2008 GEELY CK ABS

292Section 3 Removal and InstallationI.Precautions for Removal1. Use the scan meter to locate the fault causes before proceeding to service.
2. wipe the surface clean with the cleaning agent without mineral oil before service; be careful to keep it
clean during service, only the lint-free cloth can be used to wipe the removed parts.
3. Only the original spare part can be used, and the package of the new spare part shall not be removed until
the installation.
4. Return liquid pump motor and the HCU is a type of integral structure and can not be separated.
5. When the system is opened, do not use compressed air or move the vehicle.
6. Use proper plug to clog each hydraulic outlet as soon as the ABS assembly is removed.
7. Remove other components that may interfere.
8. Please use the DOT 4 brake fluid, do not use the mineral oil.
9. Use the brake fluid to immerse the seal and the O ring, do not use the engine oil or brake grease.
10. After service, check the regular brake system and ABS brake function for normal and reliable operation.
11. Check all hydraulic pipe union for leakage.II. HECU Removal1. Turn off the ignition switch and disconnect the battery negative ground cable.
2. Remove the wire connector from the ABS HECU assembly.
3. Depress the brake pedal >60mm and hold it with the pedal retainer to close the master cylinder center
valve so that the brake fluid will not flow out from the outlet when the system is opened.
4. Put a clean cushion under the hydraulic regulator.
5. Remove the brake pipe (A, B) on the HCU connected to the master cylinder and place the mark, then
use a plug to clog the outlet immediately.
6. Remove the brake fluid pipe(1-4) leading to the wheels, then use a plug to clog the outlet immediately.
7. Remove the nut attaching the HECU to the bracket.

2938. Remove the whole HECU from the bracket.
ABS HECU Assembly
ABS HECU Brake Pipe Removal Schematic

295V. ABS Assembly ReinstallationNote: the plug of the ABS assembly hydraulic outlet can only be removed after the brake pipe is
installed, lest the foreign object will enter the brake system.1. Install the ABS assembly to the bracket, tighten the torque: 20+4Nm.
2. Remove the plug of the hydraulic outlet, installed the brake pipe. Make sure that the brake pipe is
correctly installed.
3. Install the brake pipe connected to the master cylinder.
4. The brake pipe torque is 12+4Nm (M10 x 1) and 15+3Nm (M12 x 1).
5. Fill the new brake fluid into the reservoir until the liquid level reach the MAX and bleed it as specified.
6. With the ignition switch ON, ABS Warning Light must goes on for 1.7 seconds then goes off.
7. Clear the DTC memory, check if there is DTC again.
8. Drive the vehicle to confirm the ABS function (you must feel that the pedal rebound).VI. ECU ProgramNote: when replacing the HECU or ECU, you shall program the new ECU, otherwise the ABS
Warning Light flashes and the system can not operate normally.Use the scan meter to program the ECU based on the following procedure:Connect the scan meter with the diagnostic interfaceSelect function 07, Press OK button to confirmEnter code 01901 and Press OK button to confirmSelect function 07, Press OK button to confirm, quit the diagnosticEnd

297Part IV Air Conditioner and Inside &
Outside TrimChapter 1 A/C SystemA/C system consists of refrigerating and heating system. The Refrigeration system mainly comprises
compressor, condenser and evaporator. The refrigerant circulation absorbs the heat in the air and discharge
the vapour to lower the temperature in and dehumidify the compartment. The heating system is mainly
composed of heat exchanger and heater. It heats the compartment throught the heat exchanger by heating
the air with the heat from the cooling water in the engine. The control of air temperature, humidity and
velocity of flow in the compartment is realized by independent or joint working of heating and Refrigeration
system.Section 1 The Structure & Working Principle of Refrigeration SystemThe structure of Refrigeration system is shown in Figure 1.
Figure 1 The Structure and Working Principle of Refrigeration System
1. Compressor 2. Condenser 3.Receiver/Drier
4.Pressure Relief Valve 5.Expansion Valve 6.Evaporator 7.Blower
Refrigeration system uses vapor compressing refrigeration cycle, comprising the compressor, condenser,
pressure relief valve, evaporator, blower , expansion valve, receiver/drier and pipe.
It's working principle is as shown in the Figure 1. The compressor (1) sucks in the refrigerant gas in the

