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Body Repair Manual

S5 Series
Warning

Warning

The repair works of the vehicle are dangerous. The repair personnel not receiving the related vehicle
repair training will probably cause repair failure or even loss of properties and personal injuries. Only the
technical personnel receiving the related vehicle repair training and having actual repair experiences are
allowed for repair works.
The repair procedures contained in this manual, including parts “Warning” and “Caution”, are prepared
by technical training personnel of Haima Automobile Co., Ltd. Before the repair operations, the repair
personnel shall carefully read this manual to understand general safety procedures. The technical personnel
shall abide by the “Warnings” and “Cautions” to reduce the injury hazard and the possibility of vehicle
damage and potential safety problems arising from the improper repairs and services. It’s of equal importance
that it should be understood that the “Warnings” and “Cautions” do not include everything and are impossible
to warn all hazardous consequences arising from the violations of the operation procedures.
The repair recommendations and related procedures contained in this manual are the effective service
and repair methods. Some repair operations require the use of special tools. The personnel using the
procedures or tools not recommended by Haima Automobile must take cautions to guarantee the safety of
personnel and vehicle.
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. The factors are not
limited to the above mentioned ones.
Haima Automobile reserves the right to change the design of the vehicle and contents of this manual
without prior notice to the users and will not be liable for any consequence thereof.
Preface

Preface

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 S5 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.
Understanding this manual is of great importance for correct repairs and maintenances of the vehicle.
Please always carry this manual with you to obtain reference information in a fast and convenient manner.
The contents contained in this manual, including graphs and technical specifications, are the latest data
available at the preparation of this manual. When the changes in some contents influence the repairs and
maintenances of the vehicle, please obtain the supplemental data of related parts from the dealers of Haima
Automobile. This manual shall be kept updated frequently.
Haima Automobile reserves the right to change the technical specifications and contents of this manual
without prior notice and will not be liable for any consequence thereof.
The copyright of this manual is reserved. Without prior written consent, no part of this manual can be
duplicated or used in any form, including photocopy, recording, and information storage and searching
system.

HAIMA CAR CO., LTD.


Henan, China
Contents

Contents

Chapter 1 Overview
How to use this manual .................................................................................................................................... 1
Repair Precautions............................................................................................................................................ 4
Efficient Replacement of Body Panels ............................................................................................................. 5

Chapter 2 Sizes
Bottom of Body (Planar Sizes)......................................................................................................................... 9
Bottom of Body (Linear Sizes)....................................................................................................................... 10
Front of Body 1 .............................................................................................................................................. 11
Front of Body 2 .............................................................................................................................................. 12
Side Wall Framework..................................................................................................................................... 13
Interior of Body .............................................................................................................................................. 14
Rear of Body................................................................................................................................................... 15

Chapter 3 Structure
Body Parts ...................................................................................................................................................... 16
Name and Materials of Parts .......................................................................................................................... 17

Chapter 4 Replacement of Panels


Front Bumper Anti-Collision Beam Assembly .............................................................................................. 18
Engine hood lock bracket assembly ............................................................................................................... 19
Water tank support assembly.......................................................................................................................... 20
Ventilation Cover Plate Mounting Plate Installation Assembly ..................................................................... 21
Front wheel casing assembly.......................................................................................................................... 22
Front longitudinal beam assembly.................................................................................................................. 25
Front longitudinal beam and front floor connecting plate assembly .............................................................. 27
Side wall front connecting plate assembly ..................................................................................................... 28
A-Pillar ........................................................................................................................................................... 29
B-Pillar ........................................................................................................................................................... 31
C-Pillar ........................................................................................................................................................... 33
Side Wall Lower Portion ................................................................................................................................ 37
C-Pillar Inner Portion ..................................................................................................................................... 39
Roof ................................................................................................................................................................ 41
Roof (with Sunroof) ....................................................................................................................................... 42
Rear Wall Panel Assembly ............................................................................................................................. 43
Rear Floor....................................................................................................................................................... 44
Contents
Rear Floor Fuel Tank Maintenance Panel ...................................................................................................... 45
Rear Floor Upper Crossbeam Assembly ........................................................................................................ 46

Chapter 5 Water-Proof and Rust-Proof Treatment


Sealing of Body .............................................................................................................................................. 47
PVC Coating................................................................................................................................................... 53
Overview I-1

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.
locations for the body sheet metal parts. This  The relevant operation precautions are given in
information is of great importance for the some sections. Please carefully read and
disassembly and installation of the sheet metal understand these precautions before any operation
parts. procedure.

