2008 GEELY MK change time

Geely “MK” series sedans (JL7132U,JL7132HU,JL7152U,JL7152HU,JL7162U) are brand
new superior models developed by Geely Group who has fully proprietary intellectual property
rights. As a result of the three years of involvements and efforts of the experts from Geely Automo-
bile Research Institute, these sedans reach international leading level in model design, power,
sense of comfort, safety and manufacturing technology while featured in beautiful appearance,
economy, environment protection and safety. The meaning of MK implied that Geely Automobile
has a great development from caterpillar to butterfly. With respect to the power, Geely “MK” series
sedans are equipped with 1.3L, 1.5L, and 1.6L EFI engines developed and manufactured by Geely
itself, and has reached “Chinese III” (Euro III) emission standard.
This manual contains a detailed description of the structures and principles, servicing and adjustment,
removal, assembling technology and matching clearance of the parts of the Geely “MK” sedans
with torque information of the bolts and nuts as well as schematic diagram for special tool operation.
This manual also introduces the transmission control system of the automatic transmission models,
vehicle electric circuits and elaborates ABS system, SRS, BOSCH M7.9.7 electronic control fuel
injection and ignition system, rear parking radar, sound, air conditioning and onboard hands-free
phone system. You can refer to this manual for the information about the regular maintenance,
servicing, adjustment, troubleshooting, removal and installation procedure, specific operations of
the “MK” sedans.
This manual covers the matching relation among the engine assembly, transmission assembly and
the vehicle, but does not have the further description of the structures and principles of the engine
and transmission assemblies and their servicing process. You can refer to the service manuals
solely prepared for engine assembly and transmission assembly for these information.
All information in this manual is based on the latest products released at the time of publication of
this manual. However, the specifications and procedures may need to be modified, and the subse-
quent change will be revealed in later versions.
This manual is prepared by Geely Automobile Research Institute under the assistance of technical
staff from Zhejiang Geely Automobile Co., Ltd and Geely International Corporation. Readers
discovering during the use of this manual the errors and careless omissions due to limited skills of
the preparers and tight schedule are encouraged and pled to contact Geely International in time for
our timely correction of the mistakes.ForewordGeely International Corporation
Nov . 2007

2-12Section 2 Maintenance Category and Content of MK SedanAs the vehicle is being used, its technical performance changes as the mileage accumulates and being affected by
various factors, which results in decrease of power, fuel economy, safety, and increase of emission pollutions,
noise and incidents. So timely maintenance during vehicle usage eliminates potential risks and prevents incidents
from happening, improves vehicle integrity and technical functionality, and prolongs useful life of the vehicle.
According to the vehicle technical requirements and usage history, maintenance of freedom Cruiser sedan can be
classified into several categories.I. first time maintenanceFirst time maintenance is also called breaking-in maintenance. It is performed when the vehicle mileage has
accumulated to 1500~2500km in breaking-in period. First time maintenance must be conducted at the appointed
service shops. It includes:
1. Check if there is any leak in engine, transmission, and differential. Fix if there is any.
2. Replace engine oil filter, engine oil and ATF for A/T.
3. Check the level of engine coolant, braking fluid, windshield washing fluid, power steering fluid and if there
is any leak. Refill if the level is too low and repair if there is any leak.
4. Check if there is any damage in triangle arm and ball joint, connection ball joint, triangle arm flexible hinge,
or the ball joint is loose. If there is, fix or replace it.
5. Check if the drive shaft dust cover is damaged. If there is, replace it.
6. Check if there is any leak in steering mechanism, or front and rear absorber and fix it there is any.
7. Check the tire pressure, front 230kpa, and rear 210kpa.II. Regular maintenanceAfter first time maintenance, the vehicle is in regular usage life. During regular use, the vehicle needs to be
maintained regularly according to the way it is used in.
1.Regular maintenance for vehicles used under extreme bad conditions. Any of the condition below is defined
as extreme bad condition:
(1) Frequent start.
(2) Often drive the vehicle in dusty circumstances.
(3) Drive the vehicle in hot areas (such as in summer in the south).
(4) Often drive in cold areas (often runs short trips, engine temperate cannot reach regular work temperature).
Vehicles ran under extreme bad conditions need to be maintained every 5000km.
2. Regular maintenance for vehicles Vehicles that have not been through extreme bad conditions need to be
maintained every 7500km.
Regular maintenance is required to be performed at Geely service shop, too.
List of parts that need to be replaced regularly is in table 1.
Maintenance timetable is in table2.III. Geely maintenance programGeely recommends following Geely maintenance program.
The intervals of maintenance schedules are determined by mileage meter or time periods. Maintain the vehicle
when either meets the schedule. For details, please refer to the schedule.Usage and Maintenance of MK Series - Maintenance Category and Content of MK Sedan

