, to avoid oil, chemicals, particularly electrolyte corrosion, if it is dirtied, wash it with appropriate soap and water.

·If seat belt is damaged, please replace a new one.

·One seat belt is used only for one person, children can not use the

same seat belt with their parents.

·The users do not embellish the seat belt to avoid influencing its operation performance. (VI) Jack, spare wheel kept position

1. Jack Put jack under left front seat. Raise seat and engine cowl, turn anticlockwise jack handle spindle to be taken out. When putting it, turn clockwise jack handle spindle to be put there, see Fig. 1.2-13. Put jack handle spindle on the left lower side of the instrument panel, see Fig. 11.2-14.

2. Spare wheel Open rear vehicle door, unscrew tightening bolt, then the spare wheel can be removed.

Fig. 1.2-13 Fig. 1.2-14

Chapter I. Whole Vehicle

(VII) Instrument panel and control mechanism, see Fig. 1.2-15.(taking

hard plastic instrument panel as an example)

Fig. 1.2-15 Instrument

1. Braking oil tank filler 2. Lighting and turn light switch 3. Choke pull button 4.

Electric wiper and washer switch 5. Alarm lamp switch 6. Odometer 7. Warning

indictor lamp 8. Water-temperature gauge 9. Fuel meter of fuel tank 10. Ash tray 11.

Glove box 1 2. Blower and air-conditioner switch 13. Air-cond itioner contr ol panel 14.

Ventilating system 15. Ignition equipment 16. Fog-lamp switches 17. Selection electric

part switches 18. Cigarette lighter(selection) 19. Radio cassette player

(VIII) Combination instrument, see fig. 1.2-6

1. Speedometer

Indicate the instantaneous speed of vehicle and record accumulation of

miles.

2. Fuel meter of fuel tank

When ignition switch is on gear ON, fuel meter indicates the fuel

quantity within fuel tank.

Chapter I. Whole Vehicle

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

When fuel gauge pointer points at F, the fuel tank is full; when it

points at E, the fuel tank is nearly empty, see Fig. 1.2-17.

(a) for engine with carburetor (b) for electronic fuel injection

engine

Fig. 1.2-16

3. Water-temperature meter

When ignition switch is on gear ON, pointer can indicate the coolant

temperature within engine. When the pointer fluctuates in C section,

engine water temperature is normal; when the pointer exceeds H,

showing the temperature is over high, if the engine is over hot, do not

continue to drive, see Fig. 1.2-18.

Fig. 1.2-17 Fig. 1.2-18

4. Motor oil pressure indicator lamp (red)

When ignition switch is on gear ON and the engine flameouts,

indicator lamp is bright; after

The engine starts, the indicator lamp should black out. If the engine

starts the lamp is still bright or the lamp is lightened during running,

showing engine lubricating oil pressure is deficient, it should be repaired

immediately, see Fig. 1.2-19a.

5. Charge indicator lamp (red)

When ignition switch is on gear ON and engine flameouts, indicator

lamp I bright; after the engine starts the lamp should black out. If the

engine starts the lamp is still bright or the lamp is lightened during

running, showing the engine has not charged up to battery or circuitry

fault appears, it should be repaired immediately, see fig. 1.2-19b.

Fig. 1.2-19

6. Left-turning indicator lamp (green), see Fig. 1.2-19c.

7. Right-turning indicator lamp (green), see Fig. 1.2-19d.

8. Distant light indicator lamp (blue), see fig. 1.2-19e.

9. Parking indicator lamp (red), see fig. 1.2-19f.

10. Braking fluid alarming lamp (red).

When ignition switch is on gear ON and engine flameouts, indicator is

bright; after the engine starts, the lamp should black out.

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Chapter I. Whole Vehicle

If the engine starts the lamp is still bright or the lamp is lightened during running, showing the braking fluid in fuel tank is deficient, please fill it. If the braking fluid is filled out, the lamp is still bright, the braking system should be repaired, see Fig. 1.2-19g.

11. (Electronic fuel injection engine) Engine fault alarming lamp (red) When ignition switch is on gear ON, and engine flameouts, alarming lamp is bright; after engine starts, the lamp should black out. If the engine starts the lamp is still bright or the lamp is lightened during running, showing electric injection system has fault, it should be sent to maintenance shop to repair immediately, see Fig. 1.2-19h. (IX) Ignition switch Ignition switch has 4 gears, as shown in Fig. 1.2-20.

1. OFF gear: Key can be taken out and inserted only in this position, and the power supply of engine and auxiliary units is cut off.

2. ACC gear: When key is on this position the power supply of electric components is switched on, electric equipment such as radio cassette play can be used.

3. ON gear: Turn the key clockwise to the ON position, ignition circuitry is turned on.

4. ST gear: Continue to turn the key to the START position, start engine, after releasing, the key automatically return to the ON position.

Fig. 1.2-20

Note:

·Starting engine does not exceed 5 seconds each time, if the engine is not started once, it must be started again after 5-10 seconds. If the engine is not successfully started many times, fuel system and ignition system should be examined.

·When engine does not work, do not put key on the ON position for a long time, otherwise, the electric energy of battery shall be consumed. (X) Combination switch

1. Lighting switch When lighting switch is set on the left side of steering wheel. When it is on the OFF position, turn off lighting; when turning forward to one gear, front and rear small lamp, instrument lamp and rear license lamp lighten; when turning forward further to 2 gear, front and rear small lamps, instrument lamp, and front and rear license lamps lighten, see Fig.

1.2-21(a).

2. Overtaking signal lamp, steering lamp switch Handle is in non-working state when it is on middle position. Push forward the handle to lighten right-turning lamp; pull backward the handle to lighten left-turning lamp; raise the handle to lighten overtaking signal lamp, release the handle to return automatically to middle position, overtaking signal lamp black out.

Fig. 1.2-21

Chapter I. Whole Vehicle

3.High/low beam switch of far-reaching lamp and near-field lamp Put lamplight switch on gear 2 position. When the handle is on middle position, near-field lamp is bright; press the handle, to make the handle be in lower side position, far-reaching lamp is bright, see Fig. 1.2-22.

4. Windshield wiper and washer switch It is set on the right side of steering wheel. Wiper switch has 3 gear positions, turning to the INT position is intermittent gear, to the LO position is lower speed gear, to the HI position is high speed gear, to the OFF position , the wiper is turned off, see Fig. 1.2-23. Windshield washer and wiper both use one control handle. When the handle is raised the power is switched on, cleaning mixture spray on windshield glass; after releasing, the handle resets automatically, spray stops, see Fig. 1.2-23.

Fig. 1.2-22 Fig. 1.2-23

Windshield

washer

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Rear windshield wiper, washer switch is on instrument panel; the type is shown in Fig. 1.2-24. After pressing wiper switch, rear wiper is in working state; press the wiper switch again, the wiper stops working and resets Keep in pressing the washer button on rear wiper and washer switch, rear washer is swathed on, cleaning mixture is sprayed from injector, when releasing the button, the washer stops working.

Note: (1) Spraying time per time does not exceed 5 seconds, the interval time is not less than 25 seconds. (2) When windshield glass is dry, please do not scrape dirt with wiper, to avoid scraper and windshield are damaged.

Wiper switch mark (white)

Washer switch mark (white)

Fig. 1.2-24

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

(XI) Horn

Horn switch is on steering panel. Press any point on the button to

make the horn sound, see Fig. 1.2-25.

Fig. 1.2-25 Fig. 1.2-26

(XII) Indoor lamp switch

ON gear is to turn on the light, OFF gear is to turn off the light, see

Fig. 1.2-26.

(XIII) Warning lamp switch

On the combination switch shell under steering wheel there is a red

button, which is warning switch. When pulling out this switch, front,

rear and side steering lamps are all bright, showing that this vehicle

has emergency or stops to repair, to make drivers of vehicles passing

by notice, see fig. 1.2-27.

(XIV) Choke pull button (carburetor engine) When air temperature is lower, first pull out pull button, then start

engine, after the engine started successfully, pull button must be pushed completely, see Fig. 1.2-28.

Chapter I. Whole Vehicle

Fig. 1.2-27 Fig. 1.2-28

(XV) Glove box

Pulling lock button according to the direction indicated by arrowhead in

Fig. 1.2-29 can open glove box; pushing the glove box door slightly may

shut the glove box door.

(XVI) Cigarette lighter and ash tray

When ignition switch is on the ON gear or ACC gear, cigarette lighter

can be used. When wanting to light cigarette, push according to the

arrowhead direction, after several seconds, the cigarette lighter shall exit

automatically along “ chattering” sound, pull out it to light cigarette.

Note: After thirty seconds when pushing, it is not ejected yet, showing

cigarette lighter has fault, at that time the cigarette lighter should be pull

out to repair. Pulling out outwards slightly can pull out ash tray. The ash tray needs to

be cleaned, first press the board on the ash tray pulled out, then pull outward slightly, the whole ash tray ca n be pulled out to clean. After cleaning, push it inwards slightly forcibly, it is in right position, see Fig.

1.2-31.

Chapter I. Whole Vehicle

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Fig. 1.2-29 Fig. 1.2-30

(XVII) Sun screen

When the vehicle runs in face of the sun, pull sun screen downwards

to your requiring position to keep glaring sunlight out; after using it,

push it to the original position, see Fig. 1.2-32.

Fig. 1.2-31 Fig. 1.2-32

(XVIII) Ventilation unit

There are 6 ventilation orifices. Pull 4 adjustable grilles, adjust blown air

current direction to your satisfactory position, and see Fig. 1.2-33,

1.2-34.

Fig. 1.2-33 Fig. 1.2-34

(XIX) Air-conditioner and heater unit

1. Name and function

As shown in Fig. 1.2-35.

Fig. 1.2-35

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

① Heater unit switch: There are 4 gear positions, which are

used for controlling heater unit power supply and heater unit rotation speed.

② Air-conditioner switch: A/C, ON-OFF) Pressing heater unit

switch and rotating can make air-conditioner system running..

③ Inside and outside air conversion handle: Show air current

source. Placing it on “ ” position is for inbreathing fresh air from the outside of the vehicle, on “ ” position is for inside air circulation.

④ Temperature regulation handle: Be used for switching on

and switching off the coolant pipeline from engine and regulating air supplying temperature. “COOL” shows cold, “HOT” shows hot.

⑤ Conversion handle of air supply: Shows air current

direction and function.

⑥ Shows blowing to upper part of the body. ⑦ Shows blowing to the upper part and leg simultaneously. ⑧ Shows blowing to leg. ⑨ Shows air current blowing to windshield glass, defrost and

defog.

Move handle ○

to○6, move handle ④ to “COOL” position, move handle ③ to “ ” position, turn heater unit switch ① to your expected gear position, press A/C. ON-OFF switch ② , air-conditioner shall start working.

Note: When handle ○

switch ○

shall turn off automatically, that is, air-conditioner shall

is turned to “ ” position, A/C.ON-OFF

stop working.

3. Heater control

Move handle ○ “HOT” position, handle ○

to your expected gear position, handle ○4 to

to “ ”position, heater unit switch

① to your expected gear position, heater unit shall start working.

4. Quick defrost control

Move handle ○

to “ ” position, turn heater unit switch to the highest gear,

○

to ○9position, handle ○4to “HOT” position, handle

quick defrost can be done.

Chapter I. Whole Vehicle

Note:

! Pre-cooling: When you park in point-blank sunlight, you should

crank down vehicle window, and switch on air-conditioner for several minutes, to make the hot air in the vehicle blow out.

! When the vehicle runs in urban area, refrigeration efficiency is

very low, so in this case, you should drive in low speed, to get enough cooling air.

! After air-conditioner works for a long time, carbonic acid gas

or cigarette smoke can make eyes uncomfortable, at that time,

the vehicle window should be opened to ventilate. (XX) Parking braking handle When you park, you must use parking braking. When parking braking handle is pulled up, braking action is produced on two rear wheels; pull slightly parking braking handle and press the button at the top of parking braking handle with thumb, put parking braking handle into the bottom, to relieve braking force. Different vehicle types have different parking braking handle positions, as shown in Fig. 1.2-36.

Fig. 1.2-36

Chapter I. Whole Vehicle

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

(XXI) Pedal

Fig. 1.2-37

1. Clutch pedal Clutch pedal is used for controlling of power transferring from engine to transmission. Thread on the pedal, cut off power transfer, you can operate gear selection and gear shift; disengage the pedal, the power

transfer shall be engaged. See ○

in Fig. 1.2-37. Note: When driving, do not often put your feet on clutch pedal, to avoid to cause the quick abrasion clutch and separate bearing.

2. Braking pedal Threading on the pedal can produce braking force on four vehicle

wheels. See ○

in Fig. 1.2-37.

Note:

! Rain and snow road surface shall influence braking effect. ! If squeal appears in braking process, brake should be

repaired.

! If braking pedal is suddenly threaded to a lower position, or

thread like on sponge, or braking distance gets long, braking system should be repaired.

3. Accelerator pedal Accelerator pedal is used for controlling throttle opening. When driving, thread on accelerator pedal, engine rotating speed increases, and power output and vehicle speed increase too. See ③ in Fig.

1.2-37.

(XXII) Gearshift handle All gear positions of 5-gear type transmission are shown in Fig. 1.2-38. For 4-gear type transmission, positions of the first, second, third and fourth gears and reverse gear are all the same as the positions in the figure. Note: When the vehicle is going forward, reverse gear cannot be shifted into, when going astern, advance gear cannot be shifted into. Shift of advance gear and reverse gear should be carried out after the vehicle stops.

Fig. 1.2-38 II Examination and breaking-in of new vehicle (I) Examination and breaking-in of new vehicle The user should examine the following items after receiving a new vehicle:

1. Connection and tightness of all positions, particularly transmission, steering, braking, suspension and wheel, etc.

2. Liquid level of radiator and its compensation bucket.

3. Oil level of engine, transmission and rear axle.

4. Presence or absence of blow-by, water leak and oil leak.

5. Liquid level of accelerator.

6. Tire pressure.

7. Installation of engine accessories and tightness of transmission belt.

8. Operating state of electric equipment, lamplight, horn and instrument.

9. Operating state of braking system and the presence and absence of oil leak on all pipeline joints, and examine the liquid level of braking oil tank.

10. Operating state of clutch.

11. Normal or abnormal of steering mechanism.

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

12. Presence and absence of abnormal sound of engine and transmission system.

13. Driver tools and accessories are complete or not. (II) New vehicle breaking-in The operating life, working reliability and using economical efficiency of a vehicle depend greatly on earlier operating conditions. Before a new vehicle is driven normally, it must pass a breaking-in stage, that is, let the vehicle run at little load and low speed, to make parts adaptation have a stage of breaking-in, so as to improve their surface quality and combination precision, to avoid earlier abrasion. The breaking-in mileage of new vehicle is 1000km. If the condition is permitted, had best to extend breaking-in mileage to 2500km. The following regulations should be conformed to during breaking-in stage:

1. Drive on flat and good road surface.

2. Avoid quick start, rapid acceleration and fast pull-up.

3. Control strictly vehicle speed, all gear speed does not exceed specified value (see Table 1.2-1).

Running mileage

Vehicle speed not exceeding (km/h)

Gear 1 Gear 2 Gear 3 Gear 4 Gear 5 (km) 0-200 13 22 34 48 64 200-800 13 22 34 48 64 800-1500 20 33 51 73 97 1500-2500 27 44 69 95 105

Note: For 4-gear transmission, refer to the speed limitation of the first 4 gears.

4. Within 200km of initial running, the vehicle must run emptily; during 200-1000km period, persons carried by the vehicle (loading weight) do not exceed 70% of specified number (loading weight).

5. Particularly ay attention to engine water temperature and engine oil pressure.

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6. Often check the temperature of wheel hub and braking drum, regulate them when it is necessary.

7. When running, often shift, do not run at the same gear for a long time, and do not drive at high speed

8. When breaking-in mileage reaches 500km, examine the tightness of steering system, suspension and transmission shaft, tighten when necessary, examine presence and absence of braking pipeline leakage, if have any, eliminate them in time. During breaking-in stage, maintain according to the following contents, then operate normally.

1. Carry out maintenance according to the items after breaking-in stage (1000km) in regular maintenance.

2. Change engine, transmission and lubricating oil in rear axle. III Fuel, coolant, lubricating oil and grease (I) Fuel 90#(GB17930-1999) unleaded gasoline for vehicle should be used. Note: Vehicle with electronic fuel injection engine should use 93#(GB17930-1999) unleaded gasoline for vehicle. (II) Coolant Please use antifreeze solution all year. The type of domestic antifreeze solution is ethanediol water-type antifreeze solution. The using principle is that the freezing point of antifreeze solution is 5℃ lower than the lowest air temperature of local temperature. Antifreeze solution must be changed once every two years. (III) Braking fluid Use 9208 braking fluid. (IV) Grease of lubricating oil

1. Lubricating oil Engine 10W/30 SE(GB11121-1995) gasoline engine oil Transmission 85W/90 GL-4 or GL-5 grade gear oil or 18#

hyperbole gear oil

Rear axle 80W/90 (GB13985-92) hyperbole gear oil

2. Chassis grease

Lithium-base grease

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Chapter I. Whole Vehicle

Section 3 Service and maintenance of vehicle

1. Routine maintenance

Routine maintenance means daily maintenance before departure and

after traveling, is the foundation of regular maintenance. Taking

cleaning and observation as the key. Besides washing inside and

outside body, cleaning glass, the main contents are:

1. To check the normality or abnormality of lighting, instrument,

wiper, brake, steering and suspension and so on.

2. To check the presence and absence of abnormal sound of engine

and chassis.

3. To check the presence and absence of leakage of water, oil and gas;

and leakage current; whether there are enough water, fuel, lubricating

oil, tire air pressure or not, if not, supplement if necessary..

4. To check whether wheel, steering, transmission and suspension are

connected tightly or not.

