engine GEELY CK 2008 Workshop Manual

360(I) Front Sheet Metal, Cowl PartsThe main function of the front sheet metal and the cowl parts is forming an engine compartment to supply the
engine and accessories with a protective cover and to absorb the most energy when vehicle encounters
frontal impaction, protecting mud from being splashed by the front wheels, and meeting the requirements of
body design in appearance. It is mainly composed of front cross member assembly, LH/RH front mud guard
and front side member assembly, engine hood front support plate assembly, hood lock bracket assembly,
cowl assembly, cowl upper assembly.
1. Front Cross Member Assembly
The front cross member assembly is mainly composed of the front cross member welding sub-assembly,
front cross member bottom plate assembly, LH/RH side member end plate by welding them together, and its
dismantle diagram as shown in the Figure 5-2.
2. Lh/Rh Front Mudguard And Front Side Member Assembly
LH/RH front mud guard and front side member assembly is mainly composed of LH/RH front mudguards
and LH/RH side members by welding them together.
It is mainly used to mount some mounting brackets such as the engine LH/RH side suspension bracket, LH/
RH front suspension shock absorber bracket, etc. and to mount the LH/RH front fenders.
3. Engine Hood Front Support Plate Assembly
Engine hood front support plate is mainly composed of LH/RH headlamp mounting bracket assembly, hood
front support plate sub-assembly, and LH/RH front support plate reinforcement, by welding them together.
Engine hood front support plate assembly is used to mount radiator, engine hood lock, radiator grille, front
bumper, and headlamp.
4. Engine Hood Lock Bracket Assembly
Engine hood lock bracket assembly is used to mount the engine hood lock, also to strengthen the intensity and
rigidity of the front body by connecting the engine hood front support plate and front cross member.
5. Cowl Assembly
Cowl assembly is mainly composed of cowl inner and outer plate assembly and cowl lower cross member, by
welding them together.
Cowl assembly and front floor, LH/RH front mud guard (LH/RH front pillar), cowl upper baffle is welded
together, which forms a framework with great torsional strength. It generates great resistance to lateral
impact and rolled deformation.
Cowl inner and outer plate assembly is sandwich structure. 3mm of asphalt plate lies in the interlayer, which
is to cut off the noise and heat generated from the engine.

3616. Cowl Upper Assembly
Cowl upper assembly is mainly composed of cowl upper outer plate, cowl upper LH/RH end plate assembly,
instrument panel mounting plate, steering column mounting bracket upper/lower plate, cowl lower inner plate,
ventilator cover, etc., by welding them together.
Figure 5-2 Dismantle diagram of front sheet metal and cowl parts
1 Front Cross Member 2 Hood Lock Bracket Assy. 3 LH/RH Side Member End Plate
4 Engine Hood Front Support Plate Assy. 5 LH/RH Front Cross Member 6. LH/RH Front Mud Guard
7 Front Cross Member Assy. 8 Cowl Inner And Outer Plate Assy. 9 LH/RH Front Mud Guard
Reinforcement 10 Cowl Upper Baffle12 375683910 64Front

366II. Removable Sheet Metal Parts
(I) Engine Hood, Front Fender1. Engine hood is mainly used to protect the engine, meet the whole vehicle design, and make the mainte-
nance convenient. It also has an effect of isolating the engine noise. The engine hood has a double-insurance
lock system. The release of the first lock is controlled by the drawing cable that is under the instrument panel.
As to the release of the second lock, you should firstly release the first one and the hood will open, and then
move the hood lock hook. The double-insurance lock system is designed for safety, especially in the course
of running with a high-speed, to prevent the engine hood from being raised, which often causes traffic
accidents. The angle of the hood that is fully opened is 52°.As shown in Figure 5-8
Figure 5-8 Engine Hood Hinge
1Hinge Bracket 2 Hinge Arm 3 Pin Shaft(II) Front FenderThe matching relationship between the front fender and hood, front door is as shown in the Figure 5-9.
Figure 5-9 Section Around The Front Fender
A) The matching relationship with the hood (5mm ± 0.5mm)
B) The matching relationship with the front door (5mm ± 0.5mm) 13252
†while fully open
Engine Hood
outer plate
Engine Hood
inner plate
AEngine HoodFront fender
Front door
Front fender
B

3781. Material Of punching Parts
In order to improve the rigidity of the body, high-tensile steel plate is adopted in many key parts of the
body to reinforce the body on the place that force concentrates (Figure 5-22).
(Figure 5-22) High-Tensile Steel Plates
1. Engine Hood Outer Plate 2. LH/RH Fender 3. LH/RH Central Pillar Inner Plate
4. Trunk Lid Outer Plate5. LH/RH Door Outer Plate21354

3812 Adopt sound insulating material to reduce the noise in the compartment.
For the heat, vibration and sound insulation of the body, they are a systematic engineering. Besides you
take measures on effectively improving the rigidity of the body and sealing technique, the following
measures can be taken in the body design and manufacturing:
a. Sound insulating material: paste a layer of asphalt board on the floor and FR/RR fenders. Add
insulation pads on the cowl and the floor.
b. Sound absorbing material: adopt formed carpet which is composed of front floor carpet and rear
floor carpet.
The FR/RR floor carpets are integrated with the floor and sound absorbing pad. It is required that the
floor and the pad will not peeled when torn by outside force.
3. Sealing
An elaborate concern is taken from design and manufacturing on the body sealing. Sealing is very important
for the operation performance of dust prevention, water proofing, corrosion prevention, heat protection, heat
preservation, noise reduction, etc. Especially, the floor and cowl are located in the harshest outside environment.
The mud splashing from road, dust and sand, wheel noise, engine noise and hot air will get in the interior
environment by every opening.
After the body assemble welding completes, apply a line of sealant on all joints of the body to avoid water and
vapor permeating into the metal joint and also to ensure the quality for the following painting.(Figure 5-25).
Besides, a layer of stone-strike proofing paint is applied on the bottom of the body. The paint has good sealing
effect. For the sealing of mounting parts on the body, traditional methods are generally adopted, such as
rubber sealing ring, cover, rubber strip, special-shaped sealing strip, etc. But in order to make more minute
and rigorous considerations in design and manufacturing of structural parts and the stability of the dimension
relationship of contacting sealing. For windshield and rear back door glass, a natural-curing high-tensile
sealant is adopted in sealing. It represents the advanced modern techniques in reliability and mounting technology.5-25 1. 2. 3. Figure 5-39 Area Where Chloride Ethylene Plastisol Is Applied
1. Front Mud Guard 2. Rear Side Wall 3. Rear Wheel HouseFront