HAIMA M3 Series Body Repair Manual
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HAIMA M3 Series Body Repair Manual

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Body Repair Manual
M3 Series

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Summary of Contents for HAIMA M3 Series

  • Page 1 Body Repair Manual M3 Series...
  • Page 2 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.
  • Page 3 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 M3 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.
  • Page 4 Overview I-2 Chapter 1 Overview How to use this manual Effective replacement of body sheet metal parts The contents of this chapter include the welding The welding types and locations are indicated by   type, number of welds, and shearing-cutting symbols.
  • Page 5 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.
  • Page 6 Overview I-3 Linear Sizes The linear sizes refer to the actual sizes between The standard points and sizes are symmetric with   two standard points. 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.
  • Page 7 Overview I-4 Repair Precautions Precautions Layout of workshop During working, wear safety helmet and safety The layout of workshop is of great importance to  protective shoes to prevent injuries. Wear protective the safety and working efficiency. articles depending on the working characteristics, Protection of vehicle including gloves, protective goggles, earplugs, and Use the seat and floor covers.
  • Page 8 Overview I-5 Efficient Replacement of Body Panels Selection of cutting and welding portions Efficient disassembly of body panels parts impossible complete  Measurement of body replacement, adopt the cutting and welding Before the disassembly or rough cutting, firstly  methods and operate with cautions. To cut the measure the damaged body portions and their portions without reinforcement ribs, select the surroundings as per the standard reference sizes.
  • Page 9 Overview I-6 Installation Preparations Use of welding primer Grind the hatched portion shown in the figure below, To prevent corrosion, remove the paint, grease  drill a hole on 3~4 pieces of metal panels stacked and other substances from new parts and welding together, and weld tightly together these metal portions and then apply welding primer.
  • Page 10 Overview I-7 Efficient Installation of Body Panels Observation and checking of pre-welding sizes As the shape of welding head of the spot welding  Adjust the standard sizes as per the body size machine influences the welding strength, always  descriptions and install new parts to correct maintain the welding head under best status.
  • Page 11 Overview I-8 Inspection of welding strength Insert a chisel between plates to check the The mounting portions for engine, chassis, and   separation of plates, in order to determine the seat belt are significant safety portions in terms welding strength. If the plates are separated, of the welding strength.
  • Page 12 Overview I-8 Sealing of Body Apply the body sealant at the needed locations Use of Sound Insulation Floor  For the portions difficult to apply sealant after Adopt the sound insulation layer.   the installation, apply the sealant before the installation.
  • Page 13 Dimensions Chapter 2 Dimensions PLANE DIMENSIONS CAR UNDERBODY ............................. II-2   LINEAR DIMENSIONS CAR UNDERBODY ........................... II-3   FRONT CAR BODY 1 ..................................II-4   FRONT CAR BODY 2 ..................................II-5   SIDE FRAME....................................... II-6   INTERIOR CAR BODY ..................................II-7   REAR CAR BODY ....................................
  • Page 14 Dimensions Plane Dimensions Car Underbody Z=0, the plane is the lower plane of the parallel longitudinal floor beam, which goes through the rotation center of rear suspension torsion beam (no-load) Point Name Dimension Point Name Dimension symbol symbol Datum hole of front Φ9 Auxiliary datum hole Φ18...
  • Page 15 Dimensions front car body rear floor assembly Mounting hole of Φ82 Auxiliary datum hole Φ18 front suspension of rear floor assembly Mounting hole of Datum hole of rear Φ16 front frame tail board Mounting hole of front frame Linear Dimensions Car Underbody II-3...
  • Page 16 Dimensions Front Car Body 1 II-4...
  • Page 17 Dimensions Front Car Body 2 II-5...
  • Page 18 Dimensions Side Frame II-6...
  • Page 19 Dimensions Interior Car Body II-7...
  • Page 20 Dimensions Rear Car Body II-8...
  • Page 21 Structure Chapter 3 Structure PARTS AND COMPONENTS OF CAR BODY......................III-2 PART NAME AND MATERIAL ............................. III-3 III-1...
  • Page 22 Structure Parts and Components of Car Body III-2...
  • Page 23 Structure Part Name and Material Spare tire support assembly Rear towing hook High-strength reinforcing plate assembly Comp/part name steel Back pillar inner plate assembly Engine hood assembly Rear combination lamp Front top beam holder assembly 2# top beam Filler cap assembly 3# top beam Reinforcing plate of A pillar Roof panel...

  • Page 24: Table Of Contents

    Replacement of Plates Chapter 4 Replacement of Plates UPPER BEAM ASSEMBLY OF WATER TANK ......................IV-2   LOWER BEAM ASSEMBLY OF WATER TANK ......................IV-3   UPPER BEAM EDGE BEAM ASSEMBLY OF WATER TANK..................IV-5   UPPER EDGE BEAM INNER PLATE ASSEMBLY OF WHEEL GUARD ..............IV-7   SIDE FRONT CONNECTING PLATE..........................