5. Eliminate the fault of the day.

II. Schedule of regular service and maintena nce

Mileage Number of months or kilometers, whichever comes first

Engine

Ignition system

Fuel system

Electric equipment Harness and lighting fitting J·T Chassis and body

Fan belt : degree of tightness, damage J·T J·T·G G J·T·G Timing belt: degree of tightness, damage J·T·G J·T·G J·T·G J·T·G Valve clearance J·T J·T J·T J·T Cylinder head, intake and exhaust manifoldbolt: degree of tightness N N N N Engine oil filter G G G G G G G Engine oil G Every 5000 km, replace once Coolant J·B J·B J·B J·B G J·B J·B Cooling system hose and joint: leakage, damage, degree of tightness J·T·G Exhaust pipe and accessories: leakage, damage, degree of tightness J·T·G J·T·G J·T·G J·T· G High voltage wire: worsening, damage J·T·G J·T·G J·T·G J·T·G Distributor cap and distributor arm: abrasion, fracture J·T·G J·T·G J·T·G J·T·G Spark plug J·T·G R J·T·G R J·T·G R J·T·G Ignition timing J·T·G G G G G G G Ignition advance unit J·T J·T J·T J·T J·T J·T J·T J·T J·T J·T·G J·T·G Air filter core Q Q Q Q G Q Q Throttle stay and carburetor shaft Every 10000km , I.T.R.G. Fuel pipe and joint: leakage, damage J·T·G J·T·G Gasoline filter G Idle and idle mixture J·T J·TT J·T J·T Crankshaft box ventilation hose and connector J·T J·T·G J·T·G J·T·G PCV val ve J·T J·T· G J·T·G J·T·G Fuel evaporation control system hose and connector J·T J·T·G

Clutch pedal free travel J·T J·T J·T J·T Brake drum and friction burr, brake disc and brake tongs: abrasion, damage J·T J·T·G Braking pipe: leakage, damage J·T J·T·G Braking fluid J·B J·B G J·B Braking pedal free travel J·T J·T J·T J·T J·T J·T J·T Braking rod and stay: travel, damage J·T J·T J·T J·T J·T J·T J·T Tire: abrasion, pressure J·T J·T J·T J·T J·T J·T J·T Wheel, wheel nut: damage, degree of tightness J·N J·N J·N J·N J·N J·N J·N Absorber : oil leakage, damage J·T J·G J·G J·G Drive-shaft J·T J·G J·G J·G Transmission and rear axle: oil leakage, oil level G J·T·G J·T·G G J·T·G J·T·G Steel plate spring J·T·G R R R Steering: degree of tightness, damage, noise J·T J·T·G J·T·G J·T·G Door hinge R R R Test drive Carry out test drive after each maintenance

( X1,000km )

Number of month

(Month)

Breakin g-in

period

10 20 30 40 50 60 Time interval:

6 12 18 24 30 36

Note: Letters in the table stand for meanings, B—supplement, J—check ,T—regulate, Q—clean, sweep, R—lubricate , G—replace(If it coexists with other items replace if necesary)

Chapter I. Whole Vehicle

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

III. Service and maintenance items

(I) Engine

1. Water pump(fan) belt

(1) Check and adjustment

1) Check the presence and absence of crack, break, distortion,

abrasion and cleanliness of belt. Check belt tension force. Press the

belt with thumb(about 10kg force), if it bends 6-9mm, show the

tension force is appropriate, as shown in Fig. 1.4-1.

Fig. 1.4-1

2) If the belt is too tight or too loose, adjust alternator location to

make its tension force to the specified value.

3) Unscrew alternator adjusting bolt and generator fixing bolt, move

the generator, to adjust the belt tension force to the specified value.

See Fig. 1.4-2.

4) Screw down alternator adjusting bolt and generator fixing bolt.

Note: All checking and adjusting work mentioned above must be done in

the state that the engine stops running.

(2) Replacing belt

1) Unscrew alternator adjusting bolt and generator fixing bolt, and move

alternator towards inside.

2) Change belt.

3) Move alternator towards outside, and adjust the belt to the specified

tension force.

4) Screw alternator adjusting bolt and generator fixing bolt.

Note: All adjusting work mentioned above must be done in the state that

the engine stops running and radiator temperature is lower.

Fig. 1.4-2

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Operation and Service Manual on VANTAGE TruckALL & VanGO Series

2. Valve clearance (1) Dismount valve cover. (2) Check the valve clearance of air intake and exha ust, and adjust if necessary. Standard valve clearance: 0.13-0.18mm (when the engine is cool),

0.23-0.28mm (when the engine is hot). (3) Install valve cover, and screw bolt to specified torque.

3. Engine bolt (1) When checking cylinder head bolt, valve cover must be dismounted. The tightening torque of cylinder cover bolt is 55-60 N·m(5.5-6.0kg•••m). (2) When fastening cylinder head, cylinder gasket should be under the even stress. The sequence of screwing bolts is shown in Fig. 1.4-3.

Fig. 1.4-3

(3) The tightening torque of cylinder cover bolt is 4-5 N·m

(0.4-0.5kg•m).

(4) Check the fitted tightness of air intake and exhaust branch nut, and screw it to the specified torque if necessary. See Fig. 1.4-4.

The tightening torque of exhaust branch nut: 18-23 N·.M (1.8-2.3kg.m). The tightening torque of air intake branch nut: 18-23 N·m (1.8-2.3kg•

m).

Fig. 1.4-4

4. Engine oil cleaner replacement

(1) Unscrew engine oil cleaner with engine oil cleaner handle.

Note: Before equipping new engine oil cleaner, “O” ring must be daubed

oil (engine oil can be used).

(2) Turn new cleaner with hand into cleaner connection frame until

cleaner “O” ring contact to installation surface.

(3) Turn 3/4 circles more with engine oil cleaner handle.

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Chapter I. Whole Vehicle

Note: in order to prevent oil leakage, it is necessary to guarantee the

engine oil cleaner screwed tightly, but it is not over tight.

(4) After installing engine oil cleaner, start engine to check whether

there is oil leakage.

(5) replacement of engine oil

Before discharging engine oil, first check whether the engine leaks

oil. If there is oil leakage, first repair oil leakage position before

carrying out the following work.

(1) Remove discharge screw plug, to discharge all oil.

(2) After engine oil is discharged, wipe up discharge screw plug and

plug hole, then reinstall discharge screw plug, and screw it tightly. The tightening torque : 20-25 N·m(2.0-2.5kg•m).

(3) Screw off the engine oil filler cap on the valve cover to fill

engine oil, until the oil level reaches the mark position on oil level

gauge(between the lowest and the highest).

Engine oil capacity table

Oil under pan capacity 3.0L

Engine oil cleaner capacity 0.2L

Other 0.3L

Total 3.5L

6. Replacement of engine coolant Note: In order to avoid scald, when the temperature of engine and

radiator is high, do not remove radiator cap, at that time if removing the radiator cap, coolant and vapor shall eject under the pressure effect.

(1) After engine is cooled, remove radiator cap.

(2) Remove radiator discharge orifice cock to discharge coolant, as

shown in Fig. 1.4-6.

1.Reference line 2. Low level line 3. Full level line (3) Dismount hydraulic accumulator ①, empty liquid. See Fig. 1.4-7.

Fig. 1.4-5 Fig. 1.4-6

Fig. 1.4-7

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Operation and Service Manual on VANTAGE TruckALL & VanGO Series

(4) Screw discharge orifice cock, and install the hydraulic accumulator at the original position. Fill up coolant into radiator, and run engine at idle speed, until affirm that engine coolant pass through one large cycle at least, then stop running engine. After temperature drops, fill up the radiator again, cover the radiator cap and screw it. (5) Pour coolant into hydraulic accumulator and make liquid level reach to “FULL” mark Coolant capacity table

Engine, radiator and heater 3.4L Hydraulic accumulator 0.6L Total 4.0L

7. Cooling system hose and joint (1) Check visually the presence and absence of leakage or chap, break of cooling system hose. Check whether they are damaged or not, and also check the tightness of connecting clip. (2) The hopes with leakage, chap, break or other damage shall be replaced. At the same time the clip that cannot maintain appropriate tightness should be also replaced.

8. Exhaust pipe and accessories Note: In order to avoid scald, when the temperature of exhaust system is still high, do not touch it. Any relevant service of exhaust system should be done after the system is cooled. When do regular service work or the vehicle is lifted due to other service, check exhaust system according to the following steps: (1) Check the presence and absence of da mage, aging and over distortion of rubber parts. (2) Check the presence and absence of leakage, connection looseness, hollow and damage of exhaust system. If bolts or nuts are loose, screw them to specified torque. The tightening torque: exhaust pipe nut: 35-45N·m(3.5-4.5kg•m) Exhaust pipe bolt: 35-50N·m(3.5-5.0kg•m) (3) Check the presence and absence of damage, leakage, cracking, looseness of the position near the body, and the condition that makes exhaust infiltrate the inside body.

(4) Any bad cases must be resolved immediately.

(II) Ignition system

1. Ignition circuitry (secondary wire)

(1) Check whether secondary wire is broken, and the connection is firm

or not.

(2) Measure resistance value of secondary wire. The resistance value of secondary wire: Standard---16 kΩ/m Operation limit---20 kΩ/m

(3) Replace aged secondary wire.

Note: Check every secondary wires, to guarantee that their ends are

inserted firmly into joint elements. Any burned jointer must be replaced.

2. Distributor cap and distributor arm

(1) Check whether distributor cap is broken or not.

(2) Check whether center electrode and connector are abraded, the

position is shown in Fig. 1.4-8.

Fig. 1.4-8

(3) Check whether distributor arm is broken, and electrode is abraded.

(4) If you find the bad cases mentioned above, please repair or replace

them if necessary.

Note: If there is dust or dirt on the inside distributor, wipe up them

with soft cloth.

3. Replacement of spark plug

(1) Dismount secondary wire from spark plug. Note that the spark

plug cap (protective sleeve) on secondary wire should be held,

pull out secondary wire, as shown in Fig. 1.4-9.

Fig. 1.4-9

(2) Loosen spark plug with spark plug spanner, and remove it.

Note: New spark plugs which conform to specific calorific power

range and size must be replaced (refer to engine manual).

(3) Install new spark plug, and screw the spark plug to the specified torque. The tightening torque of spark plug : 20-30N·m(2.0-3.0kg·m). (4) Aim secondary wire at spark plug, and insert it, do not push the flexible wire part, push the protective sleeve part.

4. Ignition timing check Check ignition timing to guarantee its correct set. If it does not conform to the specified value, it should be regulated. For relevant check and regulating steps, please refer to engine manual.

5. Distributor ignition advance unit Check whether ignition advance unit operate normally. For relevant check steps, please refer to engine manual. (III) Fuel system

1. Clearing and replacement of air filter cartridge (1) Dismount air filter cover. (2) Take out filter cartridge from filter. bowl (3) Clean the filter cartridge or replace new one. When cleaning the filter cartridge, use compressed air to blow off dust from the inside filter cartridge. See Fig. 1.4-10.

Fig. 1.4-9

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

(4) Equip filter cartridge into air filter bowl.

Note: After the vehicle runs in dusty area, check whether filter

cartridge is full of dust, if it is, it must be cleaned.

(5) Cyclone duster

Dismount dust pocket from cyclone duster, and clear off the inside

dust pocket, as shown in Fig. 1.4-11.

Dust pocket Loosen Dust pocket

Screw Dust

Fig. 1.4-11

Throttle cable, choke cable and throttle shaft

Lubricate rotation position, and guarantee when choke pull button is

pulled, every parts of choke system operate smoothly.

3. Fuel tank, fuel pipeline and connector

(1) Check visually the presence and absence of oil leakage of fuel

pipeline and connector, check the presence and absence of hose chap

and break, at the same time check the tightness of all clips

The hose with break possibility must be replaced.

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(2) Check visually the gasket of fuel tank cap. If there are cases of

abrasion, break and distortion, replace the gasket.

4. Replacement of gasoline filter

Filter must be replaced regularly. The replacement method is as follows:

(1) Disconnect the inlet and outlet hoses of filter, and dismount the filter

from the vehicle.

(2) Install a new one in place, and connect the inlet and outlet hoses to

the filter.

Note: For gasoline filter for carburetor engine, the upper side is for

connecting the outlet tube and the lower part is for connecting inlet tube.

See Fig. 1.4-12

Fig. 1.4-12

1. Inlet 2. Outlet

5. Engine idle and idle mixture

Check idle and idle mixture, and regulate if necessary.

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Operation and Service Manual on VANTAGE TruckALL & VanGO Series

For the check and regulation steps of idle and idle mixture, refer to

operation manual on engine.

(IV) Exhaust pollution control system

Crankcase ventilation hose and connector

Check the presence and absence of leakage and break of crankcase

ventilation hose. If there is any bad case, repair or replace it. Check

hose connector to guarantee its tightness and firmness.

2. PCV (forced ventilation of crankcase) valve check

(1) Dismount the hose connecting tee joint to PCV valve.

(2) Start engine. Engine shall run at idle; press one end of the hose

with thumb to check the negative pressure in the hose. If the hand is

gripped by the hose, showing that PCV valve is in good state, as

shown in Fig. 1.4-13.

Fig. 1.4-13

(2) Stop engine running, and connect the hose on the tee joint.

3. Fuel evaporation control system

1) Check the presence and absence of crack, damage or over bending of the hose, check whether all clips are damaged.

2) If you find any bad cases, repair and replace them.

3) Refer to engine manual to check the vapor channel of activated charcoal container. (V) Electric equipment

1. Lamplight Check whether all lamps work normally, if is necessary, repair or replace relevant parts.

2. Harness and connector (1) Check whether all wires are damaged, connectors are connected well. (2) All clamps and clips must clam harness firmly. (3) The wires in bad state should be replaced. (VI) Chassis and body

1. Check of clutch pedal free travel (1) Check clutch pedal free travel. Free travel: 20-30mm. (2) Daub grease on hook and connect positions of clutch stay.

2. Brake disc, brake tongs brake drum and brake shoe (1) Brake disc and brake tongs Dismount wheel and clamp, but do not make brake hose separate clamp.

2) Check the presence and absence of over abrasion, damage and distortion of brake tongs and brake disc of front disc brake. Replace relevant parts if necessary. When reinstalling, it should be noted that bolts are screwed to the specified torque. (4) Brake drum and brake shoe

1) Dismount wheel and brake shoe

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

2) Under the condition that wheels and brake drum are dismounted, check whether brake drum and friction facing is over-abraded, whether brake wheel cylinder leaks oil. Replace relevant parts if necessary.

3. Brake line check Check whether brake hose and oil pipe are cla mped correctly, there are oil leakage, crack, gall and other da mage. Replace relevant parts if necessary. Note: After replacing any brake line or hose, be sure to discharge air in the system.

4. Check and replacement of brake fluid (1) Check whether there is leaked brake fluid around brake master cylinder and brake oil tank. If there is oil leakage, it is necessary to maintain. (2) Check brake fluid level. If brake fluid level is lower than the lowest fluid level, it is necessary to compensate brake fluid. Note: The brake system of the vehicle has been fill composite type brake fluid in the factory, so do not pour other types of fluid or mix other types of fluid. Do not use old or used brake fluid, and the brake fluid taken from unsealed container, either. (3) Change brake fluid every two years. The steps to change brake fluid are: discharge the fluid remaining in brake system completely, then pour new brake fluid into the system, and discharge the air in the system. For exhaust description, please refer to Section 7 of Chapter 3.

5.Brake pedal Check brake pedal free travel. For check steps, please refer to Section 7 of Chapter 3.

6. Parking brake lever and stay (1) Check whether every tooth crest of ratchet plate is abraded or damaged. If there is abrasion or damage case, the abraded or damaged ones must be replaced.

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(2) Pull up parking brake lever with single hand completely, to make brake act fully, while pulling brake lever, listen to the total tooth gap quantity that crawl lever passing carefully (each “chattering” sound stands for passing one tooth). If passed tooth gap quantity exceeds 8, it is necessary to regulate parking brake stay. Parking brake lever travel: within 3-8 ratchets (when brake lever pull up in 20 kg force). For travel measurement and parking brake regulation, refer to Section 7 of Chapter 3. (3) Parking brake stay Check whether brake stay is damaged, moves smoothly, if the stay shows worsening, it should be replaced.

7. Tire check and transposition (1) Check whether tire is abraded unevenly or over abraded. If there is such case, please replace it. (1) Check charging pressure of each tire, and regulate the pressure to

the specified value if necessary. Note: Tire charging pressure must be checked in the state of tire cooling. The specified tire charging pressure can be consulted from tire logo and this manual. (3) Tire transposition use About the details of the above-mentioned steps, please refer to Section 8 of Chapter 3.

8. Wheel and wheel nut (1) Wheel felly Check whether each wheel felly has drop, distortion and crack. The wheel felly damaged badly should be replaced. (2) Wheel bearing

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Operation and Service Manual on VANTAGE TruckALL & VanGO Series

1) Check whether front wheel bearing is abraded, caught or loose.

2) Check whether rear wheel bearing is abraded, caught or loose.

(3) Wheel nut

Check whether wheel nut is screwed, and screw is screwed to the

specified torque if necessary. See Fig. 1.4-14. The screwing torque of wheel nut: 50-80 N·m(5.0-8.0kg·m).

Fig. 1.4-14

9. Absorber

(1) Check the presence and absence of absorber oil leakage, hollow

and other damage on sleeve; and of break and aging of upper pivot

rubber lining, and rear absorber bush.

(2) Part replacement is determined according to the above-mentioned

check result.

10. Transmission shaft

(1) Check whether universal joint and spline of transmission shaft is

loose. If you hear “chattering” sound, damaged parts should be replaced.

See Fig. 1.4-15

Fig. 1.4-15

(2) Check the tightness of transmission shaft bolts, and screw them if

necessary The tightening torque: 18-28 N·m (1.8-2.8 kg·m)

11. Check and replacement of gear oil

(1) Check

1) Check the presence and absence of oil leakage of transmission case

and rear axle shell. If there is, repair oil leakage position.

2) When checking oil level, guarantee that the oil level is horizontal.

3) Dismount the filler plug. When inserting fingers into the filler, you

can know the oil level approximately. If the oil level is close to the filler,

showing that the oil filling is proper, as shown in Fig. 1.4-16.

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Fig. 1.4-16

1. Transmission filler 2. Transmission oil

If gear oil is deficient, fill the specified brand gear oil to the

above-mentioned oil level.

4) Dismount rear axle filler plug. The oil level can be checked from

the filler, the method is the same as the above, gear is deficient, please

fill some.

(2) Oil replacement

Note: Before oil replacement, first check the presence and absence of

oil leakage. If there is oil leakage, it is necessary to repair first , then

fill specified amount of new oil.

Oil capacity: 1.3L

Oil brand: 80W/90(GB13985-92) GL-5(or GL-4) grade gear oil or

18# hyperbola gear oil.

2) Rear axle

Oil capacity: 1.3L

Oil brand: 80W/90(GB13985-92) hyperbola gear oil.

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Fig. 1.4-17

1. Filler plug 2. Discharging oil screw plug

Fig. 1.4-18

1. Discharging oil screw plugs 2. Filler plug

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Operation and Service Manual on VANTAGE TruckALL & VanGO Series

12. Suspension (1) Check whether the presence and absence of abrasion and break of spring, if there is over abrasion and break case, the spring should be replaced. (2) Check the tightness of bolt and nut, and screw them to the specified value if necessary.

13. Steering system (1) Check the steering wheel free travel and looseness, when checking, put the vehicle on flat ground, and the wheels face right ahead. Steering wheel free travel: 0-30mm (2) Check whether the joint of steering shaft is loose or damaged. If there is loose or da mage case, replace relevant parts. (3) Check the tightness of bolts and nuts, and screw them if necessary. (4) Check the presence and absence of break and other damage of dust cap of steering rack, if there is, replace them. (5) Check whether dust cap of globular pin is damaged, if it is damaged, replaces it with a new one. (6) Check front wheel positioning, if there is change, regulate it to the specified value. (7) While the vehicle is running, abnormal resistance and chattering should not occur on steering wheel absolutely, if occurring, it must be repaired.

