Ikco XU7JPL3 - Page 2

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Chapter:

Section:

Product:

SAMAND

XU7JPL3

Body Repairs

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.

Main Page

Contents3
Body & Body Repairs6
Technical Data7
Body Dimensions9
Measurements, Rear Body and Side11
Measurements, Body B Pillar12
Measurements, Underbody13
Finish Paints14
Setting of Badges16
Special Tools17
Technical Description20
Body Design20
Safety22
Reinforcement23
Galvanised Parts24
Permissible Joints30
Pillar Designations32
Windscreen and Rear Window32
Window Lifts33
Door Mirrors33
Surface Treatment34
Corrosion34
Sealant36
Underseal (Anti-Chip)38
Cavity Sealant40
Painting Galvanised Sheet42
Adjustment and Replacement43
Bodywork Repairs43
Checking the Body Dimensions43
Cutting44
Welding45
Grinding45
Welding Galvanised Sheet Metal46
Primer46
Method of Zinc Coating Electro-Zinc and Galvanised Panels for Repair47
Preparing the Surface47
Choice of Anode48
Setting up48
Depositing Zinc49
Jig Mounting50
Replace Front Subframe Fixing Nut52
Complete Front Wheel Arch Replace54
Cutting Damaged Panels57
Replace Front Wing Inner Panel and Half Front Panel68
Replacing Front of a Front Side Member and Front Lower Cross Member73
Replace Part Front Side Member and Front Wing Inner Panel Side Panel79
Side Member Centre Part Replace85
Bodyside Outer a Pillar and Reinforcement Front Hinge Replace91
Right Hand Side Member Replacement (Engine Mounting Bracket)98
Windscreen Pillar Replace99
Replace a Centre Pillar and Inner Panel104
Outer Sill Panel Replace112
Replacing a Roof Support118
Tail Panel Assembly Replace120
Roof Panel Replace124
Replacing a Rear Wing Without Removing the Rear Screen128
Replacing a Rear Wing Cutting the Rear Quarter Panel135
Replacing a Part Wheel Arch Assembly142
Replacing a Part Rear Floor Assembly152
Part Rear Side Member Repair159
Hood Removal165
Hood Fitting165
Hood Hinge Removal and Fitting165
Hood Stay Removal and Fitting166
Hood Stop Adjustment166
Hood Release Cable Removal167
Hood Latch Removal and Fitting168
Hood Release Pull Removal and Fitting168
Front Wheel Arch Removal and Refitting169
Front Fender Removal and Refitting170
Doors Removal and Refitting171
Door Striker Adjustment172
Front Door Glass Removal173
Front Door Glass Refitting174
Front Door Electric Window Lift Regulator Removal and Refitting175
Front Door Front Slide Removal and Refitting176
Door Mirror Glass Removal and Refitting177
Front Door Electric Mirror Removal and Refitting178
Rear Door Fixed Glass Removal and Refitting179
Door Check Arm Removal and Refitting180
Door Key Lock Removal and Refitting181
Door Latch Removal and Refitting183
Door Moulding Removal and Refitting186
Front Window Glass Removal and Refitting187
Rear Window Glass Removal and Refitting192
Trunk Lid Removal and Refitting193
Trunk Lid Adjustment194
Trunk Lid Lock Striker Removal and Refitting195
Trunk Lid Latch Removal and Refitting196
Trunk Lid Lock Cable Removal and Refitting197
Trunk Lid Key Lock Removal and Refitting199
Trunk Lid Lock Motor Removal and Refitting201
Trunk Lid Finisher Trim Removal and Refitting202
Fuel Filler Flap Removal and Refitting203
Front Bumper Removal and Refitting204
Rear Bumper Removal and Refitting207
Front Structure/Cooling Pack Removal and Refitting209
Seals Removal and Refitting212
Door Rubbing Strip Protectors Removal and Refitting215

Ikco XU7JPL3 - Page 2

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