brake fluid GEELY MK 2008 Workshop Manual

Table of ContentsIII Section 2 Front Driveshaft .............................................................................................. 4-19
Section 3 Front Wheel Hub ............................................................................................ 4-30
Section 4 Rear Wheel Hub and Bearing Assembly ....................................................... 4-35
Chapter 5 Front Suspension System................................................................................ 4-38
Section 1 Front Suspension System .............................................................................. 4-38
Section 2 Front Suspension ........................................................................................... 4-40
Section 3 Front Wheel Alignment ................................................................................... 4-43
Section 4 Front Strut Assembly ...................................................................................... 4-46
Section 5 Front Lower Swing Arm Assembly ................................................................. 4-49
Section 6 Front Stabilizer Bar and Link Rod Assembly .................................................. 4-53
Chapter 6 Rear Suspension System................................................................................. 4-54
Section 1 Rear Suspension System ............................................................................... 4-54
Section 2 Rear Wheel Alignment ................................................................................... 4-56
Section 3 LH/RH Rear Suspension Coil Spring ............................................................. 4-57
Section 4 Rear Absorber Installation Assembly ............................................................. 4-60
Section 5 Rear Suspension Crossmember .................................................................... 4-62
Chapter 7 Wheel.................................................................................................................. 4-66
Section 1 Tire Inspection and Wheel Replacement ....................................................... 4-66
Chapter 8 Power Steering System.................................................................................... 4-67
Section 1 Power Steering System .................................................................................. 4-67
Section 2 Steering Drive and Control Mechanism ......................................................... 4-69
Section 3 Steering Pipeline Component ........................................................................ 4-73
Section 4 Power Steering Gear ...................................................................................... 4-75
Chapter 9 Brake System.................................................................................................... 4-79
Section 1 Brake System ................................................................................................. 4-79
Section 2 Brake Fluid ..................................................................................................... 4-81
Section 3 Brake Pedal ....................................................................................................4-82
Section 4 Brake Master Cylinder Assembly ................................................................... 4-85
Section 5 Vacuum Booster ............................................................................................. 4-91
Section 6 Front Brake Disc ............................................................................................. 4-94

Adjust seat back angle
Move seat forward or backward angleUsage and Maintenance of MK Series - Usage of MK Series2-7212.How to use ignition switch
(1) LOCK when key is at this position, it can be pulled out and inserted in easily. The function of this position
is to lock steering wheel. If the key cannot be turned from LOCK to ACC, please rotate the steering wheel slightly
while turning the ignition key.
(2) ACC radio and cigarette lighter is turned on when key is at this position.
(3) ON when key is at this position, the following indicator is on: battery charging, ABS, brake fluid level,
park brake, engine coolant temperature, engine MIL, airbag oil pressure.
(4) START Turn the key to this position to start the engine. When engine is started, release the key
immediately. It returns to ON automatically. When engine is on, do not turn the key to this position.
Notice:
(1) Do not pull the key out or turn it to LOCK before the car is fully stopped, or there will be dangers caused
by locking steering wheel or disabling some safety functions.
(2) It is prohibited to drive the car with engine turned off to ensure functioning of braking and steering booster.
(3) Do not let the key stay at ON for a long time when engine is off, or the battery fully discharged.
(4) Shift to neutral gear before ignition key is switched to START.
(5) Turn the steering wheel lightly after the car is fully stopped to make sure it is locked.
3.Unlock Steering Wheel
How to unlock steering wheel: insert ignition key, turn the steering wheel lightly and switch the ignition key.
Steering wheel is unlocked.
4.Adjust seat position
Seat back angle and cushion angle of front seats in MK-1 sedan can be adjusted.
(1) Adjust seat back angle
Turn around adjusting handle, and adjust seat back to appro
priate position.
(2) Move seat forward or backward
Steps:
a. pull adjusting handler up
b. Move the seat forward or backward, and adjust the seat to
appropriate position.
c. Put the handler down and move the seat again till it is
locked.
Attention: adjust the seat only when the car is fully stopped
to ensure safety.
(3) Front head rest can be adjusted in two ways.
Push the head rest from back to front, there are three fixed
positions to lock.If pushed over the final locking position,the
head rest can return to the original position after hand
withdraws.
(4) Fold Rear Row Seat
The seat back can be tilted forward so that the trunk will be
used to the last degree.
a. Remove the head rest
b. Unlock the seatback and fold it down.
Split seatback can be folded separately on demand.

2-85. Actions to ensure vehicle working condition and safe driving.
