Page 1 SAMAND (XU7JPL3) Service Manual Body & Body repairs...
Page 2 Product: Chapter: Section: SAMAND XU7JPL3 Body Repairs SAMAND Service Manual Foreword: This Service Manual contains descriptions of the following categories for the Samand: Body and Body Repairs This manual should be used as service manual and s workbook for training instructors and technicians. We reserve the right to introduce...
Page 3 Contents Body & body repairs Technical data Special tools Technical description Adjustment and replacement...
Page 6 Body & body repairs Samand...
Page 7 Technical data Sound absorbing panels Area Type Area Type Area Type Adhesive & primer used when changing glass Samand...
Page 8 W78D001 Samand...
Page 9 Body Dimensions Item Dimension (mm) Description Samand...
Page 10 & " W78D002 Samand...
Page 11 Measurements, rear body and side 12,13 W78D003 Item Dimension (mm) Description Samand...
Page 12 Measurements, body B pillar W78D004 Item Dimension (mm) Description Samand...
Page 13 Measurements, underbody " W78D005 Item Dimension (mm) Description Samand...
Page 14 Finish paints Colour code Colour Paint Type Model Year IMPORTANT WARNING Samand...
Page 15 Corrosion protection products Samand...
Page 16 Setting of badges 17.5 17.5 W78D006 Samand...
Page 17 Special tools & & " " T.JIG SEFAC Jig Equipment Samand...
Page 18 Bonded glass removal kit W78R058 Bonding kit and Mastic gun W78R059 Suction grips W78R060 Samand...
Page 19 T.COMM. Samand...
Page 20 Technical description Body design W78S001 Serviceability Durability Samand...
Page 21 W78S031 W78S032 Samand...
Page 22 Crash and Safety Safety Caution Samand...
Page 23 Reinforcement " W78S003 Samand 1.8i Important Samand...
Page 24 Galvanised parts Samand...
Page 25 " & " & & "...
Page 26 Galvanised parts Samand...
Page 27 & " & " " &...
Page 28 Galvanised parts Samand...
Page 29 "& & "' " "% "$ "# "" "! " " " & " !& !" " &...
Page 30 Permissible joints W78S018 W78S019 Samand...
Page 31 W78S020 W78S022 W78S023 Samand...
Page 32 Pillar designations Windscreen and rear window Samand...
Page 33 Window lifts W78S009 Door mirrors W78S010 Samand...
Page 34 Surface treatment Corrosion The surface treatment process 175¡ ± 5¡C 145¡ ± 5¡C W78S011 Samand...
Page 35 Intermediate coat. Cleaning Inspection. Degreasing. Oven hardening. Grinding. Phosphatizing. Cleaning. Washing. Anti-corrosive treatment. Electrocoating (ED). Oven hardening. Oven hardening. Top coat. Noise suppression mats. Oven hardening. Sealing. Final inspection. Oven hardening. Inspection and grinding. Cleaning. Samand...
Page 36 Sealant W78S012 Samand...
Page 37 W78S013 Sealant Samand...
Page 38 Underseal (anti-chip) W78S014 Samand...
Page 39 Underseal (anti-chip) W78S015 Samand...
Page 40 Cavity Sealant W78S016 Samand...
Page 41 Cavity Sealant W78S017 Samand...
Page 42 Painting galvanised sheet Important. Samand...
Page 43 Adjustment and replacement Bodywork repairs Checking the body dimensions Samand...
Page 44 Cutting W78R131 Warning Samand...
Page 45 Welding Grinding Important Important Samand...
Page 46 Welding galvanised sheet metal Primer Cleaning Important Primer Samand...
Page 47 Method of Zinc coating Electro-zinc and galvanised panels for repair Kit contents W78R133 1 Preparing the surface W78R134 Samand...
Page 48 2 Choice of anode W78R135 3 Setting up Samand...
Page 49 5 Depositing zinc W78R136 Samand...
Page 50 Jig Mounting W78R137 W78R138 W78R139 Samand...
Page 51 " W78R140 Samand...
Page 52 Replace front Subframe fixing nut. W78R141 W78R142 W78R143 Samand...
Page 53 " W78R144 W78R145 Samand...
