2008 GEELY FC suspension

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

Brief introduction on Geely model “FC”Basic parametersTable 1 Complete vehicle basic parametersUnit
Item nameNumber
Dimension parametersOverall
dimension
Wheel trackLength
Width
Height
Front wheel
Rear wheel
Wheel base
Front suspension
Rear suspensionPassenger numberPersonParameters±15±15±20±10±10±30±30Left lamp
Right lamp
Left lamp
Right lampLeft and
right
inclination
Down
inclinationComplete vehicle herb massMax. total massFront axle
Rear axle
Front axle
Rear axle
Weight distributionNo
load
Full
loadMin. turning diameter
Min. gound clearance
Approach angle (full load) Departure angle (full load)Front wheel camber
Kingpin inclination angle
caster angleConvergence of front wheelsRear wheel camberConvergence of rear wheelsLeft wheel: inside/outside
Right wheel:inside/outside CanderaBrief introduction on Geely model “FC” Basic parameters
Mass parameters
Traverse ability
Front wheel alignment
parameters
Rear wheel
alignment
parameters Front wheel
steering
wheel
Head lamp light
High beam
optical axisLuminous intensity of
high beam of head lamp1

Brief introduction on Geely model “FC” Basic parametersTable 2 Types and parameters of main assemblyModel
TypeElectric injection system modelBore
StrokeDelivery capacityCompression ratioMax. power
Max. torque
Idling speedIgnition sequenceMin. fuel consumptionTypeMain gear box ratioTypes and parameters
JL4G184-cylinderin-line, four-stroke, water-cooling, double over-head
camshaft, 16-valve, CVVT multipoint injection gasoline engineUnited Automotive Electronic Systems Co., Ltd. M7.9.7 electric injection system5 gears synchronizer of constant mesh gearDry single, diaphragm spring, constant pressure
Rack-and-pinion steering gear with hydraulic powerDouble pipeline, vacuum boosterwith ABS +EBD anti-lock systemDisc brake
Disc brake
Strut-type front independent suspensionLongitudinal swinging arm and anti-twist beam compound rear suspensionBreakawayBalI cage and tripot type constant velocity universal jointLoaded all-metal body
Honeycomb cordierite carrier, noble metal catalyst
Swirl or swash plate compressorItem nameNumber
Engine1st gear
2nd gear
3rd gear
4th gear
5th gearReverse gearClutch type
Steering gear
Tire
Body structureSpecification
Air pressureRadial
tireTail gasAir
condi-
tioning
systemUnit



//
.
//
/
/.



2
Transmission
Each gear ratio
Braking
system
Sus-
pension
Drive
axleType
Front brake
Rear brakeFront suspension type
Rear suspension typeRim
Type
Drive shaftCatalytic converterCompressor typeNominal refrigerating capacityRefrigerant

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

Maintenance period-Table on maintenance period at severe conditionsTable on maintenance period at severe conditionsAccording to the driving conditions listed below, maintenance should be performed to the items that
should be maintained more frequently (for other items not listed, please see Table on maintenance
period at normal conditions) 7 A-1: Driving on rugged, muddy or melting snow road Inspection of brake pad and brake disc Every 5,000 km or 3 moths Inspection of brake pipeline and hose Every 10,000 km or 6 moths Inspection of ball joint and dust cover Every 10,000 km or 6 moths Inspection of drive shaft dust cover Every 10,000 km or 12 moths Inspection of the steering wheel, steering linkage and gear box oilEvery 5,000 km or 3 moths Check of front and rear suspension Every 10,000 km or 6 moths
A-2: Driving on dusty road Replacement of engine oil Every 5,000 km or 6 moths Replacement of engine oil filter Every 5,000 km or 6 moths Inspection or replacement of air filter core I: Every 2,500 km or 3 moths
R: Every 10,000 km or 6 moths Inspection of brake block and brake disc Every 5,000 km or 3 moths Replacement of air conditioner cleaning filter screen Every 15,000 km
B-1: Towing tail vehicle, equipped with camp frame or top storage racks Replacement of engine oil Every 5,000 km or 6 moths Replacement of engine oil filter Every 5,000 km or 6 moths Inspection of brake pad and brake disc Every 5,000 km or 3 moths Inspection or replacement of transmission oil Every 60,000 km or 24 moths Inspection of front and rear suspension Every 10,000 km or 6 moths Screwing down the bolts and nuts of the chassis and vehicle bodyEvery 10,000 km or 6 moths
B-2: Repeated on short-distance driving within 8 km and the temperature is below 0 °C Replacement of engine oil Every 5,000 km or 6 moths Replacement of engine oil filter Every 5,000 km or 6 moths
B-3: Vehicles driven for long distance under idle speed or low speed over a long period of time, such as police car, taxi or deliverytruck. Replacement of engine oil Every 5,000 km or 6 moths Replacement of engine oil filter Every 5,000 km or 6 moths Inspection of PCV valve and pipelines Every 5,000 km or 6 moths Inspection of brake block and brake disc Every 5,000 km or 3 moths
B-4: Continuously driving at high speed for more than 2 hours frequently (With 80% of max. vehicle speed) Replacement of transmission oil Every 40,000 km or 12 moths
B-5: Vehicles driven with idle speed or low speed over a long period of time or frequently accelerated or
decelerated, such as student car of driving training class. Replacement of engine oil Every 3,000 km or 3 moths Replacement of engine oil filter Every 3,000 km or 3 moths Inspection of PCV valve and pipelines Every 3,000 km or 3 moths

