2008 GEELY FC ignition

Engine mechanismEngine assemblyInspection1. Check coolant.
2. Check engine oil.
3. Check battery.
4. Check air filter assembly.
5. Check spark plug [4G18-3705113].
6. Check drive belt [4G18-1307107].Hint: do not check belt tension, because automatic tensioner is applied.7. Check ignition timing.(a) Warm up engine.
(b) Connect timing lamp to engine.
(c) Check ignition timing at idle speed.
Ignition timing: before top dead center Note: when checking ignition timing, place
transmission at neutral position.
Hint: After run the engine for 5 seconds with rotating
speed of 1000-1300rpm, check the engine could
recover to idle running.8. Check engine idle speed.(a) Warm up engine and run it at idle speed.
(b) Read engine rotating number in data flow with diagnostic instrument.
(c) Check idle speed.
Idle speed: about 750-850rpm
Notes:When checking idle speed, place cooling fan at OFF position.Turn off all auxiliary devices and air conditioner.Engine mechanism - Engine assemblyK-line 26

9. Check compression pressure.(a) Warm up engine.
(b) Remove ignition coil.
(c) Remove spark plug.
(d) Check cylinder compression pressure.
(1) Install cylinder compression pressure gauge on spark plug hole.
(2) Wide open throttle.
(3) Measure the pressure during crankshaft rotating.
Notes:Ensure to use fully charged battery to make the rotating speed of engine reach or exceed 250rpm.When measuring other items, please repeat steps (1) to (3). Finish the measurement as soon as possible.
Compression pressure: 1080kPa
Min pressure: 1000kPa
Difference among cylinders: 100kPa
(4) If the compression pressure of one or more cylinders is too low, inject a small amount of engine oil
from spark plug hole into the cylinder with low pressure, and repeat steps (1) to (3) to check
pressure.If the pressure increases after engine oil is injected, the piston ring of this cylinder or the
cylinder has been worn or scratched.If the pressure is still too low, the valve may be stuck or not fully closed, or the cylinder head
gasket leaks.10. Check CO/HC.(a) Start engine.
(b) Keep the rotating speed of engine at 2500rpm for about 180 seconds.
(c) When the engine is idle running, insert the test bar of CO/HC gauge into exhaust pipe at least 40cm.
(d) Immediately check idle speed and CO/HC concentration at 2500rpm.
Hints:Finish test within 3 minutes.Perform the test under 2 analog states (idle speed and 2500rpm) according to measuring meth-
ods and sequences specified by Emission Regulations.
(e) If CO/HC concentration is not within specified value, perform trouble shooting according to the
following sequences.
(1) Check the function of oxygen sensor.
(2) See possible failure causes listed in the table below, and repair and correct if necessary.Engine mechanism - Engine assembly27

Engine mechanism - Engine assemblyCO HC Trouble occurrence Possible causes 28 Normal HighUnstable idle speed
Low HighUnstable idle speed
(HC readings not stable)
High HighUnstable idle speed
(black smoke emission)1. Ignition system malfunctionIgnition timing incorrect Spark plug too dirty, short circuit or clearance
incorrect
2. Valve clearance incorrect
3. Air inlet and exhaust valve leaky
4. Cylinder leaky
1. Vacuum leak:PCV hoseIntake manifoldThrottle bodyIdle speed stepping motorVacuum booster and pipelines
2. Fire caused by too thin mixing ratio
1. Air filter core blocked
2. PCV valve blocked
3. EFI system malfunctionFuel pressure regulator malfunctionWater temperature sensor malfunctionIntake pressure sensor malfunctionECU malfunctionInjection nozzle malfunctionThrottle position sensor malfunction

Engine mechanism - Valve clearanceValve clearanceAdjustment1. Remove engine plastic hood components.
2. Remove ignition coil components [4G18-3705110].
3. Remove cylinder head cover components [4G18-
1003130].
4. Remove engine right bottom shield.
5. Turn crankshaft to cylinder 1 compression top dead
center position.(a) Turn crankshaft pulley to align its groove with “o” mark on
timing chain hood.
(b) Check dot marks on camshaft timing sprocket and VVT
timing sprocket, and they should be in a line on timing chain
hood surface as shown in the diagram.
Hint: if not, turn crankshaft for one circle again
and align the above marks.6. Check valve clearance.(a) Only check the valves shown in the diagram.
(1) Measure the clearance between valve tappet and cam-
shaft with plug gauge.
(2) Record valve clearance measuring value exceeding
specification, and this value will be used to determine
valve tappet thickness that needs change.
Valve clearance (cold vehicle)Intake airExhaust(b) Turn crankshaft for one circle ), and cylinder 4 is
turned to compression top dead center position.
(c) Only check the valves shown in the diagram. Measure valve
clearance (see step (a)).7. Remove drive beltSlowly turn drive belt tensioner clockwise to loosen it.
Then remove drive belt and put back drive belt tensioner slowly
and gently. 30 Mark
Mark
Mark
Timing chain
hood surface
Groove

