Ikco SAMAND User manual

SAMAND(XU7JPL3)
Service Manual
Body & Body repairs

Chapter: Section:
Product:
SAMAND XU7JPL3
Body Repairs
I
SAMAND
Service Manual
Foreword:
This Service Manual contains descriptions of the following categories for the
Samand:
Body and Body Repairs
This manual should be used as service manual and s workbook for
training instructors and technicians. We reserve the right to introduce
change without prior notice.

Contents
Body & body repairs
Technical data
Sound absorbing panels ................................................... 2
Glass adhesive & primer ................................................... 2
Body dimensions
Upper body ........................................................... 4
Rear body & side ....................................................... 6
Body B pillar .......................................................... 7
Underbody ............................................................ 8
Finish paints ........................................................... 9
Corrosion protection ..................................................... 10
Setting of badges ....................................................... 11
Special tools
SEFAC Jig Equipment ..................................................... 13
Bonded glass removal kit ................................................... 14
Bonding kit and Mastic gun ................................................. 14
Suction grips ............................................................ 14
Technical description
Body design ............................................................ 17
Crash and Safety ......................................................... 19
Reinforcement ........................................................... 21
Galvanised parts ......................................................... 22
Permissible joints ......................................................... 28
Pillar designations ........................................................ 30
Windscreen & rear window ................................................. 30
Window lifts ............................................................. 31
Door mirrors ............................................................ 31
Surface treatment ........................................................ 32
Sealant ................................................................ 34
Underseal (anti-chip) ...................................................... 36
Cavity sealant ........................................................... 38
Painting galvanised ....................................................... 40
Adjustment and replacement
Bodywork repairs ......................................................... 41
Checking the body dimensions .............................................. 41
Cutting ................................................................. 42
Welding ................................................................ 43
Welding galvanised sheet metal .............................................. 44

Primer ................................................................. 44
Method of Zinc coating Electro-zinc and galvanised panels for repair .................. 45
Jig Mounting ............................................................ 48
Replace front Subframe fixing nut. ............................................ 50
Complete front wheel arch replace ............................................ 52
Front wing inner panel & half front panel, plus front wing inner panel upper closing panel. . . 66
Replacing the front of a front side member and the front lower cross member ........... 71
Replacing a part front side member and a front wing inner panel side panel. ............ 77
Side member centre part replace ............................................. 83
Bodyside outer A pillar and reinforcement Front hinge replace ....................... 89
Right hand side member replacement (engine mounting bracket) ..................... 96
Windscreen pillar replace ................................................... 97
Replace a centre pillar and inner panel ........................................ 102
Outer sill panel replace ....................................................1101
Replacing a roof support ................................................... 116
Tail panel assembly replace ................................................. 118
Roof panel replace ....................................................... 120
Replacing a rear wing without removing the rear screen ............................ 126
Replacing a rear wing cutting the rear quarter panel ............................... 133
Replacing a part wheel arch assembly ......................................... 140
Replacing a part rear floor assembly .......................................... 150
Part rear side member repair ................................................ 157
Hood .................................................................. 163
Hood hinge ............................................................. 163
Hoodstay .............................................................. 164
Hood stop adjustment ..................................................... 164
Hood release cable ....................................................... 165
Hood Latch ............................................................. 166
Hood release pull ......................................................... 166
Front wheel arch ......................................................... 167
Front fender ............................................................. 168
Doors ................................................................. 169
Door striker ............................................................. 170
Front door glass ......................................................... 171
Front door electric window lift regulator ........................................ 172
Front door front slide ...................................................... 174
Door mirror glass ......................................................... 175
Front door electric mirror ................................................... 176
Rear door fixed glass ...................................................... 177
Door check arm .......................................................... 178
Door key lock ........................................................... 179
Door latch .............................................................. 181
Door moulding ........................................................... 184
Front window glass ....................................................... 185
Rear window glass ....................................................... 186
Trunk lid ............................................................... 187

Trunk lid adjustment ...................................................... 192
Trunk lid lock striker ....................................................... 193
Trunk lid latch ........................................................... 194
Trunk lid lock cable ....................................................... 195
Trunk lid key lock ......................................................... 197
Trunk lid lock motor ....................................................... 199
Trunk lid finisher trim ...................................................... 200
Fuel Filler Flap ........................................................... 201
Front bumper ............................................................ 202
Rear Bumper ............................................................ 205
Front structure/cooling pack ................................................. 207
Seals .................................................................. 210
Hood seals ............................................................. 210
Door seals .............................................................. 211
Trunk lid seal ............................................................ 212
Gutter seal .............................................................. 212
Door rubbing strip protectors ................................................ 213

Body & body repairs
1
Samand

Samand
2Technical data
Technical data
Sound absorbing panels
Area Type No.
Front door LH/RH Magnetic noise proof 1
Rear door LH/RH Magnetic noise proof 2
Rear quarter LH/RH Magnetic noise proof 3
Adhesive & primer used when changing glass
Adhesive kit (window glass) PVC sealing & wedging product 8142600
Paint primer ?
Area Type No.
Front floor Fusible self-adhesive sound damping 5
Front floor L/H Fusible self-adhesive sound damping 6
Front floor R/H Fusible self-adhesive sound damping 7
Central floor Fusible self-adhesive sound damping 8
Trunk floor L/H Fusible self-adhesive sound damping 9
Trunk floor R/H Fusible self-adhesive sound damping 10
Trunk floor L/H Fusible self-adhesive sound damping 11
Trunk floor R/H Fusible self-adhesive sound damping 12
Trunk floor L/H Fusible self-adhesive sound damping 13
Trunk floor R/H Fusible self-adhesive sound damping 14
Area Type No.
Roof Magnetic noise proof 4

