key GEELY FC 2008 Workshop Manual

Engine cover/automobile door
Engine cover......................................................
366
Adjustment.....................................................
366
Front automobile door........................................
367
Subassembly.................................................
367
Overhaul........................................................
369
Adjustment.....................................................
372
Rear automobile door.......................................
373
Overhaul........................................................
373
Adjustment....................................................
375
Trunk cover.........................................................
377
Adjustment....................................................
377
Torsion spring of trunk cover.............................
378
Change..........................................................
378
Exterior/inner trim board
Front bumper....................................................
379
Subassembly................................................
379
Change..........................................................
380
Rear bumper......................................................
381
Subassembly................................................
381
Change..........................................................
382
Name plate........................................................
383
Change..........................................................
383
Exterior seal tape of left front door glass (LH)...
384
Change..........................................................
384
Exterior seal tape of left rear door glass...........
385
Change..........................................................
385
Light fender........................................................
386
Change..........................................................
386
Top left trim tape.................................................
387
Replacement.................................................
387
Left lower fender of automobile body (LH)........
388
Subassembly................................................
388
Change..........................................................
389
Inner trim board of top........................................
390
Change..........................................................
390Automobile control system
Ignition switch and anti-versa lock key warning switch.394
Malfunction phenomenon table.....................
394
Inspection......................................................
394
Electrical schematic diagram..............................
395

Engine mechanism - Timing chain assembly(2) Use damping pulley bolts to turn crankshaft with its key
toward upward.
(b) Install timing chain on crankshaft timing sprocket and
align the chain link having yellow mark with timing mark
of crankshaft timing sprocket.
Hint: there are 3 yellow chain links on the timing chain.(c) Install crankshaft timing sprocket with special tool.
(d) Install timing chain on camshaft timing sprocket and
align the chain link having yellow mark with camshaft
timing sprocket.27. Install chain guide rail components.Torque: m28. Install chain tension rail components.Torque: 29. Install speed sensor signal panel.Install signal panel with “F” mark toward forward.Toward portSet key
Yellow
mark
Timing mark
Special tool
Color (yellow) mark
Timing mark 47

Engine mechanism - Timing chain assembly(b) Coat engine oil on the chain tensioner, and then install
it.
Torque: Note: when installing the chain temsioner, buckle
on the hook again if plunger has ejected.33. Install damping pulley.(a) Align the key groove on the damping pulley with the
key on the crankshaft, and slide damping pulley in.
(b) Install damping pulley bolts with special tool.
Torque: (c) Turn crankshaft counterclockwise to separate the hook
from lock pin on the plunger.
(d) Turn crankshaft clockwise, and check the chain ten-
sion rail is blocked by plunger.
Hint: if the plunger does not eject, press the chain ten-
sion rail toward chain tensioner with screwdriver
or fingers to separate the hook from lock pin and
make the plunger eject.Special
tool 49 Pushing intoSeparationHook
Pin
TurningPlunger
Pushing
intoTurning

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 - Crankshaft front oil seal assembly5. Remove crankshaft front oil seal.(a) Cut oil seal lip with blade.
(b) Prize out oil seal with flat screwdriver whose sharp end is
winded with tape.
Note:check crankshaft is damaged after removing oil
seal, and repair with abrasive paper (#400) if it
is damaged.6. Install crankshaft front oil seal.(a) Coat a little MP grease on new oil seal lip.
Note: do not let oil seal lip contact with foreign
matters.
(b) Gently knock new oil seal in with special tool and hammer
until the seal surface is parallel and level with the end sur-
face edge of mounting hole.
Note: wipe off redundant grease on crankshaft.7. Install damping pulley.(a) Align the key groove on the pulley with the key on the
crankshaft, and slide pulley in.
(b) Install pulley bolts with special tool.
Torque: m8. Install right engine mounting assembly.Torque: 9. Check there is oil leakage.Cut
position
Prizing out
Special
tool61Special
tool

Lubrication - Oil pump assemblyOil pump assemblyReplacement1. Remove timing chain assembly (see Page 45).
2. Remove oil pump assembly [4G18-1011100].Remove 5 bolts, oil pump and oil pump gasket.3. Install oil pump assembly.(a) Install new gasket on cylinder body.
(b) Align the guide groove of oil pump drive rotor with the key
on crankshaft, and slide the oil pump in.
(c) Install oil pump with 5 bolts.
Torque: 76

