diagram GEELY FC 2008 User Guide

Engine mechanism - Valve clearance(n) Check intake side camshaft bearing cover forward re-
mark and figure, and tighten the bolts as sequences
shown in the diagram.
Torque: (o) Align alignment mark on the chain with timing mark on
camshaft timing sprocket, and place exhaust camshaft
in cylinder head.
(p) Temporarily lock fixed bolts.
(q) Check exhaust side camshaft bearing cover forward
remark and figure, and tighten the bolts as sequences
shown in the diagram.
Torque: (r) Install camshaft front bearing cover.
Torque: (s) Fix camshaft with adjustable wrench and then tighten
the fixed bolts of camshaft timing sprocket.
Torque: Note: be careful not to damage valve lifter.33Timing remark chain linkTiming markTighteningFixing

Engine mechanism - Valve clearance(t) Check the matching marks on timing chain and cam-
shaft timing sprocket, and then align the groove of crank-
shaft pulley with the timing mark on timing chain hood
as shown in the diagram.
(u) Install chain tensioner.
(1) Check o-ring is clean, and buckle on the hook as
shown in the diagram.
(2) Coat engine oil on the chain tensioner, and then
install it.
Note: when installing the chain temsioner, buckle
on the hook again if plunger has ejected.
(3) Turn crankshaft counterclockwise to separate the
hook from lock pin on the plunger.Mark
Mark
Mark
Timing chain
hood surface
GroovePressing in 34 Lifting
HookPressing
inPinTurning Pin Separation
Hook

Engine mechanism - Valve clearance(4) Turn crankshaft clockwise, and check the sliding
parts are 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.11.Install cylinder head cover components.(a) Install cylinder head cover gasket on cylinder head cover.
(b) Eliminate all old sealant (FIPG) materials.
(c) Coat sealant on 2 positions shown in the diagram.
Notes:Wipe off all the oil stains on junction plane.After coating sealant, finish installation of cylinder head
cover within 3 minutes.After installing, do not refill engine oil within 2 minutes.
(d) Install cylinder head cover components with 9 bolts, 2 seal washers and 2 nuts.
Evenly tighten bolts and nuts at several times.
Torque:
Short bolt: Nut, long bolt etc.: m12. Install drive belt tensioner device.Torque: nut: Bolt: 13. Install fixing bracket absorber on the left of engine.Torque: 14. Check there is oil leakage.Sealant 35 Plunger
TurningPushing

Engine mechanism - Engine assembly30. Disassemble left end front stabilizer link
assembly.Fix bolts with hex socket wrench, and then remove nuts.
Hint: perform the same steps at another side.31. Disassemble lower left control arm assembly.(a) As shown in the diagram, remove bolt and 2 nuts.
(b) Disassemble drive shaft from shaft hub with plastic
hammer.
Hint: perform the same steps at another side.32. Remove oil return pipe assembly.After removing 3 retaining clips and 2 bolts of power steer-
ing oil reservoir, remove the oil return pipe from vehicle.33. Remover engine assembly [4G18-1000000] and
transmission assembly.(a) Erect engine hanger.
(b) Remove 4 bolts, 2 nuts and right engine mounting
assembly.
(c) Remove through bolt and nut, and then remove left
engine mounting assembly from vehicle.
(d) As shown in the diagram, remove 6 bolts.
(e) Carefully remove engine assembly and transmission
assembly from vehicle. 38

34. Remove power steering pump assembly.
35. Remove sub frame together with side member.(a) Remove front engine mounting assembly and rear en-
gine mounting assembly from engine assembly.
(b) Remove sub frame assembly.36. Remove starter mounting components
[4G18-3708100].
37. Remove transmission assembly.(a) Fix crankshaft with special tool, ant then remove 6 bolts.
(b) Remove transmission assembly.38. Remove clutch assembly [4G18-1601000]
and flywheel components [4G18-1005120J].(a) Fix crankshaft with special tool, ant remove clutch
assembly at first.
(b) Then remove flywheel components.39. Remove throttlesupporting plate [4G18-1008202].
40. Remove intake manifold assembly [4G18-
1008200].(f) As shown in the diagram, install front and rear hooks of
engine.
Torque: Hint: install engine hooks to front and rear sides of
engine.
(g) Lift engine assembly with chain pulley block and en-
gine lifting device.Engine mechanism - Engine assemblySpecial tool39 41. Remove exhaust manifold upper heat shield components [4G18-1008120].
42. Remove exhaust manifold assembly [4G18-1008100].
43. Remove fuel rail injector assembly [4G18-1112100].
44. Remove ignition coil installation components.
45. Remove oil level gauge tube components [4G18-1002140].
46. Remove temperature regulator assembly [4G18-1306100].
47. Disassemble warm air water outlet pipe components [4G18-1300100].
48. Remove oil pressure alerter [4G18-3757100].Remove oil pressure alerter with SST.49. Remove the hoses on all hose joint of engine.Remove clips and hose.50. Remove drive belt tensioner device.
51. Remove phase sensor [4G18-3600030].Engine hook
FrontRear

