ECU GEELY MK 2008 Workshop Manual

General Information - Repair Instruction1-6IllustrationRemoval/installation2. For Vehicles Equipped With SRS Airbag and Seat Belt Pretensioner
Tip: This is equipped with an SRS (Supplemental Restraint System), such as the driver airbag assembly,
front passenger airbag assembly airbag ECU and seat belt pretensioner. Failure to carry out service operations in
the correct sequence could cause the supplemental restraint system to unexpectedly deploy during servicing,
possibly leading to a serious accident. Further, if a mistake is made in servicing the supplemental restraint
system, it is possible the SRS may fail to operate when required. Before servicing (including removal or instal-
lation of parts, inspection or replacement), be sure to read the following items carefully, then follow the correct
procedure described in this manual.
(1) General NoticeInstall Remove
Install Remove a. Malfunction symptoms of the supplemental restraint system are difficult to confirm, so the diagnostic
trouble codes become the most important source of information when troubleshooting. When troubleshooting
the supplemental restraint system, always inspect the diagnostic trouble codes before disconnecting the battery.
b. Work must be started after 90 seconds from the time the ignition switch is turned to the "LOCK"
position and the negative (-) terminal cable is disconnected from the battery. (The supplemental restraint system
is equipped with a back--up power source so that if work is started within 90 seconds of disconnecting the
negative (-) terminal cable from the battery, the SRS may deploy.) When the negative (-) terminal cable is
disconnected from the battery, memory of the clock and audio systems will be cancelled. So before starting
work, make a record of the contents memorized by the each memory system. Then when work is finished, reset
the clock and audio systems as before. To avoid erasing the memory of each memory system, never use a back-
up power supply from another battery.

General Information - Repair Instruction1-7 (3) Driver Airbag Assembly
a. When removing the driver airbag assembly or handling a new driver airbag assembly, it should be placed
with the steering wheel top surface facing up. Storing the steering wheel with its top surface facing downward
may lead to a serious accident if the airbag deploys for some reason. In addition do not store a driver airbag
assembly on top of another one.
b. Never measure the resistance of the airbag squib. (This may cause the airbag to deploy, which is very
dangerous.)
c. Grease should not be applied to the driver airbag assembly and the pad should not be cleaned with
detergents of any kind. (2) Clock Spring (in combination switch)
The steering wheel must be fitted correctly to the steering col-
umn with the clock spring at the neutral position, otherwise clock
spring disconnection and other troubles may result.
c. Even in cases of a minor collision where the SRS does not deploy, the driver airbag assembly, front
passenger airbag assembly and seat belt pretensioner should be inspected.

e. Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.

f. Before repairs, remove the airbag ECU if shocks are likely to be applied to the sensor during repairs.

g. Never disassemble and repair the airbag ECU assembly, driver airbag assembly, front passenger airbag
assembly or seat belt pretensioner.

h. If the airbag ECU assembly, driver airbag assembly, front passenger airbag assembly or seat belt
pretensioner has been dropped, or if there are cracks, dents or other defects in the case, bracket or connector,
replace them with new ones.

i. Do not directly expose the airbag ECU assembly, driver airbag assembly, front passenger airbag assem-
bly or seat belt pretensioner to hot air or flames.

j. Use a volt/ohmmeter with high impedance (10 k ohm/ V minimum) for troubleshooting of the electrical
circuit.
Information labels are attached to the periphery of the SRS components. Follow the instructions on the
notices.
After work on the supplemental restraint system is completed, check the SRS warning light MarkCorrectWrongd.
k.

