Haima M3. Chassis System. Service Manual - part 1

 Clutch 

System 2A-1 

 

Volume II Chassis System 

 
Chapter 10  Clutch System........................................................................................................................2A-1 

Chapter 11  List of tires and drive shafts................................................................................................... 2B-1 

Chapter 12  Wheels and tires..................................................................................................................... 2C-1 

Chapter 13  Suspension system.................................................................................................................2D-1 

Chapter 14  Steering system...................................................................................................................... 2E-1 

Chapter 15  Brake system.......................................................................................................................... 2F-1 

 

 
 

 Clutch 

System 2A-1 

 

Chapter 10 

Clutch System  

 

Basic steps.................................................................................................................................................2A-2 

Removal/installation of clutch oil pipe .............................................................................................2A-2 

Cluch pedal................................................................................................................................................2A-2 

Check of clutch pedal........................................................................................................................2A-2 

Free stroke of clutch pedal ................................................................................................................2A-2 

Decoupling point of clutch pedal ......................................................................................................2A-2 

Release stroke of clutch pedal...........................................................................................................2A-2 

Removal/installation of clutch pedal.................................................................................................2A-2 

Mounting instructions for clutch pedal .............................................................................................2A-4 

Clutch master cylinder ..............................................................................................................................2A-4 

Removal/installation of clutch master cylinder.................................................................................2A-4 

Disassembly/assembly of clutch master cylinder..............................................................................2A-5 

Instructions for disassembly/assembly of position-limiting seat.......................................................2A-6 

Clutch slave cylinder.................................................................................................................................2A-6 

Removal/installation of clutch slave cylinder ...................................................................................2A-6 

Disassembly/assembly of clutch slave cylinder ................................................................................2A-6 

Clutch device.............................................................................................................................................2A-7 

Check of clutch release bearing ........................................................................................................2A-7 

Instructions for removal of clutch pressure plate and friction plate ..................................................2A-7 

Instructions for removal of guide bearing .........................................................................................2A-7 

Instructions for flywheel removal .....................................................................................................2A-7 

Mounting instructions of flywheel ....................................................................................................2A-7 

Mounting instructions for guide bearing ...........................................................................................2A-7 

Mounting instructions for clutch friction plate..................................................................................2A-8 

Mounting instructions for clutch pressure plate ................................................................................2A-8 

Check of clutch pressure plate ..........................................................................................................2A-8 

Check of clutch friction plate ............................................................................................................2A-8 

Check of clutch release bearing ........................................................................................................2A-9 

Check of guide bearing .....................................................................................................................2A-9 

Mounting instructions for clutch pressure plate ................................................................................2A-9 

Flywheel....................................................................................................................................................2A-9 

Check of flywheel .............................................................................................................................2A-9 

 

 

 

 Clutch 

System 2A-2 

 

Basic steps 

Removal/installation of clutch oil pipe 

Note 

●

  The oil reservoir is shared by the clutch and 

brake system. 

1.  Provided the clutch is disassembled in any 

case, add in the clutch oil (brake oil) and 
drain the air, check the oil for leakage after 
installing the clutch. 

2.  Disassemble the clutch oil pipe with a special 

tool, i.e. double open end wrench, and 
assemble it together with a torque connecting 
rod and above tool. 

3.  Ensure that the clutch flange nut shall be 

tightened up to the specified torque.(refer to 
the basic steps, torque and specifications) 

Cluch pedal 

Check of clutch pedal 

Measure the distance from upper surface of clutch 
pedal rubber to the carpet. 

●  If incorrect, check whether the clutch pedal is 

wrongly assembled. 

206- 212mm (8. 11- 8. 35in) (for reference) 

 

Height of pedal 

 

Free stroke of clutch pedal 

Measure the free stroke of clutch. The free stroke 
of clutch pedal is the distance required until a 
resisting force is felt by pressing down the clutch 
pedal by hands. 

●  If incorrect, check whether the clutch pedal is 

wrongly assembled. 

Free stroke of pedal: 5 to 14mm (0. 2 to 0. 55in) 

 

Decoupling point of clutch pedal 

1.  Apply the parking brake, and pack the mat 

wood under front and rear wheels. 

2.  Start the engine, and make it idling. 

3.  Don’t step the clutch pedal, and put the gear 

lever slowly in reverse gear. 

4.  In case of hearing the gear noises, keep the 

gear lever in position. 

5.  Step down the clutch pedal slowly. 

6.  When the noises of gear disappears, keep the 

clutch pedal unchanged (decoupling point of 
clutch pedal). 

