GEELY MK 2008 Workshop Manual

7-29Fig. 5-38 (e) Luggage CompartmentApply sealant
Apply sealant Body Repair -Features and Composition of Automobile Body

7-30Fig. 5-38 (f) DoorApply sealant
Apply sealant
Apply sealant
Apply sealant
Apply sealant
Apply sealant Body Repair -Features and Composition of Automobile Body

7-31Fig. 5-38 (g) Engine Hood & Luggage Compartment LidApply sealant
Apply sealant
Apply sealantBody Repair -Features and Composition of Automobile Body

7-32Fig. 5-38 (h) Antirust Position on Body Steel PanelEngine hood
Engine dood hinge
Front door upper hingeRear door upper hinge
Front door lower hingeRear door lower hingeOil tank capDoor Body Repair -Features and Composition of Automobile Body

7-33Fig. 2-38 (i) Filling Position of Foaming MaterialBody Repair -Features and Composition of Automobile Body

4. Surface Treatment
Surface treatment shall be strict, careful and all-around. Though this car is not a deluxe sedan, it nearly has no
difference with the deluxe sedan in the surface treatment.
a. Phosphoric acid processing
Phosphoric acid processing is also called pretreatment before painting. After removing the grease on the body
by washing, apply zinc phosphate onto the body, with a thickness under 3
but also can help to increase adhesion in the next coating process.
b. Cathode electrophoresis
In the practical application, the electrophoresis painting shows many advantages, such as high efficiency, good
quality, safety and cost effectiveness. It is accompanied with four electrochemical phenomena including
electroanalysis, electrophoresis, electrodeposition and electroosmosis. The cathode electrophoresis is much better
than the anode electrophoresis both in the features and advantages. Incomparably, the process is strict extremely.
c. Intermediate coat
The intermediate coat is also called intermediate layer, which is located between the primer and the surface
paint. Its function is to improve the evenness of the painted work piece and the primer and provide the surface paint
with a good base to improve the paint's brightness and richness and improve the decoration of the entire coat.
d. Surface paint
The surface paint is the last coat in the multiple coats, which directly affect the vehicle's decoration,
weatherability and appearance etc. Great attention shall be made when selecting the surface paint, including its
adaptability, cost-effectiveness and usability. All performance indexes shall meet the national standard and
industrial standard. The paint shall be even and smooth.
e. Protective coat
For those vehicles parked outside for a long time (more than three months) or used for shipping, water-soluble
protective wax shall be applied on the outside surface of the body. This agent contains ultraviolet absorbent. Before
selling the vehicle, wash it with soap detergent and flush it with clean water, to make the paint brighter.7-34Fig. 5-38 (j) Painting Position of Impact-proof CoatPVC Impact-proof Coat Body Repair -Features and Composition of Automobile Body m. It not only can protect the work piece,
1U

7-35Section 5 Painting Techniques After Body RepairIn the practical use, various factors may cause painting damage, such as traffic accident, component rust,
premature damage due to bubble, and local color change etc. It is necessary to make repair locally as the following
steps:I. Base Processing (Pretreatment)1. Remove the paint, and remove the coating on the plate work.
2. Cut the edges and corners, and polish the metal plate without paint and the uneven paint at the edge.
3. Blow and clean the dust and dirt, and remove the grease with degreasant.II. Primer Processing1. Apply the self-drying primer on the bare metal surface.
2. Leave the primer drying naturally, or dry it with the infrared radiator.
3. Apply the self-drying oily putty or polyester putty on the plate work surface.
4. Leave the putty drying naturally or artificially.
5. Polish the putty manually to remove the uneven parts.
6. Polish it manually in water to clear the sandpaper lines.
7. Wash the dirt, polish the oil dirt and putty slurry.
8. Wipe the oil dirt on the polishing surface.
9. Cover the part not to be repaired with protective shield or paper.III. Painting Intermediate Coat1. Paint the second primer.
2. Leave the primer drying naturally or dry it.
3. Find out the sand hole or sandpaper line.
4. Polish it manually in wet condition.
5. Wash the part clean, and leave it drying naturally. (The number of putty applying and polishing depends on the
evenness of the surface to be repaired.)IV. Preparing to Paint Surface Paint1. Paste paper on the surface not to be painted.
2. Remove the dust and grease on the local surface paint.
3. Mix the color the same with that of the vehicle's surface paint.
4. Prepare the paint.V. Painting Surface Paint1. Paint the part with fast-drying surface paint 3-4 times and synthetic resin paint 2-3 times.
2. Leave it drying naturally or dry it.VI. Polishing1. After painting, burnish the part with wax to clear the shadow and improve the effect.
2. After painting, tear off the paper and wipe the ground paint.
3. Check the appearance and quality.Body Repair -Painting Techniques After Body Repair

