roof GEELY MK 2008 Workshop Manual

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

Chapter 14 Outside Rearview Mirror................................................................................. 6-37
Chapter 15 Door Protecting Stripe.................................................................................... 6-38
Chapter 16 Carpet and Insulator....................................................................................... 6-39
Chapter 17 Moonroof Assembly (Optional)...................................................................... 6-40
Chapter 18 Plug List........................................................................................................... 6-42Part 7 BodyChapter 1 Survey................................................................................................................ 7-1
Section 1 Body Structure ................................................................................................ 7-1
Chapter 2 Body Repair....................................................................................................... 7-9
Section 1 Body Damage Forms and Requirements for Repair ...................................... 7-9
Section 2 Typical Technique of Body Panel Repair ....................................................... 7-16
Section 3 Repair After Body Damage ............................................................................ 7-16
Section 4 Features and Composition of Automobile Body ............................................ 7-24
Section 5 Painting Techniques After Body Repair ......................................................... 7-35
Section 6 Service Data For for Body .............................................................................. 7-36Attachment: Body Key Dimensions
Appendix: Torque Table of the Fasteners for Important AssemblyTable of Contents VI

Chapter 2 Usage and Maintenance of MK SeriesSection 1 Usage of MK Series1. Instrument Panel Overview1.Instrument Panel Outlet Vent
2. Instrument Panel
3.Upper Glove Compartment
(Front Passenger Airbag Cover)
4.Sunshade
5.Dome Light And Sunroof
Switch
6.Inside Rearview Mirror
7.Glove Box
8. Power Window Regulator
Switch
9. Manual Transmission Shift
Lever Or Automatic Transmis-
sion Shift Lever
10.Parking Brake Control Lever
11.Engine Hood Release Handle
12.Power Window Lock
13.Power Door Lock Switch1.Left Combination Switch
2.Right Combination Switch
3.Display
4.Audio
5.Short-Distance Odometer
Adjustment Button
6.Instrument Panel Brightness
Adjustment Switch
7.Hazard Warning Light
8.A/C Control Panel
9.Ash Tray
10.Defroster Switch
11.Cigarette Lighter
12.”A/C“ Switch
13.Ignition Switch
14.Tilt Steering Adjustment
Handle
15.Theft-Deterrent Indicator
16.Power Outside Rearview
Mirror Control SwitchUsage and Maintenance of MK Series - Usage of MK Series2-6

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

Transmission ControlAutomatic Transmission Shift Mechanism4-8Component ViewAutomatic Shifter Panel
Dust-Proof Sliding Plate
Gear Range Display
Shift Lock Release Button
Cap
Bulb
Button Spring
Gear Range Indicator
Wire Harness
Shift Lock Unit
Solenoid
Shift Lock Control ArmShift Lever Sub-AssemblyControl Shaft Key Retaining
Cable Control
Arm Slot Pin Shift Lever SupportHandle Connecting RodShift Lever Button Shift Lever Knob Cover
Spring Automatic Shift Handle
Spring Inner Rod
Precoated Part -

IV. Location of light systemRear reading light
High-mount stoplight
Rear combination light
Rear license light
Front reading light ( power sunroof )
Side turn light
Front foglight Front combination lightRear Radar
SensorLight System -Light System Introduction5-27

4. Danger alarm lamp switch assembly
Check whether danger alarm lamp switch is connected.
Check whether two terminals are connected when switch works.
If it doest not meet stipulation, replace the switch.
5. Door lamp switch (on fastener)
Check whether door lamp switch is connected
When switch works, check whether connection is established
between terminal and bodywork earthing.
If it doest not meet stipulation, replace the switch.
6. Trunk lamp switch assembly
Check whether trunk lamp switch is connected
When switch works, check whether connection is established between terminal and bodywork earthing.
If it doest not meet stipulation, replace the switch.
7. Front reading light assembly (with power sunroof)
Check whether terminals of indoor roof lamp assembly are
connectedSwitch motion Testing terminal Status
ON 1-2 ON
OFF 1-2 OFFSwitch motion Testing terminal Status
ON (door is closed) 1- GND ON
OFF (door is not closed) 1- GND OFF
Switch motion Testing terminal Status
ON 1- GND ON
OFF 1- GND OFFSwitch motion Testing terminal Status
ON 1-2 ON
OFF 1-2 OFF If it does not meet stipulation, replace roof lamp or switch.
8. Rear reading light assembly
Check whether back row reading light assembly is connected
When switch works, check whether two terminals are connectedSwitch motion Testing terminal Status
ON 1- 2 ON
OFF 1- 2 OFF If it doest not meet stipulation, replace the switch.211Light System -Light System Malfunction Inspection5-33

