battery GEELY FC 2008 User Guide

Engine mechanism - Engine assemblyEngine assemblyReplacement1. Take measures to prevent gasoline leaking.
2. Remove engine right bottom shield.
3. Remove engine left bottom shield.
4. Discharge coolant.
5. Remove front wheels.
6. Remove engine plastic hood components.
7. Remove battery.
8. Remove air filter assembly.
9. Remove air filter hose.
10. Remove battery tray.
11. Disassemble fuel hose assembly.
12. Remove throttle cable assembly.
13. Disassemble radiator hose inlet end.
14. Disassemble radiator hose outlet end.
15. Disassemble cold air pipe inlet hose.
16. Disassemble cold air pipe outlet hose.
17. Remove transmission control pull cable assembly.
18. Disassemble warm air water inlet hose [4G18-1300102].
19. Disassemble warm air water outlet hose [4G18-1300108].
20. Disassemble the hoses of all joints to connect vehicle body end.
21. Uncouple engine wire harness.(a) Remove glove compartment door.
(b) Remove engine wire harness from engine ECU and junction block.
(c) Pull out engine wire harness.
(b) Remove engine wire harness from junction block of engine room.
(e) Remove vehicle body earth wire. 36

(k) Insert special tool into location hole on left side of sub
frame and vehicle, and then tighten bolts up to speci-
fied torque.
Torque: bolt A: Bolt B: m
(l) As shown in the diagram, tighten 2 bolts.
Torque: Note: after installing sub frame, check the sub
frame is aligned with location hole on
vehicle.78. Install compressor.Torque: 79. Install lower left control arm assembly.(a) Install drive shaft to steering knucle.
(b) Install lower left control arm.
Torque: Hint: perform the same steps at another side.80. Install front left shaft hub nut.(a) Install fixed nut with socket wrench (39mm).
Torque: (b) Drive the cutout part of hub nut into groove with chisel.
Hint: perform the same steps at another side.81. Install left end front stabilizer link assembly.Fix bolts with hex socket wrench.
Torque: Hint: perform the same steps at another side.82. Install left side transversal lever assembly.(a) Connect transversal lever assembly to steering knucle
and install new nuts.
Torque: Note:Do not coat lubricant on thread and conical surface.After tightening nuts up to specified torque, con-
tinue turning nuts for 60¡ãand insert open pin.
(b) Insert new open pin.83. Connect fuel hose assembly.
84. Install battery tray.Torque: Engine mechanism - Engine assembly 43

Engine mechanism - Engine assembly85. Install alternator mounting components.Torque: 12mm bolt head A: 14mm bolt head B: 86. Install drive belt.
87. Install engine wire harness and all hoses
not connected.(a) Check and connect all joints of engine wire harness.
(b) Check and connect all hoses.88. Install transmission control pull cable assembly
and valve control pull cable.
89. Install air filter assembly and its hose.
90. Install steering middle shaft assembly.(a) Align alignment mark on steering middle shaft.
(b) Install 2 bolts.
Torque: m
(c) Install steering column cover.91. Install front exhaust pipe assembly.
92. Install front chassis bracket.Torque: 93. Install battery and connect wire.
94. Install engine plastic hood components.
95. Install front wheel and engine bottom shield.
96. Refill transmission lubricant.
97. Refill engine oil.
98. Refill coolant.
99. Check there is oil leakage.
100. Check there is coolant leakage.
101. Check idle speed and ignition timing.
102. Check CO/HC.Alignment
mark
Sliding in
Pulling 44

Cooling - Cooling fan systemCooling fan systemOn-vehicle inspection1. Check cooling fan function at low temperature (below 95).(a) Turn ignition switch to ON.
(b) Check cooling fan is stopped.
Hint: if it is not stopped, check cooling fan relay and water temperature sensor, or check the
joint or wire harness between them.
(c) Uncouple water temperature sensor joint.
(d) Check cooling fan runs.
If it does not run, check fuse, cooling fan relay, engine ECU and cooling fan, or check there is short
circuit between them.
(e) Connect back water temperature sensor joint.2. Check cooling fan function at high temperature (above 95).(a) Start engine and increase coolant temperature up to above Hint: water temperature is the value measured by water temperature sensor on water outlet.
(d) Check cooling fan runs.
Hint: if it does not run, please replace water temperature sensor.3. Check cooling fan.(a) Uncouple cooling fan joint.
(b) Connect battery and ampere meter to cooling fan joint.
(c) Check cooling fan runs normally and check ampere meter reading.Standard current: 712A
(d) Connect back cooling fan joint.Inspection1. Electronic fan relay [67000064]
2. Electronic fan relay II [67000072]
3. Cooling fan speed adjusting resistance assembly
[67000001]Measure resistance between terminals with ohmmeter.
Resistance: at normal temperature: 1.368 Specified
conditions
Normal stateConductionConductionTerminal connected
by three-use meter Conditions
Supply battery voltage
to No. 1 and No. 2
terminals
Specified
conditions
Normal stateConductionConductionTerminal connected
by three-use meter Conditions
Supply battery voltage
to No. 1 and No. 2
terminals

Starting and charging - Starting systemStarting and chargingStarting systemInspection1. Starter installation componentsNote: this test must be finished within 3 to 5 seconds to
avoid burning out coil.
(a) Remove nut at C terminal to uncouple wire of field coil.
(b) As shown in the diagram, connect battery wire to electro-
magnetic switch, and check drive pinion is pushed outside,
(pull-in coil and hold-in coil).
(c) As shown in the diagram, uncouple negative wire from ter-
minal C after the above connections, and check drive pin-
ion is still at the state of being pushed outside.(Hold-in coil)
(d) Push drive pinion toward armature side, and measure the
clearance between drive pinion end and stop ring.
Standard clearance: 1.0~5.0mm
(e) Uncouple negative wire from electromagnetic switch
housing, and check drive pinion returns back to original
position toward inside.79Terminal C
Terminal 50Terminal C
Terminal 50Terminal C
Terminal 50

