Saipa 141 Body Repair Manual
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Saipa 141 Body Repair Manual

69hp at 5500rpm
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Body Repair Manual
x100RM2J/4/1
X100WD2H/4/1

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Summary of Contents for Saipa 141

  • Page 1 Body Repair Manual x100RM2J/4/1 X100WD2H/4/1...
  • Page 2 In the name of Gad SAIPA 141 Maintaining and repairing manual Body and trimming...
  • Page 3 SAIPA 141 / Maintaining and repairing manual Body and trimming...

  • Page 4: Table Of Contents

    Assembling and disassembling of side mirrors ……………………...………. 40 Assembling and disassembling of tape ………………………………..………. 41 Assembling and disassembling of side tapes …………………………..……… 42 sealering place ………………………………………………………………..…. 44 Installing the damaged parts ………………………………………………..…. 46 Welding types ………………………………………………………………..….. 48 SAIPA 141 / Maintaining and repairing manual Body and trimming...

  • Page 5: Preface

    PREFACE This manual is prepared by the engineers of SAIPA automotive manufacturing group to help the engineers and technicians of the 141 vehicle. It is recommended that the repairmen and technicians carefully study this book and follow its repair instructions. By doing so, the time will be saved and the quality of repairing will be increased.
  • Page 7 Body Manual...
  • Page 8 SAIPA 141 / Maintaining and repairing manual Body and trimming...

  • Page 9: Troubleshooting Tables

    Looseness of belt to pillar Crush or vibration Tighten bolts to standard connections Malfunction of seat beet Malfunction of light or Replace harness if fail caution light harness replace the defected part SAIPA 141 / Maintaining and repairing manual Body and trimming...

  • Page 10: Cutting Line Positions After The Crash

    Cutting line positions after the crash Side panel Cutting line of X141 vehicle X=2920 mm X=2260 mm X=1990mm X=2640mm SAIPA 141 / Maintaining and repairing manual Body and trimming...

  • Page 11: Repairing Body Smoothing Tool

    General Tools Planish general tools The general tool for catching & moving the glass. Grind Stone Tool Rasping tool for removing ripple SAIPA 141 / Maintaining and repairing manual Body and trimming...
  • Page 12 Specific tools Spray Gun Oxygen and acetylene capsule Wired brush SAIPA 141 / Maintaining and repairing manual Body and trimming...
  • Page 13 Specific tool Sealant pump general tool Shears for cutting metal sheets Clasp to hold , two together parts SAIPA 141 / Maintaining and repairing manual Body and trimming...
  • Page 14 Specific tool Clips to hold, body parts Planish pump general tool Special pincer for separating spot weld SAIPA 141 / Maintaining and repairing manual Body and trimming...
  • Page 15 Specific tool Some types of planish general tool (Planish fistic) SAIPA 141 / Maintaining and repairing manual Body and trimming...

  • Page 16: Assembling And Disassembling Of The Engine Hood

    Open the engine hood and hold it with the retainer lever. 2- Tag the engine hood hinge in order to reinstalling. 3- Open the glass cleaner hoses. (As shown in the fig.1) SAIPA 141 / Maintaining and repairing manual Body and trimming...

  • Page 17: Regulating The Engine Hood

    Loosen the door lock screws and lineup it with engine hood. (As shown in fig.3) SAIPA 141 / Maintaining and repairing manual Body and trimming...

  • Page 18: Assembling And Disassembling Of Grill And Front And Rear Logo

    Assembling the front logo Logo and the strip are stock on the grill by means of glue or plastic welding. SAIPA 141 / Maintaining and repairing manual Body and trimming...

  • Page 19: Assembling And Disassembling Of Trunk Lid And Fuel Caps Opener

    2- Detach the lever wire from the trunk lid lock. 3- Open the fuel cap and detach the mount- ing nut. Now disassemble the assembly (Assem- bling is the inverse of the disassembling). SAIPA 141 / Maintaining and repairing manual Body and trimming...