Page 54 Complete front wheel arch replace W78R146 W78R147 W78R148 Samand...
Page 55 " W78R149 W78R150 W78R151 Samand...
Page 56 W78R152 & & & & & W78R153 W78R154 Samand...
Page 57 Cutting damaged panels. W78R155 W78R156 " W78R157 Samand...
Page 58 W78R158 W78R159 W78R160 Samand...
Page 59 & & & & W78R161 W78R162 W78R163 Samand...
Page 60 W78R164 W78R165 W78R166 Samand...
Page 61 " W78R167 W78R168 W78R169 Samand...
Page 62 W78R170 & & & W78R171 W78R172 Samand...
Page 63 W78R173 W78R174 W78R175 Samand...
Page 64 !" !" !" W78R176 W78R177 W78R178 Samand...
Page 65 W78R179 !& W78R180 " W78R181 Samand...
Page 66 " "! " "! W78R182 "# "" "$ "" W78R183 "% W78R184 Samand...
Page 67 "& "' "' "' W78R185 W78R186 Samand...
Page 68 Replace front wing inner panel and half front panel assy plus front wing inner panel upper closing panel. W78R187 W78R188 W78R189 Samand...
Page 69 " " " W78R190 W78R191 W78R192 Samand...
Page 70 W78R193 W78R194 W78R195 Samand...
Page 71 W78R196 " W78R197 W78R198 Samand...
Page 72 & W78R199 W78R200 W78R201 Samand...
Page 73 Replacing the front of a front side member and the front lower cross member W78R202 W78R203 W78R204 Samand...
Page 74 " W78R205 W78R206 & W78R207 Samand...
Page 75 W78R208 W78R209 W78R210 Samand...
Page 76 " W78R211 W78R212 & & W78R213 Samand...
Page 77 W78R214 W78R215 W78R216 Samand...
Page 78 " W78R217 W78R218 & W78R219 Samand...
Page 79 Replacing a part front side member and a front wing inner panel side panel. W78R220 W78R221 W78R222 Samand...
Page 80 " " W78R223 W78R224 & W78R225 Samand...
Page 81 W78R226 W78R227 " W78R228 Samand...
Page 82 W78R229 & W78R230 W78R231 Samand...
Page 83 " " " W78R232 Warning W78R233 W78R234 Samand...
Page 84 & W78R235 W78R236 Samand...
Page 85 Side member centre part replace W78R237 W78R238 W78R239 Samand...
Page 86 " W78R240 W78R241 & W78R242 Samand...
Page 87 W78R243 W78R244 W78R245 Samand...
Page 88 W78R246 W78R247 & W78R248 Samand...
Page 89 W78R249 W78R250 " W78R251 Samand...
Page 90 W78R252 & W78R253 !" W78R254 Samand...
Page 91 Bodyside outer A pillar and reinforcement Front hinge replace W78R257 W78R258 W78R259 Samand...
Page 92 W78R260 " " " " " " W78R261 W78R262 Samand...
Page 93 W78R263 & & & W78R264 W78R265 Samand...
Page 94 W78R266 W78R267 W78R268 Samand...
Page 95 " W78R269 W78R270 W78R271 Samand...
Page 96 & & & & & W78R272 W78R273 W78R274 Samand...
Page 97 W78R275 W78R281 Samand...
Page 98 Right hand side member replacement (engine mounting bracket) W78R276 W78R277 W78R278 Samand...
Page 99 Windscreen pillar replace W78R337 W78R338 W78R339 Samand...
Page 100 W78R340 " " " " W78R341 W78R342 Samand...
Page 101 W78R343 W78R344 W78R345 Samand...
Page 102 " " " W78R346 W78R347 W78R255 Samand...
Page 103 & W78R256 Samand...
Page 104 Replace a centre pillar and inner panel W78R297 & W78R298 W78R299 Samand...
Page 105 W78R300 " " W78R301 W78R302 Samand...
Page 106 W78R303 W78R304 & & W78R305 Samand...
Page 107 W78R306 W78R307 W78R308 Samand...
Page 108 W78R309 " " W78R310 W78R311 Samand...
Page 109 W78R312 W78R313 & & & W78R314 Samand...
