GEELY MK 2008 Workshop Manual

1 1018005004 Side Dash25.5 2
2 1018005000 Front floor13.5 4
3 1018005001 Front floor and rear floor 44.5 6
4 1018005003 Front floor30.5 2
5 1018005002 Front floor 2
6 1018005005 Rear floor 2
7 1018005006 Side dash11 2
8 1108005007 Positioning plate for taillight9.5 2
9 1018005008 Front floor9.5 4
10 1018005009 B-pillar17 2
11 1018005010 B-pillar25 4
12 1018005011 Front of Side dash20 2Chapter 18 Plug ListNo. Picture Material code Position Diameter QuantityInterior & Exterior Trim and Accessory -Plug List6-42

Interior & Exterior Trim and Accessory -Plug List6-4313 1018005012 Under the Side dash outer plate21.5 18
14 1018005013B-pillar¡¡15 2
15 1018005014 C-pillar40 6
16 1018005015 Doorsill30 6
17 1018005016 Top cover60 4 No. PictureMaterial codePosition Diameter Quantity

Part VII BodyChapter 1 SurveySection 1 Body StructureThe body is made up of main structure, movable plate work, interior/exterior trim parts, and body accessories.I. Main StructureAs shown in Fig.5-1, the main structure is made up of various assemblies and parts including engine compartment
assembly & front wall parts, floor assembly, left/right wall assembly, rear wall assembly, roof assembly and
luggage compartment main cover assembly etc.Fig. 5-1 Main Structure
1 Engine compartment assembly & front wall parts 2. Left/right wall assembly
3. Luggage compartment main cover assembly 4. Rear wall assembly 5. Floor assembly
6. Roof assembly 7. Front cross beam assembly(1) Engine Compartment Assembly & Front Wall Parts The main function of the engine compartment assembly and front wall parts is to form an engine compartment
and absorb most energy generated when the vehicle is collided from the front. The compartment provides a hood
for the engine and its accessories, which can prevent the front wheel from throwing mud. In the appearance, it
represents the body's design requirements. As shown in Fig.5-2, the engine compartment assembly and front wall
parts include front cross beam assembly, left/right longitudinal beam assembly, radiator cross beam assembly,Body -Survey7-1
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1. Front cross beam assembly
The front cross beam assembly includes front cross beam left/right support assembly, front cross beam sub-
assembly, front cross beam side support etc. They play a role in front bumper.
2. Left/right longitudinal beam assembly
The left/right longitudinal beam assembly includes left/right longitudinal bean front and mid- block assembly,
energy-absorbing beam big assembly, and left/right front damper support assembly etc.
It is mainly used to install engine left/right suspension, left/right front suspension damper, storage battery and
other accessories. In the outside, it can be equipped with left/right front fender.
3. Radiator cross beam assembly
The radiator cross beam assembly includes radiator left/right post big assembly, radiator lower cross beam big
assembly, radiator central support sub-assembly, and radiator upper cross beam big assembly etc.
It is mainly used to install radiator, condenser, engine hood lock, radiator hood, front bumper, and front
headlight.
4. Front wall lower plate assembly
The front wall lower plate connects to the floor, which separates the engine compartment from the cabin. It
includes front wall frame assembly, front wall lower main plate assembly, brake installation reinforced plate, and
front wall left/right support assembly etc.Fig. 5-2 Engine Compartment Assembly & Front Wall Parts
1. Front cross beam assembly 2. Left/right longitudinal beam assembly
3. Panel left/right support assembly 4. Front wall lower plate sub-assembly 5. Front wall upper assembly
6 Radiator cross beam assemblySurvey -Body Structure7-2123456front wall lower plate assembly, front wall upper assembly, left/right front damper support lower front plate
assembly, and right front damper right-angle support assembly.

It is mainly used to install the pipes and accessories of the brake system and clutch system.
5. Front wall upper assembly
The front wall upper assembly includes left/right hinge base mounting plate big assembly, front wall upper
front cover big assembly, VIN number mounting plate, and front wall upper rear cover big assembly etc.
It forms a high-stiffness frame structure together with the engine compartment assembly and the front wall
lower plate assembly. It can generate strong resistant to the transverse collision and rolling deformation. It can also
separate the engine compartment form the cabin, preventing the odor entering into the cabin. Consequently, it can
isolate the noise, heat and vibration.(2) Floor Assembly The floor assembly is the base work of the main structure. It is a key component that connects various
assemblies and carries the load. The vehicle performance is subject to its strength and stiffness. For the floor
assembly, see the Fig. 5-3.
The floor assembly includes front floor assembly and rear floor assembly. The front floor mid-block goes
through a ridgy channel in longitudinal direction. It can increase the longitudinal rigidity together with the lower
floor longitudinal beam. The space below under the channel is used to install various parts and components, such
as transmission gearshift rod, parking brake cable, discharge pipe with three-way catalytic converter etc. In the
cabin, there is carpet and muffle pad. The floor frame structure is made up of front floor left/right frame, front floor
main plate assembly, front floor mid-bridge assembly, rear frame assembly, rear floor rear block assembly, rear
floor mid-block assembly and longitudinal beam etc. These parts and components provide strong and reliable carry
capacity and ensure that the vehicle meets the strict driving requirement on the body.Fig. 5-3 Floor Assembly
1. Front floor left/right frame 2. Front floor main plate assembly 3. Longitudinal beam rear block 4. Rear frame assembly
5. Rear floor rear block assembly 6. Rear floor mid-block assembly 7. Front floor mid-bridge assemblySurvey -Body Structure7-371
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(3) Side Wall Assembly The left/right side wall assembly is a frame structure, which is a side component that connects the front and
rear parts of the body. As shown in Fig.5-4, it includes left/right side wall outside plate assembly, left/right wheel
assembly, left/right A post inside plate assembly, and left/right intermediate post interior plate assembly etc.Survey -Body Structure7-4Fig. 5-4 Side Wall Assembly
1. LH/RH upper front body inner pillar 2.LH/RH lower front body inner pillar 3.LH/RH no.1 crossemember joint panel
4.LH/RH roof inner rail 5.LH/RH center body inner pillar 6.LH/RH rear crossmember tee joint panel
7.LH/RH lower rear pillar remforcement panel 8.LH/RH roof rear inner panel 9.LH/RH side rear pillar inner panel
10.LH/RH luggage compartment support panel 11.LH/RH luggage compartment hinge fixing panel
12.LH/RH wheel house outer panel 13.LH/RH wheel house inner panel 14.LH/RH side panel
15.LH/RH rear combination lamp fixing panel 16.Fuel refilling cap assembly 17.LH/RH side doorsill outer reinforcement panel
18.LH/RH side doorsill inner reinforcement panel 19.LH/RH center pillar upper reinforcement panel
20.LH/RH front seat belt upper reinforcement panel 21.LH/RH roof rail upper master reinforcement panel
22.LH/RH center pillar middle reinforcement panel 23.LH/RH center pillar lower reinforcement panel
24.LH/RH roof rail assistant reinforcement panel 25.LH/RH front body pillar upper reinforcement panel
26.LH/RH front body pillar outer reinforcement panel