(1) To make sure of driving safety, execute the following inspections before driving.
a. Inspect fuel level, and add fuel when necessary.
b. Inspect illuminating lights, turning signal lights, braking signal lights to see if they work.
c.Check the position of rearview mirrors.
d.Check if breaking system functions well.
e.Check if glass of all the lights, windshield is clean.
(2) Regular inspection Perform the following regular inspections to ensure the vehicle work condition and
driving safety.
a. Check engine oil level. Park the vehicle on flat road; check the oil level with engine oil level indicator
at least 10 minutes after the engine is stopped. The oil level should be between the two marks. If it is
lower than "L" mark, add some oil; if it is higher than "F" mark, there is excessive oil, so release it.
Or investigate the cause of high oil level.
The volume between the lowest oil level ("L") and highest oil level ("F") is 1.4L.
b. Check engine coolant level. Check the level when the engine is cool. The coolant level should be between
LOW and FULL. If it is lower than "LOW", add coolant. If the coolant is much lower than Min (every
coolant fill is more than 1L) or the vehicle requires frequent fills,investigate if there is any problem with
the cooling system.
To keep the function of coolant, replace coolant every two years at the beginning of cold winter.
c. Check brake and clutch fluid level (sharing a reservoir). Brake fluid level should between the Max and
Min marks. And it is better to keep it close to the Max mark. Add fluid in time when there is not enough
fluid.
d. Check power steering fluid tank. The level should be between Max and Min marks. Refill when there
is not enough steering fluid to avoid pump stuck. It is strictly prohibited to run the vehicle without
steering fluid in any circumstances.
e. Check the charging status of battery and if the connection of battery wires is good.
f. Check tire status and pressure
g. Check the status of wipers.
(3) Observe warning lights and indicators on instrument panel.
a. There are various warning lights and indicators on the instrument panel of MK-1 sedans to indicate and
warn abnormal operations of engine, braking, and charging systems.
b. Pay attention to these lights when driving.When the warning lights or indicators are on,stop the vehicle,
check the vehicle and resolve the causes to make sure the vehicle works well or drives safely.
6. Correct ways to use new cars
Reliability and stability of components in new cars and recently repaired cars still need to be confirmed, and
relative parts are not broken-in, so they must be used carefully to ensure driving safety, to avoid abnormal damage,
and to extend the useful life of the car.
(1) Before driving inspection The following inspections must be performed on the new car to ensure car safety
and reliable operation:
a. Check if instrument panel, warning lights, and indicator, front and rear wiper and washer, and switches
work.
b. Check if the fastening of driveline, steering, suspension, wheels and other connection parts is good.Usage and Maintenance of MK Series - Usage of MK Series

2-9 c. Check levels of braking fluid, engine coolant, engine oil, transmission oil, power steering fluid, and
washing fluid to see if there is any leaking.
d. Inspect if brake pedal, clutch pedal, accelerator pedal, transmission shifter, steering wheel, choke are
loose or stuck. The free travel of clutch pedal is 5~15mm, the free travel of brake pedal is 1~6mm and
the free play of steering wheel is less than 30mm(measurement point at margin of steering wheel). if it
is out of this normal range, the clutch needs to be tuned.
e. Inspect if the connection of battery, lamps and signal lights are normal, and if the wire routing and
position are correct and not loose.
f. Inspect if the tire pressure is correct.
(2) On-road inspection If the inspection result of the above items is good, start the engine and test the car on
road, and perform the following inspections.
a. Acceleration pedal, see if the operation is smooth and if it is loose.
b. Clutch, see if there is any stuck or abnormal noise, and slip when driving.
c. Transmission,check if shifting is smooth,or rough and wrong shifting.Inspect if the display of A/T
shift lever is normal.
d. Steering, check if steering is light and smooth, and if the steering wheel turns back after steering.
e. Brake pedal, apply brake pedal to check if the braking functions well when vehicle speed is at
40km/h and if the vehicle runs off track.
f. Park brake, when parking brake handler is pulled, there should be 6~9 clicking sounds. Pull park brake
when vehicle is running at the speed of 20km/h and transmission is at neutral gear to see if it brakes.
g. Vehicle speed meter, observe the vehicle speed meter while driving. When speed changes, check if the
indicator is moving steadily or shakes.
h. Heating and air-conditioning.Try every control button to see if both heating and cooling system work
well.
i. Abnormal noise, listen carefully to see if there is any abnormal noise from engine, drive line system or
any other parts of the vehicle at a steady speed and during accelerating, and decelerating.
