belt GEELY MK 2008 Workshop Manual

Table of ContentsTable of ContentsIPart I General InformationChapter 1 How to Use This Manual.................................................................................. 1-1
Chapter 2 Repair Instruction............................................................................................. 1-3Part II Vehicle Usage and MaintenanceChapter 1 Brief Introduction of Geely MK......................................................................... 2-1
Section 1 Major Functional and Technical Data of MK Series. ...................................... 2-1
Section 2 Vehicle System Configuration ........................................................................ 2-3
Section 3 Main Vehicle Test Technical Specification ...................................................... 2-5
Chapter 2 Usage and Maintenance of MK Series............................................................ 2-6
Section 1 Usage of MK Series ....................................................................................... 2-6
Section 2 Maintenance Category and Content of MK Sedan..........................................2-12
Section 3 Daily Maintenance of MK Sedan .................................................................... 2-18Part III EngineChapter 1 Engine Assembly............................................................................................... 3-1
Section 1 Engine Inspection ........................................................................................... 3-1
Section 2 Removal of the Engine Assembly from the Vehicle ....................................... 3-5
Section 3 Drive Belt Replacement .................................................................................. 3-7
Chapter 2 Engine Mechanical............................................................................................ 3-8
Section 1 Engine Components ....................................................................................... 3-8
Section 2 Throttle Body ..................................................................................................3-12
Section 3 Valve Clearance Adjustment .......................................................................... 3-14
Chapter 3 Fuel System....................................................................................................... 3-15
Section 1 Check Fuel System Pressure ......................................................................... 3-15
Section 2 Fuel Pump Inspection ..................................................................................... 3-16
Section 3 Fuel Pump Replacement ................................................................................ 3-17

Table of ContentsV Section 1 SRS General Information ............................................................................... 5-54
Chapter 7 Air Conditioning System................................................................................... 5-72
Section 1 General Information ........................................................................................ 5-72
Section 2 Refrigerant ...................................................................................................... 5-77
Section 3 A/C Operating Mechanism ............................................................................. 5-83
Section 4 Heater, Ventilation and Air Conditioning ........................................................ 5-86
Section 5 Layont of Air Conditioning Hose ..................................................................... 5-92
Section 6 Multi-wedge belt (Connecting Compressor and Crankshaft Pulley) .............. 5-93
Section 7 Compressor Assembly .................................................................................... 5-94
Section 8 Condenser Fan and Condenser Assembly .................................................... 5-96
Chapter 8 MK-60 ABS System........................................................................................... 5-99
Section 1 ABS Diagnosis ................................................................................................ 5-99
Section 2 ABS System Check ...................................................................................... 5-103
Section 3 Removal and Installation .............................................................................. 5-138
Section 2 Power Door Lock Control System ................................................................5-142Part 6 Interior & Exterior Trim and AccessoryChapter 1 Front Seat Assembly......................................................................................... 6-1
Chapter 2 Rear Row Seat Assembly................................................................................. 6-3
Chapter 3 Front Seat Belt................................................................................................... 6-5
Chapter 4 Rear Seat Belt.................................................................................................... 6-9
Chapter 5 Dashboard, Middle Console and Instrument Panel....................................... 6-11
Chapter 6 Windshield......................................................................................................... 6-16
Chapter 7 Rear Window Glass (with Defrosting Heater Wire)........................................ 6-20
Chapter 8 Side Inner Panel Trim........................................................................................ 6-22
Chapter 9 Roof Trim............................................................................................................ 6-25
Chapter 10 Front Door Interior Trim.................................................................................. 6-27
Chapter 11 Rear Door Interior Trim................................................................................... 6-30
Chapter 12 Front Bumper................................................................................................... 6-33
Chapter 13 Rear Bumper.................................................................................................... 6-35

General Information - Repair Instruction1-6IllustrationRemoval/installation2. For Vehicles Equipped With SRS Airbag and Seat Belt Pretensioner
Tip: This is equipped with an SRS (Supplemental Restraint System), such as the driver airbag assembly,
front passenger airbag assembly airbag ECU and seat belt pretensioner. Failure to carry out service operations in
the correct sequence could cause the supplemental restraint system to unexpectedly deploy during servicing,
possibly leading to a serious accident. Further, if a mistake is made in servicing the supplemental restraint
system, it is possible the SRS may fail to operate when required. Before servicing (including removal or instal-
lation of parts, inspection or replacement), be sure to read the following items carefully, then follow the correct
procedure described in this manual.
(1) General NoticeInstall Remove
Install Remove a. Malfunction symptoms of the supplemental restraint system are difficult to confirm, so the diagnostic
trouble codes become the most important source of information when troubleshooting. When troubleshooting
the supplemental restraint system, always inspect the diagnostic trouble codes before disconnecting the battery.
b. Work must be started after 90 seconds from the time the ignition switch is turned to the "LOCK"
position and the negative (-) terminal cable is disconnected from the battery. (The supplemental restraint system
is equipped with a back--up power source so that if work is started within 90 seconds of disconnecting the
negative (-) terminal cable from the battery, the SRS may deploy.) When the negative (-) terminal cable is
disconnected from the battery, memory of the clock and audio systems will be cancelled. So before starting
work, make a record of the contents memorized by the each memory system. Then when work is finished, reset
the clock and audio systems as before. To avoid erasing the memory of each memory system, never use a back-
up power supply from another battery.

