wheel 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 Instruction1-103.Precautions for Use of Jack and Safety Stand
(1)always use the wheel stoppers when performing servicing on
level ground.
(2)use safety stand and rubber support as shown in the illustration.
(3)use the jack and safety stand to support specified location.
(4)When jacking up the front wheels of the vehicle, release the
park brake and place stoppers only behind the rear wheels. When
jacking up the rear wheels, place stoppers only before the front wheels.
(5)During the job, make sure to use safety stand instead of jack
only to support the vehicle.
(6)When only jacking up the front wheels or rear wheels, place
stoppers before or after the wheels touching the ground.
(7)when lowering the vehicle with its front wheels lifted, release
the park brake, and place the stopper only before the rear wheels.
When lowering the vehicle with its rear wheels lifted, place the stop-
per only after the front wheels. the opening of the removed inlet system parts and the engine with a
clean shop lag or gum tape.
(3)When installing the inlet system parts, check that there is no
mixing of a metal scrap.
5. Handling of Hose Clamp
(1)Before removing the hose, check the clamp position to re-tighten
it for sure.
(2)Replace a deformed or dented clamp with a new one.
(3)In case of reusing the hose, install the clamp on the hose where
it has a clamp track.
(4)For a steel band circlip, make it adjust by adding force to the
arrow mark direction after the installation.II. Vehicle Lift and Support Location1. Vehicle Conditions To Be Under Attention During Lift
(1)Generally speaking, when being lifted, the vehicle should be empty, do not lift the heavily loaded vehicles.
(2)When removing heavy parts such as engine and transmission, the center of gravity of the vehicle will move.
Place balance weight to prevent the vehicle from rolling or use special jack to support the vehicle.
2. Precautions for Use of Four-tappet Lift
(1)follow the safe operation instruction described in this manual.
(2)do not damage the tire or rim.
(3)use wheel stopper to retain the vehicle.Rubber SuportSteel Band Circlip
Clamp Trace

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'

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

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)

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