Chery S11 / Chery QQ. Manual — part 99

Chery QQ Service Manual

Section 4 Interior Wire Harness

1．Arrangement of Interior Wire Harness

Chery QQ Service Manual Body System

Chapter 2 Service of Car Body Sheet Metal

Work

2.1 Overview of maintenance for four doors and two lids

Car body mainly consists of various kinds of framework parts, panels and other parts,

technology of making door is the most complicated technology which touch upon parts stamping,
parts welding, parts assembly and unit assembly, requested dimension coordination and process
technique are very strict, therefore it is difficult to maintain the door, the standard of requested
quality is much higher; enough understanding the structure of door is very important for the
maintenance personnel to do the work smoothly.

2.1.1 Structure of door
Generally speaking, main components of door include accessories such as outside door panel、
inner door panel 、door sash、glass run channel、door hinge、door lock and door window .Inner
door panel is equipped with window lifter and door lock, partial inner door panel shall be
strengthened for security of assembly. In order to ensure safety, bumper shall be installed inside
the outside door panel. Combine inner door panel with outside door panel by means of revers,
adhere and seam welding, in connection with different stand force, weight of outside door panel
shall be light, stiffness of inner door panel shall be strong, so it can undertake considerable
impulsive force.

Main components of door unit is relatively less in amount, it consists of outside door panel、

inner door panel、glass slide、sash reinforcing slab 、door lock mount slab、hinge reinforcing slab
and bumper unit in the ordinary way; A typical diagram of door’s structure is illustrated as
follows.

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Chery QQ Service Manual Body System

2.1.2 Technological process of door maintenance:
Generally speaking, basic method of four doors and two lids maintenance is the same as
technology of common sheet metal work maintenance; the following procedures are introduced
as follows:
(1) Initial

check

Measure the relative position and dimension between gaps for door and other car body unit.

(2) Clean the door .Clean dirt and grease stain off the door with water or detergent, make it fully
dry and ready for inspection.
(3) Identification of maintenance estimation. Determine maintenance method, making
estimation for the scope and degree of door’s damage through inspection.
(4) Purge old painting .After cleaning or before repair, get rid of old painting according to
actual condition, especially in the place of obvious rust 、gap and concave ;Methods of paint
removing are introduced as follows: hand work method 、heating method、apparatus method、
chemical method。

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Chery QQ Service Manual Body System

(5) Detect after disassemble. Generally speaking, it includes measurement for geometric
dimensions between sheet metal parts of all kinds, inspect concrete location of damage, make
clear the type of damage, analyze cause of damage, determine maintenance plan.

2.1.3 Main content of door maintenance
Generally speaking, cause of door damage has something to do with the following four aspects:
defect in structural design, defect during the process of production, chemical damage while being
used, physical damage while being used. Main damage causes are introduced as follows:
1. Abrasive wear. Caused by surface friction produced by relative movement because of sheet
metal parts surface touch together and being weighted; for example, door is hanging down,
coordination gap is enlarged because of long time abrasive wear between door hinge hole and
spindle.
2. Corrosion
Oxidizing reaction of sludge-liquid and filth accumulated on surface of the metal; or rust
produced by not adopting preservative treatment after welding repair or corrosion resulted by
touching chemical substance. It occurs frequently in sandwich position and spot welding article
joint .
3 Fissure or rupture
Fissure and rupture when it is serious, caused by sheet metal fatigue in the position of stress
concentration and weak link of structure because sheet metal suffers from internal and external
stress repeatedly.
4 The hollowness and fold damage.
The hollowness means that deformation of elasticity or plasticity because of collision and forcing
of door panel.

5 The crooked and twisted damage. That kind of damage means crooked or twisted damage
because the door undertakes too much burden.

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