BG

BGBody

Body

BodyGlass

Glass

-1-

Body

BodyGlass

Glass

Appliedmodels:SUNRAYproductsmanufacturedbyJAC

SubjectPage

Instruction

Instructionand

and

andOperation

Operation

SSTforGlass...................................................................................................................................................................2

Frontwindshield..............................................................................................................................................................3

Removal/Installation

Windshield.......................................................................................................................................................................4

Fronttriangleglass...........................................................................................................................................................7

Frontdoorglass................................................................................................................................................................9

Frontdoorglassseal.......................................................................................................................................................11

Frontdoorglassregulator..............................................................................................................................................12

Leftsidewallglass.........................................................................................................................................................14

Rightsidewallglass......................................................................................................................................................17

Double-openbackdoorglass.........................................................................................................................................21

BG

BGBody

Body

BodyGlass

Glass

-2-

Instruction

Instructionand

and

andOperation

Operation

SST

SSTfor

for

forGlass

Glass

Tool

ToolIllustration

Illustration

IllustrationFunction

Function

Doorhingeadjustingwrench

Foradjustment,removalor

installationofdoorhinge

CeilingremoverForremovalofceiling

Sealantremover

Forcuttingdoorwindow

seal(usedtogetherwiththe

nexttool)

Sealcuttingblade

Forremovingwindshield

sealant(usedtogetherwith

theprevioustool)

Sealantgun

Forapplyingsealantonto

windshield

Glasssuctioncup

Forremoval/installationof

windshield

Windshieldremover

Forremovalofwindshield

molding

BG

Body Glass

-3-

In

struction

Instruction

Instructionand

and

andOperation

Operation

Front

Frontwindshield

windshield

Frontwindshieldismainlycomposedoflaminated

glassandrelevantaccessories(interiorrear-view

mirrorbase,antennaandantennaterminal,pad),

functioningforblockingwindandrainandproviding

safeandcomfortableenvironmentfordriverand

passengers.

BG

BGBody

Body

BodyGlass

Glass

-4-

Removal/Installation

Front

Frontwindshield

windshield

Removal

1.Removeglassmolding

Preparerepairkit,withthefollowingarticles

included:

Sea

lant(carbamicacid

ethylesteradhesive)

Cleaner

PrimerCloth

Woolbrush

Felt

MatNozzle

Note:

Anadditionaltubeofsealantmaybeapplied.

2.Removegrilleandwiperfromvehicleneck..

3.Removeinteriorrear-viewmirror.

4.Disconnectantennaconnector.

BG

BGBody

Body

BodyGlass

Glass

-5-

Removal/Installation

Removal/Installation(Continued)

(Continued)

Front

Frontwindshield

windshield

5.Installtheprecisecuttingblade(24mmhooktype

blade)ontothecutter.

Warning:

Whenusingtoolsforcuttingglasses,pleasewear

glovesandgogglestoavoidpossibleinjurycausedby

glassfragmentsgeneratedduringcutting.

Attention:

Incaseofthewindshieldtobereused,itisprohibitedto

usecutterorelectriccuttingtools.

6.Cutonesideandtopsideofglasssealant.

Cutthepolyurethanesealantontheoutsideof

windshieldfromtheleftlowercornertotheleft

upperpartandthenfromtheupperparttotheright

lowercorner.

Note:

Thewindshieldispositionedbytwoheightadjustable

piecesinstalledonthebottom,whichshouldbeleveled

beforecutting.

7.Cuttheglasssealantatthebottompart.

8.Cuttheglasssealantatthebottompart(continued).

Cutthesealantfromtheoutsidemidpointtoboth

sides.

9.Takethewindshielddowncarefully.

BG

BGBody

Body

BodyGlass

Glass

-6-

Removal/Installation

Removal/Installation(Continued)

(Continued)

Front

Frontwindshield

windshield

Installation

Note:

Don’tcontactthealreadytrimmedsurface,otherwise,

bondingeffectofnewsealantmaybeinfluenced.

1.Trimthesidegrooves.

�Installtheprecisecuttingblade.

�Trimthepolyurethanesealantremainedon

groovescarefully,withpolyurethanesealant

inthicknessof1mmleftonthebodyforside

trimming.

2.Wipetheglassclean.

Trimthepolyurethanesealantremainedonwindow

carefully,withpolyurethanesealantinthicknessof

1mmleftontheglassforsidetrimming.

Caution:

Glassprimercontainssolventthatcanmaketheprimer

hardenedaftervolatilizationbutalsocansoftenthe

surfacecoatofsyntheticpaint,therefore,“ZK”

polypropylenesurfacepaintmixedwithhardenershould

beappliedaroundthewindow.

3.Installthenewheightadjustingbracketsontothe

bottompartofwindshield.

�Clampthemarkpositionofwindshieldcenter

groove.

�Rotatetwoadjustingscrewstolifttheglassto

theuppermost.

�Placetheglassintowindowgrooveand

checkiftheclearancebetweenglasstopand

windowgrooveis2~4mm.Adjustwhen

necessary.

4.Installtheglass.

�Mounttheglassinplacewithcenteraligned.

�Adjustglassbasedonwindowgrooveheight

toensureproperalignment.Adjustwhen

necessary.

�Presstheglasstightlyintothesealantfrom

centerpartgraduallytobothsides.

Note:

Parkthevehicleintheplacewithambienttemperature

ofzerodegreeanddon’tdriveit24hbeforecomplete

curingofcarbamicacidethylesteradhesive.Thecuring

timeisdeterminedbytemperatureandhumidity,which

shallbeprolongedincaseoflowtemperatureand

humidity.

5.Installremainingpartsinreverseorderofremoval.

BG

BGBody

Body

BodyGlass

Glass

-7-

Removal/Installation

Front

Fronttriangle

triangle

triangleglass

glass

Removal

1.Removetherear-viewmirrorfromthewindow.

2.Removetheglass.

Compresstheglasscontinuouslyandforciblyfrom

theinsideuppercorner.

3.Peelofftheseal.

Installation

1.Insertahighstrengthcableintosealandwindow

groovetodeterminetheendpositionofcableand

makeitlappedatthecornerpart.

BG

BGBody

Body

BodyGlass

Glass

-8-

Removal/Installation

Removal/Installation(Continued)

(Continued)

Front

Fronttriangle

triangle

triangleglass

glass

2.Reinstallthewindow.

�Passthecablethroughthewindowgroove

andsticktheloweredgeofsealalongthe

edgeofwindowgroove.

�Compresstheoutsideofglasscontinuously

andforciblyandmeanwhiledrawoneendof

thecabletopressthesealontothewindow

groove.

�Repeatthoseactionuntilthewindowis

properlyinstalledandthencheckifthesealis

sealedproperly.

BG

BGBody

Body

BodyGlass

Glass

-9-

Removal/Installation

Front

Frontdoor

door

doorglass

glass

1.Disconnectthenegativecableofbattery.

2.Removetheinteriortrimpanelofdoor.

3.Disconnecttheharnessconnectorofinteriortrim

panelofdoor.

4.Peeloffthewaterproofmembrane.

BG

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BodyGlass

Glass

-10-

Removal/Installation

Removal/Installation(Continued)

(Continued)

Front

Frontdoor

door

doorwindow

window

5.Pullouttheglasssealfromtoptobottom.

6.Removetheloudspeaker.

7.Removetheglassregulatormotor.

8.Takedowntheglassfromthewindowcarefully.

BG

BGBody

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BodyGlass

Glass

-

11

-

Removal/Installation

Front

Frontdoor

door

doorglass

glass

glassseal

seal

Removal

1.Disconnectthenegativecableofbattery.

2.Peeloffthewindowglassseal.

Note:

Peeloffthewindowglasssealcompletelyfromtopto

bottomasshowninthefigure.

Installation

1.Installthesealintodoorpanelfromthefront

bottomcorner.

BG

BGBody

Body

BodyGlass

Glass

-12-

Removal/Installation

Front

Frontdoor

door

doorglass

glass

glassregulator

regulator

Removal

1.Disconnectthenegativecableofbattery.

2.Peeloffthewindowglassseal.

Note:

Peeloffthewindowglasssealcompletelyfromtopto

bottomasshowninthefigure.

3.Removethewaterproofmembrane.

4.Removetheloudspeaker.

BG

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BodyGlass

Glass

-13-

Removal/Installation

Removal/Installation(Continued)

(Continued)

Front

Frontdoor

door

doorglass

glass

glassregulator

regulator

5.Removethemountingscrewsforregulatormotor.

6.Takedowntheregulatormotor.

Installation

Installitinreverseorderofremoval.

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BGBody

Body

BodyGlass

Glass

-14-

Removal/Installation

Left

Leftside

side

sidewall

wall

wallglass

glass

Removal

1.Preparenecessarytools.

2.Peeloffthewindowglassseal.

Note:

Peeloffthewindowglasssealcompletelyfromtopto

bottomasshowninthefigure.

3.RemoveupperandlowerguardplatesofB-pillar.

4.RemoveupperandlowerguardplatesofB-pillar.

BG

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BodyGlass

Glass

-15-

Removal/Installation

Removal/Installation(Continued)

(Continued)

Left

Leftside

side

sidewall

wall

wallglass

glass

5.Installtheprecisecuttingblade(24mmhooktype

blade)ontothecutter.

Warning:

Whenusingtoolsforcuttingglasses,pleaseweargloves

andgogglestoavoidpossibleinjurycausedby

glassfragmentsgeneratedduringcutting.

Attention:

Incaseofthewindshieldtobereused,itisprohibited

tousecutterorelectriccuttingtools.

6.Removethefrontdoorwindowseal.

Note:

Peeloffthewindowglasssealcompletelyfromtop

tobottomasshowninthefigure.

7.Cuttheglasssealant,asshowninthefigure.

Note:

Twopersonsarenecessaryforremovalofglassand

oneshouldstandoutsidetoholdtheglassby

usingsuctioncup.

BG

BGBody

Body

BodyGlass

Glass

-16-

Removal/Installation

Left

Leftside

side

sidewall

wall

wallglass

glass

Installation

1.Preparerepairkit,withthefollowingarticles

included:

Sea

lant(carbamicacid

ethylesteradhesive)

Cleaner

PrimerCloth

Woolbrush

Felt

MatNozzle

Note:

Note:Anadditionaltubeofsealantmaybeapplied.

Note:

Peeloffthewindowglasssealcompletelyfromtop

tobottomasshowninthefigure.

Note:

Don’tcontactthealreadytrimmedsurface,

otherwise,bondingeffectofnewsealantmaybe

influenced.

2.Trimthesidegrooves.

�Installtheprecisecuttingblade.

Trimthepolyurethanesealantremainedongrooves

carefully,withpolyurethanesealantinthicknessof1mm

leftonthebodyforsidetrimming.

3.Wipetheglassclean.

Trimthepolyurethanesealantremainedonwindow

carefully,withpolyurethanesealantinthicknessof

1mmleftontheglassforsidetrimming.

Caution:

Glassprimercontainssolventthatcanmaketheprimer

hardenedaftervolatilizationbutalsocansoftenthe

surfacecoatofsyntheticpaint;therefore,“ZK”

polypropylenesurfacepaintmixedwithhardenershould

beappliedaroundthewindow.

