transmission oil 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

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 mechanismEngine assemblyInspection1. Check coolant.
2. Check engine oil.
3. Check battery.
4. Check air filter assembly.
5. Check spark plug [4G18-3705113].
6. Check drive belt [4G18-1307107].Hint: do not check belt tension, because automatic tensioner is applied.7. Check ignition timing.(a) Warm up engine.
(b) Connect timing lamp to engine.
(c) Check ignition timing at idle speed.
Ignition timing: before top dead center Note: when checking ignition timing, place
transmission at neutral position.
Hint: After run the engine for 5 seconds with rotating
speed of 1000-1300rpm, check the engine could
recover to idle running.8. Check engine idle speed.(a) Warm up engine and run it at idle speed.
(b) Read engine rotating number in data flow with diagnostic instrument.
(c) Check idle speed.
Idle speed: about 750-850rpm
Notes:When checking idle speed, place cooling fan at OFF position.Turn off all auxiliary devices and air conditioner.Engine mechanism - Engine assemblyK-line 26

Engine mechanism - Engine assembly30. Disassemble left end front stabilizer link
assembly.Fix bolts with hex socket wrench, and then remove nuts.
Hint: perform the same steps at another side.31. Disassemble lower left control arm assembly.(a) As shown in the diagram, remove bolt and 2 nuts.
(b) Disassemble drive shaft from shaft hub with plastic
hammer.
Hint: perform the same steps at another side.32. Remove oil return pipe assembly.After removing 3 retaining clips and 2 bolts of power steer-
ing oil reservoir, remove the oil return pipe from vehicle.33. Remover engine assembly [4G18-1000000] and
transmission assembly.(a) Erect engine hanger.
(b) Remove 4 bolts, 2 nuts and right engine mounting
assembly.
(c) Remove through bolt and nut, and then remove left
engine mounting assembly from vehicle.
(d) As shown in the diagram, remove 6 bolts.
(e) Carefully remove engine assembly and transmission
assembly from vehicle. 38

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

Engine mechanism - Engine assembly85. Install alternator mounting components.Torque: 12mm bolt head A: 14mm bolt head B: 86. Install drive belt.
87. Install engine wire harness and all hoses
not connected.(a) Check and connect all joints of engine wire harness.
(b) Check and connect all hoses.88. Install transmission control pull cable assembly
and valve control pull cable.
89. Install air filter assembly and its hose.
90. Install steering middle shaft assembly.(a) Align alignment mark on steering middle shaft.
(b) Install 2 bolts.
Torque: m
(c) Install steering column cover.91. Install front exhaust pipe assembly.
92. Install front chassis bracket.Torque: 93. Install battery and connect wire.
94. Install engine plastic hood components.
95. Install front wheel and engine bottom shield.
96. Refill transmission lubricant.
97. Refill engine oil.
98. Refill coolant.
99. Check there is oil leakage.
100. Check there is coolant leakage.
101. Check idle speed and ignition timing.
102. Check CO/HC.Alignment
mark
Sliding in
Pulling 44

Engine mechanism - Crankshaft rear oil seal assemblyReplacement1. Remove transmission assembly.
2. Remove clutch assembly and flywheel components.Fix crankshaft with special tool, remove clutch assembly at
first, and then remove flywheel components.3. Remove crankshaft rear oil seal.(a) Cut oil seal mouth with blade.
(b) Prize out oil seal with flathead screwdriver whose sharp
end is winded with tape.
Note: check crankshaft is damaged after removing oil
seal, and repair with abrasive paper (#400) if it is
damaged.4. Install crankshaft rear oil seal [4G18-1002130].(a) Coat a little MP grease on new oil seal lip.
Note: do not let oil seal lip contact with foreign
matters.
(b) Gently knock new oil seal in with special tool and hammer
until the seal surface is parallel and level with the end sur-
face edge of mounting hole.
Note: wipe off redundant grease on crankshaft.5. Install flywheel components and clutch assembly.(a) Fix crankshaft with special tool.
(b) Clean bolts and bolt holes.
(c) Coat bolts with adhesive.
Adhesive: thread locking adhesive 1234 (Kesaixin 1234)
(d) Install flywheel components.
As sequences shown in the diagram, tighten bolts at sev-
eral times.
Torque: (e) Install clutch assembly.6. Install transmission assembly.Special
tool
Cut
positionSpecial
tool62Crankshaft rear oil seal assembly

