roof GEELY CK 2008 User Guide

365(V) Roof Panel AssemblyRoof panel assembly is mainly composed of parts such as roof panel, roof front cross member, roof central
reinforcement, roof rear cross member, etc., by welding them together. Shown as the dismantle diagram 5-
6.Roof interior trim is mounted inside; and an insulation mat is pasted in its interlayer. Cohesive binder is
applied between the front/central/rear cross member and the roof panel in many points. The rainwater from
the roof panel flows out of the rear body through roof drip channel that are on the both sides of the roof panel.
Cross members and reinforcement members are used to strengthen the rigidity of the roof panel in trans-
verse direction.
Figure 5-6 Decomposition Diagram of Roof
1 Roof Panel 2 Front Roof Cross Member 3 Roof Central Reinforcement
4 Rear Roof Cross Member(VI) Trunk Shelf AssemblyTrunk shelf assembly is mainly composed of parts such as trunk shelf panel, trunk shelf front reinforcement
plate, drip channel etc., by welding them together.
Trunk shelf is welded to the LH/RH quarter, which and rear floor, the back of the quarter form a trunk.
Meanwhile, a frame that can resist to torsion is also generated. Figure 5-7 is the dismantle diagram.
Figure 5-7 Decomposition Diagram of Floor Parts.
1 Trunk Shelf Reinforcement Plate 2 Trunk Shelf Panel 3 Drip Channel1234132

4. Crashed By Perpendicular Outside Force In the Middle of The Vehicle (Figure 5-16)Outside force371FIGURE 5-16 Perpendicular outside Force in the Middle of the Vehicle
Figure 5-16 shows the situation when the middle of the vehicle is pressed by perpendicular outside force. So,
the places should be inspected are as follows:
1Front window side pillar upper and lower mounting place;
2Side window central pillar upper and lower mounting place;
3Deformation of the side window rear pillar;
4Deformation of the roof panel and its frame.
The damage when the back of the vehicle is affected by outside force is generally the same with the front.
But, the structural features should be fully considered during inspection.II. Requirements Of Body Repair1. Because of the integral body construction and the thin steel sheet, during the procedure of panel operation,
strengthen the force-loading part after reshaping, and take measures to reduce partial stress in those places
where stress gathers.
2. After the panel operation, specially make sure to spread rust-proof primer on the inner and outer surfaces
to avoid rusting.
3. When repairing the body, you can either repair the broken piece or cut off the part which has serious
deformation and then weld a new piece ordered from the manufacturer to the body.
4. When reshaping and welding a new piece, make sure that major control points on the body can be restored
into the range of design requirements.
5. After repair, as to its intensity and durability, they should be no worse than the new body.
6. After repair, the exterior trimming of the body should meet the requirements of a new body and also the
modern aesthetics and ergonomics etc that are raised by customers.

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

385Section 6 Service Data For BodyI. Service Data For Body (Table 5-1)TABLE 5-1Service Data For BodyContent Service Data
Resha ping cle aranc e be twe e n e ngine hood inne r and
oute r pla te 3mm±0. 5mm
Clea ra nce betwe en LH/RH fender and hood5mm(0,-1mm)
Clea ra nce betwee n LH/RH he adla mp and hood7mm±0.5mmClea ra nce betwe en front bumpe r a nd fe nde r≤
1mmClea ra nc e be twee n LH/RH he adlamps a nd bumper,
fender 5mm(0.-1mm)
Cle a ra nc e be twe e n fender a nd LH/RH doors 5mm(0,-1mm)，
Height error≤
0.5mm
Cle ara nce betwe en hood and bumpe r 7mm±0.5mmCle aranc e be twe en ra dia tor grille a nd hood0.5mmCowl ventila tor cover hole a nd wipe r sha ft a re
homoc entric . Coaxial Degre eNo more than 2mmClearance between door and side wall5mm(0,-1mm)
Clea ra nce betwee n door a nd sill 7mm±0.5mm
Cle aranc e be twe en fue l fill port c ove r a nd side wa ll 3mm±0.5mmClearance between rear bumper and side wall plate 1mm±0.5mmClearance between Rear tail lamp and side wall plate 1mm±0.5mmClea ra nce betwee n windshie ld a nd drip c ha nnel4—5mmGlass is lower than drip channel0.5—1mmCle ara nce betwe en gla ss a nd roof pa nel 4.5—7mm and lower tha n 0.5—1mmTrunk lid folding e dge , spot-we lding inte rval250—300mm He ight of we lding spot is no
more tha n 1mmTrunk lid inner plate fla nging sides a re highe r than
oute r pla te 1—1. 4mmCle ara nce betwe en trunk lid a nd side wa ll plate 5mm(0,-1mm)
Clearance between trunk lid and rear combination
la mp 5mm(0,-1mm)
Clea ra nce betwee n trunk lid a nd bumper 7mm±0.5mmHe ight diffe re nce of pa rts which is bila teral symme try
on the outside bodyNo more than 5mmHeight of trunk lid limit bloc k is proper. He ight of the
se a ling strip when the trunk lid is loc ked12mm