ESP GEELY FC 2008 User Guide

Assemble interlocking pin in reverse gear block liking that
shown in figure.
Assemble two connecting bolts on reverse gear swing arm
bracket liking that shown in figure, their torque is 17N•m, and
put the head of reverse gear block in corresponding hole of
reverse gear swing arm bracket.
Put the head of reverse gear swing arm in the slot between
those reverse gear shafts liking that shown in figure.
Assemble reverse gear fork, spring and fifth reverse gear guide
block on fifth reverse fork shaft, and put fifth reverse gear
pulling fork in fifth gear cover, then assemble them in clutch
shell.
Transmission—Disassemble assembly
 187 

Assemble chosen adjusting gasket in transmission shell.
Spread seal glue on joint surface of shell body liking that shown
in figure.
Screw corresponding bolts liking that shown in figure, its torque
is 29N•m.
Spread anti-loose fastening glue on connecting bolts of re-
verse shaft, and use a new gasket to cover on the bolt, then
tighten reverse shaft on transmission shell, its torque is 29N•m
Assemble shift fixing assemble on transmission shell, its torque
is 37N•m
Transmission—Disassemble assembly
 190 

Steering column system
Overhaul
1. Put the front wheels towards the front.
2. Disassemble safety airbag assembly at the side of
driver (equipping with SRS) [67000179]
Note: if disconnecting airbag joint when ignition switch
locates at ON position, checking number will record it.
(a) Put the front wheels towards the front.
(b) Use planetary sleeve wrench to loosen two planetary
screws until the concave slot around the screw contacts
the screw shell.
(c) Pull out airbag assemble from steering wheel, and
disassemble airbag joint.
(d) Disassemble the terminal.
Warning:
¡ñ¡ñ
¡ñ¡ñ¡ñWhen storing safety airbag assembly at the side
of driver, it is necessary to put the surface of
airbag assembly towards the upside.
¡ñ¡ñ
¡ñ¡ñ¡ñDo not disassemble airbag assembly.
Note: when disassembling airbag assembly, pay
attention not to pull airbag wiring harness.
3. Disassemble steering wheel assembly [67100001]
(a) Disassemble the fixed screw cap of steering wheel.
(b) Make corresponding marks on steering wheel and main
shaft assembly.
(c) Use special tool to disassemble steering wheel.
4. Disassemble upper/lower decoration plate of
steering column [64000128/64000129]
5. Disassemble left combination switch assembly
[67000078] (referring to page 298)
Steering column--Steering systemSteering column--Steering system
Steering column--Steering systemSteering column--Steering systemSteering column--Steering system
airbag joint
Correct Wrongplanetary
screws screw shell
 194 
Align the mark

Supplemental restraint system--Note
Note:
zWhen making repair, please make malfunction diagnosis by the flash light and malfunction diagnosing device
according with the method regulated in this operation manual at first, at the same time, it is necessary to check
whether there is any malfunction code before disassembling battery wire.
zForbid disassembling or repairing at any non-appointment repair station
zDo not assemble any safety lever or bumper at the front of automobile, this will influence the performance of this
airbag.
zPeople for repairing, disassembling and assembling should be trained specially.
zWhen disassembling steering wheel assembly, it is necessary to make steering wheel right, only this could disas-
semble steering wheel assembly and make helix cable locate correct position, or it will damage helix cable assembly.
zECU matches with the technical parameter of electric system, forbid using the SRS parts of other automobiles, at
the same time, it is necessary to use new product to replace any part.
zWhen repairing automobile (especially electric welding), it is necessary to close key switch, and it is best to cut off
the anode of battery.
zAfter unfolding airbag, safety airbag assembly and helix cable assembly should be changed completely.
zWhen disassembling or carrying airbag assembly, trim cover should face the upside; safety airbag assembly
could not superpose directly to avoid make wrong explosion and make any accident.
zThe inner malfunction of controller (ECU) could not repair, if it happens any malfunction, change it.
zSafety airbag assembly should be stored in the environment whose temperature is lower than 40C, relative humid-
ity is lower than 75% and is apart from electromagnetic interruption.
zForbid disassembling the airbag assembly and gas generator in it.
zForbid connect AC or DC with over 20V with ECU to avoid damage.
Supplemental restraint system
Note
Warning:
zThis product is the SRS (supplemental restraint system) equipped by JILI “YUANJIN vision” type automobile, when
the automobile frontal face is impacted heavily, this product could reduce the possible hurt for driver and passen-
ger at the front seat, but this product could not replace the safety belt. For SRS is supplemental restraint safety
system, the driver should tie safety belt. This product is single-point electronic dual-airbag system whose charac-
teristic is that all sensors and control circuits are assembled in control box and gas maker is protechny. At the
same time, this product accords with the enterprise standard “Automobile safety airbag equipment” (Q/JL001—
2001) to product.
zIn repairing process, if it does not accord with correct operation sequence to operate, SRS might happen the
accidental explosion to make heavy accident. If repair does not accord with correct procedure, even if repair does
not incur accident, SRS might disable when automobile happens accident, for example, it could not explode by
the requirement. So, when making repair (including disassembling, assembling, checking or changing any part),
it is necessary to operate by correct sequence regulated by repair manual.
zIt is necessary to confirm following works before repairing: 1. Put the ignition switch at “OFF” state. 2. Disconnect
the cathode connection of battery, and make repair after waiting for 60s. In addition, disassembled cathode
should be twisted by insulating tape to insulate. (Capacitor in ECU could keep some electric power after battery
is cut off to unfold safety airbag in some time. So, when making maintenance, if it does not wait for some time
before operating, it might incur heavy hurt accident for wrong expansion of safety airbag.)
zDo not put the parts of SRS directly under the insulation of hot air or flame.
 239 