7.  Measure the distance a (pedal stroke until the 

clutch pedal decoupling point is fully stepped 
down) and pedal stroke. 

8.  Confirm the release stroke is within the 

specified value. 

If it’s outside the specified value, check whether 
the clutch pedal and clutch master cylinder are 
correctly assembled, and drain the air out of 
clutch pipe.  

Release stroke of clutch pedal  

102.5 to 110.5(4.04 to 4.35in) (for reference) 

Pedal stroke: 116mm (4.57in) (for reference) 

 

Removal/installation of clutch pedal 

1.  Remove the air filter (refer to its external 

Free stroke of pedal

 

Release point 
of clutch pedal

 

Pedal stroke

 

 Clutch 

System 2A-3 

 

accessories, removal/installation of air filter). 

2.  Remove the battery and its cover. 

3.  Disassemble as per the shown sequence. 

4.  Assemble it in the reverse sequence of 

removal.  

5.  After installing it

, check the clutch pedal 

again (refer to the check of clutch pedal). 

 

 

1

 

Lock nut

 

2

 

Split pin

 

3

 

Pin shaft

 

4

 

Clutch master cylinder

 

5

 

Clutch pedal assembly(refer to its mounting instructions)

 

6

 

Clutch hose

 

7

 

Pedal rubber mat

 

 

 

 

 

 

 

 

 

 

 Clutch 

System 2A-4 

 

Mounting instructions for clutch pedal 

After installing it, adjust the height and free stroke 
of pedal (refer to the check of clutch pedal). 

 

Clutch master cylinder 

Removal/installation of clutch master 
cylinder 

1.  Disassemble the air filter (refer to its external 

accessories, removal/installation of air filter). 

2.  Disassemble the battery and its cover. 

3.  Disassemble them in the shown sequence. 

4.  When removing the oil pipe, immediately 

choke it up with a plug to avoid the oil 
leakage. 

5. 

Install it in the reverse sequence of removal. 

 

 

 

 

 

1 Lock 

nut 

2 Split 

pin 

3 Mineshaft 

4 Clutch 

oil 

pipe 

5 Elastic 

clamp 

6 Clutch 

master 

cylinder 

7 

Clutch pedal assembly 

8 Clutch 

hose 

 

 Clutch 

System 2A-5 

 

Disassembly/assembly of clutch master cylinder 

1.  Disassemble it in the shown sequence. 

2.  Assemble it in the reverse sequence of disassembly. 

 

 

1 Snap 

ring 

2 Clamp 

3 

Clutch oil inlet hose 

4 Position-limiting 

seat 

5 O 

ring 

6 Pushrod 

assembly 

7 Piston 

seat 

8 Secondary 

cup 

9 Limit 

mat 

10 Primary 

cup 

11 Piston 

12 Compensation 

pad 

13 Bush 

14 Washer 

15 Cylinder 

body 

 

 

 Clutch 

System 2A-6 

 

Instructions for disassembly/assembly of 
position-limiting seat 

Draw back the pour card of position-limiting seat 
inside with a special tool to remove the position-
limiting seat and piston. 

●  During the disassembly, remove the position-

limiting seat; during the assembly, install the 
position-limiting seat. 

Clutch slave cylinder 

Removal/installation of clutch slave 
cylinder 

1.  Remove the mudguard. 

2.  Remove it in the shown sequence. 

3.  Install it in the reverse sequence of removal. 

 

 

 

1 Snap 

spring 

2 Clutch 

pipe 

3 Bolt 

4 Clutch 

slave 

cylinder 

 

Disassembly/assembly of clutch slave 
cylinder 

1.  Disassemble it in the shown sequence. 

2.  Assemble it in the reverse sequence of 

disassembly. 

 

 

1 Piston 

stopper 

2 Shield 

3 Piston 

assembly 

4 Leather 

cup 

5 Spring 

seat 

6 Spring 

7 Dust 

cap 

8 Bleed 

screw 

9 O 

ring 

10 Bleed 

screw 

gasket 

11 Bush 

12 Snap 

ring 

13 Cylinder 

body 

 

 Clutch 

System 2A-7 

 

Clutch device 

Check of clutch release bearing 

Note 

●

  While cleaning the release bearing with 

cleaning oil or vapor detergent, remove the 
grease sealed in the bearing. 

1.  Turn the release bearing hardly in axial 

direction. 

●

  If the bearing can’t be turned or meets its high 

resisting force, replace the clutch release 
bearing in case of abnormal noises. 