14. Lubrication of door hinge Wipe dirt, and daub a thin layer of engine oil, open and close the door many times to guarantee the engine oil flow into axial play efficiently. (VII) Test driving After the regular check operation of all times mentioned above is finished, road test shall be done in safe area.

Note: When doing the following road test, it is necessary to select a safe area without passers-by and vehicle running, to avoid accident occurrence.

1. Engine start Check engine-starting state to prepare for test.

2. Clutch Check the following items:

! When treading on clutch pedal, the clutch should separate

thoroughly

! Disengage the pedal and accelerate, the clutch dose not skid,

and engage smoothly.

! Clutch itself has not abnormal sound or other abnormality.

3. Shift lever Check whether gearshift is easy, is not caught and the shift performance of all gears is good, not shift out automatically when shift lever puts into all gears.

4. Brake (1) Traveling brake When driving to tread on brake pedal, check the following items:

! Braking action of brake is good. ! There is no noise from the brake. ! The braking force acted on all wheels is uniform.

(2) Parking brake Check parking brake, when pulling up parking brake lever to make the brake act fully, guarantee that the vehicle does not skid when parking on 20% slope road.

5. Steering unit Check steering wheel, there should not have the feeling of catching, chattering, too tight to turn in driving.

6. Engine

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Chapter I. Whole Vehicle

• Check the engine and ensure smooth operation at different rpm

• Check the engine and ensure no abnormalities during operation

7. Body, wheel and power train

Check the body, wheels and power train, there shall be no abnormal

noise, vibration and other conditions.

8. Instruments

Check the speedometer, odometer, fuel gauge and water

thermometer, and ensure precision of their work.

9. Warning light of oil pressure, charging indication light, warning

light of brake fluid level and warning light of engine failure

Check whether the lights turn off or not during engine running. If

any one of the lights does not turn off, it shows that the corresponding

part goes wrong and need to be serviced.

10. Seat belt

Seat belt can be tightly fixed in the event of emergency braking.

Chapter II. Engine

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Chapter II. Engine

Note: The part of engine will mainly focus on service manual. The

following will only illustrate the aspects not referred in the previous

part.

Section 1 Carburetor Engine Accessories

I. Oil supply system of carburetor engine (I) Components of fuel supply system

Fuel supply system consists of fuel tank, fuel pipe, fuel filter, fuel pump, intake system and exhaust emission control devices etc. Please refer to Fig. 2.1-1.

1. Operational principle of oil supply system

Fig. 2.1-1 operational principle of oil supply system

1. Fuel tank 2. Fuel filter 3. Fuel pump 4. Intake pipe 5. Oil return pipe 6. Exhalant pipe 7. Carbon tank 8. Vacuum tube 9. Carburetor 10. Desorption pipe 11. Air filter 12. Dirt collector

13. Cool air pipe 14. Hot air pipe 15. Intake valve 16. Gas-oil separator

When the ignition switch is in the position of ON, the oil pump begins to pump and the oil is drawn from the oil tank. After being filtered by the oil filter, the filtered oil flows to the carburetor through oil pump and intake pipe. In the event that there is much oil in the float chamber of carburetor, the oil returns to the oil pump through oil return pipe.

2. Oil tank (1) Oil tank structure Oil tank is seamed from sheet steel stampings. A oil volume sensor is attached to the upper center. A pouring orifice is seamed on the side, and an oil draining plug is fixed on the bottom which is used to drain deposited water and particles in the oil tank. (2) Assembly and disassembly of oil tank The oil tank is connected to oil tank support bolts by means of four holes in the tank body. After disassembling and draining the oil tank, the pouring rubber hose shall be taken down first, and then the wirings of oil volume sensor shall be disassembled, and the last step is to release or twist out the clamping collars of the oil pipe and return oil pipe.

3. Oil filter Oil filter is barrel shaped and is cemented together by pressing plastic barrel body and barrel cover. Filter element is fixed in the interior, an oil feeding joint is fixed on the barrel body, and an oil out joint is fixed on the barrel cover. The oil filter cannot be disassembled, so a new filter shall be exchanged after driving 40000km (if the oil quality is not in the standard level, the specified mileage shall be appropriately shortened).

4. Oil pump Power oil pump is attached to the right frame side rail. Please refer to Fig. 2.1-2. (1) Power stroke When the ignition switch is turned on, the electrical current is flowed to the coil (3) through contact switch and excited the wiring. The exciting coil (3) attracts plunger (4) and makes the pull rod (12) and diaphragm (7) move upward and downward. Thus the lower volume is increased and oil is drawn to the oil chamber (11) through oil valve (10). Meanwhile, as the pull rod moves upward and makes the upper caliper trigger the spring seat, the position of springs (15) is

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Chapter II. Engine

Therefore changed resulting cut off of contact switch (2) and

electrical current and disposal of wiring magnetism as well. The diaphragm and pull rod are pushed downward under the force of gravity and elasticity, so oil in the oil chamber can push the oil valve and flow out of the oil pipe, the upper contact can be again connected. The process is reciprocated and pumps quantitative oil. (1) Assembly and disassembly check

1) When failures occur in the power oil pump, the oil pipe shall be checked to see whether there exist breakage, the pump body shall be checked to ensure no leakage, and the diaphragm shall also be checked to see whether there exist cracks. Leakage shall be disposed and the cracking part shall be exchange.

2) The contact point shall be checked to ensure no ablation. If occurs, the oil stone shall be used to smooth it and make the close contact.

Fig.2.1-2 sketch of power pump structure

1. Contact switch 2. Contact point 3. Coil 4. Plunger 5. Pump cover 6. Spring 7. Diaphragm 8. Oil out valve 9. Oil valve spring 10. Oil feeding valve 11. Oil chamber 12. Pull rod 13. Caliper 14. Spring seat 15. Displacement spring

Fig. 2.1-3 Check of the power pump flow capacity

1. Battery 2. Black/ white wiring 3. Black wiring 4. Oil pump

5. Kerosene H=50cm

3) After final completion, check the power pump flow capacity according to the method referred in Fig. 2.1-3, and the flow capacity shall be more than 500ml/min.

Oil Pump (mechanical)

(1) Introduction The pump and diaphragm assembly in the mechanical oil pump pumps petrol into carburetor float chamber. The pump and diaphragm is driven by the eccentric wheel placed on the camshaft of the engine valve mechanism, the pump rod is tightly pressed on the eccentric wheel and makes the pump and diaphragm move upward and downward. Please refer to Fig. 2.1-4.

Chapter II. Engine

Oil Pump Specifications

Discharge pressure 24.5-24.3kPa

Pump capacity 1.3L/min (200r/min)

Pump diaphragm

Fig 2.1-4

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Pump rod

(2) Disassembly

As indicated in Fig. 2.1-5, the upper and lower joints shall be marked

①, to recognize the angle position of upper body ② and lower body ③. Only if angle relation is ensured, the oil circuit can be connected.

Fig. 2.1-5

(3) Check

1) Leakage of fuel pump.

2) Breakage of oil hose.

3) Tightness of all bolts.

4) The conditions of cracking and da maging of pump diaphragm

after disassembly of the oil pump.

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Chapter II. Engine

Fig. 2.1-6

(4) Assembly

1) Put the pump diaphragm on the pump rod as indicated in Fig.

2.1.-6, and then insert the pump stay into the pump rod. Swivel it 90º at the same time of pushing the pump rod, and the pump diaphragm is attached to the pump rod④ in this way. Note: When the pump diaphragm is swiveled 90º and attached to

the pump rod, the pump diaphragm tongue piece shall be on the position of pump rod ⑤. Please refer to 2.1-6.

2) Based on the relative positions of upper body and lower body

which are marked before disassembly, screw eight screws.

3) Push pump rod ④ to the extreme position 4 or 5 times, and

make the pump diaphragm center and pump center can be matched.

Please refer to 2.1-7

4) Finally, tighten the eight screws.

Fig. 2.1-7

(II) Intake System

1. Intake system is composed of cool air intake pipe, hot air pipe,

intake valve, dirt collector and air filter etc.

2. Operational principle of intake system

The system applies dual air filtering system. As is shown in Fig.2.1-1,

the switch handle on the intake valve 15 shall be turned to the side of

“summer” in summer, and the fresh air will flow into the dirt collector 12

through cool air pipe 13 from the vehicle front side, and after being

dusted, the dusted air flows into the air filter 11 through escape pipe.

While, the switch handle on the intake valve 15 shall be turned to the

summer of “winter” in winter, and the warmed up air will flow into dirt

collector 12 through hot air pipe 14 from the vehicle front side, and after

being dusted, the dusted air flows into the air filter 11 through escape

pipe.

Chapter II. Engine

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

The thir

chamber

The first

chamber

Outlet

Inlet

The

second

chamber

Fig. 2.1-8

3. Dirt collector

Dirt collector is installed on the front of the air filter inlet, and the purpose is to filter the air which flows into the air filter.

(1) Operational principle

With the running of the engine, the air is drawn into the first chamber of

the dirt collector, and then flows into the second chamber through windmill air vane shaped diaphragm orifice ① which will exert rotary

action on the air. The centrifugal force generated by rotary air current

spread the dirt around, and the dirt will hit the internal wall of the second chamber and fall into the cup ② surrounding the wall while the dusted

air is drawn into the air filter through the third chamber. Please refer to

2.1-8.

Dirt

Release

Tighten

Fig. 2.1-9 Cleaning of dirt collector

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Chapter II. Engine

(2) Daily cleaning

Clean dirt collecting cup monthly. As is shown in Fig. 2.1-9, disassemble dirt collecting cup from the dirt collector, dump the dirt and reassemble it to the previous position.

4. Exhaust emission control device In order to prevent the petrol vapor from flowing into the air and reduce the pollution to the air, the control to oil vaporization include the following two parts: the first is to seal oil pump and increase the internal pressure of oil tank to reduce the original vaporized volume; the second is to store and intake the vaporized volume after surpassing certain pressure, and send them to the intake pipe to burn when the engine running. Exhaust emission control device include carbon tank, oil-gas separator, oil tank cover with single directional valve, exhalant pipe, vacuum pipe, desorption pipe etc. Please refer to Fig. 2.1-1. The operational principle of the system is that : intake the oil vapor from the oil tank by using the excellent quality of absorption and desorption of active carbon. When the engine is on normal operation, make desorption to the oil vapor stored in the active carbon by applying the vacuum degree of the intake system and make the active carbon restore its ability of storing and absorbing. The power stroke of the system is that: with the change of environmental temperature and pressure, the oil vapor in the oil tank exhausted from vapor escape port will be condensed through oil-gas separator, the condensed liquefied oil returns to the oil tank and the vaporized oil flow into the active carbon to be stored through the double directional valve of the carbon tank. When the engine normally runs, vacuum is created in the engine carburetor, the fresh air is drawn through the air port of carbon tank under the function of carburetor vacuum. When the fresh air passes the carbon tank, it takes the oil vapor stored in the active carbon to the engine carburetor and then flow into the combustion chamber together with intake combustible mixture to burn. When vacuum is created as a result of environmental temperature falling and oil consumption, the fresh air will be drawn from the air port of the carbon tank under the function of oil tank vacuum and flows into the oil tank through carbon tank and oil-gas separator to release the vacuum existed in the oil tank, and thus protecting the oil tank to ensure the normal operation of the engine.

II. Exhaust System Exhaust system is made up of intake pipe, muffler and relevant

accessories.

(I) Exhaust muffler

1. Muffler structure

The purpose of the exhaust muffler is to reduce the impulse of the

exhaust current and therefore reduce the exhaust noise.

The muffler welding assembly applies dual rate muffling, the first rate

adopts extending muffling and the second rate adopts expanding

muffling.

Fig. 2.1-10

1. Sealing gasket 2. Intake pipe 3. Bolt 4. Spring 5. Sealing coil

6. Muffler 7. Cushion slab

Chapter II. Engine

As the exhaust manifold of engine applies compound exhausting, the

exhaust system can be divided into two parts, namely intake pipe and

muffler welding assembly. The intake pipe cooperates with the engine

to make compound exhausting, and combines the two pipes into one

pipe.

2. Installation and function

The intake pipe is connected to the engine exhaust manifold, and

sealed by sealing gasket and then bolted together. The ball shaped

sealing gasket to seal the intake pipe and muffler welding assembly,

the cone shaped springs and bolts are used to tighten them. Rubber

pad is used to connected the muffler welding assembly and frame rail.

After connecting the intake pipe and muffler welding assembling, host

them to the frame rail and then turn it to the suitable angle to make

muffler tailpipe not interfere with other parts, the last step is to tighten

all the bolts. Refer to 2.1-10.

3. Maintenance and service

The exhaust system shall be checked when a vehicle drives every

20,000 kilometers.

The check includes the following: whether there exists damages of muffler sealing gasket and whether there exists damages of intake pipe and muffler welding assembly, and if any failure occurs, the part shall be exchanged; whether the joint point of intake pipe and engine releases, if occurs, it shall be tightened.

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

I. UAES system (ally electronics)

(I) Oil supply system

1. Electric controller 2. Water temperature sensor 3.Oil nozzle

4. Oil guide 5. Carbon tank magneto valve 6. Return oil valve

7. Induction manifold 8. Carbon tank 9.oil filters 10. Fuel tank

11. Fuel pump 12. Oil-gas separator 13. Oil pressure regulator

14. Air intake temperature and pressure sensor 15. Step motor

16. Restrictor position sensor 17. Air filter 18. Dirt collector

19. Intake pipe 20. Restrictor valve body

Section 2 Electro Engine Series of Accessories

Fig. 2.1-1 Schematic Diagram of UAES Oil Supply System

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Engine control system immediately supply power to engine electric controller after the ignition switch turn to the position of “ON” (do not start the engine). The electric controller then connects fuel pump relay and the power source is switched on. 300kPa pressure will be produced in the fuel pipe after filtered by the oil filter and then send to the oil guide rail and oil guide rail distributor on the intake manifold. After the start switch is switched on, the electric controller turns on the oil pump relay and oil pump power supply is switched on, then the electric controller controls the fuel injector of every cylinder intake pipe to inject oil regularly based on ignition signal. (As to the operational principle, please refer to engine service manual). The injection order of oil supply system is: the four nozzles injects one by one according to the sequence of one, two, three, four.

1. Fuel pump (type: D580CN1009) The fuel pump and its support assembly consist of the following parts: fuel pump, oil level sensor, flange with electric and oil circuit joint etc. (Please refer to Fig. 2.2-2).

Chapter II. Engine

Installation method

Electric fuel pump is submersible pump and the pump support assembly is installed in the oil tank. The flange is sealed to the flange which passes rubber sealing rings and the relevant parts.

(1) Oil circuit joint

The joint of intake pipe and return oil pipe outside the flange must be fixed and reliable to ensure the system to have no leakage under the pressure of 300kPa.

(2) Technical specifications

Operational voltage 6-15V DC(according to the vehicle power supply system)

rated operational voltage:12V

Systematic pressure 300kPa

Operational temperature range -40℃——+80℃

allowable operational agent high quality lead free petrol

Durability more than 100000 kilometers on

1. Harness assembly 2. Wire clip 3.

Spring 4. Guide rod 5. Pressure hose

6. Oil pump 7. Oil pump bracket 8. Oil

reservoir 9. Flange 10. Caliper 11.

Fluid level sensor assembly 12. Spring

ring 13. Holding ring 14. Oil filter

Fig.2.2-2 Fuel Pump and Support Assembly

which numbered over 90

the condition of normal running and satisfying the operational agent and without changing the installation method

Chapter II. Engine

Note:

• As the demand for electric vehicle oil supply pressure is quite high, the rubber pipe and clip must be able to ensure the pressure of more than 300kPa. Therefore, the rubber pipe and clip cannot be substituted by ordinary part, otherwise the leakage will occur in the pipe. More seriously, a fire hazard will also occur.

• The operational requirement for the fuel pump is to have enough fuel oil in the fuel tank. If there is not enough fuel oil in the fuel tank, the fuel pump may be burned to be damaged by its own poor cooling. Therefore, when the engine or the vehicle is running, enough quantity of fuel oil must be ensured in the fuel tank.

• When disassembles the fuel pump and support assembly, the pressure of fuel oil pipe must be firstly released in order to avoid hurt to people.

2. Fuel filter The fuel filter is barrel shaped and cannot be disassembled. The filter element is installed in the interior. A new fuel filter shall be exchange every 10000 kilometers’ driving. Note: As the demand for the bursting pressure endured by the electric vehicle used fuel filter is quite high (no less than 16kg), the filter cannot be replaced with carburetor vehicle used fuel filter.

3. Emission control device As the operational principle of the device, please refer to Fig.2.2-1.

With the environmental temperature and pressure changes, the petrol vapor in the petrol tank exhausted from the airport will be condensed through oil-gas separator. The condensed liquefied petrol is returned to the petrol tank and the vaporized petr ol is stored in the active carbon tank through carbon tank dual directional valve. When the engine is in normal running, the electric controller module controls carbon tank control valve and drive and adjust the volume of desorption air current.

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

The operational principle of the carbon tank is as the following: The vacuum generated in the engine intake system makes the fresh air be drawn from the carbon tank air port. When passing the carbon tank, it takes the petrol vapor in the carbon tank to the engine intake system, and then sent to the combustion chamber together with intake mixture. In the event that vacuum is created as a result of environmental temperature falling or petrol consumption, the fresh air will be drawn from the air port of the carbon tank under the function of oil tank vacuum and flows into the oil tank through active carbon tank, dual directional valve, oil-gas separator and air port to release the vacuum existed in the oil tank, and thus protecting the oil tank to ensure the normal operation of the engine. (II) Intake system As the operational principle of the intake system, please refer to Fig.2.2-1. The electric controller module measures intake temperature, pressure, engine rpm, phase signal through intake temperature and pressure sensor installed on the intake system, cooling fluid temperature sensor and Hoor sensor located in the ignition coil. Meanwhile, the system can precisely calculate the actual intake volume of the engine based on the coolant fluid temperature input signal when the engine is regularly running. When idling, the electric controller controls the intake volume by controlling the section area of idling step motor air adjusting valve. Note: When the electric controller is power off or the battery is exchanged, again learning on the step motor shall be made when restarting the engine. The steps are as follows: turn the ignition switch to the position of “ON” (do not start the engine), and restart the engine after keeping 10 seconds. (III) Exhaust system The exhaust system is composed of tri-effective catalytic converter welding assembly, muffler welding assembly and joint components. Please refer to Fig.2.2-3.

1. Catalytic converter (1) The function of catalytic converter is: convert the harmful exhausts (HC, CO, NO

, N2) to reduce air pollution.

