oil pressure GEELY FC 2008 Workshop Manual

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

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

9. Check compression pressure.(a) Warm up engine.
(b) Remove ignition coil.
(c) Remove spark plug.
(d) Check cylinder compression pressure.
(1) Install cylinder compression pressure gauge on spark plug hole.
(2) Wide open throttle.
(3) Measure the pressure during crankshaft rotating.
Notes:Ensure to use fully charged battery to make the rotating speed of engine reach or exceed 250rpm.When measuring other items, please repeat steps (1) to (3). Finish the measurement as soon as possible.
Compression pressure: 1080kPa
Min pressure: 1000kPa
Difference among cylinders: 100kPa
(4) If the compression pressure of one or more cylinders is too low, inject a small amount of engine oil
from spark plug hole into the cylinder with low pressure, and repeat steps (1) to (3) to check
pressure.If the pressure increases after engine oil is injected, the piston ring of this cylinder or the
cylinder has been worn or scratched.If the pressure is still too low, the valve may be stuck or not fully closed, or the cylinder head
gasket leaks.10. Check CO/HC.(a) Start engine.
(b) Keep the rotating speed of engine at 2500rpm for about 180 seconds.
(c) When the engine is idle running, insert the test bar of CO/HC gauge into exhaust pipe at least 40cm.
(d) Immediately check idle speed and CO/HC concentration at 2500rpm.
Hints:Finish test within 3 minutes.Perform the test under 2 analog states (idle speed and 2500rpm) according to measuring meth-
ods and sequences specified by Emission Regulations.
(e) If CO/HC concentration is not within specified value, perform trouble shooting according to the
following sequences.
(1) Check the function of oxygen sensor.
(2) See possible failure causes listed in the table below, and repair and correct if necessary.Engine mechanism - Engine assembly27

34. Remove power steering pump assembly.
35. Remove sub frame together with side member.(a) Remove front engine mounting assembly and rear en-
gine mounting assembly from engine assembly.
(b) Remove sub frame assembly.36. Remove starter mounting components
[4G18-3708100].
37. Remove transmission assembly.(a) Fix crankshaft with special tool, ant then remove 6 bolts.
(b) Remove transmission assembly.38. Remove clutch assembly [4G18-1601000]
and flywheel components [4G18-1005120J].(a) Fix crankshaft with special tool, ant remove clutch
assembly at first.
(b) Then remove flywheel components.39. Remove throttlesupporting plate [4G18-1008202].
40. Remove intake manifold assembly [4G18-
1008200].(f) As shown in the diagram, install front and rear hooks of
engine.
Torque: Hint: install engine hooks to front and rear sides of
engine.
(g) Lift engine assembly with chain pulley block and en-
gine lifting device.Engine mechanism - Engine assemblySpecial tool39 41. Remove exhaust manifold upper heat shield components [4G18-1008120].
42. Remove exhaust manifold assembly [4G18-1008100].
43. Remove fuel rail injector assembly [4G18-1112100].
44. Remove ignition coil installation components.
45. Remove oil level gauge tube components [4G18-1002140].
46. Remove temperature regulator assembly [4G18-1306100].
47. Disassemble warm air water outlet pipe components [4G18-1300100].
48. Remove oil pressure alerter [4G18-3757100].Remove oil pressure alerter with SST.49. Remove the hoses on all hose joint of engine.Remove clips and hose.50. Remove drive belt tensioner device.
51. Remove phase sensor [4G18-3600030].Engine hook
FrontRear

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 - 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 - Camshaft(h) Hold timing chain with hands and then remove intake
camshaft.
(i) As shown in the diagram, tie up the chain with bandage.
Note: be careful not to let anything fall into the timing
chain hood.10. Check VVT driver assembly [4G18-1006300].(a) Check locking state of timing sprocket.
Clip the camshaft with a jaw vice, and ensure VVT driver
is locked tightly.
Note: be careful not to damage intake camshaft.
(b) Release lock pin.
(1) As shown in the diagram, seal 5 oil ducts of intake
camshaft journal with vinyl rubber cloth.
Hint: there are 2 advance side oil ducts in the groove
of intake camshaft, and clog one of them with
rubber block.
(2) In opposite side of the groove, prick a hole on
vinyl rubber cloth of advance side oil duct surface
and delay side oil duct surface.
(3) Send in 2 oil ducts (advance side oil duct and
delay side oil duct) with the surface rubber cloth
pricked under the pressure of 150Kpa.
Warning: cover the oil ducts with cloth to avoid
oil injecting out in pushing.54Delay side
oil ductAdvance
side oil
duct
Close
OpenClose
Open
Vinyl rubber cloth
Rubber blockDelay side
oil ductAdvance
side oil
duct