4.Installtheglass.

�Mounttheglassinplacewithcenteraligned.

�Adjustglassbasedonwindowgrooveheightto

ensureproperalignment.Adjustwhennecessary.

�Presstheglasstightlyintothesealantfromcenter

partgraduallytobothsides.

Note:

Parkthevehicleintheplacewithambienttemperature

ofzerodegreeanddon’tdriveit24hbeforecomplete

curingofcarbamicacidethylesteradhesive.Thecuring

timeisdeterminedbytemperatureandhumidity,which

shallbeprolongedincaseoflowtemperatureand

humidity.

5.Installremainingpartsinreverseorderofremoval.

BG

BGBody

Body

BodyGlass

Glass

-17-

Removal/Installation

Right

Rightside

side

sidewall

wall

wallglass

glass

Removal

1.Sidewallglass.

2.Removethecurtain.

3.Removethesidepillartrimpanel.

4.Removetwomountingboltsforglass.

Attention:

Twoservicepersonsarenecessaryfortheremoval.

BG

BGBody

Body

BodyGlass

Glass

-18-

Removal/Installation

Removal/Installation(Continued)

(Continued)

Right

Rightside

side

sidewall

wall

wallglass

glass

5.Removethemountingboltsforglassandtakethe

glassdown.

Installation

Installitinreverseorderofremoval.

BG

BGBody

Body

BodyGlass

Glass

-19-

Removal/Installation

Rear

Rearside

side

sidewall

wall

wallglass

glass

Removal

1.Rearsidewallglass.

2.Removethecurtain.

3.Removeupperandlowertrimpanelsandguard

platesofpillar-D.

4.Removethemountingboltsforglassandtakethe

glassdowncarefully.

BG

BGBody

Body

BodyGlass

Glass

-20-

Removal/Installation

Rear

Rearside

side

sidewall

wall

wallglass

glass

5.Removethemountingboltsforglassandtakethe

glassdowncarefully.

Installation

Installitinreverseorderofremoval.

BG

BGBody

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BodyGlass

Glass

-21-

Removal/Installation

Double-open

Double-openback

back

backdoor

door

doorglass

glass

1.Preparerepairkit,withthefollowingarticles

included:

Sealant(carbamicacid

ethylesteradhesive)

Cleaner

PrimerCloth

Woolbrush

Felt

MatNozzle

Note:

Note:Anadditionaltubeofsealantmaybeapplied.

2.Installtheprecisecuttingblade(24mmhooktype

blade)ontothecutter.

Warning:

Whenusingtoolsforcuttingglasses,pleaseweargloves

andgogglestoavoidbeinginjuredbyglassfragments

generatedduringcutting.

Attention:

Incaseofthewindshieldtobereused,itisprohibitedto

usecutterorelectriccuttingtools.

3.Removethedouble-openbackdoorglassseal.

4.Cuttheglasssealantinthedirectionshownin

figure.

BG

BGBody

Body

BodyGlass

Glass

-22-

Removal/Installation

Double-open

Double-openback

back

backdoor

door

doorglass

glass

Note:

Don’tcontactthealreadytrimmedsurface;

otherwise,bondingeffectofnewsealantmaybe

influenced.

1.Trimthesidegrooves.

�Installtheprecisecuttingblade.

Trimthepolyurethanesealantremainedongrooves

carefully,withpolyurethanesealantinthicknessof

1mmleftonthebodyforsidetrimming.

2.Wipetheglassclean.

Trimthepolyurethanesealantremainedonwindow

carefully,withpolyurethanesealantinthicknessof

1mmleftontheglassforsidetrimming.

Caution:

Glassprimercontainssolventthatcanmaketheprimer

hardenedaftervolatilizationbutalsocansoftenthe

surfacecoatofsyntheticpaint;therefore,“ZK”

polypropylenesurfacepaintmixedwithhardenershould

beappliedaroundthewindow.

3.Installtheglass.

�Mounttheglassinplacewithcenteraligned.

�Adjustglassbasedonwindowgrooveheightto

ensureproperalignment.Adjustwhennecessary.

�Presstheglasstightlyintothesealantfromcenter

partgraduallytobothsides.

Note:

Parkthevehicleintheplacewithambient

temperatureofzerodegreeanddon’tdriveit24hbefore

completecuringofcarbamicacidethylesteradhesive.

Thecuringtimeisdeterminedbytemperatureand

humidity,whichisprolongedincaseoflowtemperature

andhumidity.

4.Installremainingpartsinreverseorderofremoval.

BD

BDFront/Rear

Front/Rear

Front/RearDoors

Doors

Doorsand

and

andFront

Front

FrontCompartment

Compartment

CompartmentCover

Cover

-23-

Front/Rear

Front/RearDoors

Doors

Doorsand

and

andFront

Front

FrontCompartment

Compartment

CompartmentCover

Cover

Appliedmodels:SUNRAYproductsmanufacturedbyJAC

SubjectPage

Instruction

Instructionand

and

andOperation

Operation

Frontcompartmentcover...............................................................................................................................................24

Removal/Installation

Frontcompartmentcover...............................................................................................................................................25

Radiatorcorebracket.....................................................................................................................................................28

Compartmentcoverreleasecable..................................................................................................................................29

Rightfrontdoor..............................................................................................................................................................31

Leftfrontdoor................................................................................................................................................................34

Doorouterhandle...........................................................................................................................................................37

Doorlockcylinder.........................................................................................................................................................39

Leftfrontdoorlockbody...............................................................................................................................................41

Rightfrontdoorlockbody.............................................................................................................................................44

Doorseal........................................................................................................................................................................46

Double-openbackdoor..................................................................................................................................................47

Double-openbackdoorouterhandle.............................................................................................................................50

Double-openbackdoorlatch.........................................................................................................................................52

Double-openbackdoorlockanddriverod....................................................................................................................53

Double-openbackdoorlock..........................................................................................................................................55

Double-openbackdoorseal...........................................................................................................................................57

BD

BDFront/Rear

Front/Rear

Front/RearDoors

Doors

Doorsand

and

andFront

Front

FrontCompartment

Compartment

CompartmentCover

Cover

-24-

Instruction

Instructionand

and

andOperation

Operation

Front

Frontcompartment

compartment

compartmentcover

cover

BD

BDFront/Rear

Front/Rear

Front/RearDoors

Doors

Doorsand

and

andFront

Front

FrontCompartment

Compartment

CompartmentCover

Cover

-25-

Removal/Installation

Front

Frontcompartment

compartment

compartmentcover

cover

1.Openthefrontcompartmentcover.

2.Markbelowthemountingboltsoffrontfender.

3.Removefourmountingboltsonbothleftandright

sides.

4.Twopersonsworktogethertoliftthefront

compartmentcoverdown.

BD

BDFront/Rear

Front/Rear

Front/RearDoors

Doors

Doorsand

and

andFront

Front

FrontCompartment

Compartment

CompartmentCover

Cover

-26-

Removal/Installation

Removal/Installation(Continued)

(Continued)

Front

Frontcompartment

compartment

compartmentcover

cover

1.Installthecoverwithmountingmarksproperly

aligned.

2.Twopersonsworktogethertoinstallthefront

compartmentcover.

BD

BDFront/Rear

Front/Rear

Front/RearDoors

Doors

Doorsand

and

andFront

Front

FrontCompartment

Compartment

CompartmentCover

Cover

-27-

Inspection/Adjustment

Front

Frontcompartment

compartment

compartmentcover

cover

1.Theadjustmentdirectionoffrontcompartment

coverisshowninthefigure.

2.Asshowninthefigure,clearancebetweenleft/right

sideofthecoverandfendershallmeetthe

requirements.

3.Adjusttheheightofpadandensuretheheightof

bothfenderandcovermeettherequirementsafter

theclosingoffrontcompartmentcover.

BD

BDFront/Rear

Front/Rear

Front/RearDoors

Doors

Doorsand

and

andFront

Front

FrontCompartment

Compartment

CompartmentCover

Cover

-28-

Removal/Installation

Radiator

Radiatorcore

core

corebracket

bracket

1.Removethelockbodyoffrontcompartmentcover.

2.Removemountingboltsforradiatorcorebracket.

3.Removemountingboltsforradiatorcorebracket.

Installation

Installitinreverseorderofremoval.

BD

BDFront/Rear

Front/Rear

Front/RearDoors

Doors

Doorsand

and

andFront

Front

FrontCompartment

Compartment

CompartmentCover

Cover

-29-

Removal/Installation

Compartment

Compartmentcover

cover

coverrelease

release

releasecable

cable

1.Openthefrontcompartmentcover.

2.Removethecablehandleoffrontcompartment

coveranddisconnectthecable.

3.Removethefrontgrille.

4.Removemountingboltsforlockbody.

BD

BDFront/Rear

Front/Rear

Front/RearDoors

Doors

Doorsand

and

andFront

Front

FrontCompartment

Compartment

CompartmentCover

Cover

-30-

Removal/Installation

Removal/Installation(Continued)

(Continued)

Compartment

Compartmentcover

cover

coverrelease

release

releasecable

cable

5.Disconnectthecable.

6.Removethecable.

Installation

Installitinreverseorderofremoval.

BD

BDFront/Rear

Front/Rear

Front/RearDoors

Doors

Doorsand

and

andFront

Front

FrontCompartment

Compartment

CompartmentCover

Cover

-31-

Removal/Installation

Right

Rightfront

front

frontdoor

door

1.Disconnectthenegativecableofbattery.

2.Removethefrontbumper.

(RefertoRemovalofFrontBumper,ExteriorTrim.)

3.Removethefender.

(RefertoRemovalofFender,Exterior

Trim.)

4.Disconnecttherightdoorharnessconnector.

BD

BDFront/Rear

Front/Rear

Front/RearDoors

Doors

Doorsand

and

andFront

Front

FrontCompartment

Compartment

CompartmentCover

Cover

-32-

Removal/Installation

Removal/Installation(Continued)

(Continued)

Right

Rightfront

front

frontdoor

door

5.Removemountingscrewsforrightfrontdoor

check.

6.Removemountingscrewsforhinges.Twopersons

shallworktogethertoremovethedoor.

BD

BDFront/Rear

Front/Rear

Front/RearDoors

Doors

Doorsand

and

andFront

Front

FrontCompartment

Compartment

CompartmentCover

Cover

-33-

Inspection/Adjustment

Right

Rightfront

front

frontdoor

door

1.Adjustdoorhinges.

2.Adjustdoorlatchesinfourdirectionsshowninthe

figure.

BD

BDFront/Rear

Front/Rear

Front/RearDoors

Doors

Doorsand

and

andFront

Front

FrontCompartment

Compartment

CompartmentCover

Cover

-34-

Removal/Installation

Left

Leftfront

front

frontdoor

door

1.Disconnectthenegativecableofbattery.

2.Removethefrontbumper.

(RefertoRemovalofFrontBumper,ExteriorTrim.)

3.Removethefrontfender.

(RefertoRemovalofFender,Exterior

Trim.)

