Chery S11 / Chery QQ. Manual — part 101

Chery QQ Service Manual Body System

to take the small weld nugget as positioned weld according to interspaces of 30mm-50mm, carry
out welding in order after knocking ,make the surface to be flattened. In the case of welded seam
which needs high intensity, it is better for you to adopt two sided welding mothod.
(7) Flatten the welded seam with flat hammer, eliminate the welding pressure, then shaping it,
and polish the welded seam with rotary sander.

2.2.4 Recovery of fold
Fold includes “live folding”and“dead folding”according to damage degree of sheet metal pieces,
“live folding” means the slight fold which is can be eliminated directly by knocking the
protruding with hammer. “dead folding”refers to the serious folded part which squeeze together
tightly, two edges of the fold will become more and more “dead”, even cannot be relaxed if you
directly knock the protruding with hammer, therefore it is called “dead folding”.In principle,
recovery of fold is to open the “dead fold” first, make it unfolded gradually ,and make it become
“living fold”, then change the“live folding”to rough and uneven in surface, recover the rough and
uneven ones accordingly. The repair procedures are introduced as follows:
(1)Put the straightening force opposite to percussive force on the folded place adopting unfolding
method, make the fold unfolded, make the fold relaxed.
(2) Dismantle the damage parts and put it on the surface plate, begin from inside of the fold, you
can use suitable tools for prizing it open, heating with welding blow lamp while prizing it open,
turn the “dead fold” to “living fold”.
(3) Flatten the “living fold” from inside fold area with hammer. The knocking point shall be put
on the most protruding place. At the same time, it is necessary for you to make the surface plate
to play the role of mat while knocking. After it is ok, you can rotate the parts to knock the other
side until the folded parts are unfolded totally.
(4) Make it recover basically by means of heating and knocking while measuring with the
sample.
(5) After installing the finished parts in the vehicle body, you can check it according to the
sample; you can make further and finer straightening work in order to make it achieve the goal
eventually.
(6)You can adopt digging recovery method if it is impossible for you to repair the serious folded
damage in local position of sheet metal parts.

2.3 Welding of four doors and two lids
The following welding methods can be applicable to door welding: oxygen acetylene weld 、
CO2 blocking welding、hand work arc welding、resistance spot welding、brazing .Furthermore,
in order to not make the vehicle lower its own strength and durability, you’d better adopt the
same welding method as original maker’s as possible as you can, size and type of all welding
sockets shall be similar to the original maker’s.
In the case of appearance quality, defects such as burn-through, half point,fissure and large
amounts of fins for weld nugget shall be prohibited, surface of weld nugget shall be smooth and
good-looking, obvious twisted deformation shall not be allowed, depth of press mark shall be

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Chery QQ Service Manual Body System

less than 20% of the plate thickness; As to whether or not strength of weld nugget is strong

enough, you can make use of shovel and hammer to carry out negate damaging test. You can
knock in between two weld nuggets with shovel,to see whether or not it will be sealing off, you
can knock it with hammer for the recovery. Flash shall be prohibited in the case of welded
seam, lapping welded seam shall be good looking, defects such as air hole and fissures on
surface shall be prohibited, and defects such as undercutting, overlapping and burn-through shall
be prohibited while welding.

2.4 Installation of four doors and two lids
Installation of door and lid mainly involve levelness, clearance and hinge moment of force, the
concrete procedures are introduced as follows:
2.4.1 Put your right hand in the installation hole, hold the upper edge of door frame tightly with
left hand; make lower edge of door panel and upper edge of wind hole touch tightly, then make
the door panel and wind hole edge keep close together perfectly.

Inspect surface
quality

2.4.2 Put 4mm iron of plug and magnet on the illustrated position properly, iron of plug has
clearance under control, magnet has levelness under control.

Prevent
knocking
down the

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Chery QQ Service Manual Body System

2.4.3 Tighten the M8×22 combination bolts in proper order by hand, then hold the front end of
wrench by left hand shown as the illustration, hold the handle by right hand, operate vertically,
make the door hinge and hull structure body tightened.

T=25±3N.m

Vertical
operation

Separation 4±1mm

Separation 4.5 ±
1.0mm

2.4.4 Adjustment: After adjusting the rear door assembly, it is necessary for you to tune-up the
levelness, clearance and alignment between rear door assembly and the lateral enclosure,
levelness of a～b is -1.3（0～0.5）mm, requested clearance is 4.0±0.5mm；levelness of b～c is
0,requested clearance is 4.0±0.5mm；Levelness of c～d is 0,requested clearance is 4±0.5mm；
levelness of d～f is －0.7，requested clearance is 4.5±1.0mm；Alignment needs the door crest
line is slightly higher 0.1～0.3mm than the crest line of lateral enclosure.
While adjusting front door assembly, it is necessary for you to tune-up the levelness and
clearance between the front door assembly and upper part of lateral enclosure, the levelness is
-1.3(0～0.5)mm，requested clearance is 4.5±1.0mm；Levelness and clearance between front door
assembly and lower part of lateral enclosure, levelness is -0.7(-1.0～0)mm，requested clearance
is 4.5±1mm；levelness, clearance and alignment between front door assembly and rear door
assembly, levelness is -0.3(0～0.5)mm，requested clearance is 4±1mm,alignment of front door
crest line is slightly higher 0.1～0.3mm than the crest line of rear door. Top of front door and
rear door, alignment of front door and rear door bottom part is 0±1.0mm。
While adjusting the rear back door assembly, it is necessary to tune-up the levelness, clearance
and alignment of rear back door assembly and the lateral enclosure, levelness above point a is
±0.5mm，requested clearance is 4.4±1mm；levelness below point b is 0.8（-0.5～0）mm,
requested clearance is 5.4±1mm；levelness above point a～b is 3.5（-1～0）mm，requested
clearance is 4.4±1mm；tune-up the levelness and clearance of rear back door and the roof, the
levelness is 0.4（-0.5～0）mm, requested clearance is 0.4（-0.5～0）mm. Alignment between rear
back door and rear wing is 0.
While adjusting the engine head assembly, tune-up properly the clearance, levelness and
alignment between the engine head and the wing, clearance is 4±1mm，,requested levelness is
1±0.5mm；fix the engine head assembly on the hinge with M6×12 Allen bolts by hand, tighten it
with pneumatic screwdriver (model: LUM 25 hr05),technological torque is T=10±1Nm；The
engine head assembly and the wing are transitive smoothly; alignment of front end is 0±1mm.

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Chery QQ Service Manual Body System

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2.5.2 Dimension of vehicle body

b

a

c

d

2.5.2.1 Side view