34. Remove power steering pump assembly.
35. Remove sub frame together with side member.(a) Remove front engine mounting assembly and rear en-
gine mounting assembly from engine assembly.
(b) Remove sub frame assembly.36. Remove starter mounting components
[4G18-3708100].
37. Remove transmission assembly.(a) Fix crankshaft with special tool, ant then remove 6 bolts.
(b) Remove transmission assembly.38. Remove clutch assembly [4G18-1601000]
and flywheel components [4G18-1005120J].(a) Fix crankshaft with special tool, ant remove clutch
assembly at first.
(b) Then remove flywheel components.39. Remove throttlesupporting plate [4G18-1008202].
40. Remove intake manifold assembly [4G18-
1008200].(f) As shown in the diagram, install front and rear hooks of
engine.
Torque: Hint: install engine hooks to front and rear sides of
engine.
(g) Lift engine assembly with chain pulley block and en-
gine lifting device.Engine mechanism - Engine assemblySpecial tool39 41. Remove exhaust manifold upper heat shield components [4G18-1008120].
42. Remove exhaust manifold assembly [4G18-1008100].
43. Remove fuel rail injector assembly [4G18-1112100].
44. Remove ignition coil installation components.
45. Remove oil level gauge tube components [4G18-1002140].
46. Remove temperature regulator assembly [4G18-1306100].
47. Disassemble warm air water outlet pipe components [4G18-1300100].
48. Remove oil pressure alerter [4G18-3757100].Remove oil pressure alerter with SST.49. Remove the hoses on all hose joint of engine.Remove clips and hose.50. Remove drive belt tensioner device.
51. Remove phase sensor [4G18-3600030].Engine hook
FrontRear

Engine mechanism - Engine assembly64. Install temperature regulator assembly.(a) Check temperature regulator assembly o-ring.
(b) Install temperature regulator assembly as shown in the
diagram.
(c) Install engine water inlet pipe joint components.
Torque: 65. Install oil level gauge tube components.
66. Install ignition coil mounting components.Torque: m67. Install fuel rail injector assembly.(a) Install isolator on cylinder head.
(b) Install fuel rail injector assembly.
Torque: (c) Install fuel pipe retaining clip.68. Install exhaust manifold gasket and exhaust
manifold assembly.Torque: 69. Install exhaust manifold upper heat shield
components.Torque: 70. Install intake manifold assembly.Install new gasket and intake manifold assembly.
Torque: m71. Install throttle supporting plate.Torque: 72. Install flywheel components and clutch assembly.(a) Fix crankshaft with special tool.
(b) Clean bolts and bolt holes.
(c) Coat bolts with adhesive.
Adhesive: thread locking sealant 1234 (Kesaixin 1234).
(d) Install flywheel components.
As sequences shown in the diagram, tighten bolts at
several times.
Torque: 885Nm
(e) Install clutch assembly.Special
tool 41

Engine mechanism - Engine assembly85. Install alternator mounting components.Torque: 12mm bolt head A: 14mm bolt head B: 86. Install drive belt.
87. Install engine wire harness and all hoses
not connected.(a) Check and connect all joints of engine wire harness.
(b) Check and connect all hoses.88. Install transmission control pull cable assembly
and valve control pull cable.
89. Install air filter assembly and its hose.
90. Install steering middle shaft assembly.(a) Align alignment mark on steering middle shaft.
(b) Install 2 bolts.
Torque: m
(c) Install steering column cover.91. Install front exhaust pipe assembly.
92. Install front chassis bracket.Torque: 93. Install battery and connect wire.
94. Install engine plastic hood components.
95. Install front wheel and engine bottom shield.
96. Refill transmission lubricant.
97. Refill engine oil.
98. Refill coolant.
99. Check there is oil leakage.
100. Check there is coolant leakage.
101. Check idle speed and ignition timing.
102. Check CO/HC.Alignment
mark
Sliding in
Pulling 44

Engine mechanism - Timing chain assemblyTiming chain assemblyReplacement1. Remove engine left bottom shield.
2. Remove engine right bottom shield.
3. Discharge coolant.
4. Remove engine plastic hood components.
5. Remove drive belt.
6. Remove power steering pump assembly.
7. Remove alternator assembly.
8. Uncouple engine wire harness.(a) Remove ignition coil joint, PS fuel pressure switch joint,
fuel line control joint and speed sensor joint.
(b) Remove bolts and nuts of fixed earth wire and put aside
engine wire harness.9. Remove ignition coil assembly.
10. Remove cylinder head cover components.(a) Remove fuel pipe retaining clip and 2 PCV hoses from
cylinder head cover.
(b) Remove 9 bolts, 2 seal washers, cylinder head cover
components and gasket.11. Remove right engine mounting assembly.(a) Remove PS oil pump reservoir and put it aside.
(b) Place wooden block between jack and engine, prop-
erly place the jack, and then remove right engine mount-
ing assembly.12. Turn crankshaft to cylinder 1 compression top
dead center position.
13. Remove damping pulley components
[4G18-1005110].Remove pulley bolts with special tool.
Remove damping pulley components with special tool.Special
tool
Special
tool45