lock GEELY FC 2008 User Guide

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

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 - Drive beltDrive beltReplacement1. Remove engine right bottom shield.
2. Remove drive beltSlowly turn drive belt tensioner clockwise to loosen it.
Then remove drive belt and put back drive belt tensioner slowly
and gently.3. Install drive beltSlowly turn drive belt tensioner clockwise to loosen it.
Then install drive belt and put back drive belt tensioner slowly
and gently.29

Engine mechanism - Valve clearanceValve clearanceAdjustment1. Remove engine plastic hood components.
2. Remove ignition coil components [4G18-3705110].
3. Remove cylinder head cover components [4G18-
1003130].
4. Remove engine right bottom shield.
5. Turn crankshaft to cylinder 1 compression top dead
center position.(a) Turn crankshaft 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 again
and align the above marks.6. Check valve clearance.(a) Only check the valves shown in the diagram.
(1) Measure the clearance between valve tappet and cam-
shaft with plug gauge.
(2) Record valve clearance measuring value exceeding
specification, and this value will be used to determine
valve tappet thickness that needs change.
Valve clearance (cold vehicle)Intake airExhaust(b) Turn crankshaft for one circle ), and cylinder 4 is
turned to compression top dead center position.
(c) Only check the valves shown in the diagram. Measure valve
clearance (see step (a)).7. Remove drive beltSlowly turn drive belt tensioner clockwise to loosen it.
Then remove drive belt and put back drive belt tensioner slowly
and gently. 30 Mark
Mark
Mark
Timing chain
hood surface
Groove

Engine mechanism - Valve clearance8. 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 right engine mounting
assembly.9. Remove drive belt tensioner device [4G18-
1300200].Hint: operate the jack up and down to remove bolts.10. Adjust valve clearance.Note: do not turn crankshaft before installing chain
tensioner.
(a) Turn crankshaft to cylinder 1 top dead center position.
(b) Align the marks on timing chain and camshaft timing
sprocket.
(c) Remove 2 bolts and chain tensioner.
(d) Fix camshaft with adjustable wrench and then loosen
the fixed bolts of exhaust camshaft timing sprocket.
Note: be careful not to damage valve lifter.
(e) As sequences shown in the diagram, loosen camshaft
bearing cover bolts on exhaust camshaft at several
times and remove the bearing cover at the same time.
(f) As shown in the diagram, remove exhaust camshaft
timing sprocket.Painting
mark
LooseningFixing 31

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 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

Engine mechanism - Engine assembly22. Remove drive belt.Drive belt tensioner could turn belt tensioner clockwise to
loosen it.23. Remove alternator mounting components [4G18-
3701100].
24. Remove compressor assembly.
25. Remove front chassis bracket.
26. Remove front exhaust pipe assembly.
27. Remove steering middle shaft assembly.(a) Remove steering column seal hole cover.
(b) Make alignment mark on steering middle shaft.
(c) Remove 2 bolts and steering middle shaft.
(d) Remove steering column cover.28. Remove the nuts on left side of front shaft hub.(a) Completely knock out the concave part of fixed nuts with
special tool and hammer.
Notes:Completely knock out the concave part of fixed
nuts before removing the fixed nuts.Do not damage thread of drive shaft.Do not sharpen the sharp end of special tool.Place the special tool in groove with its plane facing
upward.
(b) Remove fixed nuts with socket wrench (30mm).
Hint: perform the same steps at another side.29. Disassemble left side transversal lever assembly.Disassemble transversal lever assembly from steering
knuckle with special tool.
Hint: perform the same steps at another side.Alignment
markSpecial tool
Special tool37Sliding outLifting