2.  Install it in the reverse sequence of removal. 

 

1 Clutch 

slave 

cylinder 

2 Manual 

transmission 

3 Protection 

cover 

4 

Clutch release bearing 

5 

Clutch release fork 

6 Clutch 

assembly 

7 

Clutch friction plate 

8 Guide 

bearing 

9 Flywheel 

Instructions for removal of clutch 
pressure plate and friction plate (see the 
details of HM483Q engine repair manual) 

1.  Attach the special tool SST(as shown in the 

figure). 

2.  Loosen the bolt at a time in cross mode, until 

its spring pressure is released. 

3.  Disassemble the clutch pressure plate and 

friction plate. 

 

Instructions for removal of guide bearing 

Note 

●

  The guide bearing shall not be commonly 

removed, unless it needs to be replaced. 
Remove the guide shaft with a special tool 

SST (as shown in the figure). 

 

 

Instructions for flywheel removal 

1.  Lock the flywheel with a special tool SST(as 

shown in the figure). 

2.  Disassemble the mounting bolt evenly in the 

cross sequence. 

3.  Disassemble the flywheel. 

 

 

Mounting instructions of flywheel 

1.  Install the flywheel on the crankshaft. 

2.  Before installing the bolt, clean its threads 

and apply the sealant to its threads. 

Note 

●

  In case of applying the new bolt, don’t apply 

the sealant to it. 

3.  Pre-tighten the lock bolt of flywheel by hands. 

4.  Install the special tool SST on the flywheel 

(as shown in Figure). 

5.  Tighten the lock bolt gradually in the cross 

sequence. 

 

 

Mounting instructions for guide bearing 

Note 

●

 Install the guide bearing as per the 

instructions below. Installed depth of guide 
bearing 

0 - 0.4mm (0-0.115in) 

 

 Clutch 

System 2A-8 

 

 

1.  Install the new guide bearing with a special 

tool SST (as shown in Fig.). 

 

Mounting instructions for clutch friction 
plate 

1.  Keep the position of clutch friction plate with 

a special tool SST (as shown in Fig.). 

 

Mounting instructions for clutch pressure 
plate 

1.  Install the special tool SST(as shown in Fig.). 

2.  Tighten the bolt evenly in the cross sequence. 

 

Check of clutch pressure plate 

1.  Measure the wears of diaphragm spring. 

  If above-normed, replace the clutch pressure 

plate. 

Depth<0.6mm (0.024in ) 

 

2.  Measure the flatness of pressure plate with a 

ruler and thickness gauge. 

  If above-normed, replace the clutch assembly. 

Max. clearance 5mm(0. 02in) 

3.  Apply the dial indicator when checking the 

diaphragm spring. 

4.  Turn the flywheel to check the axial runout of 

diaphragm. 

  If above-normed, replace the clutch pressure 

plate. 

Axial runout≤0.6mm(0. 024in) 

 

Check of clutch friction plate 

1.  Measure the depth of rivets to friction plate 

surface with a vernier gauge. 

  If above-normed, replace the clutch friction 

plate with depth≤0.3mm(0.01in). 

 

 

2.  Measure the axial runout of clutch friction 

plate with a dial indicator. 

  If above-normed, replace the clutch friction 

plate. 

Axial runout ≤ 0.7mm (0.028in) 

 

Flywheel

 

Guide bearing

 

 Clutch 

System 2A-9 

 

 

 

Check of clutch release bearing 

Note 

●

  While cleaning the release bearing with 

cleaning oil or vapor detergent, remove the 
grease sealed in the bearing. 

Turn the release bearing hardly in axial direction. 

●

  If the bearing can’t be turned or meets its high 

resisting force, replace the clutch release 
bearing in case of abnormal noises. 

 

 

Check of guide bearing 

Don’t disassemble the guide bearing, and turn the 
bearing hardly in axial direction. 

  If the bearing can’t be turned or meets its high 

resisting force, replace the clutch release 
bearing in case of abnormal noises. 

 

Mounting instructions for clutch pressure 
plate 

1.  Install the special tool SST (as shown in Fig.). 

2.  Tighten the bolt evenly in the cross sequence. 

Flywheel 

Check of flywheel 

1.  Install the dial indicator on the cylinder body. 

2.  Measure the axial runout of flywheel. 

  If above-normed, replace the flywheel. 

