fuel GEELY FC 2008 User Guide

Fuel-Injection nozzle assembly9. Install fuel rail component [4G18-1112110].(a) Check injection nozzle o-ring and replace if there is damage.
(b) Install isolator on cylinder head.
(c) Install fuel rail component together with injection nozzle.
Torque:(d) Install fuel pipe fixing clip.
Torque: m10. Check the function of electric fuel pump and check there is fuel leakage.
19

Fuel - Fuel pump assemblyFuel pump assemblyRemoving, installing and disassembling, assembling1. Take measures to prevent gasoline leaking
2. Remove rear seat cushion assembly
3. Remove rear floor repairing hole cover
4. Remove No. 2 fuel evaporation assemblyNotes:
zCheck there is contaminant looked like dirt around the joint before operating and clean it off in the
case of contaminant.
zBe careful of the contaminant looked like dirt, because fast-joint depends on o-ring to seal fuel pipe
and joint.
zDo not perform this operation with tools.
zDo not bend or distort nylon hose.
zCover the joint with plastic bag after removing the fuel hose.
zWhen the joint is stuck with fuel pipe, clip the hose with fingers and rotate carefully to release the
hose, and then remove it.5. Remove fuel tank main fuel hose and oil return pipe assemblyNotes:
zCheck there is contaminant looked like dirt around the joint before operating and clean it off in the
case of contaminant.
zBe careful of the contaminant looked like dirt, because fast-joint depends on o-ring to seal fuel pipe
and joint.
zDo not perform this operation with tools.
zDo not bend or distort nylon hose.
zCover the joint with plastic bag after removing the fuel hose.
zWhen the joint is stuck with fuel pipe, clip the hose with fingers and rotate carefully to release the
hose, and then remove it.6. Remove fuel pump assembly(a) Screw off fuel pump tighten nut (plastic fuel tank) or remove
6 screws (iron fuel tank).
(b) Pull out fuel pump assembly.
Notes:
zDo not damage fuel pump filter screen.
zBe careful not to bend the measuring oil arm of fuel gauge
float unit.7. Install fuel pump assemblyTorque: 8 N.m8. Install rear floor repairing hole coverInstall rear floor repairing hole cover with butyl rubber cloth.9. Check there is fuel leakage. 20

Fuel - Fuel tank assemblyFuel tank assembly1. Take measures to prevent gasoline leaking
(see Page 14)
2. Remove rear seat cushion assembly
3. Remove rear floor repairing hole cover
4. Remove No. 2 fuel evaporation assembly
5. Remove fuel tank main fuel hose and oil return pipe
assembly
6. Remove fuel pump assembly
7. Discharge fuel
8. Remove front floor bracket
9. Remove front exhaust pipe assembly(a) Move away carpet and remove oxygen sensor joint.
(b) Remove front exhaust pipe assembly10.Disassemble the vent pipe of fuel hose
11.Disassemble filler pipe from fuel tank
12.Remove No. 2 fuel evaporator hose assemblyPress fuel hose joint and then pull out the hose.
Notes:Check there is contaminant that looked like dirt around the
joint before operating and clean it off in the case of
contaminant.Be 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.13.Disassemble fuel tank main fuel hose assemblyClip the protrusion part of fixing ring and move lock claw toward
open direction, and then pull out the hose as shown in the
diagram.
Notes:Check there is contaminant looked like dirt around the joint
before operating and clean it off in the case of contaminant. 21 Removing, installing and disassembling, assemblingFuel pipe clipNylon pipeO-ring
Pipe

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

Exhaust gas controlExhaust gas control systemOn-vehicle inspection1. Check oxygen sensor.(a) Let the engine run at idle speed for 3 minutes to ensure oxygen sensor reaches operating tempera-
ture of 350(b) Place digital universal meter at DC voltage gear, and connect 2 terminals respectively to (gray) pin
and (black) pin of sensor, and voltage should fluctuate
quickly between 0.1-0.9V at the moment.
Warning:Perform inspection immediately after warming
up vehicle.If voltage change could not be confirmed,
it is necessary to heat oxygen sensor again.Exhaust gas control - Exhaust gas control system2. Check rotating speed after fuel cut off.(a) Accelerate engine at least to 3500rpm.
(b) Check the operating noise of injection nozzle with listening device.
(c) When throttle is released, check the operating noise of injection nozzle recovers after stop.3. Check fuel evaporation exhaust control system.(a) Check the pipe clamps of connecting pipeline between
charcoal canister and carbon canister solenoid valve are
firmly clipped and check there is leakage.
(b) Check there is trouble with fuel evaporation exhaust con-
trol system with failure diagnostic instrument.4. Visually check hose, joint and hot fin.Check cracks, leakage and damage.
Hint: the disconnecting of engine oil level gauge, oil opening
cover and PCV hose may cause running failure of engine.
The cracks, looseness and not connecting at the intake
system between throttle and cylinder head will result in
redundant air entering and running failure of engine.23

5. Check heater resistance of heated oxygen sensor.(a) Uncouple oxygen sensor joint.
(b) Place digital universal meter at ohm gear, and connect 2 terminals respectively to 1# (white) pin and
2# (black) pin, and the resistance under normal temperature is 166. Check fuel tank cover.Visually check fuel tank cover and gasket are distorted or damaged.Exhaust gas control - Exhaust gas control system 24 Oxygen sensor
Main relay

Engine mechanism - Engine assemblyCO HC Trouble occurrence Possible causes 28 Normal HighUnstable idle speed
Low HighUnstable idle speed
(HC readings not stable)
High HighUnstable idle speed
(black smoke emission)1. Ignition system malfunctionIgnition timing incorrect Spark plug too dirty, short circuit or clearance
incorrect
2. Valve clearance incorrect
3. Air inlet and exhaust valve leaky
4. Cylinder leaky
1. Vacuum leak:PCV hoseIntake manifoldThrottle bodyIdle speed stepping motorVacuum booster and pipelines
2. Fire caused by too thin mixing ratio
1. Air filter core blocked
2. PCV valve blocked
3. EFI system malfunctionFuel pressure regulator malfunctionWater temperature sensor malfunctionIntake pressure sensor malfunctionECU malfunctionInjection nozzle malfunctionThrottle position sensor malfunction

Engine mechanism - Engine assemblyEngine assemblyReplacement1. Take measures to prevent gasoline leaking.
2. Remove engine right bottom shield.
3. Remove engine left bottom shield.
4. Discharge coolant.
5. Remove front wheels.
6. Remove engine plastic hood components.
7. Remove battery.
8. Remove air filter assembly.
9. Remove air filter hose.
10. Remove battery tray.
11. Disassemble fuel hose assembly.
12. Remove throttle cable assembly.
13. Disassemble radiator hose inlet end.
14. Disassemble radiator hose outlet end.
15. Disassemble cold air pipe inlet hose.
16. Disassemble cold air pipe outlet hose.
17. Remove transmission control pull cable assembly.
18. Disassemble warm air water inlet hose [4G18-1300102].
19. Disassemble warm air water outlet hose [4G18-1300108].
20. Disassemble the hoses of all joints to connect vehicle body end.
21. Uncouple engine wire harness.(a) Remove glove compartment door.
(b) Remove engine wire harness from engine ECU and junction block.
(c) Pull out engine wire harness.
(b) Remove engine wire harness from junction block of engine room.
(e) Remove vehicle body earth wire. 36

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