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Project: N 125

Service manual of exterior system

No. N125-NAM-PV-CS-G9-25

Version:1.0

edit:

proofread:

check:

standardization:

countersign:

permit:

Anhui Jianghuai Automobile Co., Ltd.

Year month date

Table of Contents

TOC

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1. JAC Icon Replacement

1.1 JAC icon r e moval

1.1.1 JAC icon is Sticked directly to front grille with glue, so just pull off in X direction when removing;

1.2 JAC icon installation

1.2.1 Clean the JAC icon metal mounting surface with a clean cloth.

1.2.2 Uncover Double-sided adhesive paper on the back of J, A, C 3 icons, and then on the back of J, A, C 3 icons,

aiming at the cylindrical alignment sheet metal holes, insert and pressure, making the double-sided adhesive

tape and metal plate is fully Adhesive;

Caution:

■JAC icon can be installed on the front grille.

2. Front mold trim panel replacement

2.1 front mold trim panel removal

2.1.1 First using the cross opener pry off 6 cross screws① on the front trim panel ②, and then pull off front light

decorations following direction

1、Cross screws and flat washer Assembly (Q220B4213F71) , 2、Front grille

assembly (Front engine cover) (8402010W5000) 3、front mold decoration trip

Caution:

■Before removing the front light decorations, it is recommended that the front grille assembly (Front Door) to be

removed first.

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2.2 front mold trim strip mounting

2.2.1 Stick non-woven fabrics, sponge, and non-woven cloth - pillars mat to the front trim panel

2.2.2 The Front trim panel 2 main positioning post and auxiliary positioning pin alignment sheet metal master the

hole and Secondary positioning holes, snap the trim 3.

2.2.3 Install the cross screws and flat washer assembly ① to the front trim panel mounting hole through metal

plate mounting holes, pre-tight;

2 2.4 Adjust the front trim panel so that the metal clearance is within the standard;

2.2.5 Finally, using cross opener to tighten 6 cross screws① at torque of 3-4N•m;

Caution:

The installation of front trim panel goes before installation of the front grille.

3. Replacement of outside rear view mirror

3.1 Outside mirror removal

3.1.1 Remove the connector of harness assembly on the left front door of outside rear mirror;

3.1.2 Screw off the 3 bolts on outside rear view mirror, remove the outer mirror assembly;

1 、 the left outside mirror assembly (8202100W5000) 2 、 left front door harness

assembly (4012100W5020) 3、hexagon bolt, spring washer and flat washer combination

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3.2 Outside mirror installation

Installation in the opposite order of removal.

Caution:

■During installation of outside Mirror, must ensure that all components of outside mirror are assembled well in

advance,insert 3 mounting points of outside mirror to the corresponding metal mounting holes and tighten the

bolts.

4. Front bumper replacement

4.1 Front bumper removel

4.1.1 First, screw off 2 screws connecting the front bumper and the left/right side mounting plate;

4.1.2 Remove 2 bolts and 4 xpansion card buckle connecting front bumper and anti-collision beam;

1, 6 hexagon head screws, spring washers and flat washers combination (Q1460620F62)

2, expansion card buckle (5522101 U 2152) 3, front bumper assembly (2803100W5000)

4.1 .3 Pull out the front bumper in X direction;

4.1.4 Take off 4 bolts in connection of front bumper collision frame assembly and the Left/Right Front Floor supporting

carling, and remove the front bumper collision frame assembly;

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1、hexagon head screws, spring washers and flat washer combination (Q1460620F62)

2、Front bumper collision frame assembly (2803200W5000)

Caution:

■Before removing front bumper, disconnect the front fog light connector.

4.2 Front bumper installation

Installation is the reversed order of removal.

Caution:

Before front bumper installation, must ensure that all parts of front bumper are installed in advance.

5. Replacement of inside rear view mirror

5.1 The inside rear view mirror removal

5.1.1 using cross opener to screw off the screws, take off the inside rear view mirror from bottom to the top;

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5.2 The inside rear view mirror installation

Installation is the reversed order of removal；

6. Foot Pedal replacement

6.1 foot pedal removal

6.1.1 Remove left/right foot pedal directly in Z direction;

1 、 The inside rear view mirror assembly (8201100W5000) 2 、 Front Windshield

(5206001W5000)

3、the inside rear view mirror (8210901U1512)

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6.2

installation of foot pedal

Place the foot pedal buckle on the footrest into the metal mounting holes;

7. Front wing panel replacement

7.1 Front wing panel removal

7.1.1 Break off cable clamp, remove the left/right engine fender Rubber;

7.1.2 Remove the Left/Right Front Fender bolts and then remove expansion card buckle, then remove the Left/Right

Front Fender;

