brake GEELY MK 2008 Workshop Manual

It is mainly used to install the pipes and accessories of the brake system and clutch system.
5. Front wall upper assembly
The front wall upper assembly includes left/right hinge base mounting plate big assembly, front wall upper
front cover big assembly, VIN number mounting plate, and front wall upper rear cover big assembly etc.
It forms a high-stiffness frame structure together with the engine compartment assembly and the front wall
lower plate assembly. It can generate strong resistant to the transverse collision and rolling deformation. It can also
separate the engine compartment form the cabin, preventing the odor entering into the cabin. Consequently, it can
isolate the noise, heat and vibration.(2) Floor Assembly The floor assembly is the base work of the main structure. It is a key component that connects various
assemblies and carries the load. The vehicle performance is subject to its strength and stiffness. For the floor
assembly, see the Fig. 5-3.
The floor assembly includes front floor assembly and rear floor assembly. The front floor mid-block goes
through a ridgy channel in longitudinal direction. It can increase the longitudinal rigidity together with the lower
floor longitudinal beam. The space below under the channel is used to install various parts and components, such
as transmission gearshift rod, parking brake cable, discharge pipe with three-way catalytic converter etc. In the
cabin, there is carpet and muffle pad. The floor frame structure is made up of front floor left/right frame, front floor
main plate assembly, front floor mid-bridge assembly, rear frame assembly, rear floor rear block assembly, rear
floor mid-block assembly and longitudinal beam etc. These parts and components provide strong and reliable carry
capacity and ensure that the vehicle meets the strict driving requirement on the body.Fig. 5-3 Floor Assembly
1. Front floor left/right frame 2. Front floor main plate assembly 3. Longitudinal beam rear block 4. Rear frame assembly
5. Rear floor rear block assembly 6. Rear floor mid-block assembly 7. Front floor mid-bridge assemblySurvey -Body Structure7-371
2
133
5
6

The body repair starts from the primary rectification or rough rectification. The deformation can be removed
with the supporting method. The angle of the supporting force shall be close to the angle of the external force that
caused the damage. Apply a counterforce at the back of the pulling force point to adjust the supporting force. Make
measurement on the deformation generated in the supporting process. To remove the internal stress, heat the
corresponding parts. For different rectification methods, see Fig. 5-24.
2. Reinforcement
When the local damage, rupture or crack occurs on various components, repair can be made by reinforcement.
Especially for those parts on which damage occurs frequently, special reinforcement measures shall be taken.
However, random reinforcement or component welding shall be avoided, which may affect the body's status.
The reinforcement includes bushing reinforcement, patching reinforcement, arc inlay, and angle plate reinforcement.
3. Local Removal & New Parts Replacement
For the parts with serious corrosion, they must be removed. For the ruptured parts, they shall be replaced
entirely. For the posts manufactured with thin plate by punch, they shall be ordered from the manufacturer. When
the molding is made independently, all specifications (including material, section dimensions and thickness etc.)
shall meet the original design requirement. For the ruptured post (including cross beam), if it is replaced entirely,
it must be connected in the same manner as that of the original post.II. Repair for Body Outside Plate1. Damage Type
a. Crack & Rupture
In the running process, the body vibrates continuously and burdens the loads. When the vehicle makes accident
acceleration, sharp swerve an emergency brake, the body will keep in an inertial status. When the vehicle runs on
the uneven road, bend and distortion will happen on the body.
Affected by these external forces for a long time, crack and rupture may occurs on the stress concentrated parts
and weak structure on the body outside plate.
The stress mostly concentrate on the corner, hem and narrow part of the outside plate, so crack and rupture often
occur on these parts.
b. Corrosion
The corrosion on the outside plate is mostly caused by the mud and water on the metal surface. Only in special
case, it results from the chemical corrosion by chemicals. When the corrosion occurs, rust may appear on the
outside plate and fall gradually, resulting in a hole. On the skirt outside plate and launder, corrosion usually occurs
on the seams between door and frame and the interlayer between the outside plate and the frame.
c. Cave-inFig. 5-24(a) Drawing Rectification Fig. 5-24(b) Drawing & Supporting
RectificationFig. 5-24(c) Auxiliary Force-receiving
Point Rectification7-17washerBody Repair -Repair After Body Damage

