gas type GEELY FC 2008 Workshop Manual

Brief introduction on Geely model “FC” Basic parametersTable 2 Types and parameters of main assemblyModel
TypeElectric injection system modelBore
StrokeDelivery capacityCompression ratioMax. power
Max. torque
Idling speedIgnition sequenceMin. fuel consumptionTypeMain gear box ratioTypes and parameters
JL4G184-cylinderin-line, four-stroke, water-cooling, double over-head
camshaft, 16-valve, CVVT multipoint injection gasoline engineUnited Automotive Electronic Systems Co., Ltd. M7.9.7 electric injection system5 gears synchronizer of constant mesh gearDry single, diaphragm spring, constant pressure
Rack-and-pinion steering gear with hydraulic powerDouble pipeline, vacuum boosterwith ABS +EBD anti-lock systemDisc brake
Disc brake
Strut-type front independent suspensionLongitudinal swinging arm and anti-twist beam compound rear suspensionBreakawayBalI cage and tripot type constant velocity universal jointLoaded all-metal body
Honeycomb cordierite carrier, noble metal catalyst
Swirl or swash plate compressorItem nameNumber
Engine1st gear
2nd gear
3rd gear
4th gear
5th gearReverse gearClutch type
Steering gear
Tire
Body structureSpecification
Air pressureRadial
tireTail gasAir
condi-
tioning
systemUnit



//
.
//
/
/.



2
Transmission
Each gear ratio
Braking
system
Sus-
pension
Drive
axleType
Front brake
Rear brakeFront suspension type
Rear suspension typeRim
Type
Drive shaftCatalytic converterCompressor typeNominal refrigerating capacityRefrigerant

Brake--Front brake assemblyFront brake assemblyOverhaul1. Disassemble front wheels.
2. Discharge brake liquid.Note: do not spill the brake liquid on paint surface of automobile body, if having, wash it cleanly.3. Disassemble brake branch pump assembly.(a) Disassemble the bolts and gaskets of brake hose joint on
brake branch pump, then disassemble brake hose.
Hint: the gasket has two types: two sheets type or one
type.
(b) Fix sliding pin of cylinder body to disassemble two bolts.4. Disassemble brake block of front wheels.(a) Disassemble brake block with muffle gasket.
(b) Disassemble muffle gasket from every brake block.5. Disassemble support sheet of brake block.
6. Disassemble sliding pin of brake branch pump.Disassemble sliding pin on branch pump bracket.7. Disassemble dustproof cover on brake branch pump.Disassemble two dustproof covers from brake branch pump
of disk.8. Disassemble left front brake branch pump.Disassemble two bolts and brake branch pump bracket.9. Disassemble dustproof cover of branch pump.Use screw driver to disassemble oil seal loop and dustproof
cover.10. Disassemble the piston of brake branch pump.(a) Put a cloth or similar thing between piston and branch pump.
(b) Use compressed air to disassemble piston from branch
pump.
Warning: when using compressed air, do not put your
finger at the front of piston.
Note: you could not be splashed by brake liquid.11. Disassemble oil seal of piston.Use screw driver to disassemble oil seal of piston from branch
pump.12. Disassemble exhaust bolt of branch pump.Brake branch pump
Dustproof cover141