Note
 The number of welds at asterisk (A) varies depending on different shearing-connecting locations.
 When the drilling is required during the installation of new parts, take cautions not to completely drill
through the sheet metal parts.

Symbol
 The following 6 symbols are used to indicate the welding types during the replacement of body sheet metal
parts.
Symbol Meaning Symbol Meaning
Continuous MIG welding
Spot welding
(shearing-connecting location)
CO2 gas shielded arc welding (plug
Braze welding
welding)
CO2 spot welding Rough shearing location
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.
 The imaginary lines are different for different vehicle models.
Example:

Z=0 plane is the plane that passes through the rotation center of rear suspension torsion beam (under no-load
condition) and parallels with the lower plane of floor longitudinal beam.

Point symbol Name Hole diameter or nut size mm (in)


A Front anti-collision beam datum hole Ø15(0.59)
B Front body main datum hole Ø25(0.98)
C Front suspension mounting hole Ø86.6(3.41)
D Front beam mounting hole M14(0.55)
E Front beam mounting hole M14(0.55)
F Front body secondary datum hole Ø20(0.79)
G Rear longitudinal beam main datum hole Ø13(0.51)
H Rear longitudinal beam secondary datum hole Ø25(0.98)
I Rear beam datum hole Ø20(0.79)
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.
Symbol
The following 8 symbols are used to indicate standard points.
Symbol Meaning Symbol Meaning
Center of round hole Port and gap of steel plates
Center of elliptical hole Bolt pin
Edge of hole Center of rectangular hole
Groove Edge of rectangular hole
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.
mask.
 Use the insulation shield, in order to prevent the
heat and spark from damaging the glasses and
seats during welding. Welding Dust-proof
 Protect the accessories including trims and goggles mask
insertion strips during welding.

Earplug Safety goggles

Welding gloves
Mask

Cotton gloves Protective shoes

Guard against short-circuit


Use of Traction Apparatus  While disassembling the wires or electric
 When a traction apparatus is used, the working apparatus, disconnect the negative cable of
personnel shall keep away from the working zone battery.
and take cautions in suing the safety cable.

Removal of hazardous articles


 Within the area using open fire, move away the
fuel tank and plug the connecting pipes of the
fuel tank, in order to prevent fuel leakage.
Overview I-5

Efficient Replacement of Body Panels


Selection of cutting and welding portions
Efficient disassembly of body panels
 For the parts impossible for 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.
locations yielding to minimum welding
Upon detection of deformation, conduct initial
deformation for cutting.
correction with frame repair device.

Disassembly of connected parts


Guard against body deformation  While disassembling the connected parts, protect
 Disassemble with fixtures or jack and reinforce the insertion strips, trims, and parts with pipes.
the portions to be roughly cut and their Rough cutting of damaged panels
surroundings, in order to prevent body  Ensure that there is no damaged part due to heat
deformation. near or in the opposite side of this part. (such as
pipe hoses and wire harnesses)
Leave overlapping parts of 30~50mm
(1.18~1.97in) at the cutting and connecting
portions and then roughly cut the damaged body
panels.
Overview I-6

Installation Preparations

Use of welding primer


 To prevent corrosion, remove the paint, grease Grind the hatched portion shown in the figure below,

and other substances from new parts and welding drill a hole on 3~4 pieces of metal panels stacked

portions and then apply welding primer. together, and weld tightly together these metal
panels, in order to eliminate the further development
of gap.

Determination of welding methods Rough Cutting of New Parts


 If the overall thickness of weld points is higher  For cutting and splicing portions, leave
than or equals to 3mm(0.12in), adopt CO2 overlapping parts of 30~50mm {1.18~1.97in} on
shielded welding for rivet welding. the body side and then roughly cut the new parts.

Drilling for CO2 shielded welding


 For the locations in which the spot welding can’t
be adopted, drill a hole with drilling machine or
hand-held drilling machine for CO2 shielded
welding.
mm {in}
Panel thickness Hole diameter
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}
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.
positions.

