JAC S2. Service Manual — part 5

Rear Vehicle Door

Rear Vehicle Door

53

VI、Outer Handle Fastener Assembly of Rear Vehicle Door

（I）Removal

1. Remove lock core cover of outer handle of rear vehicle door Refer to

“Lock core cover of outer handle of rear vehicle door”

2. Remove outer handle assembly of rear side vehicle door

1). Pull right and take down outer handle assembly of rear side

vehicle door

△

Note Please don’t lose sealing pad of outer handle

fastener.

（II）Check

1. Extrinsic check of outer handle assembly

1). Check whether surface of outer handle assembly is flat, whether there is effecting usage deformation of scratch, air bubble.

（III）Installation

1. Install outer handle fastener assembly of rear side vehicle door

1). Install outer handle fastener to outer handle seat from

outside vehicle;

2. Install lock core cover of outer handle of vehicle door

Rear Vehicle Door

Rear Vehicle Door

54

VII、Outer Handle Seat Assembly of Rear Vehicle Door

（I）Removal

1. Open engine compartment cover

2. Disconnect battery negative electrode

3. Remove triangle window cover plate assembly of rear vehicle door Refer to

“”rear vehicle door trim panel assembly

4. Remove rear vehicle door trim panel assembly Refer to

“”rear vehicle door trim panel assembly

5. Remove installation bracket of rear vehicle door handle panel Refer to

“”waterproof membrane rear vehicle door

6. Remove waterproof membrane rear vehicle door Refer to

“”waterproof membrane rear vehicle door

7. Remove outer handle cover of rear vehicle door Refer to

“”outer handle cover of rear vehicle door

8. Remove outer handle fastener assembly of rear vehicle door Refer to

“”outer handle fastener assembly of rear vehicle door

9. Remove outer handle seat assembly of rear vehicle door

1). Remove fixed bolt of outer handle seat;

2). Disconnect outside open rod of rear vehicle door, and take

out outer handle seat assembly between rear vehicle door

inner and outer panel;

△

Note Before disconnecting battery negative electrode,

it needs to lift window to the highest position to be

convenient to take out outer handle seat of rear vehicle

door.

（II）Check

1. Extrinsic check of outer handle assembly

1). Check whether surface of outer handle assembly is flat, whether there is effecting usage deformation of scratch, air bubble.

（III）Install

1. Install outer handle seat assembly of rear vehicle door

1). Install outside open rod of rear vehicle door, and place

outer handle seat to installation position;

2). Tighten fixed bolt of outer handle seat;

Tighten torque

5~7N·m

2. Install outer handle fastener assembly of rear vehicle door

3. Install outer handle cover of rear vehicle door

4. Install waterproof membrane rear vehicle door

5. Install installation bracket of rear vehicle door handle panel

6. Install rear vehicle door trim panel assembly

7. Install triangle window cover plate assembly of rear vehicle door

8. Connect battery negative electrode

9. Close engine compartment cover

VIII、Rear Side Vehicle Door Limiting Device

Rear Vehicle Door

Rear Vehicle Door

55

（I）Remove

1. Open engine compartment cover

2. Disconnect battery negative electrode

3. Remove triangle window cover plate assembly of rear vehicle door Refer to

“”rear vehicle door trim panel assembly

4. Remove rear vehicle door trim panel assembly Refer to

“”rear vehicle door trim panel assembly

5. Remove installation bracket of rear vehicle door handle panel Refer to

“”waterproof membrane rear vehicle door

6. Remove waterproof membrane rear vehicle door Refer to

“”waterproof membrane rear vehicle door

7. Remove rear side vehicle door limiting device

1). Remove 2 fixed nuts

① connecting limiting device and

vehicle door;

2). Remove fixed bolt

② connecting limiting device and

vehicle body;

3). Take out limiting device from inside vehicle door;

（II）Installation

1. Install rear side vehicle door limiting device

1). Install limiting device from inside vehicle door;

2). Tighten 2 fixed nuts

① of limiting device and vehicle door;

Tighten torque

7.8~11.8N·m

3). Tighten fixed bolt

② connecting limiting device and

vehicle body;

