oil GEELY FC 2008 Workshop Manual

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

Replacement...................................................
72
Coolant.................................................................
73
Replacement...................................................
73
Lubrication
Lubricating system...............................................
74
On-vehicle inspection......................................
74
Oil filter assembly.................................................
75
Replacement....................................................
75
Oil pump assembly...............................................
76
Replacement....................................................
76
Ignition
Ignition system.....................................................
77
Inspection........................................................
77
On-vehicle inspection......................................
77
Starting and charging
Starting system.....................................................
79
Inspection........................................................
79
Charging system..................................................
81
Precautions......................................................
81
On-vehicle inspection......................................
82
Alternator components..............................................
84
Replacement....................................................
84
Starter components..............................................
85
Replacement....................................................
85
Front suspension
Front suspension system....................................
86
Table on trouble occurrence...........................
86
Front wheel alignment.........................................
87
Adjustment......................................................
87
Front absorber and helical spring.......................
90
Overhaul..........................................................
90
Handling..........................................................
93
Lower left control arm assembly.........................
94
Replacement...................................................
94Front stabilizer bar...............................................
96
Overhaul..........................................................
96
Front left lower control arm ball joint assembly
..
99
Replacement...................................................
99
Rear suspension
Rear suspension system....................................
100
Table on trouble occurrence..........................
100
Rear wheel alignment.........................................
101
Adjustment.....................................................
101
Rear strut assembly...........................................
102
Overhaul........................................................
102
Handling.........................................................
104
Rear stabilizer bar..............................................
105
Overhaul........................................................
105
Rear shaft assembly...........................................
106
Overhaul........................................................
106
Tire and wheel
Wheel and tire system.......................................
109
Inspection......................................................
109
Drive shaft
Drive shaft.......................................................
111
Notes.............................................................
111
Malfunction phenomenon table....................
111
Inspection on automobile.............................
11 2
Front drive shaft.................................................
11 3
Overhaul........................................................
11 3
Left front shaft hub assembly............................
123
Change..........................................................
123
Left front shaft hub bolt......................................
128
Change..........................................................
128
Left rear shaft hub and bearing assembly........
129
Change..........................................................
129
Left rear shaft hub bolt.......................................
131
Change..........................................................
131

Brake
Brake system......................................................
132
Notes..............................................................
132
Remove malfunction...........................................
133
Malfunction phenomenon table.....................
133
Brake liquid.........................................................
135
Discharge the air in brake system.................
135
Brake pedal assembly........................................
136
Adjustment.....................................................
136
Change..........................................................
137
Vacuum booster assembly.................................
138
Inspection on automobile...............................
138
Change..........................................................
138
Front brake assembly.........................................
141
Overhaul........................................................
141
Rear brake assembly.........................................
144
Overhaul........................................................
144Hydraulic pressure control unit (equipping with ABS)...148
Inspection on automobile...............................
148
Change..........................................................
148
Speed sensor of front wheel..............................
151
Change..........................................................
151
Speed sensor of rear wheels...........................
152
Change..........................................................
152
Parking brake
Parking brake system.........................................
154
Malfunction phenomenon table.....................
154
Adjustment.....................................................
154
Parking brake handle assembly.........................
155
Change..........................................................
155
Parking front bake pull cable assembly............
156
Change..........................................................
156
Parking rear brake pull cable assembly...........
158
Change..........................................................
158
Parking brake assembly....................................
161
Overhaul........................................................
161Transmission
Disassemble assembly...................................
165
Assemble the assembly....................................
191
Steering column
Steering system..................................................
192
Note...............................................................
192
Malfunction phenomenon table.....................
192
Inspection on automobile...............................
193
Steering column system.....................................
194
Overhaul........................................................
194
Power steering
Power steering system......................................
198
Note...............................................................
198
Malfunction phenomenon table....................
199
Inspection on automobile.............................
200
Power steering oil pump assembly..................
203
Overhaul........................................................
203
Power steering gear assembly.........................
205
Overhaul........................................................
205
Air conditioner
Air conditioning system......................................
213
Note...............................................................
213
Inspection on automobile...............................
213
Inspection......................................................
214
Refrigerant..........................................................
215
Inspection on automobile...............................
215
Change..........................................................
221
Refrigerant pipeline............................................
222
Parts...............................................................
222Control assembly, air conditioner control panel (AUTO A/C)...223
Overhaul........................................................
223
Fan assembly...................................................
224
Overhaul........................................................
224
Air conditioner central heating core assembly..
227
Overhaul........................................................
227
Compressor assembly.....................................
234

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

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 systemEFI systemOn-vehicle inspection1. Inspection of the voltage of power steering oil pres-
sure sensorMeasure the voltage between PS terminal and E2 terminal
with ohmmeter2. Inspection of stepping motor(a) With engine running at idle speed, pull out the connection harness of stepping motor, and the change
of engine rotating speed indicates that the stepping motor operates normally.
(b) Pull out the connection harness of stepping motor, and measure the terminal current with universal
meter. When engine is running, there being impulse current output at the terminal indicates that there
is no trouble with ECU and stepping motor control system, and if idling is not stable at the moment
and deviates greatly from specified value, the stepping motor should be replaced. If there is no
impulse current output at the terminal, turn on air conditioner to test again, and still no impulse
current output indicates that there is trouble with ECU and stepping motor control system circuit.
(c) Check the malfunction of stepping motor circuit with diagnostic instrument.Engine control system·- EFI system 8Conditions Voltage (V) Not turning steering wheel with
engine at idle speed Turning steering wheel with
engine at idle speed 0-1.5

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

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

Fuel - Fuel pump assemblyFuel pump assemblyRemoving, installing and disassembling, assembling1. Take measures to prevent gasoline leaking
2. Remove rear seat cushion assembly
3. Remove rear floor repairing hole cover
4. Remove No. 2 fuel evaporation assemblyNotes:
zCheck there is contaminant looked like dirt around the joint before operating and clean it off in the
case of contaminant.
zBe careful of the contaminant looked like dirt, because fast-joint depends on o-ring to seal fuel pipe
and joint.
zDo not perform this operation with tools.
zDo not bend or distort nylon hose.
zCover the joint with plastic bag after removing the fuel hose.
zWhen the joint is stuck with fuel pipe, clip the hose with fingers and rotate carefully to release the
hose, and then remove it.5. Remove fuel tank main fuel hose and oil return pipe assemblyNotes:
zCheck there is contaminant looked like dirt around the joint before operating and clean it off in the
case of contaminant.
zBe careful of the contaminant looked like dirt, because fast-joint depends on o-ring to seal fuel pipe
and joint.
zDo not perform this operation with tools.
zDo not bend or distort nylon hose.
zCover the joint with plastic bag after removing the fuel hose.
zWhen the joint is stuck with fuel pipe, clip the hose with fingers and rotate carefully to release the
hose, and then remove it.6. Remove fuel pump assembly(a) Screw off fuel pump tighten nut (plastic fuel tank) or remove
6 screws (iron fuel tank).
(b) Pull out fuel pump assembly.
Notes:
zDo not damage fuel pump filter screen.
zBe careful not to bend the measuring oil arm of fuel gauge
float unit.7. Install fuel pump assemblyTorque: 8 N.m8. Install rear floor repairing hole coverInstall rear floor repairing hole cover with butyl rubber cloth.9. Check there is fuel leakage. 20