Haima S5 Body Repair Manual

Body Repair Manual

S5 Series

Warning

The repair works of the vehicle are dangerous. The repair personnel not receiving the related vehicle

repair training will probably cause repair failure or even loss of properties and personal injuries. Only the

technical personnel receiving the related vehicle repair training and having actual repair experiences are

allowed for repair works.

The repair procedures contained in this manual, including parts “Warning” and “Caution”, are prepared

by technical training personnel of Haima Automobile Co., Ltd. Before the repair operations, the repair

personnel shall carefully read this manual to understand general safety procedures. The technical personnel

shall abide by the “Warnings” and “Cautions” to reduce the injury hazard and the possibility of vehicle

damage and potential safety problems arising from the improper repairs and services. It’s of equal importance

that it should be understood that the “Warnings” and “Cautions” do not include everything and are impossible

to warn all hazardous consequences arising from the violations of the operation procedures.

The repair recommendations and related procedures contained in this manual are the effective service

and repair methods. Some repair operations require the use of special tools. The personnel using the

procedures or tools not recommended by Haima Automobile must take cautions to guarantee the safety of

personnel and vehicle.

The genuine Haima Automobile parts or the parts designated by Haima Automobile shall be used during

replacement of parts. Haima Automobile will not be liable for any problem arising from the following factors:

Insufficient training, improper use of tools, use of non-genuine Haima Automobile parts or parts other than

those designated by Haima Automobile, and the negligence of revisions to this manual. The factors are not

limited to the above mentioned ones.

Haima Automobile reserves the right to change the design of the vehicle and contents of this manual

without prior notice to the users and will not be liable for any consequence thereof.

Preface

This repair manual is intended for the use of technical personnel of Haima Automobile authorized

dealers, in order to help their repairs and maintenances of Haima S5 series vehicles. For the owner and driver

of Haima vehicles, this manual is also helpful for the vehicle repair and maintenance works within own

competency.

Understanding this manual is of great importance for correct repairs and maintenances of the vehicle.

Please always carry this manual with you to obtain reference information in a fast and convenient manner.

The contents contained in this manual, including graphs and technical specifications, are the latest data

available at the preparation of this manual. When the changes in some contents influence the repairs and

maintenances of the vehicle, please obtain the supplemental data of related parts from the dealers of Haima

Automobile. This manual shall be kept updated frequently.

Haima Automobile reserves the right to change the technical specifications and contents of this manual

without prior notice and will not be liable for any consequence thereof.

The copyright of this manual is reserved. Without prior written consent, no part of this manual can be

duplicated or used in any form, including photocopy, recording, and information storage and searching

system.

HAIMA CAR CO., LTD.

Henan, China

Contents

Chapter 1 Overview

How to use this manual .................................................................................................................................... 1

Repair Precautions............................................................................................................................................ 4

Efficient Replacement of Body Panels............................................................................................................. 5

Chapter 2 Sizes

Bottom of Body (Planar Sizes)......................................................................................................................... 9

Bottom of Body (Linear Sizes)....................................................................................................................... 10

Front of Body 1 .............................................................................................................................................. 11

Front of Body 2 .............................................................................................................................................. 12

Side Wall Framework..................................................................................................................................... 13

Interior of Body .............................................................................................................................................. 14

Rear of Body................................................................................................................................................... 15

Chapter 3 Structure

Body Parts ...................................................................................................................................................... 16

Name and Materials of Parts .......................................................................................................................... 17

Chapter 4 Replacement of Panels

Front Bumper Anti-Collision Beam Assembly .............................................................................................. 18

Engine hood lock bracket assembly ............................................................................................................... 19

Water tank support assembly.......................................................................................................................... 20

Ventilation Cover Plate Mounting Plate Installation Assembly..................................................................... 21

Front wheel casing assembly.......................................................................................................................... 22

Front longitudinal beam assembly.................................................................................................................. 25

Front longitudinal beam and front floor connecting plate assembly .............................................................. 27

Side wall front connecting plate assembly ..................................................................................................... 28

A-Pillar ........................................................................................................................................................... 29

B-Pillar ........................................................................................................................................................... 31

C-Pillar ........................................................................................................................................................... 33

Side Wall Lower Portion ................................................................................................................................ 37

C-Pillar Inner Portion ..................................................................................................................................... 39

Roof................................................................................................................................................................ 41

Roof (with Sunroof) ....................................................................................................................................... 42

Rear Wall Panel Assembly............................................................................................................................. 43

Rear Floor....................................................................................................................................................... 44

Contents

Rear Floor Fuel Tank Maintenance Panel ...................................................................................................... 45

Rear Floor Upper Crossbeam Assembly ........................................................................................................ 46

Chapter 5 Water-Proof and Rust-Proof Treatment

Sealing of Body .............................................................................................................................................. 47

PVC Coating................................................................................................................................................... 53

Overview I-1

Chapter 1 Overview

How to use this manual

Effective replacement of body sheet metal parts

 The contents of this chapter include the welding

type, number of welds, and shearing-cutting

locations for the body sheet metal parts. This

information is of great importance for the

disassembly and installation of the sheet metal

parts.

