GEELY FC 2008 Workshop Manual

Power steering--Power steering gear assembly
34. Assemble steering middle shaft.
(a) Align the mark of steering middle shaft and steering small
gear shaft.
(b) Assemble the bolt.
Torque: 35 N
x xx x
xm
35. Assemble exterior dustproof cover of steering
column.
36. Assemble auxiliary bracket assembly (64000087).
(a) Use special tool to align the right side of auxiliary bracket
with the hole of body, then lock the A bolt and B bolt
temporarily.
(b) Use special tool to align the left side of auxiliary bracket
with the hole of body, then lock the A bolt and B bolt
temporarily.
(c) Use special tool to align the left side of auxiliary bracket
with the hole of body, then lock the A bolt and B bolt.
Torque:
A bolt: 157 ± 10 N
x xx x
xm
B bolt: 113 ± 10 N
x xx x
xm
(d) Use special tool to align the right side of auxiliary bracket
with the hole of body, then lock the A bolt and B bolt.
Torque:
A bolt: 157 ± 10 N
x xx x
xm
B bolt: 113 ± 10 N
x xx x
xm
(e) After connecting with engine with one bolt and three screw
caps, hang it to auxiliary bracket.
Torque: 52 N.m ± 5 N
x xx x
xm
(f) Assemble carling to body with two bolts.
Torque: 39 ± 3 N
x xx x
xm
(g) Assemble the front suspension of engine to carling with
two screw caps.
Torque: 52 ± 5 N
x xx x
xm
Align the mark
Special
tool
Special tool
 210 

Power steering--Power steering gear assembly
37. Connect the bolts and nuts of left/right control arm
and control arm ball head.
Torque: 142 ± 10 Nx xx x
xm
Hint: connect the other side with same method.
Connect left lower control arm to steering knuckle with
bolt and two nuts.
38. Connect linking lever assembly of left/right front
stabilizer bar [64000097].
Use socket head wrench (5mm) to fix bolt, then connect sta-
bilizer linking lever with screw cap.
Torque: 74 ± 5 N
x xx x
xm
Hint: connect the other side with same method.
39. Connect the in-out oil pipe assembly of power steer-
ing gear [64000131].
(a) Connect the in-out oil pipe fixed clamp of power steering
gear with bolt.
Torque: 7.8 N
x xx x
xm
(b) Use special tool to connect the in-out oil pipe assembly of
power steering gear.
Torque: 41 N
x xx x
xm
Hint:
zUse the torque wrench whose lever length is
345mm.
zSpecial tool should be parallel with torque wrench,
only this could make practical torque value.
Hint: connect the other side with same method.
40. Connect the ball head at the left side of transversal
lever.
(a) Connect the ball head at the left side of transversal lever
with screw cap.
Torque: 49 ± 5 N
x xx x
xm
(b) Assemble new cotter pin.
Note: if cotter pin hole could not be aligned , tighten
the screw cap for 60 again.
Hint: connect the other side with same method.
 211 
Length of lever

Power steering--Power steering gear assembly
41. Connect the ball head at the right side of transver
sal lever .
42. Assemble right bottom defending board of engine
[68000004].
43. Assemble left bottom defending board of engine
[68000003].
44. Assemble front wheel
Torque: 103 ± 10 Nx xx x
xm
45. Connect steering slide shaft assembly.
(a) Align the mark between steering middle shaft and sliding
shaft.
(b) Assemble B bolt.
Torque: 35 ± 3 N
x xx x
xm
(c) Tighten the A bolt.
Torque: 35 ± 3 Nx xx x
xm
46. Assemble inner dustproof cover of steering column [64000123].
Assemble inner dustproof cover of steering column with two screw caps.
47. Make front wheel face the front
Hint: lift up front wheel shaft.
48. Assemble helix cable assembly (equipping with SRS).
49. Assemble steering wheel assembly [67010001].
(a) Align the mark between steering wheel and main shaft of steering column.
(b) Lock the fixed screw cap of steering wheel temporarily.
50. Add power steering oil (referring to page 200).
51. Exhaust the air in power steering system (referring to page 200).
52. Check the central point of steering wheel.
(a) Check the central point of steering wheel.
(b) Lock the fixed screw cap of steering wheel.
Torque: 50 ± N
x xx x
xm
53. Assemble safety airbag assembly at the side of driver (equipping with SRS) [67010011].
54. Check whether there is oil leakage.
55. Check the engine cover assembly.
56. Adjust the engine cover assembly.
57. Check and adjust the front wheel alignment (referring to page 87).
 212 

