lock 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

Replacement.................................................
308
Left front door loudhailer....................................
309
Change..........................................................
309
Left front small loudhailer..................................
310
Change..........................................................
310
Rear loudhailer..................................................
311
Change..........................................................
311
Outdoor antenna...............................................
312
Change..........................................................
312
Circuitry
Power supply......................................................
313
Components..................................................
313
Horn system
Horn system.......................................................
316
Position..........................................................
316
Inspect...........................................................
316
Windshield/window glass/wing mirror
Electric window control system..........................
317
Position drawing............................................
317
Inspect the car...............................................
317
Malfunction phenomena table.......................
319
Inspect...........................................................
319
Front windscreen................................................
321
Change..........................................................
321
Rear ventilation window.....................................
324
Change..........................................................
324
Fog defrost system............................................
327
Position drawing...........................................
327
Malfunction phenomena table......................
327
Inspect...........................................................
328
Electric rearview mirror control system(option).
329
Inspect the vehicle.........................................
329
Position drawing...........................................
331
Trouble table.................................................
331
INSPECT.......................................................
332Panel / combination panel
combination panel
..............................................
334
Trouble table..................................................
334
Vehicle inspection..........................................
335
Inspection......................................................
339
Panel..................................................................
340
Preparation....................................................
340
Change..........................................................
340
Combination instrument assembly.....................
347
Disassembly and assembly...........................
347
Chair
Front chair..........................................................
348
Subassembly.................................................
348
Overhaul........................................................
349
Rear chair (separating type)...............................
352
Overhaul........................................................
352
Rear chair (fixing type).......................................
354
Overhaul........................................................
354
Anti-stealing and door lock
Electric door lock control system........................
355
Position of parts.............................................
355
Inspection on automobile...............................
355
Malfunction phenomenon table.....................
358
Inspection......................................................
359
Electronic anti-stealing system...........................
361
Electric sunroof
Sunroof.................................................................
362
Overhaul........................................................
362
Specification for sunroof function......................
364
Inspection for sunroof function......................
364
Inspection for sunroof switch........................
365
Position of parts............................................
365
Malfunction phenomenon table....................
365

Engine cover/automobile door
Engine cover......................................................
366
Adjustment.....................................................
366
Front automobile door........................................
367
Subassembly.................................................
367
Overhaul........................................................
369
Adjustment.....................................................
372
Rear automobile door.......................................
373
Overhaul........................................................
373
Adjustment....................................................
375
Trunk cover.........................................................
377
Adjustment....................................................
377
Torsion spring of trunk cover.............................
378
Change..........................................................
378
Exterior/inner trim board
Front bumper....................................................
379
Subassembly................................................
379
Change..........................................................
380
Rear bumper......................................................
381
Subassembly................................................
381
Change..........................................................
382
Name plate........................................................
383
Change..........................................................
383
Exterior seal tape of left front door glass (LH)...
384
Change..........................................................
384
Exterior seal tape of left rear door glass...........
385
Change..........................................................
385
Light fender........................................................
386
Change..........................................................
386
Top left trim tape.................................................
387
Replacement.................................................
387
Left lower fender of automobile body (LH)........
388
Subassembly................................................
388
Change..........................................................
389
Inner trim board of top........................................
390
Change..........................................................
390Automobile control system
Ignition switch and anti-versa lock key warning switch.394
Malfunction phenomenon table.....................
394
Inspection......................................................
394
Electrical schematic diagram..............................
395

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

Note: *1 Indicating that check valve noise and engine vibration condition, and adjust them if necessary.*2 It is suggested that see operating modes on page 116 of operating instruction to perform.*3 Indicating that check once every 20000km or 12 moths after 80000km or 48 months.*4 Indicating that check water tank and condenser are blocked by leaves, dust or insects, and clean
hose connections.*5 Replace at initial 60000km, and replace every 30000km in future.*6 Only “Geely genuine ultra-long engine coolant” or equivalent high-quality ethylene glycol engine
coolant without silicate, amines, nitrite, borate and with long-life compound organic acid technology
are allowed to use, and coolant should be repeated several times until it is filled up.*7 Indicating that check once every 20000km or 12 moths after 80000km or 48 months.Maintenance period-Table on maintenance period at normal conditions 6