) from the engine tailpipe into harmless exhausts (H2O,

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Chapter II. Engine

Fig. 2.2-3 Structure Chart of Exhaust System

1. Tri-effective catalytic converter welding assembly 2. Muffler

welding assembly 3. Joint component

(2) Catalytic converter structure

Catalytic converter includes a piece of ceramics carrier wrapped

by backing strap and inserted in a section of tube shaped body case.

The hole of the carrier is painted with catalyst coating (Pt, PD, Rh).

Note:

• The fuel oil used must be of high quality lead free petrol (over

RON90, and lead volume is less than 0.005L etc), as leaded petrol

will damage tri-effective catalytic converter and the components of

electric control system as hereafter will interfere with the normal

operation of the parts.

• The tri-effective catalytic converter shall not be stricken and strongly vibrated, as the interior ceramics carrier may be broken to block the exhaust system.

• When a fire occurs, namely the engine does not run regularly after start, the engine power significantly decreases or other abnormal phenomenon which indicates there exists failures in the ignition system, please contact with service station quickly. If necessary, low speed and short distance driving can be made at low engine rpm.

• Try to avoid frequently cold start and long time run the engine during the starting period (fuel oil is injected to the cylinder during the starting period, and will be exhausted to the tri-effective catalytic converter without being burned which will cause damages to the converter).

• When the oil in the tank is nearly used up, irregular oil supply will result in the damage to the tri-effective catalytic converter.

• Do not apply the method of pulling or pushing to start the engine (the fuel oil without being burned will flow into the tri-effective catalytic converter which will cause damages to the converter). Note For Maintenance And Service

• Maintenance shall be made regularly to ensure the normal operation of the electric control system. If any abnormal condition occurs, it shall be timely repaired to ensure exhaust level of vehicle and long life time of the tri-effective catalytic converter.

• The exhaust pipe sealing gasket must be replaced when replacing a new component.

• No foreign particles shall be fallen into the tri-effective catalytic converter during assembly. Otherwise, the tri-effective catalytic will be damaged.

• Check whether there exists gas leakage or other abnormal noises of exhaust system joints and check whether the electric system works normally after the normal running of the engine. II. DELPHI system

(1) Oil supply system When the ignition switch is switched on, the engine control system immediately supplies power to the engine electric control module. In the event that the engine start switch is turned on, once the system detects the first impulse signal of the crankshaft rotation, the electric controller connects fuel pump relay. Power source of the fuel pump is switched on and the fuel oil is pumped and pressed by electric oil pump from the oil pump, then the fuel oil is sent to the fuel oil guide rail and guide rail distributor above the engine to make the fuel injector installed on each cylinder regularly inject after filtered by the fuel filter.

Chapter II. Engine

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

The injection order shall be grouped injection: cylinder 1 and 4 are

grouped together, and cylinder 2 and 3 are grouped together.

1. Fuel pump (type: DELPHI25330569)

As to the fuel pump and support assembly components, please refer to

UAES system.

(1) Installation method

Electric fuel pump is submersible pump and the pump support

assembly is installed in the oil tank. The flange is sealed to the flange

through rubber sealing rings and oil tank flanges.

Fig.2.2-4 Schematic Diagram of Fuel Supply System

1. Electric controller 2. Oil nozzle 3. Fuel oil pressure adjustor

4. Crankshaft position sensor 5. Carbon tank magneto valve 6. Return oil pipe 7. Induction manifold 8. Carbon tank 9. Fuel filter 10. Fuel tank 11. Fuel pump 12. Fluid-gas separator 13. Oil guide 14. Water temperature sensor 15. Intake pressure sensor

16. Step motor 17. Restrictor position sensor 18. Air filter

19. Dirt collector 20. Intake pipe 21. Restrictor valve body

22. Intake temperature sensor

(2) Technical specifications

Operational voltage 6-15V DC(according to the vehicle

power supply system) Rated operational voltage:12V Systematic pressure 300kPa Operational temperature range -40℃——+80℃ Allowable operational agent high quality lead free petrol (over

RON90, and lead volume is less

than 0.005g/L) Durability more than 100000 kilometers on

the condition of normal running and satisfying the operational agent and without changing the installation method

Please refer to UAES system to see the notes.

2. As to the fuel filter, please refer to UAES system. (II) Intake system As to the schematic diagram of the intake system, please refer to Fig.

2.2-4. The engine electric controller precisely measures the engine rpm and various input signals through intake temperature sensor (MAT) installed on the intake system, coolant agent temperature sensor (MAP) and crankshaft position sensor (CPS) located on the transmission flywheel cover. Meanwhile, the system exactly meters the actual intake volume of the engine based on the input signals of the coolant agent temperature sensor when the engine is on real time running. When idling, the electric controller controls the intake volume by controlling the section area of idling step motor air adjusting valve. (III) Exhaust system Exhaust system is composed of tri-effective catalytic converter welding assembly, muffler welding assembly and joint component. Please refer to Fig.2.2-5. Please refer to UAES system to see the notes.

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Chapter II. Engine

Fig.2.2-5 Structure Chart of Exhaust System

1.Tri-effective catalytic converter welding assembly

2. Muffler welding assembly 3. Joint component

Chapter III. Chassis

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Chapter III. Chassis

Section 1 Clutch

I. Introduction Clutch in the vehicle is single, dry, diaphragm spring clutch. Diaphragm spring outer side is a whole body, inner rings have some center pointing release fingers. The friction pad of the clutch is installed on the transmission input shaft through splines. Four torsion buffer springs are attached to the clutch friction pad. Diaphragm springs are fixed to the clutch pressure plate by using rivets which are taken as the support point of diaphragm springs.

Flywheel

Crankshaft

Clutch plate

Clutc

Fig.3.1-1a

ressure plate

Transmission input shaft

Clutch release

bearing

When the clutch is jointed, diaphragm spring outer rings are tightly presses on the pressure plate which tightly presses the friction pad on the flywheel. When the clutch pedal is pressed, the release fork push the releasing bearing to move left, and release bearing push diaphragm spring inner ring release finger. Diaphragm springs make the spring outer ring move right based on rivet and drive the pressure plate separate from the friction pad. The clutch thus on the separation condition at the same time, and thus the engine power is cut off. This type of clutch is of simple structure, complete separation, excellent heat emission, compact size, and need not to be adjusted.

Fig.3.1-1b Clutch

1. Clutch friction pad 2. Clutch pressure plate 3. Spring washer

4. Clutch bolt 5. Clutch release bearing 6. Clutch release pin

7. Liner 8. Clutch release shaft 9. Return spring 10. Sizing bolt

11. Clutch release pipe

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

II. Disassembly The prerequisite for disassembling the clutch is that the transmission has been disassembled in the correct order. The disassembly procedure is as the following: ① Disassemble the six bolts used to tighten the clutch, and then take the clutch pressure plate and clutch friction pad out. ② Disassemble the clutch release bearing from the front of the transmission shaft.

③ Disassemble the flywheel. ④ Disassemble the transmission input shaft side bearing from the

flywheel. III. Examine the components

1. Wearing of the clutch friction pad Measure the hollow depth of each rivet head, namely the distance between rivet head and friction lining surface to check the wearing condition of each friction lining. If the hollow depth of any hole has reached to the wearing limit, a new clutch friction pad assembly shall be exchanged.

Hollow depth of rivet head

Standard Operating limit

1.2mm 0.5mm

2. Fit clearance of clutch friction pad splines Rotate the clutch friction pad installed at the transmission input shaft to check the spines clearance. If the clearance exceeds the operating limit, a new clutch friction pa d assembly shall be exchanged. The clearance means the displacement number on the circumference measured by using micrometer gauge.

Fit clearance of splines

Operating limit

0.8mm

Chapter III. Chassis

3. Clutch pressure plate Check the friction spring rivet of the clutch pressure plate to find whether there exists release. If the rivet releases or begins to release, that is the clutch pressure plate produces “clatter” noise when the clutch pedal is pressed, a new clutch pressure plate assembly shall be exchanged. Check the wearing condition of the joint point between diaphragm spring release fingers and clutch release bearing. If the condition is quite serious, a new clutch pressure plate shall be exchange.

4. Release bearing Rotate the release bearing to make it free run, if there exists the condition of obstruction, “clatter” noise or other abnormal noises, a new release bearing shall be exchanged.

5. Transmission input shaft side (I shaft) bearing Rotate the release bearing to make it free run, if there exists the condition of obstruction, “clatter” noise or other abnormal noises, a new release bearing shall be exchanged.

6. Flywheel Check whether there exists wearing or damages on the contact surface between flywheel and clutch friction pad. IV. Assembly Assemble the clutch according to the reverse order of disassembly. The important steps are as follows. ① The flywheel bolt shall be tightened by applying the specified tightening torque 40-50N·m. ② Install the clutch pressure plate on the flywheel. Note that the two sizing bolts shall not be omitted. The tightening torque of the clutch pressure plate shall be 18-28N·m. ③ The lubricating grease shall be appropriately coated on the release bearing base before assemble the release bearing. ④ A small quantity of lubricating grease shall be coated on the release fork and input shaft end.

⑤ The two impressing marks shall be aligned when install clutch release arm to clutch release bearing.

Chapter III. Chassis

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

V. Maintenance

1. Free stroke of clutch pedal ① Press the clutch pedal, stop pressing when feels the clutch resistance and measure the distance (namely free stroke of clutch pedal). The free stroke of clutch pedal shall be 20-30mm. ② If the free stroke of clutch pedal is out of the specified range, then adjust it by adjusting the clutch pulling thread adjust nut (on the side of pedal and release arm). ③ After completing adjusting the clutch pedal, the clutch pulling thread side screw shall exceeds the adjust nut 1-5mm.

2. Lubrication of clutch pulling thread Lubricating grease shall be coated on the hook part ① of the clutch pulling thread.

15-25 N·m

Fig.3.1-2

1. Clutch pedal 2. Clutch pulling threading joint

3. Clutch pulling thread

Route of clutch pulling thread

A directional vie w

Framework

Dragrod bracket

Suspension framework

Radiator

Clip

B directional view

Clip

C directional vie

D directional vie

E directional view

Fig.3.1-2 VI. Tightening torque If there occurs releasing on the bolt or nut, they are must be tightened with specified tightening torque.

Component tightening torque

N·m

Flywheel bolt 40-50 Clutch pressure plate bolt 18-28 Clutch release arm bolt and nut 10-16 Clutch pulling thread lock nut 15-25

Clip

Clutch

pulling

thread

Choke valve pulling thread

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Chapter III. Chassis

Section 2 Transmission

I. Introduction

The transmission is gear meshed type, and has five (four) driving

gears, one reverse gear and is operated by flexible shaft.

Fig.3.2-1

1. Gearlever 2. Speed selecting arm 3. bracket base 4. Ball base 5. Lining 6. Speed

selecting return spring 7. Gear shifting handle assembly 8. Gum cover 9. Cylindrical roller

10. The first pre ssure spring of gear shifting handle shaft 11 . Washer 12. Reverse gear lock

spring 13. Reverse gear lock ball 14. Fork arm 15. Limit stop 16. The second pressure

spring of gear shifting handle shaft 17. Reverse gear shifting spacer 18. Gear shifting cover

body

II. Gear shifting control

1. Gear shifting control system is mainly composed of the following

parts. (Please refer to Fig.3.2-1) Gear lever is connected to gear shifting

arm and speed selecting arm on the transmission by two pieces of

flexible shafts (shift flexible shaft and speed selecting flexible shaft).

2. Disassembly

Five gear transmission

Four gear transmission

Chapter III. Chassis

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

1) Gearlever

① Disassemble the front gearlever assembly. ② Disassemble the shift flexible shaft from the gearlever. ③ Disassemble the speed selecting arm.

2) Shift flexible shaft and speed selecting flexible shaft ① Disassemble the shift flexible shaft and the speed selecting flexible shaft from the transmission side gear shifting arm and gear selecting arm.

② Disassemble the front gearlever assembly. ③ Disassemble the shift flexible shaft and the speed selecting

flexible shaft from the gearlever and bracket.

3) Gear shifting cover body ① Disassemble the shift flexible shaft and the speed selecting flexible shaft from the gear shifting arm and gear selecting arm after ensuring the gearlever is on the neutral position.

② Disassemble the gear shifting cover body from the transmission. ③ Disassemble gear shifting arm and gear shifting arm axle. ④ Disassemble reverse gear lock screws, coil springs, reverse gear

lock ball.

⑤ Pull the cylindrical roller out from the cover body. ⑥ Pull the gear shifting handle shaft from the cover body and

disassemble the second spring, fork spring, washer and the first spring. ⑦ Disassemble the limit stop. Note: The step is unnecessary as to four gear type transmission.

3. Examine the components

1) Fork arm and gear shifting arm axle Check each lever arm end to see whether there exists wearing. If occurs, it shall be exchanged. The limit stop shall also be examined as to five-gear type transmission.

2) Oil seal of gear shifting arm axle and gear selecting arm axle

Check each component to see whether there exist wearing, damage or deformation. If occurs, they shall be exchanged. The oil seal is recommended to be used when reassembling.

3) Spring Check each spring to see whether there exists weakness or damage. If occurs, it shall be exchanged.

4) Shifter fork axle Visually examine each joint point between fork axle (the first gear, the second gear, the third gear, the fourth gear and reverse gear) and fork arm to see whether there exists any wearing. If occurs, the worn fork axle must be replaced.

5) Gearlever and bracket Check each lining and washer to see whether there exists any wearing. If occurs, it must be replaced. If there exists obstruction to the gearlever action, lubrication grease needs to be coated.

4. Assembly Assemble according to the reverse order of disassembly. The important steps are illustrated in the following. Note: All the components must be coated with gear oil before installed into the gear shifting cover body.

1) Shifting control body ① Install reverse gear limit stop. Note: The step only applies to five gear type transmission. ② Install the second spring, fork arm, washer and the first arm to the cover body. The tightening torque of reverse gear limit screw is 18-28N·m (Please refer to Fig.3.2-2). Note: As to four gear type transmission, spacer is installed between the second spring and gearlever.

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Chapter III. Chassis

Fig.3.2-2

1. The second spring 2. Reverse gear limit pawl 3. Gear lever

4. Washer 5. The first spring

③ Insert the gear shifting handle axle into the gear shifting cover

body until groove “A” on the axle aligns with pin hole “B” on the

gear shifting cover body. The lever arm of fork arm and the arm

center line on the gear shifting handle axle must be on the same level.

(Please refer to Fig.3.2-3) ④ Install gear shifting arm axle and screw it to the specified torque

13-20N·m.

Fig.3.2-3

1. Fork arm lever arm 2. Cylindrical roller

3. Gearing shifting handle axle arm ⑤ Install the iron ball, springs and screws, and screw the screws to the specified torque 8-14N·m. ⑥ Simulate the gear shifting and gear selecting action and pull the gear selecting arm and gear shifting arm to check the flexibility of their action. ⑦ The joint surface must be cleaned when install the gear shifting cover body to the transmission rear case body, and then the sealant shall be coated on the joint surface. ⑧ Screw the gear shifting cover body bolt to the specified torque 18-28N·m. ⑨ Connect the speed shifting flexible lever and the speed selecting flexible to each rocking arm respectively. The speed selecting flexible lever shall not be assembled to the gear shifting rocking arm and the speed shifting flexible lever shall not be assembled to the gear selecting rocking arm. ⑩ After completion of connecting flexible levers, operate the gearlever to check the effectiveness and flexibility when putting into a gear or choosing a gear. If there exists any problem, please refer to the service manual to continue operation.

Chapter III. Chassis

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

2) Speed operating flexible lever and speed operating lever

Assemble according to the reverse order of disassembly.

3) Washer and lining

The washer and lining must be installed on the correct position, and

lubrication grease shall be coated on the positions indicated below.

22-35 N·m

2.2-3.5 Kg·m

4-7 N·m

0.4-0.7 K

·m

8-12 N·m

0.8-0.7 K

·m

B directional vie

Fig.3.2-4

1. Speed shifting handle assembly 2. Dust proof cover 3. Gearlever 4.

Bracket base 5. Speed shifting flexible lever assembly 6. Dust proof and

pressure resistant plate 7. Hose seal lock 8. Speed selecting flexible lever

assembly 9. Gear selecting arm assembly 10. Speed selecting return spring

←: lubrication grease A (99000-25010) shall be coated

4) Flexible lever

The installation position shall not be mixed when install the speed

shifting flexible lever and speed selecting flexible lever to the

transmission control lever or speed operating flexible lever. Please refer

to Fig.3.2-4 and Fig.3.2-5 to ensure correct joint. Check whether the

operation lever cans flexibly selecting and shifting gears after the

completion of installing all the components.

A directional vie w

Washer Flexible lever end head

Speed shifting flexible lever assembly

Flexible lever grommet

Flexible lever guide component

Flexible lever

end head

Was he r

Coated with water proof sealant

Flexible lev er gromment

board

Speed selecting flexible

lever assembly

Fig.3.2-5

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Chapter III. Chassis

5. Maintenance Adjustment of flexible shaft Note:

• Each lubricating part listed in Fig.3.2-4 must be checked before adjustment to ensure adequate lubrication and there exists no wearing on the lining and other components. Maintenance shall be made based on particular conditions.

• Speed shifting flexible cannot be adjusted. It can only be replaced if failure occurs. If gearlever can be easily and effectively put from neutral position (vertical state) to the third gear or fourth gear, it indicates that speed selecting flexible shaft is on good condition. If gearlever cannot be easily and effectively put from neutral position (vertical state) to the third gear or fourth gear, the following method can be used to adjust the speed selecting flexible shaft:

1) Slightly operate gearlever toward left, making the speed selecting shaft incline from the current neutral position to the second gear side (gear selecting position). If gearlever ca n be easily and effectively put in the third gear and fourth gear from this point, release speed selecting flexible shaft adjusting bolt “A” indicated in Fig.3.2-6 and tighten bolt “B” until gearlever can be easily and effectively put in the third gear and fourth gear.

2) Slightly operate gearlever toward right, making the speed selecting shaft incline from the current neutral position to the reverse gear side (gear selecting position). If gearlever ca n be easily and effectively put in the third gear and fourth gear from this point, release speed selecting flexible shaft adjusting bolt “B” indicated in Fig.3.2-6 and tighten bolt “A” until gearlever can be easily and effectively put in the third gear and fourth gear.