Axial runout≤0.2mm (0. 0084in) 

 

 

 

List of tires and drive shafts 2B-1 

 

Chapter 11  List of tires and drive shafts 

 

Common procedures ............................................................................................................................... 2B-2 

Description and operation ...................................................................................................................... 2B-2 

Diagnostic data and procedures............................................................................................................. 2B-4 

 

 

 

 

 

List of tires and drive shafts 2B-2 

 

Common procedures 

Attentions for wheels and tires 

Removal and installation of wheels and tires 

The removal and installation steps of wheels and 
tires are not mentioned in this section. In case of 
removing the wheels, their tightening torque is 
100-120N.m {10-12.0kgf.m, 73.5-88ft.lbf} during 
the installation.  

Keypoints for removal of lock nut 

1.  Hit the flattening of lock nut out with a small 

chisel and hammer. 

2.  Apply a braking force to lock the hub. 

3.  Remove the lock nut. 

 

Keypoints for mounting the lock nut 

1.  Apply a braking force to lock the nut. 

2.  Install the new lock nut up to fixed torque of 

300-350N.m {30-35.0kgf.m, 219-255.5ft.lbf}. 
At the fixed torque, first hit it up to the 
specified torque before loosening it, and hit it 
up to the specified torque again. 

3.  Flatten the lock nut as per the shown 

requirements. 

 

Drive shaft 

Keypoints for removal of right drive shaft and 
drive axle 

1.  Remove the riveting bolt and nut. 

2.  Wrap the cloth on the ball joint dust cover. 

3.  Pry down the lower swing arm from steering 

knuckle. 

 

 

4.  As shown in figure, insert a crowbar between 

right drive shaft and transmission drive axle, 
and disengage the drive shaft from the 
transmission drive axle. 

 

Keypoints for installation of snap ring 

1.  Attach a new snap ring to the connecting shaft, 

make its opening up, and ensure that the 
diameter of snap ring shall not exceed the 
value specified in technical requirements for 
installation. 

2.  After installing the snap ring, measure its 

outer diameter. In case of exceeding the value 
specified in technical requirements, 
additionally renew the snap ring and repeat 
Steps 1& 2.  

 

Check of drive shaft 

1.  Check the dustproof rubber sleeve of drive 

shaft for cracks or damages, grease for 
leakage or hoop for loosening. 

2.  Check the drive shaft for bends or cracks, 

universal joint or spline for wears. If 
necessary, repair or replace the drive shaft 

Technical requirements for snap 
ring outer diameter snap ring

Snap ring 

Outer diameter

Opening 

0.5mm(0.2in) 
or above

Fabric 

 

List of tires and drive shafts 2B-3 

 

and dustproof rubber sleeve or hoop. 

 

Removal and installation of drive shaft 

Attentions 

1.  Before performing the following procedures, 

be sure to first remove ABS wheel speed 
sensor, otherwise it may the open circuit of 
wires due to wrong pull or operation. 

Therefore, first remove the axle end of ABS 
wheel speed sensor, place it in appropriate 
position, and ensure it can’t be wrongly 
pulled during the repair of car. 

2.  In case of removing the drive shaft with a 

shaft bracket, it may cause the deformation of 
connecting shaft bracket, so the drive shaft 
and connecting shaft shall be removed and 
installed as a whole. 

.

①

  Drain all the oil out of transmission drive axle. 

.

②

  Remove the hub of steering knuckle. 

.

③

  Remove it in the sequence shown in the table. 

.

④

  Install it in the reverse sequence of removal. 

 

1 Lock 

nut 

Refer to the keypoints for removal of M lock nut. Refer to the keypoints for installation of 
M lock nut. 

2 

Ball joint of steering tie rod end socket 
Refer to the keypoints for steering tie rod end socket ball joint. 

3 

Lower control arm ball joint 

4 

Left drive shaft 
Refer to the keypoints for removal and installation of M drive shaft. 

5 

Drive shaft and connecting shaft 
Refer to the keypoints for removal and installation of M drive shaft and transmission drive 
axle.  

6 Drive 

shaft 

Refer to the keypoints for removal of M drive shaft. 

7 Snap 

ring 

Refer to the keypoints for installation of M snap ring. 

 

List of tires and drive shafts 2B-4 

 

 

Keypoints for removal of drive shaft 

1.  Remove the riveting bolt and nut. 

2.  Wrap the cloth on the dustproof rubber sleeve 

of ball joint. 

3.  Pry the lower control arm out of steering 

knuckle. 

 

4.  Attach the spare nut to drive shaft to make the 

nut flush with the end of drive shaft. 

5.  Hit the nut lightly with a copper hammer to 

loosen the drive shaft from front hub. 

6.  Take the drive shaft out of hub. 

 

Note: the sharp edge of drive shaft will scratch the 
oil seal, so it’s specially careful to remove the 
drive shaft from the transmission drive axle. 

