engine GEELY FC 2008 Manual PDF

Starting and charging - Charging systemCharging systemPrecautions1. Check positive and negative wire of battery is con-
nected correctly.
2. When performing quick charge to battery, please
uncouple battery wire.
3. Do not test with high-pressure insulation resistance
tester.
4. do not uncouple battery wire during engine running.
81

1. Check battery voltage.(a) If extinguishing time of engine is not more than 20 minutes
after driving, please turn on ignition switch and electric
equipment (head lamp, blower motor and rear window
defog line etc.) for about 60 seconds to eliminate surface
charging during driving.
(b) Turn ignition switch to OFF, and then switch off electric
equipment system.
(c) Measure the voltage between battery negative (-) terminal
and positive (+) terminal.
Standard voltage: 12.5~12.9V at 20.
Hint: if the voltage is lower than standard
specification, please charge battery.
(d) As shown in the diagram, check battery window.
Hints:Green: OKWhite: requiring chargeBlack: replacing battery2. Check battery joint, fusible link and slow fuse (100A).(a) Check battery joint is loose or eroded.
(b) Check fast fuse and slow fuse (100A) are in conduction.3. Check drive belt.(a) Check belt is excessively worn or cable is broken etc.
Hints:If any inferior part is found, please replace drive
belt.It is allowable for the crack at the edge of drive belt
rib.
If there is block falling with belt rib, please replace with
new belt.
(b) Check the belt is correctly installed in guide groove.
Hint:Check with hands to ensure that the belt does
not slide out from the groove of pulley bottom.4. Visually check alternator wire harness.Check the condition of wire is perfect.Starting and charging - Charging systemOn-vehicle inspectionGreen White Black5. Listen to whether there is abnormal sound with alternator.There should not be abnormal sound with alternator during engine running.6. Check the circuit of charge alarm light.(a) Turn ignition switch to “ON”, and check charge alarm light is on.
(b) Start engine, and charge alarm light should be off.
Hint: if the function of charge alarm light does not conform to the regulation, please perform
trouble shooting to the circuit of charge alarm light.82

Starting and charging - Charging system7. Check charging system circuit at no load.(a) If there is battery/alternator tester, please connect tester
to charging system circuit as manufacturer instruction.
(b) If there is no battery/alternator tester, please connect volt-
meter to charging system circuit as the following way.
zUncouple wire on engine terminal B, and connect wire
on negative (-) test bar of ampere meter.
zConnect positive (+) test bar of ampere meter to alter-
nator terminal B.
zConnect positive (+) test bar of voltmeter to alternator
terminal B.
zConnect negative test bar of voltmeter to earth.8. Check charging system circuit at load.(a) Turn on high beam of front combination lamps with engine running at 2000rpm,and turn blower to
“HI” position.
(b) Check the reading of ampere meter.
Standard amperage: 30A or more.
Hints:If amperage is less than standard value, please repair alternator.If battery is under the state of full charge, amperage may be less than standard value sometimes. (c) Check charge system circuit.
(1) Check the readings of ampere meter and voltmeter with engine from idle speed to 2000rpm.
Standard current: 10A or less.
Standard voltage: 12.9~14.9V.
Hints:If voltmeter reading is more than standard value, please replace with new voltage regulator.If voltmeter reading is less than standard value, please check voltage regulator and alternator
as the following way.
(2) Earth terminal F, start engine and check voltage of
terminal B.
Hints:If voltmeter reading is more than standard value,
please replace with new voltage regulator.If voltmeter reading is less than standard value,
please check alternator.83Ampere meter
Uncoupling
terminal B wire
VoltmeterAlternatorBatteryTerminal F

Starting and charging - Alternator componentsAlternator componentsReplacement1. Remove engine right bottom shield.
2. Remove drive belt.Slowly turn drive belt tensioner clockwise to loosen the belt,
then remove drive belt and put back the tensioner slowly to
completely loosen it.3. Remove alternator components.(a) Remove rubber cover and nuts.
(b) Uncouple alternator joint.
(c) Remove 2 bolts and alternator.4. Install alternator components.Torque:12mm head bolt : m
14mm head bolt : 84