General Information - Repair Instruction1-93. Electronic Control Device
(1) Removal of the battery terminal cable
a. Before performing electrical servicing, disconnect the nega-
tive (-) cable from the battery in order to avoid short for burnout.
b. When disconnecting the terminal cable, turn off the ignition
and light switches, loosen the cable nut and raise the cable straight
up without twisting or prying it.
c. When disconnecting the terminal cable from the battery, all
information stored in the clock, radio and DTC shall be deleted,
therefore, these information shall be checked before disconnection.
(2) Processing of Electronic Parts
a. Do not open the cover or case of the ECU unless absolutely
necessary. (If the IC terminals are touched, the IC may be destroyed
by static electricity.)
b. To pull apart electrical connectors, pull on the connector itself,
not the wires.
c. Be careful not to drop electrical components, such as ECU
or relays. If they are dropped on a hard floor, they should be replaced
and not reused.
d. When steam cleaning an engine, protect the electronic
components, air filter and emission-related components from water.
e. Never use an impact wrench to remove or install tempera-
ture switches or temperature sensors.
f. When checking continuity at the wire connector, insert the
tester probe carefully to prevent terminals from bending.
4. Remove and Installation of Engine Intake Parts
(1) If any metal scrap is mixed in the inlet pass, that may give
a bad effect to the engine.
(2) When removing and installing of the inlet system parts, close (6) Airbag ECU
a. Never reuse the airbag ECU involved in a collision when the SRS has deployed.
b. The connectors to the airbag sensor assembly should be connected or disconnected with the airbag ECU
mounted on the floor. If the connectors are connected or disconnected while the airbag ECU is not mounted to
the floor, it could cause undesired inflation of the supplemental restraint system.
c. Work must be started after 60 seconds from the time the ignition switch is turned to the "LOCK" position
and the negative (-) terminal cable is disconnected from the battery, even if only loosing the set bolts of the
airbag ECU.
(7) Wire Harness and Connector
The SRS wire harness is integrated with the instrument panel wire harness assembly. All the connectors in
the system are a standard yellow color. If the SRS wire harness becomes disconnected or the connector becomes
broken due to an accident, etc., repair or replace it.Negative(-)
Cable
Wrong

General Information - Repair Instruction1-114. Precautions for Use of Swing Arm Type Lift
(1) follow the safe operation instruction described in this manual.
(2) use bracket with rubber support as shown in the illustration.
(3) make the center of gravity of the vehicle as close as possible to that of the lift ("L" should be smaller).
(4) adjust the bracker height, level the vehicle, align the groove of the bracket with the safety stand
support location.
(5) the arm should be locked during the job
(6) lift the vehicle until the tires become round.Swing the vehicle to make sure of stable vehicle.
5. Precautions for Use of Plate Type Lift
(1) follow the safe operation instruction described in this manual.
(2) use the support of the plate type lift.
(3) make sure to secure the vehicle in the specified position. Left and right set position
Front and rear set position Place the vehicle over the center of the lift. Align the cushion gum ends of the plate with the attachment
lower ends (A, C). Align the attachment upper end (B) with the front jack supporting point.Support Position
Jack Lifting Position Jack Position
Center of Gravity of the Vehicle
(empty load)

2-85. Actions to ensure vehicle working condition and safe driving.
(1) To make sure of driving safety, execute the following inspections before driving.
a. Inspect fuel level, and add fuel when necessary.
b. Inspect illuminating lights, turning signal lights, braking signal lights to see if they work.
c.Check the position of rearview mirrors.
d.Check if breaking system functions well.
e.Check if glass of all the lights, windshield is clean.
(2) Regular inspection Perform the following regular inspections to ensure the vehicle work condition and
driving safety.
a. Check engine oil level. Park the vehicle on flat road; check the oil level with engine oil level indicator
at least 10 minutes after the engine is stopped. The oil level should be between the two marks. If it is
lower than "L" mark, add some oil; if it is higher than "F" mark, there is excessive oil, so release it.
Or investigate the cause of high oil level.
The volume between the lowest oil level ("L") and highest oil level ("F") is 1.4L.
b. Check engine coolant level. Check the level when the engine is cool. The coolant level should be between
LOW and FULL. If it is lower than "LOW", add coolant. If the coolant is much lower than Min (every
coolant fill is more than 1L) or the vehicle requires frequent fills,investigate if there is any problem with
the cooling system.
To keep the function of coolant, replace coolant every two years at the beginning of cold winter.
c. Check brake and clutch fluid level (sharing a reservoir). Brake fluid level should between the Max and
Min marks. And it is better to keep it close to the Max mark. Add fluid in time when there is not enough
fluid.
d. Check power steering fluid tank. The level should be between Max and Min marks. Refill when there
is not enough steering fluid to avoid pump stuck. It is strictly prohibited to run the vehicle without
steering fluid in any circumstances.
e. Check the charging status of battery and if the connection of battery wires is good.
f. Check tire status and pressure
g. Check the status of wipers.
(3) Observe warning lights and indicators on instrument panel.
a. There are various warning lights and indicators on the instrument panel of MK-1 sedans to indicate and
warn abnormal operations of engine, braking, and charging systems.
b. Pay attention to these lights when driving.When the warning lights or indicators are on,stop the vehicle,
check the vehicle and resolve the causes to make sure the vehicle works well or drives safely.
6. Correct ways to use new cars
Reliability and stability of components in new cars and recently repaired cars still need to be confirmed, and
relative parts are not broken-in, so they must be used carefully to ensure driving safety, to avoid abnormal damage,
and to extend the useful life of the car.
(1) Before driving inspection The following inspections must be performed on the new car to ensure car safety
and reliable operation:
a. Check if instrument panel, warning lights, and indicator, front and rear wiper and washer, and switches
work.
b. Check if the fastening of driveline, steering, suspension, wheels and other connection parts is good.Usage and Maintenance of MK Series - Usage of MK Series