 The spot welding points shall be staggered from


the original welds.
Welding precautions
 Before the welding, use a material same with that
of the body for a welding test, in order to inspect
the welding strength.

Precautions for spot welding


 The shape of welding head of the spot welding
machine shall be fabricated as per D=(2×t)+3. In
even of different thickness between upper steel
plate and lower steel plate, the thinner steel plate
shall prevail.
Overview I-8

Inspection of welding strength


 The mounting portions for engine, chassis, and  Insert a chisel between plates to check the
seat belt are significant safety portions in terms separation of plates, in order to determine the
of the welding strength. Insert a chisel between welding strength. If the plates are separated,
the plates in spacing of 4 or 5 welding points and weld once again near the previous welding
in spacing of 10 common welding points to position.
inspect the welding strength.  Correct the shape of the checked portion.

 As shown in the figure below, insert a chisel


between the plates as per the quantity of plates.
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.

Application of Primer
 Use the primer at the needed locations. Acronym
Fr Front
Rr Rear
RH Right
LH Left
Ctr Center
G/E Gasoline engine
D/E Diesel engine

Use of anti-rust agent M Metal

 Apply anti-rust agent (paraffin and machine oil) MC Mica

on the back surface of welding points.


Sizes II-9

Chapter 2 Sizes
Bottom of Body (Planar Sizes)

Z=0 plane is the plane that passes through the centerline of front wheels and parallels with the lower plane of
floor longitudinal beam under half load condition.

Point Point
Name Size Name Size
symbol symbol
A
Front suspension Rear floor assembly
B M12 H Φ16
system mounting hole main datum hole
Front body main Rear floor assembly
C Φ16 I Φ18
datum hole secondary datum hole
Front shaft mounting Rear plate main datum
D Φ93.3 Φ20
hole hole
J
Front suspension Rear plate secondary
E M12 14×12 long hole
system mounting hole datum hole
Sizes II-10

Bottom of Body (Linear Sizes)

Measurement Dimension
position (mm)
1 449.05
2 453.38
3 928.32
4 1269.36
5 1262.92
6 385.72
7 385.72
8 1481.4
9 1481.58
10 907.96
11 907.93
12 823
13 820
14 324.34
15 309.55
16 1681
17 1660.82
18 1068
Sizes II-11

Front of Body 1

A/A' B/B' Measurement Dimension


position (mm)
1 688.2
2 970
3 958
4 656.5
5 460.2
C/C' D 6 1063.4
7 525.9
8 310.3
9 335.7
10 473.9
11 603.7
12 459.1
Sizes II-12

Front of Body 2

A/A' B/B' C/C'

Measurement Dimension
position (mm)
1 1183.4
D/D' E/E' F 2 786.3
3 1510.6
4 1405.6
5 322.7
6 1249.7
7 747.2
8 1274.7
G 9 853.5
10 471.2
11 122.3
Sizes II-13

Side Wall Framework

B'

Measuremen Dimension
t position (mm)
1 514.36
2 591.4
3 1265.33
4 1420.89
5 1117.31
6 1114.15
7 1157.65
8 1061.85
9 1028.83
10 927.85
11 575.98
12 899.8
13 539.41
14 907.13
15 1021.41
16 820.18
17 349.93
18 553.16
D/D' 1229.67
G/G' 1465.79
I/I' 1211.72
J/J' 1224.28
Sizes II-14

Interior of Body

Measurement Dimension
position (mm)
1 747.1
2 866.07
3 1386.55
4 1401.96
5 1159.65
6 783.03
7 985.26
8 991.62
9 848.49
10 969.37
C/C' 1397.8
D/D' 1380
E/E' 1158.48
F/F' 1302.49
G/G' 1383.67
H/H' 1135.88
I/I' 1306
Sizes II-15

Rear of Body

Measurement Dimension
position (mm)
A/A' B/B' 1 621
2 687.1
3 910.1
4 976.8
5 1081.6
6 1103.9
7 1202
C/C' D 8 434.1
9 550
10 673.4
11 976.8
Structure III-16

