Outline
Warning
The maintenance of vehicles is a dangerous job. If
you haven’t received relevant training in the
maintenance, the possibility of injury, property loss
and maintenance failure will increase. The
maintenance procedures in the workshop manual
were prepared for the technical training for Haima
Automobile staff. In the maintenance operations, only
the technical personnel having received the relevant
training and practical experience in the maintenance
have the ability for more secure operation. However,
the user of this manual can at least understand the
general safety procedures.
This manual includes the parts of “Warnings” and
“Cautions”, which are applicable to the dangers
usually not encountered by general technicians during
the maintenance. The technical staff should follow
the “Warnings” and “Cautions” to reduce injury
hazards and vehicle damage due to improper service
or maintenance and the risk of insecurity. It is also
important to understand that the “Warnings” and
“Cautions” are not all inclusive and it is impossible to
give warnings to all dangerous consequences caused
by the violation of operating procedures.
The circuit diagrams and specifications contained in
this manual have been provided at time of
publication. The Haima automobile products reserve
the right either to change the vehicle design or to
modify the contents of this manual without prior
notice to users and assumes no responsibility.
The genuine Haima auto-part products or its
equivalents should be used in case of part
replacement. Those using the quality lower than that
of the Haima genuine auto-vehicle parts should fully
guarantee that the personal security and vehicle
safety are not at risk. The Haima automobile assumes
no responsibility for the problems caused by use of
the manual, the causes of which include the
insufficiency of service-related training, improper use
of tools, use quality lower than that of the Haima
genuine auto-parts and replacements, or ignorance of
the manual revisions, but the cause of which is not
limited to the above.
Outline
Body work maintenance manual
Model series S3
Foreword
This Bodywork Maintenance Manual is designed for
the use of FAW Haima technicians to help them carry
out the FAW Haima automobile maintenance. In
terms of the FAW Haima vehicle owners and drivers,
this manual is also very helpful when they carry out
the vehicle service and maintenance within their
capacity.
It is very important to well understand this manual
for correct service and maintenance. For quick and
easy access to the reference information, the manual
should be always kept at your hand.
The contents of this manual, including the charts and
technical parameters are the latest information
obtained at the copy time of the manual. When some
changes will affect your vehicle maintenance, you
can obtain from the FAW Haima automobile dealers,
the relevant supplementary materials. The manual
shall be kept regularly updated.
The FAW Haima Automobile Co. Ltd, reserves the
rights either to change the technical parameters, or to
modify the manual contents without prior notice, for
which, FAW Haima Automobile Co. Ltd assumes no
obligations. All rights reserved for the manual.
Without the written permission by the manual, any
parts of the manual are not allowed, by any of ways
(electronic or mechanical) to copy and use, including
photocopying, recording, or applicable to the
information storage and retrieval systems.
Hainan FAW Haima Automobile
Sales Co.,Ltd
Hainan · China
Applicable models:
The models, which this manual is applicable to, are
those starting with the VIN shown in the next page.
The relevant information is referred to the next page.
Contents
Name Chapter
Outline I
Dimension II
Structure III
Replacement of plate part IV
Waterproof and anti-rust treatment V
Bodywork plastic parts VI
Basic colour assortment of body
colours
VII
Outline
Vehicle identification code (VIN)
LH16CHAL**H～
LH16CKAL**H～
Outline
Outline
How to Use This Manual: ..............................1
Precautions to the maintenance ......................4
Efficient replacement of body plates ..............5
How to Use This Manual
I-1
How to Use This Manual:
Efficient replacement of body panels
● The information contained in the part concerns
the welding type applied by the body panel
parts, number of electric welds and positions of
removal and installation.
● The welding type, position and instruction are
expressed by the symbols.
● There are locations to be noted at some places.
Prior to the maintenance, the contents of
precautions should be read through and
understood.
Example:
Precautions
● The number of spot welding joints is expressed by the symbols (A) of the cutting and joint locations.
● Cares must be given when drilling for the installation of new parts. Don't drill to the outer panel to ensure
the integrity of outer plate.
Symbol
● The following 6 symbols are used to indicate the welding type for the replacement of body panels
Symbol Meaning
●
Spot welding
■
CO
2
arc welding (EDM welding)
+
CO
2
spot welding
Symbol Meaning
Continuous gas protection welding
(cutting and binding positions)
Brazing
Rough cutting position
Rear fender
Removal
Operation part
Operation type
C
utting and joint
positions
16 points
Welding area and welding type
R
ough cutting
position
Cutting and joint positions
Rough cutting position
10 points
5 points
8 points
2 points
8 points
8 points
How to Use This Manual
I-2
Vehicle Body Dimension
Plane Dimension
● The plane dimension is the measured size
obtained through the projection of some
reference points on a plane.
● The standard points and size are related to the
centre symmetry of bodywork other than special
instructions.
● The imaginary line varies depending on different
models
Example:
Point
Specifications Diameter of hole or bolt
A Hole of crossbeam 1#
RH: Ø10(0.4)
LH: Ø10×24
(0.4×0.5)
B Reference hole of front frame Ø16(0.6)
C
Mounting surface centric hole
of front suspension
Ø102(4.02)
D Mounting bolt of suspension M12(0.5)
E
Mounting bolt of front
suspension
Ø10(0.4)
F
Mounting hole of front
suspension crossbeam
Ø10(0.4)
Point
Specifications Diameter of hole or bolt
G Reference hole of vehicle B Ø10(0.6)
H Reference hole of vehicle B Ø16×22 (0.6×0.9)
I
Mounting hole of rear suspension
cross beam
Ø12(0.5)
J
Mounting surface centric hole of
rear suspension
Ø80(3.1)
K Reference hole of rear frame Ø12(0.5)
Imaginary line
Vehicle Section
Skeleton map
Bottom plate of
bodywork
T
he R/Ls size will change following
the centre of vehicle
A
ll units are in mm (in) other than special
instructions
The hole sizes and shape
s at both
sides are different
Bolt size
Aperture
Symbol point
How to Use This Manual
I-3
Linear Dimension
● The straight line is the actual size between two
standard points.