  • Page 20: Assembling And Disassembling Front Bumper

    (4 screws and 3 plugs) 4- Open the connection screws between bumper and connection bar and fender as shown in the picture. 5- Open 5 plugs on the lower part of the bumper. SAIPA 141 / Maintaining and repairing manual Body and trimming...
  • Page 21 Assembling and disassembling of parts 6- Open the screws connecting bracket and separate the bumper. SAIPA 141 / Maintaining and repairing manual Body and trimming...

  • Page 22: Assembling And Disassembling Rear Bumper

    1- Open the bolts at the bracket. 2- Open the nuts between the fender and the tire. Then Open the depicted bolts and detach the bumper. Do the reverse to assemble the bumper. SAIPA 141 / Maintaining and repairing manual Body and trimming...

  • Page 23: Assembling And Disassembling Of Rear Door Retainer Lever

    2- Open the mounting bolts by the means of the wrench. 3- Open the lower mounting bolt to the door. Caution: Assembling is the inverse of the disassem- bling. SAIPA 141 / Maintaining and repairing manual Body and trimming...

  • Page 24: Assembling And Disassembling Of Doors Glass

    2- Remove the rear door spring pin accord- ing to the depicted method in the figure and detach the handle (to disassembling the rear door trim). 3- Open the window mounting bolts. SAIPA 141 / Maintaining and repairing manual Body and trimming...

  • Page 25: Opening The Front And Rear Doors Lock

    Remove the rod handle from the locks di- rection and detach it from handle direction. Open the lock bolts and remove the lock. Assembling is the inverse of the above steps. SAIPA 141 / Maintaining and repairing manual Body and trimming...

  • Page 26: Assembling And Disassembling Of Front Door Body

    For regulating the tolerances between the door and the body, loose the hinges bolts and regulate the door. Then bolts must be tightened. Tightening torques for the hinges bolts are as follows: 16-23N.m (1.6-2.3 Kg.m) SAIPA 141 / Maintaining and repairing manual Body and trimming...

  • Page 27: Assembling And Disassembling Of Tab Of The Doors Lock

    First detach the trimming and all the attach- ments. Then remove the center guide by opening the nuts and bolts. Move the rear part of the rear door down- ward and detach the power window brack- SAIPA 141 / Maintaining and repairing manual Body and trimming...

  • Page 28: Assembling And Disassembling Of Fender

    Assembling and disassembling the fenders: First detach all the connected components to the defender like the bumpers and front lamps. Then open the linkage bolts between the fender and the lamp housing. SAIPA 141 / Maintaining and repairing manual Body and trimming...
  • Page 29 Assembling and disassembling of parts At the end of the above steps open the fender bolt that is in the door and remove the fender. SAIPA 141 / Maintaining and repairing manual Body and trimming...

  • Page 30: Assembling And Disassembling Of Front And Rear Lamps

    Assembling and disassembling of parts Assembling and disassembling the front lamps Front lamp components 1- Front lamp left side. 2- Front lamp right side. 3- Front lamp bracket mounting. 4- bolt SAIPA 141 / Maintaining and repairing manual Body and trimming...
  • Page 31 (refer to the assembling and disassembling the grill). 2- Open the depicted screws by a wrench. 3- Detach the lamp sockets. Assembling is the inverse of the disassem- bling. SAIPA 141 / Maintaining and repairing manual Body and trimming...
  • Page 32 Assembling and disassembling the rear warning lamps, license plate lamp and the license plate upper cover: 1- Rear warning lamp 2- License plate lamp 3- License plate lamp bulb 4- Bolt 5- License plate upper cover SAIPA 141 / Maintaining and repairing manual Body and trimming...
  • Page 33 Do the reverse for the assembling. Regulating the front lamps: Be sure that the tire pressure is standard. After that place the vehicle on a smooth surface and regulate the lamps. SAIPA 141 / Maintaining and repairing manual Body and trimming...