General Information - Repair Instruction1-7 (3) Driver Airbag Assembly
a. When removing the driver airbag assembly or handling a new driver airbag assembly, it should be placed
with the steering wheel top surface facing up. Storing the steering wheel with its top surface facing downward
may lead to a serious accident if the airbag deploys for some reason. In addition do not store a driver airbag
assembly on top of another one.
b. Never measure the resistance of the airbag squib. (This may cause the airbag to deploy, which is very
dangerous.)
c. Grease should not be applied to the driver airbag assembly and the pad should not be cleaned with
detergents of any kind. (2) Clock Spring (in combination switch)
The steering wheel must be fitted correctly to the steering col-
umn with the clock spring at the neutral position, otherwise clock
spring disconnection and other troubles may result.
c. Even in cases of a minor collision where the SRS does not deploy, the driver airbag assembly, front
passenger airbag assembly and seat belt pretensioner should be inspected.

e. Never use SRS parts from another vehicle. When replacing parts, replace them with new parts.

f. Before repairs, remove the airbag ECU if shocks are likely to be applied to the sensor during repairs.

g. Never disassemble and repair the airbag ECU assembly, driver airbag assembly, front passenger airbag
assembly or seat belt pretensioner.

h. If the airbag ECU assembly, driver airbag assembly, front passenger airbag assembly or seat belt
pretensioner has been dropped, or if there are cracks, dents or other defects in the case, bracket or connector,
replace them with new ones.

i. Do not directly expose the airbag ECU assembly, driver airbag assembly, front passenger airbag assem-
bly or seat belt pretensioner to hot air or flames.

j. Use a volt/ohmmeter with high impedance (10 k ohm/ V minimum) for troubleshooting of the electrical
circuit.
Information labels are attached to the periphery of the SRS components. Follow the instructions on the
notices.
After work on the supplemental restraint system is completed, check the SRS warning light MarkCorrectWrongd.
k.

General Information - Repair Instruction1-8 (5) Seat Belt Pretensioner
a. Never measure the resistance of the seat belt pretensioner. (This may cause the seat belt pretensioner to
activate, which is very dangerous.)
b. Never disassemble the seat belt pretensioner.
c. Never install the seat belt pretensioner in another vehicle.
d. Store the seat belt pretensioner where the ambient temperature remains below 80°C and away from
electrical noise without high humidity.
e. When using electric welding, first disconnect the connector (yellow color and 2 pins) before starting
work.
f. When disposing of a vehicle or the seat belt pretensioner alone, the seat belt pretensioner should be
activated before disposal. Perform the operation in a safe place away from electrical noise.
g. The seat belt pretensioner is hot after activation, so let it cool down sufficiently before the disposal.
However never apply water to the seat belt pretensioner.
h. There should be no oil or water on the seat belt, no cleanser should be used to wash it. d. Store the driver airbag assembly where the ambient temperature remains below 93°C , without
high humidity and away from electrical noise.
e. When using electric welding, first disconnect the airbag connector (yellow color and 2 pins) under the
steering column near the combination switch connector before starting work.
f. When disposing of a vehicle or the driver airbag assembly alone, the airbag should be deployed using an
SST before disposal. Perform the operation in a safe place away from electrical noise.
(4) Front Passenger Airbag Assembly
a. Always store a removed or new front passenger airbag assembly with the airbag rupture surface facing
up. Storing the airbag assembly with the airbag rupture surface facing down could cause a serious accident if the
airbag inflates.
b. Never measure the resistance of the airbag squib. (This may cause the airbag to deploy, which is very
dangerous.)
c. Grease should not be applied to the front passenger airbag assembly and the airbag door should not be
cleaned with detergents of any kind.
d. Store the airbag assembly where the ambient temperature remains below 93°C , without high humidity
and away from electrical noise.
e. When using electric welding, first disconnect the airbag connector (yellow color and 2 pins) installed on
the assembly before starting work.
f. When disposing of a vehicle or the airbag assembly alone, the airbag should be deployed using an SST
before disposal. Perform the operation in a safe place away from electrical noise.Correct
Wrong

