GEELY FC 2008 Repair Manual

Engine mechanism - Timing chain assembly34. Install speed sensor.Torque: 35. Install engine fixing bracketTorque: 36. Install water pump mounting components
[4G18-1307100].(a) Install new o-ring on water pump.
(b) Install water pump with 6 bolts.
Torque: bolt A: m37. Install drive belt tensioner device.Torque: nut: Bolt: m38. Install right engine mounting assembly.Torque: 39. Install cylinder head cover components.(a) Install gasket to cylinder head cover.
(b) Eliminate all old seal materials.
(c) Coat sealant on 2 positions shown in the diagram.
Sealant: silicon rubber flange sealant 1596
(Kesaixin 1596).
Notes:Eliminate all grease on contact surface.After coating sealant, finish installation of cylinder
head cover within 3 minutes.After installing, do not refill engine oil within 2
minutes.
(d) Install cylinder head cover and cable bracket with 9 bolts,
2 seal washers and 2 nuts.
Torque: nut: Bolt: m40. Install ignition coil mounting components.Torque: 50

Engine mechanism - Timing chain assembly41. Install alternator mounting components.Torque: 12mm bolt head: 14mm bolt head: m42. Refill coolant.
43. Check there is coolant leakage.
44. Check there is oil leakage.
51

Engine mechanism - CamshaftCamshaftReplacement1. Remove engine hood.
2. Remove ignition coil assembly.
3. Remove cylinder head cover assembly.
4. Remove engine right bottom shield.
5. Turn crankshaft to cylinder 1 compression top dead
center position.(a) Turn damping pulley to align its groove with “o” mark on
timing chain hood.
(b) Check dot marks on camshaft timing sprocket and VVT
timing sprocket, and they should be in a line on timing chain
hood surface as shown in the diagram.
Hint: if not, turn crankshaft for one circle (360) again
and align the above marks.6. Remove drive belt.Slowly turn drive belt tensioner clockwise to loosen it.Then
remove drive belt and put back drive belt tensioner slowly and
gently.7. Remove right engine mounting assembly.(a) Remove PS oil pump reservoir and put it aside.
(b) Place wooden block between jack and engine, properly
place the jack, and then remove engine fixing bracket shock
absorber.8. Remove drive belt tensioner assembly.Hint: operate the jack up and down to remove bolts. 52Mark
Mark
Mark
Timing chain
hood surface
Groove

Engine mechanism - Camshaft9. Remove camshaft.Note: do not turn crankshaft before installing timing chain
tensioner.
(a) Turn crankshaft to cylinder 1 top dead center position.
(b) Make marks on timing chain and camshaft timing sprocket.
(c) Remove 2 bolts and chain tensioner.
(d) Fix camshaft with variable wrench and then loosen the fixed
bolts of camshaft timing sprocket.
Note: do not damage valve lifter.
(e) As sequences shown in the diagram, loosen camshaft bear-
ing cover bolts on exhaust camshaft at several times and
remove the bearing cover at the same time.
(f) As shown in the diagram, remove exhaust camshaft tim-
ing sprocket.
(g) As sequences shown in the diagram, loosen camshaft bear-
ing cover bolts on intake camshaft at several times and
remove the bearing cover at the same time.Painting
mark
Fixing
Loosening53

Engine mechanism - Camshaft(h) Hold timing chain with hands and then remove intake
camshaft.
(i) As shown in the diagram, tie up the chain with bandage.
Note: be careful not to let anything fall into the timing
chain hood.10. Check VVT driver assembly [4G18-1006300].(a) Check locking state of timing sprocket.
Clip the camshaft with a jaw vice, and ensure VVT driver
is locked tightly.
Note: be careful not to damage intake camshaft.
(b) Release lock pin.
(1) As shown in the diagram, seal 5 oil ducts of intake
camshaft journal with vinyl rubber cloth.
Hint: there are 2 advance side oil ducts in the groove
of intake camshaft, and clog one of them with
rubber block.
(2) In opposite side of the groove, prick a hole on
vinyl rubber cloth of advance side oil duct surface
and delay side oil duct surface.
(3) Send in 2 oil ducts (advance side oil duct and
delay side oil duct) with the surface rubber cloth
pricked under the pressure of 150Kpa.
Warning: cover the oil ducts with cloth to avoid
oil injecting out in pushing.54Delay side
oil ductAdvance
side oil
duct
Close
OpenClose
Open
Vinyl rubber cloth
Rubber blockDelay side
oil ductAdvance
side oil
duct