298evaporator (6) via the expansion valve (5) for compression and generates high temperature and pressure
vapor which then is cooled into liquid through the condenser (2) and dried in the receiver/drier (3), then
restrict the expansion valve and enable certain amount of refrigerant liquid to be vapored into low tempera-
ture and pressure vapor in the evaporator, meanwhile, absorb large amount of heat and perform heat ex-
change with the air sucked in by the blower, then distribute the cooled air to the vehicle compartments. Cycle
the operation until the compartments gets the desired temperature.
See Table 1 for the Refrigeration system parameter.
Table 1 Refrigeration system parameterParameter
Control the mixture of c ool and hot air
N o m in a l R e f r ig e r a t io n / W 4 2 0 0
Displac ement/(mL/r) 108
Model SW-5H11
Elec tromagnetic Clutc h Pow er Diss ipation/W 45
SW-100/135
Maximum Airflow /(m3/h)400
Airflow adjustment 4th Shift Manual
Motor Pow er Consumption/W 180
Dimension/mm 18×302×630
Heat Exchange/W 9400
Air Resistance/Pa
≤156
Fan Motor Current/A
≤8
Fan Motor RPM /(r/min) 2900±200
Dimension/mm 86×213×235
Refrigeration/W 4200
Thermal Expansion Valve Inner Balanc e 1.5 ton
4PK830
630±20 Re f r ig e r a n t F ill/ g Blo w e r
Condens er
Evapor ator
D r iv e b e lt Item
Temperature adjustment method
Compr es s or
Lubric ant /mL

305•Compared with the early used mineral oil, the SW-100 type compressor oil is of comparatively high
moisture absorption performance. If you mix the moisture object with the SW-100 type compressor oil, it
will damage the Refrigeration system. Therefore, after treating the compressor oil or removing the
refrigeration system components, the lid shall be covered immediately to prevent the SW-100 type
compressor oil from absorbing the moisture.Section 5 The Refrigeration System Operation ProcedureI. Refill RefrigerantNotice:•During the filling of refrigerant into the refrigeration system, be careful that it is required to
have the professionals operate under the specified standard and procedure, otherwise it will
reduce the A/C efficiency greatly and even damage the refrigeration system components.
Refill the HFC-134a refrigerant
Refill Preparation1. Install the inflating equipment.
2. Connect the low pressure tube to the low pressure
refill valve.
3. Connect the high pressure tube to the high pressure
refill valve.
4. Connect the intermediate tube to the vacuum pump.Vacuumization:1. Open all valves.Notice:•Close all valves of the manifold gauge immediately after the vacuum pump stops operation. If
the valve is still open after the vacuum pump stops operation, then the vacuum pump oil will
return to refrigerant circulation loop and reduce the A/C efficiency.2. Start the vacuum pump and run it for 15min.
3. Check if the readings at high and low sides of the manifold gauge fall within the range of -101 kPa{-760
mmHg }. Close the valves of the manifold gauge.Check the air tightness:1. Stop the vacuum pump and have it wait for 5min.
2. Check the high pressure side of the manifold gauge and the reading at the low pressure side.
•Check for leakage if the reading changes and vacuumize it again.
•Refill the new HRC-134a refrigerant if the reading doesn't change.To low pressure fill valveLow Pressure GaugeHigh Pressure
GaugeConnect the high
pressure refill valveLow Pressure TubeHigh Pressure TubeLow Pressure
Manual ValveHigh Pressure
Manual ValveVacuum PumpIntermediate Tube
Refrigerant Steel Jar