  • Page 34: Assembling And Disassembling Of Front And Rear Glass

    Finally, take out the front glass by a special tool. SAIPA 141 / Maintaining and repairing manual Body and trimming...
  • Page 35 Then clean about five centimeters wide of the windshield glass support surface and apply the sealer as 16 millimeters wide from the glass edge. Wait until it dries. SAIPA 141 / Maintaining and repairing manual Body and trimming...
  • Page 36 After drying the primer put the sealer in the 5 mm of the glass edge with 11mm thick- ness and by the means of a special tool. You can smooth the sealer if it is needed. SAIPA 141 / Maintaining and repairing manual Body and trimming...
  • Page 37 If there is any leakage, dry it completely and seal it again. Make sure that there is no leakage from the installation position, do the inverse of dis- assembling steps. SAIPA 141 / Maintaining and repairing manual Body and trimming...
  • Page 38 Assembling and disassembling of parts Assembling and disassembling the rear window glass: Rear window assembling and disassem- bling procedures are exactly the same as for the windshield window glass. SAIPA 141 / Maintaining and repairing manual Body and trimming...

  • Page 39: Assembling And Disassembling Of Windshield

    Then rotate the screw driver to make them comparted. Caution: Detach the motor if it is needed. Do the re- verse for assembling and make sure about the depicted regulations. SAIPA 141 / Maintaining and repairing manual Body and trimming...

  • Page 40: Assembling And Disassembling Of Side Mirrors

    Open the mounting bolts of the quarter cover and remove it. Open the mounting bolts of the mirror on the body and remove the mirror. Do the reverse for assembling the mirror. SAIPA 141 / Maintaining and repairing manual Body and trimming...

  • Page 41: Assembling And Disassembling Of Tape

    For re installation you should clean the mounting position, use primer and glove and stick them. Caution: It is better not to use a removed strip again. SAIPA 141 / Maintaining and repairing manual Body and trimming...

  • Page 42: Assembling And Disassembling Of Side Tapes

    If there is any problem in separating the glue, use a warmer to warm the strip. Make sure that there is no dirt on the strips before assembling. Then, stick bilateral glue on the strip. SAIPA 141 / Maintaining and repairing manual Body and trimming...
  • Page 43 Then regulate the strip with its position and stick it. Caution: The adhesion degrades at temperatures below 20°C. So it is better to warm the body before sticking the strip SAIPA 141 / Maintaining and repairing manual Body and trimming...

  • Page 44: Sealering Place

    1- All around the doors and between the door strip and the face. 2- Sealing the engine hood between the door strip and the engine panel SAIPA 141 / Maintaining and repairing manual Body and trimming...
  • Page 45 Assembling and disassembling of parts Samples for the sealing of the body edges The places where the insulator panels are placed in the floor and the body panel SAIPA 141 / Maintaining and repairing manual Body and trimming...

  • Page 46: Installing The Damaged Parts

    The number of the weld point is about 6-7 per each 20 cm and where there is a need to strengthening it should be 8-9 weld points. SAIPA 141 / Maintaining and repairing manual Body and trimming...
  • Page 47 Caution 5: Remove the surface color by the appropri- ate means and identify the cutting line. Select the cutting line from the places that has the minimum curves. SAIPA 141 / Maintaining and repairing manual Body and trimming...

  • Page 48: Welding Types

    This type works with a brass bar which is melt by heat. This type is used for the parts which are less exposed. The advantage of this type is its resistance and availability. SAIPA 141 / Maintaining and repairing manual Body and trimming...
  • Page 49 The advantage of this type is that, it is trimmed easily and also its smooth surface is proper for exposed parts. SAIPA 141 / Maintaining and repairing manual Body and trimming...
  • Page 50 4- PVC: It is used for the sealing the under part of the vehicle room. You can use Terostat-3215 for mastics and terolan-6535 for the spot. SAIPA 141 / Maintaining and repairing manual Body and trimming...
  • Page 51 Let it to dry after the coloring. Then use two layers of starlit and dryer. After that use abrasive with number 1500- 2000 to remove the coarseness. After that the surface is ready to polish. SAIPA 141 / Maintaining and repairing manual Body and trimming...

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