Table 3Section 2 Removal of the Engine Assembly from the Vehicle1. Avoid petrol overflowing (Disconnect from the fuel tank).
2. Remove the front wheel.Figure 1-5Engine AssemblyRemoval of the Engine Assembly from the Vehicle3-5CO
Normal
Low
HighHC
High
High
HighProblems
Bad idle speed
Bad idle speed
(HC reading fluctuates)
Bad idle speed
(Black smoke exhausts)Causes
1. Ignition fault:
Incorrect ignition timing;
Dirt, short circuit, or incorrect spark plug gap.
2. Incorrect valve gap.
3. Suction and exhaust valve leak.
4. Cylinder leaks.
1. Vacuum leaks.
PCV pipe . manifold;
Idle speed control valve;
Brake booster pipeline.
2. Spark lacks since the mixed gas is too thin.
1. Air filter is blocked.
2. PCV valve is blocked.
3. EFI system fails.
ECU fails.
Pressure regulator of fuel oil is out of order.
Water temperature sensor does not work.
Suction pressure/temperature sensor fails.
Injector fails.
The throttle position sensor fails.3. Discharge the coolant completely.
4. Remove the air filter assembly with hose (see Figure 1-5).
(1) Disconnect the joint of the temperature sensor and the wire
plug.
(2) Disconnect the vent duct from the hose of the air filter.
(3) Release the wire clip bolt on the air filter.
(4) Disconnect the hose of the air filter from the throttle body.
(5) Remove 3 bolts and the air filter assemblies.
5. Remove the battery.
6. Remove the fuel pipe sub-assembly.
7. Disconnect the water pipe; disconnect the water outlet pipe of the
heater from the air conditioner pipe.
8. Release the nut and remove the accelerator control cable. -

Section 2 Radiator Replacement1. Replace the radiator.
(1) Open the radiator cover.
(2) Open the water drain valve and discharge the coolant.
(3) Disconnect the water inlet pipe of the radiator.
(4) Disconnect the water outlet pipe of the radiator.
(5) Disconnect the input pipe of the oil cooler of the automatic transmission (automatic transmission).
(6) Disconnect the output pipe of the oil cooler of the automatic transmission (automatic transmission).
(7) Remove 4 bolts of the radiator mounting support (see Figure 5-8).Figure 5-8
Figure 5-9Cooling SystemRadiator Replacement3-24 (8)Remove the radiator assembly, remove 4 bolts, and separate
the fan and the fan housing (see Figure 5-9).
(9) Mount the cooling fan assembly.
a. Secure the compensating tank assembly on the cooling fan support with bolts; torque: 16 N.m.
b. Mount the fan and the fan housing with 3 bolts; torque: 7.5N.m.
c. Mount the cooling fan assembly on the radiator assembly with 3 bolts; torque: 16N.m.
d. Connect the overflow pipe on the compensating tank assembly and the radiator assembly, and fasten
with the elastic ring.
e. Mount the radiator assembly in the reverse order of dismounting. -

