2008 GEELY MK lock

Fig. 5-11 Rear Door
1. Rear door inner panel 2. Rear door inner lock mounting panel 3. Rear door glass rail 4. Rear inner plate cross beam
5. Rear door outer panel 6. Door bumper assembly 7. Rear door lower hinge assembly
8. Rear door upper hinge assembly 9. Rear door inner plate hinge reinforced panel(3) Luggage Compartment Cover Assembly As shown in Fig. 5-12, the luggage compartment cover assembly includes luggage compartment cover outside
plate, luggage compartment cover inside plate, luggage compartment cover hinge mounting plate, and luggage
compartment cover lock core mounting plate etc. Fig. 5-12 Luggage Compartment Cover
1. Hinge torsion spring 2. Hinge mounting panel 3. Luggage compartment cover hinge
4. Luggage compartment cover inside panel 5. Luggage compartment cover outside panel
6. Luggage compartment cover lock core mounting panel1234568
79
1Survey -Body Structure7-8

II. General Repair Principle1. Precaution
(a) Vehicle Protection
In the welding process, make sure to protect the paint, windshield,
seat and carpet with heat-resistant and fireproof covering.
(b) Safety Measures
(1)When pulling the body or crossbeam with drawing device, do
not stand at the position in the same line of the drawing cable,
and make sure to use safe drawing cable.
(2)Before repairing, make sure to check whether there is any
leakage. In case of any hole, remove it immediately.
(3)When welding near to the oil tank, make sure to remove the
oil tank first, and block the oil pipe.
(c) Protective Article
In the repairing process, make sure to wear uniforms, helmet and
safety shoes. In addition, according to the different work types,
wear proper gloves, welding mask, goggle, earplug, face cover,
and dust respirator etc. Wear the protective devices properly as
the table below.Body Repair -Body Damage Forms and requirements For Repair7-11Seat covering Windshield
coveringWrongWrongItem
Dust Respirator
Mask
Goggles
Safety Shoes
Welded Goggle
Earplug
Welded Mask
Welded Gloves Code
A
B
C
D
E
F
G
H

The cave-in is mainly caused by collision and extrusion. For the light cave-in damage, the metal doesn't extend,
which is plastic deformation. If the collision or extrusion is serious, the metal plate will rupture. For the vehicles
running in the city, it is common that collision damage occurs on the side wall.
d. Bend & Distortion
Bend and distortion belong to mechanical damage. Bend and distortion may have a variety of causes, such as
collision or extrusion, alternating loads generated by the vibration, accident acceleration, emergency brake, sharp
swerve and body torsion caused by poor road.
For the light distortion, it shall be confirmed by test. For the serious bend and distortion, it is obvious in the
appearance. Generally, the distortion can be fixed according to the clearance of the frames and the change of their
relative positions.
e. Unsoldering
The unsoldering is caused by the poor fusion between different metal plates.
2. Outside Plate Repair
a. Repair for Crack
(a) CO2 Welding
The crack on the metal outside plate can be repaired by CO2 welding. In the welding process, align the two
metal plates, and weld the outside crack of the plate first. If the crack doesn't exceed 50mm, the welding shall start
from the rear part of the crack and continue along the crack and edge. If the crack is a little longer, several points
shall be welded first at a certain space. After welding several points, finish them and then weld the crack block
by block. By so doing, it can prevent the metal overroasting and plate deformation caused by too high temperature.
If the crack is located in the position that burden heavy force and it is convenient to carry out the welding operation,
a double-welding method can be used. After the spot welding is made outside, carry out the welding inside. After
the inside welding is completed, make the welding outside in the same manner.
After the welding, put a sizing block inside, and beat from the outside welding line with hammer to removeFig. 5-25 Concave Body Filling Repair b. Repair for Local Damage
For the local corrosion or serious mechanical damage on the outside plate, if it can't be repaired in common
method, the patching or pasting repair method can be used.
Repair Method:
(a). Fix the patching scope;
(b). Cut the paper sample;
(c). Cut the plate as per the sample;
(d). Adhere the molded plate on the surface of the patching part;
(e). Line out the profile along the plate edge with needlepoint, and cut off the damaged or corroded part;Body Repair -Repair After Body Damage7-18the retaining stress. Finally, finish the welding
seam properly to make it even and smooth for
painting.
(b) Solder Filling
For the fine concavo-convex plate with
damage and crack on its surface, it can be re-
paired with a solder filling method. (Fig. 5-25)