Engine mechanism - Camshaft(4) Ensure whether the timing sprocket of VVT driver
will turn toward timing advance direction in de-
creasing the pressure of timing delay oil duct.
(5) When camshaft timing sprocket turns at max.
timing advance position, release the air pressure
in timing delay side oil duct, and then release the
air in timing advance side oil duct.
Hint: camshaft timing sprocket will turn only af-
ter the lock pin is released.
(d) Check the fixing state of max. delay position.
Ensure camshaft timing sprocket assembly is fixed at
max. delay position.11. Remove VVT driver assembly.(a) Clip the camshaft with a jaw vice, and ensure VVT driver
is locked tightly.
Warning: be careful not to damage camshaft.
(b) As shown in the diagram, seal 5 oil ducts of camshaft
journal with vinyl rubber cloth.
Hint: there are 2 advance side oil ducts in the
groove of camshaft, and clog one of them
with rubber block.
(c) In opposite side of the groove, respectively prick a hole
on vinyl rubber cloth of advance side oil duct surface
and delay side oil duct surface.
(d) Send in 2 oil ducts (advance side oil duct and delay
side oil duct) with the surface rubber cloth pricked
under the pressure of 150Kpa.
Warning:cover the oil ducts with cloth to avoid
oil injecting out in pushing.
(e) Ensure whether the timing sprocket of VVT driver will
turn toward timing advance direction in decreasing the
pressure of timing delay oil duct.
Hint: camshaft timing sprocket will turn toward
advance direction only after the lock pin is
released.
(f) When camshaft timing sprocket turns at max. timing
advance position, release the air pressure in timing
delay side oil duct, and then release the air in timing
advance side oil duct. Warning: if the air pressure in timing advance side oil duct is released earlier than that
in timing delay side oil duct, VVT driver assembly will move suddenly toward
delay side, and the lock pin will be damaged.
(c) Check rotating is smooth.
Besides max. delay position, turn VVT driver assembly within rotating rang and check rotating is
smooth.
Warning: Perform inspection with hands but not with
compressed air.55Delay side
oil ductAdvance
side oil
duct
Close
OpenClose
Open
Vinyl rubber cloth
Rubber block
Delay side
oil ductAdvance
side oil
ductDropping
pressure
Maintaining
pressure Delay side
oil ductAdvance
side oil
duct
Dropping
pressure
Maintaining
pressure Delay side
oil ductAdvance
side oil
duct

Engine mechanism - CamshaftWarning: if the air pressure in timing advance side oil duct is released earlier than that in
timing delay side oil duct, VVT driver assembly will move suddenly toward
delay side.This will cause the damage of lock pin.
(g) Remove VVT drive fixed bolts.
Notes:
It is strictly forbidden to remove other 4 bolts.
Under the condition of repeating using camshaft
timing sprocket, release lock pin at first, and then
install sprocket.12. Install VVT driver assembly.
13. Install camshaft.Put VVT driver assembly together with intake camshaft.
(a) As shown in the diagram, gently make VVT assembly
hold camshaft and turn it toward left until straight pin is
inserted into groove.
Warning: it is strictly forbidden to turn camshaft
timing sprocket toward timing delay side
(toward right).
(b) Check there is no clearance between sprocket flange
and camshaft.
(c) Fix camshaft timing sprocket and then tighten flange
bolt.
Torque: 70 ±5N.m
(d) Check VVT driver assembly could move to timing
delay side and is locked at max. timing delay position.
(f) As shown in the diagram, align alignment mark with
timing mark on camshaft timing sprocket, and install
timing chain on the timing sprocket.
(g) Check forward mark and figure, and tighten bolts as
sequences shown in the diagram.
Torque: 13 ±0.78N.m
(h) Align alignment mark on the chain with timing mark on
camshaft timing sprocket, and place exhaust camshaft
in cylinder head.Straight pin
key
grooveFlange bolt
Straight pin56Timing remark
chain linkTiming mark
Timing remark chain link
Timing mark

Engine mechanism - Camshaft(i) Temporarily tighten fixed bolts.
(j) Check forward mark and figure, and tighten bolts as
sequences shown in the diagram.
Torque: ±0.78N.m
(k) Install camshaft front bearing cover.
Torque: 23 ±1.38N.m
(l) Fix camshaft with variable wrench and then tighten the
fixed bolts of exhaust camshaft timing sprocket.
Torque: 54 ±10.8N.m
Note: be careful not to damage valve lifter.
(m)Check the alignment marks on timing chain and cam-
shaft timing sprocket, and then align the groove of damp-
ing pulley with the timing mark on timing chain hood as
shown in the diagram.Fixing
Tightening57Mark
Mark
Mark
Timing chain hood
Groove

Engine mechanism - Camshaft(n) Install chain tensioner components.
(1) Check o-ring is clean, and buckle on the hook as
shown in the diagram.
(2) Coat engine oil on the chain tensioner, and then
install it.
Torque: 9 ±1.8N.m
Note:when installing the chain temsioner,
buckle on the hook again if plunger has
ejected.
(3) Turn crankshaft counterclockwise to separate the
hook from lock pin on the plunger.
(4) Turn crankshaft clockwise, and check the sliding
parts are blocked by plunger.
Hint: if the plunger does not eject, press the ten-
sion rail toward chain tensioner with
screwdriver or fingers to separate the hook
from lock pin and make the plunger eject.Pushing into
Turning Plunger
Pushing into58Lifting
Hook Pressing
in
Pin
PinHook Sepa-
rate

Engine mechanism - Camshaft14. Adjust valve clearance.
15. Install cylinder head cover components.(a) Install gasket to cylinder head cover.
(b) Eliminate all old sealant (FIPG) materials.
(c) Coat sealant on position shown in the diagram.
Sealant: silicon rubber flange sealant 1596 (Kesaixin
1596).
Notes:Eliminate all oil on contact surface.After coating sealant, finish installation of cylinder
head cover within 3 minutes.After installing, do not refill engine oil within 2
minutes.
(d) Install cylinder head cover and harness bracket with 9
bolts, 2 oil seal washers and 2 nuts.
Evenly tighten bolts and nuts at several times.
Torque: nut: 29 ±5.8N.m
Bolt: 69 ±13.8N.m16. Install drive belt tensioner device.Torque: nut: 29 ±5.8N.m
Bolt: 69 ±13.8N.m17. Install right engine mounting assembly.Torque: 52N.m18. Check there is oil leakage.
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