ignition GEELY MK 2008 User Guide

Table 3Section 2 Removal of the Engine Assembly from the Vehicle1. Avoid petrol overflowing (Disconnect from the fuel tank).
2. Remove the front wheel.Figure 1-5Engine AssemblyRemoval of the Engine Assembly from the Vehicle3-5CO
Normal
Low
HighHC
High
High
HighProblems
Bad idle speed
Bad idle speed
(HC reading fluctuates)
Bad idle speed
(Black smoke exhausts)Causes
1. Ignition fault:
Incorrect ignition timing;
Dirt, short circuit, or incorrect spark plug gap.
2. Incorrect valve gap.
3. Suction and exhaust valve leak.
4. Cylinder leaks.
1. Vacuum leaks.
PCV pipe . manifold;
Idle speed control valve;
Brake booster pipeline.
2. Spark lacks since the mixed gas is too thin.
1. Air filter is blocked.
2. PCV valve is blocked.
3. EFI system fails.
ECU fails.
Pressure regulator of fuel oil is out of order.
Water temperature sensor does not work.
Suction pressure/temperature sensor fails.
Injector fails.
The throttle position sensor fails.3. Discharge the coolant completely.
4. Remove the air filter assembly with hose (see Figure 1-5).
(1) Disconnect the joint of the temperature sensor and the wire
plug.
(2) Disconnect the vent duct from the hose of the air filter.
(3) Release the wire clip bolt on the air filter.
(4) Disconnect the hose of the air filter from the throttle body.
(5) Remove 3 bolts and the air filter assemblies.
5. Remove the battery.
6. Remove the fuel pipe sub-assembly.
7. Disconnect the water pipe; disconnect the water outlet pipe of the
heater from the air conditioner pipe.
8. Release the nut and remove the accelerator control cable. -

Component ViewFigure 2-3Engine MechanicalEngine Components3-10adjusting support
with power steering
Vane pump assembly with
power steering
Pump support with
power steeringHex. flange
bolt M6¡Á50
Ignition coil
Ignition coilinstallation bracket
Bolt M8¡Á31Fuel oil pipe subassembly
Fuel oil pipe clip
Vent ductSecondary wireBypass hose
Rear end housingWater outlet
pipe housing
No.1 heat shield of
exhaust manifoldOil filter assembly
Washer
Exhaust manifold
Support of exhaust
manifoldO-ring
Fastener of
No.1
injectorInjector
O-ring
Throttle assemblySuction manifold Washer
WasherKnock sensor
Water temperature sensorCrankshaft position sensorGenerator assemblyNo.1 support of compressor
Air conditioner compressorWater inlet pipe housing -

Chapter 3 Fuel SystemSection 1 Check Fuel System PressureOn-board inspection
1. Check the operation of the fuel pump.
(1) Connect the positive and the negative of the battery to
appropriate connector sockets of the fuel pump (see Figure 3-1).
Attention: Do not start the engine.
If there is pressure present, you will hear that the fuel is flowing.
If there is no pressure present, check the fusible cutout, fuse, EFI
open-circuit relay, fuel pump, ECM (Electronic Control Module) and
circuit joint.
(2) Turn the ignition switch to "OFF".
2. Check the pressure of the fuel.
(1) Check whether the battery voltage is more than 12V.
(2) Disconnect the negative wiring cable from the battery.
(3) Mount a pressure gauge on the fuel input pipe
(see Figure 3-2).
(4) Connect the negative terminal of the battery.
(5) Measure the fuel pressure.
Fuel oil pressure: 265-304kPa
If the pressure is low, check the fuel pipe and connection,
fuel pump, and fuel filter. If the pressure is too high,
replace the regulator.
(6) Start the engine. Measure the fuel pressure at idle speed. The
fuel pressure is 265-304KPa. If the pressure is unsatisfactory, checkFigure 3-1
Figure 3-3 Figure 3-2Fuel SystemCheck Fuel System Pressure3-15the fuel pump, pressure regulator, and injector, and replace if necessary.
(7) After shutting down the engine, check the fuel pressure and
keep the specified pressure for about 5 minutes. The fuel pressure is:
147KPa.
3. The fuel oil pressure regulator (DR) (see Figure 3-3).
Mounting position: On the distributing pipe for fuel.
Faults: Too low or too high fuel pressure, or hard to start.
General causes: Using poor fuel for a long time results in: 1.
strainer blocked; 2. serious leakage caused by particles and impurities.
Other reasons: Man-made mechanical damage, etc.
Maintenance precautions: During maintenance: 1. Never impact the diaphragm element with high pressure
gas; 2. Never clean it with aggressively corrosive liquid; 3. No distortion caused by external force.
Easy measuring method: For the system with oil return, connect a pressure gauge for the fuel on the suction
pipe, start the engine, and run at idle speed. Now, the fuel pressure in the engine should be about 260KPa; pull out
the vacuum pipe of the fuel pressure regulator, and the pressure should be 300KPa approximately.Battery
T conector
Hose
Hose
Fuel Inlet Pipe
Fuel Pipe
Conector -