(f). Flatten the edge with hammer or sizing block, and remove the burr with file to make sure that it is aligned
with the both side alternative plates with a clearance not more than 1mm;
(g). Replace the plate, and clamp it with pincers. Carry out the spot welding along the seam at a space of
approximately 50mm;
(h). Make the welding from the center to both sides alternately block by block. Which can reduce the
deformation;
(i). Strike the welding line with the hammer or sizing block to remove the retaining stress. Polish the welding
lien wit the file or manual grinding wheel to make it even and smooth for the painting.
c. Repair for Accidented Damage
(a). Plate work flattening
When the accidented damage occurs on the plate work of the body, it can be repaired by means of beating.
In the repair process, start from Point C as shown in Fig. 5-26. Put the sizing block on the convex point, and beat
it with the hammer and change the block's position correspondingly. When the convex point is flattened, the
concaved part in Point B will rise. Similar wit the original profile of the plate, for the remaining dent, a sizing block
with the same radian can be employed. Press the bottom of the plate with hand, and beat the high point of the dent
with the hammer. (Fig. 5-27)Fig. 5-27 Plate Work Flattening (II)
A. Hammer B. Plate work
C. Sizing block Fig. 5-26 Plate Work Flattening (I)
A. Impact point B. Concaved point after impact
C. Convex point after impactFig. 5-28 Heating & Planishing
Convex Point
1. Heating pointBody Repair -Repair After Body Damage7-19 In the beating process, beat the work piece heavily at the beginning and lightly at the end. Attention shall
be paid to reduce the number of beating as possible as it can. Don't beat the same points repeatedly to prevent the
metal plate extending locally, which can complicate the repair work.
For the larger arc concave, a sizing block can be used under the center of the concave. The area of the sizing
block shall be a little larger. Jack the concaved plate up with a supporting tool. Sometime, heat the concaved part
to wine color to reduce the force. When jacking the plate up, a little excess is acceptable. (Fig. 5-28)
(b) Thermal contraction
When the concave is jacked up, if the plate extends seriously and the area is large, the thermal contraction
method can be used in case that the traditional methods don't work. (Fig. 5-29)
Heat the work piece to cerise color with oxyacetylene flame. The heating scope depends on the degree of extension.
If the extension is serious or the area is large, the heating point shall be larger relatively (diameter: approx.20-
30mm). If the extension is not serious or the area is small, the heating point shall be a little smaller (diameter:
approx.10-15mm). After the heating, beat the heating point immediately. In the beating process, a proper sizing
block is used under the plate. After it is cooled down, beat it lightly with the hammer.
The contraction starts from the highest point to the center, and then to the edge. Heat and flatten the extended
part repeatedly till the plate is flattened fully. If the convex part is too high, compress it to one half of the original
height. After it is cooled down, heat it at the original heating point till the other half of convex part is removed.

In addition, there are some other repair methods, such as beating repair (Fig. 5-31), plate reshaping repair
(Fig. 5-32), damaged plate work cutting repair (Fig. 5-33) and welding point cutting repair (Fig. 5-34).(a) Beating RepairFig. 5-31(b) Direct Beating on Deformed Surface(c) Edge & Corner Repair(d) Plane Repair
(a) Beating Modification (b) Check Fine Roughness with FileFig. 5-32Body Repair -Repair After Body Damage7-21Sizing block
Use sizing block
Knife
Knife
Steel plate
Start
Sizing block
FinishBeat
Hammer
Sizing block
Sizing block Hammer
BeatCheck evennessFile
Flexible file

