low beam GEELY MK 2008 User Guide

Chapter 4 Light SystemSection 1 Light System IntroductionI. Composition Light system comprises external illumination and signal system and internal illumination system.
The function of the external illumination and signal system is to illuminate the road ahead and send signals
to other vehicles.
The internal illumination system provides internal illumination for driver and passengers.II. Precaution for service1. Precaution when repairing electrical equipments
Disconnect the battery ground cable.
2. Precaution when replacing a headlamp bulb
(1) Before replacing a halogen bulb, turn the headlamp OFF to make it cool.
(2) When installing a new halogen bulb, do not touch the glass part of the bulb with bare hands.
(3) If there is oil stain on the surface of halogen bulb (headlamp and front fog lamp) when the lamps are
turned ON, its service life will be shortened.
(4) Halogen bulbs (headlamp and front fog lamp) have pressurized gas inside and require special handling.
They can explode if dropped to ground. The glass fragments will splash up.
(5) When replacing, make sure to use the bulbs with the same power, same model.
(6) After the bulb is installed, make the lamp holder tight.III. Bulb specificationsRemark: All bulbs are made by Philips Corp..Light System-
Light System Introduction5-26Name Specifications
Headlamp (High beam and Low beam) H1 12V 55W
Turn signal lamp PY21W 12V 21W
Position lamp W5W 12V 5W
Front fog lamp H3 12V 55W
Rear combination lamp (Turn signal lamp) PY21W 12V 21W
Rear combination lamp (Brake / Position lamp) P21/5W 12V 21/5W
Rear combination lamp (Rear fog lamp) P21W 12V 21W
Rear combination lamp (Back-up lamp) P21W 12V 21W
Interior lamp (dome lamp) R5W 12V 5W
Rear row reading lamp C5W 12V 5W
Side turn signal lamp W5W 12V 5W
High mounted stop lamp (incl. rear trunk lamp) W5W 12V 5W
License plate lamp W5W 12V 5W
Door courtesy lamp W5W 12V 5W

Symptom
Front fog lamp dose not light up with light control
switch HEADLAMP (Head lamp is normal).
Only one side front fog lamp dose not lightSuspected Area
1. Fog lamp fuse
2. Front fog lamp relay
3. Light switch assembly
4. Harness
1. Bulb
2. HarnessSection 2 Light System Malfunction InspectionSuspected Area
1. Bulb
2. LH or RH headlamp fuse
3. Harness
1. Lamp switch assembly
2. Harness
1. Bulb
2. LH or RH headlamp fuse
3. Harness
1. Lamp switch assembly
2. Harness
1. Lamp switch assembly
2. Harness
1. Bulb
2. Harness
1. Bulb
2. Harness
1. Fuse
2. Light control switch
3. Harness
1. Beam control switch
2. Harness2. Front fog lamp systemSymptom
"Low beam" dose not light (One side)
"Low beam" dose not light (All)
"High beam" dose not light (One side)
"High beam" dose not light (All)
Light dose not flash (Dimmer)
Headlamp is dim
Only one side tail lamp lights
Tail lamps on both sides do not light (Headlamp
is normal)
Tail lamps on both sides do not light (Headlamp
is abnormal)Light System -Light System Malfunction Inspection5-28I. Light system problem symptoms table: Description:
The table below can help you find the causes of malfunction. These figures show the most possible
malfunctions in order of priority. Inspect each part in the order given. If necessary, repair or replace these parts.
1. Headlamp and tail lamp

Switch motion Testing terminal Status
ON
1-2 ON
(gear lever is in reverse gear)
OFF 1-2 OFFSwitch position Testing terminal Status
OFF EL2-FF-RF OFF
Front foglight EL2-FF ON
Rear foglight EL2-FF-RF ONSwitch position Testing terminal Status
Low beam EL1-HL ON
High beam EL1-HU ON
PASSING EL1-HU-PASS ON (2) Check whether headlight dimmer switch is connected
Check whether terminals are connected when switch is in each position according to the table.
If it does not meet stipulation, replace the switch.
(3) Check whether direction indicator switch is connected
Check whether terminals are connected when switch is in each position according to the table.
If it doest not meet stipulation, replace the switch.
(4) Check whether front and rear foglight switch is connected
Check whether terminals are connected when switch is in each position according to the table.
If it doest not meet stipulation, replace the switch.
2. Reversing light switch assembly
Check whether reversing light switch assembly is connected
Check whether two terminals are connected when switch works
according to the tableSwitch position Testing terminal Status
Left turn FU-TL ON
Straight ahead FU-TL-TR OFF
Right turn FU-TR ON
If it doest not meet stipulation, replace the switch.
3. Brake lamp switch assembly
Check whether brake lamp switch assembly is connected
Check whether two terminals are connected when brake lamp
switch works
If it doest not meet stipulation, replace the switch.Step down brake pedal 1-2 ON
Release brake pedal 1-2 OFF2 1Light System -Light System Malfunction Inspection5-321
2 ON
OFFRelease PushSwitch motionTesting terminal Status