The cave-in is mainly caused by collision and extrusion. For the light cave-in damage, the metal doesn't extend,
which is plastic deformation. If the collision or extrusion is serious, the metal plate will rupture. For the vehicles
running in the city, it is common that collision damage occurs on the side wall.
d. Bend & Distortion
Bend and distortion belong to mechanical damage. Bend and distortion may have a variety of causes, such as
collision or extrusion, alternating loads generated by the vibration, accident acceleration, emergency brake, sharp
swerve and body torsion caused by poor road.
For the light distortion, it shall be confirmed by test. For the serious bend and distortion, it is obvious in the
appearance. Generally, the distortion can be fixed according to the clearance of the frames and the change of their
relative positions.
e. Unsoldering
The unsoldering is caused by the poor fusion between different metal plates.
2. Outside Plate Repair
a. Repair for Crack
(a) CO2 Welding
The crack on the metal outside plate can be repaired by CO2 welding. In the welding process, align the two
metal plates, and weld the outside crack of the plate first. If the crack doesn't exceed 50mm, the welding shall start
from the rear part of the crack and continue along the crack and edge. If the crack is a little longer, several points
shall be welded first at a certain space. After welding several points, finish them and then weld the crack block
by block. By so doing, it can prevent the metal overroasting and plate deformation caused by too high temperature.
If the crack is located in the position that burden heavy force and it is convenient to carry out the welding operation,
a double-welding method can be used. After the spot welding is made outside, carry out the welding inside. After
the inside welding is completed, make the welding outside in the same manner.
After the welding, put a sizing block inside, and beat from the outside welding line with hammer to removeFig. 5-25 Concave Body Filling Repair b. Repair for Local Damage
For the local corrosion or serious mechanical damage on the outside plate, if it can't be repaired in common
method, the patching or pasting repair method can be used.
Repair Method:
(a). Fix the patching scope;
(b). Cut the paper sample;
(c). Cut the plate as per the sample;
(d). Adhere the molded plate on the surface of the patching part;
(e). Line out the profile along the plate edge with needlepoint, and cut off the damaged or corroded part;Body Repair -Repair After Body Damage7-18the retaining stress. Finally, finish the welding
seam properly to make it even and smooth for
painting.
(b) Solder Filling
For the fine concavo-convex plate with
damage and crack on its surface, it can be re-
paired with a solder filling method. (Fig. 5-25)

1 Engine right insulator x body JQ184C1025(3 pcs)43~58 43~58
2 Brake pedal with bracket assy. x central cross member Q151B0820(1 pcs)22~29 22~29
3Brake pedal with bracket assy. x brake master cylinder
Q32008(4 pcs)22~29 22~29
with vacuum booster assy.
4 Clutch pedal x central cross member Q1840816(1 pcs)/22~29
5 Clutch pedal x clutch master cylinder Q32208(2 pcs)/22~29
6 Accelerator pedal Q32208(2 pcs)22~29 22~29
7 LH/RH front brake pipe component x HECU controller Null13~18 13~18
8 LH/RH rear brake pipe component I x HECU controller Null13~18 13~18
9Brake master cylinder No. 1 and No.2 pipe component
Null13~18 13~18
x HECU controller, brake master cylinder
10Clutch hydraulic hose assy. x master cylinder oil outlet pipe componentNull13~18 13~18
11 Steering column assy. x universal joint assy.Q151B0820TF2(1 pcs)22~29 22~29
12 (LH & RH) front shock absorber component x body37~45 37~45
13 (LH & RH) rear shock absorber component top nut Q341C10(2 pcs) 22~29 22~29
14(LH & RH) front shock absorber piston rod x front
Q330B12(2 pcs)31~38 31~38
suspension bracket sub-assy.
15 (LH & RH) rear seat belt assy. x body7/16" bolt ( )39~53 39~53
16 (LH & RH) front seat belt assy. x body7/16" bolt( )39~53 39~53
17 (LH & RH) front buckle assy. x body7/16" bolt( )39~53 39~53
18 RR seat belt buckle and lap belt assy. x body7/16" bolt( )39~53 39~53
19 LR buckle assy. x body7/16" bolt( )39~53 39~53
20 Rear axle assy. x bodyJQ14012110TF2(2 pcs)73~103 73~103
21 (LH & RH) rear shock absorber x rear axle JQ320B12(2 pcs)47~56 47~56
22LH & RH brake pipe component III x LH & RH rear
Null13~18 13~18
drum brake with wheel hub assy.
23LH & RH rear brake hose x LH & RH rear brake pipe component IIINull13~18 13~18
24 LH/RH rear drum brake with wheel hub assy. x rear axleMounting nut (8pcs)60~72 60~72
25LH/RH rear brake pipe component I x LH/RH rear brake pipe component IINull13~18 13~18Appendix: Torque Table of the Fasteners for Important AssemblyTorque N.m
No.
JL7132HU
JL7152HUJL7132U
JL7152U
JL7162UAppendix-Torque Table of the Fasteners for Important AssemblyIArea Fastener
front suspension
support sub-assy.
Mounting nut (6 pcs)

