wheel GEELY FC 2008 Manual PDF

Power steering--Power steering oil pump assembly
Power steering oil pump assembly
Overhaul
1. Disassemble front wheel
2. Disassemble right bottom defender board [68000004]
3. Disassemble driving belt.
4. Disassemble oil storage tank to the No. 1 oil pipe
of power steering pump
Disassemble fixed clamp, and take down the oil storage tank
to the No. 1 oil pipe of power steering pump.
5. Disassemble in-out oil pipe assembly of power
steering gear [64000131]
(a) Use special tool to disassemble in-out oil pipe assembly.
(b) Disassemble the bolts and disconnect the fixed clamp of
in-out oil pipe.
6. Disassemble rear bracket of power steering pump
Disassemble the bolt and rear bracket of power steering pump.
7. Disassemble power steering oil pump assembly
[64000132]
(a) Disconnect the joint of oil pressure switch.
(b) Disassemble two bolts, two screw caps, then take down
the power steering oil pump assembly.
8. Assembly power steering oil pump assembly
(a) Assemble power steering oil pump assembly with two
bolts and two screw caps.
Torque: 37 N
x xx x
xm
(b) Connect the joint of oil pressure switch.
Note: the joint could not contact any oil.
9. Assemble the rear bracket of power steering oil pump assembly
Assemble rear bracket of power steering oil pump assembly with bolts.
Torque: 37 N
x xx x
xm
Hint:Insure the stop lever of bracket has contacted the body of power steering pump, then
tighten the bolt.
 203 
Special tool

10. Connect the in-out oil pipe assembly of power
steering gear [64000131]
(a) Assemble fixed clamp of in-out oil pipe with bolt.
Torque: 7.8 N
xm
(b) Connect in-out oil pipe with special tool.
Torque: 41 Nz
xm
Hint:
zUse torque wrench whose lever length is 345 mm.
zSpecial tool should be parallel with torque wrench,
only this could make practical torque value.
11. Connect the N0. 1 oil pipe of oil storage tank to power steering oil pump assembly.
Connect oil pipe with fixed clamp.
12. Assemble driving belt.
13. Assemble front wheel.
Torque: 103 ± 10 Nx xx x
xm
14. Add power steering oil.
15. Exhaust the air in power steering system.
16. Check whether there is any oil leakage.
17. Assemble right bottom defender board of engine [68000004].
Power steering--Power steering oil pump assembly
Special
tool
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 204 

Power steering gear assembly
Overhaul
1. Make front wheel face the front
2. Disassemble safety airbag assembly at the side of driver
(equipping with SRS) [6701011]
3. Disassemble steering wheel assembly [67010001].
4. Disassemble dust-proof cover in steering column
[64000123].
Disassemble two screw caps, then take down the dust-proof
cover.
5. Disassemble steering sliding shaft assemble
(a) Make mark on sliding yoke and steering middle shaft.
(b) Loosen A bolt and disassemble B bolt, then disassemble
sliding shaft.
6. Disassemble front wheel
7. Disassemble right bottom defender board [68000004].
8. Disassemble left bottom defender board [68000003].
9. Disconnect left end terminal of transversal lever
(a) Disassemble cotter pin and screw cap.
(b) Use special tool to disassemble the left end terminal of
transversal lever from steering knuckle.
Hint: disassemble the other with same method.
10. Disassemble right end terminal of transversal lever.
11. Disassemble in-out oil pipe assembly of power
steering gear [64000131].
(a) Use special tool to disassemble in-out oil pipe assembly
of power steering gear.
Power steering--Power steering gear assembly
Align the mark
Special tool
Special tool
 205 

Power steering--Power steering gear assembly
29. Assemble steering No.2 dust-proof cover.
(a) Insure steering gear hole is not plugged by lubricating
grease.
Hint: if hole is plugged, the pressure in dust-proof
cover when steering wheel turns after combin-
ing will change.
(b) Assemble dust-proof cover, fixed clamp and new iron wire.
Note: do no t hurt or bend dust-proof cover.
(c) After coiling dust-proof cover with iron wire for two circles,
turn it for several circles to fix it.
(d) Liking that shown in figure, bend iron wire to rotating di-
rection to prevent it from hurting dust-proof cover.
Hint: assemble the other side with same method.
30. Assemble No.1 dust-proof cover of steering gear.
31. Assemble left ball head of transversal lever .
(a) Screw locking cap and transversal lever ball head in gear
terminal lever until aligning the mark.
(b) After adjusting front wiring harness, tighten the screw cap
(referring to page 80).
Torque: 74 ± 5 N
xm
Hint: assemble the other side with same method.
32. Assemble right ball head of transversal lever .
33. Assemble power steering gear assembly [64000133].
(a) Assemble power steering gear assembly on beam with
four bolts.
Torque: 58 N
xm
 209 
Align the mark

