brake fluid GEELY MK 2008 Owner's Manual

Brake System -Vacuum Booster4-93Replacement1. Discharge the brake fluid.
Note:
Never spray the brake fluid on the paint surface, otherwise wash it immediately.
2. Unfix the clutch fluid tank pipe (manual transaxle).
3. Remove the brake master cylinder.
4. Remove the HECU assembly (with ABS).
5. Remove the vacuum booster.
(1) Unfix the vacuum tube from the brake booster.
(2) Remove the return spring, clip and pin.
(3) Remove the four nuts and U-clip.
(4) Pull out the vacuum booster and washer.
6. Install the vacuum booster.
(1) Install the vacuum booster and new washer.
(2) Install and fasten the vacuum booster nut.
Torque: 25N.m
(3) Install the return spring, clip and pin.
7. Install the vacuum booster push bar.
8. Install the brake actuator. (with ABS)
9. Install the brake master cylinder.
10. Connect the clutch fluid pipe.
11. Add the brake fluid to the reservoir.
12. Discharge the air in the brake master cylinder.
13. Discharge the air in the brake pipeline.
14. Check and adjust the height of the brake pedal.
15. Check the free stroke of the pedal.
16. Check the reserved distance of the pedal.
17. Discharge the air in the clutch tank pipe (manual transmission).
18. Check and adjust the clutch pedal (manual transmission).
19. Check the level height in the brake reservoir.
20. Check the brake fluid whether there is any leakage.
21. Check the clutch fluid whether there is any leakage (manual transmission).

Repair1. Remove the front wheel.
2. Discharge the brake fluid.
Note:
Never spray the brake fluid on the paint surface, otherwise wash it immediately.Brake System -Front Brake Disc4-95Sliding Pin Dust Shields3. Remove the front disc brake cylinder.
(1) Remove the connector bolt and washer from the front disc
bake cylinder, and unfix the tube.
(2) Fasten the sliding pin on the front disc brake cylinder, and
remove the two bolts.
4. Remove the front brake pad package (only the pad).
(1) Remove the two brake pads with muffle washers.
(2) Remove muffle and heat isolation washers from the brake
pads.
5. Remove the support pad of the front brake pad.
Remove the two friction block from the brake cylinder support.
6. Remove the sliding pin of the front disc brake cylinder.
7. Remove the two dust shields
Remove the two dust shields from brake cylinder support.
8. Remove the left front disc brake cylinder support.
Remove the two bolts, and then take out the left front disc brake
cylinder support.
9. Remove the dust shield of the brake cylinder.
Remove the retaining ring and dust shield with screwdriver.Braking Disc Cylinder Bracket

Brake System -Front Brake Disc4-9611. Remove the front brake piston.
(1) Put a piece of cloth or equivalent between the brake cylinder
and the piston.
(2) Blow the piston out of the brake cylinder with compressed air.
Warning:
In the blowing process, the finger shall not be placed before the
piston.
Note:
Don't spray the brake fluid.
12. Remove the piston oil seal.
Take out the oil seal from the brake cylinder with screwdriver.
13. Check the brake cylinder and piston.
Check the cylinder wall and piston whether there is rust or scar.
14. Check the lining thickness of the brake pad.
Measure the lining thickness with ruler.
Standard Thickness: 10.0mm
Minimum Thickness:1.0mm
15. Check the abrasion indicator steel strap of the front brake.
Make sure the abrasion indicator steel strap has adequate flexibility and has no deformation, crack or damage.
All rust, dirt and other impurities shall be cleaned out.
16. Check the thickness of the brake disc.
Measure the thickness of the brake disc with screw micrometer.
Standard Thickness: 20.0mm
Minimum Thickness: 18.0mm
17. Remove the front brake disc.
(1) Make mark on the brake disc and wheel hub.
(2) Remove the brake disc.
18. Install the brake disc.
Tips:
Install the disc at the minimum swing position.

Brake System -Front Brake Disc4-9827. Install the support piece of the front brake pad.
Remove the two support pieces of the brake pad from the front disc brake cylinder support.
28. Install the brake lining block component.
Note:
When replace the abrasion brake lining block, replace the muffle
pad simultaneously.
(1) Apply the disc brake lube on both sides of all muffle pads
(2) Install muffle pads on all brake lining blocks.
(3) The abrasion indicator face upwards. Install a inner brake
lining block, then install a outer lining block.
Note:
Don't apply the oil or lube on the friction surface of the brake pad and brake disc.
29. Install the front disc brake wheel cylinder.
(1) Install the front disc brake wheel cylinder with two bolts.
Torque: 34N.m
(2) Install the new washer and tube with bolt.
Torque: 30N.m
Tips: Fasten the tube in the lock hole of the brake wheel
cylinder reliably.
30. Add the brake fluid to the storage tank.
31. Discharge the air in the brake cylinder.
32. Discharge the air in the brake pipeline.
33. Check the level height in the storage tank.
34. Check the brake fluid whether there is any leakage.
35. Install the front wheel.
Torque: 103N.m

