GEELY CK 2008 Workshop Manual

364 (IV) Rear Back Panel PartsRear back panel assembly is mainly composed of parts such as rear back panel, rear back panel reinforcement,
trunk lock mounting plate, trunk lid cross member, etc., by welding them together. Figure 5-5 is the dismantle
diagram.
Figure 5-5 Dismantle Diagram of Rear Quarter Assembly
1 Rear Floor 2 Rear Back Panel 3 Rear Back Panel Reinforcement 4 Trunk Lid Lock Mounting
Plate 5 Trunk Lid Cross Beam
The rear back panel is used for effect of a cross member to strengthen the intensity of the rear part of the
body and form an opening of the trunk. 12345

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

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

367(III) Door AssemblyThe door adopts limit hinges. The hinge is mounted on the front pillar of the door frame.
A door is mainly composed of the door outer and inner plate, anti-impact bar and door reinforcement plate.
The structure of the door is complicated, because it is a movable part. It is designed to form a sealed
compartment with the main body and relevant parts, and also convenient for drivers and passengers to get in
and out of the vehicle. And the devices on the door have to bear high-frequency operation. So it must meet
very high requirements in reliability and durability.
The inner and outer plates are both molded from a whole steel plate, which is for improving the rigidity and
assembly accuracy. In order to assure the safety when the vehicle is crashed on the side of the body; anti-
impact bar and central reinforcement plate are equipped in the door.
Door plate assembly is composed of the outer and inner sub-assemblies. Use a special folded edge machine
to wrap along the full circle of the door outer plate and the inner plate sub-assemblies to get them together.
As shown in Figure 5-10 & 5-11
Figure 5-10 Dismantle Diagram of Front Door Plate
1 Front Door Inner Plate2 Front Door Window Glass Rail 3 Front Door Inner Upper Rein-
forcement Plate 4 Front Door Inner Middle Reinforcement Plate 5 Front Door Upper Hinge
6 Front Door Lower Hinge 7 Front Door Hinge Reinforcement 8 Door Anti-impact Bar Assy.
9 Front Door Outer Plate123456798

368Figure 5-11 Dismantle Diagram of Rear Door Plate
1 Rear Door Inner Plate2 Rear Door Window Glass Rail 3 Rear Door Inner Upper Reinforce-
ment Plate 4 Rear Door Inner Middle Reinforcement Plate 5 Rear Door Upper Hinge
6 Rear Door Lower Hinge 7 Rear Door Hinge Reinforcement 8 Door Anti-impact Bar Assy.
9 Rear Door Outer Plate(IV) Trunk Lid Welding AssemblyTrunk lid assembly is mainly composed of parts such as trunk lid outer plate, trunk lid inner plate, trunk lid
hinge mounting plate, trunk lid lock mounting plate, etc., by welding them together. As shown in Figure 5-12
Figure 5-12 Decomposition Diagram of Trunk Lid
1 Hinge Mounting Plate 2 Hinge Spring 3 Trunk Lid Hinge 4 Trunk Lid Inner Plate
5 Trunk Lid Lock Mounting Plate 6 Trunk Lid Outer Plate6237489151223645

369Chapter 2 Body RepairSection 1 Body Damage Forms and Requirements for RepairI. Body Damage FormsThe body damage forms are deformation caused by crash, overload, fatigue and corrosion, and tearing,
rusting, water & dust leaking.
The damage of the body is caused not only by overload, also by being often in an abnormal operating status
when the door or other parts are damaged. However, at most times, accidents like crash and turnover result
in bending and torsioning deflection because of the great overload on partial areas.
General conditions of the body damage are as follows:
1. The Front Central Is Crashed (Figure 5-13)
Figure 5-13 The Front Central Is Crashed
Because the front central is damaged by outside force, the left and right hood is usually stretched inwards;
therefore, the following are the key places to inspect.
1Nearby the left and right mounting place of the hood;
2Nearby the left and right mounting connection place of the front cross member.

3702. Crashed By Outside Force Ahead Or From The Left Side (Figure 5-14)
Figure 5-14 Crashed By Outside Force Ahead Or From The Left Side
Figure 5-14 shows the situation when the front is pressed or the left side is crashed by outside force. Under
this kind of situation, the outside force spreads from the left (or right) of the hood to the front suspension
mounting place, to get this part easily deformed.
3. Crashed By Outside Force Forming An Angle To The Center Line Of The Vehicle (Figure 5-
15)
FIGURE 5-15 Outside Force Forming An Angle to The Center Line of The Vehicle
Figure 5-15 shows the situation when it is crashed by outside force forming an angle to the centerline of the
vehicle. When the force is too great, the hood bottom and the front window side column will be affected.Outside force

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.