Tighten torque

20~24N·m

2. Install waterproof membrane rear vehicle door

3. Install installation bracket of rear vehicle door handle panel

4. Install rear vehicle door trim panel assembly

5. Install triangle window cover assembly of rear vehicle door

6. Connect battery negative electrode

7. Close engine compartment cover

Tail Gate and Fuel Filler Port

Tail Gate and Fuel Filler Port

56

Tail Gate and Fuel Filler Port

I、Summary

（I）Structure Overview

Position Diagram

1. Opening handle of fuel filler port cover

2. Wire drawing assembly of fuel filler port cover

3. Fuel filler port cover assembly

4. Tail door

5. Lock assembly of tail door

6. Left hinge assembly of tail door

7. Right hinge assembly of tail door

8. Left side air supporting rod assembly of tail door

9. Right side air supporting rod assembly of rail door

（II）Maintenance Parameter/Technical Parameter

SN

ITEMS

Adjustment parameter

1

Proper alignment of left/right hinge

axle

of trunk

Φ0.5mm

（III）Torque Parameter

SN

ITEMS

Torque

（N·m）

1

Vehicle body side fixed nut of trunk cover hinge

25~29

2

Hinge side fixed bolt of trunk cover

30~36

3

Fixed bolt of fuel filler port cover

7~11

II、Air Supporting Rod Assembly of Tail Door

（I）Removal

1. Remove air supporting rod assembly of tail door

Tail Gate and Fuel Filler Port

Tail Gate and Fuel Filler Port

57

1). Open tail door, pry clap spring on upper part of air supporting

rod, and disconnect connection of air supporting rod and ball

head pin;

2). Pry clamp spring on lower part of air supporting rod, and

disconnect connection of air supporting rod assembly and ball

head pin of air supporting rod and bracket assembly;

3). Take down air supporting rod assembly;

△

Note This process needs partner to help support to prevent

tail door dropping.

（II）Installation

1. Install air supporting rod assembly of tail door

1). Connect fairly thick end of air supporting rod assembly and ball

head pin and bracket assembly;

2). Connect the other end of air supporting rod assembly to ball

head pin on vehicle door;

△ Note Installation position of both ends of air supporting

rod assembly can’t be exchanged.

III、Tail Door Assembly

（I）Removal

1. Open engine compartment cover
2. Disconnect battery negative electrode
3. Remove rear threshold guard panel assembly (left) Refer to "Rear threshold guard panel assembly"
4. Remove rear seat cushion assembly Refer to "Rear seat backrest"
5. Remove rear seat backrest assembly Refer to "Rear seat backrest"
6. Remove lower fixed bracket assembly of rear seat backrest (left) Refer to "Lower trim panel assembly of C pillar"
7. Remove lower trim panel assembly of C pillar (left) Refer to "Lower trim panel assembly of C pillar"
8. Remove upper trim panel assembly of C pillar (left) Refer to "Upper trim panel assembly of C pillar"

Tail Gate and Fuel Filler Port

Tail Gate and Fuel Filler Port

58

9. Remove tail door assembly

1). Remove fixed bolt connecting tail door transition wiring harness

grounding point and vehicle body, disconnect wiring harness

connector, unplugging left wiring harness rubber jacket of tail

door, and pull out tail door transition wiring harness;

2). Unplugging right rubber jacket of tail door, and disconnect rear

washing water pipe in rubber jacket;

3). Pry clamp spring on upper end of air supporting rod, and

disconnect connection of air supporting rod and ball head pin;

△Note This process needs partner to help support to prevent tail

door dropping.

4). Mark position of tail door hinge assembly relative to tail door,

and remove 2 fixed bolts connecting tail door and hinge both

in left and right side;

5). Take down tail door assembly;

（II）Installation

1. Install tail door assembly

1). Install 2 fixed bolts connecting hinge and tail door both in left

and right side according to marked position;

Tighten torque 30~36N·m
△ Note Pay attention to face difference of tail door assembly and

side wall components.

2). Connect upper end of air supporting rod and ball head pin;

Tail Gate and Fuel Filler Port

Tail Gate and Fuel Filler Port

59

3). Cross tail door transition wiring harness into vehicle from

wiring harness rubber jacket hole, connect wiring harness

connector inside vehicle, tighten fixed bolt connecting tail

door transition wiring harness grounding point and vehicle

body, and install left side tail door wiring harness rubber

jacket;

4). Connect rear washing water pipe in tail door right side rubber

jacket, and install right rubber jacket;

2. Install upper trim panel assembly of C pillar (left)

3. Install lower trim panel assembly of C pillar (left)

4. Install lower fixed bracket assembly of rear seat backrest (left)

5. Install rear seat backrest assembly

6. Install rear seat cushion assembly

7. Install rear threshold guard panel assembly (left)

8. Connect battery negative electrode

9. Close engine compartment cover

Tail Gate and Fuel Filler Port

Tail Gate and Fuel Filler Port

60

IV、Tail Door Hinge Assembly

（I）Removal

1. Open engine compartment cover

2. Disconnect battery negative electrode

3. Remove rear threshold guard panel assembly (left) Refer to "Rear threshold guard panel assembly"

4. Remove rear seat cushion assembly Refer to "Rear seat backrest"

5. Remove rear seat backrest assembly Refer to "Rear seat backrest"

6. Remove lower fixed bracket assembly of rear seat backrest (left) Refer to "Lower trim panel assembly of C pillar"

7. Remove lower trim panel assembly of C pillar (left Refer to "Lower trim panel assembly of C pillar"

8. Remove upper trim panel assembly of C pillar (left) Refer to "Upper trim panel assembly of C pillar"

9. Remove tail door assembly Refer to "Tail door assembly"

10. Remove tail door hinge assembly

1). Remove 3 buckles on rear part of platfond, pull down rear part

of platfond, mark position of tail door hinge relative to vehicle

body, remove 2 fixed nuts connecting tail door hinge and

vehicle body, and take down tail door hinge assembly;