Steering column--Steering systemSteering column--Steering system
Steering column--Steering systemSteering column--Steering systemSteering column--Steering system
13. Disassemble ignition switch key tank assembly
(a) Put ignition switch key tank on ACC position.
(b) Pull down stop pin and pull out key tank assembly with
right-angled screwdriver.
14. Disassemble ignition switch assembly
Disassemble two screws, and take down ignition switch
assembly.
15. Assemble ignition switch with locking core and key
assembly [68000019]
Assemble ignition switch with locking core and key assembly
with two screws.
16. Assemble ignition switch key tank assembly
(a) Make sure ignition switch key tank assembly locates at
ACC position.
(b) Assemble ignition switch key tank.
17. Steering locking function
(a) When taking out the key, check whether steering locking
organization is locked.
(b) When inserting the key, and turning to ACC, check whether
the steering locking organization is released.
18. Assemble electronic anti-stealing loop assembly
[67000009]
19. Assemble ignition switch clamp [68000020]
20. Assemble steering shaft assembly
(a) Assemble steering column assembly with three bolts.
Torque: 21 ± 2 Nxm
 196 

Air conditioner--Condenser Assembly(b) Disassemble two bolts.
(c) Pull the component on the top of water tank assembly back
to disassemble the condenser assembly.6. Disassemble the drier(a) Use 10mm hexagon wrench to disassemble the cover and
filter core from regulator.
(b) Disassemble two O-shape rings from the cover.
(c) Use the acutilingual pliers to disassemble the drier.7. Assemble the drier.(a) Use the acutilingual pliers to assemble the drier.
(b) Put the O-shape ring in the cover.
(c) Spread freezing lubricant at the connecting part between
the O-shape ring and the cover.
Refrigerant oil: 100PG
(d)Use the 10mm hexagon wrench key to assemble the cover
to condenser assembly.
Torque: 12.3 N⋅ ⋅⋅ ⋅
⋅m8. Assemble condenser assembly.
9. Assemble Refrigerant NO.1 high pressure hose.(a) Disassemble the cover from the tie –in of the pipe.
(b) Daub enough Refrigerant oil to lubricate at the connecting
part between the O-shape ring and the cover.
Refrigerant oil: 100PG
(c) Use the bolt to connect Refrigerant high pressure hose
with condenser assembly.
Torque: 5.1 N⋅ ⋅⋅ ⋅
⋅mInner hexagon
socket wrench
Adjuster 237 

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 

2. Inspection for indicating light of safety airbag
(1) When set the ignition switch at ON position, confirm whether the indicating light illuminates.
(2) After illuminating for five seconds, confirm whether indicating light extinguishes forever.
(3) If starting ignition switch for five seconds, indicating light does not extinguish (flash or illuminate for long
time), confirm the position of system malfunction with special diagnostic tool according to the flash
situation of indicating light.
3. System diagnosis
Safety airbag controller (KD4.1) will implement a series of cycle diagnostic testing to check whether the
function of airbag system has been prepared completely. This test will prevent restraint system from
exploding wrongly and insure the necessary explosion in impact. If finding any malfunction, safety airbag
controller (KD4.1) will store a applicable malfunction code and turn on indicating light to indicate a mal-
function state to be easy to maintain.
4. Malfunction judgment
(1) Malfunction category
System malfunction could be divided into three categories: power supply malfunction, subassembly
assembling malfunction and ECU inner malfunction.
a. Power supply malfunction
Normal working voltage of ECU is 9-18 V, related working voltage is 12 V. When automobile key is
turned to ACC gear, ECU connects power and begins to self-check, indicating light extinguishes
after illuminating for five seconds, this shows there is not any malfunction in ECU and exterior
subassembly, they could work normally. When automobile power voltage is less than 9V or higher
than 18V, ECU will self-check again. If self-checking could pass, ECU works normally, and indicat-
ing light extinguishes; if self-checking could not pass, it is necessary to self-check again, this self-
checking could be made six times, if indicating light illuminates all the time after six times, there is
some malfunction in power supply.
b. Assembling malfunction of airbag subassembly
Assembling malfunction of airbag subassembly is that malfunction which only needs to change or
repair airbag subassembly without needing to change ECU, including the situation that airbag
subassembly is not connected completely. If happening this malfunction when connecting power
supply, indicating light will flash N times at first, then it will illuminate all the time until malfunction is
removed. If happening impact in malfunction term, ECU could explode the channel of good part
and record every malfunction when exploding.
c. Inner malfunction of controller
Inner malfunction is the malfunction happening in ECU body, when happening this malfunction,
ECU could not explode airbag, and will record the impacting acceleration.
Note: common repairer could not repair this inner malfunction, if happening this malfunction,
it is necessary to change ECU.
(2) Malfunction state display
Malfunction treatment
1. Basic procedure of malfunction diagnosis
zAfter assembling new electronic control unit of safety airbag system, indicating light of safety airbag
system will extinguish forever after flashing for 5 seconds when ignition switch is at state of ON, this
shows airbag system works normally. At this time, the system does not need to repair, it is necessary
to make system diagnosis and repair when showing any situation except this.
zIf indicating light of safety airbag system does not illuminate when ignition switch is at the state of ON,
check the related circuits of indicating light, then operate it to make it enter working state.
Supplemental restraint system--Malfunction treatment
 244 
Warning light illuminate Scanning ECU by connecting Find the malfunction Deal with Clean the code
and does not extinguish diagnostic instrument malfunction