steering 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

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

II. Introduction of major systems Table 2 Models and technical data of major systems.
JL7132U JL7152U JL7162U JL7132HU JL7152HU
4
MR479Q MR479QA MR481QA MR479Q MR479QAIn-line 4 cylinder In-line 4 cylinder In-line 4 cylinder In-line 4 cylinder In-line 4 cylinder78.7 78.7 81.0 78.7 78.7
69.0 77.0 77.0 69.0 77.0
1.342 1.498 1.587 1.342 1.498
9.3 : 1 9.8 : 19.6 : 19.3 : 1 9.8 : 1
63/6000 69/6000 78.7/6000 63/6000 69/6000
110/5200 128/3400 137/4400 110/5200 128/3400
800±50
1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
259 279 269 259 279
JL-S160 JL-S160A JL-Z110 JL-Z130
3.182 3.087 3.087
1.895 1.634 1.634
1.250 1 1
0.909 / /
0.703 / /
3.083 2.29 2.29
4.308 3.317 3.317
Hydraulic Gear-rack
Hydraulic, X-type pipe
Vacuum booster, Front Wheel Disc, Rear Wheel Drum
McPherson suspension strut system
Twist beam independent suspension system
85/60R15(1175/65R14)
230(Front)/210(Rear)
Aluminum 15X6J (Iron 14X5 1/2JJ)
45
Unitary construction body Unit
mm
mm
L
kw/r/min
N.
m/r/min
r/min
g/kw.
h
KPa
L Item Description
Drive Type ID
1
2
3
4
5
6
7
8
9
10EngineModel
Type
Bore Diameter
Piston play
DisplacementCompression RatioMax Power
Max Torque
Idle Speed
Ignition Sequenceminimum fuel consumption rateTransmission
Braking
system
suspension
Tire Clutch Type
Steering type
Model
Booster type
Front
Rear
Specification
Tire pressure
Wheel
Fuel Tank Capacity
Body structureSingle disc, Plate and dry SpringBrief Introduction of Geely MK - Major Functional and Technical Data of MK Series.2-2Model
1st gear
2nd gear
3rd gear
4th gear
5th gear
Reverse gearFinal Drive Ratio /Front Wheel Drive ›‹
2
800±50800±50
800±50
800±50

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)

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

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