4.Disconnectthedoorharnessconnector.

BD

BDFront/Rear

Front/Rear

Front/RearDoors

Doors

Doorsand

and

andFront

Front

FrontCompartment

Compartment

CompartmentCover

Cover

-35-

Removal/Installation

Left

Leftfront

front

frontdoor

door

5.Removemountingscrewsforleftfrontdoorcheck.

6.Removemountingscrewsforhinges.Becausethe

doorisheavy,sotwoservicepersonsarenecessary

fortheremovalofdoor.

BD

BDFront/Rear

Front/Rear

Front/RearDoors

Doors

Doorsand

and

andFront

Front

FrontCompartment

Compartment

CompartmentCover

Cover

-36-

Inspection/Adjustment

Left

Leftfront

front

frontdoor

door

1.Adjustdoorhingesinfourdirectionsshowninthe

figure.

2.Adjustdoorlatchesinfourdirectionsshowninthe

figure.

BD

BDFront/Rear

Front/Rear

Front/RearDoors

Doors

Doorsand

and

andFront

Front

FrontCompartment

Compartment

CompartmentCover

Cover

-37-

Removal/Installation

Left

Leftfront

front

frontdoor

door

doorouter

outer

outerhandle

handle

1.Disconnectthenegativecableofbattery.

2.Removedoortrimpanel.

3.Removedoorwaterproofmembrane.

4.Unscrewmountingscrewsfordoorhandle.

BD

BDFront/Rear

Front/Rear

Front/RearDoors

Doors

Doorsand

and

andFront

Front

FrontCompartment

Compartment

CompartmentCover

Cover

-38-

Removal/Installation

Removal/Installation(Continued)

(Continued)

Left

Leftfront

front

frontdoor

door

doorouter

outer

outerhandle

handle

5.Disconnectthedoorhandlelinkageandremove

mountingscrewsfordoorhandle.

6.Takedownthedoorhandle.

BD

BDFront/Rear

Front/Rear

Front/RearDoors

Doors

Doorsand

and

andFront

Front

FrontCompartment

Compartment

CompartmentCover

Cover

-39-

Removal/Installation

Left

Leftfront

front

frontdoor

door

doorlock

lock

lockcylinder

cylinder

1.Disconnectthenegativecableofbattery.

2.Removetheinteriortrimpanelofdoor.

3.Removewaterproofmembrane.

4.Removemountingscrewsfordoorhandle.

BD

BDFront/Rear

Front/Rear

Front/RearDoors

Doors

Doorsand

and

andFront

Front

FrontCompartment

Compartment

CompartmentCover

Cover

-40-

Removal/Installation

Removal/Installation(Continued)

(Continued)

Left

Leftfront

front

frontdoor

door

doorlock

lock

lockcylinder

cylinder

5.Removedoorhandle.

6.Removedoorlockcylinder.

BD

BDFront/Rear

Front/Rear

Front/RearDoors

Doors

Doorsand

and

andFront

Front

FrontCompartment

Compartment

CompartmentCover

Cover

-41-

Removal/Installation

Left

Leftfront

front

frontdoor

door

doorlock

lock

lockbody

body

Removal

1.Disconnectthenegativecableofbattery.

2.Removethedoortrimpanel.

3.Peeloffthewaterproofmembrane.

4.Removethreemountingscrewsforlockbody.

BD

BDFront/Rear

Front/Rear

Front/RearDoors

Doors

Doorsand

and

andFront

Front

FrontCompartment

Compartment

CompartmentCover

Cover

-42-

Removal/Installation

Removal/Installation(Continued)

(Continued)

Left

Leftfront

front

frontdoor

door

doorlock

lock

lockbody

body

5.Removethelinkageoflockbody.

6.Takeoutthewholelockbody.

BD

BDFront/Rear

Front/Rear

Front/RearDoors

Doors

Doorsand

and

andFront

Front

FrontCompartment

Compartment

CompartmentCover

Cover

-43-

Removal/Installation

Removal/Installation(Continued)

(Continued)

Left

Leftfront

front

frontdoor

door

doorlock

lock

lockbody

body

Installation

1.Installthelockbodyintodoor.

2.Connecteachlinkageproperly.Asforotherparts,

pleaseinstalltheminreverseorderofremoval.

BD

BDFront/Rear

Front/Rear

Front/RearDoors

Doors

Doorsand

and

andFront

Front

FrontCompartment

Compartment

CompartmentCover

Cover

-44-

Removal/Installation

R

Right

ight

ightfront

front

frontdoor

door

doorlock

lock

lockbody

body

Removal

1.Disconnectthenegativecableofbattery.

2.Removemountingscrewsfordoor.

3.Removedoortrimpanel.

4.Peeloffthewaterproofmembrane.

BD

BDFront/Rear

Front/Rear

Front/RearDoors

Doors

Doorsand

and

andFront

Front

FrontCompartment

Compartment

CompartmentCover

Cover

-45-

Removal/Installation

Removal/Installation(Continued)

(Continued)

R

Right

ight

ightfront

front

frontdoor

door

doorlock

lock

lockbody

body

5.Removethreemountingboltsfordoorlock.

6.Disconnectthedoorlinkageandthenremovethe

lockassembly.

Installation

Installitinreverseorderofremoval.

BD

BDFront/Rear

Front/Rear

Front/RearDoors

Doors

Doorsand

and

andFront

Front

FrontCompartment

Compartment

CompartmentCover

Cover

-46-

Removal/Installation

Door

Doorseal

seal

1.Removethestepplate.

2.Peeloffdoorsealfromtoptobottom.

Attention:

Afterremovalofdoorseal,pleasedon’ttensiontheseal

forcibly.

Installation

Installitinreverseorderofremoval.

BD

BDFront/Rear

Front/Rear

Front/RearDoors

Doors

Doorsand

and

andFront

Front

FrontCompartment

Compartment

CompartmentCover

Cover

-47-

Removal/Installation

Double-open

Double-openback

back

backdoor

door

Removal

1.Disconnectthenegativecableofbattery.

2.Disconnecttheharnessofleftdoor.

3.Removeboltsfordoorhinge.

4.Removeboltsfordoorhinge.

Attention:

Becausethedouble-openbackdoorisheavy,sojack

maybeappliedwhennecessarytoholdthedoor,during

which,usesomeclothwrappingthejackedparttoavoid

damagetopaintsurface.

BD

BDFront/Rear

Front/Rear

Front/RearDoors

Doors

Doorsand

and

andFront

Front

FrontCompartment

Compartment

CompartmentCover

Cover

-48-

Removal/Installation

Removal/Installation(Continued)

(Continued)

Double-open

Double-openback

back

backdoor

door

5.Removeboltsforrightdoorhinge.

6.Removeboltsforrightdoorhinge.

Attention:

Becausethedouble-openbackdoorisheavy,sojack

maybeappliedwhennecessarytoholdthedoor,during

which,usesomeclothwrappingthejackedparttoavoid

damagetopaintsurface.

BD

BDFront/Rear

Front/Rear

Front/RearDoors

Doors

Doorsand

and

andFront

Front

FrontCompartment

Compartment

CompartmentCover

Cover

-49-

Removal/Installation

Double-open

Double-openback

back

backdoor

door

Installation

1.Aftertheinstallationofbackdoor,lower/upper

clearanceshouldbeadjustedproperly.

BD

BDFront/Rear

Front/Rear

Front/RearDoors

Doors

Doorsand

and

andFront

Front

FrontCompartment

Compartment

CompartmentCover

Cover

-50-

Removal/Installation

Back

Backdoor

door

doorouter

outer

outerhandle

handle

Removal

1.Removeinnerhandleshieldofbackdoor.

2.Removemountingscrewsforbackdoorinner

handleassembly.

3.Disconnectthelinkage.

4.Disconnectthelinkagewithouterhandle.

BD

BDFront/Rear

Front/Rear

Front/RearDoors

Doors

Doorsand

and

andFront

Front

FrontCompartment

Compartment

CompartmentCover

Cover

-51-

Removal/Installation

Removal/Installation(Continued)

(Continued)

Back

Backdoor

door

doorouter

outer

outerhandle

handle

5.Removemountingscrewsforouterhandle.

6.Removeouterhandle.

Installation

Installitinreverseorderofremoval.

BD

BDFront/Rear

Front/Rear

Front/RearDoors

Doors

Doorsand

and

andFront

Front

FrontCompartment

Compartment

CompartmentCover

Cover

-52-

Removal/Installation

Back

Backdoor

door

doorlatch

latch

1.Removemountingscrewsforbackdoorlatch.

2.Removethebackdoorlatch.

Installation

Installitinreverseorderofremoval.

BD

BDFront/Rear

Front/Rear

Front/RearDoors

Doors

Doorsand

and

andFront

Front

FrontCompartment

Compartment

CompartmentCover

Cover

-53-

Removal/Installation

Outer

Outerlock

lock

lockof

of

ofback

back

backdoor

door

Removal

1.Removeinnerhandleshield.

2.Removemountingscrewsforinnerhandle.

3.Disconnectthelinkageofinnerhandle.

4.Disconnectthelinkagewithdoorlock.

BD

BDFront/Rear

Front/Rear

Front/RearDoors

Doors

Doorsand

and

andFront

Front

FrontCompartment

Compartment

CompartmentCover

Cover

-54-

Removal/Installation

Removal/Installation(Continued)

(Continued)

Outer

Outerlock

lock

lockof

of

ofback

back

backdoor

door

5.Removethreemountingboltsfordoorlock.

6.Removethelinkageassembly.

Installation

Installitinreverseorderofremoval.

BD

BDFront/Rear

Front/Rear

Front/RearDoors

Doors

Doorsand

and

andFront

Front

FrontCompartment

Compartment

CompartmentCover

Cover

-55-

Removal/Installation

Inner

Innerlock

lock

lockof

of

ofback

back

backdoor

door

Removal

1.Removeinteriortrimpanelofbackdoor.

2.Removetheuppermountingbracketofdoorlock.

3.Removethelowermountingbracketofdoorlock.

4.Removemountingscrewsfordoorlatch.

BD

BDFront/Rear

Front/Rear

Front/RearDoors

Doors

Doorsand

and

andFront

Front

FrontCompartment

Compartment

CompartmentCover

Cover

-56-

Removal/Installation

Removal/Installation(Continued)

(Continued)

Inner

Innerlock

lock

lockof

of

ofback

back

backdoor

door

5.Disconnectcirclipbetweendoorlatchandlinkage.

6.Thecirclipisshowninthefigure.Removethelock

linkageassembly.

Installation

Installitinreverseorderofremoval.

BD

BDFront/Rear

Front/Rear

Front/RearDoors

Doors

Doorsand

and

andFront

Front

FrontCompartment

Compartment

CompartmentCover

Cover

-57-

Removal/Installation

Back

Backdoor

door

doorseal

seal

Removal

1.Peeloffthesealforciblyfromtoptobottom.

Installation

Installitinreverseorderofremoval.