 The welding types and locations are indicated by

symbols.

 The relevant operation precautions are given in

some sections. Please carefully read and

understand these precautions before any operation

procedure.

Note

 The number of welds at asterisk (A) varies depending on different shearing-connecting locations.

 When the drilling is required during the installation of new parts, take cautions not to completely drill

through the sheet metal parts.

Symbol

 The following 6 symbols are used to indicate the welding types during the replacement of body sheet metal

parts.

Symbol Meaning Symbol Meaning

Spot welding

Continuous MIG welding

(shearing-connecting location)

CO2 gas shielded arc welding (plug

welding)

Braze welding

CO2 spot welding

Rough shearing location

Overview I-2

Body sizes

Planar sizes

 The planer sizes refer to the sizes measured from certain reference points projected onto certain plane.

 The standard points and sizes are symmetric with respect to the body center, unless otherwise explicitly

specified.

 The imaginary lines are different for different vehicle models.

Example:

Z=0 plane is the plane that passes through the rotation center of rear suspension torsion beam (under no-load

condition) and parallels with the lower plane of floor longitudinal beam.

Point symbol Name Hole diameter or nut size mm (in)

A Front anti-collision beam datum hole Ø15(0.59)

B Front body main datum hole Ø25(0.98)

C Front suspension mounting hole Ø86.6(3.41)

D Front beam mounting hole M14(0.55)

E Front beam mounting hole M14(0.55)

F Front body secondary datum hole Ø20(0.79)

G Rear longitudinal beam main datum hole Ø13(0.51)

H Rear longitudinal beam secondary datum hole Ø25(0.98)

I Rear beam datum hole Ø20(0.79)

Overview I-3

Linear Sizes

 The linear sizes refer to the actual sizes between

two standard points.

 The standard points and sizes are symmetric with

respect to the center of the vehicle, unless

otherwise specified.

Example:

The sizes are different between left and

right sides with respect to center of vehicle.

Symbol

The following 8 symbols are used to indicate standard points.

Symbol Meaning Symbol Meaning

Center of round hole

Port and gap of steel plates

Center of elliptical hole

Bolt pin

Edge of hole

Center of rectangular hole

Groove

Edge of rectangular hole

Overview I-4

Repair Precautions

Layout of workshop

 The layout of workshop is of great importance to

the safety and working efficiency.

Protection of vehicle

 Use the seat and floor covers.

 Use the insulation shield, in order to prevent the

heat and spark from damaging the glasses and

seats during welding.

 Protect the accessories including trims and

insertion strips during welding.

Use of Traction Apparatus

 When a traction apparatus is used, the working

personnel shall keep away from the working zone

and take cautions in suing the safety cable.

Precautions

During working, wear safety helmet and safety

protective shoes to prevent injuries. Wear protective

articles depending on the working characteristics,

including gloves, protective goggles, earplugs, and

mask.

Welding

goggles

Dust-proof

mask

Earplug

Safety goggles

Welding gloves

Mask

Cotton gloves

Protective shoes

Guard against short-circuit

 While disassembling the wires or electric

apparatus, disconnect the negative cable of

battery.

Removal of hazardous articles

 Within the area using open fire, move away the

fuel tank and plug the connecting pipes of the

fuel tank, in order to prevent fuel leakage.

Overview I-5

Efficient Replacement of Body Panels

Efficient disassembly of body panels

Measurement of body

 Before the disassembly or rough cutting, firstly

measure the damaged body portions and their

surroundings as per the standard reference sizes.

Upon detection of deformation, conduct initial

correction with frame repair device.

Guard against body deformation

 Disassemble with fixtures or jack and reinforce

the portions to be roughly cut and their

surroundings, in order to prevent body

deformation.

Selection of cutting and welding portions

 For the parts impossible for complete

replacement, adopt the cutting and welding

methods and operate with cautions. To cut the

portions without reinforcement ribs, select the

locations yielding to minimum welding

deformation for cutting.

Disassembly of connected parts

 While disassembling the connected parts, protect

the insertion strips, trims, and parts with pipes.

Rough cutting of damaged panels

 Ensure that there is no damaged part due to heat

near or in the opposite side of this part. (such as

pipe hoses and wire harnesses)

Leave overlapping parts of 30~50mm

(1.18~1.97in) at the cutting and connecting

portions and then roughly cut the damaged body

panels.

Overview I-6

Installation Preparations

Use of welding primer

 To prevent corrosion, remove the paint, grease

and other substances from new parts and welding

portions and then apply welding primer.

Determination of welding methods

 If the overall thickness of weld points is higher

than or equals to 3mm(0.12in), adopt CO2

shielded welding for rivet welding.