Air conditioner--Air conditioning system
Air conditioner
Air conditioning system
Note
1. Do not dispose Refrigerant in sealed space or near
flame.
2. Wear glasses to protect your eyes.
3. Do not let liquid Refrigerant contact with your eyes
or skin.
If liquid Refrigerant contacts with your eyes or skin:
(a) Wash the contacted part with much water.
Warning: do not knead your eyes or skin.
(b) Spread clean Vaseline on your skin.
(c) Go to doctor or hospital for special cure.
4. Forbid heating it or making it expose the flame.
5. Forbid dropping the Refrigerant tank or shake it
intensively.
6. Do not operate compressor when Refrigerant is lack.
If the Refrigerant in cooling system is lack, it will incur com-
pressor burned out for lacking lubrication. So it is necessary
to avoid.
7. Do not open the high pressure valve of filling instru-
ment package when compressor is working.
If opening the valve at this time, Refrigerant will flow back into
refrigerant tank to incur the tank will break. So only the low
pressure valve could be opened or closed.
8. Do not fill Refrigerant too much.
Too much refrigerant will make many problems such as lack
cooling degree, oil consumption, too hot engine and so on.
Inspection on automobile
1. Check the No.1 pressure switch.
(a) Control for electromagnetic clutch:
Check the function of pressure switch.
(1) Assembly filling instrument package.
(2) Connect the anode lead of OUM meter to No. 4 termi-
nal and connect cathode lead to No. 1 terminal.
(3) Liking that shown in figure. When refrigerant pressure
is changed, check the conduction between terminals.
wrong correct
Low-pressure
sideHigh-pressure
side
Not
conductionCon-
duction
Not
conduction
 213 

Air conditioner--Air conditioning system
If resistance does not accord with the regulation, it is necessary to change heat sensitive resistance.
If the function does not accord with the regulation, it is
necessary to change pressure switch.
(b) Control for cooling fan:
Check the function of pressure switch.
(1) Connect the anode lead of OUM meter to No. 2 termi-
nal and connect cathode lead to No. 3 terminal.
(2) Liking that shown in left figure. When refrigerant pres-
sure is changed, check the conduction between
terminals.
If the function does not accord with the regulation, it is
necessary to change pressure switch.
Inspection
11
111..
...No.1 thermal resistor
(a) Check the resistance between No.1 terminal and No.2 ter-
minal of No.1 heat sensitive resistance at different
temperatures, liking that shown in figure.
Conduc-
tion Not conduc-
tion
 214 
Resistance:
--
---22
22255
555--
---11
11155
555--
---55
55555
55511
11155
55522
22255
55533
33355
55544
44455
55555
55555
55566
66655
55577
77755
55588
88855
555
11
11155
555
11
11100
00088
88866
66644
44422
222
22
22200
000
Resistance
Temperature

Refrigerant
Inspection on automobile
1. Inspection of refrigerant quantity
Observe the visible window on high pressure liquid pipe.
Testing condition:

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Engine runs at the speed of about 1500 rpm.

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Fan speed is controlled at “HI” position.

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A/C switch turns to ON.

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Temperature control turns to “MAX. COOL” position.

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Automobile doors are opened.
Air conditioner--Refrigerant
Item Phenomenon Refrigerant quantity Verify
1There is air bubble on window. Lack (1)Use leakage measurer to check whether there is any leakage,
if necessary, repair it.
(2)Add refrigerant until air bubble disappears.
2 There is no air bubble on window. Without, full or too full Referring to item 3 and 4.
3There is no temperature difference on Without or little (1)
Use leakage measurer to check whether there is any leakage, if necessary, repair it.
outlet and inlet of compressor (2)Add refrigerant until air bubble disappears.
4There is obvious temperature difference Applicable or too much Referring to item 5 and 6.
on outlet and enter of compressor.
5Window becomes clear after air Too much (1)Reclaim refrigerant.
conditioner is closed. (2)Exhaust air and supply applicable clean refrigerant.
6After air conditioner is closed, refrigerant Applicable -
makes bubble, then becomes clear.
*When environment temperature is normal and refrigerant is enough, it is normal when there is no
bubble in window.
2. Use filling instrument package to check the refrigerant pressure.
This is a type to use filling pressure meter to check the malfunction position. In following situations, read
the meter.
Testing condition:
zSwitch is set up at inner air cycle, and the inlet temperature is 30-50°C.
zEngine runs at the speed of 1500 rpm.
zSet up the speed control switch of fan at “HI” position.
zTemperature control switch is set up at “COOL” position.
zA/C switch turns to “ON”.
zAutomobile door is opened completely.
Hint:please pay attention to that the show of meter might change little for environment tem-
perature changes.
View window
 215 

