2008 GEELY MK dimensions

Chapter 14 Outside Rearview Mirror................................................................................. 6-37
Chapter 15 Door Protecting Stripe.................................................................................... 6-38
Chapter 16 Carpet and Insulator....................................................................................... 6-39
Chapter 17 Moonroof Assembly (Optional)...................................................................... 6-40
Chapter 18 Plug List........................................................................................................... 6-42Part 7 BodyChapter 1 Survey................................................................................................................ 7-1
Section 1 Body Structure ................................................................................................ 7-1
Chapter 2 Body Repair....................................................................................................... 7-9
Section 1 Body Damage Forms and Requirements for Repair ...................................... 7-9
Section 2 Typical Technique of Body Panel Repair ....................................................... 7-16
Section 3 Repair After Body Damage ............................................................................ 7-16
Section 4 Features and Composition of Automobile Body ............................................ 7-24
Section 5 Painting Techniques After Body Repair ......................................................... 7-35
Section 6 Service Data For for Body .............................................................................. 7-36Attachment: Body Key Dimensions
Appendix: Torque Table of the Fasteners for Important AssemblyTable of Contents VI

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

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)
14351431
1934.5 1450
4343 848 2502 992

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
point
Value
ToleranceMeasuring
point
Value
ToleranceMeasuring
point
Value
Tolerance
Measuring
point
Value
Tolerance

2. Left/Right Side Wall PartsAppendix-
Body Key Dimensions7-39
Item Description
Diameter of Hole
XY Z
A,a
Lower joint between side outer panel ane roof panel
£ ­ 202.21 +/-636.33 736.57
B,b Taillamp installation hole 5 2190.8 +/-679.49 632.24
S,s
Joint between side outer panel and taillamp panel
£ ­ 3154.87 +/-516.76 784.2
G-n 1710±2.5
4
g-N 1710±2.5
I-o 1208±2.5
4
i-O 1208±2.5
M-n 1548±2.5
4
m-N 1548±2.5
M-q 1568±2.5
4
m-Q 1568±2.5
Q-r 1423±2.5
4
q-R 1423±2.5
E-f 1464±2.5
4
e-F 1464±2.5
H-i 1583±2.5
4
h-I 1583±2.5
M-r 1545±2.5
4
m-R 1545±2.5
N-o 1567±2.5
4
n-O 1567±2.5
I-h 1583±2.5
4
i-H 1583±2.5
E-b 2840±2.5
4
e-B 2840±2.5
T-s 2540±2.5
4
t-S 2540±2.5
Capital letter shows points in the right side and small letter show ones in the left side.Left and right are symmetrical
Item Description
Diameter of Hole
XY Z
C,c
FR upper door hinge installation hole
13(M8 nut) 316.9 +/-742.96 569.3
D,d
FR Lower door hinge installation hole
13(M8 nut) 327.8 +/-759.62 257.8
E,e A-pillar upper assembling mark 681.96 +/-615.09 945.67
F,f A-pillar lower assembling mark 443.19 +/-686.75 219.43
G,g
Upper joint between side outer panel and roof panel
851.588 +/-508.37 1092.37
H,h FR door sill assembling mark 913.56 +/-682 120
I,i Roof side panel assembling mark 1154.83 +/-539.8 1097.59
J,j B-pillar front assembling mark 1369.03 +/-664.67 833.91
K,k
RR upper door hinge installation hole
15(M8 nut) 1401.94 +/-748.88 596.46
L,l
RR lower door ringe installation hole
15(M8 nut) 1354.63 +/-767.12 272.82
M,m B-pillar rear assembling mark 1493.1 +/-672.96 812.59
N,n RR door sill assembling mark 1774.79 +/-682 120
O,o Roof side panel assembling mark 1711.65 +/-531.82 1108.55
P,p Roof side panel assembling mark 2241.04 +/-604.31 940.02
Q,q Rear fender assembling mark 2315.25 +/-658.16 712.07
R,r Rear fender assembling mark 2044.43 +/-682 316.52
E-e F-f F-g/H-h I-i J-j
1230±2.5 1374±2.5 1364±2.5 1080±2.5 1329±2.5
M-m N-n O-o P-p Q-q R-r
1346±2.5 1364±2.5 1064±2.5 1029±2.5 1316±2.5 1364±2.5
Measuring
point
Value
E-h 1555±2.5
4
e-H 1555±2.5
E-j 1457±2.5
4
e-J 1457±2.5
F-j 1717±2.5
4
f-J 1717±2.5
Measuring
point
Value
ToleranceTolerance

3. Body Opening Part (Back View)
A-d 1504±2.5
4
a-D 1504±2.5
C-d 1191±2.5
4
c-D 1191±2.5
f-G 1217±2.5
4
F-g 1217±2.5
e-B 1599±2.5
4
E-b 1599±2.5
h-I 1003±2.5
4
H-i 1003±2.5
(mm)
Item Description
Diameter of Hole
XYZ
A,a
Back window glass fastener installation hole
11.5¡Á8.52327.46 +/-374.49 1118.41
B,b
Rear absorber spring support hole
18 2506.99 +/-534.81 550.09
C,c Tall lamp installation hole 5 3190.8 +/-679.49 632.24
D,d Rear bumperinstallation bole 15 3202.45 +/-428.13 195.64
E,e B-pillar rear assembly mark - 1493.1 +/-672.96 812.59
F,f
Rear joint between side outer panel and roof panel
- 2310.74 +/-598.88 1106.12
G,g
Joint between side outer panel and luggage compartment
- 2816.19 +/-569.92 831.4
H,h
Joint between side outer panel and tail lmap panel
- 2987.01 +/-569.92 798.34
I,i
Rear joint between side outer panel and rear end panel
- 3327.63 +/-325.23 500.2Appendix-Body Key Dimensions7-40
Measuring
point
Value
Tolerance