7.1.3 Remove the Left/Right Rear Fender bolts and screws, and then remove expansion card buckle, and finally remove

the Left/Right Rear Fender. Torque of self-tapping screws and bolts are (5-6)N.M and (9-11)N M;

1、left foot pedal assembly (8405100W5000) 2、left mounting outer plate assembly

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1. Engine fender rubber buckle （8403304LE010） 2. Left engine fender rubber (8403103 W5000)

3. Hexagonal head bolt, spring washers and flat washers combination （ Q1460620F62 ） 4. Large washer

（Q402B06F62）. 5. Cross head screws and flat washers combination （Q220B4816F71） 6. Left Rear Fender

（8403102W5000）

7. Expansion Card buckle (86590 - 28000) 8. Left Front Fender (8403101 W5000)

7.2 Front wing panel installation

Installation is in reverse order of removal, torque of self-tapping screws and bolts are (5-6)N.M and (9-1)N.M;

8、Front mold side panel replacement

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8.1 Front mold side panel removal

8.2 Front mold side Panel Installation

9、Rear mold fender replacement

Important job - Assembly

● As showed in the picture, install self-tapping screws and

bolts in the order of 1, 2, 3, 4, pre-tension;

● Adjust the interval between front mold mask and front

mold panel/the doors, living up to the standard-setting;

● As showed in the picture, install self-tapping screws and

bolts in the order of 1, 2, 3, 4 with torque of (5-6)N·m and

(9-11)N·M;

Important job - Removing

a. Using a wrench and cross opener, respectively,

remove the 2, 3 bolts and 1, 4 screws;

b. Pull The front mold side panel down directly;

Do not damage the body painting.

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9.1 Rear mold fender removal

9.2 Rear mold fender installation

10、The front windshield replacement

Important job - Removing

● Use the wrench to remove the fixing bolts in the order

of I, II, III, IV, V, VI, VII VIII, and then remove the rear

mountin

mold fender

;

Important job - Assembly

● Install the Rear mold fender, aiming locating hole A at

corresponding hole on metal, installation in advance;

● Install the rest of installation hole as the order of I, II,

III, IV, V, VI, VII VIII, penetrate and tighten screws

with torque of 9-11N·M, and finally tighten the hole.；

1. Rear mold hood

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10.1 The front windshield removal

10.2 The front Window Installation

Important job - Assembly

1) Clean the installation metal face with a clean cloth with

glass cleaner, cool down 1 - 2 minutes;

2) Brush the glue evenly to the car window surface;

3) Put the window on the location with glass glue, and clean

the black frame area of glass with glass cleaner;

4) Install the Window adhesive assembly along the glass

edge, ensuring it is well adhesive; when temperature is low,

put the adhesive assembly into the oven to heat; Otherwise,

it is too hard to stick;

Important job - Removing

c. From the flange and each corner of car body, tear off

the seal.

d. Put copper wire of φ0.5mm through glass cement on

top of A-pillar, both one people in and out of

window drag, separating glass and metal plate, and

slowly push out the glass to remove it.

Do not damage glass surface.

1. Front windshield 2. Front windshield adhesive tape

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、

Rear window replaceme nt

11.1 Rear window assembly removal

Important job - Removing

In the cab, take body metal flange off

the wind window adhesive strip,andfirmly

push the windshield outside;

2. Along with length of adhesive tape

5) Paint the glue in the certain area evenly and get dry;

6) Paint the glass glue to the sticking area along the

adhesive tape with glue guns; width: 7 to 9 MM, high: 10 -

14 MM, Triangle glass glue outer edge cover the inner

edge.

7) after the glue, put the front windshield to the body metal

pedal borders, limited post align to pedal limited hole, tie

with bandage to prevent it getting off, and put it in still for

more than 12 hours, during which time avoid flip cab.

aquaseal One-component

polyurethane glass paint

1. Rear windshield 2. Rear windshield adhesive tape

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11.2 Rear Window Installation

12. The front combination light and light bulb replacement

Important job - Assembly

The glass trademark is placed in the lower left,

adjust the glass center to the seal lower connection.

2. Put rope with width ofФ 5-6mm

through the edge. Rotate rope one lap, then make it

doublication with lower center of the glass.

3. Adjust Glass in the center of the window, press

the glass from outside, then drag the rope from inner side,

instal the rear windshield adhesive tape to car body

flange.

4. Tap the adhesive tape with a rubber hammer ,

making the body flange fully connect the seal.

Note: Do not distort glue, nor make it off rear

windshield, otherwise there will be water

leakage.