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 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

57. Assemble control cable of air mixing flow choke
(manual air conditioner).
(a) Connect control cable of air mixing flow choke to air condi-
tioner control assembly.
(b) Set up drag arm at “MAX>COOL” position.
(c) Assemble inner pull cable terminal to control lever.
(d) Press down lightly the fixed clamp of pull cable by the ar-
row direction in left figure, then assemble exterior pull cable
to fixed clamp.
Air conditioner--Air conditioner central heating core assembly
Connection Clearance Wrong
 233 
Hint:Operate temperature control lever, check whether the control lever keep silent and does
not return at the position of “MAX.COOL” and “MAX.HOT”.
(e) Disassemble control cable of air mixing flow choke from air conditioner control assembly.
58. Assemble upper panel assembly.
59. Assemble air conditioner control assembly.
60. Assemble helix cable.
61. Assemble steering wheel.
62. Check whether the steering wheel position is right.
63. Check horn button assembly.
64. Assemble horn button assembly.
65. Check SRS warning light.
66. Assemble refrigerant No.1 low pressure hose.
(a) Spread Refrigerant oil on new O-shape loop and assemble
it on hose.
(b) Assemble refrigerant No.1 low pressure hose and fixed
clamp.
Hint:After installation, check the fixed situation of
pipeline fixed clamp claw.
67. Assemble refrigerant liquid pipe A.
(a) Spread Refrigerant oil on new O-shape loop and assemble it on hose.
(b) Assemble refrigerant liquid pipe A and fixed clamp.
Hint: After installation, check the fixed situation of pipeline fixed clamp claw.
68. Add cooling water.
69. Heat the engine.
70. Check whether the cooling water leaks.
71. Fill the refrigerant, regulated quantity: 660 ± 10g.
72. Check whether the refrigerant leaks.

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 

Supplemental restraint system--Note
Special tools and measurers which any safety airbag repairing position should have:
Changeable subassembly which safety airbag repairing position should have:
a. Safety airbag assembly at the side of driver;
b. Safety airbag assembly at the side of passanger;
c. Helix cable assembly.
d. ECU assembly;
e. Steering wheel.
I. Safety airbag joint
No. ItemApplicable
(1) Terminal dual-locking organization
(2) Airbag anti-explosive organizationJoint 3, 4, 7, 8
(3) Checking organization of electric circuit connection
(4) Inadequacy connection protection organization Joint 4
(5) Joint dual-locking organization Joint 2
(6) Joint dual-locking organizationJoint 6, 7, 10
Safety airbag at the
side of passengerSafety airbag at
the side of driver
Helix
cable
Airbag controller
1. All safety airbag joints should be yellow to be easy to distinguish the joints on other automobile parts,
this could guarantee the safety performance and reliability of safety airbag joint, each kind of joint has
special function and design.
 240 
Number
a
b
c
d
eFunction
Disassemble airbag subassembly on steering wheel
Assemble and disassemble big nut on steering column
Assemble and disassemble ECU and safety airbag assembly
at the side of passenger on automobile body.
Used for electric measurement on wiring harness
Used for resistance measurement of electric ignition device
of airbag subassembly. Name and type of tool
5S hexagon wrench
Socket wrench 18S
14S socket wrench
Numeric multi-meter DT 992 type
Electric detonator tester
QJ992 type
Short
wiring
harness

(4) Joint locking organization:
Lock the locking clasp of joint to fasten the connection of joint.
2. When the automobile front face is impacted, and generated force is bigger than the standard pre-set,
airbag will work automatically. The sensor in safety airbag controller will feel the impact, at the same
time, it will judge the generation of impact by inner arithmetic to make ignition electric current. Electric
current will flow in gas generator to make explosive function, then two gas generators in airbag at the
side of driver and passenger will make gas to increase quickly inner pressure of airbag and rush out
the trim cover of steering wheel and instrument panel. After airbag charging is closed, the gas ejects
from the gas outlet at the side or at the back of airbag.
II. Disassemble the connecting joint of lower helix cable and wiring harness of steer-
ing wheel.
1. Put your finger on sliding block.
2. Move the sliding block to release the clasp.
3. Pull out the male joint.
Liking that shown in figure: some joints of wiring harness use the female joints in the right part of figure,
some designs of helix cable is similar with the joints in the left part.
III.Connect the connecting joint of lower helix cable and wiring harness of steering wheel.
1. Liking that shown in figure, align locking part of male joint and sliding block of female joint in same
direction to avoid mutual friction.
Supplemental restraint system--Note
 242 
Sliding block
Sliding block
Disconnect completely