GEELY MK 2008 Workshop Manual

Chapter 2 Body RepairSection 1 Body Damage Forms and requirements For RepairI. Damage Type The damage type includes deformation, crack, rust-through, water leakage, dust leakage and the like caused
by collision, overload, fatigue, and corrosion.
The body damage is not merely caused by the huge force. As some parts (such as door etc.) are damaged, the
vehicle stays in an abnormal status, which also can cause damage. In most cases, the bend and torsion is caused
by huge local load in the impact or turnover accident.
Typical Body Damage:
1. Front Center Collision (Fig. 5-13)Fig. 5-13 Front Center CollisionBody Repair -Body Damage Forms and requirements For Repair7-9 For the damage caused by the collision on the front center, it usually makes the engine compartment front part
and the engine hood left/right side extend inwards so the following positions shall be checked:
a. Ambience of the left/right assembling position of the hood plate
b. Ambience of the joints of the front cross beam and the left/right longitudinal beam
2. Front External Force or Left External Force (Fig. 5-14)Fig. 5-14 Front External Force or Left External Force As shown in Fig. 5-14, when the front is pressed or the left side end is acted by the external force, the external
force will spread to around the front suspension mounting position from the left/right side of the hood, so
deformation occurs easily in this position.

3. External Force Having an Angle with Vehicle Centerline (Fig. 5-15)Body Repair -Body Damage Forms and requirements For Repair7-10Fig. 5-15 External Force Having an Angle with Vehicle Centerline As shown in Fig. 5-15, when the vehicle is acted by an external force having an angle with its centerline, the
force will affect the hood root and the front window side post if it is strong enough.
4. Body Side Center Acted by External Force in Upright Direction (Fig. 5-16)Fig. 5-16 Body Side Center Acted by External Force in Upright Direction As shown in Fig. 5-16, when the body side center is acted by an external force in the upright direction, check
the following positions:
a. Front window side post upper/lower installation position;
b. Side window intermediate post upper/lower installation position;
c. Side window rear post deformation;
d. Roof and frame deformation.
When the body is acted by an external force on the rear part, its damage is the same as that caused by an external
force on the front part. Check the parts in full consideration of the rear structure and feature.External ForceExternal Force

II. General Repair Principle1. Precaution
(a) Vehicle Protection
In the welding process, make sure to protect the paint, windshield,
seat and carpet with heat-resistant and fireproof covering.
(b) Safety Measures
(1)When pulling the body or crossbeam with drawing device, do
not stand at the position in the same line of the drawing cable,
and make sure to use safe drawing cable.
(2)Before repairing, make sure to check whether there is any
leakage. In case of any hole, remove it immediately.
(3)When welding near to the oil tank, make sure to remove the
oil tank first, and block the oil pipe.
(c) Protective Article
In the repairing process, make sure to wear uniforms, helmet and
safety shoes. In addition, according to the different work types,
wear proper gloves, welding mask, goggle, earplug, face cover,
and dust respirator etc. Wear the protective devices properly as
the table below.Body Repair -Body Damage Forms and requirements For Repair7-11Seat covering Windshield
coveringWrongWrongItem
Dust Respirator
Mask
Goggles
Safety Shoes
Welded Goggle
Earplug
Welded Mask
Welded Gloves Code
A
B
C
D
E
F
G
H

III. Correct & Efficient Repair1. Removal
(a) Measure dimension before removal
Before removal and cutting operation, make measurement as
the body dimension drawings. Make sure to pull the damaged
body or crossbeam with drawing device.
(b) Cutting part
When working on the cutting part, make the cutting in a straight
position without reinforced plate.
(c) Boring/cutting precaution
In the boring or cutting operation, make sure whether there is
any oil pipe or cables etc on its back side, otherwise they may
be damaged.
(d) Removal of ambient components
When removing the ambient components, make sure to adhere
protective tape on the body and disassembly tool to prevent the
body or ambient components being damaged.
2. Installation Preparation
(a) Precaution
When the steel plate to be welded exceeds 3mm
thick, make hole-filling welding with MIG welder.
Tips: If the total thickness exceeds 3mm, the spot can not
provide adequate welding strength.7-12Cutting position
Reinforced plate
Bend positionWrongLarger than 3mmBody Repair -Body Damage Forms and requirements For Repair

Plate Thickness Hole Diameter
<1.0 >5
1.0~1.5 >6.4
>1.5 >87-13 (b) Apply special paint for spot welding
Remove the paint film from the new parts to be welded and the
body, and apply the special paint for spot welding.
(c) Bore for hole-filling welding
In the position that can not carry out the spot welding, bore it
with borer or bit to make hole-filling welding.
Unit: mm
(d) Precaution for electronic parts
(1) In the welding process, the electronic parts may be damaged
due to the current in the body.
(2) Before the welding, cut the cathode connection of the
storage battery, and put the ground end of the welder on the
ambiance of the welding area.
(e) Rough cutting of joint parts
In the rough cutting process in the connecting area, an overlap
of 20~30mm must be reserved on the new parts.
3. Installation
(a) Measure before Welding
Before installing the lower body or the parts of the engine
compartment, make sure to make measurement as the body
dimension drawing, to ensure the correctness. After the
installation, reconfirm whether the assembling is proper.Hole filling
Overlap
Pneumatic saw
Body dimension
drawingBody Repair -Body Damage Forms and requirements For Repair

