ZD103 Workstation Operation Instruction Manual

Rear wheel arch / steering system sub-assembly workstation · 6 operations, illustrated edition | Compiled from the original process cards for training and display-board use

Step 10 Install the yaw rate sensor assembly at the position shown. Step Tightening Tighten the fixing bolts with a torque wrench.

Tightening torque: 700±50 N·m

Step 10 Install the "rear wheel arch front body bracket" on the left side of the frame as shown in the view in direction A in the figure. Step 20 Install the "rear wheel arch front body bracket" on the right side of the frame symmetrically to the left side.

Tightening torque: 700±50 N·m

Step 10 Install the rear wheel arch center tube beam at the position shown. Step 20 Install symmetrically on the left and right sides and tighten with the matching bolts.

Tightening torque: 700±50 N·m

Step 10 (Front) Left/right front body assembly of the rear wheel arch: before installation, confirm that the rear wheel arch front body bracket has been installed. Step 20 (Front) Install the left front assembly of the rear wheel arch at the position shown. Step 30 (Front) The figure shows the installation method for the left front assembly; the right front assembly of the rear wheel arch is installed symmetrically to the left side. Step 10 (Middle) Left/right middle body installation of the rear wheel arch: before installation, confirm that the rear wheel arch center tube beam has been installed. Step 20 (Middle) Install the (left) middle body assembly of the rear wheel arch at the position shown. Step 30 (Middle) Install the right middle body assembly of the rear wheel arch symmetrically to the left side. Step 10 (Rear) Left/right rear body sub-assembly of the rear wheel arch (shown for the left side): first remove the 4 fixing bolts of the anti-spray mud flap and fold it open to expose the installation positions of the rear combination lamp and the tube beam. Step 30 (Rear) Install the left rear combination lamp at the position shown in Fig. 2; note that the license plate lamp must face downward; secure the combination lamp with the 4 fixing nuts from the inside of the wheel arch. Step 40 (Rear) Select the left rear tube beam per Fig. 3, insert the tube beam front fixing bracket into the wheel arch body facing the direction of vehicle travel, align the front and rear mounting holes, and tighten with bolts. Step 50 (Rear) Re-secure the anti-spray mud flap with 4 screws/bolts. Step 60 (Rear) The right rear wheel arch rear body sub-assembly is installed symmetrically to the left side. Step 80 (Assembly) Rear body assembly installation: install the left rear wheel arch rear body assembly at the position shown; the right side is symmetrical to the left side.

Left/right front body assembly of rear wheel arch ×1 each; Left/right middle body assembly of rear wheel arch ×1 each; Left/right rear wheel arch tube beam assembly ×1 each; Left/right rear combination lamp ×1 each; Left/right rear wheel arch rear body assembly ×1 each; Hex bolt with spring and flat washer assembly × matched per area; Hex flange bolt/nut × matched per area

Tightening torque: 700±50 N·m; Carefully verify the license plate lamp orientation of the combination lamp and the insertion direction of the tube beam

Step 10 Hoist the EHPS (Electro-Hydraulic Power Steering gear) onto the subframe at the position shown. Step 20 After aligning the EHPS with the 5 fixing holes on the subframe, hand-start the heavy-duty spring washers and bolts to pre-tighten them, then tighten to the final torque of 550 N·m.

Tightening torque: 550±20 N·m

Step 10 Install the electric oil pump bracket and the steering oil line retaining bracket 1 at the positions shown. Step 20 When installing steering oil line retaining bracket 1, keep the top edge of the bracket level. Step 30 Tighten to 65 N·m. Step 10 (Pump body) Hoist the electric oil pump; align the pump's 4 fixing holes with the holes in the pump fixing bracket and the subframe, then tighten. Step 20 (Pump body) Tighten to 65 N·m. Step 10 (Ground) Secure the other end of the ground strap harness supplied with the pump to the frame position shown; before installation, scrape the paint off the contact surfaces between the ground strap terminal and the frame to ensure a good ground.

Electric oil pump bracket ×1; Steering oil line retaining bracket 1 ×1; Electric oil pump ×1; Steering oil line retaining bracket 2 ×1; Hex flange bolt (coarse shank) × several; All-metal hex flange lock nut ×1

Tightening torque: 65±5 N·m; The ground contact surface must have the paint scraped off to ensure continuity

This page is compiled from process cards ZD103-1020 ~ ZD103-1070 (Anhui Windrose Holdings Co., Ltd.) and is for workshop visual training display only; official production shall follow the controlled process documents.