fuel GEELY FC 2008 Workshop Manual

Preface
Geely “FC” is an automobile with high performance/price ratio and it meets the requirement
of national safety, energy saving, emission regulations and personal use. This automobile is
a completely new and excellent model produced by Zhejiang Geely Automobile Co., Ltd with
development in self-reliance of Geely group and with self-dominated intellectual property
right. It characterizes elegant appearance,
energy conservation and environmental protection,
safety and comfort. “FC” is a product opening a completely new viewpoint of automobile
selection, because it is developed on the basis of creative design thinking that breaks through
all established customs and it features perfectly balanced performance of power, space,
safety, manipulation and comfort. “FC” is a competitive product for Geely developing brand
and exploring mid-level automobile market, which takes over the company philosophy “make
good cars that common people can afford, and let Geely cars go to the whole world” of Geely
automobile. “FC” is combination of creativity and intelligence of quite a large number of
automobile experts, who have been developing and searching with great concentration for
more than 30 months, and it fully embodies persistent Geely style of fashion appearance
and high performance/price ratio.
“FC” is equipped with engine JL4G18 completely developed and produced by Geely group.
Engine JL4G18 applies the following advanced technology such as VVT, full aluminum cylin-
der body, plastic intake manifold, completely new VVT inside seal method, completely new
OCV valve filtering method etc. with M7.9.7 electric injection system of BOSCH, and its
index on power efficiency, economical efficiency, and safety efficiency etc. reaches leading
level of national model with the same type. This engine features strong power, low fuel
consumption, low noise and high power per liter etc.
We start to compile “FC” Automobile Maintenance Manual, which is divided into 27 sec-
tions with detailed description of overall structure and maintenance of engine 4G18.VVT;
inspection and repair of engine BOSCH M7.9.7 electric control fuel injection system; struc-
ture and maintenance of chassis; structure and maintenance of FC electrical equipment;
structure and maintenance of ABS anti-lock brake system; structure and maintenance of
SRS air bag; structure and maintenance of auto air conditioning system; structure and main-
tenance of vehicle body etc. Information is detailed and accurate, contents are in systematic
coherence and description is concise and comprehensive.
This manual is compiled from structure, which prompts “FC” service personnel to master

Brief introduction on Geely model “FC”
Basic parameters...................................................
1
Maintenance period
Regular maintenance items...................................
4
Table on maintenance period at normal conditions5
Table on maintenance period at severe conditions..
7
Engine control system
EFI system.............................................................
8
On-vehicle inspection........................................
8
Inspection..........................................................
9
Throttle body assembly........................................
13Removing, installing and disassembling, assembling...13
Fuel
Fuel system..........................................................
14
Precautions......................................................
14
On-vehicle inspection......................................
16
Inspection........................................................
17
Injection nozzle assembly....................................
18
Replacement...................................................
18
Fuel pump assembly...........................................
20Removing, installing and disassembling, assembling....20
Fuel tank assembly.............................................
21Removing, installing and disassembling, assembling.....21
Exhaust gas control
Exhaust gas control system...............................
23
On-vehicle inspection......................................
23
Inspection........................................................
25
Engine mechanism
Engine assembly..................................................
26Inspection........................................................
26
Drive belt..............................................................
29
Replacement...................................................
29
Valve clearance....................................................
30
Adjustment......................................................
30
Engine assembly.................................................
36
Replacement...................................................
36
Timing chain assembly.......................................
45
Replacement...................................................
45
Camshaft.............................................................
52
Replacement...................................................
52
Crankshaft front oil seal assembly.....................
60
Replacement...................................................
60
Crankshaft rear oil seal assembly......................
62
Replacement...................................................
62
Cylinder cover gasket components.....................
63
Replacement...................................................
63
Exhaust
Exhaust pipe assembly........................................
65Removing, installing and disassembling, assembling.....65
Cooling
Cooling system....................................................
66
On-vehicle inspection......................................
66
Inspection........................................................
66
Cooling fan system..............................................
68
On-vehicle inspection......................................
68
Inspection........................................................
68
Water pump assembly........................................
69
Replacement...................................................
69
Temperature regulator components...................
71
Replacement...................................................
71
Radiator with electronic fan assembly................
72Contents

Brief introduction on Geely model “FC” Basic parametersTable 2 Types and parameters of main assemblyModel
TypeElectric injection system modelBore
StrokeDelivery capacityCompression ratioMax. power
Max. torque
Idling speedIgnition sequenceMin. fuel consumptionTypeMain gear box ratioTypes and parameters
JL4G184-cylinderin-line, four-stroke, water-cooling, double over-head
camshaft, 16-valve, CVVT multipoint injection gasoline engineUnited Automotive Electronic Systems Co., Ltd. M7.9.7 electric injection system5 gears synchronizer of constant mesh gearDry single, diaphragm spring, constant pressure
Rack-and-pinion steering gear with hydraulic powerDouble pipeline, vacuum boosterwith ABS +EBD anti-lock systemDisc brake
Disc brake
Strut-type front independent suspensionLongitudinal swinging arm and anti-twist beam compound rear suspensionBreakawayBalI cage and tripot type constant velocity universal jointLoaded all-metal body
Honeycomb cordierite carrier, noble metal catalyst
Swirl or swash plate compressorItem nameNumber
Engine1st gear
2nd gear
3rd gear
4th gear
5th gearReverse gearClutch type
Steering gear
Tire
Body structureSpecification
Air pressureRadial
tireTail gasAir
condi-
tioning
systemUnit



//
.
//
/
/.