Brief Introduction of Geely MK - Vehicle Configuration2-4Electric
deviceInterior
deviceAdjustable steering wheelRemark: - denote standard configuration Z - standard C - comfortable D - luxury S - dark interior trim
T - light colored interior trim R - mixed colorType Item Name
No.
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51Standard Comfortable Luxury
Single Disc Single Disc 6 Discs6 speakers (2 Tweeters) 6 speakers (2 Tweeters) 6 speakers (2 Tweeters)Front seat back trash bag
6/4 split foldable rear seat
Cable-controlled oil tank cap
Cable-controlled trunk
plastic
leather
Power window (with one-touch function)
Remote control central door lock
Power rearview mirror with turn signal lightSmart remote control key (control the closure of the
door and window and the delay of the vehicle lights)Adjustable intermittent wiper
On-board handsfree handset
Anti-clamp retractive power window
Central pointer type instrument
Temperature display
Hi-fi CD audio
MP3 function
Speaker
Freon-free A/C system
Air cleaner
ABS + EBD
Driver side airbag
Front passenger side airbag
Telescopic steering columnFront seat belt pretensioner /height adjustableRear row triple-person seat belt
Anti-glaze inner rearview mirror
Anti-explosion and anti-leak plastic oil tank
Rear windshield defroster function
High-mounted stop light
Four-door anti-impact beam
Digital display rear parking radar
Follow me home light delay systemSafety
device

2-13For servicing items whose deadlines have expired, they should be maintained at the same intervals as before. The
intervals are recorded in maintenance schedule.
Rubber hoses
Used in cooling and heating system, braking and fuel-feeding systems should be inspected by qualified Geely
technicians according to Geely maintenance schedule.
There are all very important maintenance items. Hoses must be replaced immediately should there be any aging
or damage. Please pay attention, rubber hoses age as time goes by, and they may have problems of inflation, wear,
or crack.
Special Tips
If the vehicle is driven under one or more of the following circumstances, the maintenance items should be
carried out more frequently. See attached maintenance schedule.
A Road condition
1. drive on rough, muddy or skiddy roads
2. drive on dusty roads.
B driving condition
1. Repeat driving within 8km a few times, or when the outdoor temperature is below 0 degree centigrade.
2. Idle the car drive at a low speed for a long time, such as police car, taxi, or door to door delivery vehicles.
3. Continuously drive the car at high speed for more than 2 hours (80% of the max speed).IV. Regular inspections1. weekly schedule

inspect engine oil level and cleanness
inspect engine coolant level
inspect brake fluid level

inspect windshield wash fluid level
inspect power steering fluid level
2. monthly inspections

inspect water pump belt
inspect electrolyte level in battery
inspect tire air pressure and wear

inspect steering wheel
inspect brake
inspect acceleration pedal
3. inspection when driving (low speed)

inspect speed meter and water temperature
check steering wheel power and if vehicle runs off-track

check if the front wheels skid or swing
inspect if brake functions or if the vehicle runs off-track when brake is functioning
4. other inspection items
Eliminate problems immediately when there is anything abnormalUsage and Maintenance of MK Series - Maintenance Category and Content of MK Sedan

2-14
V. Table 1 List of parts to be replaced regularlyThe intervals in the part list are for cars driven under normal condition. If the car is driven in special circumstances,
the replacement can be advanced from the schedule above.SystemParts need to be replaced regularly
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22Brake master cylinder cup valve and dust coverBrake master cylinder cup
Brake hose
Brake caliper valve
Brake booster rubber
Brake booster vacuum hose
Brake fluid
MT Transmission oil
AT Transmission oil
Steering fluid
Air Cleaner
Air c leaner f ilter
Lubricant
Oil filter
Fuel filter
Coolant
All hoses
Canister
Timing beltWedge belt (including the power steering pump,
air conditioner compressor and generator belts)PCV system
Spark plugEvery 2 years (or as required)
Every 2 years (or as required)
Every 2 years (or as required)
Every 4 years (or as required)
Every 2 years (or as required)
Every 4 years (or as required)
Every 2 years,or 40000km (or as required)
Every 2 years,or 40000km (or as required)
Every 2 years,or 40000km (or as required)
Every 2 years,or 40000km (or as required)
To be cleaned every 10,000km and changed
every 30,000km (or as required)
First 2500km or 2 months. Every 7500km or
6 months afterward (or as required)
First 2500km or 2 months. Every 7500km or
6 months afterward (or as required)
Every 5000km (or as required)
Every 40000km (or as required)
Every year (or as required)
Every 2 years (or as required)
Every 60000km (or as required)
Every 120000km (or as required)
Every 50000km (or as required)
Every 20000km or 12 months (or as required)
Every 20000km (or as required)Intervals
DrivelineSteering SystemBraking
SystemEngineA/C System
(API) SG or above(Table 1)Usage and Maintenance of MK Series - Maintenance Category and Content of MK Sedan