6. Tightening torque Unit: N·m

Fastener Tightening

torque Reverse gear limit screw 18-28 Reverse gear lock ball screw 8-14 Reverse gear arm axle nut 13-20 Reverse gear cover bolt 18-28

Fig.3.2-6

Chapter III. Chassis

III. Transmission (five gear type)

1. Introduction

Fig.3.2 – 7a

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

CA6350 series micro vehicle adopts two types of transmissions: five

gear type transmission is installed on 456 series engine and four gear type transmission is installed on 462 series engine. Four gear type transmission has four driving gears, each of which has an inertia synchronizer and one reverse gear, the fourth gear is direct gear. Four gear type transmission has five driving gears, each of which has an inertia synchronizer and one reverse gear, the fourth gear is direct gear. Transmission cover is divided into the upper cover body and the lower cover body in structure. The upper cover body has three prong axle gear assembly and the lower cover body has countershaft. The rear of the transmission has a extending part, namely rear cover body which has reverse gear. The front of the transmission cover body is clutch cover, the two cover bodies are combined together. The transmission input shaft (the first shaft) is also the driven shaft of the clutch, while the transmission output shaft (the second shaft) is extended from the rear part of the transmission and cooperates with the driving splinted fork. The synchronizer used in the transmission is sliding inertia synchronizer. The synchronizer can be used to avoid smashing during gearshift, ensure smooth gearshift, facilitate operation and increase the durability of the transmission. As to the five gear type, please refer to Fig.3.2-7a and Fig.3.2-7b.

1. The first axle assembly 2. Rolling bearing 3. The first axle bearing 4. C type lock ring 5. Collar ring 6. Oil

seal 7. The second axle 8. Cylindrical roller 9.thrust washer 10. The first gear 11. Lining 12. Needle

bearing 13. The second gear 14. The third gear 15. Needle bearing 16. The fifth gear 17. Thrust washer 18.

Needle bearing 19. Bearing 20. C type lock ring 21. Bearing 22. Collar ring 23. Collar ring 24.

Countershaft 25. The fifth driving gear 26. Front bearing of countershaft 27. Collar ring 28. Middle bearing of

countershaft 29. Bearing 30-1. Low speed commutating gear cover 30-2 outer gear ring 31. Low speed

synchronizing ring 32. Elastic ring 33. Spring clamp ring 34-1. High speed commutating gear ring 34-2 outer

gear ring 35. The fifth gear synchronizing ring 36. High speed synchronizing ring 37-1 reverse gear and the fifth

gear commutating gear 37-2. Outer ring 38. Slide block 39. The fifth gear slide blocks 40. Reverse gear

countershaft 41. Sizing pin 42. Reverse gear countershaft assembly 43. Shield ring 44. Reverse driving gear

45. Reverse driven gear 46. Lining 47. Odometer worm shaft 48. Odometer driven gear 49. Lining 50.

Rubber ring 51. Rubber cup assembly 52. Oil seal ring assembly 53. Spring clamp ring

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Chapter III. Chassis

Deceleration dr ive gear

High gear shifting fork

The third gear

The second gear

：Low gear shifting fork

The first gear

Reverse gear shifting f ork

Reverse dri ving gear

The fift h gear drivin g gear

The second axle

Countershaf

The fift h gear drivin g gear

Reverse dri ven gear

Reverse countershaft assembly

Fig.3.2-7b

Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series

2. Each gear ration of transmission The first gear 3.652 The second gear 1.947 The third gear 1.432 The fourth gear 1.000 The fifth gear 0.795 Reverse gear 3.466

3. Disassembly

1) Disassemble the negative pole (-) and the positive pole (+) tie wire from the battery binding post.

2) Disassemble the reversing lamp switch leading wire.

3) Disassemble controlling wire and the positive pole (+) tie wire from the motor.

4) Disassemble the motor form the transmission cover body and disassemble the battery negative pole (-) tie wire from the transmission cover.

5) Release the reversing lamp leading wire from the clip.

6) Disassemble the speedometer driving flexible shaft from the transmission cover body.

7) Disassemble the oil draining bolt and drain the gear oil from the transmission.

8) Disassemble the clutch pull thread from the clutch release lever.

9) Disassemble the gear selecting flexible shaft from each rocking arm and bracket.

10) Disassemble the transmission shaft and disassemble the hot air hose clip from the transmission cover body.

11) Disassemble the clutch lower plate from the transmission cover body.

12) Disassemble the bolt which is used to tighten the engine cylinder block and transmission cover body.

Note: Check again to ensure no part is still connected to other parts or has not been disassembled before disassembling the transmission.

13) Disassemble the transmission rear bracket from the body.

14) Disassemble the transmission.

4. Breakdown

1) Replace clutch release shaft lining

① Disassemble the clutch release shaft. ② Disassemble the springs from the clutch release shaft. ③ Disassemble the clutch release lever from the shaft. ④ Disassemble the clutch release shaft from the transmission cover

body. ⑤ A suitable amount of lubricating grease must be coated on the lining inner surface if reassembles the lining, and tap the lining into the transmission cover body until its surface becomes flat.

2) Break down the upper and lower case

① Disassemble the clutch release shaft from the transmission first axle. ② Disassemble the front cover bolts, and pull the front cover out by

means of 3 longer M6 type ordinary bolts. ③ Disassemble the gear shifting cover and the speedometer driven gear lining. ④ Disassemble the bolts which are used to tighten the rear case, and disassemble the rear case. ⑤ Disassemble the bolts which are used to tighten the upper and lower case, and break down the upper and lower case.

3) Disassemble the second axle and the first axle ① Take the first gear out by hand. Do not fall the high speed synchronizing ring. ② Disassemble the collar ring blocks the odometer worm shaft, and slide the high speed synchronizing ring, the third gear and needle bearing out from the second axle. ③ Disassemble the collar ring blocks the odometer worm shaft, and slide the odometer worm shaft out. Disassemble the collar ring which is on the second axle and which blocks the rear bearings. ④ Take the five gear washer, cylindrical roller, fiver gear, five gear synchronizing ring and five gear needle bearing from the second axle. ⑤ Disassemble collar ring, reverse gear synchronizer, reverse gear, reverse gear needle bearing.

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

⑥ Disassemble the thrust washer and the reverse gear lining from the second axle. Note: The cylindrical roller may be fallen during the process of disassembly. Do not miss the cylindrical roller. What’s more, the ball bearing cannot disassembled simultaneously together with the above-mentioned washers and linings.

⑦ Disassemble the cylindrical roller from the second (central) axle. ⑧ Disassemble the first gear, needle bearing and synchronizer ring

from the second axle. ⑨ Disassemble the first gear lining, low speed synchronizer and synchronizer ring, the second gear and the second gear bearing.

4) Disassemble the countershaft

① Disassemble the countershaft connected with gear. ② Disassemble the countershaft rear bearing. ③ Disassemble the countershaft five gear and the countershaft

reverse gear. ④ Disassemble the collar ring the countershaft. Press the countershaft out to the extended case side by using hydraulic press machine, disassemble the bearing and take the countershaft assembly out.

5) Disassemble gear shifting fork and axle

All the gear shifting fork must be on the neutral position before disassembly. ① Pull the reverse gear shifting fork. The sizing balls and springs located in the hole may jump out during the operation, do not miss them. ② Pack the elastic cylindrical pin of the low speed gear shifting fork out (do not pack it too high to avoid damage the cover body) and pull the declutch shift shaft out. Do not spring the sizing ball, lock ball and springs too far. ③ Pack the elastic cylindrical pin of the high speed gear shifting fork out according the above-mentioned steps and pull the declutch shift shaft and shifting fork out.

5. Inspect the components

1) Gear

Chapter III. Chassis

Examine whether there exists wearing, damage or discoloration on each part. If any problem occurs, replace a new part.

2) Synchronizer, commutating ring, outer ring and slide block Examine whether there exists wearing or damage each part. If any problem occurs, replace a new part.

3) Shifting fork and outer ring Examine whether there exists wearing or damage on the contact surface. Measure the maximum clearance between shifting fork and outer ring. The maximum clearance shall be 1mm.

4) The second axle Examine whether there exists wearing, damage or discoloration on each part of the second axle. If any problem occurs, replace a new part.

5) Bearing and lining Examine whether there exists wearing, damage or discoloration. As to the bearing, it must be checked to see its flexibility and whether there exists noise. If any problem occurs, replace a new part.

6) The first axle Examine whether there exists any wearing on the cone part ①, gear ring ②, gear tooth ③ and splines ④ according to Fig.3.2-8. If any serious problem occurs on any part of the first axle, a new axle must be replaced.

7) Gear and synchronizing ring Install the ring to the corresponding gear cone. Measure the gear clearance between two circumferences. If the clearance is less than the maximum operation limit, it shall be replaced based on the actual need. Examine whether there exists abnormal wearing on the (gear) outer cone and the (ring) inner cone. Ensure the surface contact is evenly and complete contact and no waved wearing occurs on the surface. The worn part must be replaced. If the clearance between ring and gear and the condition of cone surface satisfy the specified requirements, the correct synchronizing action will occur during gear shifting.

Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Clearance between gearing ring and tooth

Standard Operation limit

Low gear, direct gear 1.0-1.4mm 0.5mm

Five gear 1.21-1.6mm 0.5mm

Fig.3.2-8

Fig.3.2-9

8) Chamfered edge tooth of synchronizing ring (outer tooth) and outer ring (inner ring) The synchr onizing ring and commutating ring has three grooves respectively which locate the slide block and which are supported by expanding springs. In this way, the two rings of the commutating ring and end side can move together. As the outer ring connects the commutating ring by inner tooth, the outer ring and the commutating ring and ring can move together. During the meshing process, the outer ring is pushed aside (by gear shifting fork) and pushes the ring to the cone surface of the gear. The push force is passed by three slide blocks. The rings being to rotate through the friction of gear cone and the (inner) ring cone. However, as the slide blocks are obstructed by the commutating ring that is the rings are turned, while the outer ring continues moves the rings forward to the cone of the gear. As the rings cannot move forward any more, the outer ring releases the slide blocks and straddles on the rings. Meanwhile, the first contact occurs between the chamfered edge of the ring tooth and the outer ring inner tooth which makes the inner tooth of the outré ring align with the groove of the ring tooth. When the outer ring continues to move forward and slides into the ring, the rings will rotate at the almost same speed with the gear. Therefore, the outer ring can easily slide in the clutch tooth of the clutch. The first contact mesh is determined by the slide block and groove width or the clearance between slide block and the inner groove. When the synchronizer is correctly installed on the axle, push and turn each synchronizer and observe whether the mesh is 3/1. Otherwise, it indicates the total wear extent (sum of groove, slide block and chamfered edge tooth) exceeds the limit. In this case, the whole synchronizer assembly must be replaced. Mesh between synchronizer ring and outer ring chamfered edge tooth: Chamfered edge tooth contact length of relative top shall exceed 1/3 of chamfered edge length.

9) Synchronizer ring Measure the width of each groove, examine whether there exists wearing on the slide block groove of each synchronizer ring. If the width exceeds the limit, it must be replaced. (Please refer to Fig.3.2-11).

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Chapter III. Chassis

Slide block groove width

of synchronizer ring

Standard Operation limit

10.1mm 10.4mm

Fig.3.2-10

Fig.3.2-11

10) Sizing spring of declutch shift shaft If the problem of “gear slides out of mesh” occurs, measure the free length of spring. If the free length is less than the operation limit, the spring must be replaced.

Free length of spring

Standard Operation limit

25.5mm 21.0mm

11) Handle axle Examine whether there exists wearing on the handle axle. If occurs, it must be replaced. As to the rear case lining, measure the radial clearance between the lining hole and slide fork of transmission shaft and examine whether there exists damage on the rear case cover. If the slide fork of transmission shaft can rock in the lining because of wearing, and thus rocks the transmission shaft, the rear case cover of the slide fork of the transmission shaft must be replaced. It is not complete to only replace the lining.

Rocking volume between transmission shaft and lining

Standard Operation limit

10.1mm 10.4mm

6. Important steps for installation Note:

• Each part must be cleaned and the specified gear oil must be coated on the sliding surface of the bearing and gear before installation.

• During reassembly, a new collar ring must be used instead of an old one.

• Tighten each bolt and nut by using the specified tightening torque list in the next part of the section.

1) The second axle and the first axle

Assemble according to the reverse order of disassembly. Pay attention to the installation direction of each washer, gear, commutating ring and outer ring. The cylindrical roller must be attached to the second axle. ① Attach the second gear bearing, the second gear, the synchronizer ring, low speed commutating spring and the outer ring to the second axle. Pay attention to the installation order during operation. After placed on each synchronizer, the three splines of the commutating ring have to be inserted into the grooves of each ring in order.

Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Then use the hydraulic press machine to install the first gear lining and the two linings on the second gear are the same. ② Install the first gear needle bearing, collar ring, synchronizer ring, the first gear, cylindrical roller and washer to the second gear. Insert the cylindrical roller into the hole of the axle and install the thrust washer to make its groove locate above the cylindrical roller. To ensure the correct order of the thrust washer, the fillet of the encircle must face to the central bearing of the second axle. ③ Install the central axle, pay attention to the installation order. Install the cylindrical roller and washer. The fillet of the encircle must face to the central bearing of he second axle and the groove must be located above the cylindrical roller during operation. ④ Press the reverse gear lining. Prevent the cylindrical rollers installed based on the step ③ fall out during operation. ⑤ Install the reverse gear bearing, the reverse gear and the reverse gear commutating ring/outer ring. To ensure the correct installation order, the lower diameter and longer cam side must face the transmission rear side during installing the commutating ring and insert the collar ring of the reverse gear into the groove of the second gear. ⑥ Install five gear bearing, five gear synchronizer ring and five gear. Then install the cylindrical roller and the thrust washer, the oil pan of the thrust washer shall face the five gear. ⑦ Press the second gear rear bearing. Insert the collar ring into the groove of the second axle. ⑧ Install the third gear bearing, the third gear, the high speed synchronizing commutating ring/outer ring. The cam side of higher outer diameter shall face the three gear side. Then, insert the collar ring into the groove of the second axle.

⑨ Install the odometer worm shaft to the second axle. ⑩ Install the synchronizer ring, the needle bearing and the first axle.

2) Countershaft and reverse gear countershaft ① Tap the front side of the countershaft into the cover body. And tap the countershaft slightly into the front bearing by using a plastic hammer. On the above-mentioned condition, tap the bearing into the countershaft and the lower cover body. ② Insert the front collar ring of the countershaft into the groove.

③ Install the countershaft reverse gear and five gear to the countershaft.

Then tap the rear bearing of the countershaft to the axle. ④ Install the reverse gear countershaft and the washers to the reverse gear axle and then install the pin. Install the completed assembly to the lower cover body.

3) Gear shifting fork, pin and fork pin Note: The three gear shifting axles have its respectively sizing ball and spring, while the declutch shift shaft shall be orderly installed in the two lock balls and one roller between each axle. ① Install the three sizing springs to the three holes of the upper cover body, and install the sizing ball to the top of the sizing spring in the hole. ② Insert the third and fourth gear declutch shift shaft into the cover body. ③ Press down the sizing ball of the third and fourth gear. After the self-lock pin is installed into the low gear declutch shift shaft, insert the axle into the upper cover body according to ② and ③.. Install the fork and tap the fork axle until the surface between fork axle and fork become flat. ④ Install the lock ball and sizing ball to the upper cover body, insert the axle into the upper cover body according to ② and ③.

4) Transmission lower cover body and upper cover body ① On the condition that the countershaft assembly, reverse gear countershaft and reverse gear axle has been installed to the lower cover body, check whether the two sizing pins locate on the two sides of the lower cover body. ② The two matching surfaces of the upper and lower cover body must be clean. ③ Check whether the thrust washer has been installed in the grooves of the front bearing and middle bearing of the second axle.

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Chapter III. Chassis

④ Install the first axle and the second axle to the lower cover body. ⑤ Sealant shall be coated evenly on the matching surface of the

lower cover body. ⑥ Insert the three gear shifting fork into the three grooves of the outer rings of the second axle respectively and install the upper cover body to the lower cover body. ⑦ Screw the cover body bolt to the specified torque 18-28N·m.

5) The rear case cover

① Check whether the sizing pin has been correctly installed. ② Lubricating grease shall be coated on the oil seal mouth. ③ Clean the rear case cover surface matches with the transmission

cover body and coat the sealant evenly on it.

④ The three gear shifting axles must be on the neutral position. ⑤ Install the rear case cover to the transmission cover body and screw the rear cover bolt by apply the specified torque 18-28N·m. ⑥ Clean the gear shifting cover surface matches with the

synchronizing transmission cover body and coat the sealant evenly on it. ⑦ Lubricating grease shall be coated on the speedometer driven gear and its lining. Install the speedometer and lining.

6) Front cover of the first axle

① Lubricating grease shall be coated on the oil seal mouth. ② A Clean the contact surface matches with the transmission cover

body and coat the sealant evenly on it.

③ Tighten the bolt to the specified torque 18-28N·m. ④ Rotate the first axle of the transmission and check the flexibility

of rotation. ⑤ Check the operation condition of each gear selecting and gear shifting axle.

7) Clutch release bearing Lubricating grease shall be coated on the inner surface of it.

Others A certain amount of gear oil shall be infused in the transmission according to the complete assembly or reassembly state and the installation condition of transmission.

7. Maintenance and service Gear oil Note: Sealant shall be coated on the screwed part of the infusing bolt and draining bolt. Tighten the two bolts to the specified torque 36-54N·m. Check whether there exists the condition of oil leakage. If occurs, it must be immediately repaired. Oil capacity of the transmission: 1.3L, type: 80W/90 (GB13985-1992) GL-5 (or GL-4) gear oil or NO.18 hyperbolic curve gear oil. Note: The existence of oil leakage shall be checked no matter when lift the automobile or make maintenance even if gear oil does not need to be replaced.

8) Tightening torque specifications

Unit: N·m (refer to Fig.3.2-12)

Fastener Tightening torque

1. Reverse gear cover bolt 18-28

2. Reverse gear lock bolt 8-14

3. Reverse gear arm nut 13-20

4. Reverse gear limit bolt 18-28

5. Tightening upper and lower case cover bolt 18-28

6. Tightened rear case cover bolt 18-28

7. Infusing and draining bolt of transmission 36-64

8. The front cover bolt of the first axle 18-28

9. Clutch release arm nut 10-16

10. Speedometer driven wheel lining bolt 4-7

Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Fig.3.2-12 Tightening Torque Specification

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Fig.3.2-13a

1. The first axle assembly 2. Needle bearing 3. The first axle bearing 4. C type lock ring

5. Collar ring 6. Oil seal 7. The sec ond axl e 8. Cylindrical roller 9. Thrust washer 10. The

first gear 11. Lining 12. Needle bearing 13. The second gear 14. Needle bearing 15. The

third gear 16. Needle bearing 17. Bearing 18. C type lock ring 19. Collar ring 20.

Countershaft 21. The front bearing of countershaft 22. Collar ring 23. The rear bearing of

countershaft 24. Collar ring 25. Low speed commutating ring 26 .Outer ring 27. Low speed

synchronizi ng ring 28. Spring collar ring 29. High speed co mmutat ing ring 30. Outer ring 31.

High speed sync hronizing ring 32. Spring collar ring 33. Low gear co mmutating ring 34. Outer

ring 35. Slide block 36. Reverse gear countershaft 37. Sizing pin 38. Reverse mid dle gear

assembly 39. Shield ring 40. Reverse driving gear 41. Reverse driven gear 42. Lining 43.