Chapter 3 Structure
Body Parts

35 37
34

32
31 36

29 25
24 26
30
33
28
18 21
23
19
7
22 8
16
15
27
3
13 6
9
11
20
10

14 17

12 5

4
2
1
Structure III-17

Name and Materials of Parts

No. Part name High strength steel


1 Front door assembly (left) *
2 Rear door assembly (left) *
3 Side wall outer panel tier-1 assembly (left) *
4 Front fender assembly (left)
5 Side wall front connecting plate assembly (left) *
6 Side wall outer panel reinforcement plate assembly (left) *
7 Pillar-C inner panel assembly (left) *
C-pillar inner panel and wheel casing connecting plate
8 *
assembly (left)
9 Rear wheel casing (left) *
10 Side wall front inner panel assembly (left) *
11 Front bumper anti-collision beam assembly *
12 Water tank support assembly *
13 Front longitudinal beam (right) *
14 Front longitudinal beam (left) *
15 Front wall panel outer side crossbeam assembly *
16 Front wall assembly *
17 A-pillar lower inner panel assembly (left) *
18 Doorsill assembly (right) *
19 Front floor assembly *
20 Doorsill assembly (left) *
21 Rear longitudinal beam assembly (left) *
22 4# crossbeam subassembly *
23 Rear floor front crossbeam assembly *
24 Rear longitudinal beam assembly (right) *
25 Rear floor panel assembly *
26 Rear plate assembly *
27 A-pillar lower inner panel assembly (right) *
28 Front fender assembly (right)
29 Engine hood system *
30 Front top beam subassembly *
st
31 Roof 1 crossbeam *
32 2# top beam *
33 Middle top beam *
34 Roof *
35 Roof middle rear crossbeam *
36 Roof rear crossbeam assembly *
37 Liftgate assembly
Pleacement of Panels IV-18

Chapter 4 Replacement of Panels


Front Bumper Anti-Collision Beam Assembly
Disassembly

Two bolts Two bolts

1. Water tank support assembly


2. Front bumper anti-collision beam assembly

• Due to lateral symmetry of the body, only the right view is given here.

Installation

Two bolts Two bolts

1. Water tank support assembly


2. Front bumper anti-collision beam assembly

• While installing new parts, install all parts at correct locations, in order to ensure that the sizes of all parts are
consistent with standard body after installation.
Pleacement of Panels IV-19

Engine hood lock bracket assembly


Disassembly
Two bolts

Two bolts

1. Water tank support assembly


2. Front bumper anti-collision beam assembly
3. Engine hood lock bracket assembly

Installation

Two bolts

Two bolts

1. Water tank support assembly


2. Front bumper anti-collision beam assembly
3. Engine hood lock bracket assembly

• While installing new parts, install all parts at correct locations, in order to ensure that the sizes of all parts are
consistent with standard body after installation.
Pleacement of Panels IV-20

Water tank support assembly


Disassembly

Two bolts Two bolts

Two bolts

Two bolts

One bolt
1. Water tank support assembly
2. Front longitudinal beam assembly (right)
3. Front bumper anti-collision beam assembly

• Due to lateral symmetry of the body, only the right view is given here.

Installation

Two bolts

Two bolts

One bolt
1. Water tank support assembly
2. Front longitudinal beam assembly (right)
3. Front bumper anti-collision beam assembly

• While installing new parts, install all parts at correct locations, in order to ensure that the sizes
of all parts are consistent with standard body after installation.
Pleacement of Panels IV-21

Ventilation Cover Plate Mounting Plate Installation Assembly


Disassembly

Two
bolts

Three
Three bolts
bolts

1. Ventilation cover plate mounting plate installation assembly


2. Front wall assembly

Installation

Two
bolts

Three
Three bolts
bolts

1. Ventilation cover plate mounting plate installation assembly


2. Front wall assembly

• While installing new parts, install all parts at correct locations, in order to ensure that the sizes of all parts are
consistent with standard body after installation.
Pleacement of Panels IV-22

Front wheel casing assembly


Disassembly

3 welds

4 welds 1

6 welds
6 welds

9 welds

3 welds

8 welds
Pleacement of Panels IV-23

4 welds

3 welds
1. Front wheel casing assembly (right)
2. Front longitudinal beam subassembly (right)
3. A-pillar lower inner panel assembly (right)
4. Front wall assembly

• Due to lateral symmetry of the body, only the right view is given here.