Page 110 W78R315 W78R316 W78R317 Samand...
Page 111 " W78R318 Samand...
Page 112 Outer sill panel replace W78R319 " W78R320 W78R321 Samand...
Page 113 W78R322 & & & & & & & W78R323 W78R324 Samand...
Page 114 W78R325 W78R326 W78R327 Samand...
Page 115 " W78R328 W78R329 W78R330 Samand...
Page 116 W78R331 & W78R332 W78R333 Samand...
Page 117 W78R334 W78R335 W78R336 Samand...
Page 118 Replacing a roof support W78R348 NOTE: W78R349 W78R350 Samand...
Page 119 W78R351 W78R352 W78R353 Samand...
Page 120 Tail panel assembly replace W78R354 W78R355 W78R356 Samand...
Page 121 W78R357 W78R358 W78R359 Samand...
Page 122 W78R360 W78R361 W78R362 Samand...
Page 123 W78R363 W78R364 W78R365 Samand...
Page 124 Roof panel replace W78R366 W78R367 W78R368 Samand...
Page 125 " W78R369 W78R370 Samand...
Page 126 W78R372 WARNING & & W78R373 W78R375 Samand...
Page 127 W78R376 W78R377 Samand...
Page 128 Replacing a rear wing without removing the rear screen W78R378 W78R379 W78R380 Samand...
Page 129 W78R381 " W78R382 W78R383 Samand...
Page 130 W78R384 & W78R385 W78R386 Samand...
Page 131 W78R387 " W78R388 W78R389 Samand...
Page 132 & W78R390 W78R391 W78R392 Samand...
Page 133 W78R393 W78R394 " W78R395 Samand...
Page 134 W78R396 W78R397 W78R398 Samand...
Page 135 Replacing a rear wing cutting the rear quarter panel W78R399 W78R400 W78R401 Samand...
Page 136 W78R402 " " W78R403 W78R404 Samand...
Page 137 W78R405 W78R406 & & & & W78R407 Samand...
Page 138 W78R408 W78R409 W78R410 Samand...
Page 139 W78R411 & W78R412 W78R413 Samand...
Page 140 W78R414 W78R415 W78R416 Samand...
Page 141 W78R417 " W78R418 W78R419 Samand...
Page 142 Replacing a part wheel arch assembly W78R420 W78R421 W78R491 Samand...
Page 143 W78R492 " " W78R493 W78R423 Samand...
Page 144 W78R424 W78R425 & W78R429 Samand...
Page 145 W78R430 W78R433 W78R435 Samand...
Page 146 W78R436 W78R438 W78R494 Samand...
Page 147 W78R442 W78R441 W78R444 Samand...
Page 148 W78R445 " W78R446 W78R448 Samand...
Page 149 W78R449 W78R450 & & & & W78R451 Samand...
Page 150 W78R495 W78R496 W78R452 Samand...
Page 151 W78R453 Samand...
Page 152 Replacing a part rear floor assembly W78R454 W78R455 W78R456 Samand...
Page 153 W78R457 " W78R458 W78R459 Samand...
Page 154 W78R460 & W78R461 W78R462 Samand...
Page 155 > Section A-A W78R463 W78R464 W78R465 Samand...
Page 156 W78R466 " W78R467 W78R468 Samand...
Page 157 W78R469 W78R470 & & W78R471 Samand...
Page 158 W78R472 W78R473 W78R474 Samand...
Page 159 Part rear side member repair W78R475 W78R476 W78R477 Samand...
Page 160 W78R478 W78R479 W78R480 Samand...
Page 161 W78R481 W78R482 W78R483 Samand...
Page 162 W78R484 " W78R485 W78R486 Samand...
Page 163 W78R487 W78R488 & W78R489 Samand...
Page 164 W78R490 Samand...
Page 165 Hood To remove Note. W78R001 To fit Note Hood hinge To remove To fit " W78R002 Samand...
Page 166 Hood stay To remove To fit W78R003 Hood stop adjustment W78R004 Samand...
Page 167 Hood release cable To remove W78R005 W78R006 W78R007 Samand...
Page 168 W78R008 Hood Latch To remove Refit W78R009 Hood release pull To remove To refit " W78R010 Samand...