Brake--Front brake assembly23.Assemble dustproof cover of branch pump..(a) After spreading lithium soap base glycol lubricating grease
on new dustproof cover of branch pump, assembling it in
brake branch pump.
Hint: dustproof cover should be assembled in branch
pump firmly.
(b) Use wrench to assemble fixing loop.
Note: do not damage dustproof cover.24. Assemble brake branch pump bracket.Use two bolts to assemble brake branch pump bracket.
Torque: 106
± ±± ±
± 10 N
⋅ ⋅⋅ ⋅
⋅m25. Assemble dustproof cover of brake branch pump
bracket.(a) Spread lithium soap base glycol lubricating grease on new
dustproof cover.
(b) Assemble two dustproof covers in front brake branch pump
bracket.26. Assemble sliding pin of front brake branch pump.(a) Spread lithium soap base glycol lubricating grease on the
surface of sliding part and sliding pin.
(b) Assemble two sliding pins in front brake branch pump
bracket.27. Assemble support sheet of brake block.143 28. Assemble brake block.Note: when changing brake block, muffle gasket should be changed with brake block at the same
time.
(a) Spread brake lubricating grease on both sides of every muffle gasket.
(b) Assemble muffle gasket on every brake block.
(c) When assembling inner brake block, abrasion indicator should face the upside.
Note: do not attach oil dirt or lubricating grease on the surface of brake block and brake disk.29. Assemble brake branch pump assembly.(a) Use two bolts to assemble brake branch pump.
Torque: 34
± ±± ±
± 3N
⋅ ⋅⋅ ⋅
⋅m
(b) Use joint bolt to assemble new gasket and brake hose.
Torque: 30
± ±± ±
± 3N
⋅ ⋅⋅ ⋅
⋅m
Hint: Gasket has two types: two sheets type and one type.
Bracket soft pipe should be assembled in localizing hole of branch pump firmly.30. Add brake liquid in storage tank.
31. Discharge the air in brake main pump.
32. Discharge the air in brake pipeline.
33. Check the liquid level of storage tank.
34. Check whether the brake liquid leaks.
35. Assemble front wheels.Torque: 103
± ±± ±
± 10 N
⋅ ⋅⋅ ⋅
⋅m

Brake--Rear brake assemblyRear brake assembly
OverhaulHint: overhaul procedure for right side is same as the left side.1. Disassemble rear wheels.
2. Discharge brake liquid.Note: do not spill the brake liquid on paint surface of automobile body, if having, wash it cleanly.3. Disassemble brake block of rear wheels.(a) Disassemble fixing clamp of anti-vibration spring.
(b) Disassemble two guide pins of brake block and brake block
with muffle gasket.
(c) Take down muffle gasket from every brake block.4. Disassemble left rear brake branch pump.(a) Disassemble the joint, bolt and gasket of brake hose of brake
branch pump, then disassemble brake hose.
Hint: gasket has two types: two sheets type and one
sheet type
(b) Disassemble two bolts and brake branch pump.5. Disassemble the bushing of brake branch pump.Disassemble two bushings from brake branch pump.6. Disassemble dustproof bushing of rear brake.Disassemble three dustproof bushings.7. Disassemble dustproof cover of branch pump.Use screw driver to disassemble fixing loop and dustproof cover.8. Disassemble the piston of brake branch pump.(a) Put a cloth or similar thing between the piston and branch
pump.
(b) Use compressed air to disassemble piston from branch
pump.
Warning: when using compressed air, do not put your
fingers at the front of piston.
Note: do not let brake liquid splash on you.9. Disassemble oil seal of piston.144

Brake--Rear brake assembly19. Assemble piston of Rear brake branch pump(a) Spread lithium soap base glycol lubricating grease on the
piston.
(b) Assemble piston on brake branch pump.
Note: do not force piston to assemble in branch pump
compulsively.20. Assemble dustproof cover of branch pump.(a) Spread lithium soap base glycol lubricating grease on new
dustproof cover of branch pump.
(b) Assemble dustproof cover in brake branch pump.
Hint: dustproof cover should be assembled in branch
pump firmly.
(c) Use screw driver to assemble fixing loop.
Note: do not damage dustproof cover.21. Assemble dustproof bushing of rear brake.(a) Spread lithium soap base glycol lubricating grease on the
surface of three dustproof bushings.
(b) Assemble three dustproof bushings in brake branch pump.22. Assemble the bushing of brake branch pump
bracket.Assemble two bushings of brake branch pump bracket.23. Assemble brake branch pump.(a) Assemble branch pump with two bolts.
Torque: 47
± ±± ±
± 4N
⋅ ⋅⋅ ⋅
⋅m
(b) Assemble new gasket and brake hose with joint bolt.
Torque: 30
± ±± ±
± 3N
⋅ ⋅⋅ ⋅
⋅m
Hint:zGasket has two types: two sheets type and one
sheet type.zBrake soft pipe should be assembled in localizing
hole of branch pump firmly.146Brake branch pump
Dustproof cover
Dustproof cover
Brake branch pump