cthere are some malfunctions, indicating light will indicate them. If exterior malfunctions are historical,
after they are removed, indicate will disappear.
done displayed or historical malfunction is only set up again by server. Inner malfunction or “impact
record” of safety airbag controller (KD4.1) could not be set up again, in this situation, it is necessary to
change safety airbag controller (KD4.1).
(3) micro controller, independent indicating light illuminates.
Microprocessor having obvious malfunction state could not work, so it could not control the work of indicat-
ing light. In this situation, indicating light will illuminate directly by applicable circuit without considering the
micro-processor, liking that shown in following:
zThe battery providing electricity for safety airbag controller (KD4.1) disables: indicating light illumi-
nates by the automatic light driving function.
zInner working voltage loses: indicating light illuminates usually.
zNew setup caused by the unsuccessful watchdog trigger: indicating light flashes
zMicro-processor does not work: indicating light illuminates usually
zInsert of connecter of safety airbag controller (KD4.1) is wrong: indicating light illuminates usually by
short circuit stick.
Take example to specify diagnostic step:
If finding indicating light of safety airbag illuminates usually, even if it extinguishes at last, you could check
by follow step. First is to check the part happening malfunction with diagnostic tool.
Then make by the checking step for corresponding position.
a. If scan result is inner malfunction or safety airbag has exploded, at this time, change the ECU directly.
b. Malfunction has been removed.
Supplemental restraint system--Repair
 248 

Supplemental restraint system--Remove malfunction
Remove malfunction
Malfunction table
lThe voltage disappears (fuse is cut off)
l Combination instrument happens malfunction
lWiring harness between instrument package
and ECU unit has malfunction Malfunction Test statePossible reason
Indicating light of
safety airbag
system does not
illuminateWarning circuit of safety
airbag system happens
malfunction
1. Indicating light of safety airbag system does not illuminate
Diagnostic procedure
When making first malfunction test, we advise shaking wiring harness and plug to test whether there is
discontinuous bad contact in wire, if having this problem, please verify whether the connection of plug, terminal
and wiring harness is correct and is not damaged, if it is not this problem, please make by next step.
(1) Check other wiring harnesses and indicating lights of instrument package
a. Set ignition switch at ON position,
b. Are other warning indicating lights illuminating?
If illuminating: set ignition switch on LOCK position, then make next operation.
If not: check the power supply system and grounding system of instrument package (fuse), then
make step 5.
(2) Check the bulb
Warning: wrong treatment for safety airbag system parts will incur safety airbag and pre-
tension safety belt are opened accidentally, this might happen heavy accident. Please read
service warning of safety airbag system before disposing safety airbag parts.
a. Set ignition switch at LOCK position,
b. Cut off cathode wire of battery and keep this state for 60 seconds at least,
c . Disassemble combination instrument,
d. Measure whether corresponding two pins of indicating light of safety airbag could conduct,
Yes: make next step,
No: change the bulb of indicating light.
(3) Check the wiring harness connection between ECU unit and instrument package .
a. Set ignition switch at LOCK position,
b. Cut off cathode wire of battery,
c . Cut off the plug of instrument package ,
d. Check whether corresponding circuit of indicating light could conduct,
Yes: make next step,
No: change the wiring harness, then make step 5.
 251 
Number Malfunction removing itemSpecification
1 Indicating light of safety airbag system does not illuminate Warning circuit of safety airbag system happens malfunction
2 Indicating light of safety airbag system illuminates usually Warning circuit of safety airbag system happens malfunction or
there is exterior malfunction