Installation

3 welds

4 welds 1

6 welds
6 welds

9 welds
Pleacement of Panels IV-24

3 welds

8 welds

4 welds

1. Front wheel casing assembly (right)


2. Front longitudinal beam subassembly (right)
3. A-pillar lower inner panel assembly (right) 3 welds

4. Front wall assembly

• While installing new parts, install all parts at correct locations, in order to ensure that the sizes of all parts are
consistent with standard body after installation.
Pleacement of Panels IV-25

Front longitudinal beam assembly


Disassembly

Rough cutting position

Internal cutting and


connecting positions

Rough cutting position

Internal cutting and


connecting positions

• Roughly shear as per the location shown in the figure to remove the damaged parts.
Pleacement of Panels IV-26

Installation

Rough cutting position

Internal cutting and


connecting positions

Rough cutting position

Internal cutting and


connecting positions

• To cut and connect new panels, cut as per the location shown in the above figure and scrape the cutting and
connecting locations of new panels.
• While installing new and used panels, place each part to correct location, in order to ensure that the sizes at
the connections are consistent with the body size diagram and standard sizes.
• Trial assemble the beam fasteners and used panels and then adjust the inner side of front longitudinal beam.
• Adjust and cut the outer side as per the location shown in the above figure and properly weld new parts. Pay
attention not to damage the outer sides of beam fasteners on the used parts.
• Grind each connection on the inner and outer sides with a grinding wheel and then complete the surface
treatment.
• The disassembly method is same for longitudinal beam assembly (left).
Pleacement of Panels IV-27

Front longitudinal beam and front floor connecting plate assembly


Disassembly

• Due to lateral symmetry of the body, only the right view is given here.

Installation

• While installing new parts, install all parts at correct locations, in order to ensure that the sizes of all parts are
consistent with standard body after installation.
Pleacement of Panels IV-28

Side wall front connecting plate assembly


Disassembly

• Due to lateral symmetry of the body, only the right view is given here.

Installation

• While installing new parts, install all parts at correct locations, in order to ensure that the sizes of all parts are
consistent with standard body after installation.
Pleacement of Panels IV-29

A-Pillar
Disassembly (Only the left view is given due to symmetry between left and right sides)

• Before the disassembly of pillar, firstly drill holes at zone (A) and disassemble the connectors between lower
side wall and front body.
• Disassemble lower and upper bolts (6 pieces) from the inner side.
• Drill holes at zone (B) and roughly cut at zone (C) and then disassemble the lower portion on the outer side of
the front pillar.
• Roughly cut and drill holes at zone (D) and disassemble the reinforcement parts.
Pleacement of Panels IV-30

Installation

• While splicing new and used panels, trial assemble the new panels and measure and adjust each part as per
the standard sizes of the body, in order to ensure that the locations of new parts are consistent with the
standard sizes.
• Before installing new parts, rivet, weld, and drill in advance. If there are three or four layers of panels such as
outer panel, reinforcement part, and inner panel, rivet, weld, and drill for all layers, except the innermost
inner panel.
• Firstly install the inner side and then install the outer side.
• Before the trial assembly of new parts, check and ensure the fit conditions of related parts.
Pleacement of Panels IV-31

B-Pillar
Disassembly

• Roughly cut at zone (A), drill at zone (B), and disassemble the lower portion of B-pillar outer panel.
• Cut and drill at zone (C) and disassemble the B-pillar reinforcement plate.
• Drill at zone (D) and disassemble the B-pillar inner panel.
• The inner panel and side wall outer panel reinforcement plate can be reused if they are not damaged during
disassembly.
Pleacement of Panels IV-32

Installation

• While splicing new and used panels, trial assemble the new panels and measure and adjust each part as per the
standard sizes of the body, in order to ensure that the locations of new parts are consistent with the standard
sizes.
• Before installing new parts, rivet, weld, and drill in advance. If there are three or four layers of panels such as
outer panel, reinforcement part, and inner panel, rivet, weld, and drill for all layers, except the innermost inner
panel.
• Firstly install the inner side and then install the outer side.
• Before the trial assembly of new parts, check and ensure the fit conditions of related parts.
Pleacement of Panels IV-33