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 

Safety belt--Front safety belt
(d) Explode safety belt pre-tension crimper.
(1) Confirm there is no one in automobile and in 10m scope apart from automobile.
(2) Press down working switch of special tool and explode safety belt pre-tension crimper.
Hint: when LED of working switch of special tool illuminates, safety belt pre-tension crimper will
explode charged gas at the same time.
(e) Treatment for safety belt pre-tension crimper.
Hint: when scraping automobile, it is necessary to explode safety belt pre-tension crimper,
then it could be scraped with automobile.
2. Only treatment for safety belt pre-tension crimper (Treatment type for exploding front
seat safety belt).
Note:
zwhen only exploding safety belt pre-tension crimper,
forbid using the automobile belonging to customer to
explode safety belt pre-tension crimper.
zWhen exploding safety belt pre-tension crimper, it is
necessary to accord with following step.
(a) Disassemble safety belt.
Hint:cut off safety belt at its position closing to
shrinker.
(b) Confirm the function of special tool.
(c) Assemble special tool.
(1) Connect two joints of special tool to the joint of safety
belt pre-tension crimper.
Note: to avoid damaging the joint and wiring har-
ness of special tool, do not lock the twice lock
of dual-lock organization.
(2) Place the safety belt pre-tension crimper on ground, and
cover it with tyre.
Note:Place the safety belt pre-tension crimper lik-
ing that shown picturey.
(3) Place th special tool above 10mm away from tire
Note: do not damage special tool and wiring har-
ness carefully.
(d) Explode safety belt pre-tension crimper.
(1) Connect red fixed clamp of special tool to the anode of
battery (+), black fixed clamp to cathode of battery (-).
(2) Confirm there is not anyone in 10m apart from the tyre
binding safety belt pre-tension crimper.
(3) Press down working switch of special tool to explode
safety belt pre-tension crimper.
Hint: when LED of working switch of special tool
illuminates, safety belt pre-tension crimper
will explode at the same time.
Special
toolSpecial
tool
Special
toolSpecial
tool Special
toolBattery
Over 10m
 272 

Windshield/bodywork glass/wing mirror--Front windscreen
Front windscreen
Change
Clues on: Please assemble as the disassembly opposite sequence. Assemble directions could
be got when necessary.
1. Disassemble right front pillar trim board assembly [68010017] (referring to page 390)
2. Disassemble left front pillar trim board assembly [68010014] (referring to page 390)
3. Disassemble inner rear mirror assembly [67010013] (referring to page 390)
4. Disassemble right sun shade [68010085] (referring to page 390)
5. Disassemble left sun shade [68010084] (referring to page 390)
6. Disassemble interior front headlamp assembly [67010075] (referring to page 390)
7. Disassemble passenger handle (referring to page 390)
8. Disassemble sun shade pothook [68010086] (referring to page 390)
9. Disassemble top interior trim board
Disassemble top interior trim board
10.Disassemble top left trim tape [68000128]
11. Disassemble top right trim tape [68000129]
12. Disassemble front windscreen sealed trim board [68000062]
(a) Use blade to cut trim tape as the drawing.
Note: Do not cut the bodywork.
(b) Disassemble rudimental trim type.
steel wire
 321  13. Disassemble front windscreen assembly [68000061]
(a) Use a steel wire to drill through windows and bodywork.
(b) Tie something like wood block at both the end of steel wire.
Clues on: Stick adhesive tape on the bodywork at work
to prevent paintwork from scraping.
Clues on: When separate window, do not damage
paintwork and interior trim board. When disassemble
front windscreen,put a plastic board between steel wire
and panel to prevent scratching the panel.
(c) Pull steel wire along front windscreen around, remove
agglutinant.
(d) Disassemble front windscreen.
Note: When cut front windscreen down, leave aggluti-
nant as much as possible on the bodywork.
14.Clean front windscreen assembly [68000061]
Use white gasoline to clean front windscreen around.
15. Assemble windscreen orientation plastic button

