JAC HFC4DA1-2C engine. Instruction — part 42

FT Four-Wheel

Four-Wheel

Four-Wheel Alignment

Alignment

- 185 -

Instruction

Instruction and

and

and Operation

Operation

Four-wheel

Four-wheel alignment

alignment

alignment parameters

parameters

Front wheel camber

0.75±1°

1.25°

Kingpin caster

1.5±1.5°

1°

Kingpin inclination angle

12.75°±1°

1.25°

Toe-in

0～2mm

This vehicle is light-duty bus, with integral rear axle.
Rear wheel parameters cannot be adjusted during
four-wheel alignment.
1.

Front wheel camber：
Camber refers to the angle included between
geometry centerline and plumb line of tire viewed
from the front of vehicle. Tire upper edge deviates
to the inside (approaching to engine) or outside
(deviated from engine):

�

Zero camber refers to the state that the tire
centerline is coincided with the plumb line.

�

Positive camber refers to the state that the tire
centerline is located outside of plumb line.

�

Negative camber refers to the state that the tire
centerline is located inside of plumb line.

�

Excessive camber may lead to outside wear of
tire and too small camber may lead to inside
wear of tire. In case of inconsistency between
two wheel cambers, the vehicle shall be pulled
to one side of the larger camber.

Toe-in

Toe-in definition

definition

Front wheel toe-in is observed from the front of
vehicle and measured when two wheel axles are of
the same height. Front and rear end distance
difference between left and right tire centerline is
known as the total toe-in, as shown in the figure:
Zero toe-in: Left and right tire centerline distance
at front and rear end is equal: A=B.
Positive toe-in: Left and right tire centerline
distance at front end is less than that at rear end:
A<B.
Negative toe-in: Left and right tire centerline
distance at front end is larger than that at rear end:
A>B.

Toe-in function
It is used for elimination of tire skidding caused by
camber. The effect of wheel camber shall make the
wheel top face tilted outwards and the wheel shall
roll outwards during running, thus skidding is
formed, which shall lead to tire wear. The toe-in
functions to eliminate tire skidding due to camber,
as shown in the figure:

Front

Wheel toe-in:
Wheel toe-out:

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FT Four-Wheel

Four-Wheel

Four-Wheel Alignment

Alignment

- 186 -

Toe-in effect

�

Effect of positive toe-in: Tire outside wear due
to excessive positive camber takes the form of
feature. Touch it from the inside to outside and
sharp needle like feeling can be felt on the
tread outer edge.

�

Effect of negative toe-in: Tire inside wear due
to excessive negative camber takes the form
of feature. Touch it from the outside to inside
and sharp needle like feeling can be felt on the
tread outer edge.

In case of inconsistency between two wheel toe-in,
the vehicle shall be pulled to one side of the
smaller toe-in.

Kingpin

Kingpin caster

caster

Kingpin

Kingpin caster

caster

caster definition

definition

It refers to the angle included between the steering axis
and the line vertical to ground, which indicates the
forward and backward inclination of the line between
the upper ball joint or strut top and the lower ball joint
viewed from the side of vehicle (called the imaginary
steering

axis). There are three kinds of caster, viz.

positive caster, negative caster and zero caster.

Caster

Caster adjustment

adjustment

adjustment (generally

(generally

(generally nonadjustable

nonadjustable

nonadjustable)

As for the adjustment of caster, make analysis and
judgment as per different vehicle models at first and
then

make

adjustment

through

adjusting

washer,

eccentric camshaft, eccentric ball joint, girder slot, or
balance bar.
Inclination

Inclination

Inclination angle

angle

angle definition

definition

Definition of inclination angle: The angle included
between the steering axis and the plumb line viewed

from the front of vehicle.

Kingpin inclination angle mainly functions for the
realization of auto return after steering and the increase
of adhesion force of vehicle. Kingpin inclination angle
is unadjustable and its standard value can be achieved
by the replacement of defect parts.
As for four-wheel alignment of SUNRAY vehicles, only
the data adjustment for front wheels can be realized but
not for rear wheels. Among various parameters of front
wheels, the camber and toe-in are adjustable. Determine
the camber at first and then adjust the toe-in in order to
ensure the stability of vehicle straight running.
Common faults:

Abnormal wear of tire: Middle part wear, tire
shoulder wear, eccentric wear, feature-like wear,
serrated wear, wavy wear and spotty wear.

