ZZ-FCM1 Workstation Operation Instruction Manual

Door Sub-assembly (Hinges, Window Regulators, Glass) · Illustrated version of 8 operations | Compiled from the original process card for training and display

About the illustrations:

The original process card for this station repeatedly notes "see attached drawing / as shown in the figure", but the images embedded in the digital export are only the company logo and the "Controlled" version stamp — there are no actual process diagrams or photos. This page therefore does not show an illustration area. To view the original drawings, please check the official process card file in the paper system or PDM. 0100

Step 10: As shown, install the upper hinge assembly and tighten the fixing bolts: follow the sequence of "primary locating first, then secondary locating" — first pre-tighten the bolt at the primary locating hole, then tighten the bolt at the secondary locating hole, to avoid hinge misalignment. Step 20: As shown, install the lower hinge assembly and tighten the bolts; the M8 bolt tightening torque must be controlled at 23±3 N·m and verified with a torque wrench — this is a safety-critical control point (marked with ☆ in the original operation name).

Hinge bolt tightening torque (M8): 23±3 N·m. Check the static torque by sampling 2 pieces per shift; safety-critical item (S-class); the inspection record must be filed.

Step 10: As shown, install the right window regulator assembly. Step 20: As shown, install the right quarter window sealing strip and the right rear quarter window glass assembly; after installation, check that the sealing strip is pressed fully into place — this is an important control point for preventing water leakage. Step 30: As shown, install the right window regulator mounting rail assembly and the right lower window regulator mounting rail assembly: during installation, first apply a certain pushing force to the rear side of the rail so that it fits into place, then tighten the bolts; M6 bolt tightening torque: 9±1 N·m.

Rail mounting bolt tightening torque (M6): 9±1 N·m (the inspection table for this operation did not have separate data; the value is taken from the step operation requirements)

Step 40: As shown, install the right glass run channel assembly; check that the right-angle datum is seated in place. Step 50: As shown, insert the right regulator glass assembly from between the rail and the side outer panel down until it reaches the right window regulator of the cab, then install the bolts; M6 bolt tightening torque: 9±1 N·m. Step 60: As shown, install the right inner belt molding assembly. Step 70: As shown, install the right window cover panel assembly (note: apply primer to the 3M adhesive bonding area of the corresponding sheet metal first) and the right outer belt molding assembly; M6 bolt tightening torque: 9±1 N·m.

Window cover panel / belt molding mounting bolt tightening torque (M6): 9±1 N·m; 3M adhesive primer usage approx. 10 ml (Hengying brand 954); apply the primer before bonding

Step 10: As shown, install the rear lock assembly and snap the cable into place; tighten the internal screws in sequence 1 to 5. Step 20: As shown, install the front lock assembly and snap the cable into place. Step 30: As shown, install the floor lock assembly and snap the cable into place; secure the floor lock harness with cable ties. Step 40: As shown, install the hidden exterior handle assembly and snap the cable harness into place; the lock cylinder assembly must have its cable snapped in place first, then be installed; then adjust the gap between the exterior handle and the door outer panel, which must meet DTS standard requirements — this is an important quality control point. Step 50: As shown, install the door interior handle assembly; M6 bolt tightening torque: 9±1 N·m.

Interior handle mounting bolt tightening torque (M6): 9±1 N·m; the gap between the exterior handle and the door outer panel must meet DTS requirements

Step 10: As shown, install the courtesy lamp and snap the harness into place. Step 20: As shown, install the door-end guide pin. Step 30: As shown, install the anti-pinch strip assembly and snap the harness into place. Step 40: As shown, install the right door buffer blocks. Step 50: As shown, temporarily fasten the mechanical key to the door for later matching/verification with the complete vehicle.

Tightening torque for the fastening bolts in this operation (M6): 9±1 N·m

Step 10: As shown, install the drag-chain harness assembly. Step 20: As shown, install the right body waterproof film (I) and press the periphery firmly into place to prevent water seepage. Step 30: As shown, install the right body waterproof film (II) and press the periphery firmly into place.

Related fastening screw torque (M6): 9±1 N·m

Step 10: As shown, install the right body waterproof film (I), right body waterproof film (II), plug (Φ16 mm), plug (Φ24 mm), plug (Φ12 mm), plug (Φ35 mm), and patch (Φ20 mm); note: the mounting surface must be kept clean, all parts must be pressed fully into place, and no edge lifting is allowed.

Step 10: As shown, install the door trim panel assembly. Step 20: As shown, install the cable cover; M6 bolt tightening torque: 9±1 N·m.

Trim panel / cover mounting bolt tightening torque (M6): 9±1 N·m

This page is compiled from the WH platform ZZ-FCM1 door sub-assembly process card (Anhui Windrose Holdings Co., Ltd.) and is for workshop visual training only; official production shall follow the controlled process documents.