（II）Installation

1. Install tail door hinge assembly

1). Install 2 fixed nuts connecting tail door hinge and vehicle body

according to marked position;

Tighten torque

25~29N·m

2). Install 3 buckles on rear part of platfond;

2. Install tail door assembly

3. Install upper trim panel assembly of C pillar (left)

4. Install lower trim panel assembly of C pillar (left)

5. Install lower fixed bracket assembly of rear seat backrest (left)

6. Install rear seat backrest assembly

7. Install rear seat cushion assembly

8. Install rear threshold guard panel assembly (left)

9. Connect battery negative electrode

10. Close engine compartment cover

V、Fuel Filler Port Cover Assembly

（I）Removal

1. Remove plastic fuel tank cover assembly

1). Open fuel filler port cover assembly, rotate out plastic fuel tank

cover assembly anticlockwise;

2). Disconnect connecting drawstring connecting plastic fuel tank

cover assembly and fuel filler port cover assembly;

Tail Gate and Fuel Filler Port

Tail Gate and Fuel Filler Port

61

3). Take down plastic fuel tank cover assembly;

2. Remove fuel filler port cover assembly

1). Remove 2 fixed bolts of fuel filler port cover assembly;

2). Take down fuel filler port cover assembly;

（II）Installation

1. Install fuel filler port cover assembly

1). Place fuel filler port cover assembly to installation position, and

tighten 2 fixed bolts;

Tighten torque

7~11N·m

2. Install plastic fuel tank cover assembly

1). Connect drawstring of plastic fuel tank cover assembly and fuel

filler port cover assembly, and rotate in plastic fuel tank cover

assembly clockwise;

2). Close fuel filler port cover assembly;

（III）Adjustment

1. Adjust fuel filler port cover assembly

1). Open fuel filler port cover assembly;

2). Loosen 2 fixed bolts of fuel filler port cover assembly;

3). Adjust up/down and left/right direction to make clearance of

fuel filler port cover assembly and side fuel filler port cover

hole is even;

4). Tighten fixed bolts after adjusting.

5). Close fuel filler port cover assembly;

Tail Gate and Fuel Filler Port

Tail Gate and Fuel Filler Port

62

VI、Wiredrawing Assembly of Fuel Filler Port Cover

（I）Removal

1. Open engine compartment cover

2. Disconnect battery negative electrode

3. Remove front door threshold guard panel assembly (left) Refer to "Front door threshold guard panel assembly"

4. Remove rear threshold guard panel assembly (left) Refer to "Rear threshold guard panel assembly"

5. Remove lower trim panel assembly of B pillar (left) Refer to "Lower trim panel assembly of B pillar"

6. Remove rear seat cushion assembly Refer to "Rear seat backrest"

7. Remove rear seat backrest assembly Refer to "Rear seat backrest"

8. Remove lower fixed bracket assembly of rear seat backrest (left) Refer to "Lower trim panel assembly of C pillar"

9. Remove lower trim panel assembly of C pillar (left) Refer to " Lower trim panel assembly of C pillar"

10. Remove upper trim panel assembly of C pillar (left) Refer to "Upper trim panel assembly of C pillar"

11. Remove tail door threshold assembly Refer to "Tail door threshold assembly"

12. Remove side trim panel assembly of trunk (left) Refer to "Side trim panel assembly of trunk"

13. Remove opening handle of fuel filler port cover

1). Open carpet, remove fixed bolt of opening handle of fuel filler

port cover, and take down wiredrawing assembly of fuel filler

port cover from behind;

2). Disconnect connection of wiredrawing assembly of fuel filler

port cover and opening handle of fuel filler port cover, and

take down opening handle of fuel filler port cover;

14. Remove wiredrawing assembly of fuel filler port cover

1). Disconnect connection of wiredrawing assembly of fuel filler

port cover and fuel filler port cover seat and vehicle body, and

pull out wiredrawing assembly of fuel filler port cover from

fuel filler port;

Tail Gate and Fuel Filler Port

Tail Gate and Fuel Filler Port

63

（II）Installation

Note Check whether guard jacket on wiredrawing is complete before installing.

