Haima S5 Body Repair Manual

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＇
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
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
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

• 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.
Engine hood lock bracket assembly

Disassembly
Two bolts
Two bolts

3. Engine hood lock bracket assembly
Installation
Two bolts
Two bolts

3. Engine hood lock bracket assembly
Water tank support assembly

Disassembly
Two bolts Two bolts
Two bolts
Two bolts
One bolt
2. Front longitudinal beam assembly (right)
Installation
Two bolts
Two bolts
One bolt
2. Front longitudinal beam assembly (right)
• 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.
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

Front wheel casing assembly

Disassembly
3 welds
4 welds 1
6 welds
6 welds
9 welds
3 welds
8 welds
4 welds
3 welds
1. Front wheel casing assembly (right)
2. Front longitudinal beam subassembly (right)
3. A-pillar lower inner panel assembly (right)
Installation
3 welds
4 welds 1
6 welds
6 welds
9 welds
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
Front longitudinal beam assembly

Disassembly
Rough cutting position
Internal cutting and

connecting positions

• Roughly shear as per the location shown in the figure to remove the damaged parts.
Installation


• 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).
Front longitudinal beam and front floor connecting plate assembly

Disassembly
Installation
Side wall front connecting plate assembly

Disassembly
Installation
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.
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.
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.
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.
C-Pillar
Disassembly (left and right)
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.
Installation
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.
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
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.
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.

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.
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.
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.
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).
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.
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.
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
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
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.
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)
Application of Sealant on Bottom of Body

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)
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

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

Haima S5 Body Repair Manual

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Haima S5 Body Repair Manual

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Body Repair Manual

HAIMA CAR CO., LTD.

Chapter 4 Replacement of Panels

Chapter 5 Water-Proof and Rust-Proof Treatment

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

The sizes are different between left and

Earplug Safety goggles

Cotton gloves Protective shoes

Guard against short-circuit

Removal of hazardous articles

Efficient Replacement of Body Panels

Disassembly of connected parts

Use of welding primer

Determination of welding methods Rough Cutting of New Parts

Drilling for CO2 shielded welding

Efficient Installation of Body Panels

 The spot welding points shall be staggered from

Precautions for spot welding

Inspection of welding strength

 As shown in the figure below, insert a chisel

Use of anti-rust agent M Metal

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

on the back surface of welding points.

Bottom of Body (Linear Sizes)

A/A＇ B/B＇ Measurement Dimension

A/A＇ B/B＇ C/C＇

Side Wall Framework

Name and Materials of Parts

No. Part name High strength steel

Chapter 4 Replacement of Panels

Two bolts Two bolts

1. Water tank support assembly

Two bolts Two bolts

1. Water tank support assembly

Engine hood lock bracket assembly

1. Water tank support assembly

1. Water tank support assembly

Water tank support assembly

Two bolts Two bolts

Ventilation Cover Plate Mounting Plate Installation Assembly

1. Ventilation cover plate mounting plate installation assembly

1. Ventilation cover plate mounting plate installation assembly

Front wheel casing assembly

1. Front wheel casing assembly (right)

4. Front wall assembly

Front longitudinal beam assembly

Rough cutting position

Internal cutting and

Rough cutting position

Internal cutting and

Rough cutting position

Internal cutting and

Rough cutting position

Internal cutting and

Front longitudinal beam and front floor connecting plate assembly

Side wall front connecting plate assembly

Side Wall Lower Portion

C-Pillar Inner Portion

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

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

Roof (with Sunroof)

1. Front top beam subassembly 2. Roof with sunroof

Rear Wall Panel Assembly

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