Figure 5-6
Figure 5-7Above 93°CFigure 5-5Cooling SystemSystem Inspection3-235. Fan
(1) At low temperature (lower than 83°C), check the operation of
the cooling fan.
a. The ignition switch is set to ON.
b. The cooling fan should stop.
c. Disconnect the connector of the water temperature sensor.
(see Figure 5-5)
d.Touch the ground with a wire.
e.Check if the cooling fan rotates.
f. Re-connect the connector of the water temperature sensor.
(2) At high temperature (more than 93°C), check the operation of
the fan (see Figure 5-6).
a. Start the engine, and enable the coolant temperature higher
than 93°C.
b.Check whether the cooling fan rotates.
If not, replace the water temperature switch.
(3) Check the cooling fan (see Figure 5-7).
a. Disconnect the joint of the cooling fan.
b. Connect the battery and the ammeter with the connector.
c. The cooling fan should rotate stably and check the current
readings.
Standard current: 5.7-7.7A.
d. Connect the connector of the cooling fan.disconnectBattery Amper meter -

The valve body fails.
12. The vehicle shifts before or after some gear points in the running status.
The vehicle switch or parking switch fails.
13. The vehicle has poor acceleration in running.
(1)The clutch or brake fails.
(2)The engine system fails.
14. The vehicle vibrates when it runs at a constant speed or accelerating speed.
(1)The hydraulic torque clutch pressure or hydraulic torque meter fails.
(2)The engine system or valve fails.
15. The acceleration switch system fails.
(1)The acceleration switch or ignition switch fails.
(2)The connector or automatic transmission control unit fails.I. Automatic transmissions Removal1. Put the select lever in "N" position
2. Remove 3 bolts of the flexibility plate (engine side)
3. Remove starter and 2 cooling hoses.
4. Disconnect neutral switch connector and odometer sensor.
5. Loosen the drain screw under the housing to bleed ATF and tighten the drain screw with sealing glue when
assembling. Tightening torque is 29~35N.m
6. Loosen the locking bolt for select lever cable.
7. Remove Drive Shaft LH&RH, using plastic stopper in the oil sealing of differential.
8. Detach suspension bolts.
9. Separate transmission from engine after bolts between engine and transmission remove.II. Automatic Transmission Installation1. Check whether torque converter of the transmission is in the right position, the methods as follows:
Check whether the distance from 3 anchor point of torque converter to front contact face of the transmission
box A 28mm , If the space A<28 mm, try install again. The way to install is that left hand catch hold of the
central anchor column of the converter and make it in alignment with input shaft as near as possible, push the torque
converter in rotating way by right hand until it gets to the bottom to meet the requirement of A 28 mm. (See
figure 7-1 and 2)
2. Install Flexibility plate and central plate on the crankshaft end face with 6 bolts in the direction of Figure 2.
Tightening torque is 45~55 N.m. Turn the longer hole of the Flexibility plate to the lowest of the engine position
in order to connect torque converter.Section 2 Hydraulic Torque Converter and TransaxleAutomatic Transaxle Assembly Hydraulic Torque Converter and Transaxle3-30 -

4-108. Install the automatic shifter assembly
Install it in place in the reverse order of removal.
9. Check and adjust the shift lever position
(1) Check that the starter works only when the shift lever is in P position, but doesn't work in other positions.
(2) Move the shift lever, check whether the display of the gear range indicator is consistent with the actual gear
range.
(3) Check that the key can be pulled out in P position.
(4) Except the P position, the ignition key can not be turned to LOCK position with the shift lever in other
positions.
(5) Check that when shift release button is pressed down, the shift lever can be transferred to other positions
from the P position.
10. Adjustment
(1) When moving shift lever among the positions, make sure to
move the shift lever in a stable way, operate properly and the
positive display is correct.
Gear positions able to be operated without pressing down the
knob button are:
R N D,L 2 D N
Gear positions able to be operated only when the knob button
is pressed down are:
2 L,N R P
(2) Gear positions able to be operated only when the knob button
is pressed down, the ignition switch is turned ON and the
brake pedal is depressed are:
P R
(3) Start the engine, make sure the vehicle drives ahead when the
shift lever is moved from N position to D position, and back
up when the shift lever is set to R position.Depress the brake pedal, press down the shift
lever knob button to shift the gear position.
(ignition switch must be turned ON)
press the knob button to shift
the gear position
Normal shiftTransmission ControlAutomatic Transmission Shift Mechanism -