Starting and charging - Starting system(f) Connect magnetic field coil wire to terminal C.
(h) Torque: (i) Clamp starter with jaw vice.
(j) As shown in the diagram, connect battery with ampere
meter.
(k) Read current value displayed on ampere meter.
(l) Current value specification: 90 A or lower at 11.5 V.2. Starter relay80Terminal 50Terminal 30Ampere
meter Specified
conditions
Normal stateConductionConductionTerminal connected
by three-use meter Conditions
Supply battery voltage
to No. 1 and No. 2
terminals

Starting and charging - Charging systemCharging systemPrecautions1. Check positive and negative wire of battery is con-
nected correctly.
2. When performing quick charge to battery, please
uncouple battery wire.
3. Do not test with high-pressure insulation resistance
tester.
4. do not uncouple battery wire during engine running.
81

1. Check battery voltage.(a) If extinguishing time of engine is not more than 20 minutes
after driving, please turn on ignition switch and electric
equipment (head lamp, blower motor and rear window
defog line etc.) for about 60 seconds to eliminate surface
charging during driving.
(b) Turn ignition switch to OFF, and then switch off electric
equipment system.
(c) Measure the voltage between battery negative (-) terminal
and positive (+) terminal.
Standard voltage: 12.5~12.9V at 20.
Hint: if the voltage is lower than standard
specification, please charge battery.
(d) As shown in the diagram, check battery window.
Hints:Green: OKWhite: requiring chargeBlack: replacing battery2. Check battery joint, fusible link and slow fuse (100A).(a) Check battery joint is loose or eroded.
(b) Check fast fuse and slow fuse (100A) are in conduction.3. Check drive belt.(a) Check belt is excessively worn or cable is broken etc.
Hints:If any inferior part is found, please replace drive
belt.It is allowable for the crack at the edge of drive belt
rib.
If there is block falling with belt rib, please replace with
new belt.
(b) Check the belt is correctly installed in guide groove.
Hint:Check with hands to ensure that the belt does
not slide out from the groove of pulley bottom.4. Visually check alternator wire harness.Check the condition of wire is perfect.Starting and charging - Charging systemOn-vehicle inspectionGreen White Black5. Listen to whether there is abnormal sound with alternator.There should not be abnormal sound with alternator during engine running.6. Check the circuit of charge alarm light.(a) Turn ignition switch to “ON”, and check charge alarm light is on.
(b) Start engine, and charge alarm light should be off.
Hint: if the function of charge alarm light does not conform to the regulation, please perform
trouble shooting to the circuit of charge alarm light.82

Starting and charging - Charging system7. Check charging system circuit at no load.(a) If there is battery/alternator tester, please connect tester
to charging system circuit as manufacturer instruction.
(b) If there is no battery/alternator tester, please connect volt-
meter to charging system circuit as the following way.
zUncouple wire on engine terminal B, and connect wire
on negative (-) test bar of ampere meter.
zConnect positive (+) test bar of ampere meter to alter-
nator terminal B.
zConnect positive (+) test bar of voltmeter to alternator
terminal B.
zConnect negative test bar of voltmeter to earth.8. Check charging system circuit at load.(a) Turn on high beam of front combination lamps with engine running at 2000rpm,and turn blower to
“HI” position.
(b) Check the reading of ampere meter.
Standard amperage: 30A or more.
Hints:If amperage is less than standard value, please repair alternator.If battery is under the state of full charge, amperage may be less than standard value sometimes. (c) Check charge system circuit.
(1) Check the readings of ampere meter and voltmeter with engine from idle speed to 2000rpm.
Standard current: 10A or less.
Standard voltage: 12.9~14.9V.
Hints:If voltmeter reading is more than standard value, please replace with new voltage regulator.If voltmeter reading is less than standard value, please check voltage regulator and alternator
as the following way.
(2) Earth terminal F, start engine and check voltage of
terminal B.
Hints:If voltmeter reading is more than standard value,
please replace with new voltage regulator.If voltmeter reading is less than standard value,
please check alternator.83Ampere meter
Uncoupling
terminal B wire
VoltmeterAlternatorBatteryTerminal F

Air conditioner--Air conditioner central heating core assembly
3. Disconnect refrigerant No.1 low pressure hose.
Note:
after disassembling the pipeline, it is necessary to cover
the joint to prevent humidity or dust from entering in
system.
4. Disconnect refrigerant liquid pipe A.
Hint:disconnect liquid pipe A with the method being
same as No.1.
5. Disconnect water outlet hose of heating.
(a) Slide out fixed clamp and disassemble water outlet hose
of heating.
6. Disconnect water intake hose of heating.
Slide out fixed clamp and disassemble water intake hose of
heating.
7. Disassemble cathode wire of battery.
8. Make front wheels face the front.
9. Disassemble safety airbag assembly at the side of
driver.
10. Disassemble steering wheel.
11. Disassemble combination instrument cover
[68000077].
12. Disassemble combination instrument assembly
[68000081].
13. Disassemble ventilation orifice assembly at the left
side of panel [68010010].
14. Disassemble ventilation orifice assembly at the right
side of panel [68010011].
Air conditioner central heating core assembly
Overhaul
1. Disassemble radiator cover.
2. Reclaim HFC-134a(R134a)
 227 
low pressure
hose
liquid pipe A