26LH/RH rear brake pipe component II x rear brake hose assy.Null13~18 13~18
27 front suspension cross member (front part) x bodyJQ1401280TF2(2 pcs)94~110 94~110
28 Front suspension cross member (rear part) x bodyJQ1401455TF2(2 pcs)110~130 110~130
29 Engine right mount x right insulator JQ319B10(1 pcs)49~60 49~60
30 Engine left mount x left insulator JQ184C1030(2 pcs)43~58 43~58
31 Engine left LH x bodyJQ184B12140(1 pcs)94~110 94~110
32 Engine x automatic transmissionJQ140BD1255TF2(2 pcs)/ 55~70
33 Engine x automatic transmissionJQ140BD1260TF2(1 pcs)/ 55~70
34 Engine x automatic transmissionJQ140C1040TF2(1 pcs)/ 43~58
35 Engine x automatic transmission JQ140C1020(3 pcs) /43~58
36 Engine x automatic transmissionJQ140BD1255TF2(2 pcs)55~70 /
37 Engine x automatic transmissionJQ140BD1045TF2(1 pcs)43~58 /
38 Engine x automatic transmissionJQ140C1040TF2(1 pcs)43~58 /
39 Engine x automatic transmission JQ140C0820(3 pcs)22~29 /
40 Starter x transmissionJQ146C1040TF2(2 pcs)30~60 30~60
41 Engine left bracket x transmission JQ184C1030(3 pcs)43~58 43~58
42 Engine rear bracket x engine JQ184C1025(2 pcs)43~58 43~58
43 Engine rear bracket x engine JQ184C1020(1 pcs)43~58 43~58
44 Compressor bracket x engine JQ146C1035(1 pcs)43~58 43~58
45 Compressor bracket x engine JQ146C1030(3 pcs)43~58 43~58
46Power steering pump with bracket assy. (without reservoir) x engineQ1420825(3 pcs)22~29 22~29
47Power steering pump with bracket assy. (without reservoir) x engineQ14201030(1 pcs)43~58 43~58
48 Oil pump adjustment bracket x engine JQ146C1030(2 pcs)43~58 43~58
49Oil pump adjustment bracket x power steering pump
JQ146C1030(1 pcs)43~58 43~58
with bracket assy. (without reservoir)
50Oil pump mounting bracket x power steering pump with
JQ142C1085(2 pcs)43~58 43~58
bracket assy. (without reservoir)
51Oil pump mounting bracket x power steering pump with
Q40110(1 pcs)43~58 43~58
bracket assy. (without reservoir)
52Oil pump mounting bracket x power steering pump with
Q361C10(1 pcs)43~58 43~58
bracket assy. (without reservoir)
53 Rear insulator x front suspension cross member JQ184C1060(1 pcs)43~65 43~65Appendix-Torque Table of the Fasteners for Important AssemblyIITorque N.m
No.
JL7132HU
JL7152HUJL7132U
JL7152U
JL7162U Area FastenerAppendix: Torque Table of the Fasteners for Important Assembly

54 Rear insulator x front suspension cross member JQ319C10(2 pcs)43~65 43~65
55 Front stabilizer bar x front suspension cross member Q1400825(4 pcs)22~29 22~29
56Power steering gear with tie rod assy. x front suspension cross memberJQ184B1265(2 pcs)125~152 125~152
57High/low pressure oil pipe assy. x power steering gear with tie rod assy.Null25~32 25~32
58LH & RH lower suspension swing arm x front susJQ1401280TF2(2 pcs)125~152 125~152
pension cross member rear
59LH & RH lower suspension swing arm x front sus
JQ320B12(2pcs)125~152 125~152
pension cross member rear
60LH & RH lower suspension swing arm x front sJQ1401280TF2(2 pcs)83-103 83-103
uspension cross member front
61Front stabilizer bar x LH & RH lower suspension swing arm assy.JQ33808(2 pcs)22~29 22~29
62(LH & RH) front brake hose x (LH & RH) front disk13~18 13~18
brake with steering knuckle assy.
63 Engine rear insulator x rear bracket Q184C10105(1 pcs)61~74 61~74
64High pressure oil pipe assy. x power steering pump with bracket assy.Union bolt51~63 51~63
65(LH & RH) lower swing arm ball joint x (LH & RH) disk
JQ38312(2 pcs)83~103 83~103
brake with steering knuckle assy.
66LH & RH brake with steering knuckle assy. x power
Q383B10(2 pcs)30~40 30~40
steering gear assy. with tie rod assy.
67(LH & RH) front disk brake with steering knuckle assy.
JQ1841450TF2(4 pcs)125~152 125~152
x (LH & RH) front shock absorber
68(LH & RH) front disk brake with steering knuckle assy.
JQ320C14(4 pcs)125~152 125~152
x (LH & RH) front shock absorber
69 LH/RH constant velocity drive shaft assy. Set nut190~230 190~230
70(LH & RH) front brake hose x (LH & RH) front brake pipeNull13~18 13~18
71Front suspension reinforcement member x front
JQ1401020(4 pcs)43~58 43~58
suspension cross member, body
72 Oil tank component x bodyJQ146Db0835A(4 pcs)22~29 22~29
733-way catalytic converter assy. x engine exhaust manifoldJQ189C1058TF2E(4 pcs)40~60 40~60
74 Intermediate muffler x 3-way catalytic converter assy. JQ1461035(2 pcs)40~60 40~60
75 Intermediate muffler x 3-way catalytic converter assy. JQ32010(2 pcs)40~60 40~60
76 Primary muffler x intermediate muffler JQ1461035(2 pcs)40~60 40~60Appendix-
Torque Table of the Fasteners for Important AssemblyIIITorque N.m
No.
JL7132HU
JL7152HUJL7132U
JL7152U
JL7162U Area FastenerAppendix: Torque Table of the Fasteners for Important Assemblybrake hose union
bolt (2 pcs)