Seal

Rope

Seal

Center

Left

Right

Connection

Push

Pull

Rubber

hammer

Winshield

Seal

Car flange

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12.1 The front combination lamp removal

1. Remove the front bumper (refer to FRONT

BUMPER).

2. Open the front cover, using a 10# wrench remove

the headlight front mounting bolts （M6X15）.

3. Open the door, between door and side panels, using

8 #socket wrench remove the rear mounting bolts

of front headlight （2XM6X10）.

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4. Unplug connector, take off front headlight.

12.2 The headlight bulb removal

Before removing low and high beam headlights, turn signal lights, position light bulb, it is necessary to remove the

headlights from car. And then put aside high/low Beam rubber cover, replace low and high beam light bulb, position light

bulb. Counter-clockwise twist the turn signal bulb socket to replace it.

12.3 The headlight installation

Installation is the reversed order of removal.

13. Side turn signal lights and light bulb replaceme nt

13.1 Side turn signal lamps and Bulb Removal

1. Using a straight screwdriver gently pry off the turn

signal, take out the side turn signal lights from the

door.

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2. Disconnect the turn signal connector, and then

remove turn signal lights. Counter-clockwise twist the

bulb socket to remove the side turn signal light bulb.

13.2 Side turn signal lights installation

Installation is the reversed order of removal.

Replacement of the front fog lamp bulb

14.1 FRONT FOG LIGHTS AND Bulb Removal

1. Lying under front bumper, you can see the fog light

installation point and plug-ins. Disconnect front fog

light connector.

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2. Remove 4 screws with cross screwdriver and

remove the front fog lights.

Counter-clockwise Twist the bulb socket and remove the

front fog light bulb.

14.2 Front fog lamp installation

Installation is the reversed order of removal.

15. Top light and light bulb replacement

15.1 Remove top lamp and Bulb

1. Pry off the top light transparent masks with straight

screwdriver, and then remove the top light bulb

with hand.

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2. Open glasses box, remove two upper fixing screws

with cross screwdriver.

3. Pry off top light in front of glasses box with slotted

screwdriver, and take the top light from the ceiling.

4. Remove the top light connector, take the dome light

off.

15.2 dome light installation

Installation is the reversed order of removal.

16. Replacement of the door lamp bulb

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16.1 Door Light Bulb Removal

1. Remove door cover unit (refer to door cover unit).

2. Disconnect Door Light connector and remove the

door cover unit.

3. Remove the door lamp connector, and make it

away from the door panels. Counter-clockwise

Twist the bulb socket, you can remove the door

light bulb for replacement.

16.2 Door light bulb installation

Installation is the reversed order of removal.

17. Replacement or license plate light and its bulb.

17.1 License Plate Lamp and Bulb Removal

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1. Disconnect license lamp connector.

2. Remove 2 mounting screws of License Plate

Lamp with cross screwdriver.

3. Take off license plate light. License Plate Lamp

assembly needs to be replaced before light bulb

replacement .

17.2 License Plate Lamp installation

Installation is the reversed order of removal.

18. Combination rear lamp and light bulb replacement

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18.1 combination rear light and bulb removal

1. Disconnect the rear combination lamp connector.

2. Remove rear combination light nut (2XM 8) with a

13# socket wrench.

3. Remove combination rear lamp.

4. Use a flathead screwdriver to pry the combination

rear lamp cover, and then counter-clockwise twist the

bulb off.

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18.2 combination rear light installation

Installation is the reversed order of removal.

19. Lamp diagnostic and testing

19.1 position lights, license plate light does not work

steps Operating Yes No

T urn the Light Switch to position light. Check if the small light

relay pin 87 has output voltage?

To step 2 To step 3

2 Check if the fuse F 55, F 56 are normal.

3 Check if the fuse of SB 11 is normal. To step 4

4 Check if the small light relay pin 85 is low voltage? To step 5 To step 7

5 Check if light switch pin 1 is low voltage? To step 6 To step 8

6 Check if light switch is functioning properly?

7 Check if the small light relay pin 85 wire to BCM is normal?

8 Check if light switch pin 1 wire to BCM is normal? To step 9

9 Check if BCM is functioning properly?

19.2 The front dome light does not work

steps Measures Yes No

1 Check if the top light bulb has voltage? To step 2 To step 4

2 Check if the top light bulb filament is fusing? To step 5 To step 3

3 Check if light switch is functioning properly? To step 7 To step 8

4 Check if the fuse of F51 is fusing? To step 6 To step 2

5 Replace the bulb.

6 Replace the fuse.

7 Check ground wiring harness connection

8 Replace the top light.

19.3 High/Low Beam Lights do not work

Steps Measures Yes No

1 Turn the ignition switch ON, check if fuse F32 has 12V voltage? To step 3 To step 2

2 Replace the fuse.

3 Check the headlight relay pin 86 is 12V? To step 4 To step 9

4 Lighting switch 2 Pin connector is low voltage? To step 6 To step 5

5 Light switch is functioning properly? To step 8 To step 7

6 Replace the headlight relay

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7 Replace Light Switch.