C-Pillar
Disassembly (left and right)
Pleacement of Panels IV-34

14 Points

13 Points (A)

7 Points (B)

10 Points (B)
19 Points (B)

8 Points (B)
10 Points (B)

• Roughly cut at zone (A), drill at zone (B), and disassemble the rear part of B-pillar outer panel.
• The quantity of spot welds (B) is related to the cutting location.
• There are bonding points of spot welding sealant at the rear wheel casing.
Pleacement of Panels IV-35

Installation
Pleacement of Panels IV-36

14 Points

13 Points (A)

7 Points (B)

10 Points (B)
19 Points (B)

8 Points (B)
10 Points (B)

• Before the installation of new parts, add body sealant at the rear wheel casing (Refer to section Body Sealing
for application locations of sealant).
• Install new and used parts, trial assemble new parts, and measure all portions to ensure consistent sizes.
• Before the trial assembly of new parts, ensure the fit conditions of related parts.
Pleacement of Panels IV-37

Side Wall Lower Portion


Disassembly

• Roughly cut at zone (A), drill at zone (B), and disassemble the lower portion of outer panel.
• The change in quantity of spot welds (B) is related to the cutting and splicing locations.
• After drilling at zone (C), cut by segments to disassemble the side wall outer panel reinforcement parts
Pleacement of Panels IV-38

Installation

• While installing new parts, trial assemble and measure each part to ensure consistent sizes.
• After the trial assembly of new parts, ensure the fit conditions of related parts.
• Firstly install the inner panel and then install the outer panel.
Pleacement of Panels IV-39

C-Pillar Inner Portion


Disassembly (Only the left view is given due to symmetry between left and right sides)

Note: There is no plug welding point at right side.


Pleacement of Panels IV-40

1. C-pillar inner panel and wheel casing 2. C-pillar inner panel tier-2 assembly
connecting plate assembly
3. Pillar-C inner panel reinforcement plate 4. C-pillar inner panel tier-1 assembly
assembly
5. Rear wheel casing outer panel 6. Rear wheel casing tier-1 assembly
7. Rear wheel casing outer panel front
connecting plate
• Disassemble the outer panel before disassembling the inner panel. Please refer to section Repair of C-Pillar
Outer Panel for the detailed disassembly and installation of outer panel.
• Drill holes at zone (A) and disassemble the bolts (a) to disassemble the C-pillar inner panel.
• Drill at zone (B) to disassemble the C-pillar inner panel and wheel casing connecting plate assembly.
• Drill holes at zone (C) and plug welds to disassemble the wheel casing outer panel, rear wheel casing tier-1
assembly, and rear wheel casing outer panel front connecting plate.
• Drill at zone (D) and disassemble bolts (b) to disassemble the C-pillar inner panel reinforcement plate
assembly.
• Drill at zone (E) to disassemble C-pillar inner panel reinforcement plate assembly and C-pillar inner panel
tier-1 assembly.
• The left and right parts are symmetric, unless otherwise specified.

Installation
• While installing new parts, trial assemble and measure each part to ensure consistent sizes.
• After the trial assembly of new parts, ensure the fit conditions of related parts.
• Firstly install the inner panel and then install the outer panel.
Pleacement of Panels IV-41

Roof
Disassembly

1. Front top beam subassembly 2. Roof 3. Roof 1st crossbeam


4. 2# top beam 5. Middle top beam 6. Roof middle rear crossbeam
7. Roof rear crossbeam assembly

• While disassembling the roof, cut the damping sealant between roof and top beam.

Installation
• Before installing the roof, apply damping sealant to the locations shown in the figure.
• While installing new parts, conduct trial assembly to ensure good fit of related parts.
Pleacement of Panels IV-42

Roof (with Sunroof)


Disassembly

1. Front top beam subassembly 2. Roof with sunroof


3. Sunroof frame assembly 4. Middle top beam assembly
5. Roof middle rear crossbeam 6. Roof rear crossbeam assembly

• While disassembling the roof, cut the damping sealant between roof and top beam and sunroof frame.