Drilling for CO2 shielded welding

 For the locations in which the spot welding can’t

be adopted, drill a hole with drilling machine or

hand-held drilling machine for CO2 shielded

welding.

mm {in}

Panel thickness Hole diameter

0.60-0.90{0.02-0.03} 5{0.19}

0.91-1.20{0.04-0.05} 6{0.23}

1.21-1.80{0.051-0.07} 8{0.31}

1.81-4.50{0.071-0.017} 10{0.39}

Grind the hatched portion shown in the figure below,

drill a hole on 3~4 pieces of metal panels stacked

together, and weld tightly together these metal

panels, in order to eliminate the further development

of gap.

Rough Cutting of New Parts

 For cutting and splicing portions, leave

overlapping parts of 30~50mm {1.18~1.97in} on

the body side and then roughly cut the new parts.

Overview I-7

Efficient Installation of Body Panels

Observation and checking of pre-welding sizes

 Adjust the standard sizes as per the body size

descriptions and install new parts to correct

positions.

Welding precautions

Precautions for spot welding

 The shape of welding head of the spot welding

machine shall be fabricated as per D=(2×t)+3. In

even of different thickness between upper steel

plate and lower steel plate, the thinner steel plate

shall prevail.

 As the shape of welding head of the spot welding

machine influences the welding strength, always

maintain the welding head under best status.

 The spot welding points shall be staggered from

the original welds.

 Before the welding, use a material same with that

of the body for a welding test, in order to inspect

the welding strength.

Overview I-8

Inspection of welding strength

 The mounting portions for engine, chassis, and

seat belt are significant safety portions in terms

of the welding strength. Insert a chisel between

the plates in spacing of 4 or 5 welding points and

in spacing of 10 common welding points to

inspect the welding strength.

 As shown in the figure below, insert a chisel

between the plates as per the quantity of plates.

 Insert a chisel between plates to check the

separation of plates, in order to determine the

welding strength. If the plates are separated,

weld once again near the previous welding

position.

 Correct the shape of the checked portion.

Overview I-8

Sealing of Body

 Apply the body sealant at the needed locations

 For the portions difficult to apply sealant after

the installation, apply the sealant before the

installation.

Application of Primer

 Use the primer at the needed locations.

Use of anti-rust agent

 Apply anti-rust agent (paraffin and machine oil)

on the back surface of welding points.

Use of Sound Insulation Floor

 Adopt the sound insulation layer.

Acronym

Fr Front

Rr Rear

RH Right

LH Left

Ctr Center

G/E Gasoline engine

D/E Diesel engine

M Metal

MC Mica

Sizes II-9

Chapter 2 Sizes

Bottom of Body (Planar Sizes)

Z=0 plane is the plane that passes through the centerline of front wheels and parallels with the lower plane of

floor longitudinal beam under half load condition.

Point

symbol

Name Size

Point

symbol

Name Size

A

B

Front suspension

system mounting hole

M12 H

Rear floor assembly

main datum hole

Φ16

C

Front body main

datum hole

Φ16 I

Rear floor assembly

secondary datum hole

Φ18

D

Front shaft mounting

hole

Φ93.3

Rear plate main datum

hole

Φ20

E

Front suspension

system mounting hole

M12

J

Rear plate secondary

datum hole

14×12 long hole

Sizes II-10

Bottom of Body (Linear Sizes)

Measurement

position

Dimension

(mm)

1 449.05

2 453.38

3 928.32

4 1269.36

5 1262.92

6 385.72

7 385.72

8 1481.4

9 1481.58

10 907.96

11 907.93

12 823

13 820

14 324.34

15 309.55

16 1681

17 1660.82

18 1068

Sizes II-11

Front of Body 1

Measurement

position

Dimension

(mm)

1 688.2

2 970

3 958

4 656.5

5 460.2

6 1063.4

7 525.9

8 310.3

9 335.7

10 473.9

11 603.7

12 459.1

B/B＇A/A＇

C/C＇

D

B/B＇

Sizes II-12

Front of Body 2

Measurement

position

Dimension

(mm)

1 1183.4

2 786.3

3 1510.6

4 1405.6

5 322.7

6 1249.7

7 747.2

8 1274.7

9 853.5

10 471.2

11 122.3

B/B＇ C/C＇

D/D＇ E/E＇

F

G

A/A＇

Sizes II-13

Side Wall Framework

Measuremen

t position

Dimension

(mm)

1 514.36

2 591.4

3 1265.33

4 1420.89

5 1117.31

6 1114.15

7 1157.65

8 1061.85

9 1028.83

10 927.85

11 575.98

12 899.8

13 539.41

14 907.13

15 1021.41

16 820.18

17 349.93

18 553.16

D/D＇ 1229.67

G/G＇ 1465.79

I/I＇ 1211.72

J/J＇ 1224.28

B＇

Sizes II-14

Interior of Body

Measurement

position

Dimension

(mm)

1 747.1

2 866.07

3 1386.55

4 1401.96

5 1159.65

6 783.03

7 985.26

8 991.62

9 848.49

10 969.37

C/C＇ 1397.8

D/D＇ 1380

E/E＇ 1158.48

F/F＇ 1302.49

G/G＇ 1383.67

H/H＇ 1135.88

I/I＇ 1306

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Haima S5 Body Repair Manual

Haima S5 Body Repair Manual

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