  • Page 25: Upper Beam Assembly Of Water Tank

    Replacement of Plates Upper Beam Assembly of Water Tank Removal • Because the car body is bilaterally symmetric, only right view of the car body is provided here. Installation IV-2...

  • Page 26: Lower Beam Assembly Of Water Tank

    Replacement of Plates • Each component shall be kept on correct position during installation of a new part to make sure that dimensions of each portion upon installation are consistent with those of the car body. Lower Beam Assembly of Water Tank Removal IV-3...
  • Page 27 Replacement of Plates • Because the car body is bilaterally symmetric, only right view of the car body is provided here. Installation IV-4...

  • Page 28: Upper Beam Edge Beam Assembly Of Water Tank

    Replacement of Plates • Each component shall be kept on correct position during installation of a new part to make sure that dimensions of each portion upon installation are consistent with those of the car body. Upper Beam Edge Beam Assembly of Water Tank Removal IV-5...
  • Page 29 Replacement of Plates • Because the car body is bilaterally symmetric, only right view of the car body is provided here. Installation IV-6...

  • Page 30: Upper Edge Beam Inner Plate Assembly Of Wheel Guard

    Replacement of Plates • Each component shall be kept on correct position during installation of a new part to make sure that dimensions of each portion upon installation are consistent with those of the car body. Upper Edge Beam Inner Plate Assembly of Wheel Guard Removal IV-7...
  • Page 31 Replacement of Plates • Because the car body is bilaterally symmetric, only right view of the car body is provided here. Installation • Each component shall be kept on correct position during installation of a new part to make sure that dimensions of each portion upon installation are consistent with those of the car body.

  • Page 32: Side Front Connecting Plate

    Replacement of Plates Side Front Connecting Plate Removal • Because the car body is bilaterally symmetric, only right view of the car body is provided here. Installation • Each component shall be kept on correct position during installation of a new part to make sure that dimensions of each portion upon installation are consistent with those of the car body.

  • Page 33: Front Lower Plate Assembly Of Ventilation Hood

    Replacement of Plates Front Lower Plate Assembly of Ventilation Hood Removal Installation • Each component shall be kept on correct position during installation of a new part to make sure that dimensions of each portion upon installation are consistent with those of the car body. IV-10...

  • Page 34: Front Anti-Collision Beam Assembly

    Replacement of Plates Front Anti-collision Beam Assembly Removal Installation • Install as per the assembly sequence shown in the picture. IV-11...

  • Page 35: Ventilation Hood Assembly

    Replacement of Plates Ventilation Hood Assembly Removal Installation • Each component shall be kept on correct position during installation of a new part to make sure that dimensions of each portion upon installation are consistent with those of the car body. IV-12...

  • Page 36: Wheel Guard Assembly

    Replacement of Plates Wheel Guard Assembly Removal View 1 IV-13...
  • Page 37 Replacement of Plates View 2 • Because the car body is bilaterally symmetric, only right view of the car body is provided here. IV-14...
  • Page 38 Replacement of Plates Installation View 1 IV-15...
  • Page 39 Replacement of Plates View 2 • Each component shall be kept on correct position during installation of a new part to make sure that dimensions of each portion upon installation are consistent with those of the car body. IV-16...

  • Page 40: Front Longitudinal Beam Assembly (Front Segment

    Replacement of Plates Front Longitudinal Beam Assembly (Front Segment) Removal • Because the car body is bilaterally symmetric, only right view of the car body is provided here. IV-17...
  • Page 41 Replacement of Plates Installation • Each component shall be kept on correct position during installation of a new part to make sure that dimensions of each portion upon installation are consistent with those of the car body. IV-18...

  • Page 42: Front Longitudinal Beam Assembly

    Replacement of Plates Front Longitudinal Beam Assembly Removal IV-19...
  • Page 43 Replacement of Plates • Conduct rough cutting as per the position shown in the picture to remove the damaged part. IV-20...
  • Page 44 Replacement of Plates Installation IV-21...
  • Page 45 Replacement of Plates • Conduct cutting and level the cutting and connection positions of a new plate as per the positions shown in the picture; • Each component shall be placed on correct position during installation of a new or old plate to make sure that the dimension of the connection is consistent with that in the dimensional drawing of car body and with standard dimension;...

  • Page 46: Rear Extension Beam Assembly Of Front Longitudinal Beam

    Replacement of Plates Rear Extension Beam Assembly of Front Longitudinal Beam Removal • Because the car body is bilaterally symmetric, only right view of the car body is provided here. IV-23...
  • Page 47 Replacement of Plates Installation • Each component shall be kept on correct position during installation of a new part to make sure that dimensions of each portion upon installation are consistent with those of the car body. IV-24...