Component ViewIgnition switch cylinder
Conical head bolt
snap ring
Upper and lower Steering
column panel
Ignition switch bracket
Ignition switch assembly
snap ring Steering column
Main shaft¡ôMain shaft bearing A/T lock cablePower Steering System-Steering Drive and Control Mechanism4-70Non-reusable parts

Power Steering System-Steering Drive and Control Mechanism4-7213. Remove the No.2 steering countershaft assembly.
(1) Make a mark on the fit between main shaft and countershaft.
(2) Remove bolt and countershaft.
14. Remove the ignition switch bracket.
(1) Use the punch pin to make a mark on the 2 conical head bolt.
(2) Drill the 2 conical head bolts with the diameter of 3-4mm drill
bit.
(3) Remove the bolts and bracket for the ignition switch with the
thread die.
15. Remove fixing panel on the steering column.
16.Remove the ignition switch lock core assembly.
(1) Turn the ignition switch to "ACC" position.
(2) press the stop pin and pull the lock core out.
17. After checking or replacing the steering column pipe assembly, install all parts in a reverse order.
Note:
(1) After installing the ignition switch lock core, check the operation of the steering locking function: when
pulling out the key, the steering device is locked; when the key is inserted and turned to ACC position, the
steering device is unlocked.
(2) Tighten the 3 bolts.
(3) Make sure all cables are connected reliably.
(4) After adjusting the combination switch as well as the top shell and bottom shell of the steering pipe shield,
fasten the three screws connecting the combination switch and the steering column assembly.
(5) Tighten the set bolt between the universal joint fork and the steering gear assembly with a torque of
22~39N.m.
(6) Install dust cover and its press plate.
(7) When installing the steering wheel assembly, align the steering wheel assembly and the fit mark of the
steering main shaft assembly. Tighten the special quincunx bolt with a torque of 33~59N.m.
(8) Check the airbag. It is not allowed to use a airbag part removed from another vehicle.
(9) Check the SRS warning lamp.Thread die Installation mark

Check1. Check the brake booster.
(1) Air tightness check
a. Start the motor, and shut it down after one or two minutes,
then step on the pedal several times slowly.
Tips:
If the pedal goes down greatly at the first step, but it gradually
goes up after the second and third steps, it means the air
tightness is good.Brake System -Vacuum Booster4-92 b. When the motor is running, step down the brake pedal, and then shut down the motor.
Tips:
If the reserved distance does not change thirty seconds after
the pedal is stepped down, it means the air tightness is good.
(2) Operation check
a. When the ignition switch stays in OFF position, step on the
pedal several times, and then check that the reserved
distance should not change.
b. Step down the pedal, and start the motor.
Tips:
If the pedal goes down a little, it means the operation is ok.
2. Check the vacuum one-way valve.
(1) Check the vacuum one-way valve.
a. Slide the clip to unfix the vacuum tube.
b. Remove the vacuum one-way valve.
c. Check the booster is ventilated to the motor.
d. In case of any failure, replace the vacuum one-way valve.ONOFFPositiom 1Positiom 2Positiom 3 Good Poor

II. Charging system inspection1. Check battery working voltage
(1) After having driven the vehicle and in the case that 20 minutes
have not passed after having stopped the engine,turn the ignition
switch ON and turn on the electrical system (headlight,blower
motor) for 60 seconds to remove the surface charge.
(2) Turn the ignition switch OFF and turn off the electrical
systems. Then measure the battery voltage between the nega
tive and positive terminals of the battery.
Standard voltage: 12.5-12.9V at 20°C
Hint:
If the voltage is less than specification, charge the battery.
2. Check battery terminals, fuse box and fuse
(1) Check that the battery terminals are not loose or corroded.
(2) Check if fuse box and fuse for continuity.
3. Inspect drive belt
(1) Check the belt for excessive wear, frayed cords etc.
Hint:
If any defect has been found, replace the drive belt.
Cracks on the rib side of a belt are considered acceptable. If the
belt has chunks missing from the ribs, it should be replaced.
(2) Check that the belt fits properly in the ribbed grooves.
Hint:
Check with your hand to confirm that the belt has not slipped out
of the groove on the pulley.
4. Check alternator wiring
Check that the wiring is in good condition.Automobile Starting, Power Supply System -Charging system5-45. Listen for abnormal noises from alternator
Check that there is no abnormal noise from the alternator while the engine is running.
6. Inspect charge warning light circuit
Turn the ignition ON. Check that the charge warning light comes on. Start the engine. Check that the light
goes off.
Hint:
If the light does not work as normal, troubleshoot the charge warning light circuit.