Needle bearing 44. Collar ring 45. Odometer worm shaft 46. Odometer driven gear 47. Lining

48. Oi l seal assembly 49. Rubber ring 50. Elastic ring 51. Collar ring

Chapter III. Chassis

Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series

gear s

Underdrive gea

The third gear

High gear shifting fork

The second gear

hifting for

Shaft 1

The first gear

Low gear shifting fork

Shaft2

Countershaft

Reverse dri ven gear

Reverse middle gear assembl y

Fig.3.2-13b

III. Transmission (four gear type)

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Chapter III. Chassis

Note: Please refer to the content of five gear type transmission for the unmentioned aspects.

1. As to the introduction, please refer to Fig.3.2-13a and Fig.3.2-13b.

2. Each gear ration of transmission The first gear 3.429 The second gear 2.109 The third gear 1.379 The fourth gear 1.000 Reverse gear 3.600

3. Disassembly (please refer to five gear type)

4. Breakdown Please refer to five gear type for unmentioned aspects.

1) Disassemble the second axle and the first axle. ① Take the first gear out by hand. Do not fall the high speed synchronizing ring. ② Disassemble the collar ring blocks the odometer worm shaft, and slide the high speed synchronizing ring, the third driven gear and needle bearing out from the second axle. Disassemble the collar ring blocks the odometer worm shaft, and slide the odometer worm shaft out. ③ Disassemble the collar ring which is on the second axle and which blocks the rear bearings. ④ Disassemble reverse gear commutating ring, reverse gear and reverse gear needle bearing. ⑤ Disassemble the bearing lining and the reverse gear lining from the second axle by using hydraulic press machine. Note: The cylindrical roller may be fallen during the process of disassembly. Do not miss the cylindrical roller. What’s more, the ball bearing cannot disassembled simultaneously together with the above-mentioned washers and linings. ⑥ Disassemble the cylindrical roller and the (central) bearing from the second axle. ⑦ Disassemble the first gear, needle bearing and synchronizer ring from the second axle. ⑧ Disassemble the first gear lining, the commutating ring, ring, the second gear and the second gear bearing by using the hydraulic press machine.

2) Disassemble the countershaft

① Disassemble the countershaft connected with gear.

② Disassemble the countershaft rear bearing. ③ Disassemble the countershaft reverse driven gear.

3) Disassemble gear shifting fork and axle Please refer to five gear type for disassembly method.

5. Inspect the components Please refer to five gear type for the corresponding method.

6. Important steps for installation Note:

• Each part must be cleaned and the specified gear oil must be coated on the sliding surface of the bearing and gear before installation.

• During reassembly, a new collar ring must be used instead of an old one.

• Tighten each bolt and nut by using the specified tightening torque list in the next part of the section.

1) The second axle and the first axle Assemble according to the reverse order of disassembly. Pay attention to the installation direction of each washer, gear, commutating ring and outer ring. The cylindrical roller must be attached to the second axle. ① Attach the second gear bearing, the second gear, the synchronizer ring, the commutating ring/ outer ring to the second axle. Pay attention to the installation order during operation. After placed on each synchronizer, the three splines of the commutating ring have to be inserted into the grooves of each ring in order. Then use the hydraulic press machine to install the first gear lining. ② Install the first gear needle bearing, spring collar ring, synchronizer ring, the first gear, cylindrical roller and thrust washer to the second axle. Insert the cylindrical roller into the hole of the axle and install the thrust washer to make its groove locate above the cylindrical roller. To ensure the correct order of the thrust washer, the fillet of the encircle must face to the central bearing of the second axle.

③ Install the central axle, pay attention to the installation order. ④ Install the cylindrical roller and thrust washer. The fillet of the

encircle must face to the central bearing of he second axle and the groove must be located above the cylindrical roller during operation.

Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series

⑤ Press the reverse gear lining. Prevent the cylindrical rollers installed based on the step ④ fall out during operation. ⑥ Install the reverse gear bearing, the reverse gear and the reverse gear commutating ring/outer ring. To ensure the correct installation order, the lower diameter and longer cam side must face the transmission rear side during installing the commutating ring. ⑦ Insert the collar ring of the reverse gear into the groove of the second gear. ⑧ Install the third gear bearing, the third gear, the third and fourth gear synchronizer ring and the commutating ring/outer ring. The cam side of higher outer diameter shall face the third gear side. Insert the collar ring into the groove of the second axle.

⑨ Install the odometer worm shaft to the second axle. ⑩ Install the synchronizer ring, the needle bearing and the first axle.

② Insert the front collar ring of the countershaft into the groove. ③ Install the countershaft reverse gear and the fifth gear to the

countershaft. Then insert the rear bearing of the countershaft to the axle. ④ Install the reverse gear countershaft and the shield ring to the reverse gear axle and then install the pin.

3) Gear shifting fork, axle and fork pin Please refer five gear type for the corresponding installation method.

② The two matching surfaces of the upper and lower cover body must be clean. ③ Check whether the thrust washer has been installed in the grooves of the front bearing and middle bearing of the second axle.

④ Install the first axle and the second axle to the lower cover body. ⑤ Sealant shall be coated evenly on the matching surface of the lower

cover body. ⑥ Insert the three gear shifting fork into the three grooves of the outer rings of the second axle respectively and install the upper cover body to the lower cover body. ⑦ Screw the cover body bolt to the specified torque 18-28N·m.

5) The rear case cover Please refer to five gear type for the corresponding installation method.

6) Front cover of the first axle Please refer to five gear type for the corresponding installation method.

7) Clutch release bearing Please refer to five gear type for the corresponding installation method.

7. Maintenance and service Gear oil Note: Sealant shall be coated on the screwed part of the infusing bolt and draining bolt. Tighten the two bolts to the specified torque 36-54N·m. Check whether there exists the condition of oil leakage before replacing gear oil. If occurs, it must be immediately repaired. Oil capacity of the transmission: 1.0L, type: 85W/90 (GB13985-1992) GL-5 (or GL-4) gear oil or NO.18 hyperbolic curve gear oil. Note: The existence of oil leakage shall be checked no matter when lift the automobile or make maintenance even if gear oil does not need to be replaced.

8. Tightening torque specification Please refer to five gear type.

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Section 3 Driving Axle

I. Introduction

The driving axle in the vehicle is single section, open type and

coreless dual universal joints structure. The front end is connected to

the transmission output through driving axle splines, the rear end is

connected to the real axle cardinal tooth flange through universal joint

flange.

The spider of each universal joint is tightly matched with four needle

bearings and oil seal.

Chapter III. Chassis

To the transmission

output shaft

Driving axle splines yoke

Universal joint

Driving axle

Fig.3.3-1 Driving Axle

To the rear axle

cardinal t ooth flange

Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series

II. Disassembly

1. Lift the vehicle.

2. Disassemble the driving axle bolt and nut.

3. Pull the driving axle. If the vehicle is lifted horizontally, and the oil height of the transmission oil satisfies the corresponding specification, the transmission oil shall be firstly drained. Then pull the driving axle out from the rear end of the transmission, otherwise the transmission oil will flow out. C. Assembly Assemble according to the reverse order of disassembly. Note:

• Tighten the driving axle bolt and nut by applying the specified tightening torque. The tightening torque of the driving axle bolt shall be 15-25N·m.

• If the oil is drained out in order to disassemble the driving axle, new gear oil which satisfies the specified type shall be infused to the specified oil height after installation of the driving axle. D. Maintenance and service As wearing will occur if the driving axle splines yoke, spider and needle bearing are long time used, check these parts to see the existence of wearing in the case that the universal joint produces noise of “chattering”. The noise made by the universal joint at the economical driving speed is quite regular, so the existence of wearing can be easily recognized. The noise will be particularly distinct on the condition of starting and idler sliding (due to the brake function of the engine inside the power train). As the driving has experienced strict dynamic balance test, the whole driving axle assembly shall be replaced if the driving axle produces noise. Disassembly of the driving axle to replace the universal joint can be adopted in the case that special tool is at hand. However, the disassembled driving axle must be made dynamic balance test before assembled to a vehicle.

Section 4 Rear Axle

I. Introduction

The rear axle structure of the vehicle is hypoid gear single stage main

retarded, integral pressing a nd welding axle housing, semi floating half

axle.

Fig.3.4-1

1. Driving, driven bevel gear 2. Differential housing 3. Cylindrical roller bearing 4. Bearing adjuster 5. Half axle gear, planetary gear

6. Half axle gear pad 7. Planetary gear axle 8. Planetary gear pad

9. Conical roller bearing (7306E) 10. Driving gear adjusting pad

11. Wave shape elastic sleeve 12. Main retarded housing and fastener

13. Conical roller bearing (7305E) 14. Oil seal 15. Rear axle housing welding assembly

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Chapter III. Chassis

II. Disassembly

1) Release parking brake lever.

2) Lift the vehicle and disassemble the real wheel.

3) Disassemble the oil draining bolt, and drain the gear oil completely from the rear axle.

4) Pull the brake drum out by using M8 bolt.

5) Rotate the sizing spring pin and pull the sizing spring out from the brake shoe.

6) Disassemble the parking brake cross bracing wire from the parking brake draw arm and disassemble the brake shoe.

7) Disassemble the split washer and disassemble the parking brake cross bracing line from the brake bottom board.

8) Disassemble the brake pipe from the brake cylinder. Protect the pipe by using bleeding screw to prevent brake fluid from flowing out.

9) Disassemble the brake bottom board nut from the axle housing flange.

10) Pull the half axle with brake bottom board out by using special tool.

11) Pull the half axle out.

12) Grind the two corresponding parts of the thrust washer to a quite thin extent by using the grinding wheel to disassemble the driving axle bolt. III. Disassembly

1) Fix the driving conical gear flange to not rotate, and disassemble the lock bolt on it.

2) Mark on the upper cover of two bearing saddles respectively (the upper cover is divided into the right and the left) in order that they can be clearly distinguished during reassembly.

3) Disassembly the upper cover of the right and left side bearing saddles after releasing the bolt used to tighten locking plate and bearing cover blot, and lift the differential assembly from the main retarder housing.

4) Pull the right side bearing from the differential housing by using special tool.

5) Disassemble the bolts of the fastened driven conical gear and the differential housing, and take down the driven conical gear.

6) Pull the planetary gear and the planetary gear shaft after disassembling the elastic cylindrical pin.

7) Pull the left side bearing of the differential by using special tool and take down the half axle gear and half axle gear pad. IV. Maintenance and service

1. Half axle gear clearance Compare the measured clearance with the clearance indicated in the following table. Increase or decrease the pad height to adjust the clearance based on particular need.

Half axle gear clearance 0.1-0.2mm

Pad height series 0.9, 1.0, 1.1, 2mm Note: If the half axle gear clearance of the differential is not easily measured (by applying fuse piece), measure the axial clearance of the half axial gear. If the maximum value is 0.37, it shows the clearance is qualified.

2. Determine the height of driving gear adjusting pad The number of adjusting pad used on driving conical gear depends on different vehicle. The number of adjusting pad needed on each vehicle must be determined during reassembly in order to located the driving conical gear on the correct position (when the driving conical gear and driven conical gear meshes, suitable clearance can be obtained). Calculate the height of driven conical gear adjusting pad (refer to Fig.3.4-2). The adjusting pad between the inner side surface of the driving conical gear rear bearing (30306/P06) and driving conical gear can be calculated according the following formula.

Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series

computation expression: H=C-A-B A=85+δ in the formula: C means the actual assembly distance of master retarder housing A means the actual assembly distance of driving conical gear B means the actual assembly distance of driven conical gear rear bearing (30306/P06)

means the difference value between the best actual assembly distance of the driving conical and the theoretical assembly distance H can only be progressed, not being able to deleted, and the integral times of 0.05 shall be selected.

Fig.3.4-2 Five kinds of height for adjusting pad are selectable. Select the suitable pad size and combine them to make their total height reach the wanted height as possible. The adjusting pad size for driving conical gear is: 0.05, 0.10, 0.30,

0.50, 1.00, unit is mm

3. Adjust the pretension of the driving conical gear bearing Adjust the pretension of the driving conical gear bearing according to the following steps:

Firstly, press the outer ring of driving conical gear rear bearing and

driving conical gear front bearing respectively. Then install the deter mined adjusting pad of driving conical gear to the driving conical gear and install the inner ring of the rear bearing coated with hyperbolic curve gear oil into the main retarder housing together with driving conical gear. Install the adjusting pad of wave shaped driving conical gear along the driving gear axle, and then press the front bearing inner ring coated with hyperbolic curve gear oil. Finally press the driving gear flange and tighten the locking nut by applying 190N·m tightening torque. Do not install the oil seal. The tightening torque used to rotate the driving conical gear is 0.3-0.7N·m (excludes the friction torque of oil seal). The bearing must be lubricated when measures the pretension of the bearing and the driving conical gear must be rotated 5 rounds continuously along the same direction. Note: The wave shaped elastic sleeve will be pressed when rotates the driving conical gear locking nut to adjust the pretension of driving gear bearing. Therefore, a new wave shaped elastic sleeve must be used during adjustment.

4. Adjust the pretension of the differential Install dial indicator to the flange end of the main retarder, and make the retarder contactor tip to the left side bearing cover end. Release the right side (driving conical gear side) adjuster for one round and then tighten it until the contactor of the dial indicator begins to start. Then rotate the adjuster for one or two grooves, the pretension load of the differential is

0.3-0.7 N·m.

5. Examine and adjust the flank clearance of the driving and driven conical gear Examine the driving and driven conical gear clearance by using method indicated on Fig.3.4-3. Pay attention to apply the regular method to install the differential assembly, and screw the bearing cover nut to 10-20N·m. Align the dial indicator spindle to the “root” of the driving conical gear driving side (two flange sides), fix the driving conical gear tightly and rotate the gear back and forth. The reading number of the dial indicator is the clearance value, and the flank clearance value range shall be 0.1-0.2mm.

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Fig.3.4-3 Rotate the left and right side adjuster and change the axial position of the driven conical gear and thus adjust the flank clearance of the driving and driven conical gear. The back and forth of the left side and right side adjusters must be equal in order to not alter the adjusted bearing pretension. Measure the flank clearance on the position of about trisection of the driven conical gear, the value shall be in the range of 0.1-0.2mm and clearance variation shall not exceed 0.08mm.

6. Examine and adjust the tooth fla nk contact mark graph of the driving and driven conical gear The driving and driven conical gear mesh shall have suitable clearance, and fine tooth flank contact condition as well to avoid “gear noise” and prevent the standard double side gear tooth flank from enduring excessive pressure during the process of driving. The following method shall be used to examine the contact condition between driving conical gear and driven conical gear after obtaining the specified clearance effect: coat leaded ointment on the positive driving tooth flank and negative driving tooth flank of the gear, then hold the driving conical gear to make it “brake and stop” by one hand and rotate the driven conical gear back and forth by the other hand. Examine the tooth flank contact by referring to the following graphs after obtaining the mark graph. (Fig.3.4-4)

Chapter III. Chassis

Mesh mark of driving and driven conical gear and clearance adjustment

Mesh mark of driving and driven conical gear

Convex side (positive driving)

Concave side (negative driving)

Move the driven

Adjustment method

conical gear to the driving conical gear, take the driving conical gear away if the clearance is too small

Move the driven

conical away from the driving conical gear, and move the driving conical gear nearer if the clearance is too much

Move the driving

conical gear to the driven conical gear, take the driven conical gear away if the clearance is too small

Move the driving

conical away from the driven conical gear, and move the driven conical gear nearer if the clearance is too much

Correct graph

About right oriented on the central position

Fig.3.4-4

Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series

7. Tighten the differential bearing cover bolt by applying the tightening torque of 50-60N·m after adjusting the gear meshing mark. Install the adjuster locking piece and take down the driving gear conical gear flange. Lubricating grease shall be evenly coated between the mouth and assistant mouth of driving conical gear oil. Sealant shall be coated on the oil seal outer diameter and then press the oil seal into the main retarder housing. Install the driving gear flange and tighten the nut by applying the tightening torque of 120-190N·m, and lock the nut by sing rivet as well. V. Assembly Assemble according to the reverse order of disassembly. Pay attention to the following points. Note:

· The driving conical gear and the driven conical gear must be replaced in pair.

· Tightening torque

Items N·m Differential bearing cover bolt 50-65 Driven conical gear and differential housing bolt 65-80 Driving conical gear nut 120-190 Oil draining bolt 40-70

· Driven conical gear bolt Bolt tightened from the driven conical gear to the differential housing will be experienced cutting force when transmitting torque. Therefore these bolts are specially manufactured bolts and cannot be substituted by common bolts. The bolts must be coated with thread locking grease when installs the driven conical gear to the main retarder housing and then tighten them.

· Driving conical gear bearing Install the two conical roller bearings to the driving conical gear by using the forcing machine only cooperating with special tool. Press the outer ring into the main retarder housing, while press the inner ring into the driving conical gear.

· Differential end bearing

Install the bearings into the differential housing by applying special tool. Do not apply tapping method to install the bearings. VI. Assembly Assemble according to the reverse order of disassembly.

1. Assemble the half axle assembly

1) Install the left or right brakes, bearing isolation washer, bearing with dust proof cover (6027-Z/P6) to the half axle in order. Then press the bearing on the forcing machine. Press the bearing isolation washer to neighbor the shaft shoulder and the bearing can run freely.

2) The inner hole incline face of the bearing isolation washer shall be installed to the direction of half axle convex shoulder.

3) The dust proof cover shall be towards the half axle convex shoulder when installs the bearing. And the cover shall be installed evenly on the position of inner ring.

4) The NO.2 lithium based lubricating grease shall coated on the bearing with dust proof bearing (6027-Z/P6). No foreign matters shall be affixed to or entered in.

5) Put the new bearing thrust washer in the pot arch and warm it to 100-150℃ and install it to the half axle after keeping 10-15 minutes. Press it to the bearing by applying the forcing machine, the contact part shall be coated with lubricating oil before pressing.

6) The thrust washer shall not have the axial and radial looseness action after pressing. Note: Protect the outer surface of the thrust washer to avoid damages.

7) Water proof sealant shall be coated on the joint point between the rear axle and brake bottom board.

8) Install the half axle into the rear axle housing and screw the nuts used to tighten the brake bottom board to the specified tightening torque 18-28N·m.

9) Disassemble the deflation screw protecting cap from the pipe end and connect the brake pipe to the brake cylinder and then screw the pipe joint to the specified tightening torque 14-28N·m.

10) Water proof sealant shall be coated on the contact surface between brake bottom board and parking brake cross bracing wire, then thread the parking brake cross bracing wire into the brake bottom board and tighten it by using split washer.

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

11) Connect the parking brake pulling arm to the parking brake cross

bracing wire and install the brake shoe on it.

12) In order to maximize the clearance between parking brake shoe

and parking brake drum, put the screw into the self adjusting meshing

position of brake clearance and push the gear segment according to

the method indicated below before installing the brake drum

(Fig.3.4-5).