Section 4 Front Fog Lamp ReplacementI. Removal1. Remove front bumper. (see bumper replacement)
2. Remove electrical connector.
3. Remove fixed bolt (as shown in the figure).
4. Remove front foglight assembly.II. Installation1. Install front foglight assembly.
2. Mount fixed bolt.
3. Mount electrical connector.
4. Mount front bumper.
5. Adjust vehicle state.
6. Adjust front foglight beam.III. Replacement of front head light bulb Remove dust shield by rotating anticlockwise
Pull out bulb plug
Press and loosen steel wire clip
Pull out lamp holder, take off bulb
Replace bulbLight System -Front Fog Lamp Replacement5-351-Turn light dust shield
2-Low beam dust shield
3-High beam, front position lamp dust shieldIII. Replacement of front foglight bulb1. Press and rotate anticlockwise, take off dust hood
2. Take out bulb
3. Replace bulbIV. Adjustment of front foglight beam1. Adjust tire pressure in standard value
2. Start up engine
3. Turn on foglight switch
4. Adjust foglight beam turn screw to adjust foglight beam in the vertical direction.
Description:
Turn screwdriver anticlockwise to make beam upward, or turn screwdriver clockwise to make it downward.

Notes:
If noise occurred does not belong to any of the above-mentioned situations, please find out the cause according
to "receiving problem".
5. CD phonograph
CD phonograph (hereafter referred to as CD) uses laser beam to read digital signals recorded on CD, then revert
to analog signal of music.
Notes:
Don't attempt to break down or apply oil to any component of the phonograph. Do not insert anything other
than a CD into optical disk cartridge.
Notes:
CD phonograph uses invisible laser beam, could generate harmful radialization, always operate phonograph
according to instructions.
6. Maintenance
(1) Cleaning of magnetic tape phonograph, magnetic head:
a. Open tape cartridge gate with your finger, use a pencil or a similar article to insert guider.
b. use cleaning pen or cotton swabs with detergent to wipe magnetic head surface, idler wheel or guide
pulley.
(2) CD phonograph, CD cleaning:
If CD is dirty, use soft cloth to wipe the surface from CD center radially outwards.
Notes:
Don't use ordinary recorder detergent or antistatic protectant. 4. Noise problem
Detailed description of noise problem fed back by customers is of great importance for analyzing and
eliminating noise interference, the table below may be used for diagnosis.Audio System -Audio System Description5-39Noise condition
Noise occurs in special position
Noise occurs when receiving small
signal
Noise only occurs at night
Noise occurs in special position
during driving Radio wave
AM
FMCause
Most probably external noise
Broadcast from local station might broadcast the same
program. If program is the same, one of them might be
disturbed
Most probably from remote interference
Most probably is multiplex interference due to FM
frequency changeExample:
Magnetic head
Guide pulley
Idler wheel

1. Front cross beam assembly
The front cross beam assembly includes front cross beam left/right support assembly, front cross beam sub-
assembly, front cross beam side support etc. They play a role in front bumper.
2. Left/right longitudinal beam assembly
The left/right longitudinal beam assembly includes left/right longitudinal bean front and mid- block assembly,
energy-absorbing beam big assembly, and left/right front damper support assembly etc.
It is mainly used to install engine left/right suspension, left/right front suspension damper, storage battery and
other accessories. In the outside, it can be equipped with left/right front fender.
3. Radiator cross beam assembly
The radiator cross beam assembly includes radiator left/right post big assembly, radiator lower cross beam big
assembly, radiator central support sub-assembly, and radiator upper cross beam big assembly etc.
It is mainly used to install radiator, condenser, engine hood lock, radiator hood, front bumper, and front
headlight.
4. Front wall lower plate assembly
The front wall lower plate connects to the floor, which separates the engine compartment from the cabin. It
includes front wall frame assembly, front wall lower main plate assembly, brake installation reinforced plate, and
front wall left/right support assembly etc.Fig. 5-2 Engine Compartment Assembly & Front Wall Parts
1. Front cross beam assembly 2. Left/right longitudinal beam assembly
3. Panel left/right support assembly 4. Front wall lower plate sub-assembly 5. Front wall upper assembly
6 Radiator cross beam assemblySurvey -Body Structure7-2123456front wall lower plate assembly, front wall upper assembly, left/right front damper support lower front plate
assembly, and right front damper right-angle support assembly.