BD

BDFront/Rear

Front/Rear

Front/RearDoors

Doors

Doorsand

and

andFront

Front

FrontCompartment

Compartment

CompartmentCover

Cover

-58-

BP

BPInterior/Exterior

Interior/Exterior

Interior/ExteriorTrims

Trims

-59-

Interior/Exterior

Interior/ExteriorTrims

Trims

Appliedmodels:SUNRAYproductsmanufacturedbyJAC

SubjectPage

Instruction

Instructionand

and

andOperation

Operation

Instrumentpanel.............................................................................................................................................................60

Removal/Installation

Instrumentpanel.............................................................................................................................................................61

Rooflining.....................................................................................................................................................................69

TrimpanelofA-pillar....................................................................................................................................................74

TrimpanelofB-pillar....................................................................................................................................................75

TrimpanelofC-pillar....................................................................................................................................................78

Sidewallwindowtrimpanel..........................................................................................................................................80

TrimpanelofD-pillar....................................................................................................................................................84

Interiortrimpanel..........................................................................................................................................................86

Frontdoortrimpanel.....................................................................................................................................................88

Double-openbackdoortrimpanel.................................................................................................................................89

Interiorrear-viewmirror................................................................................................................................................91

Sunvisor........................................................................................................................................................................92

Curtains..........................................................................................................................................................................93

Luggagerack..................................................................................................................................................................94

Stepplateassembly........................................................................................................................................................96

Frontbumper..................................................................................................................................................................97

Rearbumper...................................................................................................................................................................99

Frontgrille...................................................................................................................................................................101

Fender..........................................................................................................................................................................102

Frontdoorskirttrimpanel...........................................................................................................................................106

Frontsidewallskirttrimpanel....................................................................................................................................107

Middlesidewallskirttrimpanel.................................................................................................................................108

Rearwheelskirttrimpanel..........................................................................................................................................109

Reartiremudguard......................................................................................................................................................110

BP

BPInterior/Exterior

Interior/Exterior

Interior/ExteriorTrims

Trims

-60-

Instruction

Instructionand

and

andOperation

Operation

Instrument

Instrumentpanel

panel

BP

BPInterior/Exterior

Interior/Exterior

Interior/ExteriorTrims

Trims

-61-

Removal/Installation

Instrument

Instrumentpanel

panel

1.Removethenegativecableofbattery.

2.Removetheuppercoverofsteeringwheel.

3.Therearetwomountingscrewsontheleftand

rightsidesofuppercoverofsteeringwheel.

4.Unscrewthemountingnutsofsteeringwheeland

takedownthesteeringwheel.

BP

BPInterior/Exterior

Interior/Exterior

Interior/ExteriorTrims

Trims

-62-

Removal/Installation

Removal/Installation(Continued)

(Continued)

Instrument

Instrumentpanel

panel

5.Removetheinstrumentcover.

6.Removefourmountingscrewsofinstrument.

7.Removetheharnessconnectorsofinstruments.

8.Removethreemountingscrewsonthelowercover

ofsteeringwheelandtakedownthelowercover.

BP

BPInterior/Exterior

Interior/Exterior

Interior/ExteriorTrims

Trims

-63-

Removal/Installation

Removal/Installation(Continued)

(Continued)

Instrument

Instrumentpanel

panel

9.Removefourmountingscrewsoftheclockspring

andtakedowntheclockspring.

10.Removethreemountingscrewsofcombined

switchandtakedowntheswitch.

11.RemovetwomountingscrewsofrearA/Ccontrol

panel.

12.DisconnecttheharnessofrearA/Ccontrolpanel.

BP

BPInterior/Exterior

Interior/Exterior

Interior/ExteriorTrims

Trims

-64-

Removal/Installation

Removal/Installation(Continued)

(Continued)

Instrument

Instrumentpanel

panel

13.RemovetwomountingscrewsofA/Ccontrol

panel.

14.DisconnecttheharnessofA/Ccontrolpanel.

15.Removeaudiocoverwithtool.

16.Disconnecttheharnessconnectorofaudiocover.

BP

BPInterior/Exterior

Interior/Exterior

Interior/ExteriorTrims

Trims

-65-

Removal/Installation

Removal/Installation(Continued)

(Continued)

Instrument

Instrumentpanel

panel

17.Removefourmountingscrewsofaudio.

18.Disconnecttheharnessconnectorofaudio.

19.Removethelowercoverofinstrumentpanel.

20.Removetheglovebox.

BP

BPInterior/Exterior

Interior/Exterior

Interior/ExteriorTrims

Trims

-66-

Removal/Installation

Removal/Installation(Continued)

(Continued)

Instrument

Instrumentpanel

panel

21.Loosentwomountingscrewsofinstrumentpanel.

22.Removethemountingboltontheleftsideof

instrumentpanel.

23.Removethemountingboltontherightsideof

instrumentpanel.

Note:

Therearethreemountingscrewsoninstrument

panelintotal,respectivelyontheleft,middleand

rightpart.

24.Removetwomountingboltsontheleftsideof

instrumentpanel.

BP

BPInterior/Exterior

Interior/Exterior

Interior/ExteriorTrims

Trims

-67-

Removal/Installation

Removal/Installation(Continued)

(Continued)

Instrument

Instrumentpanel

panel

25.Removetwomountingboltontherightsideof

instrumentpanel.

26.Removetheshiftlever.

27.Removethemountingboltsforshiftlever

assembly.

28.Removetheinstrumentpanelcarefully.

Note:

Twoservicepersonsarenecessaryforremovalof

instrumentpanel.

BP

BPInterior/Exterior

Interior/Exterior

Interior/ExteriorTrims

Trims

-68-

Removal/Installation

Instrument

Instrumentpanel

panel

Installation

1.Duringtheinstallationofinstrumentpanel,the

clockspringshouldbeinstalledunderthepremise

thatthewheelsfaceforwardanditshouldbe

rotatedclockwiseuntilrotationdisabled(rotating

withproperforceinsteadofusingtoomuchforce),

andthenrotatedcounterclockwisebythreecircles

withcenteringtrianglemarksaligned.

2.Installotherpartsinreverseorderofremoval.

BP

BPInterior/Exterior

Interior/Exterior

Interior/ExteriorTrims

Trims

-69-

Instruction

Instructionand

and

andOperation

Operation

Roof

Rooflining

lining

BP

BPInterior/Exterior

Interior/Exterior

Interior/ExteriorTrims

Trims

-70-

Removal/Installation

Roof

Rooflining

lining

Removal

1.Removethenegativecableofbattery.

2.Removecurtains.

3.RemoveupperandlowertrimpanelsofB-pillar.

4.Removeluggageracksonboltleftandrightsides.

BP

BPInterior/Exterior

Interior/Exterior

Interior/ExteriorTrims

Trims

-71-

Removal/Installation

Roof

Rooflining

lining

5.Removeinteriorceilinglamp1.

6.Removeinteriorceilinglamp2.

7.Removerightsunvisor.

8.Removeleftsunvisor.

BP

BPInterior/Exterior

Interior/Exterior

Interior/ExteriorTrims

Trims

-72-

Removal/Installation

Roof

Rooflining

lining

9.Removefrontinteriorceilinglamp.

10.Removeclipsofrearroofliningandtakedownthe

rearrooflining.

11.Removeclipsofmiddleroofliningandtakedown

themiddlerooflining.

12.Removeclipsoffrontroofliningandtakedown

thefrontrooflining.

BP

BPInterior/Exterior

Interior/Exterior

Interior/ExteriorTrims

Trims

-73-

Removal/Installation

Roof

Rooflining

lining

Installation

Twoservicepersonsarenecessaryforinstallationof

rooflining,toavoidfractureofroofinteriortrim.

BP

BPInterior/Exterior

Interior/Exterior

Interior/ExteriorTrims

Trims

-74-

Removal/Installation

Right/Left

Right/Leftupper

upper

uppertrim

trim

trimpanel

panel

panelof

of

ofA-pillar

A-pillar

Removal

1.RemoveleftuppertrimpanelofA-pillarwithtool.

2.RemoverightuppertrimpanelofA-pillarwith

tool.

Installation

Installitinreverseorderofremoval.

BP

BPInterior/Exterior

Interior/Exterior

Interior/ExteriorTrims

Trims

-75-

Removal/Installation

Right

Rightupper/lower

upper/lower

upper/lowertrim

trim

trimpanel

panel

panelof

of

ofB-pillar

B-pillar

Removal

1.Removecurtains.

2.Removetwomountingscrewsforrightlowertrim

panelofB-pillarandthenremovethelowertrim

panel.

3.Removeamountingscrewforuppertrimpanelof

B-pillarandthenremovetheuppertrimpanel.

Installation

Installitinreverseorderofremoval.

BP

BPInterior/Exterior

Interior/Exterior

Interior/ExteriorTrims

Trims

-76-

Removal/Installation

Removal/Installationfor

for

forB-pillar

B-pillar

B-pillarTrim

Trim

TrimPanel

Panel

Left

Leftupper/lower

upper/lower

upper/lowertrim

trim

trimpanel

panel

panelof

of

ofB-pillar

B-pillar

Removal

1.Removecurtains.

2.Removetwomountingscrewsforleftlowertrim

panelofB-pillarandthenremovethelowertrim

panel.

3.Removemountingboltsforseatbelt.

4.Removemountingscrewsforrightuppertrim

panelofB-pillarandthenremovetheuppertrim

panel.

BP

BPInterior/Exterior

Interior/Exterior

Interior/ExteriorTrims

Trims

-77-

Removal/Installation

Left

Leftupper/lower

upper/lower

upper/lowertrim

trim

trimpanel

panel

panelof

of

ofB-pillar

B-pillar

Installation

Installitinreverseorderofremoval.

BP

BPInterior/Exterior

Interior/Exterior

Interior/ExteriorTrims

Trims

-78-

Removal/Installation

Removal/Installationfor

for

forC-pillar

C-pillar

C-pillarTrim

Trim

TrimPanel

Panel

Left/Right

Left/Righttrim

trim

trimpanel

panel

panelof

of

ofC-pillar

C-pillar

Removal

1.Removecurtains.

2.Removerightupperandlowertrimpanelsof

C-pillar.

3.RemoverighttrimpanelofC-pillar.

4.Removeleftupperandlowertrimpanelsof

C-pillar.

BP

BPInterior/Exterior

Interior/Exterior

Interior/ExteriorTrims

Trims

-79-

Removal/Installation

Removal/Installation(Continued)

(Continued)

Left/Right

Left/Righttrim

trim

trimpanel

panel

panelof

of

ofC-pillar

C-pillar

5.RemovelefttrimpanelofC-pillar.

Installation

Installitinreverseorderofremoval.

BP

BPInterior/Exterior

Interior/Exterior

Interior/ExteriorTrims

Trims

-80-

Removal/Installation

Right

Rightside

side

sidewall

wall

wallwindow

window

windowtrim

trim

trimpanel

panel

Removal

1.Removecurtains.

2.Removeuppertrimpanel1andlowertrimpanel1

ofrightsidewallwindowpillar.

3.Removeuppertrimpanel2andlowertrimpanel2

ofrightsidewallwindowpillar.

4.Removetrimpanelforrightsidewallwindow

pillar.