Page 169 Front wheel arch To remove " W78R011 & W78R012 To refit Samand...
Page 170 Front fender To remove " W78R013 W78R014 & & & To refit W78R015 Samand...
Page 171 Doors To remove W78R016 " W78R017 To refit Note: Samand...
Page 172 Door striker To adjust W78R018 Samand...
Page 173 Front door glass Special tools W78R019 To remove W78R020 Note: " W78R021 Samand...
Page 174 W78R022 W78R023 To refit & Note: W78R024 Samand...
Page 175 Front door electric window lift regulator To remove W78R025 " W78R026 To refit Samand...
Page 176 Front door front slide To remove W78R027 " W78R028 To refit Note: Samand...
Page 177 Door mirror glass To remove Note: W78R029 W78R030 Samand...
Page 178 Front door electric mirror To remove W78R031 W78R032 W78R033 Samand...
Page 179 Rear door fixed glass Note: To remove " W78R034 W78R035 To refit W78R036 Samand...
Page 180 Door check arm To remove W78R037 W78R038 To refit " W78R039 Samand...
Page 181 Door key lock To remove (with trim pad in place) 12.7 12.7 W78R040 W78R041 W78R042 Samand...
Page 182 W78R043 & W78R044 To refit Important: W78R045 Samand...
Page 183 Door latch To remove W78R046 " W78R047 W78R048 Samand...
Page 184 Front door W78R049 Rear Door & W78R050 Front and Rear doors & W78R051 Samand...
Page 185 W78R052 W78R053 " To refit " " W78R054 Samand...
Page 186 Door moulding To remove W78R055 To refit W78R056 W78R057 Samand...
Page 187 Front window glass Tools W78R058 W78R059 W78R060 Samand...
Page 188 Front window glass To remove W78R061 W78R062 W78R063 Samand...
Page 189 & & W78R064 W78R065 W78R066 Samand...
Page 190 " W78R067 W78R068 0mm W78R069 Samand...
Page 191 W78R070 W78R071 W78R072 Samand...
Page 192 W78R073 Rear window glass Removal/refitting Samand...
Page 193 Trunk lid To remove W78R074 W78R075 To refit Samand...
Page 194 Trunk lid adjustment W78R076 Adjust: W78R077 Trunk lid lift W78R078 Samand...
Page 195 Trunk lid lock striker To remove W78R079 Trunk lid striker adjust. W78R080 Samand...
Page 196 Trunk lid latch To remove " To refit W78R081 Trunk lid latch adjustment To adjust W78R082 Samand...
Page 197 Trunk lid lock cable To remove W78R083 W78R084 W78R085 Samand...
Page 198 " W78R086 To refit Samand...
Page 199 Trunk lid key lock To remove W78R087 W78R088 " W78R089 Samand...
Page 200 W78R090 W78R091 To refit Samand...
Page 201 Trunk lid lock motor W78R092 W78R093 To refit " W78R094 Samand...
Page 202 Trunk lid finisher trim To remove W78R095 W78R096 To refit Samand...
Page 203 Fuel Filler Flap To remove W78R097 W78R098 To refit Note: W78R099 Samand...
Page 204 Front bumper To remove W78R100 " " W78R101 W78R102 Samand...
Page 205 W78R103 & & W78R104 W78R105 Samand...
Page 206 W78R106 To refit W78R107 Samand...
Page 207 Rear Bumper To remove W78R108 W78R109 W78R128 Samand...
Page 208 " " W78R129 W78R130 To refit W78R110 Samand...
Page 209 Front structure/cooling pack Cooling pack To remove W78R111 Note: " W78R112 To refit W78R113 Samand...
Page 210 W78R114 & W78R115 W78R116 Samand...
Page 211 " W78R117 W78R118 To refit W78R119 Samand...
Page 212 Seals Hood seals To remove W78R120 W78R121 Samand...
Page 213 Door seals To remove W78R122 W78R123 Samand...
Page 214 Trunk lid seal W78R124 W78R125 Gutter seal To remove To refit W78R126 Samand...
Page 215 Mouldings Door rubbing strip protectors To remove W78R127 To refit Samand...

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Ikco SAMAND Service Manual

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