Foton Tunland & Pika Service Repair Manual 2011 (FTSM-201110 Volume 1) – PDF Download

Description

Foton Tunland & Pika Service Repair Manual – Volume 1, 2011

This is the first volume of the Foton repair manual published under document number FTSM-201110, edition November 2011, printed October 2011 by Beiqi Foton Motor Co., Ltd. Volume 1 is the foundation volume of the whole set: it teaches you how to work on the vehicle safely, tells you which tools and sealants each job needs, publishes the service specifications and tightening torques, and then carries the entire diagnostics section – ABS, engine control, SRS, transfer case, body systems – plus the full vehicle maintenance schedule. Everything a technician needs before touching a single fastener on a Tunland or Pika is in this one file.

File Details

• Manual type: Service / repair manual (Volume 1 of a 3-volume set)
• Publisher: Beiqi Foton Motor Co., Ltd
• Document number: FTSM-201110
• Edition: November 2011 (printing October 2011)
• Language: English
• Page count: 898 pages
• File format: PDF

Chapters Covered

The top-level chapters of Volume 1, exactly as the manual numbers them:

• 01 – Introduction
• 02 – Preparation
• 03 – Service Specifications
• 04 – Diagnostics
• 05 – Vehicle Maintenance

01 – Introduction

How the manual is written and how to use it: the diagnostics / replacement / inspection logic behind every procedure, the conventions for exploded views and part tables, and the warning hierarchy used throughout (Danger, Warning, Attention). It then covers vehicle identification – where the VIN label sits at the front right of the dashboard and where the VIN plate is found under the engine hood – plus the rear drive axle serial number stamped on the axle tube and the transmission shaft serial number printed on the shaft tube. The general service guideline follows: shop safety, lifting and supporting positions, glued parts and sealant practice, gasket and fuse rules, clip and vacuum hose handling, and the torque-wrench extension formula T’=TxL2/(L1+L2) for when you use a special tool or extended handle. There is a dedicated SRS precaution section – the 90-second backup power window after battery disconnection, clock spring alignment, horn button assembly handling and storage limits – and the electric test procedure with conduction, voltage and short-circuit test methods.

02 – Preparation

Per-system tool and supply lists, broken down by job family: seat belt, transmission, vehicle control system, wheel and tire, door and engine hood, windscreen and backview mirror, power steering, engine mechanical, engine control system, SRS, wiper and washer, brake, rear suspension, intake, cooling, clutch, door lock, heating and air conditioning, emission control, exhaust, start and charge, front suspension, axle and transmission shaft, fuel, lubrication, dashboard and instruments, diagnostics, park brake, steering system and seating. Each entry names the special tools, recommended tools, workshop equipment and the specified fluids, sealants and greases – for example GL-5 gear oils for the transmission, DOT4 brake fluid, R134a refrigerant charge, and the Foton-authorized coolants by engine type.

03 – Service Specifications

The measurement and torque chapter, organised system by system. It carries the JC538 transmission ratios and synchroniser ring clearances, tire pressures for the 265/70R16 and 265/65R17 fitments, door and engine hood gap and evenness figures, the 4G69 gasoline engine’s full mechanical data (cam heights, valve and guide clearances, valve spring free height, piston and ring clearances, crankshaft and cylinder block limits), sensor resistances for the engine control system, brake lining and disc limits, front wheel alignment angles, front and rear axle backlash and bearing data, fuel tank volume and level sensor values, and the complete fastener torque tables for every assembly covered in the volume. This is the chapter you keep open while the torque wrench is in your hand.

04 – Diagnostics

The largest chapter in the book and the reason this volume earns its place on the bench. Every system gets a DTC list, a defect phenomenon table ranked by likelihood, circuit diagrams, connector pin definitions with wire colours, and step-by-step test procedures with the expected meter readings written into the flowchart. Covered: Anti-lock Braking System (wheel speed sensors front and rear, valve relay, return pump, ABS warning lamp), the gasoline engine control system (MAP, intake air temperature, coolant temperature, throttle position, front and rear oxygen sensors, knock sensor, crankshaft position sensor, fan circuits, injector circuits, canister purge valve, plus a full engine symptom diagnosis section for no-start, cold start, unstable idle, high idle, stalling, poor acceleration), the SRS system (power supply codes, driver and passenger airbag igniter resistance, ground and battery short codes, seat belt pre-tensioner circuits), transfer case, speedometer, clutch pedal position, CAN bus, reverse radar, power windows, rear windscreen defrost, power rearview mirrors, power door locks, wiper and washer, air conditioning, audio system, horn, lighting, combination instrument, combined display, body controller, tire pressure monitoring and front axle clutch. Wiring is given as colour-coded circuit diagrams with connector codes such as A006, C013, C035 and C040 so you can trace a fault to a pin.

05 – Vehicle Maintenance

The scheduled service chapter. It opens with the regular service items and intervals for the 4G69 gasoline engine, the E2.8 diesel and the chassis and electrical parts, then the extreme-condition schedule for uneven or muddy roads, dusty roads, salina roads, towing, short cold-start journeys, taxi-style low-speed running and sustained high-speed driving. Inspection procedures follow: electrical system, battery, airbag, seat belt, park brake and brake pedal, door stopper and hinges, windscreen drain, engine compartment components, toothed timing belt, accessory belt, steering ball joint and dust shield, chassis bolt retorquing, headlight aim, wiper and washer, vehicle underside, suspension components and ball joints, power steering level, braking system, brake disc and drum measurement, tires, exhaust and coolant level. The replacement section then walks through air filter elements, air conditioning filter, engine oil and filter for both engines, spark plugs, fuel filter assembly and element, coolant, brake fluid, manual gearbox lubricant for the JC538 and R5M21, rear main reducer gear oil, front main reducer gear oil and differential oil – with fill volumes, lubricant grades and drain and filler plug torques.

What This Volume Lets You Do

The Foton Tunland & Pika service repair manual Volume 1 covers the jobs that decide whether a repair succeeds or comes back: reading the right DTC and following the manufacturer’s test sequence instead of swapping parts, tightening to the published figure with the published thread treatment, measuring wear against the limit rather than by feel, and servicing on the interval the factory set. You get the ABS wheel speed sensor resistance windows and the exact connector pins to probe, the 4G69 mechanical wear limits, the JC538 synchroniser clearances, the torque tables for brake calipers, suspension mountings and driveline flanges, and the maintenance schedule in both normal and severe-duty form.

Because this is the introduction, specification and diagnostics volume, it also works as a stand-alone reference: when you are mid-job on a wiring fault or a torque value you do not need the repair procedures volume beside you, you need this one.

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Instant PDF Delivery

Delivered as a PDF download the moment payment clears – no shipping, no waiting on a courier. Open it on a laptop in the workshop, a tablet on the lift or a phone at the roadside, print the pages you need for the job and keep the file for the next one. Bookmark your regular jobs and work straight from the screen. Whether you are a workshop technician, a fleet maintainer or an owner who does their own servicing, this Foton Tunland & Pika service repair manual gives you the factory procedure, the factory number and the factory test sequence for the 2011 model year.