height GEELY MK 2008 Workshop Manual

General Information - Repair Instruction1-114. Precautions for Use of Swing Arm Type Lift
(1) follow the safe operation instruction described in this manual.
(2) use bracket with rubber support as shown in the illustration.
(3) make the center of gravity of the vehicle as close as possible to that of the lift ("L" should be smaller).
(4) adjust the bracker height, level the vehicle, align the groove of the bracket with the safety stand
support location.
(5) the arm should be locked during the job
(6) lift the vehicle until the tires become round.Swing the vehicle to make sure of stable vehicle.
5. Precautions for Use of Plate Type Lift
(1) follow the safe operation instruction described in this manual.
(2) use the support of the plate type lift.
(3) make sure to secure the vehicle in the specified position. Left and right set position
Front and rear set position Place the vehicle over the center of the lift. Align the cushion gum ends of the plate with the attachment
lower ends (A, C). Align the attachment upper end (B) with the front jack supporting point.Support Position
Jack Lifting Position Jack Position
Center of Gravity of the Vehicle
(empty load)

Part II Vehicle Usage and MaintenanceChapter 1 Brief Introduction of Geely MKSection 1 Major Functional and Technical Data of MK Series.I. Vehicle performance and structural data Table 1 vehicle dataVehicle Usage and Maintenance - Brief Introduction of Geely MK2-1JL7162U
JL7152U JL7132UUnit
mm
mm
person
kg
m
mm
°
mm Item ID
1
2
3
4
5DimensionDimension
Axle4342
1692
1435
1450
1431
2502
848
992
5
150mm
15°
20°
-0°30'±45'
1±2mmLength
Width
Height
Front
Rear
Wheelbase
Front Suspension
Rear suspension
Number of passengersWeightCurb weight
Front Axle
Rear Axle
Vehicle
Front
Rear CurbGross Vehicle
Weight
Road
adaptabilityMinimum turning diameter
Minimum Ground Clearance
Approach angle
Deviation angleWheel
Posi-
tioningLeft: Inner/out
Right: inner/outMax turning angleof front wheel
Front wheel leaning angle
Kingpin inward leaning angle
Kingpin rearward leaning angle
Left front wheel toe-in
Rear wheel outwardJL7132HU JL7152HU1090(1040)
660(640)
430(400)
1460(1410)
780(760)
680(650)1080
665
415
1450(1455)
780(785)
670 10.4m
°
°
°
°
°
°°37.2°±2°/ 32°±2°
37.2°±2°/ 32°±2°
2°0'±45' 10°0'±45'
-0°56'±45'

Table 3 Power Performance Parameter
Table 4 Economic Performance ParameterUnit
km/h
s
s
km/h
% Item Name
Maximum vehicle speedAcceleration time within the fourth gear from 30km/h to 120km/hAcceleration time from 0-100km/hMinimum stable vehicle speed within the fourth gearMaximum gradeability No.
1
2
3
4
5Unit
L/100km
L/100km
m Item Name
Fuel consumption at constant speed (60km/h)
Fuel consumption at constant speed (90km/h)Coasting distance (fully loaded, initial speed 50km/h)No.
1
2
3JL7132U JL7152U JL7162UJL7132HU JL7152HU


/JL7132U JL7152U JL7162UJL7132HU JL7152HU
4.5
550Brief Introduction of Geely MK - Vehicle Configuration2-3Section 2 Vehicle ConfigurationType
Common color
Uncommon color
Exterior
device
Seat Interior
deviceItem NameNo.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19Standard Comfortable Luxury
Firry red Firry red
Titanium silver Body colorChinese red, snow mountain white, pearl black, sky blue, ribbon silver
Crystal diamond silver, golden sand green, pineapple yellowFront chromeplated trim molding
Diamond-shape headlight
Crystal diamond taillight
Highly penetrable front fog light
Green heat insulating four-door glass
Scuff strip with same color as that of the body
Aluminum alloy wheel rim
Tire (185/60R15) (with spare tire)
Retractive antenna (A pillar)
Bumper with same color as that of the bodyLight color (T)deep color(S)mixed color(R)interior trimCentral control panel
A/C outlet vent + trim ring
Chromeplated inner handle
Sun shade (with ticket folder)
High-grade flannelette
Luxury leatherFront seat headrest front and rear angle/height adjustable function
/ /
20
2522
16.5 18
20165
33
28 30155 175 165 155
306.25.1
4.65.0
4.7
6.7
6.36.6 6.2
550 550
550 550 / /
/ / / /