Repair Repair the right side as the steps in the left side.
1. Check the thickness of the brake shoe lining.
Remove the hole plug, and check the thickness of the brake shoe
lining through the hole.
If the thickness is less than the minimum thickness, replace a new
brake shoe.
Minimum Thickness: 1.0mm
2. Remove the rear wheel.
3. Discharge the brake fluid.
Note:
Never spray the brake fluid on the paint surface, otherwise wash
it immediately.
4. Remove the rear brake drum.
(1) Loosen the parking brake rod, and remove the brake drum.
Tips: If the brake drum can't be removed easily, carry out the
following steps.
(2) Remove the hole plug, and insert a screwdriver through the
backboard to separate the brake automatic adjustment rod
and the adjustor.
(3) Rotate the adjustment wheel to reduce the length of the
adjustor with another screwdriver.
5. Check the inner diameter of the brake drum.
Measure the inner diameter of the brake drum with a brake drum
gauge or equivalent.
Standard Inner Diameter: 200.0mm
Maximum Inner Diameter: 201.0mm
6. Separate the left positioning post of the parking brake shoe.
Remove the extension spring from the front/rear brake shoe with
a special tool, and separate the left positioning post of the parking
brake shoe.
Note:
Be careful not to damage to the dust shield of the brake cylinder.
7. Remove the front brake shoe.
(1) Remove the end cap, set spring and pin with a special tool.
(2) Unfix the return spring, and remove the front brake shoe.
(3) Remove the left positioning post of the parking brake shoe.Brake System -Rear Brake Drum4-100Rotate

Brake System -Rear Brake Drum4-10213. Check the brake shoe and the brake shoe lining whether they
touch normally.
Mark the inner surface of the brake drum with chalk, joint and
abrade the brake shoe and the inner surface.
If the drum and the lining touch poorly, abrade the brake shoe or
replace a new one.
14. Remove the left front or top brake wheel cylinder.
(1) Unfix the brake oil pipe with a special tool, and collect the
brake fluid with a container.
(2) Remove the bolt and brake wheel cylinder.
15. Remove the brake cup.
(1) Remove the two dust shields from the brake cylinder.
(2) Remove the two pistons and springs.
(3) Remove the two brake cylinder caps from every piston.
16. Check the brake cylinder.
Check the cylinder wall and piston whether there is any rust or nick.
17. Remove the rear discharge screw plug of the brake drum.
18. Tighten the rear discharge screw plug of the brake drum
temporarily.
19. Install the brake wheel cylinder cup.
(1) Apply the lithium soap-base glycol lube on the two brake
wheel cylinder cups and the piston.
(2) Install two brake cylinder caps on every piston.
(3) Install the compression spring and the two pistons on the
brake wheel cylinder.
(4) Install two new dust shields on the brake wheel cylinder.
20. Install the left front or top brake cylinder.
(1) Install the brake cylinder with bolt.
Torque: 9.8N.m
(2) Connect the brake oil pipe with a special tool.
Torque: 15N.m
21. Apply the heat-resistant lube.
Apply the heat-resistant lube on the touch surface of the brake
backboard and the brake shoe.

Brake System -Rear Brake Drum4-105 (2) Measure the inner diameter of the brake drum and the
diameter of the brake shoe, and check the difference of them
whether it is a proper brake shoe clearance.
Brake Shoe Clearance: 0.3mm
Note:
Don't apply the oil or lube on the friction surface of the brake shoe
lining and brake drum.
30. Adjust the shoe clearance of the brake drum.
(1) Install two wheel hub nuts temporarily.
(2) Turn around eight teeth of the adjustor.
(3) Install the hole plug.
31. Install the rear brake drum sub-assembly.
32. Add the brake fluid to the storage tank.
33. Discharge the air in the master cylinder.
34. Discharge the air in the brake pipeline.
35. Check the level height in the storage tank.
36. Check the brake fluid whether there is any leakage.
37. Install the rear wheel.
Torque: 103N.m
38. Check the stroke of the parking brake extension rod.
39. Adjust he stroke of the parking brake extension rod.Extend