360(I) Front Sheet Metal, Cowl PartsThe main function of the front sheet metal and the cowl parts is forming an engine compartment to supply the
engine and accessories with a protective cover and to absorb the most energy when vehicle encounters
frontal impaction, protecting mud from being splashed by the front wheels, and meeting the requirements of
body design in appearance. It is mainly composed of front cross member assembly, LH/RH front mud guard
and front side member assembly, engine hood front support plate assembly, hood lock bracket assembly,
cowl assembly, cowl upper assembly.
1. Front Cross Member Assembly
The front cross member assembly is mainly composed of the front cross member welding sub-assembly,
front cross member bottom plate assembly, LH/RH side member end plate by welding them together, and its
dismantle diagram as shown in the Figure 5-2.
2. Lh/Rh Front Mudguard And Front Side Member Assembly
LH/RH front mud guard and front side member assembly is mainly composed of LH/RH front mudguards
and LH/RH side members by welding them together.
It is mainly used to mount some mounting brackets such as the engine LH/RH side suspension bracket, LH/
RH front suspension shock absorber bracket, etc. and to mount the LH/RH front fenders.
3. Engine Hood Front Support Plate Assembly
Engine hood front support plate is mainly composed of LH/RH headlamp mounting bracket assembly, hood
front support plate sub-assembly, and LH/RH front support plate reinforcement, by welding them together.
Engine hood front support plate assembly is used to mount radiator, engine hood lock, radiator grille, front
bumper, and headlamp.
4. Engine Hood Lock Bracket Assembly
Engine hood lock bracket assembly is used to mount the engine hood lock, also to strengthen the intensity and
rigidity of the front body by connecting the engine hood front support plate and front cross member.
5. Cowl Assembly
Cowl assembly is mainly composed of cowl inner and outer plate assembly and cowl lower cross member, by
welding them together.
Cowl assembly and front floor, LH/RH front mud guard (LH/RH front pillar), cowl upper baffle is welded
together, which forms a framework with great torsional strength. It generates great resistance to lateral
impact and rolled deformation.
Cowl inner and outer plate assembly is sandwich structure. 3mm of asphalt plate lies in the interlayer, which
is to cut off the noise and heat generated from the engine.

3812 Adopt sound insulating material to reduce the noise in the compartment.
For the heat, vibration and sound insulation of the body, they are a systematic engineering. Besides you
take measures on effectively improving the rigidity of the body and sealing technique, the following
measures can be taken in the body design and manufacturing:
a. Sound insulating material: paste a layer of asphalt board on the floor and FR/RR fenders. Add
insulation pads on the cowl and the floor.
b. Sound absorbing material: adopt formed carpet which is composed of front floor carpet and rear
floor carpet.
The FR/RR floor carpets are integrated with the floor and sound absorbing pad. It is required that the
floor and the pad will not peeled when torn by outside force.
3. Sealing
An elaborate concern is taken from design and manufacturing on the body sealing. Sealing is very important
for the operation performance of dust prevention, water proofing, corrosion prevention, heat protection, heat
preservation, noise reduction, etc. Especially, the floor and cowl are located in the harshest outside environment.
The mud splashing from road, dust and sand, wheel noise, engine noise and hot air will get in the interior
environment by every opening.
After the body assemble welding completes, apply a line of sealant on all joints of the body to avoid water and
vapor permeating into the metal joint and also to ensure the quality for the following painting.(Figure 5-25).
Besides, a layer of stone-strike proofing paint is applied on the bottom of the body. The paint has good sealing
effect. For the sealing of mounting parts on the body, traditional methods are generally adopted, such as
rubber sealing ring, cover, rubber strip, special-shaped sealing strip, etc. But in order to make more minute
and rigorous considerations in design and manufacturing of structural parts and the stability of the dimension
relationship of contacting sealing. For windshield and rear back door glass, a natural-curing high-tensile
sealant is adopted in sealing. It represents the advanced modern techniques in reliability and mounting technology.5-25 1. 2. 3. Figure 5-39 Area Where Chloride Ethylene Plastisol Is Applied
1. Front Mud Guard 2. Rear Side Wall 3. Rear Wheel HouseFront