2008 GEELY MK engine

Chapter 2 Body RepairSection 1 Body Damage Forms and requirements For RepairI. Damage Type The damage type includes deformation, crack, rust-through, water leakage, dust leakage and the like caused
by collision, overload, fatigue, and corrosion.
The body damage is not merely caused by the huge force. As some parts (such as door etc.) are damaged, the
vehicle stays in an abnormal status, which also can cause damage. In most cases, the bend and torsion is caused
by huge local load in the impact or turnover accident.
Typical Body Damage:
1. Front Center Collision (Fig. 5-13)Fig. 5-13 Front Center CollisionBody Repair -Body Damage Forms and requirements For Repair7-9 For the damage caused by the collision on the front center, it usually makes the engine compartment front part
and the engine hood left/right side extend inwards so the following positions shall be checked:
a. Ambience of the left/right assembling position of the hood plate
b. Ambience of the joints of the front cross beam and the left/right longitudinal beam
2. Front External Force or Left External Force (Fig. 5-14)Fig. 5-14 Front External Force or Left External Force As shown in Fig. 5-14, when the front is pressed or the left side end is acted by the external force, the external
force will spread to around the front suspension mounting position from the left/right side of the hood, so
deformation occurs easily in this position.

Plate Thickness Hole Diameter
<1.0 >5
1.0~1.5 >6.4
>1.5 >87-13 (b) Apply special paint for spot welding
Remove the paint film from the new parts to be welded and the
body, and apply the special paint for spot welding.
(c) Bore for hole-filling welding
In the position that can not carry out the spot welding, bore it
with borer or bit to make hole-filling welding.
Unit: mm
(d) Precaution for electronic parts
(1) In the welding process, the electronic parts may be damaged
due to the current in the body.
(2) Before the welding, cut the cathode connection of the
storage battery, and put the ground end of the welder on the
ambiance of the welding area.
(e) Rough cutting of joint parts
In the rough cutting process in the connecting area, an overlap
of 20~30mm must be reserved on the new parts.
3. Installation
(a) Measure before Welding
Before installing the lower body or the parts of the engine
compartment, make sure to make measurement as the body
dimension drawing, to ensure the correctness. After the
installation, reconfirm whether the assembling is proper.Hole filling
Overlap
Pneumatic saw
Body dimension
drawingBody Repair -Body Damage Forms and requirements For Repair

7-14 (b) Precaution
(1) For the number of spot welding, it depends on the following
principles.
S pot welding:1.3 times of the number specified by the manufacturer
Hole-filling welding: more than the number specified by the
manufacturer
(2) When carrying out the hole-filling welding, MIG welder
shall be used. It is not allowed to use the oxyacetylene
welding or braze welding outside the specified area.
(c) Abrasion after welding
(1) After the welding, make sure to check the welding position
whether it is welded firmly.
(2) When abrading the welding position with disc abrader,
never abrade it too much, which may weakens the strength
of the welding position.
(d) Precaution of spot welding
(1) The shape of the spot welder head may affect the strength
of the welding.
(2) Make sure to remove the paint film on the surface of the spot
welding and the contact surface of the welder head.
(e) Position of spot welding
In the spot welding process, overlap with the old welding
position shall be avoided.
4. Anti-rust Processing
(a) Apply sealant
In the waterproof and antirust part operation, make sure to
apply the sealant on the joint of the steel plates,door,and engine
hood corner.Wrong CorrectWrong
Spot welding head scraper
New welding position
Old welding
positionSealant gunBody Repair -Body Damage Forms and requirements For Repair