It is mainly used to install the pipes and accessories of the brake system and clutch system.
5. Front wall upper assembly
The front wall upper assembly includes left/right hinge base mounting plate big assembly, front wall upper
front cover big assembly, VIN number mounting plate, and front wall upper rear cover big assembly etc.
It forms a high-stiffness frame structure together with the engine compartment assembly and the front wall
lower plate assembly. It can generate strong resistant to the transverse collision and rolling deformation. It can also
separate the engine compartment form the cabin, preventing the odor entering into the cabin. Consequently, it can
isolate the noise, heat and vibration.(2) Floor Assembly The floor assembly is the base work of the main structure. It is a key component that connects various
assemblies and carries the load. The vehicle performance is subject to its strength and stiffness. For the floor
assembly, see the Fig. 5-3.
The floor assembly includes front floor assembly and rear floor assembly. The front floor mid-block goes
through a ridgy channel in longitudinal direction. It can increase the longitudinal rigidity together with the lower
floor longitudinal beam. The space below under the channel is used to install various parts and components, such
as transmission gearshift rod, parking brake cable, discharge pipe with three-way catalytic converter etc. In the
cabin, there is carpet and muffle pad. The floor frame structure is made up of front floor left/right frame, front floor
main plate assembly, front floor mid-bridge assembly, rear frame assembly, rear floor rear block assembly, rear
floor mid-block assembly and longitudinal beam etc. These parts and components provide strong and reliable carry
capacity and ensure that the vehicle meets the strict driving requirement on the body.Fig. 5-3 Floor Assembly
1. Front floor left/right frame 2. Front floor main plate assembly 3. Longitudinal beam rear block 4. Rear frame assembly
5. Rear floor rear block assembly 6. Rear floor mid-block assembly 7. Front floor mid-bridge assemblySurvey -Body Structure7-371
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(2) Front FenderFront fender plays a role in front wheel apron and rotect person safty.And at the same tirne,if also woork as vehicle
styling parts.
For the match relationship between the front fender & engine hood and the front door, see Fig. 5-9.Fig. 5-9 Front Fender related to surrounding parts
A) With Engine Hood (4mm¡À1mm)
B) With Front Door (5mm¡À1mm)(3) Door Assembly Doors have LH/RH front door and rear door.
The door uses hinge gemel with limiting device, which is an open structure.
The door includes door outside plate, door inside plate, bumper and hinge reinforced plate etc.
The door has a complex structure, which is a movable component on the body. It helps the passengers get on/
off the vehicle and form an enclosed cabin with the main structure and the relevant parts. Meanwhile, the doors
are used frequently, so there is high requirement on their reliability and durability.
The outside/inside plate is molded by one complete steel sheet, which can improve the stiffness and precision.
In order to improve the safety when the vehicle is collided from the side, four doors are equipped with door
bumpers.
As shown in Fig. 5-10 and Fig. 5-11, the door assembly is made up of outside plate assembly and inside plate
assembly.Fig. 5-10 Front Door
1. Front door inner panel 2. Left front door inner reinforced panel 3. Front door window opper rail 4. Door lock reinforced panel
5. Left front door inner plate cross beam 6. Front door outer panel 7. Door bumper assembly
8. Front door upper hinge assembly 9. Front door lower hinge assembly 10. Hinge reinforced panel assemblySurvey -Body Structure7-7Engine hood
Front fenderFront door
Front fenderA
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Fig. 5-11 Rear Door
1. Rear door inner panel 2. Rear door inner lock mounting panel 3. Rear door glass rail 4. Rear inner plate cross beam
5. Rear door outer panel 6. Door bumper assembly 7. Rear door lower hinge assembly
8. Rear door upper hinge assembly 9. Rear door inner plate hinge reinforced panel(3) Luggage Compartment Cover Assembly As shown in Fig. 5-12, the luggage compartment cover assembly includes luggage compartment cover outside
plate, luggage compartment cover inside plate, luggage compartment cover hinge mounting plate, and luggage
compartment cover lock core mounting plate etc. Fig. 5-12 Luggage Compartment Cover
1. Hinge torsion spring 2. Hinge mounting panel 3. Luggage compartment cover hinge
4. Luggage compartment cover inside panel 5. Luggage compartment cover outside panel
6. Luggage compartment cover lock core mounting panel1234568
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1Survey -Body Structure7-8

Chapter 2 Body RepairSection 1 Body Damage Forms and requirements For RepairI. Damage Type The damage type includes deformation, crack, rust-through, water leakage, dust leakage and the like caused
by collision, overload, fatigue, and corrosion.
The body damage is not merely caused by the huge force. As some parts (such as door etc.) are damaged, the
vehicle stays in an abnormal status, which also can cause damage. In most cases, the bend and torsion is caused
by huge local load in the impact or turnover accident.
Typical Body Damage:
1. Front Center Collision (Fig. 5-13)Fig. 5-13 Front Center CollisionBody Repair -Body Damage Forms and requirements For Repair7-9 For the damage caused by the collision on the front center, it usually makes the engine compartment front part
and the engine hood left/right side extend inwards so the following positions shall be checked:
a. Ambience of the left/right assembling position of the hood plate
b. Ambience of the joints of the front cross beam and the left/right longitudinal beam
2. Front External Force or Left External Force (Fig. 5-14)Fig. 5-14 Front External Force or Left External Force As shown in Fig. 5-14, when the front is pressed or the left side end is acted by the external force, the external
force will spread to around the front suspension mounting position from the left/right side of the hood, so
deformation occurs easily in this position.