Middle part wear: Too high tire pressure.
Tire shoulder wear: Too low tire pressure and
overloading.
Eccentric wear: Improper camber.
Feature-like wear: Improper toe-in.
Serrated wear: Frequent brake application under
overloading condition for a long time and tire
rotation not conducted at regular intervals.
Wavy wear: Dynamic unbalance of tire, large
circular runout of wheel end face, looseness of hub
bearing and steering knuckle, too big thrust angle
of rear wheels and etc.
Spotty wear: Shimmy under high speed rotation of
wheel, excessive clearance of bearing, ball joint
and steering rod, dynamic unbalance of tire.

Running

deviation:

Probably

caused

inconsistent kingpin inclination angle, camber,
caster, toe-in, tire pattern, shock absorber vibration
reduction effect or wheel base between left and
right wheels.

Memory

deviation:

Probably

caused

interference of upper strut support motion, wear of
shock absorber steady bearing, over sticking of ball
joint or unbalance power steering.

Torque deviation: Probably caused by stuck or
loose

ball

joint,

unequal

axle

angle

under

acceleration, nonconforming inclination angle and
included angle, or improper alignment of power
train.

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FT Four-Wheel

Four-Wheel

Four-Wheel Alignment

Alignment

- 188 -

Data

Data adjustment

adjustment

adjustment of

of four-wheel

four-wheel

four-wheel alignment

alignment

Check basic data of vehicle such as tire pressure,
fuel level, vibration reduction effect, tire wear
degree, accessories and tools. Recover it to the
delivery status.

Drive the vehicle onto the lifter, with front wheels
held at the center of front turntable of the
four-column lifter.

Maintain vehicle and tire horizontal and press the
nose by hand.

Install the sensor and claw onto the tire properly
and maintain the sensor balanced.

Turn on the four-wheel aligner and select the
current vehicle position.

Operate on the basis of the computer reminder to
measure

the

actual

four-wheel

alignment

parameters.

Compare the parameters provided by four-wheel
aligner with the standard data and calculate the
actual data for adjustment.

Lift the vehicle. As the rear wheels are of
nonadjustable rear axle, only front wheel camber
and toe-in are adjustable.

Adjustment of front wheel camber: Loosen the
mounting nut of shock absorber lower support,
knock down the lower swing arm with SST or crow
bar and record the number of washers, make
calculation and find out what kinds of washer
should be adopted on the basis of four-wheel
alignment data and actual vehicle parameters,
install the washer onto the lower swing arm and
then tighten the nut to the standard torque.
Tire camber: 0.3°. Check if it is within the normal

data range of vehicle through computer.

10. Adjustment of toe-in: Loosen the mounting nut of

tie rod, calculate the required data on the basis of
the actual toe-in and standard data, and observe if
the toe-in is within the standard range through
computer when making adjustment.
Attention:

The

adjusting

amount

should

controlled within half circle in order to avoid
inaccuracy.
Standard toe-in: 0~2mm.

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Special

Special Tools

Tools

Tools for

for

for Sunray

Sunray

Attached List-Special Tools for Sunray

Applicable model: SUNRAY products manufactured by JAC (4DA1 Series)

Tool

Tool number

number

Tool

Tool name

name

Outline

Outline drawing

drawing

Purpose/application

JAC-T8F001

Piston pin remover and
installer

Removing and installing piston pins (engine)

JAC-T8F002

Handle

Supporting use of related installer in bearing
installation (transmission)

JAC-T8F003

Flywheel stopper

Fixing flywheel for easy removal (engine)

JAC-T8F004

Cooling system tester

Checking cooling system for leakage (engine)

JAC-T8F005

Oil filter wrench

Removing and installing oil filter (engine)

JAC-T8F006

Valve oil seal installer

Installing valve oil seals (engine)

JAC-T8F007

Fuel pressure gauge

Measuring fuel pressure (engine)

JAC-T8F008

Compression gauge

Measuring cylinder pressure (engine)