Starting and charging - Starter componentsStarter componentsReplacement1. Remove engine lower left shield.
2. Remove starter components.(b) Uncouple starter joint.
(b) Remove nuts, and uncouple starter wire.
(c) Remove 2 bolts and starter.3. Install Starter components.Torque:bolt: Wire harness: 85

Front suspension - Front stabilizer barFront stabilizer barOverhaul1. Remove dust cap inside steering column (see Page 194).
2. Separate steering sliding shaft assembly (see Page 205)
3. Remove front wheels.
4. Remove right engine bottom shield.
5. Remove left engine bottom shield.
6. Remove front left stabilizer link assembly
[64000097].Remove 2 nuts and take down stabilizer link.
Hint: if ball joint rotates with nuts, please fix bolts with
hexagonal wrench (6mm).7. Remove front right stabilizer link assembly
[64000097].Hint: the removal procedures of right side are the same
as that of left side.8. Check front left stabilizer link assembly.(a) As shown in the diagram, before installing nuts, shake joint
bolts forward and backward 5 times.
(b) Shake nuts continuously with torque wrench at the speed
of one circle per 24 s, and then read out torque value at
the 5th circle.
Rotating torque: 0.05~1.0 N.m9. Separate left side transversal lever assembly (see Page 113).
10. Separate right side transversal lever assembly (see Page 113).
11. Separate oil pipe assembly (see Page 205).
12. Separate steering gear oil return pipe (see Page 205).
13. Separate lower left control arm assembly [64000091] (see Page 94).
14. Separate lower right control arm assembly [64000092] (see Page 94).
15. Remove sub frame assembly [64000087] (see Page 205).
96

16. Remove front stabilizer bar.(a) Remove 4 bolts, bracket and bush.
(b) Remove stabilizer bar.17. Install front stabilizer bar.(a) Install bracket and bush with 4 bolts.
Hint: install bush to bush stop ring outside of
stabilizer bar.18. Install sub frame assembly [64000087]
(see Page 205).Front suspension - Front stabilizer bar19. Connect lower left control arm assembly [64000091] (see Page 94).
20. Connect lower right control arm assembly [64000092] (see Page 94).
21. Connect power steering oil pipe assembly (see Page 205).
22. Connect steering oil return pipe (see Page 205).
23. Connect left side transversal lever assembly (see Page 113).
24. Connect right side transversal lever assembly (see Page 113).
25. Install front left stabilizer link assembly
[64000097].(a) Install front stabilizer link with 2 nuts.
Torque: 745 N.m
Hint: if ball joint rotates with nuts, please fix bolts with
hexagonal wrench (6mm).26. Install front right stabilizer link assembly
[64000097].Hint: the installation procedures of right side are the
same as that of left side.27. Install right engine bottom shield.
28. Install left engine bottom shield.
29. Install front wheels.Torque: 10310 N.m97Rear
side Bush stop ring Outside

18. Assemble left front lower control arm ball head as-
sembly [64000093](a) Assemble lower ball head and locking nut.
Torque: 103
± ±± ±
± 10 N
⋅ ⋅⋅ ⋅
⋅m
(b) Assemble new cotter pin.
If hole position of cotter pin could not make a line, lock the
screw cap for 60again.19. Assemble left front shaft hub assembly(a) Assemble two bolts and nuts, and assemble shaft hub as-
sembly on absorber.
Torque: 153
± ±± ±
± 10 N
⋅ ⋅⋅ ⋅
⋅m
Note: when the bolts and nuts should be used again,
spread engine oil on the thread of nuts.
(b) Push the front shaft hub assembly to the outside of
automobile, then assemble transmission shaft assembly
in the gear slot of front shaft hub assembly.
Note:
Front shaft assembly could not be pushed to outside
too much.zDo not damage the exterior joint dustproof cover of
drive shaft.zDo not damage the stator of speed sensor.20. Assemble left lower control arm assembly
[64000091]Assemble lower control arm and ball head with two nuts and
bolts.
Torque: 142
± ±± ±
± 10 N
⋅ ⋅⋅ ⋅
⋅m21. Assemble left transversal lever assembly(a) Connect transversal lever to steering knuckle.
(b) Assemble screw cap and new cotter pin.
Torque: 49
± ±± ±
± 5 N
⋅ ⋅⋅ ⋅
⋅m22. Assemble left front brake assembly [64000134]
23. Assemble front brake caliper assembly(a) Assemble brake caliper assemble on steering knuckle with
two bolts.
Torque: 106
± ±± ±
± 10 N
⋅ ⋅⋅ ⋅
⋅m24. Assemble fixing nuts of left front drive shaft
[64000083]Use torque wrench (30mm) to assemble new fixing nuts.25. Disassemble left front brake branch pump assembly
26. Disassemble left front brake assembly [64000134]
27. Check the axial clearance of bearingDrive shaft--Left front shaft hub assembly126

