radiator 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

Engine mechanism - Engine assemblyEngine assemblyReplacement1. Take measures to prevent gasoline leaking.
2. Remove engine right bottom shield.
3. Remove engine left bottom shield.
4. Discharge coolant.
5. Remove front wheels.
6. Remove engine plastic hood components.
7. Remove battery.
8. Remove air filter assembly.
9. Remove air filter hose.
10. Remove battery tray.
11. Disassemble fuel hose assembly.
12. Remove throttle cable assembly.
13. Disassemble radiator hose inlet end.
14. Disassemble radiator hose outlet end.
15. Disassemble cold air pipe inlet hose.
16. Disassemble cold air pipe outlet hose.
17. Remove transmission control pull cable assembly.
18. Disassemble warm air water inlet hose [4G18-1300102].
19. Disassemble warm air water outlet hose [4G18-1300108].
20. Disassemble the hoses of all joints to connect vehicle body end.
21. Uncouple engine wire harness.(a) Remove glove compartment door.
(b) Remove engine wire harness from engine ECU and junction block.
(c) Pull out engine wire harness.
(b) Remove engine wire harness from junction block of engine room.
(e) Remove vehicle body earth wire. 36

Cooling - Cooling syste2. Check engine coolant level in reservoir.Engine coolant level should be between “Low” and “Full” mark line.
Hint: if the level is too low, check there is leakage and refill coolant to “Full” mark line.3. Check engine coolant quality.(a) Remove radiator cap.
Warning: when the temperature of engine and radiator is high, do not remove radiator cap to
avoid being scalded, because coolant and steam will spurt under high pressure.
(b) Check there is too much rust deposit around radiator cap or at outlet and check there is flake; there
should not be oil in the coolant.
Hint: if coolant is too dirty, it is required to replace coolant.
(c) Install back radiator cap.Inspection1. Temperature regulatorHint: the figure on temperature regulator is the
opening temperature of valve.CoolingCooling systemOn-vehicle inspection1. Check there is leakage with cooling system.Warning: when the temperature of engine and radiator is
high, do not remove radiator cap to avoid be-
ing scalded, because coolant and steam will
spurt under high pressure.
(a) Refill coolant to radiator, and install radiator cap tester.
(b) Preheat engine.
(c) Pump tester to make pressure go up to 118KPa, and check
the pressure falls.
Hint: if the pressure falls, check there is leakage with
hose, radiator or water pump, and check heater,
cylinder body and cylinder head if no external leak-
age is found.66

Cooling - Cooling systeTemperatureDegree of valve opening(a) Immerse temperature regulator into water and heat
gradually.
(b) Check opening temperature of valve.
Opening temperature of valve: 8084Hint: if opening temperature of valve is not within
specified range, it is required to replace tempera-
ture regulator.
(c) Check opening of valve.
Opening of valve:2. Radiator cap assemblyNotes:If radiator is dirty, wash it with clean water.Before using radiator cap tester, dampen relief valve
and pressure valve with coolant or water.
(a) Use radiator cap tester to slowly pump radiator cap
tester, and check the air is released by vacuum valve.
Pumping speed: 1 time /(3 seconds or more)
Note: pump radiator tester with constant speed.
Hints:Pumping speed: 1 time /(3 seconds or more)If air could not be released by vacuum valve,
please replace radiator cap.
(b) Pump tester and check opening pressure of relief valve.
Standard opening pressure: 74-108KPa
Min. opening pressure: 59KPa
Note: pumping speed means that the speed could be increased after the first time pumping
speed (to close vacuum valve).
Hints:Pumping speed: 1 time within 1 secondMax. reading of tester is opening pressure.If opening pressure is less than min. value, please replace radiator cap. Hint: if degree of valve opening is not within speci-
fied range, it is required to replace tempera-
ture regulator.
(a) When temperature regulator is at low temperature (below), check valve is tightly closed.
Hint: if the valve could not be closed, it is required to
replace temperature regulator.67

Cooling - Radiator with electronic fan assemblyRadiator with electronic fan assemblyReplacement1. Discharge coolant (see Page 73).
2. Disassemble radiator water inlet hose [64000062].
3. Disassemble radiator water outlet hose [64000063].
4. Disassemble No.1 oil cooler inlet pipe (auto gear).
5. Disassemble No.1 oil cooler outlet pipe (auto gear).
6. Disassemble fixing clips of 2 wire harnesses from fan cover.
7. Remove mounting bracket assembly on radiator [64000058].
8. Remove radiator together with electronic fan assembly [64000057].
9. Remove electronic fan together with fan cover assembly [64000060].(a) Screw off fixed nuts connecting electronic fan together with fan cover assembly with radiator.
(b) Uncouple fan motor joint.
(c) Remove 2 bolts of fan.
(d) Remove fan motor at the same time.10. Replace and install as sequences opposite to the above.
11. Refill engine coolant (see Page 73).
12. Check there is leakage with coolant (see Page 66).
72