3. Definition of multi-pin plug-in unit terminal
1. Prompt:
R- red Bl- blue Y - yellow B- black P- pink G- green W- white
O- orange Gr - gray Br- brown V- purple Lg- olive drab
The first letter indicates primary color
The second letter indicates stripe colorTerminal
number1 MIL C 10 NA
2 Engine oil pressure switch YG 1 P
3 Brake fluid GR 2 R
4 Park G 3 N
5 Right turn light GB 4 D
6NA 52
7 EBD 6 L
8 Charge WR 7
9NA 8NA
10 NA 9 Sidelight GW
11 Safety belt YR 10 Start BR
12 NA 11 B+
13 Engine GY 12IG ( + ) Y
14 Safety gasbag RY 13 GND
15 NA 14 NA
16 IG ( + ) 15Speed sensor earthing B
1 NA 16 Speed signal input YR
2 Left turn light GW 17 Speed sensor power supply RY
3 High beam (+) RB 18 Key (ODO/TRIP) G
4 High beam (-) RW 19 Key (adjust brightness) YG
5 Foglight Gr 20 Key COM B
6 Rear defrost YB 21 Fuel gauge V
7 NA 22 ABS R
8 NA 23 Tachometer BBL
9 Door-lock warning lamp RBL 24 Coolant temperature gauge YWA
BCCombination Instrument System -Wiring diagram of Combination Instrument and Location of Multi-pin Plug-in Terminal5-9Definition of terminalConductor
ColorTerminal
numberDefinition of terminalConductor
Color

Suspected area
1. Wiring harness or connector
2. ECM
3. Combination instrument assy.
1. Wiring harness or connector
2. Alternator
3. Combination instrument assy.
1. Wiring harness or connector
2. Manual brake switch
3. Combination instrument assy.
1. Wiring harness or connector
2. Brake fluid level switch
3. Combination instrument assy.
1. Wiring harness or connector
2. ABS ECU or ABS warning lamp driving module
3. Combination instrument assy.
1. Wiring harness or connector
2. Airbag ECU controller
3. Combination instrument assy.
1. Wiring harness or connector
2. Airbag ECU controller
3. Combination instrument assy.
1. Wiring harness or connector
2. Front head light dimmer switch
3. Combination instrument assy.
1. Wiring harness or connector
2. Front head light dimmer switch
3. Combination instrument assy.
1. Wiring harness or connector
2. Rear defrost switch
3. Combination instrument assy. 8. Warning lamp fails
Symptom
Check that engine warning lamp does not
illuminate
Charge warning lamp does not illuminate
Park braking warning lamp does not
illuminate
Brake failure warning lamp does not
illuminate
ABS warning lamp does not illuminate
SRS warning lamp does not illuminate
Passenger's airbag indicator lamp does
not illuminate
High beam indicator lamp does not
illuminate
Rear foglight indicator lamp does not
illuminate
Rear defrost indicator lamp does not
illuminate5-16Combination Instrument System -Malfunction Symptom Table and Troubleshooting

5-209. Check park warning lamp
(1) Disconnect connector from park switch
(2) Turn ignition switch to ON, park brake warning lamp should go out.
(3) Use conductor to short connector terminal to ground, park brake warning lamp should illuminate.
10. Check park switch
(1) Disconnect connector from park switch
(2) Pull up manual brake, check whether its terminal is connected with ground
Pull up manual brake: on
Manual brake release: off
11. Brake fluid level warning lamp
(1) Disconnect connector from brake fluid level sensor
(2) Turn ignition switch to ON, brake fluid level warning lamp should go out.
(3) Use conductor to connect its connector terminal wiring harness terminals directly, brake fluid level
warning lamp should illuminate.
12. Check brake fluid level warning switch
(1) Remove tank cap
(2) Disconnect connector from tank
(3) Check whether terminals are connected.
Floater on top: off
(4) Use sucker to suck out liquid from tank
(5) Check whether terminals are connected.
Floater down: on state
(6) Pour liquid back into tank
13. Rear defrost indicator lamp
(1) Turn ignition switch to ON, and start up engine
(2) Push down defrost switch, now rear defrost indicator lamp should illuminate
(3) Turn ignition switch to OFF, rear defrost indicator lamp should go out
14. Rear foglight indicator lamp
When rear foglight illuminates, rear foglight indicator lamp should illuminate, now A5 terminal should be high
potential.
15. Safety belt warning indicator lamp
(1) Disconnect safety belt switch connector from driver side, now safety belt warning indicator lamp should
go out.
(2) Short connector terminal to ground, safety belt warning indicator lamp should illuminate.Combination Instrument System -Malfunction Symptom Table and Troubleshooting