Brake--Remove malfunction2. Check the free travel of pedal.(a) Extinguish the engine, and step brake pedal repeatedly until
there is no vacuum in vacuum booster.
(b) Press down pedal with hand until feeling the resistance,
then measure the distance of this section, liking that shown
in figure.
Free travel of pedal: 1-6mm.
If it is wrong, check the clearance of brake light switch.
Clearance of brake light switch: 0.5-2.4mm
If the clearance accords with the regulation, remove the
malfunction in brake system.3. Check the distance from pedal to floor.Release parking brake drag lever
When engine is running, step down brake pedal, then mea-
sure the distance from pedal to floor, liking that shown in figure,
Force 490 N on pedal, its distance from floor should be:
over 60mm.
If it is wrong, remove the malfunction in brake system.Brake pedal assemblyAdjustment1. Check and adjust the height of brake pedal.(a) Check the height of brake pedal.
Pedal distance from floor: 136.0-146.0mm
(b) Adjust the height of brake pedal.
(1) Disassemble lower trim board of panel.
(2) Disassemble switch joint of brake light.
(3) Loosen locking nut of brake switch, and disassemble
the switch of brake light.
(4) Loosen U-shaped clasp fixing nut of pedal lever.
(5) Turn pedal lever to adjust the height of pedal.
(6) Lock the fixing nut of lever.
Torque: 26
± ±± ±
±2 N⋅ ⋅⋅ ⋅
⋅m
(7) Assemble the switch of brake switch.
(8) Connect the switch joint of brake light.
(9) Press down the brake pedal for 5-15mm, and turn the switch of brake light to illuminate brake light,
then lock the nut.
(10) After assembling, press down the brake pedal for 5-15mm again, and confirm brake light has
illuminated.Pedal distance
from floorFree travel of
pedal Height of pedal Push rodBrake light switch136

Brake--Vacuum booster assemblyVacuum booster assemblyInspection on automobile1. Check the vacuum booster(a) Check the gas sealed performance.
(1) Start the engine, and extinguish after one or two minutes,
then step and release brake pedal slowly several times.
Hint: if the first step is lowest, second and third step
rise gradually, and this shows the gas sealed per-
formance of booster is normal.
(2) Step down brake pedal when engine is running, then
extinguish the engine.
Hint: if the distance from pedal to floor does not
change in 30 seconds, this shows gas seal perfor-
mance of booster is normal.
(b) Working inspection.
(1) When engine is at parking state, step brake pedal sev-
eral times to check brake pedal.
The height from floor should not change.
(2) Step down brake pedal, then start the engine.
Hint: if pedal drops a little, this shows working is
normal.2. Check vacuum check valve(a) Check vacuum check valve.
(1) Remove pipe clamp, and disassemble vacuum pipe.
(2) Disassemble vacuum check valve.
(3) Blow air to check: in the direction from booster to engine,
the check valve should ventilate, but its opposite direc-
tion should not ventilate.
(4) If finding any malfunction, change vacuum check valve.Change1. Discharge brake liquidNote: do not spill the brake liquid on paint surface of automobile body, if having, wash it cleanly.2. Disassemble air filter assembly [64000033]
3. Disassemble carbon canister assembly [4G18-1129020]
4. Disassemble brake main pump subassemblyGood
Bad
FirstSecondThird
Con-
ductionNot con-
duction138