Haima M3. Body Repair Manual - part 1

 

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. 

 

 

 

 

 

 

 

 

 

 

Overview I-1 

 

 

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 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.  

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

 

 

Name 

Chapter 

Overview 

Ⅰ 

Sizes 

Ⅱ 

Structure 

Ⅲ 

Replacement of Panels 

Ⅳ 

Water-Proof and Rust-Proof Treatment 

Ⅴ 

 

 

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 

type, number of welds, and shearing-cutting 

locations for the body sheet metal parts. This 

information is of great importance for the 

disassembly and installation of the sheet metal 

parts.  

 

The welding types and locations are indicated by 

symbols.  

 

The relevant operation precautions are given in 

some sections. Please carefully read and 

understand these precautions before any operation 

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 

 

Spot welding 

 

 

Continuous MIG welding 
(shearing-connecting location)   

 

CO2 gas shielded arc welding (plug 
welding) 

 

Braze 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 

two standard points.   

 

The standard points and sizes are symmetric with 

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 

Layout of workshop 

 

The layout of workshop is of great importance to 

the safety and working efficiency.   

Protection of vehicle   

 

Use the seat and floor covers.   

 

Use the insulation shield, in order to prevent the 

heat and spark from damaging the glasses and 

seats during welding.   

 

Protect the accessories including trims and 

insertion strips during welding.   

 

Use of Traction Apparatus     

 

When a traction apparatus is used, the working 

personnel shall keep away from the working zone 

and take cautions in suing the safety cable.   

 

 
 
 
 
 
 

 
 

Precautions  

During working, wear safety helmet and safety 

protective shoes to prevent injuries. Wear protective 

articles depending on the working characteristics, 

including gloves, protective goggles, earplugs, and 

mask.  

 

Welding 

goggles  

 

Dust-proof 

mask 

 

Earplug  

 

Safety goggles 

 

Welding gloves 

 

Mask  

 

Cotton gloves 

 

 

Protective shoes 

 

Guard against short-circuit   

 

While disassembling the wires or electric 

apparatus, disconnect the negative cable of 

battery.  

 

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   

Efficient disassembly of body panels   

Measurement of body   

 

Before the disassembly or rough cutting, firstly 

measure the damaged body portions and their 

surroundings as per the standard reference sizes. 

Upon detection of deformation, conduct initial 

correction with frame repair device.   

 

Guard against body deformation   

 

Disassemble with fixtures or jack and reinforce 

the portions to be roughly cut and their 

surroundings, in order to prevent body 

deformation.  

 

 
 
 
 
 
 
 

 
 
Selection of cutting and welding portions   

 

For the parts impossible for complete 

replacement, adopt the cutting and welding 

methods and operate with cautions. To cut the 

portions without reinforcement ribs, select the 

locations yielding to minimum welding 

deformation for cutting.   

 

 
Disassembly of connected parts   

 

While disassembling the connected parts, protect 

the insertion strips, trims, and parts with pipes.   

Rough cutting of damaged panels   

 

Ensure that there is no damaged part due to heat 

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 

and other substances from new parts and welding 

portions and then apply welding primer.   

 

Determination of welding methods   

 

If the overall thickness of weld points is higher 

than or equals to 3mm(0.12in), adopt CO2 

shielded welding for rivet welding.   

 

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} 

 

 

 

 

 

 

 

Grind the hatched portion shown in the figure below, 

drill a hole on 3~4 pieces of metal panels stacked 

together, and weld tightly together these metal 

panels, in order to eliminate the further development 

of gap.   

 

 

Rough Cutting of New Parts   

 

For cutting and splicing portions, leave 

overlapping parts of 30~50mm {1.18~1.97in} on 

the body side and then roughly cut the new parts.   

 

 

 

 

 

 

 

 

 

 

 

Overview I-7 

 

 

Efficient Installation of Body Panels 

Observation and checking of pre-welding sizes   

 

Adjust the standard sizes as per the body size 

descriptions and install new parts to correct 

positions.  

 

Welding precautions   

 

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. 

 

 

 

 

 

As the shape of welding head of the spot welding 

machine influences the welding strength, always 

maintain the welding head under best status.   

 

 

The spot welding points shall be staggered from 

the original welds.   

 

Before the welding, use a material same with that 

of the body for a welding test, in order to inspect 

the welding strength.   

 

 
 
 
 
 
 

 

Overview I-8 

 

 

Inspection of welding strength   

 

The mounting portions for engine, chassis, and 

seat belt are significant safety portions in terms 

of the welding strength. Insert a chisel between 

the plates in spacing of 4 or 5 welding points and 

in spacing of 10 common welding points to 

inspect the welding strength.   

 

 

As shown in the figure below, insert a chisel 

between the plates as per the quantity of plates.   

 

 

 

 

Insert a chisel between plates to check the 

separation of plates, in order to determine the 

welding strength. If the plates are separated, 

weld once again near the previous welding 

position.  

 

Correct the shape of the checked portion.   

 

 

 

 

 

 

 

 
 
 
 
 
 
 
 
 
 
 
 
 
 

 
 
 
 

 

Overview I-8

 

 

 

Sealing of Body   

 

Apply the body sealant at the needed locations   

 

For the portions difficult to apply sealant after 

the installation, apply the sealant before the 

installation.  

 

Application of Primer   

 

Use the primer at the needed locations.   

 

Use of anti-rust agent   

 

Apply anti-rust agent (paraffin and machine oil) 

on the back surface of welding points.   

 

 

 

 

Use of Sound Insulation Floor   

 

Adopt the sound insulation layer.   

 

Acronym 

Fr Front 

 

Rr Rear 

 

RH Right 

LH Left 

Ctr Center 

 

G/E Gasoline 

engine 

D/E Diesel 

engine 

M Metal 

MC Mica 

 

 

 
 
 

 

 

  

                                                     

Dimensions 

II-1 

 

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 .............................................................................................................................................................................. II-8 

 

  

                                                     

Dimensions 

II-2 

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 

symbol

 

Name

 

Dimension

 

Point 

symbol

 

Name

 

Dimension

 

A 

Datum hole of front 
anti-collision beam

 

Φ9 

F 

Auxiliary datum hole 
of front car body

 

Φ18 

B 

Main datum hole of 

Φ16 

H 

Main datum hole of 

Φ16 

  

                                                     

Dimensions 

II-3 

front car body

 

rear floor assembly

 

C Mounting 

hole 

of 

front suspension

 

Φ82 

I 

Auxiliary datum hole 
of rear floor assembly

 

Φ18 

D Mounting 

hole 

of 

front frame

 

M14 

J 

Datum hole of rear 
tail board

 

Φ16 

E Mounting 

hole 

of 

front frame

 

M14  

 

 

Linear Dimensions 

Car Underbody 

 

 

  

                                                     

Dimensions 

II-4 

Front Car Body 1 

 

  

                                                     

Dimensions 

II-5 

Front Car Body 2