3
Samand
Technical data
W78D001

Samand
4Technical data
Body Dimensions
Measurements, upper body
These measurements are suitable for determining if the car should be mounted in an alignment bench.
Item Dimension (mm) Description
1 4128.2 Total length (Body less closures)
2 814.8 FRT Fender fixing hole LH, Hole for air intake clips LH
3 889.5 FRT Fender fixing hole LH, Hole for air intake clips (Middle)
4 1338 FRT Fender fixing hole LH, Hole for air intake clips RH
5 1220 FRT Fender fixing hole LH & RH
6 486.1 Hole for FRT suspension cap LH, Hole for air intake clips (Middle)
7 1128.8 Hole for FRT suspension cap LH & RH
8 1335.3 Lower section of A pillar, Upper section of A pillar
9 1429 Distance between sill INR section LH & RH

5
Samand
Technical data
W78D002
1
9
8
547
3
2

Samand
6Technical data
Measurements, rear body and side
W78D003
16
12,13
15
16
13
11 12
10
Item Dimension (mm) Description
10 1104.2 Upper hole for FRT hinge fixing, Lower hole for RR hinge fixing
11 1175 Lower hole for FRT hinge fixing, Upper hole for RR hinge fixing
12 1017.3 Lower hole for RR hinge fixing, RR door lock striker
13 914.8 Upper hole for RR hinge fixing, RR door lock striker
14 1189 Distance between lower rear corner of PNL RR QTR OUT LH & RH
15 1160 Distance between RR bumper fixing LH & RH (PNL RR OUT)
16 1232.9 Lower rear corner of PNL RR QTR OUT LH, RR bumper fixing hole RH (PNL RR OUT)

7
Samand
Technical data
Measurements, body B pillar
17
18
17
18
17
17
W78D004
Item Dimension (mm) Description
17 1375.2 Hole for trim part fixing RH, Hole for jig location of PNL B PILLAR INR LH
18 1345 Hole for trim part fixing on PNL B PILLAR INR LH & RH

Samand
8Technical data
Measurements, underbody
W78D005
23
22
19
21
20
26
24 25
27
Item Dimension (mm) Description
19 1293.2 Hole in Xmember Radiator support RH, Floor REINF LH (location hole)
20 1096.3 Hole in Xmember Radiator support LH, Floor REINF LH (location hole)
21 600 Hole in Xmember Radiator support LH & RH
22 784 Hole in floor REINF LH & RH (location hole)
23 1394.4 Distance between sill INR section LH & RH
24 1186 Distance between RR axle REINF hole LH & RH
25 879 Distance between RR side rail hole LH & RH
26 1519.6 Hole in RR axle REINF LH, Hole in RR side rail RH
27 1170.5 Hole in RR axle REINF LH, Hole in RR side rail LH

9
Samand
Technical data
Finish paints
Colour code Colour Paint Type Model Year
9995 G Black Metallic 2001
7919 T Graphic Grey Metallic 2001
7911 H Silver Metallic 2001
5985 T Royal Blue Metallic 2001
63012 Beige Metallic 2001
3905 Bright Violet Metallic 2001
IMPORTANT
Always quote colour code when ordering paint.
WARNING
Chemical products like paint, adhesives, primer etc should be handled with care and stored and used according to
regulations.
Always read the warning labels and directions for use on the product packaging before commencing work.

Corrosion protection products
Primer
Welding primer
Sealant
Underseal (anti-chip)
Cavity sealant
Samand
10 Technical data

11
Samand
Technical data
Setting of badges
17.5
0.5 0.5
17.5
W78D006
C
25

Special tools
13
Special tools
Samand
SEFAC Jig Equipment
Universal Components SEF 2081
1 .SUV 200
2 .SUV 148-.SUV 600
3 .SUV 240
4 .SUV 100
5 .SUV315
6 SUV 140
7 .SUV 215
8 .SUV 350
9 .SUV 300
T.JIG
1
10 315 7
11 18 17
16
8
13 14 6
5
4
12
9
2
Specific Adapters SEF 2082
10 1D1G AM-SM
11 2D2G SM
12 3D3G SM
13 4D4G AM-SM
14 5D5G AM-SM
15 6D6G AM-SM
16 7D7G AM-SM
17 8D8G SM
18 9D9G AM-SM

Samand
14 Special tools
Bonded glass removal kit
FE 127511
Bonding kit and Mastic gun
Bonding kit 9798.62
Mastic gun 9798.41
Suction grips
9798.66
W78R058
W78R059
W78R060

15
Special tools
Samand
There are no specific IKCO Special Tools for body repair but all commercially available tools for body repair such as
welding equipment, grinders and welder are acceptable.
T.COMM.

Technical description
Body design
17
Technical description
Samand
W78S001
The body structure greatly influences the major characteristics of a vehicle such as crashworthiness safety, durability,
noise and vibration control performance and so on. To fulfil these decisive features, several efforts should be carried
out in the body design process down to the smallest detail. In X7, body structure has been designed based on following
requirements:
Serviceability
Torsion bending tests and analysis have been accomplished to satisfy the passengers comfort and prevent any
probable plastic deformations under service loads. In addition, based on modal and joint stiffness investigation and
component modification, the whole body frequencies have been adjusted to an acceptable range.
Durability
Several thousand kilometres have been covered in road tests, combined with a variety of component fatigue
investigations have led to a robust design, which maintains body integrity during the lifetime of the vehicle