● The standard points and size are related to the
centre symmetry of bodywork other than special
instructions.
Example:
Symbol
The following 8 symbols are used to indicate the
standard points
The R/L sizes are different depending on the centre
of vehicle
Symbol
Meaning
Hole centre
Elliptical hole centre
Hole edge
Concave edge
Symbol Meaning
Plate interface, welding seam etc.
Bolt pin
Short-shaped hole centre
Edge of rectangular hole
Body Section
Dimension
position
Skeleton map
Width
“L”
stands for
the left side of
vehicle
“L” stands for
the left side of
vehicle with
partition
Position and
shape of
reference
point
Measurement position
Dimension mm (in)
Vehicle part
Posit
i
on of detailed
standard point
No instruction in the contour map
(Size of vehicle width)
Precautions to the maintenance
I-4
Precautions to the maintenance
Layout of workshop
l The layout of workshop is very important for
the safety and work efficiency.
Vehicle protection
l Use the seat cover and floor covering.
l Use the heat shield to prevent damage on the
glass and seats by heating and sparks during the
welding process.
l The accessories such as the trims and
mouldings should be kept under protection
during the welding process.
Use of towing equipment
l In use of towing equipment, the working staff
should keep far away from the job area and use
the safety cable.
Precautions to maintenance
l During the work, wear helmet and safety shoes
to avoid injury. According to the nature of the
work, wear the protective goods such as the
gloves, goggles, ear plugs and mask
Prevention of short-circuit
l When removing the wire or electrical apparatus,
the negative electrode of battery should be
removed
Removal of hazardous materials
l In the area where open fire is used, the fuel tank
should be removed away, the pipe leading to
the fuel tank plugged prevent combustible
leakage.
Safety cable
Welding goggles
Dust masks
Ear plugs
Welding gloves
Cotton gloves
Mask
Protective shoes
Safety
goggles
Introduction
I-5
Efficient replacement of body plates
Efficient removal of body plates
Body measurement
l Prior to the removal or rough cutting, the body
damaged position and its surrounding should be
firstly measured According to the standard
reference dimension. If there is any change here,
use a frame repair device to make a rough
correction.
Prevention of body deformation
l Remove and reinforce, by use of a fixture or jack,
the positions to be cut and their surrounding to
prevent from body deformation.
Selection of cutting and welding positions
l For the parts impossible to completely replace,
the method of cutting and welding should be
applied for careful operation. If cutting the
position without reinforcement rib, the
smallest location, where the welding
deformation is likely to produce, shall be
chosen for cutting.
Removal of linked parts
l In removal of linked parts, the parts such as
the moulding, trims and pipes should be kept
under protection
Rough cutting of damaged plates
l Confirm that there are no damaged parts by
heating, nearby or in the opposite of this part
(e.g. pipe hose, wire harness etc).
l Save the grounding part in 30-50MM
(118-197IN) at the cutting and connection
places, and then carry out rough cutting on the
damaged body plate.
Wire harness
Rough cutting
position
Cutting and we
lding
positions
Introduction
I-6
Installation preparation
Use the welding primer
l To prevent the rust, remove the paint, grease
and other substances from new parts and
welding portions and apply the welding primer.
Determination of welding method
l If the total thickness of welding point is more
than or equal to 3mm (012IN), use carbon
dioxide arc welding for the rivet welding.
Punch by carbon dioxide arc welding
l For the places where the spot welding cannot be
made, use a puncher or a portable driller to
carry out the arc welding.
mm {in}
Thickness of plate Aperture
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 shadow positions as shown in following
Fig., drill on a metal plate overlaid by 3-4 pieces and
weld tightly these metal plates together so to prevent
crack expansion.
Rough cutting of new parts
l For the parts jointed by gas cutting, a grounding
portion in 30-50MM [118-197IN] at the
residual part of side body should be saved and
then the rough cutting made on new parts
3mm {0.12 in} above
Flash
Rough cutting position of side body
Rough cutting position of new parts
Introduction
I-7
Efficient installation of body plates
Observe and check the former welding size
l According to the instruction of body dimension,
adjust the standard size, and fit up the new part
on the correct position.
Precautions to the welding
Precautions to the spot welding
l The shape of spot welder head is made as per
D= (2×t)+3. If the thickness of upper plate is
different from that of the lower, the thicker one
prevails.
l As the shape of spot welder head affects the
strength of welding, the welding head should be
always kept in the optimum state
l The position of spot welding should be
staggered from the original welding
l Prior to the welding, make a welding test by use
of material same as the bodywork to check the
welding strength.
Original electric welding
Clearance: 50mm (197IN)
The clearance of repair welding is
less than 35mm (135in)
Original welding tree ×13 or more
Original welding spots of
carbon dioxide arc welding
Maintenance welding
If the thickness of plate is 3mm or
more, original welding spots or more
Diameter of nugget: 4/5
of welding head
Introduction
I-8
Body seal
l Apply the body sealant on the places as
necessary
l After the installation, the sealant shall be
applied prior to the installation for the places
where the sealant is hardly applied.
Paint the primer
l Use the primer at the locations where it is
needed in the body.
Use the rust inhibitor
l Use rust inhibitor on the welding back (wax,
oil, etc.)
Use the silencer floor
l Use the sound insulation layer
Abbreviation
Fr Front
Rr Rear
RH Right
LH Left
Ctr Center
G/E Gasoline engine
D/E Diesel engine
M Metal
MC Mica
/