2008 GEELY FC Workshop Manual

Brake--Remove malfunction
1. Brake block (damaged or distorted). 141, 144
2. Assembled nut (loose). 141, 144
3. Brake disk (scratched). 141, 144
4. Support sheet of brake block (loose). 141, 144
Brake noise 5. Sliding pin (abraded). 141, 144
6. Brake block (oil dirt). 141, 144
7. Brake block(sclerosesed). 141, 144
8. Support pin or return spring (invalid). 161
9. Muffle gasket (damaged). 141, 144
10. Localizing spring (damaged). 161Malfunction phenomenon Possible malfunction part Reference page134

Brake--Remove malfunction1. Add brake liquid in storage tank.Brake liquid: DOT-42. Discharge the air in brake main pump.Hint: if brake main pump or liquid storage tank is
disassembled, it is necessary to discharge the air in
brake main pump.
(a) Disassemble brake pipeline of brake main pump.
(b) Step down brake pedal slowly and keep this state.
(c) Plug oil hole with finger, then release brake pedal.
(d) Repeat (b) and (c) three times or four times.3. Discharge the air in brake pipeline.(a) Connect plastic pipe on exhaust bolt of brake branch pump.
(b) After stepping brake pedal several times, and step down
brake pedal, then release inflating bolt to discharge air.
(c) Lock exhaust bolt until brake liquid stops flowing out, then
release brake pedal.
(d) Repeat (b) and (c) until air is discharged completely.
(e) Repeat the procedure above, and release the air in brake
pipeline of every wheel.
Torque: 12.7-17.6 N
⋅ ⋅⋅ ⋅
⋅m4. Check the brake liquid storage tankCheck the liquid level in storage tank, if necessary, add brake
liquid.
Brake liquid: DOT-4.Brake liquidDischarge the air in brake systemHint: if any part of brake system has been damaged or
you disbelieve whether there is any air in brake pipeline,
it is necessary to discharge the air in brake system
completely.
Note: do not make brake liquid spill on paint surface, if
having, wash it cleanly.135

Brake--Remove malfunction2. Check the free travel of pedal.(a) Extinguish the engine, and step brake pedal repeatedly until
there is no vacuum in vacuum booster.
(b) Press down pedal with hand until feeling the resistance,
then measure the distance of this section, liking that shown
in figure.
Free travel of pedal: 1-6mm.
If it is wrong, check the clearance of brake light switch.
Clearance of brake light switch: 0.5-2.4mm
If the clearance accords with the regulation, remove the
malfunction in brake system.3. Check the distance from pedal to floor.Release parking brake drag lever
When engine is running, step down brake pedal, then mea-
sure the distance from pedal to floor, liking that shown in figure,
Force 490 N on pedal, its distance from floor should be:
over 60mm.
If it is wrong, remove the malfunction in brake system.Brake pedal assemblyAdjustment1. Check and adjust the height of brake pedal.(a) Check the height of brake pedal.
Pedal distance from floor: 136.0-146.0mm
(b) Adjust the height of brake pedal.
(1) Disassemble lower trim board of panel.
(2) Disassemble switch joint of brake light.
(3) Loosen locking nut of brake switch, and disassemble
the switch of brake light.
(4) Loosen U-shaped clasp fixing nut of pedal lever.
(5) Turn pedal lever to adjust the height of pedal.
(6) Lock the fixing nut of lever.
Torque: 26
± ±± ±
±2 N⋅ ⋅⋅ ⋅
⋅m
(7) Assemble the switch of brake switch.
(8) Connect the switch joint of brake light.
(9) Press down the brake pedal for 5-15mm, and turn the switch of brake light to illuminate brake light,
then lock the nut.
(10) After assembling, press down the brake pedal for 5-15mm again, and confirm brake light has
illuminated.Pedal distance
from floorFree travel of
pedal Height of pedal Push rodBrake light switch136

ChangeHint: after assembling, check and adjust the height, free travel of brake pedal and the height from
pedal to floor.Brake--Remove malfunctionBrake pedal bracket
Brake pedal bushing
Brake pedal shaft
Locking shaft
Brake main pump lever pin
Brake pedal Brake pedal
Rubber gasket137 N.
m: Regulated torqueDo not use the part repeatedlyLithium soap base glycol lubricating grease