  • Page 48: A Pillar

    Replacement of Plates A Pillar Removal (bilaterally symmetric, only left view provided) • First drill on position (A) before removing the pillar, and remove the connecting piece between the lower side panel and the front car body; • Remove the upper and lower bolts (6 in total) from the inner side; •...
  • Page 49 Replacement of Plates Installation • Conduct trail assembly towards a new plate when the new plate and an old plate are joined; each component shall be measured and adjusted according to standard dimensions of car body to ensure consistency between the new component position and standard dimensions;...

  • Page 50: B Pillar

    Replacement of Plates B Pillar Removal • Conduct rough cutting on area marked with (A) and drilling on area marked with (B), and remove the lower part of the B pillar outer plate; • Conduct cutting and drilling on area marked with (C), and remove the reinforcing plate of B pillar; •...
  • Page 51 Replacement of Plates Installation • Conduct trail assembly towards a new plate when the new plate and an old plate are joined; each component shall be measured and adjusted according to standard dimensions of car body to ensure consistency between the new component position and standard dimensions;...

  • Page 52: C Pillar

    Replacement of Plates C Pillar Removal (left & right) IV-29...
  • Page 53 Replacement of Plates • Conduct rough cutting on area marked with (A) and drilling on area marked with (B), and remove the rear part of the B pillar outer plate; • The quantity of spot welding point B is related to the cutting position; •...
  • Page 54 Replacement of Plates Installation IV-31...
  • Page 55 Replacement of Plates • Apply car body sealant on the rear wheel guard before installing a new component (refer to chapter of car body seal for sealant application position); • Install the new and old components, and trail assemble the new component and measure each component to ensure dimensional consistency.

  • Page 56: Lower Part Of Side Panel

    Replacement of Plates Lower Part of Side Panel Removal • Conduct rough cutting on area marked with (A) and drilling on area marked with (B), and then remove the lower part of outer plate; • The quantity of spot welding point (B) varies along the cutting and joining position; •...
  • Page 57 Replacement of Plates Installation • Trail assemble the new component and measure each component while installing the new component to ensure dimensional consistency; • After trail assembly of the new component, ensure matching situation of relevant parts; • Install the inner plate first, and then the outer plate. IV-34...

  • Page 58: Interior Of C Pillar

    Replacement of Plates Interior of C Pillar Removal (bilaterally symmetric, only left view provided) • Remove the outer plate before removing the inner plate; refer to the chapter of C pillar outer plate maintenance for details in removal and installation of outer plate; •...
  • Page 59 Replacement of Plates Installation (bilaterally symmetric, only left view provided) • Trail assembles the new component and measures each component while installing the new component to ensure dimensional consistency; • After trail assembly of the new component, ensure matching situation of relevant components; •...

  • Page 60: Roof Panel

    Replacement of Plates Roof Panel Removal • Cut the damping rubber between the roof panel and the top beam when the roof panel is removed. IV-37...
  • Page 61 Replacement of Plates Installation • Apply damping rubber on the position shown in the picture before installing the roof panel; • Conduct trial assembly while installing the new component to ensure good matching situation of relevant parts. IV-38...

  • Page 62: Roof Panel (With Sunroof

    Replacement of Plates Roof Panel (with sunroof) Removal • Cut the damping rubber between the roof panel and the top beam when the roof panel is removed. IV-39...
  • Page 63 Replacement of Plates Installation • Apply damping rubber on the position shown in the picture before installing the roof panel; • Conduct trial assembly while installing the new component to ensure good matching situation of relevant parts. IV-40...

  • Page 64: Rear Tail Board Assembly

    Replacement of Plates Rear Tail Board Assembly Removal Installation • Install in reference to the removal drawing; • Adjust installation position when a new component is installed to ensure that the installation position is consistent with the car body position of original car; •...

  • Page 65: Trunk Floor

    Replacement of Plates Trunk Floor Removal Note: remove the side panel connecting plate first before removing the floor. Installation • Install in reference to the removal drawing; • Drill holes for plug welding before installing a new component; • Measure relevant dimensions of a new component when it is installed to ensure that the dimensions are consistent with the car body dimensions;...
  • Page 66 Waterproof and Rust-proof Treatment Chapter 5 Waterproof and Rust-proof Treatment Seal of Car Body ..........................V-2   PVC Spraying ............................ V-6   Anti-rust Treatment..........................V-7  ...
  • Page 67 Waterproof and Rust-proof Treatment Seal of Car Body Sealant shall be applied on joints between plates, door sheet gaps and engine hood edges for waterproof and anti-rust effects.
  • Page 68 Waterproof and Rust-proof Treatment Sealant Hemming sealer Damping rubber...
  • Page 69 Waterproof and Rust-proof Treatment...
  • Page 70 Waterproof and Rust-proof Treatment...
  • Page 71 Waterproof and Rust-proof Treatment PVC Spraying...
  • Page 72 Waterproof and Rust-proof Treatment There are mounting holes on gluing area, which shall be covered for protection with an area of 50mm×50mm; The gluing thickness is 2mm. Anti-rust Treatment...
  • Page 73 Waterproof and Rust-proof Treatment...

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