BP

BPInterior/Exterior

Interior/Exterior

Interior/ExteriorTrims

Trims

-81-

Removal/Installation

Removal/Installation(Continued)

(Continued)

Right

Rightside

side

sidewall

wall

wallwindow

window

windowtrim

trim

trimpanel

panel

Installation

1.Installitinreverseorderofremoval.

BP

BPInterior/Exterior

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Interior/ExteriorTrims

Trims

-82-

Removal/Installation

Left

Leftside

side

sidewall

wall

wallwindow

window

windowtrim

trim

trimpanel

panel

Removal

1.Removecurtains.

2.Removeuppertrimpanel1andlowertrimpanel1

ofleftsidewallwindowpillar.

3.Removeuppertrimpanel2andlowertrimpanel2

ofleftsidewallwindowpillar.

4.Removeleftsidewallwindowpillar.

BP

BPInterior/Exterior

Interior/Exterior

Interior/ExteriorTrims

Trims

-83-

Removal/Installation

Removal/Installation(Continued)

(Continued)

Left

Leftside

side

sidewall

wall

wallwindow

window

windowtrim

trim

trimpanel

panel

Installation

Installitinreverseorderofremoval.

BP

BPInterior/Exterior

Interior/Exterior

Interior/ExteriorTrims

Trims

-84-

Removal/Installation

Upper/lower

Upper/lowertrim

trim

trimpanel

panel

panelof

of

ofright

right

rightD-pillar

D-pillar

Removal

1.Removecurtains.

2.Removemountingscrewsforuppertrimpanelof

rightD-pillarandtakedowntheuppertrimpanel.

3.Removemountingscrewsforlowertrimpanelof

rightD-pillarandtakedownthelowertrimpanel.

Installation

Installitinreverseorderofremoval.

BP

BPInterior/Exterior

Interior/Exterior

Interior/ExteriorTrims

Trims

-85-

Removal/Installation

Upper/lower

Upper/lowertrim

trim

trimpanel

panel

panelof

of

ofleft

left

leftD-pillar

D-pillar

Removal

1.Removecurtains.

2.Removemountingscrewsforuppertrimpanelof

leftD-pillarandtakedowntheuppertrimpanel.

3.Removemountingscrewsforlowertrimpanelof

leftD-pillarandtakedownthelowertrimpanel.

Installation

Installitinreverseorderofremoval.

BP

BPInterior/Exterior

Interior/Exterior

Interior/ExteriorTrims

Trims

-86-

Removal/Installation

Left

Lefttrim

trim

trimpanels

panels

panels1,

1,

1,2,

2,

2,3

3

3and

and

and4

4

4and

and

andright

right

righttrim

trim

trimpanels

panels

panels1,

1,

1,2

2

2and

and

and3

3

Removal

1.Removecurtains.

2.Removeupperandlowertrimpanelsforright

B-pillar,C-pillar,sidepillarandD-pillar.

3.Removerighttrimpanels1,2and3.

4.Removeupperandlowertrimpanelsforleft

B-pillar,C-pillar,sidepillarandD-pillar.Remove

lefttrimpanels1,2,3and4.

BP

BPInterior/Exterior

Interior/Exterior

Interior/ExteriorTrims

Trims

-87-

Removal/Installation

Removal/Installation(Continued)

(Continued)

Left

Lefttrim

trim

trimpanels

panels

panels1,

1,

1,2,

2,

2,3

3

3and

and

and4

4

4and

and

andright

right

righttrim

trim

trimpanels

panels

panels1,

1,

1,2

2

2and

and

and3

3

Installation

Installitinreverseorderofremoval.

BP

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Interior/ExteriorTrims

Trims

-88-

Removal/Installation

Left

Lefttrim

trim

trimpanel

panel

panelof

of

offront

front

frontdoor

door

doortrim

trim

trimpanel

panel

Removal

1.Removethenegativecableofbattery.

2.Removemountingscrewsofdoortrimpaneland

takedownthetrimpanel.

Installation

Installitinreverseorderofremoval.

BP

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-89-

Removal/Installation

Left

Leftdoor

door

Removal

1.Pryuptheleftdoorlowertrimpanelwithtool

carefully.

2.Pryuptheleftdooruppertrimpanelwithtool

carefully.

Installation

Installitinreverseorderofremoval.

BP

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Trims

-90-

Removal/Installation

Right

Rightdoor

door

Removal

1.Removeinnerhandlecoverofdoor.

2.Removetherightdoorlowertrimpanelwithtool.

3.Removerightdooruppertrimpanelwithtool.

Installation

Installitinreverseorderofremoval.

BP

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Interior/ExteriorTrims

Trims

-91-

Removal/Installation

Interior

Interiorrear-view

rear-view

rear-viewmirror

mirror

Removal

1.Pulltheinteriorrear-viewmirrordownwards

carefullyinthedirectionshowninthefigure.

2.Takeouttheinteriorrear-viewmirrorassembly.

Installation

Installitinreverseorderofremoval.

BP

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Interior/ExteriorTrims

Trims

-92-

Removal/Installation

Sun

Sunvisor

visor

Removal

1.Removemountingscrewsofrightsunvisor.

2.Takedownthesunvisor.

3.Removemountingscrewsofleftsunvisorandtake

downthesunvisor.

Installation

Installitinreverseorderofremoval.

BP

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Interior/ExteriorTrims

Trims

-93-

Removal/Installation

Curtains

Removal

1.Pryoutthecurtainsliderailwithscrewdriverand

makeitseparatedfromtheclipsmountedonthe

trimpanel.

2.Clipsarepositionedatthemiddleofeachpillarand

atthemiddleofeachsidewindowglass.

3.Removethemountingscrewsofcurtainplugand

takedownthecurtain.

Installation

Installitinreverseorderofremoval.Installthesliderail

inorderfromfronttoback.

BP

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-94-

Removal/Installation

Luggage

Luggagerack

rack

Removal

1.Twoservicepersonsarenecessaryforremovalof

luggagerack,inordertoavoidpersonalinjuryand

damagetoluggagerack.

2.Removemountingnutsforluggagerack.

3.Holdtheluggagerackduringtheremoval.

4.Removebracketsofluggagerack.

BP

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Trims

-95-

Removal/Installation

Removal/Installation(Continued)

(Continued)

Luggage

Luggagerack

rack

Installation

Installitinreverseorderofremoval.

BP

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Trims

-96-

Removal/Installation

Step

Stepplate

plate

plateassembly

assembly

Removal

1.Removemountingscrewsofstepplate.

2.Takedownthestepplateassembly.

Installation

Installitinreverseorderofremoval.

BP

BPInterior/Exterior

Interior/Exterior

Interior/ExteriorTrims

Trims

-97-

Removal/Installation

Front

Frontbumper

bumper

Removal

1.Removethenegativecableofbattery.

2.Removescrewsoffrontgrilleandtakedownthe

frontgrille.

3.Removethefronttrimpanel.

4.Disconnecttheharnessconnectoroffoglamp.

BP

BPInterior/Exterior

Interior/Exterior

Interior/ExteriorTrims

Trims

-98-

Removal/Installation

Front

Frontbumper

bumper

5.Removemountingscrewsofbumper.

6.Removefourmountingscrewsofbumper.

7.Takedownfrontbumper.

InstallationInstallitinreverseorderofremoval.

BP

BPInterior/Exterior

Interior/Exterior

Interior/ExteriorTrims

Trims

-99-

Removal/Installation

Rear

Rearbumper

bumper

1.Removethenegativecableofbattery.

2.Removemountingscrewsbelowrearbumper.

3.Removemountingscrewsfromrearbumper.

4.Removesidemountingscrewsfromrearbumper.

BP

BPInterior/Exterior

Interior/Exterior

Interior/ExteriorTrims

Trims

-100-

Removal/Installation

Removal/Installation(Continued)

(Continued)

Rear

Rearbumper

bumper

5.Disconnecttheharnessconnectorofrearbumper

andtakedowntherearbumper.

Installation

Installitinreverseorderofremoval.

BP

BPInterior/Exterior

Interior/Exterior

Interior/ExteriorTrims

Trims

-101-

Removal/Installation

Front

Frontgrille

grille

Removal

1.Removemountingscrewsforfrontgrille.

2.Takedownthefrontgrille.

Installation

Installitinreverseorderofremoval.

BP

BPInterior/Exterior

Interior/Exterior

Interior/ExteriorTrims

Trims

-102-

Removal/Installation

Fender

Removal

1.Removethenegativecableofbattery.

2.Removethefrontgrille.

3.Removefronttrimpanelandheadlamps.

4.Disconnectharnessconnectoroffoglamp.

BP

BPInterior/Exterior

Interior/Exterior

Interior/ExteriorTrims

Trims

-103-

Removal/Installation

Removal/Installation(Continued)

(Continued)

Fender

5.Removefrontbumper.

6.Removeclearancelamps.

7.Removepadsforfrontbumper.

8.Removemountingboltsforfender.

BP

BPInterior/Exterior

Interior/Exterior

Interior/ExteriorTrims

Trims

-104-

Removal/Installation

Removal/Installation(Continued)

(Continued)

Fender

9.Removemountingboltsforfender.

10.Removerear-viewmirrortrimpanel.

11.Removemountingboltsforfender.

12.Removefrontwheeltrimpanel.

BP

BPInterior/Exterior

Interior/Exterior

Interior/ExteriorTrims

Trims

-105-

Removal/Installation

Removal/Installation(Continued)

(Continued)

Fender

13.Removemountingscrewsforfender.

14.Removemountingscrewsforfenderandtakedown

thefender.

Installation

Installitinreverseorderofremoval.

BP

BPInterior/Exterior

Interior/Exterior

Interior/ExteriorTrims

Trims

-106-

Removal/Installation

Front

Frontdoor

door

doorskirt

skirt

skirttrim

trim

trimpanel

panel

Removal

1.Removefrontdoorskirttrimpanelwithtool.

2.Clippositionoffrontdoorskirttrimpanel.

Installation

Installitinreverseorderofremoval.

BP

BPInterior/Exterior

Interior/Exterior

Interior/ExteriorTrims

Trims

-107-

Removal/Installation

Front

Frontside

side

sidewall

wall

wallskirt

skirt

skirttrim

trim

trimpanel

panel

Removal

1.Removefrontsidewallskirttrimpanelwithtool.

2.Clippositionoffrontsidewallskirttrimpanel.

Installation

Installitinreverseorderofremoval.

BP

BPInterior/Exterior

Interior/Exterior

Interior/ExteriorTrims

Trims

-108-

Removal/Installation

Middle

Middleside

side

sidewall

wall

wallskirt

skirt

skirttrim

trim

trimpanel

panel

Removal

1.Removemountingscrewsformiddlesidewallskirt

trimpanel.

2.Removemiddlesidewallskirttrimpanelwithtool.

3.Clippositionofmiddlesidewallskirttrimpanel.

Installation

Installitinreverseorderofremoval.

BP

BPInterior/Exterior

Interior/Exterior

Interior/ExteriorTrims

Trims

-109-

Removal/Installation

Rear

Rearwheel

wheel

wheelskirt

skirt

skirttrim

trim

trimpanel

panel

Removal

1.Removemountingscrews.

