Saipa 141 Operating instructions

In the name of Gad
SAIPA 141
Maintaining and repairing manual
Body and trimming

2
SAIPA141 / Maintaining and repairing manual Body and trimming

3
SAIPA141 / Maintaining and repairing manual Body and trimming
CONTENTS
Preface …………………………………………………………......................……….. 5
Troubleshooting tables ……………………………………….....................……….... 9
Cutting line positions after the crash ……………………………....................…… 10
Repairing
Body
Smoothing tool ……………………………………………………..............………… 11
Assembling and disassembling of the engine hood ……………..........…….……. 16
Regulating the engine hood ………………………………………............………… 17
Assembling and disassembling of grill and front and rear logo …………........…. 18
Assembling and disassembling of trunk lid and fuel caps opener ………......….. 19
Assembling and disassembling front bumper …………………………….......…… 20
Assembling and disassembling rear bumper …………………………….......……. 22
Assembling and disassembling of rear door retainer lever ………………....……. 23
Assembling and disassembling of doors glass ……………………………...…….. 24
Opening the front and rear doors lock ……………………………………….......… 25
Assembling and disassembling of front door body ………………………......…… 26
Assembling and disassembling of tab of the doors lock …………………........…. 27
Assembling and disassembling of the rear door triangle glass …………............. 27
Assembling and disassembling of fender ………………………………….....……. 28
Assembling and disassembling of front and rear lamps …………………........…. 30
Assembling and disassembling of front and rear glass ………………….......…… 34
Assembling and disassembling of windshield ……………………………........….. 39
Assembling and disassembling of side mirrors ……………………...........………. 40
Assembling and disassembling of tape ………………………………........………. 41
Assembling and disassembling of side tapes ………………………….......……… 42
sealering place ……………………………………………………………….........…. 44
Installing the damaged parts ………………………………………………..........…. 46
Welding types ………………………………………………………………..........….. 48

5
SAIPA141 / Maintaining and repairing manual Body and trimming
PREFACE
This manual is prepared by the engineers of SAIPAautomotive manufacturing group to help
the engineers and technicians of the 141 vehicle.
It is recommended that the repairmen and technicians carefully study this book and follow
its repair instructions. By doing so, the time will be saved and the quality of repairing will be
increased.
Finally, it is requested from all the readers to kindly submit their invaluable comments about
this book to the management of SAIPAYADAK company engineering department.
SAIPA group

Body Manual

8
SAIPA141 / Maintaining and repairing manual Body and trimming

9
SAIPA141 / Maintaining and repairing manual Body and trimming
Trouble shooting tables
Bumper
Defect type Probable cause Remedy
Damage of bumper crust Crash Replace
Damage and crushed of
Bumper foam Crush or improper atmospheric condition Replace
Damage of bumper
reinforcement Crush Replace
Damage of bracket and
connections Crush Replace or repair
Looseness and
separation of connection Crush or vibration Replace
Defect type Probable cause Remedy
Malfunction of seat belt lock Damage of spring or the
dirty of interior mechanism Replace lock set
Malfunction of releasing
button of belt lock Malfunction of lock mecha-nism Replace retainer set
erosion of belt strap Crush between door and
body Replace retainer set
Malfunction of retaining
spring Exhaustion or crash Replace retainer set
Incomplete retaining of
safety belt strip Defective spring Replace retainer set
Seat belt does not open
completely Malfunction of mechanism Replace retainer set
Seat belt does not retain Exhaustion or impact Replace retainer set
Seat belt does not open Fractured mechanism Replace retainer set
Looseness of lock
connection Crush or vibration Tighten bolts up to standard
Looseness of belt retaining Crush or vibration Tighten bolts to standard
Looseness of belt to pillar
connections Crush or vibration Tighten bolts to standard
Malfunction of seat beet
caution light Malfunction of light or harness Replace harness if fail replace the defected part

10
SAIPA141 / Maintaining and repairing manual Body and trimming
X=2920 mm
X=2260 mm
X=1990mm
X=2640mm
Cutting line positions after the crash
Side panel Cutting line of X141 vehicle

11
SAIPA141 / Maintaining and repairing manual Body and trimming
Rasping tool for removing ripple
Grind Stone Tool
Planish general tools
The general tool for catching & moving the
glass.
General Tools

12
SAIPA141 / Maintaining and repairing manual Body and trimming
Wired brush
Oxygen and acetylene capsule
Spray Gun
Specic tools

13
SAIPA141 / Maintaining and repairing manual Body and trimming
Clasp to hold , two together parts
Shears for cutting metal sheets
Sealant pump general tool
Specic tool

14
SAIPA141 / Maintaining and repairing manual Body and trimming
Special pincer for separating spot weld
Planish pump general tool
Clips to hold, body parts
Specic tool

15
SAIPA141 / Maintaining and repairing manual Body and trimming
Some types of planish general tool
(Planish stic)
Specic tool

16
SAIPA141 / Maintaining and repairing manual Body and trimming
3- Open the glass cleaner hoses.
(As shown in the g.1)
2- Tag the engine hood hinge in order to
reinstalling.
Assembling and disassembling of the
engine hood
1- To open the engine hood, get help from
someone. Open the engine hood and hold
it with the retainer lever.
Assembling and disassembling of parts

17
SAIPA141 / Maintaining and repairing manual Body and trimming
Assembling and disassembling of parts
Regulating the engine hood
Loosen the hinge screws and regulate the
engine hood in the front, back, right and left
direction, and the regulate the engine hood
lock, follow the instruction:
Loosen the door lock screws and lineup it
with engine hood. (As shown in g.3)
Assembling and disassembling of parts
4- Bring out the engine hood hinge and en-
gine hood by opening its crews.
Attention:
For assembling the engine hood follow the
aforementioned inverse, but pay attention
that the engine hood is in its right place af-
ter installing.

18
SAIPA141 / Maintaining and repairing manual Body and trimming
Assembling the front logo
Logo and the strip are stock on the grill by
means of glue or plastic welding.
Assembling and disassembling of grill
When assembling the grill, rst install its
fasteners on the grill then align the grill with
the holes and push it to the blanks.
Assembling and disassembling of parts

19
SAIPA141 / Maintaining and repairing manual Body and trimming
2- Detach the lever wire from the trunk lid
lock.
3- Open the fuel cap and detach the mount-
ing nut.
Now disassemble the assembly (Assem-
bling is the inverse of the disassembling).
Assembling and disassembling the
trunk lid and fuel cap opener lever
1- Open the mounting bolt and then cut the
trunk lid and fuel cap wires.
Assembling and disassembling of parts

20
SAIPA141 / Maintaining and repairing manual Body and trimming
5- Open 5 plugs on the lower part of the
bumper.
4- Open the connection screws between
bumper and connection bar and fender as
shown in the picture.
Assembling and disassembling front
bumper
The method of front bumper Disassembling
1- You need to open the grill in order to
opening the front bump and front lamps.
(see the disassembling of grill and lamps)
2- It is needed to put the vehicle on the jack
for opening the bumper completely.
3- Open the upper connections.
(4 screws and 3 plugs)
Assembling and disassembling of parts