Engine JAC HFC4DA1-2C. Service manual — part 166
Special
Special
Special
Special Tools
Tools
Tools
Tools for
for
for
for Sunray
Sunray
Sunray
Sunray
Tool
Tool
Tool
Tool number
number
number
number
Tool
Tool
Tool
Tool name
name
name
name
Outline
Outline
Outline
Outline drawing
drawing
drawing
drawing
Purpose/application
Purpose/application
Purpose/application
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
Preface
Preface
Preface
Preface
This SUNRAY Service Manual 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 manual 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 manual can be reproduced or used in any form or by any mean without
written permission. All Rights Reserved.
JAC INTERNATIONAL
March 2011
Body
Body
Body
Body Accessor
Accessor
Accessor
Accessories
ies
ies
ies Volume
Volume
Volume
Volume Content
Content
Content
Contentssss
- 1 -
Body
Body
Body
Body Accessor
Accessor
Accessor
Accessories
ies
ies
ies Volume
Volume
Volume
Volume Content
Content
Content
Contentssss
Body
Body
Body
Body Glass
Glass
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
Front/Rear
Front/Rear Doors
Doors
Doors
Doors and
and
and
and Front
Front
Front
Front Compartment
Compartment
Compartment
Compartment Cover
Cover
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
Removal/Installation
Removal/Installation
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
Body
Body
Body
Body Accessor
Accessor
Accessor
Accessories
ies
ies
ies Volume
Volume
Volume
Volume Content
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
Seats
Seats
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
Sealing
Sealing Elements
Elements
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
Body
Body Repair
Repair
Repair
Repair Parameters
Parameters
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
Attached
Attached List
List
List
List—
—
—
—SUNRAY
SUNRAY
SUNRAY
SUNRAY Special
Special
Special
Special Service
Service
Service
Service Tools
Tools
Tools
Tools
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