1. Install wiredrawing assembly of fuel filler port cover

1). Insert wiredrawing assembly of fuel filler port cover into square

hole of fuel filler port seat from outside of vehicle body side

wall, and connect and install;

2. Install opening handle of fuel filler port cover

1). Connect connection of opening handle of fuel filler port cover

and wiredrawing assembly of fuel filler port cover;

2). Place opening handle of fuel filler port cover to installation

position, and tighten fixed bolt;

3. Install left side trim panel assembly of trunk (left)

4. Install tail door threshold assembly

5. Install upper trim panel assembly of C pillar (left)

6. Install lower trim panel assembly of C pillar (left)

7. Install lower fixed bracket assembly of rear seat backrest (left)

8. Install rear seat backrest assembly

9. Install rear seat cushion assembly

10. Install lower trim panel assembly of B pillar (left)

11. Install rear threshold guard panel assembly (left)

12. Install front door threshold guard panel assembly (left)

13. Connect battery negative electrode

14. Close engine compartment cover

Front and Rear Bumper

Front and Rear Bumper

64

Front and Rear Bumper

I、Summary

（I）Structure Overview

Explored Diagram of Front/Rear Bumper

1. Front bumper assembly

2. Upper cover plate of front bumper

3. Front bumper beam assembly

4. Front frame assembly

5. Left fixed bracket of front bumper

6. Right fixed bracket of front bumper

Front and Rear Bumper

Front and Rear Bumper

65

1. Rear bumper assembly

2. Rear bumper beam assembly

3. Left fixed bracket of rear bumper

4. Right fixed bracket of rear bumper

（II）Torque Parameter

No.

Item

Torque

（N·m）

1

Fixed bolt of upper cover plate of front bumper

7~9

2

Fixed bracket fixed bolt of front bumper

9~11

3

Fixed bracket fixed bolt of front bumper

9~11

4

Fixed bolt of front frame assembly

20~25

5

Fixed nut of rear bumper beam

20~25

（III）Maintenance Note

(1). During dismantle and installation of parts, it shall protect the parts well from any scratch or damage.

(2).

During dismantle panel buckles; wrap up screwdriver’s edge in case of any scratch in car body or panel.

(3).

During installation of trimming, make sure fit the buckles into the right holes, then press in gently

(4).

During dismantle of big parts, team cooperation called in case of falling to cause parts damage or people injury.

(5).

During trimming’s loading or unloading, to avoid to overexert in case of parts damage or torsion

Front and Rear Bumper

Front and Rear Bumper

66

II、Upper Cover Plate of Front Bumper

（I）Removal

1. Open engine compartment cover

2. Remove upper cover plate of front bumper

1). Remove 7 expansion buckles

① and 4 fixed bolts ② of

upper cover plate of front bumper;

2). Remove 4 fixed bolts

③ of front end of upper cover plate

of front bumper;

3). Take down upper cover plate of front bumper;

（II）Installation

1. Install upper cover plate of front bumper

1). Place upper cover plate of front bumper to installation

position;

2). Tighten 7 expansion buckles

① of upper cover plate of

front bumper;

3). Tighten 4 fixed bolts

② of upper cover plate of front

bumper;

Tighten torque

7~9N

·m

4). Tighten 4 fixed bolts

③ of front end of upper cover plate

of front bumper;

Tighten torque

7~9N

·m

2. Close engine compartment cover

Front and Rear Bumper

Front and Rear Bumper

67

III、Front Bumper Assembly

（I）Removal

△Note Bumper is made of resin, please don’t force operation, and avoid to contact with oil. Don’t scratch surface of bumper when

removing.

1. Open engine compartment cover

2. Disconnect battery negative electrode

3. Remove upper cover plate of front bumper Refer to "Upper cover plate of front bumper"

4. Remove front bumper assembly

1). Remove 10 expansion buckles in lower part of front

bumper;

2). Remove 2 fixed expansion buckles ① and fixed bolt ②

both in left and right side of front bumper and front wheel

cover;

3). Handle lower flange of front bumper and pull outward to

make front bumper and fender separate, insert crowbar

into gap, disconnect connection of front bumper bracket

and lower flange of front bumper from up to down, and

separate bumper and bumper bracket;

4). Disconnect wiring harness connector of front fog light

assembly and daylight driving light assembly, and take

down front bumper assembly;

Front and Rear Bumper

Front and Rear Bumper

68

（II）Installation

1. Install front bumper assembly

1). Connect wiring harness connector of front fog light

assembly and daylight driving light assembly, and connect

lower flange of front bumper and bumper bracket in

proper order;

△Note When installing front bumper, connect it to bumper

fixed bracket in place. After installing, check whether

there is surface difference and gap in fitting position of

bumper and vehicle body.

2). Tighten 2 fixed expansion buckles ① and fixed bolt ②

both in left and right side of front bumper and front wheel

cover;

3). Tighten 10 expansion buckles in lower part of front

bumper;

2. Install upper cover plate of front bumper

3. Connect battery negative electrode

4. Close engine compartment cover