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

Section 3 Main Vehicle Test Technical SpecificationDescription
Front wheel outward leaning angle
Kingpin inward leaning angle
Kingpin rearward leaning angle
Left front wheel toe-in (mm)
Rear wheel outward leaning angle
% of braking total power vs. gross vehicle weight
% of front wheel braking power vs. front axle load
% of gap between left and right wheel brake power vs. the
greater braking power of them tworolling resistance of each wheel should not be larger than the axle load by
parking brake total power should be lighter than the test vehicle weight bysliding distance of front/rear wheels
when vehicle speed meter shows 40km/h, vehicle speed
monitor indicates
brightness of left/right headlamps
tolerance of close lamps is
tolerance of distant lamps isHarsh brake at 50km/h. the stop distance is
Rain test. 100 points is full mark. Minus one point for each
seepage. Minus 3 points for slow seepage 3 points, and minus
6 for a quick seepage. The limit of vehicle sealing isCheck leaks of the vehicle. When vehicle has run 50km, stop it and
inspect for leaks. Check if there is oil/water marks at static joints,
or if there is oil/water drops dripping down at dynamic joints
10min after the vehicle is stopped, there is a leak; if there is oil/
water marks/drops, but it does not drip down, there is seepage.Measure the temperature of transmission oil inspection hole.
Usually it is not higher than ambient temperature.
Check the surface temperature of wheel trim column. Usually
it is no higher than ambient temperature.
vehicle should be slightly steering insufficient i.e. driving on
a circle with same steering wheel angle, and accelerate from
low to high speed, the diameter of the circle increases gradually.
Maximum front wheel turning angle (inner/outer)ItemSpecification: GB18352.3-2005Brief Introduction of Geely MK - Main Vehicle Test Technical Specification2-5Inspection
line itemsRegular
quality
inspection
itemsSpecification
-0°30'± 45'
10°0'± 45'
2°0'± 45'
1±2
-0°56'± 45'
60% (no load, and full load)
20%(Front Axis),
24%(Rear Axis)
5%
20%
2 m/km
33.3 Km/h-42.1Km/h
15000 cd
(0.6-0.8)H, H refers to the central
height of headlamps.
10cm/10m19m
93 points
Daily inspection and smell with
nose
70°C
40°C
Inspect regularly
37.2°±2°/ 32°±2°Emission60% (no load),
50% (full load)

Component ViewSection 2 Clutch PedalAdjustment1. Check and adjust the clutch pedal.
(1) Lift the carpet on the floor.
(2) Check the pedal’s height is proper.
Pedal's height from oil felt: 134.3-144.3mm
(3) Adjust the pedal's height.
Loosen the lock nut, and turn the bolt till the correct pedal's
height is reached, and then tighten the lock nut.
Torque: 16N.m
(4) Check whether the pedal's free travel and push bar travel are
proper.
a. Step the pedal down till a resistance appears.
Pedal's free stroke: 5-15mm
b. Step the pedal down lightly till the resistance increase a
little.
Push bar (on the pedals top) travel: 1.0-5.0mm
(5) Adjust the pedal's free travel and push bar travel.
a. Loosen the lock nut, and turn the push bar till the pedal's
free travel and push bar travel are proper.Clutch pedal bracket
Hex. flange nut37
Clutch pedal spring
Clutch pedal
bushing
Absorber
Clutch pedal cover Clutch pedal
Transimissin RodClutch master cylinder cone
U-connector bushingClutch pedal bushing Clutch Peader AxisClip12
Master cylinder
outtet pipesetSted Band ClampMaster cylinder
Inlet hoseHydranlic clutch hose
ÒLÓ Clip
Clutch hose Bracket
BoltClutch Control SystemClutch Pedal4-13Non-reusable parts
Multi-function lubeNm :Specified torquePedal height
adjustmentClutch
pedal Travel
Push travel &
free travel adjustment
pointPedal heightPedal free travel -

b. Tighten the lock nut.
Torque: 12N.m
c. Check the pedal's height after adjusting the pedal's free
travel.
(6) Check the clutch's separating point.
a. Tension the parking brake device and install a wheel
stopper.
b. Start the motor and make it run idly. c. DonÕt step the clutch pedal,and put the gear shift lever to the reverse gear slowly till the gears engage.
d. Step the clutch pedal down slowly,and measure the travel distance between the separating point to the
pedal travel end position.
Standard distance: 25mm or above (pedal travel end position to separating point)
If the distance doesn't meet standard, carry out the following steps:
Check the pedal's height.
Check the push par stroke and pedal's free travel.
Discharge the air in the clutch fluid pipe.
Check the clutch cover and clutch disc.
Check the pedal's travel.
Pedal travel: 120-130mmReplacement1. Remove the battery negative terminal.
2. Remove the upper cover in dashboard panel.
3. Remove the lower cover in dashboard panel.
4. Remove the pane of the control board.
5. Remove the clutch pedal spring.
6. Remove the U-connector with pin on the clutch master cylinder
push bar.
Remove the clips and pins.
7. Remove the clutch pedal bracket.
Remove the two nuts and bolts, and then remove the clutch pedal
bracket.
8. Remove the clutch pedal.
(1) Remove the bolts and nuts.
(2) Remove the clutch pedal from the clutch pedal bracket.Clutch Control SystemClutch Pedal4-1425mm or more
Separating point
Max. travel
end position -

