2008 GEELY MK Workshop Manual

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

Section 3 Repair After Body Damage The body damage repair includes rectification, reshaping, reinforcing, local change, and complete replacement.
Generally, CO2 welding method is used.I Reshaping Repair1. Rectification
In general, the deformation of body is caused by accident. It can be rectified in a supporting method. In the
rectification process, apply the force in the direction against the force of accident or deformation. In most cases,
cold rectification can be used. Local heating can reduce internal stress, and the corresponding processing shall be
carried out.
For the limousine, it is preferred to rectify it with the dressing machine. All dimensions and tolerances of all
parts shall be returned to the original standard, so the mobility, serviceability and comfortableness can be
guaranteed. (Fig.5-23)Section 2 Typical Technique of Body Panel RepairFig. 5-23 Mounting Bench of Universal Dressing Machine7-16Repair Process Flow:Visual Inspection
& AppraisalRemove Remove Paint Appraise
Platework
RepairAssemble PaintBody Repair -Typical Technique of Body Panel Repair/ Repair After Body Damage

The body repair starts from the primary rectification or rough rectification. The deformation can be removed
with the supporting method. The angle of the supporting force shall be close to the angle of the external force that
caused the damage. Apply a counterforce at the back of the pulling force point to adjust the supporting force. Make
measurement on the deformation generated in the supporting process. To remove the internal stress, heat the
corresponding parts. For different rectification methods, see Fig. 5-24.
2. Reinforcement
When the local damage, rupture or crack occurs on various components, repair can be made by reinforcement.
Especially for those parts on which damage occurs frequently, special reinforcement measures shall be taken.
However, random reinforcement or component welding shall be avoided, which may affect the body's status.
The reinforcement includes bushing reinforcement, patching reinforcement, arc inlay, and angle plate reinforcement.
3. Local Removal & New Parts Replacement
For the parts with serious corrosion, they must be removed. For the ruptured parts, they shall be replaced
entirely. For the posts manufactured with thin plate by punch, they shall be ordered from the manufacturer. When
the molding is made independently, all specifications (including material, section dimensions and thickness etc.)
shall meet the original design requirement. For the ruptured post (including cross beam), if it is replaced entirely,
it must be connected in the same manner as that of the original post.II. Repair for Body Outside Plate1. Damage Type
a. Crack & Rupture
In the running process, the body vibrates continuously and burdens the loads. When the vehicle makes accident
acceleration, sharp swerve an emergency brake, the body will keep in an inertial status. When the vehicle runs on
the uneven road, bend and distortion will happen on the body.
Affected by these external forces for a long time, crack and rupture may occurs on the stress concentrated parts
and weak structure on the body outside plate.
The stress mostly concentrate on the corner, hem and narrow part of the outside plate, so crack and rupture often
occur on these parts.
b. Corrosion
The corrosion on the outside plate is mostly caused by the mud and water on the metal surface. Only in special
case, it results from the chemical corrosion by chemicals. When the corrosion occurs, rust may appear on the
outside plate and fall gradually, resulting in a hole. On the skirt outside plate and launder, corrosion usually occurs
on the seams between door and frame and the interlayer between the outside plate and the frame.
c. Cave-inFig. 5-24(a) Drawing Rectification Fig. 5-24(b) Drawing & Supporting
RectificationFig. 5-24(c) Auxiliary Force-receiving
Point Rectification7-17washerBody Repair -Repair After Body Damage

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.

Fig. 5-29 Thermal Contraction Method For those parts that are not sure whether they will contract or not, the thermal contraction method shall not
be used to avoiding any side effect. Especially for those thin plates, great attention shall be made to prevent them
from melting down or burning through.
(c) Welding ring
The welding ring method is used to repair the most seriously damaged part of the concave on the plate work
surface. Some rings are welded to connect the rods. (Shown as Fig. 11-30) When the area of the concave is large,
several rings can be welded in a parallel manner, and gets through the rod to make the pulling force act on the plate
surface evenly. The ring can be replaced by the washer. The rod pulls the washer or shaft through a coupling device.
After the concaved plate is flattened by the inertia hammer puller, remove the ring or washer and finish the welding
points.Fig. 5-30 Welding Washer StretchingBody Repair -Repair After Body Damage7-20Washer WasherHeating
Compress
loadCooling
Extend load Plate work
thermal contraction Metal bar thermal
contractionWasherShaft
Shaft Shaft Rod