Brake system GEELY MK 2008 Manual PDF

ABS HECU assy.III. Replace hydraulic control unit1. Press lock catch on joint side, remove wire harness of pump motor.
2. Remove 4 screws as as shown in the figure, the removed old screws
can not be reused.
3. Separate hydraulic control unit HCU from electronic control unit
ECU.
4. Mount new hydraulic control unit HCU onto electronic control unit
ECU.
5. Use new screw to fix ECU onto HCU, tightening moment: 3-4N.m.
6. Insert motor wiring harness, note that lock catch must be in right
position.MK-60 ABS system -
Removal and Installation5-117Schematic diagram for removal of ABS HECU brake oil pipe5. When system is opened, don't use compressed air or move the vehicle.
6. After removing ABS assembly, use appropriate plugs to plug up hydraulic delivery outlets as soon as possible.
Remove other parts that might hinder work.
7. Please use HZY4 brake fluid, do not use mineral oil.
8. Use brake fluid to soak sealing member and Oring, do not use engine oil or brake ointment.
9. After repair, check whether function of routine brake system and ABS brake is reliable and normal or not.
10. Check whether there is any leakage at all Hydraulic couplers.II. Removal of HECU1. Turn off ignition switch and disconnect storage battery minus earth wire.
2. Remove wiring harness plug from ABS HECU assembly.
3. Step down the pedal >60mm, use pedal bracket to fix it, so master cylinder center valve will be turned off, when
system is opened, brake fluid will not flow out from outlet.
4. Put a clean pad under hydraulic controller.
5. Firstly remove brake hard tube (A, B) on HCU connecting with master cylinder, make sign. Plug up the outlet
with a plug immediately.
6. Remove brake pipe (1 - 4) to wheels and make sign. Plug up the outlet with a plug immediately.
7. Remove the screw cap fixing HECU onto the bracket.
8. Remove the entire HECU from bracket.

V. Reinstallation of ABS assemblyNote: plug of hydraulic opening on ABS assembly may be removed only when brake hard tube is to be installed,
so as to avoid foreign body entering brake system
1. Mount ABS assembly to bracket and tighten it, moment is 20~24 N.m.
2. Remove the plug on hydraulic opening, mount brake hard tube, confirm that hard tube connection is correct.
3. Mount brake hard tube to master cylinder.
4. Tightening moment for assembly of brake hard tube is 12~16N.m (M10 x 1) and 15~18 N.m (M12 x 1).
5. Fill new brake fluid into tank until liquid level reaches MAX place, use specified method to exhaust.
6. Turn ignition switch to ON, ABS warning lamp must illuminate for 1. 7s, then go out.
7. Eliminate fault code memory, reread to see whether there is any fault code.
8. Finally, run the vehicle in actual situation to confirm function of ABS (you should feel rebound of pedal).VI. ECU codeNote: when replacing HECU or ECU, encode new ECU, otherwise ABS warning lamp blinks, system can not work
normally.
Use fault diagnosis instrument to encode ECU, the steps are as follows:IV. Replace electronic control unit1. Press lock catch on joint side to remove wiring harness.
2. Remove 4 screws as shown in the figure and discard them.
3. Remove hydraulic control unit HCU from electronic control unit
ECU.
4. Mount new electronic control unit ECU onto hydraulic control unit
HCU.
5. Use new screws to lock ECU on HCU, torsional moment:3-4N.m.
6. Insert motor wiring harness, note that lock catch must be in right
position.MK-60 ABS system -Removal and Installation5-118Connect fault diagnosis instrument and fault diagnosis interface
Select function 07, press OK key to confirm
Input code 04097 at code input place, press OK key to confirm
Select function 06, press OK key to confirm, exit diagnosis mode
End

VI. Filling brake fuid and bleadAfter replace HECU, besides filling and blead as per routine brake system, also blead the secondary circuit of
HECU. Steps are as follows if fault diagnosis instrument is used for operation:MK-60 ABS system -Removal and Installation5-119Perform charging blead according to routine brake system until no bubble
appears in transparent rubber tube
Connect fault diagnosis instrument and diagnostic interface
Select function 04, press OK key to confirm
Step down brake pedal and keep rebound of hydraulic pump work pedal
Release the brake, loosen left and right front brake tongs venting screws,
press " " key
Step on brake pedal for 10 times, tighten up left and right front brake
tongs venting screws, press " " key
Repeat the above Step I II III for seven times, then press " " key.
Screen displays end of exhaust, press " " key to return to "function
selection" menu
Select function 06, press OK key to exit diagnosis modeEnd

4. Knocking sensor
(1) Knocking sensor is a vibration acceleration sensor. Mounted on engine cylinder body. Sensing element of
the sensor is a piezocrystal. Vibration of engine cylinder body is transferred to piezocrystal via mass block in the
sensor. Since pressure generated by vibration of mass block is applied to piezocrystal, it generates voltage on two
polar planes and turns vibration signal into voltage signal for output.5-122Symptom
Poor accelerationPossible cause
Various liquids, such as engine oil, cooling fluid, brake fluid, water etc
contact the sensor for a long time, which cause corrosion to the sensor. Mounting torque: 20 ± 5 N.M
Repair precautions: sensor must be fitted closely to cylinder body with its metal surface, any type of washer
is not permitted for installation. For wiring of sensor signal cables, note that do not let resonance occur to signal
cables, otherwise they might be broken. Energizing of high voltage between sensor 1 # and 2 # pins must be
avoided, otherwise piezoelectric element might be damaged.
(2) Simple measuring method:
(Remove joint) turn digital multimeter to ohm position, connect two meter pens with sensor 1 #, 2 # pin
respectively, its resistance value at room temperature should exceed 1M ohm. Turn digital multimeter to millivolt
position, use a hand hammer to tap near knocking sensor, now voltage signal output should be available.
5. Oxygen sensor
(1) Its sensing element is a ceramic tube, outside is open to exhaust, inside is open to atmosphere. When
temperature of sensing ceramic tube reaches 350°C, it will have the characteristic of solid state electrolyte. Just
utilizing this characteristic, it converts concentration difference of oxygen into electric potential difference, thus
forms electrical signal output. If mixed gas is a bit concentrated, inside and outside oxyanion concentration
difference of ceramic tube is high, electric potential difference is a bit high.
A large number of oxyanions move from inside to outside, output voltage is high (approximate 900mV); if
mixed gas is a bit thin, inside and outside oxyanion concentration difference of ceramic tube is low, electric
potential difference is low, only a small quantity of oxyanions move from inside to outside, output voltage is low
(approximate 100mV).
Possible cause
1. humid water vapor ingresses inside of sensor, temperature
changes rapidly, probe is broken.
2. oxygen sensor "is poisoned". (Pb, S, Br, Si) Symptom
Poor idle speed, poor speedup, tail gas
overproof, too high oil consumption1 2 3 4Oxygen sensor Mounting torque: 40-60 N.m
Repair precautions: it is prohibited to use cleaning fluid, oily liquid or volatile solid on oxygen sensor during
repair.
(2) Simple measuring method:
(Remove joint) turn digital multimeter to ohm position, connect
two meter pens with sensor 1# (white), 2# (white) pin respectively, its
resistance value at room temperature is 1- 6 ohm.
(Connect joint) in idle speed condition, when oxygen sensor
reaches its working temperature of 350°C, turn digital multimeter to
DC voltage position, connect two meter pens with sensor 3# (grey),Engine EFI System-Engine EFI System

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
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