Engine mechanism - Camshaft(4) Ensure whether the timing sprocket of VVT driver
will turn toward timing advance direction in de-
creasing the pressure of timing delay oil duct.
(5) When camshaft timing sprocket turns at max.
timing advance position, release the air pressure
in timing delay side oil duct, and then release the
air in timing advance side oil duct.
Hint: camshaft timing sprocket will turn only af-
ter the lock pin is released.
(d) Check the fixing state of max. delay position.
Ensure camshaft timing sprocket assembly is fixed at
max. delay position.11. Remove VVT driver assembly.(a) Clip the camshaft with a jaw vice, and ensure VVT driver
is locked tightly.
Warning: be careful not to damage camshaft.
(b) As shown in the diagram, seal 5 oil ducts of camshaft
journal with vinyl rubber cloth.
Hint: there are 2 advance side oil ducts in the
groove of camshaft, and clog one of them
with rubber block.
(c) In opposite side of the groove, respectively prick a hole
on vinyl rubber cloth of advance side oil duct surface
and delay side oil duct surface.
(d) Send in 2 oil ducts (advance side oil duct and delay
side oil duct) with the surface rubber cloth pricked
under the pressure of 150Kpa.
Warning:cover the oil ducts with cloth to avoid
oil injecting out in pushing.
(e) Ensure whether the timing sprocket of VVT driver will
turn toward timing advance direction in decreasing the
pressure of timing delay oil duct.
Hint: camshaft timing sprocket will turn toward
advance direction only after the lock pin is
released.
(f) When camshaft timing sprocket turns at max. timing
advance position, release the air pressure in timing
delay side oil duct, and then release the air in timing
advance side oil duct. Warning: if the air pressure in timing advance side oil duct is released earlier than that
in timing delay side oil duct, VVT driver assembly will move suddenly toward
delay side, and the lock pin will be damaged.
(c) Check rotating is smooth.
Besides max. delay position, turn VVT driver assembly within rotating rang and check rotating is
smooth.
Warning: Perform inspection with hands but not with
compressed air.55Delay side
oil ductAdvance
side oil
duct
Close
OpenClose
Open
Vinyl rubber cloth
Rubber block
Delay side
oil ductAdvance
side oil
ductDropping
pressure
Maintaining
pressure Delay side
oil ductAdvance
side oil
duct
Dropping
pressure
Maintaining
pressure Delay side
oil ductAdvance
side oil
duct

Engine mechanism - CamshaftWarning: if the air pressure in timing advance side oil duct is released earlier than that in
timing delay side oil duct, VVT driver assembly will move suddenly toward
delay side.This will cause the damage of lock pin.
(g) Remove VVT drive fixed bolts.
Notes:
It is strictly forbidden to remove other 4 bolts.
Under the condition of repeating using camshaft
timing sprocket, release lock pin at first, and then
install sprocket.12. Install VVT driver assembly.
13. Install camshaft.Put VVT driver assembly together with intake camshaft.
(a) As shown in the diagram, gently make VVT assembly
hold camshaft and turn it toward left until straight pin is
inserted into groove.
Warning: it is strictly forbidden to turn camshaft
timing sprocket toward timing delay side
(toward right).
(b) Check there is no clearance between sprocket flange
and camshaft.
(c) Fix camshaft timing sprocket and then tighten flange
bolt.
Torque: 70 ±5N.m
(d) Check VVT driver assembly could move to timing
delay side and is locked at max. timing delay position.
(f) As shown in the diagram, align alignment mark with
timing mark on camshaft timing sprocket, and install
timing chain on the timing sprocket.
(g) Check forward mark and figure, and tighten bolts as
sequences shown in the diagram.
Torque: 13 ±0.78N.m
(h) Align alignment mark on the chain with timing mark on
camshaft timing sprocket, and place exhaust camshaft
in cylinder head.Straight pin
key
grooveFlange bolt
Straight pin56Timing remark
chain linkTiming mark
Timing remark chain link
Timing mark