1. Self adjusting shoe clearance pus

pedal

2. Quadrant

Fig.3.4-5

Chapter III. Chassis

2. Assemble the rear axle housing assembly

1) The rear axle housing assembly must be cleaned and no foreign matter enters it before assembly.

2) Put the oil baffle disc oil retaining disk of half axle oil seal into the welding assembly. Press the rear assembly welding assembly in after the hyperbolic curve gear oil is coated on the half axle oil mouth and assistance. If there exists any mark of leakage or the oil seal is taken down, a new oil seal must be used before reassembly.

3) The spring side shall face the differential when pressing the oil seal. Put in the oil seal metal framework and evenly press in. The oil seal shall not be inclined and the sealant shall be coated on the outer diameter matching position. No remaining grease shall be left on the non matching position. Press the half axle and oil baffle disc oil retaining disk of half axle. No clearance and release shall be allowed.

3. Assemble the main retarder assembly

1) Assemble the rear assembly to the assembly fixture.

2) Plane sealant shall be coated on the flange or rear axle housing of the main retarder assembly (no remaining grease shall be left on the non matching position) and install the main retarder assembly to the rear axle housing assembly. Screw thread locking sealant shall be coated on the eight combined bolts CQ1420825 and tighten it by applying the tightening torque of 15-33N·m.

3) Install the left and right half axle assembly into the left and right side of the rear axle assembly. Install the bolt and washer through the position of half axle facing the master spline and the bolt hole position of the axle housing flange, the tightening torque shall be 18-28N·m.

4) Rear axle assembly gear oil Type:80W/90W or 85W/90(GB13895) Oil capacity: 1.3L

Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Assembly data of rear axle Tightening torque unit: N·m

Items Specification Standard value

Pretension load of driving conical gear bearing (excludes oil seal resistance moment) 30305/P6 30306/P6 0.3-0.7

Pretension load of differential bearing 6027-Z/P6 0.3-0.7

Flank tooth clearance of driving and driven conical gear 0.1-0.2mm

Hyperbolic curve gear oil capacity of rear axle 1.3L Tightening torque of driving conical gear locking bolt M18×1.5 120-190 Tightening torque of driven conical gear and differential housing tighten bolt M10×1.25 65-80 Tightening torque of differential bearing cover bolt M10×1.25 50-65

Tightening torque of adjuster lock piece tighten bolt M8 15-20

Tightening torque of tighten main retarder assembly and axle housing bolt M8 15-23

Tightening torque of tighten brake bottom board used bolt M8 18-28 Oil infusing bolt M20×1.5 35-50 Oil draining bolt M12×1.25 40-70

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Section 5 Suspension System

I. Introduction

Front suspension: slide column oscillating arm type independent

suspension, coil spring and being installed with antis-way bar.

Bilateral hydraulic solid bowl type retarder. Please refer to Fig.3.5-1.

Rear suspension: lengthwise sub elliptical leaf spring, the rear end is

the swinging ring structure. Bilateral hydraulic solid bowl type

retarder. Please refer to Fig.3.5-2.

Fig.3.5-1 Front suspension system

Chapter III. Chassis

Fig.3.5-2 Rear suspension system

Note:

· The fasteners of all suspension system are quite essential and can

effect the performance of the main components and the system. The

fasteners of the same or equal design code must be used when replacing

the fasteners. Screw the fastener to the specified torque value when

replacing the fasteners.

· The suspension system components can only be replaced, and cannot

be heated and straightened by quenching.

II. Front suspension system

1. Stabilizing pull rod

Disassembly

(1) Support the vehicle and disassemble the wheels.

(2) Disassemble the front nut of stabilizing pull rod.

Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series

(3) Disassemble the rear nut of stabilizing pull rod. (4) Disassemble the stabilizing pull rod. Examination (1) Replace the stabilizing pull rod if there exists damage or deformation on it. (2) Replace the cushion pad if there exists damage, wearing or deterioration on it. Assembly: Assemble according to the reverse order from (1) to (4) of disassembly. Pay attention to that the large end of the two cushion pad face to each other and shall not be reversibly attached. Screw the nut to the specified torque. As is indicated in Fig.3.5-3.

70-90N·m

30-50N·m

Fig.3.5-3

2. Front cushion pad and coil spring Disassembly:: (1) Support the vehicle and disassemble the wheels. (2) Disassemble the oil pipe clamp card used to fix the front brake hose and disassemble the front brake hose from the oil pipe support bracket of the retarder.

(3) Release the nut of the retarder piston rod upper end to facilitate the

next disassembly work to the retarder and coil springs. (4) Disassemble the binding bolt and sizing bolt of the front retarder and the steering knuckle. Note: Safety board shall be put under the cantilever to avoid the cantilever fall onto the front brake hose. Otherwise, the hose will be damaged. (5) Disassemble the fixing nut on the upper support point and fender flap. Hold the front retarder to avoid its fall. (6) Disassemble the retarder and coil springs. If it is difficult to disassemble the front retarder from the steering knuckle, the screw or equivalent tool can be used to larger the clearance the of steering knuckle to facilitate the disassembly of the front retarder. Disassembly (1) Press the coil spring by applying special tool. (2) Keep the coil spring on the pressed condition. Fig.3.5-4 Disassemble the piston rod nut and then breakdown the components. Assembly: please refer to Fig.3.5-4 (1) Press the coil spring by applying special tool.

1. Piston Rod Nut 2. Coil Spring Washer 3. Plain Washer 4. The Upper Support Point Lining

5. The Upper Support Point Bottom Board 6. The Upper Support Point Rubber Filler Block 7. Passive Pad 8. Rubber Pad 9. Active Pad 10. Spring Upper Ba se 11. Piston Rod Protective Cover 12. Piston Rod Cushion Cover 13. Spring Coil 14. The Front Retarder

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Chapter III. Chassis

(2) Put the coil spring on the spring bottom base of the retarder and match its end and the ladder part of the spring bottom base. (3) Install the piston rod cushion cover to the piston rod. Pay attention to its direction and do not reverse install it. (4) Pull the piston rod upward as possible, and keep it in its longest position. (5) Match the upper end of the spring a nd the ladder part of the protective cover when installs the piston rod protective cover. And then install the spring upper base to the protective cover in the same way. (6) Lithium base lubricating oil used on vehicle shall be coated on the active pad after cleaning it. Install it to the spring upper base. Pay attention to the direction. (7) Lithium base lubricating oil shall be coated on all the surface of the rubber pad and install it along the outer ring of the active pad. (8) Clean the passive pad and install it by applying the method indicated in the Fig. (9) Install the upper support point rubber filler block, upper support point bottom board and upper support lining on the passive pad in order. Pay attention to the direction. Screw the piston rod nut to the specified torque, and water resistant coating (oil paint type) around the nut and piston rod threw thread. Note: Ensure the upper support point rubber filler block has been correctly installed on the upper support bottom board. Installation shall be precise. (10) Release the special tool, and reexamine the ladder part of the spring base and spring end to see whether they are matched the same as the above mentioned steps from (2) to (5). Assembly: Please refer to Fig.3.5-5. (1) Insert the retarder into the steering knuckle. (2) Align the hole of the retarder support structure with the bolt hole of the steering knuckle, and install the sizing bolt. (3) After aligning the concave hole of the retarder lower end with the bolt hole of the steering knuckle, thread the steering knuckle bolt in along the direction of the front and rear of the vehicle. Then install the washer and nut.

40-60N·m

Fig.3.5-5

(4) Install the retarder to the body and screw the nut to the specified toque: 20-30N·m. (5) Screw the sizing bolt of the steering knuckle and steering knuckle nut to the specified torque respectively. Please refer to Fig.3.5-6 (6) Install the brake hose. Do not torsion the hose. The oil pipe clamp card shall be correctly installed. 25-35N·m

30-50N·m 40-70N·m

Length of bolt out part: 3-5mm 30-55N·m

Fig.3.5-6

Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Nut

3. Cantilever

Disassembly

(1) Support the vehicle and disassemble the wheels.

(2) Disassemble the antisway bar nut, washer and lining from the

cantilever.

(3) Disassemble the stabilizing pull rod rear end nut from the

cantilever.

(4) Disassemble the cotter pin of oversize ball pin and hexagon slotted

nut.

(5) Disassemble the bolt, nut and washer connected with cantilever

and middle arm.

(6) Disassemble the oversize ball pin from the steering knuckle

together with cantilever. Pay attention to protect the screw thread of

the oversize ball pin.

(7) Disassemble the cantilever.

(8) Press the cantilever lining out by applying special tool and

hydraulic machine.

Examination

(1) Examine whether there exists crack, deformation and damage.

(2) Examine whether the rotating and swinging process of the

oversize ball pin is in balance.

(3) Install the antis-way bar to the cantilever by applying cushion pad, washer, bolt and nut. Screw the nut to the extent

Fron

which can be done by hand. Please refer to Fig.3.5-8.

30-50N·m

(4) Install the stabilizing pull rod to the cantilever, and screw the nut to the extent which can be done by hand. (5) Install the ball pin to the steering knuckle. (6) Screw all the screws and nuts to the specified

Fig. 3.5-7

Suspension arm

torque. Please refer to Fig.3.5-6. (7) Install the cotter pin to the ball pin and castellated nut, the oil paint shall be coated to avoid rust.

Length Of Bolt Out Part 3-5mm

1. Middle Arm 2. Antis-way Bar 3. Bolt 4. Cantilever 5. Track Rod Lever 6. Cushion Cover I

7. Cushi on Cove r II 8. Washer 9. Hexagon Nylon Ring Locking Nut

Fig.3.5-8

Body Center

The Part Of Painted Yellow

Suspension

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Chapter III. Chassis

4. Antis-way bar Disassembly (1) Support the vehicle and hang up the front suspension. (2) Disassemble the left and right wheels. (3) Disassemble the antis-way bar. Examination: Examine whether there exist damage or deformation on the antis-way bar and cushion cover. And replace it based on particular condition. Assembly: Please refer to Fig.3.5-8 (1) The part which is painted yellow shall be aligned with the left lining when installs the antis-way bar. (2) Screw the bolt and nut to the specified torque. C. Rear suspension system

1. Retarder Disassembly (1) Disassemble the nut of the bottom board pin. (2) Disassemble the upper end nut, and disassemble the retarder. Assembly (1) Install the retarder by referring to Fig.3.5-9. (2) Tighten the nut.

2. Leaf spring (Refer to Fig.3.5-10) Disassembly (1) Support the vehicle and disassemble the rear wheels. Hold the rear axle housing by using a safety stand. (2) Disassemble the rear wheels and pull the parking brake cross bracing wire out from fixing adhesive tape. (3) Disassemble the U bolt nut. (4) Disassemble the steel plate pin nut and spring eye bolt nut.

(5) Pull the spring eye bolt out and disassemble the leaf spring form the steel plate pin. Assembly Assemble according to the reverse order of disassembly. Note:

· Suds shall be sprayed on the lifting eye lining to facilitate to press the lining. No oil shall be on the lining.

· Install the steel plate pin from the vehicle center to the outer side.

· Align the central bolt and nut of the leaf spring with holes of U bolt

bottom board, and screw the U bolt to the specified torque.

· Screw the steel plate pin nut and spring eye nut to the specified torque on the free load condition. The tightening torque for steel plate pin nut is 30-55N·m.

· Fix the parking brake cross bracing wire by using fixing adhesive tape.

· Install the rear wheels and tighten it to the specified torque.

20-30N·m

13-20N·m

Fig.3.5-9

1. Spring Washer 2. Nut 3. P lain Washer 4. Rubber Lining 5. Rear Retarder

6. Plain Washer 7. Spring Washer 8. Nut

Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Front

40-70N·m

When pres sing spring- eye bush into leaf spring , make narro w notch side fo r ward

Front

Ups id e

otch (narrow)

Body cente

Leaf spri ng front bus h

Leaf sprin

Spring upper chair

Notch (w ide)

Rear

25-35N·m

Center bolt and nut

Spring uppe

chair

Leaf spring

The side must be aligned for each leaf spring

Rear

Screw down 4 U nt s evenly to make B height of 4

bolts and nut s equal

Fig. 3.5-10

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Section 6 Steering System

I. Introduction

Steering system consists of rack and pinion system and corresponding

steering echelon for m assembly. Rack and pinion is composed of gear

shaft, pinion and the housings which enclose the two above

mentioned components. Gear shaft support is on the deep groove ball

bearing without inner ring and needle bearing in the housing. The end

of the pinion is on the housing end lining and the other end is on the

adjusting bolt with pressure spring. The gear shaft is inclined installed on the pinion and the setting angle is 2º54″ and directly meshes

with the pinion. When the steering wheel is rotated, the gear shaft is

therefore rotated, and the pinion slide along the determined axis by

the bearing lining. Transmission mechanism is lateral shift input, one

pinion end outputs through longitudinal pull rod and is transmitted to

the steering knuckle of the steering wheel through steering cross pull

rod.

The major components in the steering system are as indicated in

Fig.3.6-1.

Chapter III. Chassis

Front end

Rack and

pinion axle

Fig.3.6-1 Steering system

1. Steering gear assembly 2. Gear oil 3. Dust proof cover

4. Steering longitudinal pull rod 5. Main steering arm 6 7. Steering

cross pull rod assembly 8. Left steering knuckle

9. Right steering knuckle

Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Please refer to Fig.3.6-2 to see the steering gear assembly.

Fig.3.6-2 Steering Gear Assembly

1. Steering gear assembly 2. Steering gear housing assembly and lining assembly 3. Gear shaft

assembly 4. Elastic collar used for holes 5. Collar ring 6. Steering gear oil seal assembly 7.

Plunger assembly 8. Pressure spring 9. Locking nut 10. Adjusti ng nut 11. Dust pro of cover

12. Pinion 13. Dust pro of cove r I 14. Du st proof cover II 15. Steel wire locking thread 16.

17. Steel wire type elastic collar 18. Boom assembly 19. Hexagon flange side nut 20. Limit

collar ring 21. Limit seat ring 22. Elastic collar ring for axle 23. Hexagon bolt

II. Disassembly

1. Steering wheel

1) Disassemble the negative wiring of the battery.

2) Disassemble the steering wheel horn cover.

3) Disassemble the steering shaft nut.

4) Steering wheel and steering column shall be marked to facilitate to be located during reassembly.

5) Disassemble the steering wheel.

2. Unit switch

1) Disassemble the upper cover of the unit switch after disassembling the steering wheel.

2) Disassemble the leading wire and clip from the universal joint.

3) Disassemble the unit switch assembly form the steering bearing frame.

3. Steering Bearing Frame

1) Disassemble the upper side bolt of the universal joint boom after disassembling the steering wheel and unit switch.

2) Disassemble the four assembling bolts on the steering bearing fixing frame.

3) Disassemble the steering bearing frame with steering shaft assembly. If there exists damage on any component of the steering bearing frame (with steering shaft), the component must be replaced. Lubricating grease must be coated on the inner side of rubber bearing and the part between rubber bearing and pad before installing the steering shaft to the steering bearing frame. Tight the elastic collar ring for axle in the ring groove of the steering shaft.

4. Universal joint of steering shaft

1) Disassemble the protective cover of the universal joint of steering shaft and universal joint bolt of the steering shaft.

2) Adjust the front wheel to make it face direct front direction.

3) Disassemble the universal joint of steering shaft.

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Chapter III. Chassis

5. Steering cross pull rod

1) Support the vehicle and disassemble the wheels.

2) Disassemble the cotter pin and steering cross pull rod groove type nut from the steering knuckle. Disassemble the steering cross pull rod ball pin assembly.

3) Mark the position of steering cross pull rod locking nut on the corresponding position of ball pin assembly screw to facilitate to assembly and adjust.

6. Steering gear

1) Disassemble the cotter pin of the steering longitudinal, groove type nut and pin axle after disassembling the wheels.

Fig.3.6-3

1. Steering cross pull rod 2. Mark on the point 3. Steering cross

pull rod end locking nut 4. Steering cross pull rod ball pin assembly

2) Disassemble the joint bolt between the steering shaft connector and gear shaft axle part.

3) Disassemble the binding bolt of the steering gear and disassemble the steering gear.

4) Disassemble the steel wire type elastic color ring of the steering gear tow ends and steel wire locking wire, and disassemble the dust proof cover.

5) Disassemble the elastic shield ring for axles on the pinion and limit shield ring. Disassemble the plunger assembly.

6) Disassemble the gear shaft dust proof cover, oil seal, elastic shield ring for holes and collar ring.

7) Disassemble the gear shaft assembly from the steering gear assembly, and disassemble the gear shaft.

8) Disassemble the pinion from the steering gear housing.

9) Pull the needle bearing which only has pressing outer ring out from the steering housing by applying special tool. III. Assemble the steering gear

1) All the components which will be reassembled must be cleaned.

2) Lubricating grease shall be coated on the needle bearing which only has pressing outer ring.

3) Press the needle bearing in the matching position of the steering housing by applying special tool. Ensure the correct assembly of needle bearing.

4) Lubricating grease shall be coated on the housing lining and all the tooth face of the pinion.

5) Slide the pinion into the steering gear housing.

6) Lubricating grease shall be coated on the gear shaft, gear shaft needle bearing and housing oil seal mouth etc.

7) Assemble the gear shaft assembly.

8) Set the collar ring into the ring groove of the steering gear housing tightly, and install the elastic shield ring for holes. The outstanding part “A” shall face the open part of the elastic shield ring and install the oil seal (new oil seal must be used). Please refer to Fig.3.6-4.

Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series

9) Lubricating grease shall be slightly coated on the sliding part which the plunger against the pinion, sealant shall be coated on the adjusting bolt. Then screw the locking nut to its maximum value and rotate it 0-90º and examine the rotating torque of the gear shaft and the smoothness of the whole action of the pinion as well.

Rotating torque of gear shaft 0.5-1.5N·m

10) Screw the locking nut to the specified torque after adjustment. Please refer to Fig.3.6-5.

11) Install the collar ring and elastic shield ring. Set the elastic shield ring in the ring groove of the pinion tightly.

12) Align the dust proof cover with the steering gear housing and convex groove of the steering pinion and locate the position. Tighten them with steel wire locking thread and steel wire type elastic collar ring. Check the dust proof cover to ensure no torsion and hollow after tightening.

13) Install the pinion boom and screw the nut to its specified torque. Please refer to Fig.3.6-6. Install the pinion frame, parallel the surface “A” of the steering gear housing with surface “B” of the boom.

Elastic shield ring for holes

Collar ring

Fig.3.6-4

Fig.3.6-5

40-60N·m

Fig.3.6-6

40-60N·m

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

IV. Assembly

1. Steering gear assembly

1) Set the front wheels (left and right) at the right front driving position.

2) Rotate the gear shaft to adjust the length of the pinion to reach the indicated value in Fig.3.6-7, set the steering pinion at the straight driving position.

