service GEELY FC 2008 Workshop Manual

Preface
Geely “FC” is an automobile with high performance/price ratio and it meets the requirement
of national safety, energy saving, emission regulations and personal use. This automobile is
a completely new and excellent model produced by Zhejiang Geely Automobile Co., Ltd with
development in self-reliance of Geely group and with self-dominated intellectual property
right. It characterizes elegant appearance,
energy conservation and environmental protection,
safety and comfort. “FC” is a product opening a completely new viewpoint of automobile
selection, because it is developed on the basis of creative design thinking that breaks through
all established customs and it features perfectly balanced performance of power, space,
safety, manipulation and comfort. “FC” is a competitive product for Geely developing brand
and exploring mid-level automobile market, which takes over the company philosophy “make
good cars that common people can afford, and let Geely cars go to the whole world” of Geely
automobile. “FC” is combination of creativity and intelligence of quite a large number of
automobile experts, who have been developing and searching with great concentration for
more than 30 months, and it fully embodies persistent Geely style of fashion appearance
and high performance/price ratio.
“FC” is equipped with engine JL4G18 completely developed and produced by Geely group.
Engine JL4G18 applies the following advanced technology such as VVT, full aluminum cylin-
der body, plastic intake manifold, completely new VVT inside seal method, completely new
OCV valve filtering method etc. with M7.9.7 electric injection system of BOSCH, and its
index on power efficiency, economical efficiency, and safety efficiency etc. reaches leading
level of national model with the same type. This engine features strong power, low fuel
consumption, low noise and high power per liter etc.
We start to compile “FC” Automobile Maintenance Manual, which is divided into 27 sec-
tions with detailed description of overall structure and maintenance of engine 4G18.VVT;
inspection and repair of engine BOSCH M7.9.7 electric control fuel injection system; struc-
ture and maintenance of chassis; structure and maintenance of FC electrical equipment;
structure and maintenance of ABS anti-lock brake system; structure and maintenance of
SRS air bag; structure and maintenance of auto air conditioning system; structure and main-
tenance of vehicle body etc. Information is detailed and accurate, contents are in systematic
coherence and description is concise and comprehensive.
This manual is compiled from structure, which prompts “FC” service personnel to master

necessary maintenance, repair and malfunction knowledge on the basis of understanding
main structure characteristics and simple principle of vision automobile. Electric control sys-
tem of “FC” automobile is particularly described with detail, and detailed steps and methods
are given for trouble shooting process. All kinds of malfunction could be eliminated quickly
and efficiently within the shortest time as long as you detect as the repair steps of this manual.
In addition, this manual is compiled with the following characteristics: in proper sequence,
clear demarcations, easy to understand, excellent in picture and its accompanying essay,
simple and clear, which is very applicable for a quite large number of “FC” automobile main-
tenance technicians and service personnel to refer to.
This manual is mainly compiled by Geely International Corporation; Geely Automobile En-
gine No. 2 Plant and engineering technicians of service corporation help complete this work.
Defects and mistakes are inevitable in this manual for limited level of compiler and limited
time, please contact Geely International Corporation if you find mistakes and careless omis-
sions in using and we can correct in time and reverse in next version.
Geely International Corporation
Nov. 2007

Fuel - Fuel tank assemblyBe careful of the contaminant that looked like dirt, because
fast-joint depends on o-ring to seal fuel pipe and joint.Do not perform this operation with tools.Do not bend or distort nylon hose.Cover the joint with plastic bag after removing the fuel hose.When the joint is stuck with fuel pipe, clip the hose with
fingers and rotate carefully to release the hose, and then
remove it.14. Remove fuel tank assembly(a) Remove parking brake pull cable retaining clip.
(b) Place jack under fuel tank. Remove fuel tank band harness and fuel
tank assembly.15. Remove fuel tank main fuel hose and oil return pipe
assembly
16. Remove No. 2 fuel evaporation hose assembly
17. Remove No. 1 fuel tank gasket
18. Remove No. 1 fuel tank protectorRemove rivet with electric drill and then remove fuel tank protector.19. Install No. 1 fuel tank protectorInstall fuel tank protector with rivet.20. Install No. 1 fuel tank gasketAs shown in the diagram, install new fuel tank gasket.21. Install fuel tank assemblyTorque: 39 N.m22. Install front exhaust pipe assemblyTorque: 40 N.m23. Install front floor bracketTorque: 30 N.m24. Install rear floor repairing hole coverInstall rear floor service hole cover with butyl rubber cloth.25. Check fuel leakage (see Page 14)
26. Check gas leakage of exhaust system
22