7-14 (b) Precaution
(1) For the number of spot welding, it depends on the following
principles.
S pot welding:1.3 times of the number specified by the manufacturer
Hole-filling welding: more than the number specified by the
manufacturer
(2) When carrying out the hole-filling welding, MIG welder
shall be used. It is not allowed to use the oxyacetylene
welding or braze welding outside the specified area.
(c) Abrasion after welding
(1) After the welding, make sure to check the welding position
whether it is welded firmly.
(2) When abrading the welding position with disc abrader,
never abrade it too much, which may weakens the strength
of the welding position.
(d) Precaution of spot welding
(1) The shape of the spot welder head may affect the strength
of the welding.
(2) Make sure to remove the paint film on the surface of the spot
welding and the contact surface of the welder head.
(e) Position of spot welding
In the spot welding process, overlap with the old welding
position shall be avoided.
4. Anti-rust Processing
(a) Apply sealant
In the waterproof and antirust part operation, make sure to
apply the sealant on the joint of the steel plates,door,and engine
hood corner.Wrong CorrectWrong
Spot welding head scraper
New welding position
Old welding
positionSealant gunBody Repair -Body Damage Forms and requirements For Repair

5. Base Anti-rust Processing
Impact-proof Coat
In order to avoid corrosion and protect the body from being damaged by bouncing stone on the road, a layer
of impact-proof coat is applied on the door threshold plate, arc area and balancing plate etc.
Tips: There are two types of painting: impact-resistant coat on the electrophoresis primer or on the surface paint
according to different types and painting positions. (See Fig.5-22)7-15IV. Repair Requirement 1. As the body is an integral structure and the steel plates used are not thick, special attention shall be paid to
reinforce the parts acted in the reshaping process in the plate work processing. For the parts that burden the stress
intensively, measures shall be taken to lower the local stress.
2. After the plate work processing, note to apply the antirust primer on the inside and outside surfaces to avoid
corrosion.
3. In the body repair process, repair the old parts; or remove the parts with serious defects and order new parts
from the manufacturer.
4. When making body reshaping or parts welding, make sure that all main control points of the body are within
the specified scope in the design.
5. The strength and serviceability of the repaired body shall not be lower than those of the new vehicle.
6. The outside decoration of the repaired body shall meet the requirements by the new vehicle body and the
drivers in various aspects, such as modern aesthetics and ergonomics etc. (b) Apply primer
In order to prevent rust and protect the body steel plate from
being damaged by the bouncing stone, sufficient primer is
applied onto the body base and inner wheel cup.
(c) Apply antirust (wax)
In order to prevent the painting part from rusting, sufficient
antirust is applied on the engine cover, door inner corner, hinge
ambiance, or in the inside welding part of the box section
structures such as side beam, body post.Fig. 5-22 Apply the impact-proof coat on the surface paint
Impact-proof coat
Surface paint
Intermediate primer
Electrophoresis primer
Steel sheet Apply the impact-proof coat on the electrophoresis primer
Surface paint
Intermediate primer
Impact-proof coat
Electrophoresis primer
Steel sheetBody Repair -Body Damage Forms and requirements For Repair

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

The cave-in is mainly caused by collision and extrusion. For the light cave-in damage, the metal doesn't extend,
which is plastic deformation. If the collision or extrusion is serious, the metal plate will rupture. For the vehicles
running in the city, it is common that collision damage occurs on the side wall.
d. Bend & Distortion
Bend and distortion belong to mechanical damage. Bend and distortion may have a variety of causes, such as
collision or extrusion, alternating loads generated by the vibration, accident acceleration, emergency brake, sharp
swerve and body torsion caused by poor road.
For the light distortion, it shall be confirmed by test. For the serious bend and distortion, it is obvious in the
appearance. Generally, the distortion can be fixed according to the clearance of the frames and the change of their
relative positions.
e. Unsoldering
The unsoldering is caused by the poor fusion between different metal plates.
2. Outside Plate Repair
a. Repair for Crack
(a) CO2 Welding
The crack on the metal outside plate can be repaired by CO2 welding. In the welding process, align the two
metal plates, and weld the outside crack of the plate first. If the crack doesn't exceed 50mm, the welding shall start
from the rear part of the crack and continue along the crack and edge. If the crack is a little longer, several points
shall be welded first at a certain space. After welding several points, finish them and then weld the crack block
by block. By so doing, it can prevent the metal overroasting and plate deformation caused by too high temperature.
If the crack is located in the position that burden heavy force and it is convenient to carry out the welding operation,
a double-welding method can be used. After the spot welding is made outside, carry out the welding inside. After
the inside welding is completed, make the welding outside in the same manner.
After the welding, put a sizing block inside, and beat from the outside welding line with hammer to removeFig. 5-25 Concave Body Filling Repair b. Repair for Local Damage
For the local corrosion or serious mechanical damage on the outside plate, if it can't be repaired in common
method, the patching or pasting repair method can be used.
Repair Method:
(a). Fix the patching scope;
(b). Cut the paper sample;
(c). Cut the plate as per the sample;
(d). Adhere the molded plate on the surface of the patching part;
(e). Line out the profile along the plate edge with needlepoint, and cut off the damaged or corroded part;Body Repair -Repair After Body Damage7-18the retaining stress. Finally, finish the welding
seam properly to make it even and smooth for
painting.
(b) Solder Filling
For the fine concavo-convex plate with
damage and crack on its surface, it can be re-
paired with a solder filling method. (Fig. 5-25)