2008 GEELY FC air conditioning

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

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

Maintenance period-Table on maintenance period at normal conditionsTable on maintenance period at normal conditionsMaintenance content:I: Inspection and correction or replacement if necessary R: Replacementmileage
reading1000kmMaintenance period
(Odometer readings or
operating monthssubject to
the first coming)Engine basic elements
1. Valve clearance*12. Drive belt
3. Engine oil (APLSJ,SL or ILSAC) *24. Oil filter*25. Cooling and heating system hose and joint*3*46. Engine coolant*5*67. CVVT oil duct filter screen
8. Exhaust pipe and fixed mount
Ignition system
9. Spark plug
10. BatteryFuel and exhaust gas control system11. Fuel filter
12. Air filter core13. Connecting conditions of fuel tank cover,
fuel pipe and fuel evaporation control valve*714. Activated carbon canister
Chassis and vehicle body
15. Brake pedal and parking brake
16. Brake pad and brake disc
17. Brake fluid
18. Brake Pipe and hose
19. Power steering oil20. Steering wheel, steering linkage and gear box oil21. Drive shaft dust cover
22. Ball joint and dust cap
23. Transmission oil
24. Front and rear suspension
25. Tire and tire pressure
26. All light, horn, wiper and washer
27. Air conditioner cleaning filter screenAir conditioning system/ secondary refrigerant7 . 5 1 5 22.5 3037.5 4553.5 60 67.5 7 582.5 90months 5

Air conditioner--Air conditioning system
Air conditioner
Air conditioning system
Note
1. Do not dispose Refrigerant in sealed space or near
flame.
2. Wear glasses to protect your eyes.
3. Do not let liquid Refrigerant contact with your eyes
or skin.
If liquid Refrigerant contacts with your eyes or skin:
(a) Wash the contacted part with much water.
Warning: do not knead your eyes or skin.
(b) Spread clean Vaseline on your skin.
(c) Go to doctor or hospital for special cure.
4. Forbid heating it or making it expose the flame.
5. Forbid dropping the Refrigerant tank or shake it
intensively.
6. Do not operate compressor when Refrigerant is lack.
If the Refrigerant in cooling system is lack, it will incur com-
pressor burned out for lacking lubrication. So it is necessary
to avoid.
7. Do not open the high pressure valve of filling instru-
ment package when compressor is working.
If opening the valve at this time, Refrigerant will flow back into
refrigerant tank to incur the tank will break. So only the low
pressure valve could be opened or closed.
8. Do not fill Refrigerant too much.
Too much refrigerant will make many problems such as lack
cooling degree, oil consumption, too hot engine and so on.
Inspection on automobile
1. Check the No.1 pressure switch.
(a) Control for electromagnetic clutch:
Check the function of pressure switch.
(1) Assembly filling instrument package.
(2) Connect the anode lead of OUM meter to No. 4 termi-
nal and connect cathode lead to No. 1 terminal.
(3) Liking that shown in figure. When refrigerant pressure
is changed, check the conduction between terminals.
wrong correct
Low-pressure
sideHigh-pressure
side
Not
conductionCon-
duction
Not
conduction
 213 

Air conditioner--Air conditioning system
If resistance does not accord with the regulation, it is necessary to change heat sensitive resistance.
If the function does not accord with the regulation, it is
necessary to change pressure switch.
(b) Control for cooling fan:
Check the function of pressure switch.
(1) Connect the anode lead of OUM meter to No. 2 termi-
nal and connect cathode lead to No. 3 terminal.
(2) Liking that shown in left figure. When refrigerant pres-
sure is changed, check the conduction between
terminals.
If the function does not accord with the regulation, it is
necessary to change pressure switch.
Inspection
11
111..
...No.1 thermal resistor
(a) Check the resistance between No.1 terminal and No.2 ter-
minal of No.1 heat sensitive resistance at different
temperatures, liking that shown in figure.
Conduc-
tion Not conduc-
tion
 214 
Resistance:
--
---22
22255
555--
---11
11155
555--
---55
55555
55511
11155
55522
22255
55533
33355
55544
44455
55555
55555
55566
66655
55577
77755
55588
88855
555
11
11155
555
11
11100
00088
88866
66644
44422
222
22
22200
000
Resistance
Temperature

47. Disassemble servo motor of air mixing flow choke
(automatic air conditioner).
Disassemble two screws and servo motor of air mixing flow
choke.
48. Disassemble air conditioner pipeline.
(a) Disassemble two screws and extending cover.
(b) Use planetary wrench (5.0mm) to disassemble two plan-
etary bolts and air conditioner pipeline.
(c) Disassemble two O-shape loops from air conditioner
pipeline.
49. Disassemble expansion valve.
(a) Disassemble expansion valve from air conditioner group.
(b) Disassemble two O-shape rings from air conditioner
pipeline.
50. Disassemble No.1 air conditioning heat sensitive
resistance.
51. Disassemble evaporator.
(a) Disassemble six screws and air conditioning group parts.
(b) Pull out evaporator.
52. Disassemble central heating core.
Disconnect fixed claw and central heating water pipe defend-
ing cover, then pull out central heating core.
Air conditioner--Air conditioner central heating core assembly
Fixing
claw
 231 

Air conditioner--Compressor assembly
Compressor assembly
Change
1. Disassemble radiator cover.
2. Reclaim HFC-134a(R134a)
3. Disconnect refrigerant No.1 low pressure hose.
(a) Disassemble the bolt from compressor and electromag-
netic clutch assembly and disconnect refrigerant low pres-
sure hose.
(b) Disassemble O-shape loop from refrigerant low pressure
hose.
Note: after disassembling the pipeline, it is necessary
to cover the joint to prevent humidity or dust from
entering in system.
4. Disconnect refrigerant No.1 high pressure hose.
(a) Disassemble the bolt from compressor and electromag-
netic clutch assembly and disconnect refrigerant high pres-
sure hose.
(b) Disassemble O-shape loop from refrigerant high pressure
hose.
Note: after disassembling the pipeline, it is necessary
to cover the joint to prevent humidity or dust from
entering in system.
5. Disassemble right bottom defending cover of engine.
6. Disassemble driving belt.
7. Disassemble compressor and electromagnetic
clutch.
(a) Disconnect the joint.
(b) Disassemble three screws and electromagnetic clutch.
8. Check the Refrigerant oil.
 234 
When upgrading compressor assembly, it is necessary to reclaim the refrigerant in system at first.
Refrigerant oil quantity added by new compressor should be calculated by following formula.
Refrigerant oil standard quantity of new compressor:
(Inner Refrigerant oil quantity of new compressor:60 ± 10ml)-(Inner discharged Refrigerant oil quantity
of old compressor)=(Refrigerant oil quantity consumed by the system when changing)
Note:
zWhen checking the Refrigerant oil quantity, please refer to the notes on page 206.
zFor there is some Refrigerant oil in automobile pipeline, if some Refrigerant oil is not discharged
when assembling new compressor, this will incur the Refrigerant oil in system is too much to make
the system heat exchange become bad and air conditioning become invalid.

Air conditioning system Defrosting systemElectrical schematic diagram--Air conditioning system Defrosting system 404