Part III EngineChpater 1 Engine AssemblyInformation about engine accessories in MK-1 Car Maintenance Manual deals with only that concerned with a
complete car. Please refer to separated Maintenance Manual for information about the engine body. Engines
concerned are MR479Q, MR479QA and MR481QA.Section 1 Engine Inspection1. Check the engine oil
(1) Check the oil level.
(2) Start the engine, and reach warm-up temperature.
(3) Shut the engine down, wait for 3-5min, and check the oil level.
(4) Check whether the oil level is in within the range marked by the scale; if it is lower than the limit (mark
L), fill oil to mark F.
(5) Keep the oil clean without any coolant or petrol mixed in and with appropriate viscosity.
2. Change oil.
(1) Start the engine. When normal temperature is reached, shut down the engine.
(2) Open the oil cap, remove the oil drain plug, and drain the oil.
(3) Tighten the oil drain plug to a specified torque 54N.m.
(4) Fill fresh oil into the crank case with oil quantity 2.8L in case of the filter not changed, 3.0L in case of the
filter changed and 3.5L in case of the dry filter.
(5) Fit on the oil filling cap.
(6) Start the engine.
(7) Shut down the engine and check the oil quantity, and fill oil to the mark F on the oil scale if necessary.
3. Replace the oil filter.
(1) Remove the oil filter.
(2) Before mounting the oil filter, apply a small quantity of engine oil to the O-ring of the new oil filter.
(3) Tight the oil filter to a specified torque (12.7N.m).
(4) Start the engine, and check whether there is any leakage
(5) Shut down the engine, check the oil quantity and fill as required.
4. Oil selection
Oil over PAI SG grade is preferred.
SAE10W-30 or SAE10W-40 is preferred, and ASE5W-30 is used in cold region in the winter.
Note: For the best effect and the greatest safety, it is advisable to use the following lubrication oil.
a. Meet the requirements of API level.
b. Select proper SAE viscosity rating within expected ambient temperature.
The lubrication oil that can not meet the requirements of SAE viscosity and API label at the same time is not
allowed.
5. Check the coolant.
(1) After the engine is cooled down, remove the radiator cover.EngineEngine Assembly3-1 -

Check1. Check the brake booster.
(1) Air tightness check
a. Start the motor, and shut it down after one or two minutes,
then step on the pedal several times slowly.
Tips:
If the pedal goes down greatly at the first step, but it gradually
goes up after the second and third steps, it means the air
tightness is good.Brake System -Vacuum Booster4-92 b. When the motor is running, step down the brake pedal, and then shut down the motor.
Tips:
If the reserved distance does not change thirty seconds after
the pedal is stepped down, it means the air tightness is good.
(2) Operation check
a. When the ignition switch stays in OFF position, step on the
pedal several times, and then check that the reserved
distance should not change.
b. Step down the pedal, and start the motor.
Tips:
If the pedal goes down a little, it means the operation is ok.
2. Check the vacuum one-way valve.
(1) Check the vacuum one-way valve.
a. Slide the clip to unfix the vacuum tube.
b. Remove the vacuum one-way valve.
c. Check the booster is ventilated to the motor.
d. In case of any failure, replace the vacuum one-way valve.ONOFFPositiom 1Positiom 2Positiom 3 Good Poor