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

Symptom Possible cause
Fail to start Man made faultSpeed sensor1 2 3Fault symptom Common cause
Dischrge overproof, increased oil consumption Man made fault5-1234#(black) pin respectively, now voltage should fluctuate quickly between 0. 1-0. 9V.
6. Speed sensor
(1) Use with oscillator. Oscillator is a fluted disc, originally has 60 teeth, but two teeth are absent. Oscillator
is mounted on crankshaft, and rotates with the crankshaft. When tooth tip passes by sensor end closely, the
oscillator which is made of ferromagnetic material cuts magnetic line of permanent magnet in the sensor, and
generates induced voltage in coil, which is output as rotating speed signal. Mounting torque: 8 ± 2 N.m
Repair precautions: use pressing in instead of hammering method for installation during repair.
(2) Simple measuring method:
(Remove joint) turn digital multimeter to ohm position, connect
two meter pens with sensor 2#, 3# pins respectively, rated resistance
at 20°C is 770-950 ohm.
(Connect joint) turn digital multimeter to AC voltage position,
connect two meter pens with sensor 2 #, 3# pins respectively, start up
engine, now voltage output should be available.
Suggestion: use oscillograph for vehicle use to check.
7. Phase sensor
(1) This sensor consists of a hall sensor and a rotor made of steel plate. Fix hall sensor, mount rotor on camshaft.
Rotor is a 180( range cylindrical face steel blade. When the blade covers hall sensor, high Level signal is output;
otherwise low level signal is output. This differentiates two different upper dead points. Repair precautions: avoid removing end cover as far as possible during repair, so as to avoid ingress of foreign
matter, which might result in abnormal damage of magnetic gate.
(2) Simple measuring method:
(Connect joint) turn on ignition switch but not start up engine, turn digital multimeter to DC voltage position,
connect two meter pens with sensor red, black conductors respectively, ensure reference voltage of 5V is available.
Start up engine, voltage output between green and black conductors should be available.
Suggestion: use oscillograph for vehicle use to check.
8. Idle speed regulator
(1) Idle speed regulator consists of a step motor and a sealing plug on its shaft, sealing plug may generate radial
displacement driven by step motor shaft, position of sealing plug determines extent of opening of by-pass airway,
so as to adjust the size of by-pass air quantity. Position of sealing plug is controlled by ECU output.Fault symptom
Too high idle speed, flameout at idle speedPossible cause
Since interior contamination is severe, regulating element
is blocked and leads to malfunction.
Repair precautions: dust and sand grain will result in damage of idle speed regulator. Intake air should be
filtered by dry air cleaner before entering idle speed regulator, filtration efficiency should exceed 99 %. ToEngine EFI System-Engine EFI System

Engine ECU5-126as to avoid damaging electronic control unit.
(1) Simple measuring method:
(Remove joint) turn digital multimeter to ohm position, connect two meter pens with primary winding pinsrespectively, rated resistance at 2 0°C is 0. 4-0. 6 ohm for 2X2 type; on secondary winding, 11-15k ohm for 2x2 type.13. Electronic control unit ECU
Possible cause
Electric overload of externally connected
device leads to burnout of components inside
ECU and results in malfunction Symptom
Unsteady idle speed, poor speedup, failure to start, too high
idle, tail gas overproof, difficult to start, malfunction of air
conditioner, malfunction of fuel injector control, flameout
Repair precautions:
1. Don't remove ECU at discretion during repair;
2. ECU may be removed more than 1 minute after removing storage battery head;
3. Store removed ECU properly;
4. It is prohibited to attach any circuit onto connecting wire of ECU.
Simple measuring method:
1. (Connect joint) use engine data K-line to read engine trouble record;
2. (Remove joint) check whether ECU connecting wire is in good condition or not, mainly check whether ECU
power supply grounded circuit is normal or not;
3. Check whether external sensor works normally, whether output signal is credible, whether circuit is in good
condition;
4. Check whether actuator works normally, whether its circuit is in good condition;
5. Finally replace ECU to conduct test.
Judgment principle: "two interchange principle" ---interchange ECU, interchange fault symptom.III. Diagnostic system Description:
When engine ECU detects a trouble, engine trouble warning lamp on instrument will illuminate. In addition,
relevant diagnostic code will be recorded in ECU memory. Connect handheld tester with diagnostic interface on
automobile, read various data from automobile ECU. Connect handheld tester with diagnostic interface. Technical
personnel may also read fault code via blinking of instrument fault warning lamp.Engine EFI System-
Engine EFI System