JAC-T8F009

Pressure gauge
connector

Playing the role of an adapter during cylinder
pressure measurement (engine)

JAC-T8F010

Valve spring compressor

Compressing valve springs and removing
valves and related parts (engine)

JAC-T8F011

Camshaft gear puller

Removing camshaft gear (engine)

JAC-T8F012

Cylinder liner installer
(including jack)

Installing cylinder liners (engine)

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Special

Special Tools

Tools

Tools for

for

for Sunray

Sunray

Tool

Tool number

number

Tool

Tool name

name

Outline

Outline drawing

drawing

Purpose/application

JAC-T8F013

Cylinder liner puller

Removing cylinder liners (engine)

JAC-T8F014

Piston installer

Installing pistons (engine)

JAC-T8F015

Crankshaft front oil seal
installer

Installing crankshaft front oil seal (engine)

JAC-T8F016

Camshaft bushing
remover/installer

Removing and installing camshaft bushing
(engine)

JAC-T8F017

V-block for camshaft
measurement

Measuring camshaft damage (engine)

JAC-T8F018

Hose clamp pliers

Removing a clamp from a hose

JAC-T8F019

Piston ring extractor

Removing and installing piston circlips
(engine)

JAC-T8F020

Valve oil seal extractor

Removing valve oil seals (engine)

JAC-T8F021

End fork clip

Securing flywheel (engine)

JAC-T8F022

Crankshaft back bearing
remover

Removing crankshaft back bearing

JAC-T8F023

Crankshaft back bearing
installer

Installing crankshaft back bearing

JAC-T8F024

Diesel common rail tool
kit

The diesel common rail tester can accurately
and effectively diagnose a diesel engine with a
diesel common rail system and test its fuel
injection.

JAC-T8B001

Shift fork lock pin
remover

Removing shift fork spring pin (transmission)

JAC-T8B002

Oil seal puller

Removing oil seals (transmission)

-------------------------------------------------------------------------------------------------------------------------------------------------------------

Special

Special Tools

Tools

Tools for

for

for Sunray

Sunray

Tool

Tool number

number

Tool

Tool name

name

Outline

Outline drawing

drawing

Purpose/application

JAC-T8B003

Clutch guide

Centering clutch discs (transmission)

JAC-T8B004

Input shaft bearing
installer

Installing input shaft bearings (transmission)

JAC-T8B005

Output shaft bearing
installer

Installing output shaft bearings (transmission)

JAC-T8B006

Countershaft front
bearing installer

Installing countershaft front bearing
(transmission)

JAC-T8B007

Input shaft protective
sleeve

Protecting front gear of input shaft
(transmission)

JAC-T8B008

Output shaft protective
sleeve

Protecting front gear of output shaft
(transmission)

JAC-T8B009

Transmission bearing
remover kit

Removing bearings on transmission
(transmission)

JAC-T8B010

Input shaft oil seal
installer

Installing input shaft oil seals (transmission)

JAC-T8B011

Transmission rear end
cover oil seal remover

Removing rear end cover oil seal
(transmission)

JAC-T8B012

Rear end cover oil seal
installer

Installing rear end cover oil seal (transmission)

JAC-T8D001

Steering linkage drawing
die

Disconnecting front end control arm ball joint
of wheel from steering knuckle (chassis)

JAC-T8D002

Interior trim crow plates

Prying door trims

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Preface

This SUNRAY Service Instruction is hereby compiled by the Customer Service

Department of JAC to help the technical service personnel correctly understand and

get familiar with SUNRAY products of JAC INTERNATIONAL better and to provide

them with the ability of quick repair and proper maintenance. This instruction comprises

five volumes: Engine Control, Engine Mechanical, Chassis, Body Electrical, and

Body Accessories.

The Body Accessories Volume details the removal methods of body accessories

including interior and exterior trims and glasses of SUNRAY long-wheelbase vehicles

as well as repair parameters of metal plates.

When replacement is necessary, only genuine spare parts recommended by JAC can

be adopted.