2-16......Inspect ......Replace7.5 15 22.5 30 37.5 45 52.5 60 67.5 75
0.5 1 1.5 2 2.5 3 3.5 4 4.5 5System Inspection itemX1000km
YearBraking
SystemBrake reservoir level
FunctionClearance between brake drum and brake liningBrake shoe sliding part and brake lining wearBrake drum wear and damage
Brake lining wear
Brake disc wear and damage
DamageFastening and damage of attachmentAbnormal noise at a jointNoise from joint,damage to arm and
shock absorber fluid leak and damageAbnormal noise at fixtureBrake
BoosterMaster brake cylinder,brakecylinder and brakecalipelBrake liguid leakFunction wear and damageBrake
Drum and
ShoeBrake Disc and
Brake LiningSuspen-sionSystemSpringAttachmentand JointSuspensionArm and
Shock
Absorber
Electri-
cal
SystemEngine
Body
and
Acces-
soryIgnition System
BatteryWiring Harnee and ClipLightingComblned InstrumentHorn,Wiper and
Washer
Defrost and
Power Door Lock
Engine
General
StatusDoor and Trunk LockHood
Seat
OthersStarting performance,abnormal noise,idle and acceleration
Valve clearance
Oil leakSpark plug working status
Lgnition time
Distributor air gap
Distributor cap condition
ConnectionFastening and damage of jointsFunction
Function
Function
FunctionLock FunctionFastening abnormal noise and damageSeat and seat belt status
LubricationUsage and Maintenance of MK Series - Maintenance Category and Content of MK Sedano
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TableEngine AssemblyEngine Inspection3-2 Note:
Check the belt distortion at the specified point (see Figure 1-1).
When mounting a new belt, set the tensioning force to specified value.
After the belt has been operated more than 5 minutes, check and ensure the distortion not exceeding specified
value. (2) Make sure that the coolant level is above the neck of the radiator.
(3) Put the radiator cover in place, pressurize to 2.0Mpa, and keep the pressure for 1minute unless the coolant
leaks. (Mount a tester on the radiator cover, start the engine, and then shut down under a pressure 2.0Mpa).
(4) Check whether the coolant quantity in the dilatation can is between the mark "Low" and "Full".
(5) Check whether the radiator cover is clean; test whether the opening pressure of the main valve is 107.8KPa
with a radiator cover tester. The minimum opening pressure is 58.5KPa.
6. Check the battery.
(1) The terminal voltage of the battery is 12.5-12.9V at 20°C, and charge when the voltage value is less than
the specified value. Check whether the fusible cutout and the fuse are loose, corrosive or on.
7. Check the air filter.
(1) Whether the cover, the case or the element of the filter is distorted, corroded or damaged.
(2) Whether the air hose is damaged.
(3) Whether the air chamber is distorted or damaged.
(4) Whether the air filter element is blocked, polluted or damaged. If the filter element is blocked slightly,
remove the dirt by blowing the element from above.
(5) Whether there is any pollutant or dirt on the air filter support.
8. Check the spark plug.
(1) Spark generation.
a. Disconnect the coupling of the injector.
b. Remove the spark plug from the secondary wire.
c. Remove the spark plug.
d. Connect the spark plug to the secondary wire.
e. Ground the spark plug.
f. Start the engine, and check whether spark is generated.
Prompt: The starting time is not more than 1-2s.
(2) Clean the spark plug: The air pressure is not greater than 588kp and the time is not more than 20s.
(3) Check whether the thread and the insulator of the spark plug are damaged. Replace if necessary.
(4) Check the electrode gap of the spark plug: 0.8±0.1mm for MR479Q and MR479QA; 1±0.05mm for
MR481QA.
9. Check the driving belt.
Belt distortion (see Table 1):
Belt pressure: 98NMeasure belt loosenessCompressor
Crank Power steering
pumpWater
pump
Alternator2 1
3Figure 1-1New belt mm Used belt mm
Generator drive belt 7~9 11.5-13.5
Power steering belt 5~6 6~8
Air conditioner belt 6.5~7 8~9 -