Section 3 Front Wheel AlignmentAdjustment:1. Check tire
2. Measure the vehicle height
Vehicle height:Tire sizeFront1 (mm)Rear2 (mm)
175 / 65R14 82H191 265
185 / 60R15 84H192 265Front Suspension System-Front Wheel Alignment4-43 1.front measure point
Measure the distance between the ground and the front underside
suspension mounting bolt center
2.rear measure point
Measure the distance between the ground and the rear axle beam mounting bolt center
Notice:
Before the wheel alignment,adjust the body to the specified height.If the body height is out of spec,adjustment
shall be done by pressing or raising vehicle body.
3. Check the Toe-in
Toe-in:
If the toe-in is out of spec, adjust the ends of rack.
4. Adjust the Toe-in
(1) Remove the clamp of the rack boot
(2) Loose the jam nut of tie rod
(3) Adjust the Toe-in by rotating the same turns of both ends of
rack.
Tips: Adjust the toe-in to the intermediate value of spec.
(4)Make sure the same length for both ends
The length difference of left and right: 1.5mm or smaller
(5)Tighten the jam nut of the tie rod
Torque: 47N.m
(6)Seat the boot and crimp the clamp
Tips: rack boot must not be twistedFront
Rear
Front

Check1. Check the tire
2. Measure the vehicle height
Notice:
Adjust the vehicle height to specified value before check the
wheel alignment
3. Check the rear toe-inSection 2 Rear Wheel AlignmentRear Suspension System-Rear Wheel Alignment4-56A+B: 0°19' ± 19' (0.31 ± 0.31°)
C+D: 3.0 ± 3.0mmToe in
( assembly ) Check and replace the related suspension parts if the toe in out of spec.
4. Check the camber
(1) Mount the camber-caster-kingpin measuring device, place the vehicle on the wheel position device
(2) Check camber
Check the damage and performance decline of suspension parts and replace if necessary, if measurement out
of spec.-0°56' ± 45' (-0.93° ± 0.75°)
45' (0.75°) or smallerCamber
Left-right deviationFront

Power Steering System-
Steering Pipeline Component4-74 (7)Shut down the motor, and check whether there is any foam or
emulsification in the oil storage. If so, discharge the air
repeatedly.
(8)Check the level height, and check whether there is any
leakage.
2. Check the level height.
(1)Park the vehicle on the horizontal road.
(2)When the motor stops running, check the level height in the oil
tank. If necessary, add some more ATF DEXRONII steering
liquid.Replacement1. Discharge the steering liquid in the power steering system.
2. Remove the power steering high & low pressure oil pipes.
3. Loosen the connector screws of the high & low pressure oil pipes on the steering gear assembly, and loosen the
oil pipe clip.
4. Loosen the drive belt.
5. Remove the power steering pump strap support assembly from the motor. Remove the 3 coupling bolts between
the power steering pump strap support assembly and the motor.
6. Install the power steering pump strap support assembly.
Fasten the steering pump strap support assembly on the motor, and tighten the M10 bolt with a torque of 45-
79N.m and M8 bolt with a torque of 16-26N.m.
7. Install the drive belt, and make sure the position is correct.
8. Install the high & lower pressure oil pipes of the power steering gear assembly.
(1) Connect the connector screw of the high and low pressure oil pipe to the steering gauge with a torque of
19-33N.m.
(2) Fasten the low pressure oil pipe on the body front baffle plate with clip.
(3) Connect the connector screw of the high pressure oil pipe to the power steering pump with a torque of
19-33N.m.
(4) Connect the connector screw of the low pressure oil pipe to the oil tank with a torque of 19-33N.
m.
9. Discharge all air in the power steering pipe system, and check the pipe system whether there is any leakage.
10. Check the oil reservoir inner fluid level Tips: The level shall stay between the lowest level and the highest level.
(3) Check whether there is any foam or emulsification. If so, discharge the power steering liquid.NormalAbnormal