high beam GEELY MK 2008 Workshop Manual

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

2-9 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

2-19 (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

Automobile Starting, Power Supply System -Charging system5-57. Inspect charging circuit without load
(1) If a battery/starter tester is available, connect the tester to the
charging circuit as per instructions.
(2) If a tester is not available, connect an ammeter and voltmeter
to the charging circuit as follows.
a. Disconnect to the wire from terminal B of the alternator
and connect it to the negative (-) pole of the ammeter.
b. Connect the positive (+) pole of the ammeter to terminal B
of the alternator.
c. Connect the positive (+) pole of the voltmeter to terminal B
of the alternator.
d. Ground the negative (-) pole of the voltmeter.
(3) Check the charging circuit
With the engine running from idle to 2,000 rpm, check the reading on the ammeter.
Standard amperage: 10A or less
Standard voltage: 12.9V-14.9V
8. Inspect charging circuit with load
(1) With the engine running at 2,000 rpm, turn on the high beam headlights and place the blower switch at "4".
Check the reading on the ammeter.
Standard amperage: 20A or more
(2) Hint:
If the ammeter reading is less than standard amperage, repair the alternator.
If the battery is fully charged, the indication value will sometimes be less than standard amperage.III. Alternator inspection1. Inspection of alternatorPullyStatorBearingBearing spacerRotorBearing cover
Bearing
Wire clipBrush
Washer
Rectifier end frameRectifier frameInsulator at wiring endBrush holderBrush holder coverBack end coverIC RugulatorAmpere Meter
BatteryVoltage MeterAlternatorDisconnect the Cable
of B terminal

3. Definition of multi-pin plug-in unit terminal
1. Prompt:
R- red Bl- blue Y - yellow B- black P- pink G- green W- white
O- orange Gr - gray Br- brown V- purple Lg- olive drab
The first letter indicates primary color
The second letter indicates stripe colorTerminal
number1 MIL C 10 NA
2 Engine oil pressure switch YG 1 P
3 Brake fluid GR 2 R
4 Park G 3 N
5 Right turn light GB 4 D
6NA 52
7 EBD 6 L
8 Charge WR 7
9NA 8NA
10 NA 9 Sidelight GW
11 Safety belt YR 10 Start BR
12 NA 11 B+
13 Engine GY 12IG ( + ) Y
14 Safety gasbag RY 13 GND
15 NA 14 NA
16 IG ( + ) 15Speed sensor earthing B
1 NA 16 Speed signal input YR
2 Left turn light GW 17 Speed sensor power supply RY
3 High beam (+) RB 18 Key (ODO/TRIP) G
4 High beam (-) RW 19 Key (adjust brightness) YG
5 Foglight Gr 20 Key COM B
6 Rear defrost YB 21 Fuel gauge V
7 NA 22 ABS R
8 NA 23 Tachometer BBL
9 Door-lock warning lamp RBL 24 Coolant temperature gauge YWA
BCCombination Instrument System -Wiring diagram of Combination Instrument and Location of Multi-pin Plug-in Terminal5-9Definition of terminalConductor
ColorTerminal
numberDefinition of terminalConductor
Color

Suspected area
1. Wiring harness or connector
2. ECM
3. Combination instrument assy.
1. Wiring harness or connector
2. Alternator
3. Combination instrument assy.
1. Wiring harness or connector
2. Manual brake switch
3. Combination instrument assy.
1. Wiring harness or connector
2. Brake fluid level switch
3. Combination instrument assy.
1. Wiring harness or connector
2. ABS ECU or ABS warning lamp driving module
3. Combination instrument assy.
1. Wiring harness or connector
2. Airbag ECU controller
3. Combination instrument assy.
1. Wiring harness or connector
2. Airbag ECU controller
3. Combination instrument assy.
1. Wiring harness or connector
2. Front head light dimmer switch
3. Combination instrument assy.
1. Wiring harness or connector
2. Front head light dimmer switch
3. Combination instrument assy.
1. Wiring harness or connector
2. Rear defrost switch
3. Combination instrument assy. 8. Warning lamp fails
Symptom
Check that engine warning lamp does not
illuminate
Charge warning lamp does not illuminate
Park braking warning lamp does not
illuminate
Brake failure warning lamp does not
illuminate
ABS warning lamp does not illuminate
SRS warning lamp does not illuminate
Passenger's airbag indicator lamp does
not illuminate
High beam indicator lamp does not
illuminate
Rear foglight indicator lamp does not
illuminate
Rear defrost indicator lamp does not
illuminate5-16Combination Instrument System -Malfunction Symptom Table and Troubleshooting