2
Transmission
Each gear ratio
Braking
system
Sus-
pension
Drive
axleType
Front brake
Rear brakeFront suspension type
Rear suspension typeRim
Type
Drive shaftCatalytic converterCompressor typeNominal refrigerating capacityRefrigerant

Brief introduction on Geely model “FC” Basic parametersTable 3 Main performance parameters of complete vehicle
UnitNumberParametersRemarksMax. vehicle speed
0-100 km/h accelerating timeAccelerating time from 30km/h to 100km/h at 4th gearMin. stable vehicle speed at 4th gear
Max. climbing speedSlide Distance (full-load, initial speed 50km/h)Fuel consumption with 4 operating modesAverage fuel consumption at specified operating modeDust sealing degree
Rain protection seal limit valueWeighted acceleration root of mean squareEquivalent mean value
Reduced comfort boundary
Average mileage to first failure
Average mileage between failures
Efficient degree Item name
Power performance 3
Economy
performance Seal
perfor-
mance
Ride
perfor-
mance
Reliability

Maintenance period-Table on maintenance period at normal conditionsTable on maintenance period at normal conditionsMaintenance content:I: Inspection and correction or replacement if necessary R: Replacementmileage
reading1000kmMaintenance period
(Odometer readings or
operating monthssubject to
the first coming)Engine basic elements
1. Valve clearance*12. Drive belt
3. Engine oil (APLSJ,SL or ILSAC) *24. Oil filter*25. Cooling and heating system hose and joint*3*46. Engine coolant*5*67. CVVT oil duct filter screen
8. Exhaust pipe and fixed mount
Ignition system
9. Spark plug
10. BatteryFuel and exhaust gas control system11. Fuel filter
12. Air filter core13. Connecting conditions of fuel tank cover,
fuel pipe and fuel evaporation control valve*714. Activated carbon canister
Chassis and vehicle body
15. Brake pedal and parking brake
16. Brake pad and brake disc
17. Brake fluid
18. Brake Pipe and hose
19. Power steering oil20. Steering wheel, steering linkage and gear box oil21. Drive shaft dust cover
22. Ball joint and dust cap
23. Transmission oil
24. Front and rear suspension
25. Tire and tire pressure
26. All light, horn, wiper and washer
27. Air conditioner cleaning filter screenAir conditioning system/ secondary refrigerant7 . 5 1 5 22.5 3037.5 4553.5 60 67.5 7 582.5 90months 5

FuelFuel systemPrecautions1. Before repairing fuel system, uncouple battery negative (-) wire at first.
2. When operating on fuel system, do not smoke or repair near fire area.
3. Do not let gasoline come into contact with rubber or leather parts.
4. Take measures to prevent gasoline leaking.(a) Uncouple electric fuel pump joint.
(b) Start engine and turn ignition switch to LOCK position
after the engine flames out.
(c) Uncouple battery negative (-) wire.
(d) Couple electric fuel pump joint.5. Fuel system(a) There will be a great amount of gasoline flowing out
when disassembling high-pressure fuel pipe,
therefore, it is required to observe the following
procedures.
(1) Take measures to prevent gasoline leaking.
(2) Disassemble fuel pipe.
(3) Completely discharge the oil in fuel pipe.
(4) Cover the fuel pipe with plastic bag to avoid pipe
damage and foreign matters entering.
(5) Place a container under the joint.
(b) When removing and installing injection nozzle, always
observe the following precautions.Fuel-Fuel system 14

Fuel-Fuel system(1) It is not allowed to use o-ring repeatedly.
(2) When installing o-ring, always be careful to avoid dam-
aging o-ring.
(3) Before installing, coat o-ring with spindle oil or gasoline.
It is not allowed to coat with engine oil, gear oil or
brake fluid.
(c) As shown in the diagram, install injection nozzle to oil feed
pipe and cylinder head.
Before installing, ensure that spindle oil and gasoline are
coated at the contact position between o-ring and oil feed
pipe.
(d) When disassembling oil feed pipe, always observe the fol-
lowing precautions.
(1) Remove oil feed pipe clips.
(2) Remove oil feed hose.
(3) Cover oil inlet of fuel distribution pipe with plastic bag
to avoid foreign materials entering the fuel distribution
pipe.injection nozzle6. Inspection of fuel leakage(1) After completing maintenance, check there is leakage with the whole fuel system.
(2) Connect hand-held tester to diagnostic joint.
(3) Turn ignition switch to ON and turn main switch of hand-held tester to ON.
(4) Switch hand-held tester to function test state.
(5) For further details, please see hand-held tester operating instruction.
(6) If there is no hand-held tester, connect battery anode and cathode to electric fuel pump joint.
(7) Ensure that there is no leakage with all parts of electric fuel pump.
(8) Turn ignition switch to LOCK.
(9) Disassemble hand-held tester from diagnostic interface joint.15o-ringoil feed pipeoil feed pipeo-ringwasherCorrect
Wrong