Chapter 5 Front Suspension SystemSection 1 Front Suspension SystemDescription on front suspension structureThis model uses strut swing arm independent suspension with stabilizer bar.
The shock absorber upper end is flexibly connected to the body through the shock absorber mounting seat, the
lower end is rigidly connected to the steering knuckle. The coil spring encloses the shock absorber (coil spring
geometrical axial line does not coincide with that of the shock absorber piston rod), and is supported between the
upper and lower spring seats.
Both ends of the stabilizer bar are connected to the shock absorber through the strut bar ball pin and the intermediate
part is supported on the lower front body by the rubber bushing and support frame.
The front cushion sleeves the shock absorber piston rod head to restrict the wheel jump limit position and plays
the role of buffer.
The thrust ball bearing, installed between the spring upper seat and the shock absorber mount, is used for the
relative rotation upon steering of the shock absorber rigidly connected to the steering knuckle to the shock absorber
mount flexibly connected to the body.
"L" type lower swing arm is secured to the lower engine compartment with the press plate through elastic rubber
bushing and hinge, and its outer end is connected to the steering knuckle through the ball stud pin which is attached
to the lower swing arm by 3 high intension bolts. The ball stud pin can be removed and replaced when it is worn.
The ball seat material is saturated polyester containing oil, featured in comparatively high intensity and wearability
and good self-lubrication performance. Proper amount of grease has been added during the assembly and there is
no need for additional filling during the normal operation.See the table for the front suspension technical parametersFront Suspension SystemFront Suspension System4-38Item
Shock absorber operating cylinder diameter /mm
Shock absorber piston rod diameter /mm
Shock absorber stroke/mm
Wheel camber
Wheel toe-in/mm
King pin inclination
King pin caster
Remark: the wheel alignment parameter in the table is at free load.Parameter
45
20
160
-0°30'±45'
1±2
10°0'±45'
2°0'±45' -

Power Steering System-Power Steering Gear4-77Replacement1. Drain the power steering system fluid
2. Loosen the high pressure pipes.
Loosen the high pressure pipes with special tool
3. Loosen the low pressure pipes
Loosen the low pressure pipes with special tool
4. Separate the tie rod from the steering knuckle
(1) Remove the cotter pin, loosen the groove type lock nut
(2) Separate the tie rod ball stud joint from the steering knuckle
taper hole5. Loosen the thread screw of the high and low pressure pipe on the steering gear assembly
6. Remove the boot and press plate
7. Disconnect the power steering gear assembly from the steering column
Remove the steering gear pinion shaft spline lock bolt on the universal joint yoke
8. Remove power steering gear assembly
Remove 2 steering gear assembly set bolts. Remove the power steering gear assembly
9. Installation is in the reverse order of the removal
Notice:
(1) Insert the steering gear pinion shaft spline into the spline hole of the universal joint yoke, make sure that
the positions of the notch of the steering gear pinion shaft and the lock bolt of the universal joint yoke are
correct
(2) Secure the power steering gear with 2 bolts, torque: 125~152N.m
(3) Tighten the steering gear pinion shaft spline lock bolt on the universal joint yoke, torque: 22~34N.m
(4) Install the boot and press plate
(5) Install the threaded connector of the power steering high and low pressure pipe to the power steering gear,
torque: 25~32N.m

19151915131515
Fluid level indicator lamp connectorVacuum booster assembly
Gasket25Clip26 Clip Master cylinder
Manual Transmission
#1 clutch fluid tank oil pipe
HECU assemblyClipSection 5 Vacuum BoosterComponent ViewBrake System -Vacuum Booster4-91Battery
#2 relay box, engine chamber
Return spring
Pin
Push bar
U-connector Without ABSVacuum tube
Non-reusable parts
Lithium soap base glycol lubeSpecified torque