No part of this instruction can be reproduced or used in any form or by any mean without

JAC INTERNATIONAL

March 2011

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Body

Body Accessor

Accessor

Accessories

ies

ies Volume

Volume

Volume Content

Content

Contentssss

- 1 -

Body

Body Accessor

Accessor

Accessories

ies

ies Volume

Volume

Volume Content

Content

Contentssss

Body

Body Glass

Glass

SST for Glass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BG 2

Front windshield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BG 3

Windshield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BG 4

Front triangle glass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BG 7

Front door glass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BG 9

Front door glass seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BG 11

Front door glass regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BG 12

Left side wall glass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. BG 14

Right side wall glass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BG 17

Double-open back door glass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. BG 21

Front/Rear

Front/Rear Doors

Doors

Doors and

and

and Front

Front

Front Compartment

Compartment

Compartment Cover

Cover

Front compartment cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BD 24

Front compartment cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BD 25

Radiator core bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...BD 28

Compartment cover release cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BD 29

Right front door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... BD 31

Left front door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BD 34

Door outer handle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BD 37

Door lock cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... BD 39

Left front door lock body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BD 41

Right front door lock body. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. BD 44

Door seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..BD 46

Double-open back door. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... BD 47

Double-open back door outer handle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...BD 50

Double-open back door latch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...BD 52

Double-open back door lock and drive rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . BD 53

Double-open back door lock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BD 55

Double-open back door seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BD 57

Removal/Installation

Instrument panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... BP 60

Instrument panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... BP 61

Roof lining. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BP 69

Trim panel of A-pillar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...BP 74

Trim panel of B-pillar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...BP 75

Trim panel of C-pillar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...BP 78

Side wall window trim panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BP 80

Trim panel of D-pillar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. BP 84

Interior trim panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BP 86

Front door trim panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BP 88

Double-open back door trim panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... BP 89

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Body

Body Accessor

Accessor

Accessories

ies

ies Volume

Volume

Volume Content

Content

Contentssss

-2-

Interior rear-view mirror. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...BP 91

Sun visor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...BP 92

Curtains. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BP 93

Luggage rack. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BP 94

Step plate assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. BP 96

Front bumper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BP 97

Rear bumper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BP 99

Front grille. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..BP 101

Fender. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BP 102

Front door skirt trim panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..BP 106

Front side wall skirt trim panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...BP 107

Middle side wall skirt trim panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BP 108

Rear wheel skirt trim panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BP 109

Rear tire mud guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BP 110

Seats

Driver’s seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SE 112

Front row twin bench-type seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. SE 114

Front row individual seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SE 115

Driver’s seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SE 116

Front row twin bench-type seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. SE 119

Front row individual seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SE 120

back row seats. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SE 121

Sealing

Sealing Elements

Elements

Inner acoustic baffle of front wall. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...SP 124

Outer heat shield of front wall. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SP 125

Front door seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SP 125

Rear door seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SP 126

Fender seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. SP 126

Front compartment seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. SP 127

Waterproof membrane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SP 127

Body

Body Repair

Repair

Repair Parameters

Parameters

Engine Compartment Repair Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . ...XE 130

Windshield Repair Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...XE 131

Front Door Repair Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... XE 132

Rear Double-Door Repair Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . ... XE 133

Girder Repair Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...XE 134

Attached

Attached List

List

List—

—

—SUNRAY

SUNRAY

SUNRAY Special

Special

Special Service

Service

Service Tools

Tools

-------------------------------------------------------------------------------------------------------------------------------------------------------------

BG Body

Body

Body Glass

Glass

- 1 -

Body

Body Glass

Glass

Applied models: SUNRAY products manufactured by JAC

Subject

Page

Instruction

Instruction and

and

and Operation

Operation

SST for Glass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 2
Front windshield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3

Removal/Installation

Windshield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 4
Front triangle glass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7
Front door glass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Front door glass seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...11
Front door glass regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 12
Left side wall glass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Right side wall glass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 17
Double-open back door glass. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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BG Body

Body

Body Glass

Glass

- 2 -

Instruction

Instruction and

and

and Operation

Operation

SST

SST for

for

for Glass

Glass

Tool

Illustration

Function

Door hinge adjusting wrench

For adjustment, removal or
installation of door hinge

Ceiling remover

For removal of ceiling

Sealant remover

For cutting door window
seal (used together with the
next tool)

Seal cutting blade

For removing windshield
sealant (used together with
the previous tool)

Sealant gun

For applying sealant onto
windshield

Glass suction cup

For removal/installation of
windshield

Windshield remover

For removal of windshield
molding

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BG 车身玻璃

- 3 -

Instruction

Instruction and

and

and Operation

Operation

Front

Front windshield

windshield

Front windshield is mainly composed of laminated
glass and relevant accessories (interior rear-view
mirror base, antenna and antenna terminal, pad),

functioning for blocking wind and rain and providing
safe and comfortable environment for driver and
passengers.