Chapter 4 Light SystemSection 1 Light System IntroductionI. Composition Light system comprises external illumination and signal system and internal illumination system.
The function of the external illumination and signal system is to illuminate the road ahead and send signals
to other vehicles.
The internal illumination system provides internal illumination for driver and passengers.II. Precaution for service1. Precaution when repairing electrical equipments
Disconnect the battery ground cable.
2. Precaution when replacing a headlamp bulb
(1) Before replacing a halogen bulb, turn the headlamp OFF to make it cool.
(2) When installing a new halogen bulb, do not touch the glass part of the bulb with bare hands.
(3) If there is oil stain on the surface of halogen bulb (headlamp and front fog lamp) when the lamps are
turned ON, its service life will be shortened.
(4) Halogen bulbs (headlamp and front fog lamp) have pressurized gas inside and require special handling.
They can explode if dropped to ground. The glass fragments will splash up.
(5) When replacing, make sure to use the bulbs with the same power, same model.
(6) After the bulb is installed, make the lamp holder tight.III. Bulb specificationsRemark: All bulbs are made by Philips Corp..Light System-
Light System Introduction5-26Name Specifications
Headlamp (High beam and Low beam) H1 12V 55W
Turn signal lamp PY21W 12V 21W
Position lamp W5W 12V 5W
Front fog lamp H3 12V 55W
Rear combination lamp (Turn signal lamp) PY21W 12V 21W
Rear combination lamp (Brake / Position lamp) P21/5W 12V 21/5W
Rear combination lamp (Rear fog lamp) P21W 12V 21W
Rear combination lamp (Back-up lamp) P21W 12V 21W
Interior lamp (dome lamp) R5W 12V 5W
Rear row reading lamp C5W 12V 5W
Side turn signal lamp W5W 12V 5W
High mounted stop lamp (incl. rear trunk lamp) W5W 12V 5W
License plate lamp W5W 12V 5W
Door courtesy lamp W5W 12V 5W

Symptom
Front fog lamp dose not light up with light control
switch HEADLAMP (Head lamp is normal).
Only one side front fog lamp dose not lightSuspected Area
1. Fog lamp fuse
2. Front fog lamp relay
3. Light switch assembly
4. Harness
1. Bulb
2. HarnessSection 2 Light System Malfunction InspectionSuspected Area
1. Bulb
2. LH or RH headlamp fuse
3. Harness
1. Lamp switch assembly
2. Harness
1. Bulb
2. LH or RH headlamp fuse
3. Harness
1. Lamp switch assembly
2. Harness
1. Lamp switch assembly
2. Harness
1. Bulb
2. Harness
1. Bulb
2. Harness
1. Fuse
2. Light control switch
3. Harness
1. Beam control switch
2. Harness2. Front fog lamp systemSymptom
"Low beam" dose not light (One side)
"Low beam" dose not light (All)
"High beam" dose not light (One side)
"High beam" dose not light (All)
Light dose not flash (Dimmer)
Headlamp is dim
Only one side tail lamp lights
Tail lamps on both sides do not light (Headlamp
is normal)
Tail lamps on both sides do not light (Headlamp
is abnormal)Light System -Light System Malfunction Inspection5-28I. Light system problem symptoms table: Description:
The table below can help you find the causes of malfunction. These figures show the most possible
malfunctions in order of priority. Inspect each part in the order given. If necessary, repair or replace these parts.
1. Headlamp and tail lamp

Switch motion Testing terminal Status
ON
1-2 ON
(gear lever is in reverse gear)
OFF 1-2 OFFSwitch position Testing terminal Status
OFF EL2-FF-RF OFF
Front foglight EL2-FF ON
Rear foglight EL2-FF-RF ONSwitch position Testing terminal Status
Low beam EL1-HL ON
High beam EL1-HU ON
PASSING EL1-HU-PASS ON (2) Check whether headlight dimmer switch is connected
Check whether terminals are connected when switch is in each position according to the table.
If it does not meet stipulation, replace the switch.
(3) Check whether direction indicator switch is connected
Check whether terminals are connected when switch is in each position according to the table.
If it doest not meet stipulation, replace the switch.
(4) Check whether front and rear foglight switch is connected
Check whether terminals are connected when switch is in each position according to the table.
If it doest not meet stipulation, replace the switch.
2. Reversing light switch assembly
Check whether reversing light switch assembly is connected
Check whether two terminals are connected when switch works
according to the tableSwitch position Testing terminal Status
Left turn FU-TL ON
Straight ahead FU-TL-TR OFF
Right turn FU-TR ON
If it doest not meet stipulation, replace the switch.
3. Brake lamp switch assembly
Check whether brake lamp switch assembly is connected
Check whether two terminals are connected when brake lamp
switch works
If it doest not meet stipulation, replace the switch.Step down brake pedal 1-2 ON
Release brake pedal 1-2 OFF2 1Light System -Light System Malfunction Inspection5-321
2 ON
OFFRelease PushSwitch motionTesting terminal Status

Section 4 Front Fog Lamp ReplacementI. Removal1. Remove front bumper. (see bumper replacement)
2. Remove electrical connector.
3. Remove fixed bolt (as shown in the figure).
4. Remove front foglight assembly.II. Installation1. Install front foglight assembly.
2. Mount fixed bolt.
3. Mount electrical connector.
4. Mount front bumper.
5. Adjust vehicle state.
6. Adjust front foglight beam.III. Replacement of front head light bulb Remove dust shield by rotating anticlockwise
Pull out bulb plug
Press and loosen steel wire clip
Pull out lamp holder, take off bulb
Replace bulbLight System -Front Fog Lamp Replacement5-351-Turn light dust shield
2-Low beam dust shield
3-High beam, front position lamp dust shieldIII. Replacement of front foglight bulb1. Press and rotate anticlockwise, take off dust hood
2. Take out bulb
3. Replace bulbIV. Adjustment of front foglight beam1. Adjust tire pressure in standard value
2. Start up engine
3. Turn on foglight switch
4. Adjust foglight beam turn screw to adjust foglight beam in the vertical direction.
Description:
Turn screwdriver anticlockwise to make beam upward, or turn screwdriver clockwise to make it downward.