GEELY FC 2008 Repair Manual

52. Remove speed sensor [4G18-3600010].
53. Remove knock sensor.Remove knock sensor with special tool.54. Remove water temperature sensor.Remove water temperature sensor with special tool.55. Replace engine assembly.
56. Install water temperature sensor.(a) Install new gasket to water temperature sensor.
(b) Install water temperature sensor with special tool.
Torque: 57. Install knock sensor.Install knock sensor with special tool.
Torque: m58. Install speed sensor.Install speed sensor and harness clips.
Torque: 59. Install phase sensor.Torque: 60. Install drive belt tensioner device.Torque: nut: m
Bolt: m61. Install the hoses on all hose joint of engine.Install clips and hose.62. Install oil pressure alerter.(a) Clean thread of oil pressure alerter and coat adhesive.
Adhesive: anaerobic pipe thread sealing adhesive 1545
(Kesaixin 1545)
(b) Install oil pressure alerter with special tool.
Torque: 63. Install warm air water outlet pipe components.Install new gasket and warm air water outlet pipe
components.
Torque: nut: m
Bolt: Engine mechanism - Engine assembly 40

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

Engine mechanism - Engine assembly73. Install transmission assembly.(a) Install transmission assembly.
Torque: bolt A: Bolt B: Bolt C: (b) Install 6 bolts.
Torque: 74. nstall starter mounting components.Torque: bolt: Nut: 75. Install sub frame together with side member.Install front mounting assembly and rear mounting
assembly.
Torque: front: Rear: 76. Install power steering pump assembly.Torque: 77. Install engine assembly together with
transmission assembly.(a) Erect engine together with transmission assembly on
engine crane.
(b) Install engine assembly to vehicle.
(c) Temporarily install side member and 6 bolts.
(d) Install left engine mounting assembly.
Torque: (e) Install right engine mounting assembly.
(f) Insert special tool into location hole on right side of sub
frame and vehicle.
(g) Temporarily lock bolt A at first, and then lock bolt B.
(h) Insert special tool into location hole on left side of sub
frame and vehicle.
(i) Temporarily lock bolt A at first, and then lock bolt B.
(j) Insert special tool into location hole on right side of sub
frame and vehicle, and then tighten bolts up to speci-
fied torque.
Torque: bolt A: m
Bolt B: Special
tool
Special tool42

(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 - Engine assembly85. Install alternator mounting components.Torque: 12mm bolt head A: 14mm bolt head B: 86. Install drive belt.
87. Install engine wire harness and all hoses
not connected.(a) Check and connect all joints of engine wire harness.
(b) Check and connect all hoses.88. Install transmission control pull cable assembly
and valve control pull cable.
89. Install air filter assembly and its hose.
90. Install steering middle shaft assembly.(a) Align alignment mark on steering middle shaft.
(b) Install 2 bolts.
Torque: m
(c) Install steering column cover.91. Install front exhaust pipe assembly.
92. Install front chassis bracket.Torque: 93. Install battery and connect wire.
94. Install engine plastic hood components.
95. Install front wheel and engine bottom shield.
96. Refill transmission lubricant.
97. Refill engine oil.
98. Refill coolant.
99. Check there is oil leakage.
100. Check there is coolant leakage.
101. Check idle speed and ignition timing.
102. Check CO/HC.Alignment
mark
Sliding in
Pulling 44

Engine mechanism - Timing chain assemblyTiming chain assemblyReplacement1. Remove engine left bottom shield.
2. Remove engine right bottom shield.
3. Discharge coolant.
4. Remove engine plastic hood components.
5. Remove drive belt.
6. Remove power steering pump assembly.
7. Remove alternator assembly.
8. Uncouple engine wire harness.(a) Remove ignition coil joint, PS fuel pressure switch joint,
fuel line control joint and speed sensor joint.
(b) Remove bolts and nuts of fixed earth wire and put aside
engine wire harness.9. Remove ignition coil assembly.
10. Remove cylinder head cover components.(a) Remove fuel pipe retaining clip and 2 PCV hoses from
cylinder head cover.
(b) Remove 9 bolts, 2 seal washers, cylinder head cover
components and gasket.11. Remove right engine mounting assembly.(a) Remove PS oil pump reservoir and put it aside.
(b) Place wooden block between jack and engine, prop-
erly place the jack, and then remove right engine mount-
ing assembly.12. Turn crankshaft to cylinder 1 compression top
dead center position.
13. Remove damping pulley components
[4G18-1005110].Remove pulley bolts with special tool.
Remove damping pulley components with special tool.Special
tool
Special
tool45

Engine mechanism - Timing chain assembly14. Remove drive belt tensioner device.Hint: operate the jack up and down to remove bolts.15. Remove water pump components [4G18-1307110].(a) Remove 6 bolts and water pump components.16. Remove engine stabilizer bracket on engine cross
member.
17. Remove compressor.
18. Remove speed sensor.
19. Remove chain tensioner components
[4G18-1006160].Note: do not turn crankshaft before installing chain
tensioner components.20. Remove timing chain hood components
[4G18-1006140].(a) Remove 11 bolts and nuts.
(b) Remove studs with star wrench.
(c) Pry open timing chain hood from timing chain hood pro-
trusion part between cylinder head and body with screw-
driver and remove it.
Note: be careful not to damage timing chain
hood, the contact surface of cylinder head and
body.21. Remove crankshaft front oil seal assembly
[4G18-1006150].Remove oil seal with screwdriver.22. Remove speed sensor signal panel
[4G18-3600011A].
23. Remove chain tension rail components
[4G18-1006120].
24. Remove chain guide rail components
[4G18-1006130].
25. Remove timing chain [4G18-1006110].Remove it with 2 screwdrivers.
Notes:Place a piece of cloth to protect engine.In the state of timing chain separating from timing
sprocket and turning camshaft, turn crankshaft 1/4
circle to avoid valve contacting with piston.26. Install timing chain.(a) Turn crankshaft to cylinder 1 compression top dead
center position.
(1) Turn camshaft from hexagon head part of
camshaft, and align dot marks on camshaft timing
sprocket.46

Engine mechanism - Timing chain assembly(2) Use damping pulley bolts to turn crankshaft with its key
toward upward.
(b) Install timing chain on crankshaft timing sprocket and
align the chain link having yellow mark with timing mark
of crankshaft timing sprocket.
Hint: there are 3 yellow chain links on the timing chain.(c) Install crankshaft timing sprocket with special tool.
(d) Install timing chain on camshaft timing sprocket and
align the chain link having yellow mark with camshaft
timing sprocket.27. Install chain guide rail components.Torque: m28. Install chain tension rail components.Torque: 29. Install speed sensor signal panel.Install signal panel with “F” mark toward forward.Toward portSet key
Yellow
mark
Timing mark
Special tool
Color (yellow) mark
Timing mark 47

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 assembly(b) Coat engine oil on the chain tensioner, and then install
it.
Torque: Note: when installing the chain temsioner, buckle
on the hook again if plunger has ejected.33. Install damping pulley.(a) Align the key groove on the damping pulley with the
key on the crankshaft, and slide damping pulley in.
(b) Install damping pulley bolts with special tool.
Torque: (c) Turn crankshaft counterclockwise to separate the hook
from lock pin on the plunger.
(d) Turn crankshaft clockwise, and check the chain ten-
sion rail is 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.Special
tool 49 Pushing intoSeparationHook
Pin
TurningPlunger
Pushing
intoTurning