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

Contents

Name

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.

Outline

Dimension

Structure

Replacement of plate part

Waterproof and anti-rust treatment

Bodywork plastic parts

Basic colour assortment of body colours

Chapter

I

II

III

IV

V

VI

VII

Vehicle identification code (VIN)

LH16CHAL**H ～

LH16CKAL**H ～

Outline

Outline

Outline

How to Use This Manual: ..............................1

Precautions to the maintenance ......................4

Efficient replacement of body plates ..............5

How to Use This Manual

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:

Rear fender

Removal Operation part

Operation type

Cutting and joint positions

Rough cutting position

16 points

Welding area and welding type

10 points

5 points

8 points

8 points

8 points

2 points

Rough cutting position

Cutting and joint positions

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

I-1

How to Use This Manual

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:

Vehicle Section

Bottom plate of bodywork

Symbol point

The R/Ls size will change following the centre of vehicle

Skeleton map

Imaginary line

Point

A

Specifications

Hole of crossbeam 1#

B

C

D

E

F

Reference hole of front frame

Mounting surface centric hole of front suspension

Mounting bolt of suspension

Mounting bolt of front suspension

Mounting hole of front suspension crossbeam

The hole sizes and shapes at both sides are different

All units are in mm (in) other than special instructions

Diameter of hole or bolt

RH: Ø 10(0.4)

LH: Ø 10 × 24

(0.4

× 0.5)

Ø 16(0.6)

Ø 102(4.02)

M12(0.5)

Ø

10(0.4)

Ø 10(0.4)

Point

G

H

I

J

K

Specifications

Reference hole of vehicle B

Reference hole of vehicle B

Mounting hole of rear suspension cross beam

Mounting surface centric hole of rear suspension

Reference hole of rear frame

Aperture

Diameter of hole or bolt

Ø 10(0.6)

Ø 16 × 22 (0.6

× 0.9)

Ø

12(0.5)

Ø

80(3.1)

Ø 12(0.5)

Bolt size

I-2

How to Use This Manual

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:

Body Section Dimension position

Skeleton map

Vehicle part

Position of detailed standard point

Width No instruction in the contour map

(Size of vehicle width)

“ L ” stands for the left side of vehicle

“ L ” stands for the left side of vehicle with partition

Measurement position

Position and shape of reference point

Dimension mm (in)

Symbol

The following 8 symbols are used to indicate the standard points

Symbol Meaning

Hole centre

Elliptical hole centre

Hole edge

Concave edge

The R/L sizes are different depending on the centre of vehicle

Symbol Meaning

Plate interface, welding seam etc.

Bolt pin

Short-shaped hole centre

Edge of rectangular hole

I-3

Precautions to the maintenance

Precautions to the maintenance

Layout of workshop l

The layout of workshop is very important for the safety and work efficiency.

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

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.

Welding goggles

Ear plugs

Dust masks

Welding gloves

Safety goggles

Mask

Cotton gloves

Protective shoes

Prevention of short-circuit l

When removing the wire or electrical apparatus, the negative electrode of battery should be removed

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.

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

I-4

Introduction

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.

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.

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.

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 welding positions

I-5

Introduction

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.

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.

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.

3mm {0.12 in} above

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

0.60-0.90 {0.02-0.03}

0.91-1.20 {0.04-0.05}

1.21-1.80 {0.051-0.07}

1.81-4.50

{0.071-0.017}

Aperture

5 {0.19}

6 {0.23}

8 {0.31}

10 {0.39}

I-6

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

Flash

Rough cutting position of side body

Rough cutting position of new parts

Introduction

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. l

As the shape of spot welder head affects the strength of welding, the welding head should be always kept in the optimum state

Precautions to the welding

Original electric welding

Clearance: 50mm (197IN)

The clearance of repair welding is less than 35mm (135in) 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.

Diameter of nugget: 4/5 of welding head

Original welding tree

×

13 or more

Original welding spots of carbon dioxide arc welding

Maintenance weldin g

If the thickness of plate is 3mm or more, original welding spots or more

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.

I-7

Introduction

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.

Use the silencer floor l

Use the sound insulation layer

Paint the primer l

Use the primer at the locations where it is needed in the body.

Abbreviation

Fr

Rr

RH

LH

Front

Rear

Right

Left

Ctr

G/E

D/E

M

MC

Center

Gasoline engine

Diesel engine

Metal

Mica

Use the rust inhibitor l

Use rust inhibitor on the welding back (wax, oil, etc.)

I-8