Supplemental restraint system--Remove malfunction
Diagnostic procedure
When starting to check, firstly, use special diagnostic tool and ECU to make diagnostic communication to
find the reason of malfunction, if communication could not implement, make following inspection:
(1) Check the battery
a. Measure the voltage of battery
b. Is the voltage higher than 9V?
Yes: make next operation,
No: Power supply of battery is lack, check the charging/discharging system, then make step 5.
(2) Check the conduction of wiring harness between ECU and combination meter.
a. Set ignition switch at LOCK position,
b. Cut off cathode of battery,
c. Open the defending board of central channel,
d. Disconnect the connector of instrument package ,
e. Connect the cathode of battery,
f. Set ignition switch at ON position,
g. Check whether the terminal voltage of corresponding connector of instrument is 12V (connecting
wire of power supply and instrument)
Yes: make next step,
No: check the circuit part, then make step 5 after repairing it.
h. Set ignition switch at LOCK position,
i. Check whether the corresponding terminal of instrument connector conducts with corresponding
terminal of diagnostic interface (diagnose two ends of K wire),
Yes: make next step,
No: repair or change the wiring harness, then make step 5.
j. Guarantee cathode of battery is cut off and keep this state for one minutes at least, cut off connec-
tor of ECU.
k . Disconnect the plug of instrument package,
l. Check whether it conducts between ECU plug voltage, K wire, airbag indicating light terminal and
plug of instrument package ?
Yes: make next operation,
No: change the wiring harness, then make the step 5.
m. Disassemble the ECU to check whether the terminal is good, and the short circuit stick is broken.
Yes: change the ECU,
No: connect the ECU connector again, then make next operation.
zPower supply of battery is lack
zECU has inner malfunction
zIndicating light of combination meter safety airbag has
malfunction
zPlug connection of ECU has malfunction
zPlug of combination meter contacts badly
zPower supply fuse of ECU is cut off or contacts badly
zPlug terminal of ECU contacts badly
zWiring harness between plug terminal and grounding of
ECU contacts badly
zSafety airbag circuit at the side of driver or passenger
has malfunction. Malfunction Test statePossible reason
Indicating light of
safety airbag sys-
tem illuminates
usuallyIndicating light of safety
airbag system illumi-
nates usually
2. Indicating light of safety airbag system illuminates usually
 252 

Light--Light System 280  2. Fog light System
3. Turning and emergency warning light systemEmergency warning light and turn
light does not light
Emergency warning light does
not light (turning light is normal)
Turn light does not light
(Emergency warning light is normalSide turning light does not light
(warning light is normal)
One side of turning light does not
light
One side of turning light does not
light
Only one bulb does not light1. (meter) fuse
2. (turn) fuse
3. ignition switch
4. flasher assembly
5. wiring harness
1. Emergency warning light switch
2. wiring harness
1. turn light switch
2. wiring harness
1. turn light switch
2. wiring harness
3. bulb
1. turn light switch
2. wiring harness
3. bulb
1. turn light switch
2. wiring harness
1. bulb
2. wiring harnessThe light control switch switches on,
the front fog lights do not light (front
combination lights are normal)Lamp switch turn to “HEAD”. front fog
lights do not light (front combination light
do not light)Only one front fog light do not light
Rear fog lights do not light (front
combination lights are normal)
(front fog lights are normal)
Rear fog lights do not light (front fog
lights do not light)1.(front fog light)fuse
2.fog light relay
3.fog light switch
4.wiring harness
1.other parts
2.wiring harness
1.bulb
2.wiring harness
1.fuse
2.rear fog light switch
3.wiring harness
4.bulb
1.other parts
2.wiring harness
3.bulb
4.front fog light switch
5.rear fog light switchphenomena
Possible part
Reference pagesphenomena
Possible partsReference pages