Brake--Vacuum booster assemblyVacuum booster assemblyInspection on automobile1. Check the vacuum booster(a) Check the gas sealed performance.
(1) Start the engine, and extinguish after one or two minutes,
then step and release brake pedal slowly several times.
Hint: if the first step is lowest, second and third step
rise gradually, and this shows the gas sealed per-
formance of booster is normal.
(2) Step down brake pedal when engine is running, then
extinguish the engine.
Hint: if the distance from pedal to floor does not
change in 30 seconds, this shows gas seal perfor-
mance of booster is normal.
(b) Working inspection.
(1) When engine is at parking state, step brake pedal sev-
eral times to check brake pedal.
The height from floor should not change.
(2) Step down brake pedal, then start the engine.
Hint: if pedal drops a little, this shows working is
normal.2. Check vacuum check valve(a) Check vacuum check valve.
(1) Remove pipe clamp, and disassemble vacuum pipe.
(2) Disassemble vacuum check valve.
(3) Blow air to check: in the direction from booster to engine,
the check valve should ventilate, but its opposite direc-
tion should not ventilate.
(4) If finding any malfunction, change vacuum check valve.Change1. Discharge brake liquidNote: do not spill the brake liquid on paint surface of automobile body, if having, wash it cleanly.2. Disassemble air filter assembly [64000033]
3. Disassemble carbon canister assembly [4G18-1129020]
4. Disassemble brake main pump subassemblyGood
Bad
FirstSecondThird
Con-
ductionNot con-
duction138

5. Disconnect the U-shaped joint of brake main pump
lever(a) Release fixing screw cap of lever U-shaped joint.
(b) Disassemble locking pin of U-shaped joint and lever pin of
brake main pump.6. Disassemble left front wheel
7. Disassemble vacuum booster(a) Use special tool and wrench to disassemble brake hose of
left front wheel.
(b) Disassemble the bolts, two screw caps and activated car-
bon canister bracket.
(c) Disassemble vacuum hose on vacuum booster.
(d) Disassemble four screw caps and U-shaped joint.
(e) Take out vacuum booster and gasket.8. Assemble vacuum booster with brake pump assem-
bly [64000164](a) Assemble U-shaped joint on booster lever.
(b) Assemble new gasket and vacuum booster with four nuts.
Torque: 13 N
⋅ ⋅⋅ ⋅
⋅m
(c) Connect vacuum hose to vacuum booster.
(d) Use the bolts and nuts to assemble carbon canister bracket.
Torque: 5.4 N
⋅ ⋅⋅ ⋅
⋅m
(e) Use special tool and wrench to connect brake hose of left
front wheel.
Torque: 15
± ±± ±
± 2 N
⋅ ⋅⋅ ⋅
⋅m9. Assemble left front wheelTorque: 103
± ±± ±
± 10 N
⋅ ⋅⋅ ⋅
⋅mBrake--Vacuum booster assembly139

Brake--Vacuum booster assembly140 10. Connect brake main pumpAssemble U-shaped joint pin in U-shaped joint and brake pedal, and assemble fixing clamp to U-shaped
joint pin.11. Assemble brake main pump
12. Assemble carbon canister assembly [4G18-1129020]
13. Assemble air filter assembly [64000033]
14. Add brake liquid in liquid storage tank
15. Discharge the air in brake main pump
16. Discharge the air in brake system
17. Check and adjust the height of brake pedal
18. Check the pedal free travel
19. Check the height from pedal to floor
20. Check the liquid level in storage tank
21. Check whether the brake liquid leaks

Brake--Front brake assemblyFront brake assemblyOverhaul1. Disassemble front wheels.
2. Discharge brake liquid.Note: do not spill the brake liquid on paint surface of automobile body, if having, wash it cleanly.3. Disassemble brake branch pump assembly.(a) Disassemble the bolts and gaskets of brake hose joint on
brake branch pump, then disassemble brake hose.
Hint: the gasket has two types: two sheets type or one
type.
(b) Fix sliding pin of cylinder body to disassemble two bolts.4. Disassemble brake block of front wheels.(a) Disassemble brake block with muffle gasket.
(b) Disassemble muffle gasket from every brake block.5. Disassemble support sheet of brake block.
6. Disassemble sliding pin of brake branch pump.Disassemble sliding pin on branch pump bracket.7. Disassemble dustproof cover on brake branch pump.Disassemble two dustproof covers from brake branch pump
of disk.8. Disassemble left front brake branch pump.Disassemble two bolts and brake branch pump bracket.9. Disassemble dustproof cover of branch pump.Use screw driver to disassemble oil seal loop and dustproof
cover.10. Disassemble the piston of brake branch pump.(a) Put a cloth or similar thing between piston and branch pump.
(b) Use compressed air to disassemble piston from branch
pump.
Warning: when using compressed air, do not put your
finger at the front of piston.
Note: you could not be splashed by brake liquid.11. Disassemble oil seal of piston.Use screw driver to disassemble oil seal of piston from branch
pump.12. Disassemble exhaust bolt of branch pump.Brake branch pump
Dustproof cover141