CoolantReplacement1. Discharge engine coolant.Warning: when the temperature of engine and radiator is high, do not remove radiator cap to
avoid being scalded, because coolant and steam will spurt under high pressure.
(a) Remove radiator cap.
(b) Open radiator drain valve and engine drain valve.Cooling - Coolant2. Refill engine coolant.(a) Lock 2 drain valves and pour coolant into radiator until it is full.
Hints:Press radiator water inlet hose and outlet hose with hands several times.If coolant level is too low, please refill coolant again.
(b) Screw down radiator cap.
(c) Pour coolant into expansion tank until the level is up to “FULL” mark line.
(d) Run engine with vehicle warning up until thermostat valve is opened.
Hint:During vehicle warning up, press radiator water inlet hose and outlet hose with hands
several times.
(e) Engine flames out until coolant temperature falls to “cold”. Then open radiator cap and check coolant
level.
(f) If coolant level is too low, please perform the above steps again.
(g) If coolant level is not too low, please adjust expansion tank coolant level.3. Check there is leakage with coolant.(a) Refill engine coolant to radiator, and install radiator cap tester.
(b) Pressurize radiator to 118kPa, and check there is leakage.73Engine drain valve
Radiator drain valve Radiator cap
Drain pipe

Air conditioner--Air conditioner central heating core assembly
3. Disconnect refrigerant No.1 low pressure hose.
Note:
after disassembling the pipeline, it is necessary to cover
the joint to prevent humidity or dust from entering in
system.
4. Disconnect refrigerant liquid pipe A.
Hint:disconnect liquid pipe A with the method being
same as No.1.
5. Disconnect water outlet hose of heating.
(a) Slide out fixed clamp and disassemble water outlet hose
of heating.
6. Disconnect water intake hose of heating.
Slide out fixed clamp and disassemble water intake hose of
heating.
7. Disassemble cathode wire of battery.
8. Make front wheels face the front.
9. Disassemble safety airbag assembly at the side of
driver.
10. Disassemble steering wheel.
11. Disassemble combination instrument cover
[68000077].
12. Disassemble combination instrument assembly
[68000081].
13. Disassemble ventilation orifice assembly at the left
side of panel [68010010].
14. Disassemble ventilation orifice assembly at the right
side of panel [68010011].
Air conditioner central heating core assembly
Overhaul
1. Disassemble radiator cover.
2. Reclaim HFC-134a(R134a)
 227 
low pressure
hose
liquid pipe A

Air conditioner--Compressor assembly
Compressor assembly
Change
1. Disassemble radiator cover.
2. Reclaim HFC-134a(R134a)
3. Disconnect refrigerant No.1 low pressure hose.
(a) Disassemble the bolt from compressor and electromag-
netic clutch assembly and disconnect refrigerant low pres-
sure hose.
(b) Disassemble O-shape loop from refrigerant low pressure
hose.
Note: after disassembling the pipeline, it is necessary
to cover the joint to prevent humidity or dust from
entering in system.
4. Disconnect refrigerant No.1 high pressure hose.
(a) Disassemble the bolt from compressor and electromag-
netic clutch assembly and disconnect refrigerant high pres-
sure hose.
(b) Disassemble O-shape loop from refrigerant high pressure
hose.
Note: after disassembling the pipeline, it is necessary
to cover the joint to prevent humidity or dust from
entering in system.
5. Disassemble right bottom defending cover of engine.
6. Disassemble driving belt.
7. Disassemble compressor and electromagnetic
clutch.
(a) Disconnect the joint.
(b) Disassemble three screws and electromagnetic clutch.
8. Check the Refrigerant oil.
 234 
When upgrading compressor assembly, it is necessary to reclaim the refrigerant in system at first.
Refrigerant oil quantity added by new compressor should be calculated by following formula.
Refrigerant oil standard quantity of new compressor:
(Inner Refrigerant oil quantity of new compressor:60 ± 10ml)-(Inner discharged Refrigerant oil quantity
of old compressor)=(Refrigerant oil quantity consumed by the system when changing)
Note:
zWhen checking the Refrigerant oil quantity, please refer to the notes on page 206.
zFor there is some Refrigerant oil in automobile pipeline, if some Refrigerant oil is not discharged
when assembling new compressor, this will incur the Refrigerant oil in system is too much to make
the system heat exchange become bad and air conditioning become invalid.

Air conditioner--Condenser AssemblyCondenser AssemblyInspection on the automobile1. Check the Condenser Assembly.(a) If the radiating fins of condenser assembly are dirty, wipe it with water and blow it to dry with com-
pressed air.
Notice: Do not damage the radiating fin.
(b) If the radiating fin is curved, repair it with gad screw driver or pliers.2. Check whether the Condenser leaks.(a) Use leakage detector to check whether the Refrigerant leaks at the joint of the pipelines.
(b) If it leaks, check the fastening torque of joint part.Overhaul1. Disassemble the radiator cover assembly.
2. Recycle the HFC-134a(R134a)
3. Disassemble the Refrigerant liquid pipe A.(a) Disassemble the bolt from the condenser assembly and
disconnect the Refrigerant liquid pipe A.
(b) Disassemble the O-shape ring from the Refrigerant liquid
pipe.
Notice: The pipeline should be covered immediately
to prevent damp or dust from getting into the system.4. Disassemble the Refrigerant NO.1 high pressure
hose.(a) Disassemble the bolt and the Refrigerant NO.1 high pres-
sure hose from the condenser assembly.
(b) Disassemble the O-shape ring from the Refrigerant high
pressure hose.
Notice: The pipeline should be covered immediately
to prevent damp or dust from getting into the system.5. Disassemble the condenser assembly.(a) Disassemble those two bolts and the bracket on water tank. 236 

Light--Front fog light joint
Front combination light (LH)
Subassembly
Left front combination
light units
Front combination
light bulb
Front combination
light bulb
Front combination light
bulb joint Ultrasonic sensor joint Radiator cover
assembly
Front fog light
joint
Light
seat cap
Bulb joint
Bulb
Bulb
Front fog light joint
Front bumper
 286