7.  Insert a crowbar between outer ring and 

transmission drive axle, and pry the left drive 
shaft from transmission drive axle, as shown 
in the figure below.  

 

Keypoints for installation of snap ring 

1.  While attaching a new snap ring to the 

connecting shaft, make the opening of snap 
ring up, and ensure the diameter of snap ring 

shall not exceed the specified value in 
installation technology requirements. 

2.  After the installation, measure the outer 

diameter of snap ring. If it exceeds the 
specified value, additionally renew a snap 
ring, and repeat Steps 1-2.  

Technical requirements for snap ring outer 
diameter: 26 mm {1. 02 in} 

 

Keypoints for installation of drive shaft and 
transmission drive axle 

Note 

The sharp edges of connecting shaft may scratch 
the oil seal, so it should be specially careful to 
install the drive shaft into the transmission drive 
axle. 

1.  Insert the drive shaft into the hub. 

2.  Apply ATF to the lip of oil seal. 

3.  Push the drive shaft into the transmission 

drive axle. 

 

 

4.  After the installation, draw the outer ring on 

one end of transmission drive axle forward, 
and confirm that the drive shaft is locked by 
the snap ring. 

Disassembly and assembling of drive shaft 

1.  Disassemble it in the sequence shown in the 

table. 

2.  Assemble it in the reverse sequence of 

disassembly. 

Cloth

 

Opening

Snap ring

Outer diameter

 

List of tires and drive shafts 2B-5 

 

 

 

1 

Wheel side dustproof rubber sleeve clamp 
Refer to the keypoints for disassembling M wheel side dustproof rubber sleeve clamp. Refer 
to the keypoints for assembling M wheel side dustproof rubber sleeve clamp. 

2 

Transmission drive axle side dustproof rubber sleeve clamp 
Refer to the keypoints for disassembling M transmission drive axle side dustproof rubber 
sleeve clamp. Refer to the keypoints for assembling M transmission drive axle side dustproof 
rubber sleeve clamp. 

3 Outer 

ring 

Refer to the keypoints for disassembling M outer ring. Refer to the keypoints for assembling 
M outer ring 

4 Snap 

ring 

5 

3-foot universal joint 
Refer to the keypoints for disassembling M 3-foot universal joint. Refer to the keypoints for 
assembling M 3-foot universal joint. 

6 

Dustproof rubber sleeve 
Refer to the keypoints for disassembling M dustproof rubber sleeve. Refer to the keypoints for 
assembling M dustproof rubber sleeve. 

7 

ABS sensor rotor 
Refer to the keypoints for disassembling M ABS sensor rotor. Refer to the keypoints for 
assembling M ABS sensor rotor. 

8 

Shaft and ball joint assembly 

 

 

 

 

 

 

 

List of tires and drive shafts 2B-6 

 

Keypoints for disassembling wheel side 
dustproof rubber sleeve clamp 

Note 

Only when the dustproof rubber sleeve clamp is 
replaced, it’s required to remove the dustproof 
rubber sleeve clamp with clamp forceps and scrap 
it, as shown in the figure below.  

 

Keypoints for disassembling transmission drive 
axle side dustproof rubber sleeve clamp 

Remove big or small clamp with clamp forceps. 

 

Keypoints for disassembling outer ring 

1.  Make a mark for correct assembling on the 

outer ring and shaft. 

2.  Remove the outer ring. 

 

Keypoints for disassembling 3-foot universal 
joint 

Note:  make the mark with paint, and don’t punch 
the mark. 

1.  For the purpose of correct assembly, make the 

mark on the shaft and 3-foot universal joint. 

2.  Remove the stop ring with clip forceps. 

3.  Remove 3-foot universal joint from the shaft. 

 

Keypoints for disassembling dustproof rubber 
sleeve 

Note: unless it’s necessary to replace the dustproof 
rubber sleeve ball joint and shaft assembly, don’t 
remove the dustproof rubber sleeve on wheel side 
under common conditions; remove the paper tape 
after assembling the dustproof rubber sleeve.

 

1.  Wrap the spline of shaft with a tape. 

2.  Remove the dustproof rubber sleeve. 

 

Keypoints for disassembling ABS sensor rotor 

Note:remove the sensor rotor only if 
necessary. Once the sensor rotor is removed, 
it can’t be used any longer. 

1.  Hit down ABS sensor rotor from the drive 

shaft lightly with a chisel. 

 

Keypoints for assembling dustproof rubber 

Mark 

Mark

Paper tape