2.Removerearwheelskirttrimpanelwithtool.

3.Clippositionofrearwheelskirttrimpanel.

Installation

Installitinreverseorderofremoval.

BP

BPInterior/Exterior

Interior/Exterior

Interior/ExteriorTrims

Trims

-110-

Removal/Installation

Rear

Reartire

tire

tiremud

mud

mudguard

guard

Removal

1.Removemountingscrewsforreartiremudguard

andtakedownthemudguard.

Installation

Installitinreverseorderofremoval.

SE

SESeats

Seats

-

111

-

Seats

Appliedmodels:SUNRAYproductsmanufacturedbyJAC

SubjectPage

Instruction

Instructionand

and

andOperation

Operation

Driver

’

sseat.................................................................................................................................................................112

Frontrowtwinbench-typeseat....................................................................................................................................114

Frontrowindividualseat..............................................................................................................................................115

Removal/Installation

Driver

’

sseat.................................................................................................................................................................116

Frontrowtwinbench-typeseat....................................................................................................................................119

Frontrowindividualseat.............................................................................................................................................120

backrowseats..............................................................................................................................................................121

SE

SESeats

Seats

-112-

Instruction

Instructionand

and

andOperation

Operation

Components

Componentsof

of

ofdriver

driver

’

s

sseat

seat

1.Verticaladjustableheadrest2.Angleadjustablearmrest3.Frontandrearheightadjustableseat

Eightadjustingwaysfordriver

’

sseatcanbeachieved,

viz.forward/rearwardandupward/downward

adjustmentofseat,angleforward/rearwardadjustment

ofbackrest,upward/downwardadjustmentofheadrest,

whichcanprovidethedriverwithcomfortabledriving

environment.

1

2

3

SE

SESeats

Seats

-113-

Instruction

Instructionand

and

andOperation

Operation

Driver

’

s

sseat

seat

1.Armrest2.Backrestcushion3.Headrestassembly4.Headrestlatch

5.Angleadjuster6.Plasticcover7.Backrestframe

1

2

3

4

5

6

7

SE

SESeats

Seats

-114-

Instruction

Instructionand

and

andOperation

Operation

Front

Frontrow

row

rowtwin

twin

twinbench-type

bench-type

bench-typeseat

seat

1.Armrest2.Backrestcushion3.Headrestassembly4.Headrestlatch

5.Plasticcover6.Angleadjuster7.Backrestframe

1

2

3

4

5

6

7

SE

SESeats

Seats

-115-

Instruction

Instructionand

and

andOperation

Operation

Front

Frontrow

row

rowindividual

individual

individualseat

seat

1.Backrestcushion2.Headrestassembly3.Headrestlatch4.Armrest

5.Angleadjuster6.Plasticcover7.Backrestframe

1

2

3

4

6

5

7

SE

SESeats

Seats

-116-

Removal/Installation

Driver

’

s

sseat

seat

1.Disconnectthenegativecableofbattery.

2.Removetwomountingnutsontheleftsideofseat.

3.Removetwonutsontherightsideofseatand

disconnecttheharness.

4.Takedownthedriver

’

sseatfromslidingrail.

SE

SESeats

Seats

-117-

Removal/Installation

Sliding

Slidingrail

rail

railand

and

andseat

seat

1.Pushtheslidingrailrearwardsandremovefour

mountingbolts.

2.Pulltheslidingrailforwardsandremovethree

mountingboltsontherearpart.

3.Takedowntheslidingrailassembly.

SE

SESeats

Seats

-118-

Removal/Installation

Removal/Installation(continued)

(continued)

Sliding

Slidingrail

rail

railand

and

andseat

seat

1.Installtheslidingrailontothevehicleandinstall

sevenmountingboltsinreverseorderofremoval.

2.Installtheseatontoslidingrailandtightentwo

mountingnutsontheleftside.

3.Tightentwomountingnutsontherightsideinthe

samewayandtightennutsonbothsidestothe

specifiedtorque.

Tighteningtorque:45～55N.m

SE

SESeats

Seats

-119-

Removal/Installation

Front

Frontrow

row

rowtwin

twin

twinbench-type

bench-type

bench-typeseat

seat

Removal

1.Removefourmountingboltsbelowfrontrowseat.

2.Removethefrontrowtwinbench-typeseatfrom

vehicle.

Installation

1.Installthefrontrowseatinreverseorderof

removal.

Note:

Boltsshouldbetightenedtothespecifiedtorque.

Tighteningtorque:45～55N.m

SE

SESeats

Seats

-120-

Removal/Installation

Front

Frontrow

row

rowindividual

individual

individualseat

seat

Removal

1.Removefourmountingboltsbelowfrontrowseat.

2.Removethefrontrowindividualseatfromvehicle.

Installation

1.Installthefrontrowindividualseatinreverseorder

ofremoval.

Note:

Boltsshouldbetightenedtothespecifiedtorque.

Tighteningtorque:45～55N.m

SE

SESeats

Seats

-121-

Removal/Installation

Back

Backrow

row

rowseats

seats

Removal

1.Removefourmountingboltsbelowbackrowseats.

2.Removethebackrowtwinbench-typeseatfrom

vehicle.

Installation

1.Installthebackrowtwinbench-typeseatinreverse

orderofremoval.

Note:

Boltsshouldbetightenedtothespecified

torque.

Tighteningtorque:45～55N.m

SP

SPSealing

Sealing

SealingElements

Elements

-123-

Sealing

SealingElements

Elements

Appliedmodels:SUNRAYproductsmanufacturedbyJAC

SubjectPage

Removal/Installation

Inneracousticbaffleoffrontwall................................................................................................................................124

Outerheatshieldoffrontwall.....................................................................................................................................125

Frontdoorseal.............................................................................................................................................................125

Reardoorseal...............................................................................................................................................................126

Fenderseal...................................................................................................................................................................126

Frontcompartmentseal................................................................................................................................................127

Waterproofmembrane..................................................................................................................................................127

SP

SPSealing

Sealing

SealingElements

Elements

-124-

Removal/Installation

Inner

Inneracoustic

acoustic

acousticbaffle

baffle

baffleof

of

offront

front

frontwall

wall

1.Disconnectthenegativecableofbattery.

2.Removeupperacousticbaffleoffrontwall.

3.Clip.

4.Removeloweracousticbaffleoffrontwall.

Loweracousticbaffle

offrontwall

Upperacousticbaffle

offrontwall

SP

SPSealing

Sealing

SealingElements

Elements

-125-

Removal/Installation

Outer

Outerheat

heat

heatshield

shield

shieldof

of

offront

front

frontwall

wall

1.Disconnectthenegativecableofbattery.

2.Removeclips.

3.Removeinnerpanelheatshieldofenginehood.

4.Removeheatshieldsofleftandrightfenders.

5.Removeheatshieldsofleftandrightwheels.

6.Removefrontandrightacousticbafflesoffront

wall.

Removal/Installation

Front

Frontdoor

door

doorseal

seal

1.Removethefrontdoorseal.

Innerpanelheatshieldofenginehood

Heatshieldofright

fender

Heatshieldofright

wheel

Rightheatshieldoffrontwall

Leftpanelheatshield

offrontwall

Heatshieldofleft

fender

Heatshieldofleftwheel

SP

SPSealing

Sealing

SealingElements

Elements

-126-

Removal/Installation

Rear

Reardoor

door

doorseal

seal

1.Removemiddlesealofreardoorframe.

2.Removesealofreardoorframe.

Removal/Installation

Fender

Fenderseal

seal

1.Removefenderseal.

Fenderseal

SP

SPSealing

Sealing

SealingElements

Elements

-1

27-

Removal/Installation

Front

Frontcompartment

compartment

compartmentseal

seal

1.Removetherearendsealoffrontcompartment.

2.Removethefrontsectionsealassemblyoffront

compartment.

Removal/Installation

Waterproof

Waterproofmembrane

membrane

1.Removetherearendsealoffrontcompartment.

XE

XEBody

Body

BodyRepair

Repair

RepairParameters

Parameters

-129-

Body

BodyRepair

Repair

RepairParameters

Parameters

Appliedmodels:SUNRAYproductsmanufacturedbyJAC

SubjectPage

EngineCompartmentRepairParameters.....................................................................................................................130

WindshieldRepairParameters.....................................................................................................................................131

FrontDoorRepairParameters.....................................................................................................................................132

RearDouble-DoorRepairParameters..........................................................................................................................133

GirderRepairParameters.............................................................................................................................................134

XE

XEBody

Body

BodyRepair

Repair

RepairParameters

Parameters

-130-

Engine

EngineCompartment

Compartment

CompartmentRepair

Repair

RepairParameters

Parameters

XE

XEBody

Body

BodyRepair

Repair

RepairParameters

Parameters

-131-

Windshield

WindshieldRepair

Repair

RepairParameters

Parameters

XE

XEBody

Body

BodyRepair

Repair

RepairParameters

Parameters

-132-

Front

FrontDoor

Door

DoorRepair

Repair

RepairParameters

Parameters

XE

XEBody

Body

BodyRepair

Repair

RepairParameters

Parameters

-133-

Rear

RearDouble-Door

Double-Door

Double-DoorRepair

Repair

RepairParameters

Parameters

XE

XEBody

Body

BodyRepair

Repair

RepairParameters

Parameters

-134-

Girder

GirderRepair

Repair

RepairParameters

Parameters

Sidememberrepairparameters:DiagonalL1=5068mm

SidememberlengthL2=4998mm

SidememberledgeL3=840mm

SUNRAY

SUNRAYSpecial

Special

SpecialService

Service

ServiceTools

Tools

Attached

AttachedList

List

List—

—

—SUNRAY

SUNRAY

SUNRAYSpecial

Special

SpecialService

Service

ServiceTools

Tools

Appliedmodels:SUNRAYproductsmanufacturedbyJAC

Tool

ToolNumber

Number

NumberTool

Tool

ToolName

Name

NameIllustration

Illustration

IllustrationFunction/Applied

Function/Applied

Function/AppliedPart

Part

JAC-T8F001Pistonpinpuller

Forremoval/installationofenginepistonpin

(engine)

JAC-T8F002Handle

Forinstallingbearingtogetherwithrelevant

installer(transmission)

JAC-T8F003FlywheelstopperForfixingflywheeltofacilitateremoval(engine)

JAC-T8F004

Coolingsystem

detector

Forcheckingenginecoolingsystemforleakage

(engine)

JAC-T8F005OilfilterwrenchForremoval/installationofoilfilter(engine)

JAC-T8F006

Valveoilseal

installer

Forinstallationofvalveoilseal(engine)

JAC-T8F007FuelpressuregaugeFormeasuringfuelpressure(engine)

JAC-T8F008

Compression

pressuregauge

Formeasuringenginecylinderpressure(engine)

JAC-T8F009

Pressuregauge

connector

Forconnectionwhenmeasuringcylinder

pressure(engine)

JAC-T8F010

Valvespring

compressor

Forcompressingvalvespring,removingengine

valvesandrelevantparts(engine)

JAC-T8F011CamshaftgearpullerForremovingcamshaftgear(engine)

JAC-T8F012

Cylinderliner

installer(incl.jack)

F

orinstallingcylinderliner(engine)

SUNRAY

SUNRAYSpecial

Special

SpecialService

Service

ServiceTools

Tools

Tool

ToolNumber

Number

NumberTool

Tool

ToolName

Name

NameIllustration

Illustration

IllustrationFunction/Applied

Function/Applied

Function/AppliedPart

Part

JAC-T8F013CylinderlinerpullerForremovingcylinderliner(engine)

JAC-T8F014PistoninstallerForinstallingpiston(engine)

JAC-T8F015

Crankshaftfrontoil

sealinstaller

Forinstallingcrankshaftfrontoilseal(engine)

JAC-T8F016

Camshaftbushing

puller

Forremoval/installationofcamshaftbushing

(engine)

JAC-T8F017

V-blockforcamshaft

measurement

Formeasuringdamageofcamshaft(engine)

JAC-T8F018HoseclamppliersForremovinghoseclamp

JAC-T8F019Pistonringextractor

Forremoval/installationofpistoncirclip

(engine)

JAC-T8F020

Valveoilseal

extractor

Forremovingvalveoilseal(engine)

JAC-T8F021EndforkclipForfixingflywheel(engine)

JAC-T8F022

Crankshaftrear

bearingpuller

Forremovingcrankshaftrearbearing

JAC-T8F023

Crankshaftrear

bearinginstaller

Forinstallingcrankshaftrearbearing

JAC-T8F024

Dieselcommonrail

toolkit

Dieselcommonraildetectorcandiagnose

accuratelyandefficientlythedieselengine

injectionbyperformeddieselcommonrail

system.

JAC-T8B001Forklockpinpuller

Forremovingshiftforkspringpin(transmission)

Tool

ToolNumber

Number

NumberTool

Tool

ToolName

Name

NameIllustration

Illustration

IllustrationFunction/Applied

Function/Applied

Function/AppliedPart

Part

JAC-T8B002Oilsealpuller

Forremovingoilseal(transmission)

JAC-T8B003Clutchguider

Forcenteralignmentofclutchdisc

(transmission)

JAC-T8B004

Inputshaftbearing

installer

Forinstallinginputshaftbearing(transmission)

JAC-T8B005

Outputshaftbearing

installer

Forinstallingoutputshaftbearing(transmission)

JAC-T8B006

Countershaftfront

bearinginstaller

Forinstallingcountershaftfrontbearing

(transmission)

JAC-T8B007

Inputshaftprotective

sleeve

Forprotectinginputshaftfrontendteeth

(transmission)

JAC-T8B008

Outputshaft

protectivesleeve

Forprotectingoutputshaftfrontendteeth

(transmission)

JAC-T8B009

Transmissionbearing

removaltoolkit

Forremovingtransmissionbearing

(transmission)

JAC-T8B010

Inputshaftoilseal

installer

Forinstallinginputshaftoilseal(transmission)

JAC-T8B011

Oilsealpullerof

transmissionrearend

cover

Forremovingoilsealofrearendcover

(transmission)

JAC-T8B012

Oilsealinstallerof

rearendcover

Forinstallingoilsealofrearendcover

(transmission)

JAC-T8D001

Steeringlinkage

drawingdie

Fordisengagingfrontwheelendcontrolarmball

jointfromsteeringknuckle(chassis)

JAC-T8D002

Interiortrimcrow

plate

F

orpryingupinteriortrimofvehicle

S

SU

U

UN

N

NR

R

RA

A

AY

Y

YS

S

Sp

p

pe

e

ec

c

ci

i

ia

a

al

l

lS

S

Se

e

er

r

rv

v

vi

i

ic

c

ce

e

eT

T

To

o

oo

o

ol

l

ls

s

BP interior trim (Add)

Interior trim

Suitable models:JAC multifunction commercial vehicle M209 product

Content Page

Illustration and operation

Driver seat........................................................................................................................................................................ 1

Double passenger seat...................................................................................................................................................... 2

Double passenger seat on the left side of the 2

nd

row(same as the double seat on the left of the 3rd row) ..................... 3

Single passenger seat on the right side of the third row .................................................................................................. 4

Double passenger seat on the left side of the last row(same as the double seat on the right ) ......................................... 5

Disassembly and assembly

Driver seat........................................................................................................................................................................ 6

Double passenger seat...................................................................................................................................................... 8

Double passenger seat on the rear row .......................................................................................................................... 10

Single passenger seat on the rear row ............................................................................................................................ 11

Illustration and operation

Instrument panel .......................................................................................................................................................... 12

Disassembly and assembly

Instrument panel .......................................................................................................................................................... 13

Illustration and operation

ceiling ............................................................................................................................................................................ 21

Disassembly and assembly

ceiling ............................................................................................................................................................................ 22

carpet ............................................................................................................................................................................. 28

curtain ............................................................................................................................................................................ 33

sun visor. ........................................................................................................................................................................ 34

armrest ........................................................................................................................................................................... 35

Emergency hammer ....................................................................................................................................................... 36

Left/right top protecting plate of A column ................................................................................................................... 37

Left/right bottom protecting plate of A column ............................................................................................................. 38

Right top/bottom protecting plate of B column ............................................................................................................. 39

Left top/bottom protecting plate of B column ............................................................................................................... 40

Left protecting plate of C column .................................................................................................................................. 42

Right top/bottom protecting plate of C column ............................................................................................................. 44

Left top/bottom protecting plate of D column ............................................................................................................. 46

Top/bottom protecting plate of the left front side panel air window ............................................................................. 48

Protecting plate of the rear door threshold ..................................................................................................................... 49

Left rear door ................................................................................................................................................................. 50

Right rear door ............................................................................................................................................................... 51

Left front door ............................................................................................................................................................... 52

Right front door ............................................................................................................................................................. 53

SE seat

- 1 -

Illustration and operation

Components of the driver seat

1、The seat headrest can be adjusted vertically 2、The seat can be adjusted forth and back

3、The height of the seat can be adjusted 4、The angle of the seat backrest can be adjusted

There are 8 directions can be adjusted on the driver seat: seat front and back adjust,up and down adjust, backrest

angel front and back adjust,headrest up and down adjust.it provides a comfortable driving environment for drivers.

SE seat

- 2 -

Illustration and operation

Double seat on the passenger side

1、 The seat headrest can be adjusted vertically

The seat headrest of the double seat on the passenger side can be adjusted up and down

SE seat

- 3 -

Illustration and operation

Double passenger seat on the left side of the second row(same as the double seat on the left of the 3

rd

row)

1、The armrest can be adjusted up and down

2、The button on the right side can adjust the backrest angle of the right seat

3、the handle on the left can adjust the backrest angle of the left seat

Double passenger seat on the left side of the 2

nd

row(same as the double seat on the left of the 3

rd

row) can adjust the

angles of the armrest and backrest

SE seat

- 4 -

Illustration and operation

Single passenger seat on the right side of the third row

1、The armrest can be adjusted up and down 2、The left button can adjust the backrest angle

Single passenger seat on the right side of the third row can adjust the angles of the armrest and backrest

SE seat

- 5 -

Illustration and operation

Double passenger seat on the left side of the last row(same as the double seat on the right )

Double passenger seat on the left side of the last row(same as the double seat on the right )is fixed,can not adjust

BP interior trim

- 6 -

Disassembly and assembly

Driver seat

Disassembly

1. Pull up the adjusting rod,make the seat move forth

and back on the installing bracket, reveal the 4 bolts

connecting the bracket below the seat and dismantle

them.

2. Dismantle the the connector and wire harness of the

driver seat safety belt.

SE seat

- 7 -

Disassembly and assembly

Driver seat

3.Remove the driver seat from the installing bracket.

4. Remove the 5 bolts connecting the driver seat

installing bracket and body,remove the installing

bracket.

Assembly

The assembly process of the driver seat is contract to the

disassembly process.

Note：

The torque of the bolts must reach the standard.

Tighten torque：45～55N.m

BP interior trim

- 8 -

Disassembly and assembly

Double passenger seat

Disassembly

1. Press the safety belt buckle on the right side of the

double passenger seat to release the safety belt,remove

the fixing bolts of the safety belt on the right side of the

double passenger seat.

2. Remove the 5 seat bracket cover plates on the bottom

of the double passenger seat.

3. Remove the 5 fixing bolts on the bottom of the double

passenger seat.

SE seat

- 9 -

Disassembly and assembly

Double passenger seat

4. Remove the double passenger seat from the vehicle。

Assembly

1. The assembly process of the double passenger seat is

contract to the disassembly process.

Note：

The torque of the bolts must reach the standard.

Tighten torque：45～55N.m

BP interior trim

- 10 -

Disassembly and assembly

Double passenger seat on rear row

Disassembly

1. Remove the four fixing bolts below the double

passenger seat on rear row.

2. Remove the double passenger seat on rear row

from the vehicle.

Assembly

1. The assembly process of the double passenger seat

on rear row is contract to the disassembly process.

Note：

The torque of the bolts must reach the standard.

Tighten torque：45～55N.m

SE seat

- 11 -

Disassembly and assembly

Single passenger seat on the rear row

Disassembly

1.Remove the four fixing bolts below the Single

passenger seat on the rear row.

2. Remove the single passenger seat on the rear row

from the vehicle.

Assembly

1. The assembly process of the Single passenger seat on

the rear row is contract to the disassembly process.

Note：

The torque of the bolts must reach the standard.

Tighten torque：45～55N.m

BP interior trim

- 12 -

Illustration and operation

Instrument panel

BP interior trim

- 13 -

Disassembly and assembly

Instrument panel

1. Remove the negative pole of the battery.

2. Remove the up cover of the steering wheel.

3. There are two fixing bolts on both sides of the

steering wheel up cover.

4. Unscrew the fixing bolts of the steering

wheel,remove the steering wheel.

BP interior trim

- 14 -

Disassembly and assembly

Instrument panel

5. Remove the instrument protecting cover.

6. Remove the four fixing bolts of the instrument.

7. Dismantle the wire harness connector of the

instrument.

8. Remove the two fixing bolts of the steering wheel

lower protecting cover.remove the up/low steering

wheel protecting cover.

BP interior trim

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Disassembly and assembly

Instrument panel

9. Remove the four fixing bolts of the clock

spring,remove the clock spring.

10. Remove the three fixing bolts of the combination

switch,remove the combination switch.

11. Remove the storage box in the middle and the

bolts fixing the lower instrument panel.

BP interior trim

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Disassembly and assembly

Instrument panel

12. Disconnect the control wire harness of the A/C.

13. Dismantle the audio cover with tool.

14. Disconnect the wire harness connector of the audio

cover.

BP interior trim

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Disassembly and assembly

Instrument panel

15. Remove the four fixing bolts of the audio.

16. Disconnect the connector of the audio wire harness.

17. Remove the lower protective cover of the

instrument panel.

18. Remove the glove box.

BP interior trim

- 18 -

Disassembly and assembly

Instrument panel

19. Unscrew the two fixing bolts of the instrument

panel.

20. Remove the fixing bolts of the instrument panel on

the left.

21. Remove the fixing bolts of the instrument panel on

the right.

Note：

There are three fixing bolts on the instrument

panel,which are in the left/middle/right.。

22. Remove the two fixing bolts on the left of the

instrument panel.

BP interior trim

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Disassembly and assembly

Instrument panel

23. Remove the two fixing bolts on the right of the

instrument panel.

24. Dismantle the shift lever.

25. Remove the fixing bolts of the shift lever assembly.

26. Take off the instrument panel carefully.

Note：

When lifting the instrument panel ,two servicemen are

needed.

BP interior trim

- 20 -

Disassembly and assembly

Instrument panel

Assembly

1. During the assembly process,pay attention to the

installing method of the clock spring,the wheels

must be forward.rotate the clock spring clockwise

until the spring can not move.(the force should be

proper,not too hard )then rotate anticlockwise three

times,align the triangle mark in the middle.

2. The other assembly processes are contract to the

disassembly processes.

BP interior trim

- 21 -

Disassembly and assembly

Ceiling

BP interior trim

- 22 -

Disassembly and assembly

Ceiling

Disassembly

1. Remove the negative pole of the battery.

2. Remove the curtain on the left/right side.

3. Remove the handrail on the A column.

BP interior trim

- 23 -

Disassembly and assembly

Ceiling

4. Remove the top fixing point of the safety belt on

the B pillar in the right.the entering handrail in

the middle.

5. Remove the top fixing point of the safety belt on

the B pillar in the left.

6. Remove the top handrail in the right.

7. Remove the safety hammer、fixing belt of the

curtain and the fixing bolts of the two sides

column plates

BP interior trim

- 24 -

Disassembly and assembly

Ceiling

8. Remove the A pillar trim panel.

9. Remove the top protective plate of the B pillar.

10. Remove the top protective plate of the C

pillar,top protective plate of the D pillar and the

widow frame trim plate.

11. Remove the indoor ceiling light 1.

BP interior trim

- 25 -

Disassembly and assembly

Ceiling

12. Remove the indoor ceiling light 2.

13. Remove the 6 air outlets.

14. Remove the right sun visor.

15. Remove the left sun visor.

BP interior trim

- 26 -

Disassembly and assembly

Ceiling

16. Remove the front dome light.

17. Remove the 4 hook blocks of the rear

ceiling,then dismantle the rear door lock hook

with screwdriver.

18. The ceiling is fixed by dual lock,dismantle the

locks carefully,then remove the rear parts of the

indoor ceiling.

19. Remove the clips of the front parts of the indoor

ceiling lining,dismantle the dual lock,remove the

front part of the indoor ceiling.

BP interior trim

- 27 -

Disassembly and assembly

Ceiling

Assembly

Be careful when installing the ceiling lining,two

workers are required to avoid folding the interior trim.

BP interior trim

- 28 -

Disassembly and assembly

Carpet

Disassembly

1. Remove all the seats.

2. Remove the lower protective plate of the A pillar

with tools.

3. Dismantle the lower fixing point of the safety belt

on the driver’s side with tools.

G

h

4. Remove the front door footstep.

BP interior trim

- 29 -

Disassembly and assembly

Carpet

5. Remove the lower protective cover of the

instrument panel.

6. Remove the protective cover of the hand brake.

7. Remove the middle footstep.

8. Remove the lower protective plate of the B pillar.

BP interior trim

- 30 -

Disassembly and assembly

Carpet

9. Remove the protective cover of the A/C.

10. Remove the lower protective plate of the C pillar.

11. Remove the lower protective plate of the D pillar.

12. Remove the protective plate of the rear door

threshold.

BP interior trim

- 31 -

Disassembly and assembly

Carpet

13. Unscrew the bolts of the front pressing strip,and

remove the strip.

14. Unscrew the bolts of the rear pressing strip,and

remove the strip.

15. Remove the front carpet.

16. Remove the rear carpet.

BP interior trim

- 32 -

Disassembly and assembly

Carpet

17. Remove the protective cover and leather of the

front wheel.

18. Remove the protective leather of the rear wheel.

Assembly

1. The assembly processes are in contrast to the

disassembly processes.

2. Pay attention when installing the rear carpet,two

workers are required. First, fold rear carpet from

the left/right sides and send it to the vehicle from

the rear door,then unfold and install it. Avoid

wrinkle on the carpet surface.

BP interior trim

- 33 -

Disassembly and assembly

Curtain

Disassembly

1. Pry-out the curtain sliding-rail with screwdriver,

separate it from the clips on the trim.

2. The clips are in the positions of the middle of the

pillars and windows.

3. Unscrew the fixing bolts of the curtain,and remove

it.

Assembly

1、 The assembly processes are in contrast to the

disassembly processes.

2 、 When installing the sliding rail,the correct

sequence is from the front to the back.

BP interior trim

- 34 -

Disassembly and assembly

Sun visor

Disassembly

1. Unscrew the fixing bolts of the right sun visor.

2. Remove the sun visor.

3. Unscrew the fixing bolts of the left sun visor and

remove the visor.

Assembly

The assembly processes are in contrast to the

disassembly processes.

BP interior trim

- 35 -

Disassembly and assembly

Hand rail

Disassembly

1. Dismantle the duct plug of the hand rail on the A

pillar,then unscrew the bolts.

2. Remove the hand rail on the A pillar.

3. Dismantle the duct plug of the hand rail on the

middle door,remove the bolts and hand rail.

Assembly

The assembly processes are in contrast to the

disassembly processes.

BP interior trim

- 36 -

Disassembly and assembly

Emergency hammer

Disassembly

1. Take down the emergency hammer.

2. Unscrew the bolts,remove the emergency hammer

mounting base.

Assembly

The assembly processes are in contrast to the

disassembly processes.

BP interior trim

- 37 -

Disassembly and assembly

Left/right top protective plate of the A pillar

Disassembly

1. Dismantle the left top protective plate of A pillar by

hands.

2. Dismantle the arm rail for stepping in the vehicle on

the front door,then remove the right top protective

plate of A pillar.

Assembly

The assembly processes are in contrast to the

disassembly processes.

BP interior trim

- 38 -

Disassembly and assembly

Left/right low protective plate of the A pillar

Disassembly

1. Unscrew the bolts on the Left/right low protective

plate of the A pillar with electrical gun.

2. Remove the left/right low protective plate of the A

pillar with tools.

Assembly

The assembly processes are in contrast to the

disassembly processes.

BP interior trim

- 39 -

Disassembly and assembly

right top/low protective plate of the B pillar

Disassembly

1. Unscrew the bolts on the right top/low protective

plate of the B pillar with electrical gun.then remove

the low protective plate.

2. Unscrew the fixing belts of the safety belt,remove

the arm rail for stepping on the middle door,then

remove the right top protective plate of B pillar.

Assembly

The assembly processes are in contrast to the

disassembly processes.

BP interior trim

- 40 -

Disassembly and assembly

left top/low protective plate of the B pillar

Disassembly

1. Dismantle the curtain.

2. Dismantle the two fixing bolts on the left low

protective plate of the B pillar,and remove it.

3. Dismantle the fixing bolts of the safety belt.

BP interior trim

- 41 -

Disassembly and assembly

left top/low protective plate of the B pillar

4. Dismantle the top/left protective plate of the left

front window,remove the top plate of B pillar.

Assembly

The assembly processes are in contrast to the

disassembly processes.

BP interior trim

- 42 -

Disassembly and assembly

left protective plate of the C pillar

Disassembly

1、Dismantle the curtain.

2、Dismantle the top/low protective plate of the left front

window.

3、Dismantle the top/low protective plate of the left rear

window.

Disassembly and assembly

BP interior trim

- 43 -

left protective plate of the C pillar

4、Unscrew the fixing bolts of the left protective plate of

the C pillar and remove it.

Assembly

The assembly processes are in contrast to the

disassembly processes.

BP interior trim

- 44 -

Disassembly and assembly

Right top/low protective plate of the C pillar

Disassembly

1、Dismantle the curtain.

2、Dismantle the top/low protective plate of the right

window.

3、Dismantle the low protective plate of the right C

pillar.

BP interior trim

- 45 -

Disassembly and assembly

Right top/low protective plate of the C pillar

4、Unscrew the fixing bolts on the right top protective

plate of the C pillar and remove it.

Assembly

The assembly processes are in contrast to the

disassembly processes.

BP interior trim

- 46 -

Disassembly and assembly

Left top/low protective plate of the D pillar(the D pillars are bilateral symmetry,the disassembly and

assembly processes of the right top/low protective plates of the D pillar are same as the left side)

Disassembly

1、Dismantle the curtain.

2、Unscrew the bolts on the top/low protective plate of

the left rear window and remove it.

3、Remove the left low protective plate of D pillar.

BP interior trim

- 47 -

Disassembly and assembly

Left top/low protective plate of the D pillar(the D pillars are bilateral symmetry,the disassembly and

assembly processes of the right top/low protective plates of the D pillar are same as the left side)

4、Remove the left top protective plate of the D pillar.

Assembly

The assembly processes are in contrast to the

disassembly processes.

BP interior trim

- 48 -

Disassembly and assembly

Top/low protective plate of the window on the left front side body(the disassembly and assembly

processes of the top/low protective plate of the window on the left rear and right side body are same as

this method)

Disassembly

1. Dismantle the curtain.

2. Unscrew the bolts on the top protective plate of

window on the left front side body.

3. Remove the top/low protective plate of the window

on the left front side body.

Assembly

The assembly processes are in contrast to the

disassembly processes.

BP interior trim

- 49 -

Disassembly and assembly

Protective plate of the rear door threshold

1、Dismantle the duct plugs of the rear door threshold

and buckles.

2、Unscrew the fixing bolts of the rear door threshold.

3、Remove the rear door threshold.

Assembly

The assembly processes are in contrast to the

disassembly processes.

BP interior trim

- 50 -

Disassembly and assembly

Left rear door

Disassembly

1. Pry-out the rear door trim plate carefully with

tools.

Assembly

The assembly processes are in contrast to the

disassembly processes.

BP interior trim

- 51 -

Disassembly and assembly

Right rear door

Disassembly

1. Remove the inner handle cover of the rear door.

2. Remove the right door trim plate with tools.

Assembly

The assembly processes are in contrast to the

disassembly processes.

BP interior trim

- 52 -

Disassembly and assembly

Left front door

1、Dismantle the handle and the bolt cover of the handle

on the left front door with screwdriver.

2、Dismantle the bolts of the handle base and fixing

bolts of the door plate with electrical gun.

3、Pry-out the door plate,and remove it.

Assembly

The assembly processes are in contrast to the

disassembly processes.

BP interior trim

- 53 -

Disassembly and assembly

Right front door

1、Dismantle the handle and the bolt cover of the handle

on the right front door with screwdriver.

2、Dismantle the bolts of the handle base and fixing

bolts of the door plate with electrical gun.

BP interior trim

- 54 -

3、Pry-out the door plate,and remove it.

Assembly

The assembly processes are in contrast to the

disassembly processes.