(3) Inspection after test ride check if there is anything abnormal in the vehicle while driving and conduct the
following inspections after the vehicle is parked.
a. Check electrical fan When engine coolant temperature is beyond 92.5°C, the radiator fan should be
running; When A/C is on and the pressure of refrigerant is more than 1.5 cooling ton, air conditioning
cooling fan should be running.
b. Check headlamp, method: park the car 5m away from the inspection surface (inspection board, curtain,
or wall) to the front bumper, and check if the beam from headlamp is good. The upper level if headlamp
should be 540mm above the ground, and the distance between headlamps on the two sides is 900mm.
c. Inspect engine idle speed,idle speed of hot engine is 800r/min±50r/min,when A/C compressor works,
the idle speed should be 900r/min±50r/min. If idle speed is abnormal, adjust the idle speed adjust
ment screw to adjust it.
(4) Usage of new cars in breaking-in period Follow the instructions below in the first 1500~2500km breaking
mileage to avoid wear and abnormal damage in breaking-in period, and to improve vehicle performance, fuel
economy and to extend vehicle useful life.
a. Drive steadily during breaking-in; do not accelerate harshly to avoid running engine at high speed.
Engine should not exceed 4500r/min in any gears. Especially at the early stage of breaking-in, vehicleUsage and Maintenance of MK Series - Usage of MK Series

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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2-17
VII . Additional maintenance scheduleVehicles run in special circumstances require higher frequency of maintenance as listed below. Replacement of engine oil
Replacement of engine oil filter B-1: repeated short-distance driving and outer air temperature under zero within 8km (kilometer)
Inspection of the brake friction wafer and braking drum
Inspection of the braking pad and braking disc B-2: long-term empty run and / or long-distance driving with low speed, such as police wagon, taxi or automobile delivering
goods to the customers etcEvery 2,500km (kilometer) or every 3 months
Every 5,000km (kilometer) or every 6 months
Every 10,000 km (kilometer) or every 6 months
Every 5,000km (kilometer) or every 3 monthsB-3: continuous high-speed driving for more than 2 hours (80% of the maximum vehicle speed or above)
Replacement of driving axle oil of the manual transmission
Inspection or replacement of the driving axle fluid of the
automatic transmissionEvery 40,000km (kilometer) or every 48 months
Every 40,000km (kilometer) or every 24 months Inspection of the brake friction wafer and braking drum
Inspection of the braking pad and braking disc
Inspection of the brake piping and hose
Inspection of the transmit shaft ball and joint and dust shield
Inspection of the drive shaft cover
Inspection of the steering wheel, connecting rod and steering gear
box oil
Inspection of the front and rear suspension devices
Screwing down the bolts and nuts of the chassis and vehicle body A-1: driving on bumpy, muddy or melted snow road.
Replacement of engine oil
Replacement of engine oil filter
Inspection and replacement of air filter
Inspection of the brake friction wafer and braking drum
Inspection of the braking pad and braking disc
Replacement of the air conditioner filterA-2: driving on dusty roadEvery 10,000 km (kilometer) or every 6 months
Every 5,000km (kilometer) or every 3 months
Driving for 1000 km (kilometer) for the first time and
then every 10,000 km or every 6 months
Every 10,000 km (kilometer) or every 6 months
Every 10,000 km (kilometer) or every 12 months
Every 5,000km (kilometer) or every 3 months
Every 10,000 km (kilometer) or every 6 months
Every 10,000 km (kilometer) or every 6 months
Every 5,000km (kilometer) or every 6 months
Every 5,000km (kilometer) or every 6 months
Every 2,500km (kilometer) or every 3 months
Every 10,000 km (kilometer) or every 6 months
Every 5,000km (kilometer) or every 3 months
Every 10,000km (kilometer)Usage and Maintenance of MK Series - Maintenance Category and Content of MK Sedanoo o
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2-19 (4) Tire wear limits When the wear limit mark on tire shows up as the tire wears, it must be replaced with new tires (wear limit mark
indicates the thickness of tire pattern is 1.6mm).
5. Maintenance of wiper and washer
Status of wiper and washer directly influences windshield and driver's view. So, pay attention to wipers and
washers.
(1) Wiper Check if the wiper blade has any damage, deformation, which affects windshield wiping quality
and if the wiper works well. If wiper blade does not wipe well or the wiper does not work well, fix or replace it
in time.
(2) Washer Check washing fluid level in the tank, and refill when necessary. To get best washing effects, use
specified washing fluid, refill slowly, and pay attention not to mix it with any dirt. Mix the washing fluid with some
alcohol in winter to avoid freezing.