5. Base Anti-rust Processing
Impact-proof Coat
In order to avoid corrosion and protect the body from being damaged by bouncing stone on the road, a layer
of impact-proof coat is applied on the door threshold plate, arc area and balancing plate etc.
Tips: There are two types of painting: impact-resistant coat on the electrophoresis primer or on the surface paint
according to different types and painting positions. (See Fig.5-22)7-15IV. Repair Requirement 1. As the body is an integral structure and the steel plates used are not thick, special attention shall be paid to
reinforce the parts acted in the reshaping process in the plate work processing. For the parts that burden the stress
intensively, measures shall be taken to lower the local stress.
2. After the plate work processing, note to apply the antirust primer on the inside and outside surfaces to avoid
corrosion.
3. In the body repair process, repair the old parts; or remove the parts with serious defects and order new parts
from the manufacturer.
4. When making body reshaping or parts welding, make sure that all main control points of the body are within
the specified scope in the design.
5. The strength and serviceability of the repaired body shall not be lower than those of the new vehicle.
6. The outside decoration of the repaired body shall meet the requirements by the new vehicle body and the
drivers in various aspects, such as modern aesthetics and ergonomics etc. (b) Apply primer
In order to prevent rust and protect the body steel plate from
being damaged by the bouncing stone, sufficient primer is
applied onto the body base and inner wheel cup.
(c) Apply antirust (wax)
In order to prevent the painting part from rusting, sufficient
antirust is applied on the engine cover, door inner corner, hinge
ambiance, or in the inside welding part of the box section
structures such as side beam, body post.Fig. 5-22 Apply the impact-proof coat on the surface paint
Impact-proof coat
Surface paint
Intermediate primer
Electrophoresis primer
Steel sheet Apply the impact-proof coat on the electrophoresis primer
Surface paint
Intermediate primer
Impact-proof coat
Electrophoresis primer
Steel sheetBody Repair -Body Damage Forms and requirements For Repair

1. Material of Punch Piece
In order to improve the body's rigidity, high-strength steel plates are used at many key parts on the body. For
the parts under forces, reinforced measures are carried out. (Fig. 5-36)Fig. 5-36 High-strength Steel Panel
1. Engine compartment hood outside panel
2. Left/right fender
3. Left/right mid-door post inside panel
4. Luggage cover outside panel
5. Left/right door outside panel12
3
45Body Repair -Features and Composition of Automobile Body7-24Fig. 5-35 Outline & DimensionsSection 4 Features and Composition of Automobile BodyI. Body Feature The body is an integral structure. Its main structure also is a frame, which can carry all loads. The vehicle is
designed with three compartments and five doors. With the same overall length, the space is utilized fully, which
is helpful to arrangement of passengers. (Fig. 5-35)
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1934.5 1450
4343 848 2502 992

2. Shock Absorption & Noise Isolation
(1) Body structure (Fig. 5-37)
a. Arrange the reinforced bar reasonably to improve the parts' rigidity, reduce the shock and lower the noise.
b. Apply the sealant in the floor seam to improve the floor sealing and reduce the noise in the cabin.Fig. 5-37 Front Wall Panel
1. Front wall bridge reinforced panel
2. Front wall mid-frame panel
3. Front wall lower main panel
4. Heat-isolated pad
Fig. 5-38 (a) Body floor
1. Front mud guard 2. Rear side wall 3. Rear wheel housing 4.Floor sides (2) Deadening
It is an interactive and systemic work to make the body isolate heat, shock and noise. Besides the measures
carried out to improve the body's stiffness and sealing performance, the following measures shall be taken in the
design and manufacture process.
a. Sound isolation material: add sound isolation pad on the front wall and floor.
b. Sound absorption material: add molded carpet on the front floor and rear floor.
3. Sealing
Special consideration has been given to the sealing of the body both in design process and in manufactureprocess. Sealing plays an important role in many aspects, such as dust resistance, water resistance, corrosionresistance, heat resistance, heat preservation, and noise reduce etc. Especially when the body floor and front wall
stay in a tough external condition, the mud, dust, noises (from the tire and engine) and hot air will invade into the
cabin any time.
After the body assembly is welded, sealant will be employed on all joints to prevent the water and steam
penetrating into the metal seam and ensure the quality of subsequent painting.
In addition, a thick layer of impact-proof PVC coat is applied on the base of the body, which has excellentsealing performance. For the sealing to those assemblies, the traditional sealing method is used, such as rubber sealBody Repair -Features and Composition of Automobile Body7-251
123Front4

Body Repair -Features and Composition of Automobile Body7-26Fig. 5-38 (b) Engine Compartmentring, cover, tape and dust shield etc. But these parts are more precise both in design process and in manufacture
process. For those contact seal pieces, the two-way dimension relation is more reliable. For the front windshield
and rear wall glass, a naturally hardened high-strength sealant is used, whose reliability and practicability reach
the state-of-the-art level. (Fig.5-38)Apply sealantApply sealant
Apply sealant

7-31Fig. 5-38 (g) Engine Hood & Luggage Compartment LidApply sealant
Apply sealant
Apply sealantBody Repair -Features and Composition of Automobile Body