5-68Notice
The circuit resistance of the airbag assembly (squib) cannot be measured even with a designated tester.
Since there is current flowing in the squib, when a tester is involved in measuring the resistance, sometimes
the airbag is unexpectedly deployed in case of static electricity, leading to serious accident.
(2) Check the clock spring
Check the following items, and replace the clock spring if any badness is found.
a. Check the connector and protecting tube for damage and the terminal for distortion.
b. Check the case for damage.
c. Check and see if the joint terminal at the upper end of the clock spring are in conduction with that at the
lower end.
d. A thin probe shall be inserted from the back of the yellow connector of the clock spring.
e. With reference to the figure below, insert thin probes into the current tester to check the conduction of the
terminals.VIII. Key points for scrapping the airbag assembly The airbag shall be deployed according to the following procedures before scrapping the airbag assembly or
a vehicle installed with an airbag.
1. Scrapping of an airbag assembly prior to deploymentNotice
The airbag shall be deployed before being scrapped.
The airbag shall be deployed outside the vehicle before being changed.
The airbag shall be deployed in the vicinity of a smoke detector since smoke will appear when the airbag
is deployed.
When being deployed, the airbag will create much noise. People nearby shall wear noise muffler to close
their ears. Avoid do the job within the residential areas.
Deploy inside a vehicle
1) Park the vehicle in a flat area
2) Disconnect the positive (+) and negative (-) terminal cables from the battery and remove the battery from
the vehicle.SRS (Supplemental Restraint System)-
SRS-General Information a. Check the cover for pitting, crack and distortion.
b. Check the connector of the wire harness for damage and the terminal for distortion.
c. Check the case of the gas generator for pitting, crack and distortion.
d. Check the installation status of the airbag assembly. 2. Checking
(1) Driver airbag assembly checking
Check the following items and replace the related components of the airbag assembly if any badness is found.
The old components shall be deployed before scrapping.Notice
If there is pitting, crack or distortion, replace the airbag assembly with new one. The old components of
the airbag shall be deployed before scrapping.

Fault symptom
Flameout, poor idle speedChapter 9 Engine EFI SystemI. Outline This system includes sensor that detects engine functioning. Engine ECU utilizes sensors installed at differ-
ent parts of engine to measure various working parameters of engine, accurately control oil injection quantity
according to control procedure set in engine electronic control unit, so engine could work in optimum mode
under various operating conditions, i. e. optimal power output, the most economical oil consumption, optimal
exhaust emissions. Engine ECU is capable of start up control, idle speed closed-loop control, air fuel ratio
closed-loop control, canister control, transient operation control, angle of ignition control, knocking control, air
conditioning control, coasting fuel cutoff and overspeed fuel cutoff control, ternary catalyst heating and protec-
tion control, system self-diagnosis etc.II. Inspection of control element1. Manifold intake pressure temperature sensor
(1) The part to measure intake pressure is piezo type sensor, could provide controller with "load signal "
according to the difference between atmospheric pressure and manifold pressure; controller will supply 5V
voltage, and feed back 0-5V voltage to controller according to different intake pressures. The part to measure
intake temperature is NTC type (negative temperature coefficient) sensor, resistance changes with intake
temperature, this sensor conveys a voltage representing intake temperature change to the controller.
(2) Simple measuring method:
Temperature sensor part: (remove joint) turn digital multimeter
to Ohm position, two meter pens connect sensor 1 #, 2 # pinrespectively, rated resistance is 2. 5k ohm±5% at 20°C, correspond-ing resistance value may be measured from the above characteristic
curve. Simulation method may also be used for measurement, spe-
cific procedure is to use electric drier to blast sensor (pay attention not
to be too close), observe change of sensor resistance, here resistanceEngine EFI System-Engine EFI System5-120Possible cause
There is abnormal high voltage or reverse heavy current during useVacuum
unit is damaged during repair
Repair precautions: it is prohibit to use high pressure gas to impact vacuum unit during repair; when replace
sensor case of trouble, check whether generator output voltage and current is normal or not.1 2 3 4Manifold intake pressure temperature
sensor Intake pressure sensor feature cureIntake temperature feature curve
Output voltageAbsolute pressureTemperatureResistance

