2008 GEELY FC Workshop Manual

Preface
Geely “FC” is an automobile with high performance/price ratio and it meets the requirement
of national safety, energy saving, emission regulations and personal use. This automobile is
a completely new and excellent model produced by Zhejiang Geely Automobile Co., Ltd with
development in self-reliance of Geely group and with self-dominated intellectual property
right. It characterizes elegant appearance,
energy conservation and environmental protection,
safety and comfort. “FC” is a product opening a completely new viewpoint of automobile
selection, because it is developed on the basis of creative design thinking that breaks through
all established customs and it features perfectly balanced performance of power, space,
safety, manipulation and comfort. “FC” is a competitive product for Geely developing brand
and exploring mid-level automobile market, which takes over the company philosophy “make
good cars that common people can afford, and let Geely cars go to the whole world” of Geely
automobile. “FC” is combination of creativity and intelligence of quite a large number of
automobile experts, who have been developing and searching with great concentration for
more than 30 months, and it fully embodies persistent Geely style of fashion appearance
and high performance/price ratio.
“FC” is equipped with engine JL4G18 completely developed and produced by Geely group.
Engine JL4G18 applies the following advanced technology such as VVT, full aluminum cylin-
der body, plastic intake manifold, completely new VVT inside seal method, completely new
OCV valve filtering method etc. with M7.9.7 electric injection system of BOSCH, and its
index on power efficiency, economical efficiency, and safety efficiency etc. reaches leading
level of national model with the same type. This engine features strong power, low fuel
consumption, low noise and high power per liter etc.
We start to compile “FC” Automobile Maintenance Manual, which is divided into 27 sec-
tions with detailed description of overall structure and maintenance of engine 4G18.VVT;
inspection and repair of engine BOSCH M7.9.7 electric control fuel injection system; struc-
ture and maintenance of chassis; structure and maintenance of FC electrical equipment;
structure and maintenance of ABS anti-lock brake system; structure and maintenance of
SRS air bag; structure and maintenance of auto air conditioning system; structure and main-
tenance of vehicle body etc. Information is detailed and accurate, contents are in systematic
coherence and description is concise and comprehensive.
This manual is compiled from structure, which prompts “FC” service personnel to master

necessary maintenance, repair and malfunction knowledge on the basis of understanding
main structure characteristics and simple principle of vision automobile. Electric control sys-
tem of “FC” automobile is particularly described with detail, and detailed steps and methods
are given for trouble shooting process. All kinds of malfunction could be eliminated quickly
and efficiently within the shortest time as long as you detect as the repair steps of this manual.
In addition, this manual is compiled with the following characteristics: in proper sequence,
clear demarcations, easy to understand, excellent in picture and its accompanying essay,
simple and clear, which is very applicable for a quite large number of “FC” automobile main-
tenance technicians and service personnel to refer to.
This manual is mainly compiled by Geely International Corporation; Geely Automobile En-
gine No. 2 Plant and engineering technicians of service corporation help complete this work.
Defects and mistakes are inevitable in this manual for limited level of compiler and limited
time, please contact Geely International Corporation if you find mistakes and careless omis-
sions in using and we can correct in time and reverse in next version.
Geely International Corporation
Nov. 2007

This manual is mainly for qualified vehicle technicians, but it does not in-
clude all items on repair and maintenance.
In order to avoid personnel injury and vehicle damage caused by dangerous
operation, please observe the following regulations.
zPlease read this manual carefully, and particularly fully master all con-
tents in “Precautions”.
zMaintenance methods described in the manual are quite useful for vehicle
maintenance. Please adopt specified or recommended tools in maintain-
ing vehicle as steps described in this manual; maintaining vehicle with
tools or methods not specified or recommended in this manual will cause
personnel injury or vehicle damage. Therefore, please consider ensuring
the safety of technicians and vehicle at first before performing maintenance.
zIf it is necessary to replace parts, please replace with parts of the same or
similar size with original ones. It is forbidden to use inferior parts.
zIn order to effectively avoid technician injury and vehicle damage and hid-
den danger caused by incorrect operation, it is very important to observe
“Warning” and “Notes” in this manual. It particularly needs to mention that
not all precautions on safety are included in “Warning” and “Notes” etc. in
this manual. Therefore, please fully realize that perform maintenance not
as regulations will cause dangerous consequences.
Note

Brief introduction on Geely model “FC”
Basic parameters...................................................
1
Maintenance period
Regular maintenance items...................................
4
Table on maintenance period at normal conditions5
Table on maintenance period at severe conditions..
7
Engine control system
EFI system.............................................................
8
On-vehicle inspection........................................
8
Inspection..........................................................
9
Throttle body assembly........................................
13Removing, installing and disassembling, assembling...13
Fuel
Fuel system..........................................................
14
Precautions......................................................
14
On-vehicle inspection......................................
16
Inspection........................................................
17
Injection nozzle assembly....................................
18
Replacement...................................................
18
Fuel pump assembly...........................................
20Removing, installing and disassembling, assembling....20
Fuel tank assembly.............................................
21Removing, installing and disassembling, assembling.....21
Exhaust gas control
Exhaust gas control system...............................
23
On-vehicle inspection......................................
23
Inspection........................................................
25
Engine mechanism
Engine assembly..................................................
26Inspection........................................................
26
Drive belt..............................................................
29
Replacement...................................................
29
Valve clearance....................................................
30
Adjustment......................................................
30
Engine assembly.................................................
36
Replacement...................................................
36
Timing chain assembly.......................................
45
Replacement...................................................
45
Camshaft.............................................................
52
Replacement...................................................
52
Crankshaft front oil seal assembly.....................
60
Replacement...................................................
60
Crankshaft rear oil seal assembly......................
62
Replacement...................................................
62
Cylinder cover gasket components.....................
63
Replacement...................................................
63
Exhaust
Exhaust pipe assembly........................................
65Removing, installing and disassembling, assembling.....65
Cooling
Cooling system....................................................
66
On-vehicle inspection......................................
66
Inspection........................................................
66
Cooling fan system..............................................
68
On-vehicle inspection......................................
68
Inspection........................................................
68
Water pump assembly........................................
69
Replacement...................................................
69
Temperature regulator components...................
71
Replacement...................................................
71
Radiator with electronic fan assembly................
72Contents