Front suspension - front suspension systemFront suspensionFront suspension systemTable on trouble occurrenceThis table could help you find out failure causes, and each figure in the table indicates the possible
sequence of failure causes, please check every part as the sequence, and replace if necessary.Trouble occurrence Possible trouble part Pages to refer to
1. Tire (abrasion or improper tire pressure) 109
2. Wheel alignment (incorrect) 87
Deflection/single side 3. Steering linkage (looseness or abrasion) -
4. Shaft hub bearing (abrasion) 123
5. Suspension parts (abrasion) -
6. Steering gear (poor adjustment or breakage) -
1. Vehicle (overload) -
Bottoming 2. Spring (elastic fatigue) 90
3. Absorber (abrasion) 90
1. Tire (abrasion or improper tire pressure) 109
Swaying left and right/ 2. Stabilizer bar (bending or breakage) 96shaking forward and backward3. Absorber (abrasion) 90
1. Tire (abrasion or improper tire pressure) 109
2. Wheel (poor balance) 109
3. Absorber (abrasion) 90
Front wheel shimmy 4. Wheel alignment (incorrect) 87
5. Ball joint (abrasion) 99
6. Shaft hub bearing (looseness or abrasion) 123
7. Steering linkage (looseness or abrasion) -
8. Steering gear (poor adjustment or breakage) -
1. Tire (abrasion or improper tire pressure) 109
Abnormal tire abrasion 2. Wheel alignment (incorrect) 87
3. Absorber(abrasion) 90
4. Suspension parts (abrasion) -86

Front suspension - Front wheel alignmentFrontRearIf toe-in is not within specification, please adjust left and
right levers of steering gear.4. Adjustment of toe-in(a) Remove dust cover fixing clip.FrontRearToe-in(Total)Front wheel alignmentAdjustment1. Inspection(a) Check tire is worn and inflation pressure is proper.
Tire inflation pressure under normal temperature:Tire size Front and rear kPa*1 It is used under the condition of speed below 160 km/h.
*2 It is used under the condition of speed above 160 km/h.
(b) Check tire run-out with dial indicator.
Tire run-out: 3.0mm.2. Measurement of vehicle heightVehicle height:
(General road)
(Coarse road)
Measuring point:
A. Height for ground and front wheel center
B. Height for ground and bolt center in front of lower
control arm
C. Height for ground and fixed bolt center of rear axle beam
D. Height for ground and rear wheel center
Note: adjust vehicle height to standard value before checking front wheel alignment.
If vehicle height does not conform to regulations, please shake upward and downward or lift vehicle
body to adjust vehicle height.3. Inspection of toe-inToe-in:Front87

Inside wheel38o452oOutside wheel: reference32o50Front suspension - Front wheel alignment(Coarse road)
Inside wheel39o052oOutside wheel: reference33o10Camber-031’45’Left-right error45’Caster242’45’Left-right error45’Steering shaft inclination18’45’Left-right error45’Camber-
018’45’Left-right error45’Caster230’45’Left-right error45’Steering shaft inclination1052’45’Left-right error45’A: inside
B: outsideFrontGauge If caster and steering axis inclination are not within specification, please adjust the caster and
then check parts of lower control arm is damaged or worn.(b) Loosen lock nuts at the end of transversal lever .
(c) Evenly rotate end levers of left and right rack to
adjust toe-in.
Hint: try adjusting toe-in to medium value.
(d) Ensure that the end lever length of left rack equals that
of right rack.
(e) Tighten lock nuts at the end of transversal lever.
Torque: 745 N.m
(f) Install dust cover fixing clip.
Hint: ensure that the dust cover does not distort.5. Inspection of turning angle(a) Completely rotate steering wheel to the bottom and then
measure turning angle.
Turning angle:
(General road)
(Coarse road)Wheel
alignment
tester88If left and right inside wheels are not within specification, please check the end lever length of left rack
and right rack.6. Inspection of camber, caster and steering shaft inclination(a) Install camber-caster-kingpin gauge or erect wheel alignment tester.
(b) Check camber, caster and steering-axis inclination.
Camber, caster and steering shaft inclination:
(General road)