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BG Body

Body

Body Glass

Glass

- 4 -

Removal/Installation

Front

Front windshield

windshield

Removal
1.

Remove glass molding
Prepare repair kit, with the following articles
included:

Sea

lant (carbamic acid

ethyl ester adhesive)

Cleaner

Primer

Cloth

Wool brush

Felt

Mat

Nozzle

Note:

An additional tube of sealant may be applied.

Remove grille and wiper from vehicle neck. .

Remove interior rear-view mirror.

Disconnect antenna connector.

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BG Body

Body

Body Glass

Glass

- 5 -

Removal/Installation

Removal/Installation (Continued)

(Continued)

Front

Front windshield

windshield

Install the precise cutting blade (24mm hook type
blade) onto the cutter.

Warning:

When using tools for cutting glasses, please wear
gloves and goggles to avoid possible injury caused by
glass fragments generated during cutting.
Attention:

Attention:

In case of the windshield to be reused, it is prohibited to
use cutter or electric cutting tools.

Cut one side and top side of glass sealant.
Cut the polyurethane sealant on the outside of
windshield from the left lower corner to the left
upper part and then from the upper part to the right
lower corner.

Note:

The windshield is positioned by two height adjustable
pieces installed on the bottom, which should be leveled
before cutting.

Cut the glass sealant at the bottom part.

Cut the glass sealant at the bottom part (continued).

Cut the sealant from the outside midpoint to both
sides.

Take the windshield down carefully.

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BG Body

Body

Body Glass

Glass

- 6 -

Removal/Installation

Removal/Installation (Continued)

(Continued)

Front

Front windshield

windshield

Installation
Note:

Note:

Don’t contact the already trimmed surface, otherwise,
bonding effect of new sealant may be influenced.
1.

Trim the side grooves.

�

Install the precise cutting blade.

�

Trim the polyurethane sealant remained on
grooves carefully, with polyurethane sealant
in thickness of 1mm left on the body for side
trimming.

Wipe the glass clean.
Trim the polyurethane sealant remained on window
carefully, with polyurethane sealant in thickness of
1mm left on the glass for side trimming.

Caution:

Glass primer contains solvent that can make the primer
hardened after volatilization but also can soften the
surface

coat

synthetic

paint,

therefore,

“ZK”

polypropylene surface paint mixed with hardener should
be applied around the window.

Install the new height adjusting brackets onto the
bottom part of windshield.

�

Clamp the mark position of windshield center
groove.

�

Rotate two adjusting screws to lift the glass to
the uppermost.

�

Place the glass into window groove and
check if the clearance between glass top and
window groove is 2~4mm. Adjust when
necessary.

Install the glass.

�

Mount the glass in place with center aligned.

�

Adjust glass based on window groove height
to ensure proper alignment. Adjust when
necessary.

�

Press the glass tightly into the sealant from
center part gradually to both sides.

Note:

Park the vehicle in the place with ambient temperature
of zero degree and don’t drive it 24h before complete
curing of carbamic acid ethyl ester adhesive. The curing
time is determined by temperature and humidity, which
shall be prolonged in case of low temperature and
humidity.

Install remaining parts in reverse order of removal.

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BG Body

Body

Body Glass

Glass

- 7 -

Removal/Installation

Front

Front triangle

triangle

triangle glass

glass

Removal
1.

Remove the rear-view mirror from the window.

Remove the glass.
Compress the glass continuously and forcibly from
the inside upper corner.

Peel off the seal.

Installation
1.

Insert a high strength cable into seal and window
groove to determine the end position of cable and
make it lapped at the corner part.

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JAC HFC4DA1-2C engine. Instruction — part 42

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