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
n
y
N
g
ght
N
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
m
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
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
1
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
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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
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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
n
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
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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 -
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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
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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
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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.
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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.
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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
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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°。
10
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.
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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.
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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
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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.
14
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.
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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
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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.
5
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.
3
Note: When handle ○
2
switch ○
shall turn off automatically, that is, air-conditioner shall
is turned to “ ” position, A/C.ON-OFF
stop working.
3. Heater control
5
Move handle ○
“HOT” position, handle ○
to your expected gear position, handle ○4 to
3
to “ ”position, heater unit switch
① to your expected gear position, heater unit shall start working.
4. Quick defrost control
5
Move handle ○
3
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
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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
1
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
2
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.
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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.
Chapter I. Whole Vehicle
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
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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
20
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)
1
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)
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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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Chapter I. Whole Vehicle
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.
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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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Chapter I. Whole Vehicle
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
25
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