On-vehicle inspection1. Inspection of fuel pump function(a) Connect hand-held tester to diagnostic joint.
(b) Turn ignition switch to ON and turn main switch of hand-
held tester to ON.
Note: do not start the engine.
(c) Switch hand-held tester to function test state.
(d) For further details, please see hand-held tester operating
instruction.
(e) If there is no hand-held tester, connect battery positive (+)
wire to P+ terminal and negative (-) wire to P- terminal.2. Inspection of fuel pressure(a) Preparation of inspection.
Purchase new fuel hose and take out fuel pipe joint.
(b) Take measures to prevent gasoline leaking.
(c) Disassemble fuel pipe clamp at fuel pipe joint of fuel rail
component.
(d) Disassemble fuel hose from fuel pipe of fuel rail component.
(e) As shown in the diagram, install special tool (pressure
gauge) with special tool and fuel pipe joint.
(f) Check there is fuel leakage.
(g) Start engine.
(h) Measure the fuel pressure at idle speed state.
Fuel pressure: 390~400Pa
(i) Take measures again to prevent gasoline leaking.
(j) After measuring the fuel pressure, remove special tool.
(k) Connect back fuel hose.
(l) Install fuel hose fixing clip to fuel pipe joint.
(m)Check there is fuel leakage.Fuel-Fuel systemSpecial
tool 16

(6) Connect special tool to injection nozzle joint.
(7) Connect special tool to battery for 15 seconds, and measure the injection volume with measuring
cup, each injection nozzle should be test for 2~3 times.
Injection volume:Fuel-Fuel systemInspection1. Fuel injector components [4G18-1112120](a) Check injection nozzle resistance.
(1) Measure the resistance between terminals with
ohmmeter.
Resistance: Hint: if resistance is not within specification, replace in-
jection nozzle.
(b) Injection nozzle test.
Warning: there should be no sparks during testing.
(1) Purchase new fuel pipe and take out fuel hose joint.
(2) Install special tool and fuel hose joint to fuel pipe.
Note: Only after performing precautions could the
connection operation of fuel hose joint (fast-
joint mode) be allowed to perform.
Warning: before connecting fuel pipe joint (fast-joint
mode), please read precautions carefully
(3) Install o-ring to injection nozzle.
(4) Connect special tool (joint and hose) to injection nozzle,
and hold down the injection nozzle to prevent fuel splash.
(5) Place injection nozzle into measuring cup.
Hint: install proper hose on injection nozzle to prevent
gasoline injecting out of the cup.
Engine Injection volume Uneven volume between
each injection nozzleEvery 15 secondsor lessHint: if injection volume is not within specification, replace
injection nozzle. 17 Special
toolSpecial
toolo-ring

Fuel-Injection nozzle assemblyInjection nozzle assemblyReplacement1. Take measures to prevent gasoline leaking.
2. Remove engine plastic hood components.
3. Uncouple engine wire harness [4G18-3724100].(a) Remove injection nozzle joint.
(b) Remove exhaust gas hose.4. Remove fuel pipe assembly(a) Loosen oil feed hose clips.
(b) Pull oil feed hose away from fuse distribution pipe.
Notes:zCheck there is dirt on fuel pipe and its joint before removing, and clean it off in the case of dirt.zIt is only allowed to remove with hands.zCheck there are foreign matters with the removed fuel pipe seal surface, and clean them off in the
case of foreign matters.zCover the fuel pipe with plastic bag to avoid pipe damage and foreign matters entering.5. Remove fuel pipe assemblyRemove 2 bolts and oil feed pipe (together with injection nozzle).6. Remove injection nozzle components.Pull out 4 injection nozzles from oil feed pipe.7. Install injection nozzle components.Coat a thin layer of gasoline on o-ring and rotate left and right to push injection nozzle into oil feed pipe.
Notes:
zBe careful not to rotate o-ring.
zCheck injection nozzle could rotate smoothly after it is installed, and if not replace with new o-ring.8. Install fuel hose assembly.Install fuel hose to oil feed pipe.
Notes:
zCheck there are damage or foreign matters in the binding site of fuel pipe.
zAfter installing, pull the fuel pump with hands to check the fuel pipe is bound firmly with joint. 18