Section 6 Service Data For for BodyI. Technical Repair Data (Table 5-1)Item (Clearance)
Front fender and side wall outside plate
Front fender and front door outside plate
Side wall outside plate and front/rear door
Door outside plate and side wall outside plate
Front door and rear door
Rear windshield and side wall outside plate
Luggage outside plate and side wall outside plate
Side wall outside plate and taillight & bumper
Luggage outside panel and rear taillight
Taillight and rear bumper
Side wall outside plate and refill opening
Front bumper and headlight
Left fender and front bumper
Engine cover outside plate and left front fender
Roof and front windshield
Roof and rear windshield
Left front fender and headlight
Engine cover outside plate and headlight
Side wall outside plate and front windshield Table 5-1Body Repair -Service Data For for Body7-36Technical Repair Data
Repair Data
2.5mm(+1,0mm)
5mm±1mm
5.5mm±1.5mm, Height Difference 2 mm±1.5mm
6mm±1.5mm, Height Difference 2.5mm±1.5mm
5.5mm±1mm
7mm±1.5mm
4.5mm±1.5mm
2mm±0.5
5.5mm±0.5mm
3mm(1,-0.5mm)
3.5mm(1,0mm)
3mm±1mm
1mm(1,0mm)
4mm±1mm
4mm±0.5mm
3mm±0.5mm
3mm±0.5mm
4.5mm±1mm
11mm±0.5mm

II. Supplemental Specifications on Tightening TorqueFor those fastening pieces either not specified in the "Body" part or not stated in other assemblies, the following
specifications shall apply.
Thread Dia. Thread Pitch Tightening Torque
(mm) (mm)Standard Value (N.m) Max. Value(N.m) Min. Value(N.m)
61 9 12 6
8 1.25 23 26 16
8 1 25 28 17
10 1.5 59 75 37
10 1.25 63 79 45
10 1 64 80 46
12 1.75 95 111 73
12 1.5 97 113 75
12 1.25 99 115 78
14 2 160 185 122
14 1.5 180 205 146
16 2 215 245 182
16 1.5 240 270 199
18 2.5 268 298 229
18 1.5 316 346 287
20 2.5 430 470 389
20 1.5 440 480 396Body Repair -Service Data For for Body7-37Table 5-2
Supplemental Specifications for Vehicle Body and All Assembly Fastening Piece

Appendix: Body Key Dimensions1. Engine CompartmentAppendix-Body Key Dimensions7-38
(mm)
Item Description
Diameter of Hole
XY Z
A,a
Front fender installetion hole(Front)
7(M6 nut) -336.18 +/-652.5 580.69
B,b
Front absorber spring support hole(Inside)
10 1.09 +/-519.51 641.4
C,c
Front fender installetion hole(Rear)
7(M6 nut) 62.3 +/-661.71 665.72
D Cowl panel drip charnel fixing hole 7(M6 nut) 66.13 -1.2 648.7
E,e Collision sensor installation hole 9(M8 nut) -445.74 +/-436.17 273.26
F Braking pipe instaltion hole 7(M6 nut) -49 -418.74 309.12
f
ABS actuator installatim hole(front)
9(M8 nut) -48.64 417.53 291
G,g
Radiator upper crossmermber installation hole(front)
7(M6 nut) -589.94 +/-397 452.84
H,h
Radiator side insulation gasket installation hole
10x8-621.82 +/-403.33 94.99
I Hood lock bracket installation hole 7(M6 nut) -662.61 0 36.34
J,j
FR bumper horizontal installation hole
9(M8 nut) -651.68 -487.41 275.57
K,k
Windscreen fastener installation hole
11.5x8.7-849.35 +/-357.86 111.07
L,l
Radiator uppor crossmenber installation hole
7(M6 nut) -553.26 +/-392.02 502.18
M,m Hood hinge hole(Rear) 9(M8 nut) 149.64 +/-668.27 678.44
N,n Front fender support hole 10 -368.55 +/-704.84 379.94
O,o
Joint between side outerpanel and roof panel
£ ­ 202.21 +/-636.33 736.57
P,p
Joint between side outer panel and dash panel
- 851.59 +/-508.37 1092.37
A-D 771±2.5
4
a-D 771±2.5
B-c 1183±2.5
4
b-C 1183±2.5
B-D 522±2.5
4
b-D 552±2.5
C-M 89±2.5
c-m 89±2.5
D-E 771±2.5
4
D-e 777±2.5
D-L 746±2.5
4
D-l 746±2.5
N-O 1410±2.5
A-c 1376±2.5
4
a-C 1376±2.5
I-j 547±2.5
4
I-J 547±2.5
I-H 410±2.5
4
I-h 410±2.5
O-p 1360±2.5
4
o-P 1360±2.5
A-o 1408±2.5
4
a-O 1408±2.5
I-g 580±2.5
4
i-G 580±2.5
F-b 997±2.5
f-B 1088±2.5
L-c 1231±2.5
4
l-C 1231±2.5
Measuring
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Value
ToleranceMeasuring
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Value
ToleranceMeasuring
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Value
Tolerance
Measuring
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Value
Tolerance