Chair--Rear chair (separating type)
Rear chair (separating type)
Overhaul
Hint:
When assembling, please work by the sequence opposite with
disassembling sequence, but when it has items that need to
pay special attention, it will add special specification.
1. Disassemble rear row chair cushion assembly.
Pull rear row chair cushion assembly upwards, then disas-
semble it.
Note: when disassembling, it is necessary to hold the
bracket at two sides of fixing clasp, then pull it upwards
to prevent it from distorting.
2. Disassemble rear chair head pillow assembly
[68010077]
3. Disassemble rear row chair backrest assembly.
4. Make the backrest face the front, then disassemble
four fixing clamps.
5. Disassemble four bolts and rear chair backrest
assembly.
6. Disassemble rear row chair right backrest assem-
bly [68010079]
Disassemble the bolt and rear row chair right backrest
assembly.
7. Disassemble rear row chair left backrest assembly
[68010078]
Disassemble two bolts and central backrest hinge.
8. Disassemble exterior cover of rear row backrest
(small).
(a) Disassemble fixing clamp, then disassemble rear row chair
gasket cloth.
(b) Disassemble fixing clamp, then disassemble head pillow
bracket.
(c) Disassemble exterior cover of rear row backrest with gasket.
(d) Disassemble the clamp, then disconnect exterior cover of
rear row backrest with gasket.
9. Disassemble exterior cover of rear row backrest (big).
(a) Disassemble central handrail hinge trim cover.
(b) Disassemble the bolt and central handrail.
A:100mm
Fixing
clasp
Fixing
clasp
 352 
(c) Disassemble fixing clamp, then disassemble rear row chair gasket cloth.
(d) Disassemble the clamp, then disassemble head pillow bracket.
(e) Disassemble exterior cover of rear row backrest with gasket.

Chair--Rear chair (separating type)
(f) Disassemble the clamp, then disconnect exterior cover of
rear row backrest with gasket.
10. Disassemble exterior cover of rear row chair
cushion.
Disassemble the clamp, then disconnect exterior cover of cush-
ion with gasket.
11. Assemble exterior cover of rear row chair cushion.
Use new clamp to assemble exterior cover of rear row chair
Locking loop pliers
 353 
cushion in gasket.
Hint:
zDo not damage or dirty exterior cover of cushion.
zWhen assembling clamp, it is necessary to prevent exterior cover of cushion from crinkling.
12. Assemble exterior cover of rear row chair backrest (big).
Hint:
zDo not damage or dirty exterior cover of cushion.
zWhen assembling clamp, it is necessary to prevent exterior cover of cushion from crinkling.
13. Assemble exterior cover of rear row chair backrest (small).
Use new clamp to assemble exterior cover of rear row chair backrest in gasket.
Hint:
zDo not damage or dirty exterior cover of cushion.
zWhen assembling clamp, it is necessary to prevent exterior cover of cushion from crinkling.
14.Assemble rear backrest central hinge assembly.
Use two bolts to assemble central hinge assembly.
Torque: 20 N
⋅ ⋅⋅ ⋅
⋅m
15. Assemble rear chair backrest side hinge assembly.
Use two bolts to assemble two side hinge assemblies.
16. Assemble rear row chair left backrest assembly [68010078]
Use the bolt to assemble left backrest assembly.
Torque: 8.0 N
⋅ ⋅⋅ ⋅
⋅m
17. Assemble rear row chair right backrest assembly [68010079]
Use the bolt to assemble right backrest assembly.
Torque: 8.0 N
⋅ ⋅⋅ ⋅
⋅m
18. Assemble rear row chair backrest assembly.
Use four bolts to assemble backrest assembly.
Torque: 18 N
⋅ ⋅⋅ ⋅
⋅m