Engine mechanism - Engine assembly64. Install temperature regulator assembly.(a) Check temperature regulator assembly o-ring.
(b) Install temperature regulator assembly as shown in the
diagram.
(c) Install engine water inlet pipe joint components.
Torque: 65. Install oil level gauge tube components.
66. Install ignition coil mounting components.Torque: m67. Install fuel rail injector assembly.(a) Install isolator on cylinder head.
(b) Install fuel rail injector assembly.
Torque: (c) Install fuel pipe retaining clip.68. Install exhaust manifold gasket and exhaust
manifold assembly.Torque: 69. Install exhaust manifold upper heat shield
components.Torque: 70. Install intake manifold assembly.Install new gasket and intake manifold assembly.
Torque: m71. Install throttle supporting plate.Torque: 72. Install flywheel components and clutch assembly.(a) Fix crankshaft with special tool.
(b) Clean bolts and bolt holes.
(c) Coat bolts with adhesive.
Adhesive: thread locking sealant 1234 (Kesaixin 1234).
(d) Install flywheel components.
As sequences shown in the diagram, tighten bolts at
several times.
Torque: 885Nm
(e) Install clutch assembly.Special
tool 41

(k) Insert special tool into location hole on left side of sub
frame and vehicle, and then tighten bolts up to speci-
fied torque.
Torque: bolt A: Bolt B: m
(l) As shown in the diagram, tighten 2 bolts.
Torque: Note: after installing sub frame, check the sub
frame is aligned with location hole on
vehicle.78. Install compressor.Torque: 79. Install lower left control arm assembly.(a) Install drive shaft to steering knucle.
(b) Install lower left control arm.
Torque: Hint: perform the same steps at another side.80. Install front left shaft hub nut.(a) Install fixed nut with socket wrench (39mm).
Torque: (b) Drive the cutout part of hub nut into groove with chisel.
Hint: perform the same steps at another side.81. Install left end front stabilizer link assembly.Fix bolts with hex socket wrench.
Torque: Hint: perform the same steps at another side.82. Install left side transversal lever assembly.(a) Connect transversal lever assembly to steering knucle
and install new nuts.
Torque: Note:Do not coat lubricant on thread and conical surface.After tightening nuts up to specified torque, con-
tinue turning nuts for 60¡ãand insert open pin.
(b) Insert new open pin.83. Connect fuel hose assembly.
84. Install battery tray.Torque: Engine mechanism - Engine assembly 43

Engine mechanism - Timing chain assembly30. Install crankshaft front oil seal assembly.(a) Coat a little MP grease on oil seal lip.
(b) Gently knock new oil seal in with special tool and ham-
mer until the seal surface is parallel and level with the
edge of timing chain cover.
Note: do not let oil seal mouth contact with foreign
matters.31. Install timing chain hood components.(a) Eliminate all old seal materials from contact surface.
(b) As shown in the diagram, coat sealant on the edge
(diameter 3.5mm-4.5mm).
Sealant: silicon rubber flange sealant 1596 (Kesaixin
1596).
(c) Install timing chain hood with 12 bolts and nuts.
Torque: Notes:Eliminate all grease on contact surface.After coating sealant, finish installation of timing chain
hood within 3 minutes.After installing, do not refill engine oil within 2 minutes.32. Install chain tensioner components.(a) Check o-ring is clean, and buckle on the hook as shown
in the diagram.Special
tool 48 SealantSealant widthChain cover
groove
Cylinder
head groove Sealant
concentrationEntering
Hook
PinLifting

Engine mechanism - Timing chain assembly34. Install speed sensor.Torque: 35. Install engine fixing bracketTorque: 36. Install water pump mounting components
[4G18-1307100].(a) Install new o-ring on water pump.
(b) Install water pump with 6 bolts.
Torque: bolt A: m37. Install drive belt tensioner device.Torque: nut: Bolt: m38. Install right engine mounting assembly.Torque: 39. Install cylinder head cover components.(a) Install gasket to cylinder head cover.
(b) Eliminate all old seal materials.
(c) Coat sealant on 2 positions shown in the diagram.
Sealant: silicon rubber flange sealant 1596
(Kesaixin 1596).
Notes:Eliminate all grease on contact surface.After coating sealant, finish installation of cylinder
head cover within 3 minutes.After installing, do not refill engine oil within 2
minutes.
(d) Install cylinder head cover and cable bracket with 9 bolts,
2 seal washers and 2 nuts.
Torque: nut: Bolt: m40. Install ignition coil mounting components.Torque: 50

Engine mechanism - CamshaftCamshaftReplacement1. Remove engine hood.
2. Remove ignition coil assembly.
3. Remove cylinder head cover assembly.
4. Remove engine right bottom shield.
5. Turn crankshaft to cylinder 1 compression top dead
center position.(a) Turn damping pulley to align its groove with “o” mark on
timing chain hood.
(b) Check dot marks on camshaft timing sprocket and VVT
timing sprocket, and they should be in a line on timing chain
hood surface as shown in the diagram.
Hint: if not, turn crankshaft for one circle (360) again
and align the above marks.6. Remove drive belt.Slowly turn drive belt tensioner clockwise to loosen it.Then
remove drive belt and put back drive belt tensioner slowly and
gently.7. Remove right engine mounting assembly.(a) Remove PS oil pump reservoir and put it aside.
(b) Place wooden block between jack and engine, properly
place the jack, and then remove engine fixing bracket shock
absorber.8. Remove drive belt tensioner assembly.Hint: operate the jack up and down to remove bolts. 52Mark
Mark
Mark
Timing chain
hood surface
Groove