(4) Rear Wall Parts As shown in Fig.5-5, the rear wall assembly includes rear wall plate, rear wall reinforced plate, luggage
compartment door lock mounting plate and luggage compartment door cross beam etc.Fig. 5-5 Rear Wall Assembly
1. Rear wall upper cross beam
2. Luggage compartment lock
mounting plate big assembly
3. Rear wall left double-hole plate
4. Rear wall outer plate
Fig. 5-6 Roof Assembly
1. Roof outer panel 2. Roof No.1 cross beam 3. Roof No.2 cross beam 4.Roof rear cross beam 5.Roof No.3 cross beam
6. Moon roof reinforcement panel It is mainly used as a cross beam to improve the strength of the rear part of the vehicle and form a luggage
compartment door.5) Roof Assembly The roof assembly includes roof outer panel, roof No.1 and No.2 cross beam, and roof rear cross beam etc.
Inside the roof, there is top interior decoration. There is a heat pad in the center and there is bond between the cross
beam and the roof. The rain from the roof is discharged out of the rear part through the channels at both sides. These
cross beams are used to reinforce the roof's transverse stiffness. For disassembled parts, see Fig. 5-6.(6) Luggage Compartment Main Cover Assembly The luggage compartment main cover assembly includes luggage compartment main cover sub-assembly, rear
seat hook mounting plate assembly, left/right side angle plate, drip channel and reinforced upper cross beam etc.
When the luggage compartment main cover assembly is welded to the left/right side wall, it forms a luggageSurvey -Body Structure7-51 14432526143 2

Fig. 5-7 Luggage Compartment Main
Cover Assembly
1. Luggage compartment main cover
2. Rear seat hook mounting plate assembly
3. Left/right side angle plate
4. Drip channelII. Movable Plate Work(1) Engine Hood & Front Fender The engine hood is used to protect the engine and fit the vehicle design. It is also helpful to the repair and
maintenance, and isolates the engine's noise. The engine hood has a double-lock device. The unlocking function
of the first locking is controlled by the cable handle under the instrument board. The unlocking function of the
second locking can raise the hood to a certain height. The double-lock function is designed in consideration of
safety. Especially when the vehicle is running at a high speed, it can prevent the engine hood from being raised,
which may cause traffic accident. The maximum angle at which the engine hood opens is 65°(See Fig.5-8).Fig. 5-7 Engine Hood & Front Fender
1. Engine hood
2. Hinge pin
3. Hinge support
4. Hinge
5.Inner hood panelSurvey -Body Structure7-642
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51Max. opening angle less
than 65°compartment together with the rear floor and side walls. As shown in Fig. 5-7, a torsion resistant frame is also
formed at the rear part at the same time.3
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(2) Front FenderFront fender plays a role in front wheel apron and rotect person safty.And at the same tirne,if also woork as vehicle
styling parts.
For the match relationship between the front fender & engine hood and the front door, see Fig. 5-9.Fig. 5-9 Front Fender related to surrounding parts
A) With Engine Hood (4mm¡À1mm)
B) With Front Door (5mm¡À1mm)(3) Door Assembly Doors have LH/RH front door and rear door.
The door uses hinge gemel with limiting device, which is an open structure.
The door includes door outside plate, door inside plate, bumper and hinge reinforced plate etc.
The door has a complex structure, which is a movable component on the body. It helps the passengers get on/
off the vehicle and form an enclosed cabin with the main structure and the relevant parts. Meanwhile, the doors
are used frequently, so there is high requirement on their reliability and durability.
The outside/inside plate is molded by one complete steel sheet, which can improve the stiffness and precision.
In order to improve the safety when the vehicle is collided from the side, four doors are equipped with door
bumpers.
As shown in Fig. 5-10 and Fig. 5-11, the door assembly is made up of outside plate assembly and inside plate
assembly.Fig. 5-10 Front Door
1. Front door inner panel 2. Left front door inner reinforced panel 3. Front door window opper rail 4. Door lock reinforced panel
5. Left front door inner plate cross beam 6. Front door outer panel 7. Door bumper assembly
8. Front door upper hinge assembly 9. Front door lower hinge assembly 10. Hinge reinforced panel assemblySurvey -Body Structure7-7Engine hood
Front fenderFront door
Front fenderA
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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
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