Installation
• Before installing the roof, apply damping sealant to the locations shown in the figure.
• While installing new parts, conduct trial assembly to ensure good fit of related parts.
Pleacement of Panels IV-43

Rear Wall Panel Assembly


Disassembly

1. Side wall assembly (left) 2. Rear wall panel assembly


3. Side wall assembly (right) 4. Rear floor assembly

Installation
• Install with reference to the disassembly diagram.
• While installing new parts, adjust the installation locations to ensure consistency with the original body
locations.
• While installing new parts, ensure the good fit of all related parts (liftgate and rear bumper).
Pleacement of Panels IV-44

Rear Floor
Disassembly

31 points

15 points 15 points

4 points

1. Rear floor side plate (left) 2. Rear floor


3. Spare tire tray subassembly 4. Rear floor side plate (right)

Notice: While disassembling the rear floor, firstly disassemble the upper crossbeam of the rear floor.

Installation
• Install with reference to the disassembly diagram.
• Drill holes for plug welding before installation of new parts.
• During installation of new parts, measure the related sizes to ensure consistency with body sizes.
• After installation of new parts, ensure the tight fit of all related parts.
Pleacement of Panels IV-45

Rear Floor Fuel Tank Maintenance Panel


Disassembly

1. Rear floor fuel tank 2. Middle floor 3. Sponge sealing


maintenance panel strip

• During disassembly, disassemble the 1~4 screws in turn (same for left and right sides)

Installation
• While installing new parts, firstly install sponge sealing strips on the maintenance panel as per the location
shown in the figure.
• Place the maintenance panel with sponge sealing strip at the correct position and tighten the screws as per the
sequence 1~4 shown in the figure.
Pleacement of Panels IV-46

Rear Floor Upper Crossbeam Assembly


Disassembly

28 bolts and 8 nuts

1. Side wall assembly (right) 2. Child seat right mounting bracket assembly
3. Child seat mounting bracket 4. Child seat middle mounting bracket assembly
5. Rear floor upper crossbeam assembly 6. Child seat left mounting bracket assembly
7. Rear floor upper crossbeam connecting plate 8. Side wall assembly (left)
subassembly (left)

Installation

• While installing new parts, install all parts at correct locations, in order to ensure that the sizes of all parts are
consistent with standard body after installation.
Water-Proof and Rust-Proof Treatment V- 47

Chapter 5 Water-Proof and Rust-Proof Treatment


Sealing of Body
Apply sealant to the joints between panels, gaps of door panels, and edges of engine hood for the purpose of
water-proof and rust-proof.

Sealant Application Diagram for Complete Vehicle

Application of Sealant on Right Side of Engine Application of Sealant on Left Side of Engine
Compartment Compartment
Water-Proof and Rust-Proof Treatment V- 48

The application of sealant for right outer


side of front wheel casing is shown in
the figure and the left side is symmetric
to the right side.

The application of sealant for right inner


side of front wheel casing is shown in
the figure and the left side is symmetric
to the right side.

The application of sealant for inner side


of right shock absorber upper cover
plate is shown in the figure and the left
side is symmetric to the right side.
Water-Proof and Rust-Proof Treatment V- 49

Application of Sealant for


Interior of Body (Middle)

Application of Sealant for


Interior of Body (Rear)

Application of Sealant for Right Rear


Portion of Body (Symmetric between
Left and Right Sides)
Water-Proof and Rust-Proof Treatment V- 50

Application of Sealant on Bottom of Body


Water-Proof and Rust-Proof Treatment V- 51

Folded rubber The circles shown


in the figure denote
damping rubber.

Sealant
Folded rubber

Sealant

Damping rubber

Application of Sealant for Engine Hood

Folded rubber

Sealant
Structural sealant

Folded rubber
Structural sealant

Sealant

The circles shown


in the figure
denote damping
rubber.

Application of Sealant for Right Front Door (Symmetric between Left and Right Sides)
Water-Proof and Rust-Proof Treatment V- 52

Folded rubber Sealant


Sealant
Structural sealant

The circles shown in


the figure denote
damping rubber.
Structural sealant
Folded rubber

Application of Sealant for Right Rear Door (Symmetric between Left and Right Sides)

Folded
rubber
Folded rubber

Sealant
Sealant

Application of Sealant for Liftgate


Water-Proof and Rust-Proof Treatment V- 53

PVC Coating
The mounting holes within the sealant application zone shall be shielded for protection. The protection zone is
50mm×50mm.
The sealant application thickness is 2mm.

Front wheel
casing area

Floor area

Rear wheel
casing area

PVC coating