Driveshaft--Front drive shaftTransmission shaft Left mm Right mm
A type 570.2 ± 5 842.7 ± 5
B type 570.2 ± 5 847.3 ± 5
C type 570.2 ± 5 844.7 ± 5(b) Mesh clamp type:
Liking that shown in figure, use pliers to assemble No.2
fixing clamp of inner joint dust-proof cover.32. Check front drive shaft.(a) Check whether there is any obvious clearance on exterior
joint.
(b) Check whether inner joint could slide smoothly in pushing
direction.
(c) Check whether there is any obvious clearance of inner joint
in radial direction.
(d) Check whether the dustproof cover is damaged.
Note: drive shaft assembly should keep moving on hori-
zontal position.33. Assemble left front drive shaft assembly [64000082](a) Spread ATF on gear slot of inner joint shaft assembly.
(b) Put gear slot of drive shaft in integrated transmission, then
use copper stick and hammer to knock drive shaft to its
position.
Note:zmake the placket of clasp face the downside to
assemble.zBe careful not to damage the seal oil
Hint: Whether the drive shaft contacts with gear shaft
could be felt by the sound or feeling in running process.
(c) Assemble seal board of left front swing board.34. Assemble left front shaft hub assembly.Assemble left front drive shaft assembly to left front hub assembly.
Note:zDo not damage exterior joint dustproof cover.zDo not damage the stator of speed sensor. Hint: A size, please referring to following table.Pliers
clamp121

18. Assemble left front lower control arm ball head as-
sembly [64000093](a) Assemble lower ball head and locking nut.
Torque: 103
± ±± ±
± 10 N
⋅ ⋅⋅ ⋅
⋅m
(b) Assemble new cotter pin.
If hole position of cotter pin could not make a line, lock the
screw cap for 60again.19. Assemble left front shaft hub assembly(a) Assemble two bolts and nuts, and assemble shaft hub as-
sembly on absorber.
Torque: 153
± ±± ±
± 10 N
⋅ ⋅⋅ ⋅
⋅m
Note: when the bolts and nuts should be used again,
spread engine oil on the thread of nuts.
(b) Push the front shaft hub assembly to the outside of
automobile, then assemble transmission shaft assembly
in the gear slot of front shaft hub assembly.
Note:
Front shaft assembly could not be pushed to outside
too much.zDo not damage the exterior joint dustproof cover of
drive shaft.zDo not damage the stator of speed sensor.20. Assemble left lower control arm assembly
[64000091]Assemble lower control arm and ball head with two nuts and
bolts.
Torque: 142
± ±± ±
± 10 N
⋅ ⋅⋅ ⋅
⋅m21. Assemble left transversal lever assembly(a) Connect transversal lever to steering knuckle.
(b) Assemble screw cap and new cotter pin.
Torque: 49
± ±± ±
± 5 N
⋅ ⋅⋅ ⋅
⋅m22. Assemble left front brake assembly [64000134]
23. Assemble front brake caliper assembly(a) Assemble brake caliper assemble on steering knuckle with
two bolts.
Torque: 106
± ±± ±
± 10 N
⋅ ⋅⋅ ⋅
⋅m24. Assemble fixing nuts of left front drive shaft
[64000083]Use torque wrench (30mm) to assemble new fixing nuts.25. Disassemble left front brake branch pump assembly
26. Disassemble left front brake assembly [64000134]
27. Check the axial clearance of bearingDrive shaft--Left front shaft hub assembly126