372Section 2 Typical Technology Of Body Panel RepairThe flow line of the repair technology is as follows:Section 3 Repair after Body DamageBody repair methods include calibration, reshaping, strengthening, partial replacement and renewing of a
whole part. CO2 gas protecting welding should be adopted when welded.I. Reshaping1. Calibration
The deformation of the body is usually caused by an accident. You can calibrate it by propping to its former
location. When calibrating, impose force in the opposite direction of the outside force or deformation force.
Under the most circumstances, calibration in a cool status can be adopted. The internal stress can be re-
moved by partial heating. Then you can do some corresponding aging treatment.
It is better to use body calibration machine for car body calibration. Geometric dimension and tolerance can
be restored to the former standard. Power, economy and comfortableness can be assured.
The body repair begins with a process of preliminary calibration or rough calibration. The body deformation
can be removed by propping back to its former location. The angle of the applied force for propping back
should be almost the same with the outside force that causes damage. Reaction force should be imposed at
the back of the pulling action point to make the propping force adjustable. Inspect the deformation during the
process of propping back. Proper heating is applied on correspondent parts to remove internal stress.
2. Strengthening
When partial damage, break or crackle occur on structural components, strengthening is allowed, especially
to be applied in those parts where damage often occurs. Willful strengthening or repair welding should be
avoided, because it will affect the stressing status on body.
The main ways of strengthening are sleeving and bracket reinforcement.
3. Partial And Whole Part Replacement
The parts that are badly rusted should be partially replaced. What is broken and damaged should be replace
a new one. The post pillar is pressed and molded adopting thin sheet. Parts and components are brought from
manufacturers. When they are molded by you, material, section dimension, and thickness etc should accord
with their original design requirements. When the broken post pillar (incl. cross member) is wholly replaced,
the connection way must be the same with the original one.
Appearance assessment Disassembly Paint removal Appraisal
Panel repair
AssemblyPainting

373II. Repair of Body Outer Plate1. Types Of Outer Plate Damage
1 11 1
1Break or crackle
The body always vibrates as the vehicle runs; and it bears an alternating load. When the vehicle suddenly
accelerates, sharply turns and emergently brakes, the body will be affected by inertia force. When the
vehicle runs on a rough road, the body will get bent and deformed by torsion.
If the vehicle experiences this kind of outside force in a long term, the outer plate of the body will get
broken and cracked on the parts that stress concentrates and the structure is weak.
It is easy for the stress to concentrate at the turning, edging and narrow places of the body outer plate, for
example, it is easy for the 4 corners of the slide door sash to get broken and cracked.
2 22 2
2 Corrosion
The corrosion of the body outer plate is mostly caused by mud accumulated on the surface of the metal,
which results in rust. Only in some special situations, it is caused by contacting chemical materials, which
belongs to chemical corrosion. When the metal outer plate corrodes, the rust is generated on the outer
plate, and then peels off layer by layer, so that holes appear and become bigger and bigger. Rust is easily
generated on the outer plate of the skirt, drip channel, and at the joints of doors and sashes, and at the
interlayer formed by outer plate and frame jointing places.
3 33 3
3Recess
Recess is a kind of structural damage, caused by crash or squeezing on the outer plate of the body. As to
slight recess, the metal dose not extend. It belongs to plastic deformation. When it is seriously impacted
and squeezed, the metal outer plate will be torn. For the vehicles running on city, side wall outter plates
being crashed and scratched is common.
4 44 4
4Bending and torsion
Beading and torsion deformation belongs to mechanic damage. Many causes result in this kind of situation,
such as body being crashed or squeezed, an alternating load in vibrating as the vehicle runs, sudden
acceleration, emergent brake, sharp turn and running through a bad pavement, etc. Those can all result in
bending and torsion deformation on body outer plate.
Slight deformation should be confirmed by inspection. For serious bending and torsion deformation, they
can be easily found by appearance. The deformation information can be usually defined according to the
clearance between door frame and their relative position changes.
5 55 5
5Breakup Welding
Outer plate being breakup welding is caused by bad welding between metal plates.