6. inspect and adjust headlampIncorrect beam of the headlamps affects safety of driving in the dark. So they must be inspected regularly, and be
adjusted when necessary.
7. Maintenance of inside the vehicle
The major content of maintenance inside the vehicle is cleaning, to keep the vehicle clean and provide fresh and
pleasant driving circumstance. The key points of indoor cleaning are:
(1) Ways to remove stains Get rid of dust before trying to remove stains, and then apply appropriate cleansing,and wipe the stains off with clean, soft, and not too wet cloth repeatedly.
(2) Cleansing It is better to remove stains on textile and man-made leather with hydro solvent made from soap
fluid and surface active agent. Be careful to avoid using any cleansing because they may corrode the synthetic
decoration materials more or less. Ball-pen and lipstick marks can be removed with alcohol, grease can be removed
with low Ron value gasoline, and chocolate and sugar stains can be cleaned with ammonia spirit, asphalt must be
cleaned with special cleansing.Tire Specification Tire Pressure (KPa)
Front Tire 185/60R15 84H or 175/65R14 82H 230
Rear Tire 185/60R15 84H or 175/65R14 82H 210c. Wavy wear on the tread is related to its quality and positioning of the wheels. Find out the root cause
and eliminate any problems.
d. Serious wear on the outer side beside the tread of steering wheels means the wheel outward leaning angle
is too big; wear on the inner side beside the tread means the leaning angle is too small.
e. When the toe-in value is getting smaller, the wear on the outer side of tread is in shape of saws. On the
contrary, when the inner side has the saw shape wear means the toe-in value is too big.
(2) Maintenance
a. Keep the tire pressure to specified value under any circumstances. Measure the pressure on cold tire
b. Check tire pressure regularly, and remove any indented objects that may stick through the tires.
c. Avoid oil, gasoline, and brake fluid on tires.
d. When replaced with new tires, the wheels need to be balanced and adjusted again. Or the vehicle may
shake when running at high speed and bear abnormal wear.
e. Do not mix tires of different structure, pattern, or brand on one vehicle.
(3) Tire specification and pressureUsage and Maintenance of MK Series - Daily Maintenance of MK Sedan

2-20 (3) Long time exposure to sun damages interior. So it is better to use covers on upper seat backs, and rear
separation board that are exposed to sun.
8. Maintenance of body exterior
Body exterior is to keep body cleanness and brightness to give the impression of beauty and comfort, and to avoid
rust and abnormal paint peeling off. The key points of body maintenances are:
(1) Wash body using the method below:
a. Wash the dirty things off the body by pressurized water, and then clean the body with
soft cloth of sponge from up to down.
b. Dry body surface with good white cloth. Apply brake pedal several times when driving
after the car is washed to get rid of water in braking system.
c. Do not wipe the body when it is dry. Do not clean paint surface and glass with gasoline,
coal oil, narkosid, strong lye or alcohol.
(2) Cleaning windshield glass
Do not use silicon-bronze radical products. To get better cleaning effects, use special glass cleanser.
(3) Cleaning asphalt on the body
Do not peel the asphalt off from body or bumper, but use special cleanser
(4) Paint
Scratches or slight damages can be fixed with special paint spray. It dries in the air.
(5) Cleaning exterior decoration parts and aluminum parts. Wash with water with soap fluid or cleanser, and wash with clean water. To keep the gloss of painted surface,
wax on the surface after it is dry. (6) Polish and wax the body paint polishing and waxing keeps the body bright and pretty, and protects the paint
as well.
a. Polish in winter. Make sure the vehicle body is absolutely clean and dry before
polishing, polish with fluid or milky wax.
b. Vehicle body must be absolutely dry and clean before waxing. Use waxing tools (soft
table tissue or smooth cotton cloth) to cover the body paint surface evenly with wax.
Check if the vehicle body is covered by wax: spray some water onto the paint surface,
if water drops are formed, that surface is waxed, otherwise, clean the surface and wax
it again. Attention: do not wax under sun, or in cold weather.
Attention
1) When using high pressure washing machine, do not point the washing sprayer to transmission, steering
mechanism and other rubber protection parts, or exterior decoration parts, roof welding lines, heat radiator
or engine compartment.
2) The bottom of vehicle body is made of anti-corrosion material,and has been through anti-corrosion process.
After the vehicle has been running frequently on roads de-frozen with salt for some time, clean engine
compartment and lower part of vehicle body and take some protection actions.Usage and Maintenance of MK Series - Daily Maintenance of MK Sedan