Fault symptom Possible cause
Poor speedup etc Man made fault1 2 3Throttle position sensorFault symptom Possible cause
Difficult to start Man made fault Repair precautions: pay attention to mounting position.
(2) Simple measuring method:
(Remove joint) turn digital multimeter to ohm position, connect
two meter pens with sensor 1 #, 2 # pin respectively, its resistance
value at room temperature is 2k ohm±20 %. Connect two meter pens
with 1 #, 3# pin respectively, rotate throttle, its resistance value shows
linear change with opening of throttle, while situation is reverse for
2 #, 3# pin.
Note: when observe change of resistance value, pay attention to observe whether has large leap.
3. Coolant temperature sensor
(1) This sensor is a negative temperature coefficient (NTC) thermistor, its resistance value decreases with
increase of temperature, but not a linear relationship. This thermistor is installed in a copper heat conducting sleeve.Engine EFI System-Engine EFI System5-121should drop.
Pressure sensor part: (connect joint), turn digital multimeter to DC voltage position, black meter pen is earthed,
red meter pen is connected with 3#, 4# pin respectively. In condition of idle speed, 3# pin should have reference
voltage of 5 V, 4 # pin voltage should be about 1. 3 V (specific value is related with vehicle type); in no-load
condition, open the throttle slowly, change of voltage of 4 # pin is not large; open the throttle quickly, voltage of
4 # pin may reach about 4V in no time (specific value is related with vehicle type), then it drops down to about
1. 5 V.
2. Throttle position sensor
(1) This sensor is actually corner potentiometer with linear output characteristic. Potentiometer tumbler is
mounted coaxially with throttle, when throttle rotates, it drives potentiometer tumbler to slide to certain position,
potentiometer outputs voltage signal proportional to throttle position. Mounting torque: 20 N.m(Max)
(2) Simple measuring method:
(Remove joint) turn digital multimeter to ohm position, connect two meter pens with sensor pins respectively,rated resistance at 20°C is 2.5 k ohm± 5%. Simulation method may also be used for measurement, specificprocedure is to put sensor work area into boiled water (pay attention to soak for sufficient time), observe changeof sensor resistance, now resistance should drop down to 300 ohm-400 ohm (specific value subjects to temperatureof boiled water).
Resistance value (K ohm)
No.Temperature
(°C) Temperature tolerance ±1°C Temperature tolerance ±0°C
Min. Max. Min. Max.
1 8.16 10.74 8.62 10.28 -10
2 2.27 2.73 2.37 2063 +20
3 0.290 0.354 0.299 0.345 +80

4. Knocking sensor
(1) Knocking sensor is a vibration acceleration sensor. Mounted on engine cylinder body. Sensing element of
the sensor is a piezocrystal. Vibration of engine cylinder body is transferred to piezocrystal via mass block in the
sensor. Since pressure generated by vibration of mass block is applied to piezocrystal, it generates voltage on two
polar planes and turns vibration signal into voltage signal for output.5-122Symptom
Poor accelerationPossible cause
Various liquids, such as engine oil, cooling fluid, brake fluid, water etc
contact the sensor for a long time, which cause corrosion to the sensor. Mounting torque: 20 ± 5 N.M
Repair precautions: sensor must be fitted closely to cylinder body with its metal surface, any type of washer
is not permitted for installation. For wiring of sensor signal cables, note that do not let resonance occur to signal
cables, otherwise they might be broken. Energizing of high voltage between sensor 1 # and 2 # pins must be
avoided, otherwise piezoelectric element might be damaged.
(2) Simple measuring method:
(Remove joint) turn digital multimeter to ohm position, connect two meter pens with sensor 1 #, 2 # pin
respectively, its resistance value at room temperature should exceed 1M ohm. Turn digital multimeter to millivolt
position, use a hand hammer to tap near knocking sensor, now voltage signal output should be available.
5. Oxygen sensor
(1) Its sensing element is a ceramic tube, outside is open to exhaust, inside is open to atmosphere. When
temperature of sensing ceramic tube reaches 350°C, it will have the characteristic of solid state electrolyte. Just
utilizing this characteristic, it converts concentration difference of oxygen into electric potential difference, thus
forms electrical signal output. If mixed gas is a bit concentrated, inside and outside oxyanion concentration
difference of ceramic tube is high, electric potential difference is a bit high.
A large number of oxyanions move from inside to outside, output voltage is high (approximate 900mV); if
mixed gas is a bit thin, inside and outside oxyanion concentration difference of ceramic tube is low, electric
potential difference is low, only a small quantity of oxyanions move from inside to outside, output voltage is low
(approximate 100mV).
Possible cause
1. humid water vapor ingresses inside of sensor, temperature
changes rapidly, probe is broken.
2. oxygen sensor "is poisoned". (Pb, S, Br, Si) Symptom
Poor idle speed, poor speedup, tail gas
overproof, too high oil consumption1 2 3 4Oxygen sensor Mounting torque: 40-60 N.m
Repair precautions: it is prohibited to use cleaning fluid, oily liquid or volatile solid on oxygen sensor during
repair.
(2) Simple measuring method:
(Remove joint) turn digital multimeter to ohm position, connect
two meter pens with sensor 1# (white), 2# (white) pin respectively, its
resistance value at room temperature is 1- 6 ohm.
(Connect joint) in idle speed condition, when oxygen sensor
reaches its working temperature of 350°C, turn digital multimeter to
DC voltage position, connect two meter pens with sensor 3# (grey),Engine EFI System-Engine EFI System