Replacement...................................................
72
Coolant.................................................................
73
Replacement...................................................
73
Lubrication
Lubricating system...............................................
74
On-vehicle inspection......................................
74
Oil filter assembly.................................................
75
Replacement....................................................
75
Oil pump assembly...............................................
76
Replacement....................................................
76
Ignition
Ignition system.....................................................
77
Inspection........................................................
77
On-vehicle inspection......................................
77
Starting and charging
Starting system.....................................................
79
Inspection........................................................
79
Charging system..................................................
81
Precautions......................................................
81
On-vehicle inspection......................................
82
Alternator components..............................................
84
Replacement....................................................
84
Starter components..............................................
85
Replacement....................................................
85
Front suspension
Front suspension system....................................
86
Table on trouble occurrence...........................
86
Front wheel alignment.........................................
87
Adjustment......................................................
87
Front absorber and helical spring.......................
90
Overhaul..........................................................
90
Handling..........................................................
93
Lower left control arm assembly.........................
94
Replacement...................................................
94Front stabilizer bar...............................................
96
Overhaul..........................................................
96
Front left lower control arm ball joint assembly
..
99
Replacement...................................................
99
Rear suspension
Rear suspension system....................................
100
Table on trouble occurrence..........................
100
Rear wheel alignment.........................................
101
Adjustment.....................................................
101
Rear strut assembly...........................................
102
Overhaul........................................................
102
Handling.........................................................
104
Rear stabilizer bar..............................................
105
Overhaul........................................................
105
Rear shaft assembly...........................................
106
Overhaul........................................................
106
Tire and wheel
Wheel and tire system.......................................
109
Inspection......................................................
109
Drive shaft
Drive shaft.......................................................
111
Notes.............................................................
111
Malfunction phenomenon table....................
111
Inspection on automobile.............................
11 2
Front drive shaft.................................................
11 3
Overhaul........................................................
11 3
Left front shaft hub assembly............................
123
Change..........................................................
123
Left front shaft hub bolt......................................
128
Change..........................................................
128
Left rear shaft hub and bearing assembly........
129
Change..........................................................
129
Left rear shaft hub bolt.......................................
131
Change..........................................................
131

Brake
Brake system......................................................
132
Notes..............................................................
132
Remove malfunction...........................................
133
Malfunction phenomenon table.....................
133
Brake liquid.........................................................
135
Discharge the air in brake system.................
135
Brake pedal assembly........................................
136
Adjustment.....................................................
136
Change..........................................................
137
Vacuum booster assembly.................................
138
Inspection on automobile...............................
138
Change..........................................................
138
Front brake assembly.........................................
141
Overhaul........................................................
141
Rear brake assembly.........................................
144
Overhaul........................................................
144Hydraulic pressure control unit (equipping with ABS)...148
Inspection on automobile...............................
148
Change..........................................................
148
Speed sensor of front wheel..............................
151
Change..........................................................
151
Speed sensor of rear wheels...........................
152
Change..........................................................
152
Parking brake
Parking brake system.........................................
154
Malfunction phenomenon table.....................
154
Adjustment.....................................................
154
Parking brake handle assembly.........................
155
Change..........................................................
155
Parking front bake pull cable assembly............
156
Change..........................................................
156
Parking rear brake pull cable assembly...........
158
Change..........................................................
158
Parking brake assembly....................................
161
Overhaul........................................................
161Transmission
Disassemble assembly...................................
165
Assemble the assembly....................................
191
Steering column
Steering system..................................................
192
Note...............................................................
192
Malfunction phenomenon table.....................
192
Inspection on automobile...............................
193
Steering column system.....................................
194
Overhaul........................................................
194
Power steering
Power steering system......................................
198
Note...............................................................
198
Malfunction phenomenon table....................
199
Inspection on automobile.............................
200
Power steering oil pump assembly..................
203
Overhaul........................................................
203
Power steering gear assembly.........................
205
Overhaul........................................................
205
Air conditioner
Air conditioning system......................................
213
Note...............................................................
213
Inspection on automobile...............................
213
Inspection......................................................
214
Refrigerant..........................................................
215
Inspection on automobile...............................
215
Change..........................................................
221
Refrigerant pipeline............................................
222
Parts...............................................................
222Control assembly, air conditioner control panel (AUTO A/C)...223
Overhaul........................................................
223
Fan assembly...................................................
224
Overhaul........................................................
224
Air conditioner central heating core assembly..
227
Overhaul........................................................
227
Compressor assembly.....................................
234