If the collision is not serious and the concave belongs to elastic deformation, the plate can be returned to its
original shape by pressing from the inside surface.
For some concaved parts, they can be repaired in a prizing method. The prizing method is a repair method
that needs not to disassemble the parts. According to the degree of deformation, repair the plate by means of various
clearances and the lever principle. As the prizing method doesn't disassemble the parts, it can keep the original
installation quality and improve the work efficiency.
d. Repair for Unsoldering
The unsoldering is mostly caused by the poor fusion between the welding bar and the metal plate. For the
common unsoldering, weld the metal plate again after remove the welding bar accumulated in the welding line.
For the unsoldering of the spot weld, weld the metal plate near the unsoldered point with a single-side spot welder.The new welding point is about 10-15mm from the original point. Before the spot welding, remove the oil dirt andrust in the welding point to ensure the plates are jointed in a good status. For the unsoldering in some hems, after the two plates are jointed, weld the plates spasmodically on the edgesto make the plates joining together. The welding line at every block is about 30mm long. The line space depends
on the original welding space. Another repair method for the unsoldering is plug welding. This method needs CO2 welding. Bore a dia. 6mmhole on the outside plate, and then join the two plates. Weld the hole with the CO2 welding method. In the welding
process, the welding bare shall point to the inner plate and move in a circular manner, which can make the two plates
welded together. After the welding, finish and paint it.Body Repair -Repair After Body Damage7-23

Appendix: Body Key Dimensions1. Engine CompartmentAppendix-Body Key Dimensions7-38
(mm)
Item Description
Diameter of Hole
XY Z
A,a
Front fender installetion hole(Front)
7(M6 nut) -336.18 +/-652.5 580.69
B,b
Front absorber spring support hole(Inside)
10 1.09 +/-519.51 641.4
C,c
Front fender installetion hole(Rear)
7(M6 nut) 62.3 +/-661.71 665.72
D Cowl panel drip charnel fixing hole 7(M6 nut) 66.13 -1.2 648.7
E,e Collision sensor installation hole 9(M8 nut) -445.74 +/-436.17 273.26
F Braking pipe instaltion hole 7(M6 nut) -49 -418.74 309.12
f
ABS actuator installatim hole(front)
9(M8 nut) -48.64 417.53 291
G,g
Radiator upper crossmermber installation hole(front)
7(M6 nut) -589.94 +/-397 452.84
H,h
Radiator side insulation gasket installation hole
10x8-621.82 +/-403.33 94.99
I Hood lock bracket installation hole 7(M6 nut) -662.61 0 36.34
J,j
FR bumper horizontal installation hole
9(M8 nut) -651.68 -487.41 275.57
K,k
Windscreen fastener installation hole
11.5x8.7-849.35 +/-357.86 111.07
L,l
Radiator uppor crossmenber installation hole
7(M6 nut) -553.26 +/-392.02 502.18
M,m Hood hinge hole(Rear) 9(M8 nut) 149.64 +/-668.27 678.44
N,n Front fender support hole 10 -368.55 +/-704.84 379.94
O,o
Joint between side outerpanel and roof panel
£ ­ 202.21 +/-636.33 736.57
P,p
Joint between side outer panel and dash panel
- 851.59 +/-508.37 1092.37
A-D 771±2.5
4
a-D 771±2.5
B-c 1183±2.5
4
b-C 1183±2.5
B-D 522±2.5
4
b-D 552±2.5
C-M 89±2.5
c-m 89±2.5
D-E 771±2.5
4
D-e 777±2.5
D-L 746±2.5
4
D-l 746±2.5
N-O 1410±2.5
A-c 1376±2.5
4
a-C 1376±2.5
I-j 547±2.5
4
I-J 547±2.5
I-H 410±2.5
4
I-h 410±2.5
O-p 1360±2.5
4
o-P 1360±2.5
A-o 1408±2.5
4
a-O 1408±2.5
I-g 580±2.5
4
i-G 580±2.5
F-b 997±2.5
f-B 1088±2.5
L-c 1231±2.5
4
l-C 1231±2.5
Measuring
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