2008 GEELY FC lock

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

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--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

Brake--Front brake assembly13. Check the brake branch pump and pistonCheck whether there is rust or scratch in cylinder of branch
pump and piston.14. Check the thickness of brake blockUse rule to measure the thickness of brake block.
Standard thickness: 11.00mm
Minimal thickness: 1.0mm15. Check support sheet of brake block
142Confirm the support sheet could rebound enough without any distortion, crack or abrasion, and it has
removed rust, dust and sundries completely.16. Check the thickness of brake diskUse centimeter to measure the thickness of brake disk.
Standard thickness: 25.00mm
Minimal thickness: 23.0mm17. Disassemble front brake disk(a) Make a mark on corresponding position of brake disk and shaft hub.
(b) Disassemble brake disk.18. Assemble brake diskHint: choose the position with minimal terminal run-out quantity to assemble brake disk.19. Check the terminal run-out of brake disk(a) Lock the brake disk temporarily with shaft hub nut.
Torque: 103
± ± ± ±
± 10 N
⋅ ⋅⋅ ⋅
⋅m
(b) Use centimeter to measure the terminal run-out of brake
disk on the position with 10mm apart from the exterior edge
of brake disk.
Maximal run-out quantity: 0.05mm
(c) If terminal run-out of brake disk exceeds or equals to maxi-
mal value, firstly, check the axial clearance of bearing, then
check the terminal run-out of shaft hub, if they are both
normal, adjust the terminal run-out of brake disk to eligible
value or use turning motor to turn terminal surface of brake
disk.20. Lock exhaust bolt temporarilyLock exhaust bolt temporarily on front brake branch pump.21. Assemble oil seal of piston(a) Spread lithium soap base glycol lubricating grease on new oil seal of piston.
(b) Assemble oil seal of piston on brake branch pump.
Note: do not force piston to assemble in branch pump compulsively.22. Assemble piston of front brake branch pump(a) Spread lithium soap base glycol lubricating grease on the piston.
(b) Assemble piston on brake branch pump.
Note: do not force piston to assemble in branch pump compulsively.

Brake--Front brake assembly23.Assemble dustproof cover of branch pump..(a) After spreading lithium soap base glycol lubricating grease
on new dustproof cover of branch pump, assembling it in
brake branch pump.
Hint: dustproof cover should be assembled in branch
pump firmly.
(b) Use wrench to assemble fixing loop.
Note: do not damage dustproof cover.24. Assemble brake branch pump bracket.Use two bolts to assemble brake branch pump bracket.
Torque: 106
± ±± ±
± 10 N
⋅ ⋅⋅ ⋅
⋅m25. Assemble dustproof cover of brake branch pump
bracket.(a) Spread lithium soap base glycol lubricating grease on new
dustproof cover.
(b) Assemble two dustproof covers in front brake branch pump
bracket.26. Assemble sliding pin of front brake branch pump.(a) Spread lithium soap base glycol lubricating grease on the
surface of sliding part and sliding pin.
(b) Assemble two sliding pins in front brake branch pump
bracket.27. Assemble support sheet of brake block.143 28. Assemble brake block.Note: when changing brake block, muffle gasket should be changed with brake block at the same
time.
(a) Spread brake lubricating grease on both sides of every muffle gasket.
(b) Assemble muffle gasket on every brake block.
(c) When assembling inner brake block, abrasion indicator should face the upside.
Note: do not attach oil dirt or lubricating grease on the surface of brake block and brake disk.29. Assemble brake branch pump assembly.(a) Use two bolts to assemble brake branch pump.
Torque: 34
± ±± ±
± 3N
⋅ ⋅⋅ ⋅
⋅m
(b) Use joint bolt to assemble new gasket and brake hose.
Torque: 30
± ±± ±
± 3N
⋅ ⋅⋅ ⋅
⋅m
Hint: Gasket has two types: two sheets type and one type.
Bracket soft pipe should be assembled in localizing hole of branch pump firmly.30. Add brake liquid in storage tank.
31. Discharge the air in brake main pump.
32. Discharge the air in brake pipeline.
33. Check the liquid level of storage tank.
34. Check whether the brake liquid leaks.
35. Assemble front wheels.Torque: 103
± ±± ±
± 10 N
⋅ ⋅⋅ ⋅
⋅m

Brake--Rear brake assemblyRear brake assembly
OverhaulHint: overhaul procedure for right side is same as the left side.1. Disassemble rear 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 block of rear wheels.(a) Disassemble fixing clamp of anti-vibration spring.
(b) Disassemble two guide pins of brake block and brake block
with muffle gasket.
(c) Take down muffle gasket from every brake block.4. Disassemble left rear brake branch pump.(a) Disassemble the joint, bolt and gasket of brake hose of brake
branch pump, then disassemble brake hose.
Hint: gasket has two types: two sheets type and one
sheet type
(b) Disassemble two bolts and brake branch pump.5. Disassemble the bushing of brake branch pump.Disassemble two bushings from brake branch pump.6. Disassemble dustproof bushing of rear brake.Disassemble three dustproof bushings.7. Disassemble dustproof cover of branch pump.Use screw driver to disassemble fixing loop and dustproof cover.8. Disassemble the piston of brake branch pump.(a) Put a cloth or similar thing between the piston and branch
pump.
(b) Use compressed air to disassemble piston from branch
pump.
Warning: when using compressed air, do not put your
fingers at the front of piston.
Note: do not let brake liquid splash on you.9. Disassemble oil seal of piston.144