Fig.3.6-7

153mm

40-60N·m

1.Steering gear assembly

2.Steering gear assem

ling

Fig.3.6-8

3) Then insert the steering gear shaft into the splined groove of the steering gear shaft connector.

4) Fix the steering gear assembly on the body framework and screw the steering gear assembling bots to the specified torque. Please refer to Fig.3.6-8.

Chapter III. Chassis

Fig.3.6-9

Fig.3.6-10

Fig. 3.6-10

50-80N·m

40-60N·m

Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series

5) Connect the steering longitudinal pull rod to the steering boom and screw the groove type nut within specified torque range. Please refer to Fig.3.6-9.

6) Screw the gear shaft connector bolt to the specified torque. Please refer to Fig.3.6-10.

7) Install the upper wheels and screw the wheel nuts to the specified toque 50-80N·m.

8) Lay down the supported vehicle.

9) Examine the front wiring of wheels and replace them based on particular condition.

2. Steering cross pull rod

1) Install the locking nut of the steering cross pull rod end and steering cross rod ball pin base to the steering cross pull rod. Align the locking nut with the mark on the screw.

2) Connect the steering cross pull rod to the steering knuckle. Screw the groove type nut to the specified torque range. Please refer to Fig.

3.6-11.

3) Bend the cotter pin.

4) Examine the front wiring of wheels. Screw the locking nut of steering cross pull rod to the specified torque after determination of the front wiring of wheels.

5) Screw the wheel nut to the specified torque and lay down the lifted vehicle. Note: Ensure the axes of the steering small ball pin are in the same plain when screws the locking nut of the steering cross pull rod end. No torsion shall be allowed. Please refer to Fig.3.6-12.

3. Steering bearing frame assembly

1) Align the non splined part “A” on the steering gear shaft (upper) with the bolt hole “B” on the universal joint boom, and insert the steering gear shaft (upper) into the universal joint boom.

2) Install the steering gear shaft (lower) to the universal joint boom on

the precondition of ensuring the straight driving of front wheels and

steering wheel.

30-55N·

Fig.3.6-11

Without angle

Fig.3.6-12

50-70N·m

With torsion angle

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Chapter III. Chassis

14-17

·m

1.Steering gear shaft (lower)

2. Universal joint boom

Fig.3.6-13

1. Steady rest (I) for steering gear shaft frame

2. Steering bearing frame assembly

(with ge ar shaft)

Fig.3.6-14

3) Fix the steering bearing frame, and screw the bolt to the specified

torque. Please refer to Fig.3.6-14.

Note: The nut on the universal joint boom must be tightened after

tightening the gear shaft frame fixing bolt.

4) Install the dust proof cover.

5) Install the unit switch.

6) Connect the leading wire form the unit switch and ignition switch

on the universal joint. Connect the negative wiring on the battery.

7) Install the steering wheel. Screw the steering wheel nut to the specified torque 25-40N·m.

8) Install the steering wheel horn cover. V Maintenance and service

1. Examine the steering bearing frame assembly to avoid accidental damage.

1) Examine the smoothness of the steering gear shaft rotation. If any poor condition occurs, replace the gear shaft.

2) Examine the steering bearing frame assembly and steering gear shaft to see whether there exists bending, cracking or deformation. If any poor condition occurs, replace it.

2. Steering gear shaft assembly

1) Examine whether there exists wearing or damage on the gear shaft tooth surface.

2) Examine whether there exists damage on the oil seal.

3) Examine the rotation performance of the bearing, and to see whether there exists wearing. Replace the damaged components.

3. Steering pinion Examine whether there exists flexure on the pinion, wearing or damage on the tooth surface and wearing or damage on the back of the tooth surface. If the deflection exceeds the specified value, replace the pinion. Steel wire brush shall not be used when cleans pinion.

Pinion flexibility limiting value 0.15mm

4. Steering gear housing lining Examine whether there exists wearing or damage on the pinion lining. If any poor condition occurs, replace it.

5. Steering gear shaft plunger Examine whether there exist wearing or damage on it and whether there exists deformation on the pressure springs. If any poor condition occurs, replace it.

6. Steering gear shaft and universal joint assembly Examine whether exists cracks, breakage, deformation, failure or excessive clearance on the steering gear shaft and universal joint assembly. If any poor condition occurs, replace it.

Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series

7. Steering gear dust proof cover Note: Each time to make regular maintenance and service or lift the vehicle due to certain reason, visually examine whether there exists damage or breakage on the dust proof cover.

1) Lift the vehicle.

2) Examine whether there exist breakage on the dust proof cover. Dust and water will enter through the cracks to cause the wearing of steering pinion and gear shaft if there exists breakage on the dust proof cover. Accompanied by noise and rust resulting in the failure of the steering system.

3) If any breakage is found on the dust proof cover, replace a new one.

8. Steering pull rod ball pin dust proof cover Examine each dust proof cover to see whether there exists breakage on it. If any breakage is found on the dust proof cover, replace a new one.

9. Steering wheel Park the vehicle on the ground, put the front wheels straight. Check free play and release on the condition.

Free play of steering wheel (A) 0-30mm

If the free play is not within the specified range, examine based on the following steps. If any poor condition occurs, replace it.

1) Steering cross pull rod ball pin wearing (apply the force of

0.2N·m, it can swing).

2) Steering gear shaft connector wearing.

3) Steering gear shaft or pinion wearing or damage.

Maintenance data of front alignment

Bevel wheel 4-7mm Toe-in

Midnight wheel 2-5mm

Camber angle of front wheels 1o

Caster angle of king pin 5o Toe in angle of king pin 11o30

，

The localization of front wheels is related with the angle relationship between front wheels, front suspension and ground. In general, adjustment needed for front wheels localization is only the toe-in. Camber angle of wheels and angle of king pin cannot be adjusted. Therefore, when a driving vehicle is damaged resulted from accident or collision, judge shall be done to determine whether it’s body damage or suspension damage. If it is body damage, repair is needed, and if it is suspension damage, replacement is needed.

1. Settle the toe-in

Toe-in refers t o the distance difference value between the front and rear tire center of left and right tires on the position of wheel center height. The purpose of defining toe-in is to ensure the front wheel can move smoothly (excessive toe-in will result in abnormal wearing to the tires). Please refer to Fig.3.6-15.

2. Camber angle of wheels Camber angle of wheels refers to the inclined degree which fronts wheels deviate from the straight line when viewing the front axle from the front wheels. If the front wheels top inclines outward, the camber angle of wheels is positive value. If the front wheels of top incline inward, the camber angle of wheels is negative value. Please refer to Fig.3.6-16.

3. Checks shall be done to adjust the front wheels localization

4) Components assembly is not firm or connecting is not fixed. VI. Front Alignment

Wheel cente

Body center

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Checks shall be done before adjusting the front wheel localization to ensure the precision of the front wheel localization adjustment:

Front end

1) Check all the tires to see the suitableness of charged pressure and whether the wearing condition of the tire surfaces is the same.

2) Check whether there exists looseness for the steering system and suspension system. If there exists the condition of excessive looseness, modification must be done before adjustment.

3) Check the wheels and tires to see whether there exists swing and jumping.

4) The effect of the overload of toolbox etc. must be taken into consideration. If this kind of overload often occurs on the vehicle during driving, the overload must be reserved before examining wheel

B - A= Toe-in

Fig.3.6-15

r lin

localization.

5) The state of apparatus used to examine the wheel localization must be taken into consideration, and operate according to the manufacturer’s directions.

6) The lengthwise direction and longitudinal direction must be kept in the level position regardless of what kind of toe-in.

7) Examine the front wheels to ensure it keep in the straight driving position.

4. Adjust the toe-in Toe-in can be adjusted by change the length of steering cross pull rod. Release the locking nuts of the steering cross pull rod ball pin on the two

Positive camber angle

sides. Then equally rotate the left and right steering cross pull rod and adjust the toe-in to the specified value. The length of left and right cross pull rod must be the same after adjustment.

Camber angle of wheel

Fig.3.6-16

5. Adjust camber angle of wheels and caster angle of king pin Once the condition that the camber angle of wheels or caster angle of king pin does not satisfy the specified value is found out during examination, the reason causes it must be firstly determined. If it is caused by damage, looseness, bending, hollow or wearing of the suspension components, the components must be replaced. If it is caused by the body itself, it must be repaired until satisfies the demand.

Chapter III. Chassis

Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series

6. Turing angle Inner side 34

Outer side 28

o±3o

Turning angle

Check the toe-in and turning angle by applying special apparatus after replacing the steering cross pull rod, steering cross pull rod ball pin and master steering arm. The front wheels shall be ensured to be on the condition of straight driving before measuring the turning angle. If the turning angle is not correct, check whether the two sides length of steering cross pull rod is the same. Note: If the length of steering cross pull rod is changed in order to adjust the turning angle, toe-in shall be reexamined. G. Tightening Torque

Fasteners Tightening torque

(N·m)

* 1. Steering gear shaft joint bolt 20-30 * 2. Steering gear binding bolt 40-60 * 3. Steering cross pull rod ball groove type

30-55 nut * 4. Steering cross pull r od locking nut 50-70

5. Adjusting bolt 80-110

6. Steering boom locking clamp nut 50-70 * 7. Mid arm vertical shaft clamp nut 80-150 * 8. Steering gear shaft nut 25-40 * 9. Shaft connector clamp nut 15-25 * 10. Steering gear frame fixing bolt 14-17 * 11. Steering longitudinal pull rod groove

50-80

The items marked with * need to be regularly examined.

type nut (boom side) * 12 Steering longitudinal pull rod groove type nut (master steering arm side)

30-55

Fig.3.6-17

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Chapter III. Chassis

Section 7 Brake System

I. Introduction

The vehicle applies dual pipe hydraulic brake system, front wheel disc

brake, rear wheel drum brake (brake clearance is self adjustable). The

brake has brake proportional valve. The operation system has vacuum

booster. Parking brake applies to the rear wheels and transmits power

through brake pulling wire. In addition, front wheel drum brakes and

rear wheel drum brakes with manual adjusted brake clearance can be

selected to install to the brake. Please refer to Fig.3.7-1 to see the

brake type.

Front

1. Brake master cylinder 2. Five bodies

3. Parking brake pull rod 4. Parking braking

pulling wire 5. Proportional valve

Fig.3.7-1

Rear

Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series

II. Front Wheel Disc Brake (I) Disassembly

1. brake pad

1) Loosen the front wheel nut, then support the vehicle by using a lifting jack.

2) Support the vehicle on the safety board. Disassemble the hub nut, and take the front wheel down.

3) Screw (one) clamp bolt down.

4) Disassemble the clamp. Note: Do not damage the brake hose and do not press the brake pedal during disassembly.

5) Disassemble the brake pad.

2. clamp, piston, piston gasket Disassemble the piston and piston gasket according to the following steps after disassembling the wheels.

1) Clean the clamp.

2) Screw the brake hose down from the cylinder block.

3) Screw (one) clamp bolt down.

4) Blow the compressed air into the oil cylinder through the bolt hole used to connect to the hose. Press piston out of oil cylinder by means of air pressure. Note: Do not apply compressed air with too high pressure, otherwise the piston will rush out from the oil cylinder. Blow the piston out gradually by applying suitable compressed air. Do not put your fingers before the piston.

5) Disassemble the piston gasket, do not damage the oil cylinder wall.

3. As to the disassembly of the brake disc, please refer to Section Eight. (II) Examine the components

1. Brake pad Check whether there exist wearing on the liner of the brake pad. If the wearing exceeds the limit, replace the liner.

Note: Do not use sand paper to polish the liner as the hard particles on

the sand paper will be attached on the liner and damage the brake disc. Visually examine whether the lamp leaks brake fluid when disassembles the liner. If leakage exists, it shall be repaired.

Pad height Standard Limit

Liner + pad edge 15.5mm 6.5mm

2. Oil cylinder guide column (clamp pin) Check the smoothness of the guide column. If any problem occurs, it shall be repaired or replaced. Lithium base lubricating grease used on vehicle shall be suitably coated on the outside of the guide column. The viscosity of used lubricating grease shall not be greatly effected under the low temperature of -40℃.

3. Dust proof cover for liner and oil cylinder Check whether there exists cracks or damages on each dust proof cover. If any problem occurs, replace the cover.

4. Piston gasket Undue or unevenly wearing of the liner will result in the piston cannot mover smoothly. In this case, the piston gasket shall be replaced.

5. Brake disc Check whether there exists marks of wearing or scuffing on the brake disc surface. If the scuffing is not very serious, it indicates that the brake disc is in good condition. If the scuffing is quite deep, the disc shall be replaced. Check whether the brake disc height has reached the limit.

Brake disc height

Standard Limit

10mm 8.0mm As indicated in Fig.3.2-2, measure the two points on the circumference and center by using a dial gauge as rotating the brake disc edge, in this way the end jumping value the brake disc can be obtained.

End jumping limit value of brake disc 0.15mm

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Chapter III. Chassis

Fig.3.7-2

(III) Notes for assembly Reassemble the front wheel brake according to the reverse order of disassembly, pay attention to the following notes:

· Each components shall be washed and cleaned by using the brake fluid of the same type number with the fluid in the oil cylinder before assembly/

· Do not use brake fluid with other type number or other fluid.

· Brake fluid shall be coated before assembling the piston and piston

gasket into the oil cylinder.

· Discharge the air from the pipe after assembly.

1. Piston gasket Piston gasket is used to seal the clearance between the piston and oil cylinder. New piston gasket shall be replaced during each maintenance. Do not torsion the piston gasket when inserting it into the oil cylinder groove.

2. Piston and dust proof cover

1) Install the dust proof cover to the piston before insert the piston into the oil cylinder.

2) Insert the piston with dust proof cover into the oil cylinder groove by using your fingers. (Please refer to Fig.3.7-3).

Surface B shall keep equa distance to the oil cylinder A o the whole circumference

Fig.3.7-3

3) Install the piston into the oil cylinder by using your fingers, and install the dust proof cover into the dust proof cover groove of the piston.

4) Ensure the dust proof cover has been correctly inserted into the groove of the oil cylinder. Pull the piston slightly from the oil cylinder. Do not fully pull it out.

5) Finally, push the piston into the oil cylinder.

3. Clamp The (two) clamp pins shall be checked to see whether lubricating grease

has been coated on them and whether the clamp pin inserted into each clamp pin hole can move smoothly along the axle before installing the clamp (cylinder block) to the clamp bracket.

Note: Lithium base lubricating grease shall be used in the area where

temperature is lower than -30℃ in winter.

Chapter III. Chassis Operation and Service Manual on VANTAGE TruckALL & VanGO Series

2) Loosen the wheel nut, do not take it down.

Tightening torque

Fasteners N·m

1. Fastening brake disc and hub bolt 60-70

2. Fastening dust proof cover and steering knuckle

18-25

bolt

3. Front brake hose connector bolt 20-30

4. Fastening brake tongs bolt 70-100

5. Clamp pin bolt (clamp side) 30-38

6. Clamp pin bolt (clamp bracket side) 50-60

7. Bleeding screw 9-13

4. Front brake hose Connect the hose to the clamp, and screw the front brake hose

connector bolt to the specified torque: 20-30N·m.

Note:

· Infuse the brake fluid in the brake oil cylinder and discharge the air

in the system after assembly. Carry on the brake test and check whether there exists leakage of brake fluid on each assembly parts.

· Install each tire and examine whether the tire can move smoothly

by applying the force which is less than 33N.

· Lift the front wheels by using lifting jack an make the front wheels

away from the ground.

· Do not press the brake pedal when examines the tire rotation. If the tire cannot rotate smoothly, check the following items:

· Whether the wheel bearing has been cracked

· When the brake disc rotates, whether the contact with liner is even.

III. Rear wheel drum disc (with clearance self adjusted mechanism) (I) Disassembly

1. brake drum and brake shoe

1) Make the parking brake lever on the loose condition.

3) Support the vehicle by using a lifting jack and support it on the safety board, disassemble the wheel nut and take the wheels down.

4) Pack out the brake drum by using M8 bolt. (Please Fig.3.7-4)

M8 bolt

Fig.3.7-4

5) Rotate the brake shoe sizing spring pin, disassemble the brake shoe sizing spring.

6) Take the parking brake cross bracing wire down from the parking brake draw arm, and disassemble the brake shoe.

2. Brake wheel cylinder

1) The steps to disassemble the brake drum and brake shoe is the same as above mentioned.

2) Screw the pipe connector down from the brake wheel cylinder.

3) Screw the brake wheel cylinder-assembling bolt. Cover the discharging screw of the brake wheel cylinder on the oil pipe to avoid splashing and flowing of the brake fluid. (II) Examine the components

1. Brake drum

Operation and Service Manual on VANTAGE TruckALL & VanGO Series

Chapter III. Chassis

Check whether the brake drum is clean, measure the inner diameter of

the brake drum and examine the wearing of the brake surface.

Item Standard Operation limit

Inner diameter of brake drum 220mm 222mm

Once the brake drum is disassembled, it shall be completely cleaned

and be examined to see whether there exists any cracks, scuffing or

deep groove on it. Replace the brake drum with cracks, and do not try

to weld the brake drum with cracks. Serious scuffing on the surface

will result in undue wearing to the brake liner, therefore the brake

surface of brake drum must be recovered. If there exists slight

wearing on the friction liner and groove on the brake drum, fine sand

paper shall be used to polish the brake drum. Do not carry cutting

recovery.

Note: Visually examine whether the lamp leaks brake fluid when

disassembles the liner. If leakage exists, it shall be repaired.

Fig.3.7-5

2. Brake shoe If wearing of the friction liner exceeds the operation limit, the brake shoe shall be replaced. (Please refer to Fig.3.7-5).

Brake friction liner Standard Operation Limit

Height (liner + shoe edge) 7.0mm 3.0mm If one of the brake friction liners exceeds the operation limit, a pair of friction liner in the same brake shall be simultaneously replaced.

3. Brake wheel cylinder When disassembles the brake drum, check whether there exists leakage on the wheel cylinder. If leakage occurs, the sealing part in the wheel cylinder shall be replaced. Check whether there exists damage or wearing on each component of the wheel cylinder. If any problem occurs, replace the component.

4. Brake clearance self adjusting mechanism Check whether there exists wearing or damage on each component of brake clearance self adjusting mechanism. If any problem occurs, replace the component.

5. Various Springs Check whether the springs has been damaged or the elasticity has been reduced. If any problem occurs, replace the spring. (II) Notes for assembly

1. Brake wheel cylinder

1) Tighten the brake wheel cylinder to the brake bottom board by applying the specified tightening torque.

2) Screw the pipe connector of brake hose to the specified tightening torque.

3) Take the protective cap of the discharging screw down from the pipe and install it to the discharging screw.

2. Brake shoe

1) Water proof sealant shall be coated on the contact point between brake bottom board and parking brake cross bracing wire, thread the parking brake cross bracing wire through bottom board and tighten it by caliper.

Vantage TruckALL, VanGO Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual