Bonnet:

1. Replacement of bonnet lock:

1) disassembly

① open engine bonnet

② disassemble front bumper

③ disassemble fixing bolt of lock body

④ disconnect the lock body’s pre-assembled pull-cable, then take down the lock

body

2) assembly

Assemble the lock body by following opposite sequence of disassembly procedures

2. Replacement of bonnet’s opening handle:

1) disassembly

① disassemble the buckle of bonnet’s opening handle

② disassemble lower guard plate of A column on driver’s side

③ disassemble the cross-recessed self-tapping screw on the pedestal of bonnet’s

opening handle

④ disconnect the pull-cable of engine bonnet

⑤ take off the pedestal assy of opening handle

2) assembly

Assemble the opening handle by following reversed order of disassembly procedures

3. Replacement of engine bonnet stay bar

Attention：

■Additional support must be equipped in case of vehicle damage or personal injury

while disassembling or assembling the stay-bar.

1) disassembly

① open bonnet and hold it with the support

② remove the stay bar from the clamp, then turn it left and unscrew the stay

bar

2) assembly

Follow the opposite sequence of the disassembly procedures.

4. Replacement of engine bonnet's hinge

1) disassembly

① disassemble engine bonnet. See “replacement of engine bonnet”

② disassemble fender See “replacement of fender”

③ disassemble bolts and hinge

2）Assembly

Follow the opposite sequence of the disassembly procedures.

■ Tightening torque: 32-38N.m

5. Replacement of engine bonnet

Attention:

■ Prevent damage or scratch while disassembling or assembling components

■ When removing the clip from the trim, wrap the straight screwdriver’s head

with cloth.

■ When assembling the body trim, first confirm that the snap is securely mounted

in the plate hole on the vehicle body and carefully press them in.

■ In the disassembly of some larger components, ensure at least two people should

operate in case of fall-off.

■ Do not exert too much force when disassembling and assembling some rubber

accessories.

1) disassembly

① open bonnet and hold it with the support

② mark hinge's relative position on bonnet so as to locate its position during

assembly

③ disassemble the bolts fixing bonnet and two hinges

④ disassemble bonnet from the hinge with assistance of another maintenance

personnel

2) assembly

Follow the opposite sequence of the disassembly sequence.

Front door:

1. Replacement of front door assy:

Diagram of left-front door lock assy

Serial

number

Chart number Name

1 6105160U1510 Outer handle pedestal of left-front door

2 6105112P3010

Outer handle’s pull rod of left-front

door

3 6105131U1510

Outer handle’s rear-end washer of

left-front door

4 6105130U1592 Outer handle assy of left-front door

5 6105181U1592 Outer handle’s cover of left-front door

6 6105161U1510F61 Flat-head screw with gasket

7 6105132U1510

Outer handle’s front-end gasket of

left-front door

8 10188-05143F61 T-shaped screw

9 6105140P3010 Inner handle assy of left door

10 10188-05163F61 T-shaped screw

11 14910-05000 Grommet screw

12 6105114P3010 Inner handle’s pull-cable of front door

13 6105113P3010 Inner handle’s pull table of front door

14 6105110U8510 Lock body and fastener of left-front door

15 6205130U1010 Countersunk combination screw

16 10178-08223F62 Countersunk screw

17 6105170U8510 Door lock buckle assy

Attention: for right-front door lock assy, the structures of left and right front door lock are symmetrical except for

no lock cylinder in right-front door lock

1) disassembly

① disassemble trim plate of front door (inner trim and inner handle are pre-fixed

by three screws

② disassemble water-proof membrane

③ Disassemble outer weather-strip

④ Disassemble window glass

⑤ disassemble groove and guide rail

⑥ loosen the fixing bolt of outer handle’s end-cover of front door

⑦ pull out outer handle, and take off the end-cover and lock cylinder

⑧ disassemble the fixing bolt of lock body assy

⑨ take off lock body and pull-cable

2) assembly

Follow the opposite sequence of the disassembly procedures.

Attention：

■ Please assemble all parts on their original positions.

■ after assembly, check whether door’s opening and closing are normal, and the

locking should be firm If not, please adjust or re-assemble the lock

2. Replacement of door lock buckle assy:

1) disassembly

① mark the position of current lock buckle

② disassemble fixing bolt of lock buckle

③ disassemble lock buckle

④ disassemble according to assembly status

2) assembly

Follow the opposite sequence of the disassembly procedures.

3) adjustment

① loosen the buckle’s screw

② move the buckle to the needed direction. Ensure the buckle is in the middle

of door lock.

③ tighten the fixing bolt of buckle

④ close door and check whether side difference and clearance meet the demand.

Hint: replacement of components on each door are the same.

3. Replacement of glass regulator assy:

Glass regulator and sealing system of left-front door

Serial

number

Chart number Name

6107151P3010 Lower part of rubber strip on front door’s frame

5532104U2010 Hole plug

12493-04103 T-shaped screw

6104101U1510 Washer

6104150P3010 Outer weather-strip of left-front door

6104160P3010 Guide rail’s lower part of left-front door glass

6104130P3010 Glass grooveassyofleft-frontdoor

BST18R2 Hole plug

13395-0600F71 Sawtooth flange nut

6104120P3010 Left-front door glass assy

6104140P3010 Inner weather-strip of left-front door

6107110P3010 Rubber strip on left-front door’s frame

Q1460612F62 Set assy of hexagon bolt, spring washer and flat washer

6104110P3010 Glass regulator assy on left-front door

6107130P3010 First rubber strip on left-front door

6107171P3010 Water-proof membrane of left-front door

Attention: the glass regulator and sealing system on right-front and left-front door are in symmetry.

1) disassembly

① disassemble inner trim plate and weather-strip of front door (please refer

to disassembly procedures of door trim panel)

② disassemble water-proof membrane

③ disassemble outer weather-strip. Please use cross screwdriver to unscrew the

bolt shown in red circle, then remove the weather-strip.

④ remove front door glass

Lift down regulator to the position where you can disassemble mounting bolts

easily. Then use M6 socket spanner to unscrew the two mounting bolts of glass. Last,

rotate glass in 90 degrees and pull up glass upward.

⑤ disassemble the glass groove on vehicle door

⑥ disassemble the glass regulator.

Use M6 socket spanner to unscrew the bolt 1, 2, 3, 5, 6 in order, then loosen

the bolt 4 (don’t disassemble), and pull out regulator upward through the

special-shaped hole 4.

2) assembly

Follow the opposite sequence of the disassembly procedures. The bolt’s tightening torque

is (9±2)N.m.

3) the assembly and disassembly of first rubber strip and frame rubber strip are

relatively independent. During assembly or disassembly, the positioning should be

accurate and assembly should be in place.

4. Replacement of front door hinge:

1) disassembly

Disassemble bolts and hinges from vehicle door and body with assistance of another

maintenance personnel

■ tightening torque: 30-36N.m

2) Assembly

Follow the opposite sequence of the disassembly procedures.

5. Replacement of front door stopper:

1） Disassembly

Disassemble bolts, nuts and hinges from vehicle door and body with assistance

of another maintenance personnel

■ tightening torque: fixing torque of stopper on door-end: 9-11N.m; body-end:

20-24N.m

2) assembly

Follow the opposite sequence of the disassembly procedures.

6. Replacement of front door:

1) disassembly

① disassemble the set assy of hexagon bolt, spring washer and flat washer on

stopper’s side.

■ tightening torque: 20-24N.m

Attention：

■Disassembly should be done in several times. Do not loosen all parts in one

time.

■Please disassemble from lower part to upper part.

② unplug the rubber sleeve of door harness, then unplug the door’s electric

connector.

③

Disassemble bolts and hinges from vehicle body with assistance of another

maintenance personnel.

④ lift down vehicle door with assistance of other people.

2) assembly

Follow the opposite sequence of the disassembly procedures.

Attention：

■ assembly and tightening should be done in several times. Do not tighten all

bolts in one time.

Rear door:

1. Replacement of rear door lock assy:

Left-rear door lock assembly

Serial

number

Chart number Name

1 6205160U1510 Left-rear door outer handle pedestal assy

2 6205131U1510

Outer handle’s rear-end gasket of left-rear

door

3 6205180U1592 The cover of left-rear door’s outer handle

4 6105130U1592 Outer handle assy of left door

5 6105161U1510 Flat-head screw with gasket

6 6105132U1510 Outer handle’s front-end gasket of left door

7 6205114P3010 Inner handle’s pull-cable of rear door

8 10188-05143F61 T-shaped screw

9 14910-05000 Grommet screw

10 10188-05163F61 T-shaped screw

11 6105140P3010 Inner handle assy of left door

12 6205113P3010 Inner locking pull-cable assy of rear-door

13 6205110U8510 Lock body and fastener of left-rear door

14 6205130U1010 Countersunk combination screw

15 10178-08223F62 Countersunk screw

16 6105170U8510 Locking hook assy

17 6205112P3010 Pull-rod of outer handle on left-rear door

Attention: the structures of left-rear and right-rear door lock are in symmetry.

1) disassembly

① disassemble trim plate of rear door (inner trim and inner handle are pre-fixed

by three screws)

② disassemble water-proof membrane

③ Disassemble outer weather-strip

④ Disassemble rear window glass

⑤ disassemble groove and guide rail of rear glass

⑥ loosen the fixing bolt of outer handle’s end-cover on rear door, then

disassemble the pull-rod of outer handle

⑦ Disassemble end-cover and outer handle

⑧ disassemble the fixing bolt of rear door lock body

⑨ take off lock body and pull-cable

2) assembly

Follow the opposite sequence of the disassembly procedures.

Hint: replacement of components on left and right rear door are the same.

2. Replacement of glass regulator assy:

Glass regulator and sealing system of left-rear door

Serial

number

Chart number Name

6204110P3010 Glass regulator assy on left-rear door

12493-04103 T-shaped screw

5532104U2010 Hole plug

6204130P3010 Glass groove assy of left-rear door

6104101U1510 Washer

6204150P3010 Outer weather-strip of left-rear door

BST18R2 Hole plug (Door hinge)

6204140P3010 Inner weather-strip of left-rear door

6204120P3010 Glass assy on left-rear door

6204160P3010 Rear guide rail of left-rear door glass

6207130P3010 First rubber strip on left-rear door

6207110P3010 Rubber strip on left-rear door’s frame

6207171P3010 Water-proof membrane of left-rear door

Q1460612F62 Set assy of hexagon bolt, spring washer and flat washer

13395-0600F71 Sawtooth flange nut

6207151P3010 Rubber strip’s lower part on rear door’s frame

Attention: the glass regulator and sealing system on right-rear and left-rear door are in symmetry.

1) disassembly

① disassemble inner trim plate and weather-strip of rear door (please referto

disassembly procedures of door trim panel)

② disassemble water-proof membrane

③ disassemble outer weather-strip. Please use cross screwdriver to unscrew the

bolt shown in red circle, then remove the weather-strip.

④ unscrew the mounting bolt of rear guide rail of left-rear window glass (unscrew

but not disassemble)

⑤ disassemble rear door’s window

Lift down regulator to the position where you can disassemble mounting bolts

easily. Then use M6 socket spanner to unscrew the two mounting bolts of glass. Last,

pull up the glass upward (you can pull out groove on C column first)

⑥

disassemble the glass groove

⑦ disassemble glass regulator

Use M6 socket spanner to disassemble the bolt 1, 2, 3 in sequence.

2) assembly

Follow the opposite sequence of the disassembly procedures. The bolt’s tightening torque

is (9±2)N.m.

3) the assembly and disassembly of first rubber strip and frame rubber strip are

relatively independent. During assembly or disassembly, the positioning should be

accurate and assembly should be in place.

3. Replacement of rear door hinge:

1) disassembly

Disassemble bolts and hinges from vehicle door and body with assistance of another

maintenance personnel

■ tightening torque: 30-36N.m

2) Assembly

Follow the opposite sequence of the disassembly procedures.

4. Replacement of rear door stopper:

1） Disassembly

Disassemble bolts, nuts and hinges from vehicle door and body with assistance

of another maintenance personnel

■ tightening torque: fixing torque of stopper on door-end: 9-11N.m; body-end:

20-24N.m

2) assembly

Follow the opposite sequence of the disassembly procedures.

5. Replacement of rear door hinge:

1) disassembly

① disassemble the set assy of hexagon bolt, spring washer and flat washer on

stopper’s side.

■ tightening torque: 20-24N.m

Attention：

■Disassembly should be done in several times. Do not loosen all parts in one

time.

■Please disassemble from lower part to upper part.

② unplug the rubber sleeve of door harness, then unplug the door’s electric

connector.

③

Disassemble bolts and hinges from vehicle body with assistance of another

maintenance personnel.

④ lift down vehicle door with assistance of other people.

2) assembly

Follow the opposite sequence of the disassembly procedures.

Attention：

■ assembly and tightening should be done in several times. Do not tighten all

bolts in one time.

Tail door:

1． Replacement of tail door’s pull-cable and locating bracket

Attention：

■ Additional support must be equipped in case of vehicle damage or personal

injury while disassembling or assembling the pull-cable.

1) disassembly

open and support tail door

② disassemble the bolt mounted on tail door assy, then remove the locating

bracket.

③ disassemble the bolt and flat washer mounted on cargo body assy, then remove

the tail door’s pull-cable

2）assembly:

Follow the opposite sequence of the disassembly procedures. Tightening torque:

30-36N.m

Note:

Replacement of tail door’s left and right pull-cable and locating bracket are

the same

2. Replacement of tail door’s lock assy:

1) Disassembly

① open the tail door.

② disassemble the set assy of cross-head screw and flat washer on tail door’s

inner trim panel

③ disassemble fixing bolt of lock body

④ remove the lock body on tail door

2) assembly

Follow the opposite sequence of the disassembly procedures. Tightening torque:

30-36N.m

Replacement of tail door’s left and right lock assy are the same

Attention：

■ after assembly, please open and close tail door to test the lock’s function

■ if deviation exists in the engaging of lock body and hook, please unscrew the

two fixing bolts on hook, adjust hook into proper position, then tighten the fixing

bolts.

3. Replacement of tail door’s lock buckle assy:

1) Disassembly

① open the tail door.

② disassemble fixing bolt of lock buckle

④ take out the lock buckle

2) assembly

Follow the opposite sequence of the disassembly procedures. Tightening torque

of fixing bolts: 30-36N.m

Note:

Replacement of tail door’s left and right lock buckle assy are the same

4. Replacement of tail door hinge:

）

Disassembly

①

open the tail door.

②

disassemble the mounting bolt of tail door.

■ tightening torque of mounting bolts: 30-36N.m

②

disassemble the mounting bolts on cargo body’s side

■ tightening torque of mounting bolts: 52-58N.m

）

Assembly

Follow the opposite sequence of the disassembly sequence.

5. Replacement of tail door:

1) disassembly

① open the tail door.

② disassemble the mounting bolt of tail door.

③ unplug the electrical connector of tail door

④ lift down the tail door

2） assembly

Follow the opposite sequence of the disassembly sequence.

Attention：

■ adjust the tail door after assembly. Ensure the clearance and surface

difference can meet the damand, and the opening&closing should be smooth without

interference.

Oil filler cover

1. Replacement of oil filler cover assy:

1) disassembly

① open the oil filler cover assy

② disconnect the pull-strip connecting filler cover and panel.

③ disassemble the set assy of hexagon bolt, spring washer and flat washer.

■ tightening torque: 8-11N.m

④ disassemble the oil filler cover assy

2) assembly

Follow the opposite sequence of the disassembly procedures.

2. Replacement of oil filler cover’s opening handle:

1) disassembly

① disconnect the pull-cable end on opening handle

② disconnect the tightening bolt on opening handle

■ ■ tightening torque: 8-11N.m

③ replace the opening handle on oil filler cover

2）Assembly

Follow the opposite sequence of the disassembly procedures.