Supplemental restraint system--Remove malfunction
Remove malfunction
Malfunction table
lThe voltage disappears (fuse is cut off)
l Combination instrument happens malfunction
lWiring harness between instrument package
and ECU unit has malfunction Malfunction Test statePossible reason
Indicating light of
safety airbag
system does not
illuminateWarning circuit of safety
airbag system happens
malfunction
1. Indicating light of safety airbag system does not illuminate
Diagnostic procedure
When making first malfunction test, we advise shaking wiring harness and plug to test whether there is
discontinuous bad contact in wire, if having this problem, please verify whether the connection of plug, terminal
and wiring harness is correct and is not damaged, if it is not this problem, please make by next step.
(1) Check other wiring harnesses and indicating lights of instrument package
a. Set ignition switch at ON position,
b. Are other warning indicating lights illuminating?
If illuminating: set ignition switch on LOCK position, then make next operation.
If not: check the power supply system and grounding system of instrument package (fuse), then
make step 5.
(2) Check the bulb
Warning: wrong treatment for safety airbag system parts will incur safety airbag and pre-
tension safety belt are opened accidentally, this might happen heavy accident. Please read
service warning of safety airbag system before disposing safety airbag parts.
a. Set ignition switch at LOCK position,
b. Cut off cathode wire of battery and keep this state for 60 seconds at least,
c . Disassemble combination instrument,
d. Measure whether corresponding two pins of indicating light of safety airbag could conduct,
Yes: make next step,
No: change the bulb of indicating light.
(3) Check the wiring harness connection between ECU unit and instrument package .
a. Set ignition switch at LOCK position,
b. Cut off cathode wire of battery,
c . Cut off the plug of instrument package ,
d. Check whether corresponding circuit of indicating light could conduct,
Yes: make next step,
No: change the wiring harness, then make step 5.
 251 
Number Malfunction removing itemSpecification
1 Indicating light of safety airbag system does not illuminate Warning circuit of safety airbag system happens malfunction
2 Indicating light of safety airbag system illuminates usually Warning circuit of safety airbag system happens malfunction or
there is exterior malfunction

Scrap treatment for safety airbag
Hint:
zWhen scraping a automobile with SRS or disposing safety airbag module, it is necessary to explode the airbag by
following steps at first.
zIf there is any abnormal phenomenon when exploding airbag, please contact with our service store or automobile
factory in time.
Note:
z Forbid exploding the safety airbag module that does not explode by yourself.

zWhen exploding the airbag, it will make much big explosive sound, so it is necessary to operate this out of the
automobile, please do not make this operation influence the life of near habitants to avoid their complaints.

zWhen exploding the airbag, use the battery as power supply whose voltage is (12±1)V.
zWhen exploding the airbag, operator should be apart from the exploded module and he should confirm there is
not anyone in the scope of 10m at least.

z When disposing the exploded airbag module, it is necessary to wear glove and safety glass.

zWhen airbag is exploded, the temperature of airbag module is too high, and a lot of gas with peculiar smell will
be produced, so do not make any treatment for exploded airbag in 30 minutes after exploding it.
zPlease wash your hands with water after finishing those operations above.
zDo not sprinkle water on exploded airbag module.
zWhen scraping a automobile, the safety airbag module assembled on automobile should be exploded.
I. Scrap the safety airbag module on automobile
1. Treatment before exploding:
(1) Park the automobile on flat place.
(2) Disassemble the cathode and anode of battery and disassemble the battery from automobile.
Note: do not work until disassembling the cathode and anode of battery for 60 seconds.
(3) Safety airbag assembly should be unfolded by following sequence.
2. Safety airbag assembly at the side of driver
(1) Disassemble three screws and lower cover of combination switch.
(2) Disassemble the lower end of helix cable and the joint connecting with panel wiring harness.
(3) Connect the conversion wiring harness of safety airbag with one wiring harness with over 10 m used
for unfolding, and the connecting part should be twisted with insulation adhesive tape to insulate and
prevent from wrong unfolding for static.
Note:take down the joint of helix cable from panel wiring harness, the joint of helix cable
will be short circuit automatically, this will prevent from exploding the safety airbag
assembly at the side of driver for static to make heavy accident.
Supplemental restraint system--Scrap treatment for safety airbag
 264 
(4) Connect conversion wiring harness of safety airbag on yel-
low joint of helix cable, then lead it out of automobile with
unfolding wiring harness (see following figure).
(5) Close all windows and doors, and assemble automobile
cover.
(6) Cut off the joint of wiring harness used for unfolding of safety
airbag assembly at the side of driver at the place apart from
the automobile, then connect it with two ends of battery
taken from automobile to make it explode (see following
figure).
Cover of automobile body
Wiring harness for explosion

Audio system
Audio system
Notes
1. Observe notes for disposal and operation
(a) Please explain to customers: when take battery’s negative terminal off, the memory broadcasting
station on the audio AM/FM set on the radio will be deleted. So, before taking battery
s negative
terminal off ,note the station’s information according to your need. After taking back negative terminal,
set former station again.
(b) Before disassemble/assemble the radio, inspect and take cassette and CD out in.
Clues on: the malfunction of disassemble/assemble the radio is because the tape or CD can
not take out. Do not take it out by force. Drive the car to the service station.
(c) Do not touch the audio film of loudhailer
2. Refer to instructions about using and maintaining audio system
Audio system--Audio system
 307