8 Check Light Switch 2 pin grounding harness failure.

9 Check if fuse F32 to headlight relay 86 pin wiring harness has

malfunction.

19.4 Only High Beam Lights do not work

steps Measures Yes No

Check if Light Switch 5 Pin Plug-in High Beam wires has 12 V

voltage?

To step 2 To step 4

2 Check Light Switch High Beam function To step 6 To step 3

3 Replace Light Switch.

Check if the high beam light 1 Pin Plug-in to light switch pin 5

wire is conducted.

To step 6 To step 7

5 Replace the bulb.

6 Exclude the malfunction of wire and switch.

7 Troubleshooting

19.5 Only low beam lights do not work

steps Measures Yes No

1 Check if Light Switch connector low beam wires has 12 V voltage? To step 2 To step 3

2 Replace Light Switch.

Check low beam light connector and wiring harness connector is

well contacted.

To step 4 To step 5

4 Replace the bulb.

5 Exclude the Faulty contact.

Diagnostic procedures of front fog light:

steps Measures Yes No

T urn the front fog light switch to "Fog Lights" position, turn on the

front fog lights, check if the instrument indicator works

To step 7 To step 2

2 Check if the fuse #39 is intact? To step 4 To step 3

3 Replace the damaged fuse. To step 4

Remove the front fog light relay to measure voltage of relay socket,

the voltage is normal?

To step 6 To step 5

According to the schematic check INSTRUMENT PANEL

WIRING HARNESS and front fog light switch wiring is

functioning properly? If necessary, should be repaired.

6 Replace the relay, fog lights are functioning properly? To step 7

Check Fog Light connector, ensuring that the voltage and ground is

no problem.

To step 8

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According to schematic check harness between relay and light

switch.

19.7 Diagnostic procedures of rear fpg light:

steps Measures Yes No

T urn the rear fog light switch to the "Fog Lights" position, turn on

the rear fog lights, check if the instrument indicator works?

To step 7 To step 2

2 Check if the fuse #38 is intact? To step 4 To step 3

3 Replace the damaged fuse. To step 4

Remove the rear fog light relay to measure voltage of relay socket,

the voltage is normal?

To step 6 To step 5

According to the schematic check INSTRUMENT PANEL

WIRING HARNESS and front fog light switch wiring is

functioning properly? If necessary, should be repaired.

6 Replace the relay, fog lights are functioning properly? To step 7

Check Fog Light connector, ensuring that the voltage and ground is

no problem.

To step 8 To step 9

According to the schematic check harness from the relay to the fog

light.

According to the schematic check harness from the relay and light

switch to BCM.

19.8 Diagnostic procedures of braking light:

steps Measures Yes No

1 Check if the fuse is in intact? To step 3 To step 2

2 Replace the fuse, is it still broken? To step 5 To step 3

3 Measure voltage of the Fuse is normal? To step 5 To step 4

4 Please check the engine wiring harness.

5 Separate brake switch connector and check the brake switch, making

sure the brake switch is not a problem, measure if the voltage is

normal.

To step 7 To step 6

6 Check the instrument panel harness from brake switch to the fuse.

7 Check the connector between engine and the rear body harness and

make sure it is not a problem.

To step 8

8 Check the body harness from connector to the brake lights. To step 9

9 Check the braking light and harness which connects to its harness. To step 10

10 Please check the rear body Harness locations, making sure it is well

connected to ground.

19.9 Diagnostic procedures of backup light:

steps Measures Yes No

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1 Check if the fuse is intact? To step 3 To step 2

2 Replace the damaged fuse, is the backup light normal? To step 3

3 Check the the connector between engine and cab harness,

measuring if voltage is normal?

To step 4 To step 10

4 Please check the connector between engine and body harness,

measuring if voltage is normal?

To step 5 To step 10

5 Separate reversing light switch connector, measure if connector

voltage is normal?

To step 6 To step 10

6 Please check the instrument panel harness from fuse to the

reversing light switch.

To step 7 To step 10

7 Check the body harness from reverse light switch connector to

body harness, making sure that it is not a problem.

To step 8 To step 10

8 Check the rear combination light and connector leading to its

harness.

To step 9 To step 10

9 Check the body harness location, making sure that it is well

connected to ground.

10 Exclude that the wiring harness is faulty