(1) Refrigerant system with normal function.
Meter reading
Low pressure end:
0.15-0.25Mpa
High pressure end:
1.37-1.57Mpa
(2) Water in cooling system.
Air conditioner--Refrigerant
When cooling system is
working, the pressure in low
pressure end changes to
vacuum or normal periodically.Water vapor enters refrigerant
system, and freezes on the ex-
pansion valve, the system
stops cycle in short time, when
ice melts, it returns to normal
again.(1)Change the condenser.
(2)Remove water in pipeline
with method of taking out
vacuum repeatedly.
(3)Fill applicable new
refrigerant.zDryer locates at full humidity
state.
zWater vapor of refrigerant
freezes on the outlet orifice
of expansion valve to ob-
stacle freezing cycle.
Phenomenon Possible reason Diagnose Method
(3) Lack refrigerant
Situation: too cold periodically, then lose cooling degree.
zThe pressure of high and low
pressure end is low.
zThere is air bubble on
window.
zRefrigerant leaks.Some part of refrigerant system
leaks.(1)Check it with leakage
measurer, if necessary, re-
pair it.
(2)Fill refrigerant to applicable
quantity.
(3)If meter pressure reading is
0, after checking and repair-
ing leaking position, take out
vacuum.
zRefrigerant in system lacks.
zCooling degree is not
enough.
Phenomenon Possible reason Diagnose Method
State: lack refrigerant
 216 

Air conditioner--Refrigerant
zThe pressure of high and low
pressure end is low.
zThe pipeline from condenser
to expansion valve frosts.
zRefrigerant flow in adjuster
is obstructed by impurity.zChange the condenser.zAdjuster is obstructed.
Phenomenon Possible reason Diagnose Method
State: cooling degree is not enough(4) Refrigerant cycle is poor
(5) Refrigerant does not have any cycle.
zLow pressure side is
vacuum, and pressure at
high pressure side is low.
zThe pipeline of front and
rear end of expansion
valve or adjuster frosts or
dews.
zRefrigerant flow in cool-
ing system is obstructed
by water vapor or dust.
zRefrigerant flow is ob-
structed by expansion
valve.(1)Check the expansion
valve.
(2)Remove the dirt in ex-
pansion valve with high
pressure air.
(3)Change condenser.
(4)Take out vacuum and fill
applicable refrigerant.
(5)If this is caused by ex-
pansion valve leakage,
change the valve. Refrigerant does not flow.
Phenomenon Possible reason Diagnose Method
State: not cool (sometime cool)
 217 

Air conditioner--Refrigerant
zThe pressure of high and
low pressure end is high.
zThere is no bubble on
window when engine
speed decreases.
zToo much refrigerant in
system incurs this.
zHeat dispersion of con-
denser is bad.(1)Clean the condenser.
(2)Check the function of
cooling fan.
(3)If those two items above
are normal, check the re-
frigerant quantity. Fill
applicable refrigerant.
zFilled refrigerant is too
much.
zHeat dispersion of con-
denser is bad¡ú¡ú
¡ú¡ú
¡úheat dis-
persion sheet of con-
denser is obstructed or fan
engine has malfunction.
Phenomenon Possible reason Diagnose Method
State: cooling degree is not enough.
zThe pressure of high and
low pressure end is high.
zPipeline of low pressure
end is too hot to contact.
zThere is bubble on
window.Air enters cooling system. (1)Check whether the Re-
frigerant oil is too dirt or
lack.
(2)Take our vacuum and fill
new refrigerant.
zThere is air in cooling
system.
zIt does not take out
vacuum completely.
Phenomenon Possible reason Diagnose Method
State: cooling degree is not enough.(6) Refrigerant is too much or the radiating fin of condenser is bad
(7) Air enters cooling system
Note: i f cooling system is
opened, and it does not
take out vacuum when
filling refrigerant, this
state will happen.
 218 

Air conditioner--Refrigerant
zThe pressure of high and low
pressure end is high.
zPipeline of low pressure end
frosts or dews heavily.Expansion valve has
malfunction.Check the expansion valve. zRefrigerant in low pressure
pipeline is too much.
zOpen degree of expansion
valve is too big.
Phenomenon Possible reason Diagnose Method
State: cooling degree is not enough
zThe pressure of low pressure
end is too high.
zThe pressure of high pres-
sure end is too low.There is inner leakage in
compressor.Repair or change the
compressor. zCompressor is bad.
zExpansion valve leaks or
sliding part is damaged.
Phenomenon Possible reason Diagnose Method
State: not cool(8) Expansion valve is bad
(9) Not cool
 219