Maintenance period-Table on maintenance period at severe conditionsTable on maintenance period at severe conditionsAccording to the driving conditions listed below, maintenance should be performed to the items that
should be maintained more frequently (for other items not listed, please see Table on maintenance
period at normal conditions) 7 A-1: Driving on rugged, muddy or melting snow road Inspection of brake pad and brake disc Every 5,000 km or 3 moths Inspection of brake pipeline and hose Every 10,000 km or 6 moths Inspection of ball joint and dust cover Every 10,000 km or 6 moths Inspection of drive shaft dust cover Every 10,000 km or 12 moths Inspection of the steering wheel, steering linkage and gear box oilEvery 5,000 km or 3 moths Check of front and rear suspension Every 10,000 km or 6 moths
A-2: Driving on dusty road Replacement of engine oil Every 5,000 km or 6 moths Replacement of engine oil filter Every 5,000 km or 6 moths Inspection or replacement of air filter core I: Every 2,500 km or 3 moths
R: Every 10,000 km or 6 moths Inspection of brake block and brake disc Every 5,000 km or 3 moths Replacement of air conditioner cleaning filter screen Every 15,000 km
B-1: Towing tail vehicle, equipped with camp frame or top storage racks Replacement of engine oil Every 5,000 km or 6 moths Replacement of engine oil filter Every 5,000 km or 6 moths Inspection of brake pad and brake disc Every 5,000 km or 3 moths Inspection or replacement of transmission oil Every 60,000 km or 24 moths Inspection of front and rear suspension Every 10,000 km or 6 moths Screwing down the bolts and nuts of the chassis and vehicle bodyEvery 10,000 km or 6 moths
B-2: Repeated on short-distance driving within 8 km and the temperature is below 0 °C Replacement of engine oil Every 5,000 km or 6 moths Replacement of engine oil filter Every 5,000 km or 6 moths
B-3: Vehicles driven for long distance under idle speed or low speed over a long period of time, such as police car, taxi or deliverytruck. Replacement of engine oil Every 5,000 km or 6 moths Replacement of engine oil filter Every 5,000 km or 6 moths Inspection of PCV valve and pipelines Every 5,000 km or 6 moths Inspection of brake block and brake disc Every 5,000 km or 3 moths
B-4: Continuously driving at high speed for more than 2 hours frequently (With 80% of max. vehicle speed) Replacement of transmission oil Every 40,000 km or 12 moths
B-5: Vehicles driven with idle speed or low speed over a long period of time or frequently accelerated or
decelerated, such as student car of driving training class. Replacement of engine oil Every 3,000 km or 3 moths Replacement of engine oil filter Every 3,000 km or 3 moths Inspection of PCV valve and pipelines Every 3,000 km or 3 moths

Engine control system·- EFI systemInspection1. VVT control solenoid valve assembly (4G18-1006200)(a) Resistance inspection
(1) Measure the resistance between terminals with ohmmeter
Resistance: (b) Operation inspection
Connect battery positive (+) wire to No.1 terminal and negative (-) wire to No. 2 terminal, and check
valve operation.
Note: ensure that the valve is not stuck.
Hint: if there are foreign matters in the valve, the valve could not be closed tightly and will
thus result in slight pressure being lifted toward higher direction.2. Throttle body components (4G18-1001240)(a) Inspection of throttle body
(1) Throttle valve shaft should not swing.
(2) All channels should not be blocked.
(3) Throttle valve plate should rotate flexibly and act smoothly.
(4) When the throttle is at closed position, there should be no clearance between throttle stop bolts and
throttle lever.
Note: it is not allowed to adjust the throttle stop bolts.3. Throttle position sensor (4G18-3600080)(a) Resistance inspection
(1) Remove the wiring harness connectors of throttle posi-
tion sensor.
(2) Measure the resistance between 1# pin and 2# pin with
ohmmeter, resistance value: .
(3) Connect 2 terminals respectively to 1# pin and 3# pin,
and turn the throttle, the resistance value varies linearly
with the opening of throttle, but 2# pin and 3# pin are
contrary to this.
Note:pay attention whether there is great jump with
resistance value when observing resistance change. 9

5. Water temperature sensor (4G18-3600040)This sensor applies sealing NTC thermal resistor in temperature sensor, and resistance value varies with
ambient temperature, thus slight change of outside temperature could be measured. Measuring its out-
put resistance could reflect the temperature of contact media. Signals from A and C are sent to ECU,
and Signals from B and earth are sent to instrument.
Operating principle (Fig. 1):
Note: A, B and C represent 3 pins of sensor, and see pin root for the mark. Measuring method:
(Removing the joint) place digital universal meter at ohm gear,
and connect 2 terminals respectively to 1#
pin and 2#
pin, and
the resistance under normal temperature should be more than
1M. Place digital universal meter at millivolt gear, and knock
around knock sensor with a hand hammer, there should be voltage
signal output at the moment.Engine control system·- EFI systemFig. 11 Vibration block
2 Housing
3 Piezoelectric ce-
ramics
4 Contact
5 Electric connec-
tion4. Knock sensor (4G18-3600020) 10

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