2008 GEELY MK fuel pump

Table of ContentsTable of ContentsIPart I General InformationChapter 1 How to Use This Manual.................................................................................. 1-1
Chapter 2 Repair Instruction............................................................................................. 1-3Part II Vehicle Usage and MaintenanceChapter 1 Brief Introduction of Geely MK......................................................................... 2-1
Section 1 Major Functional and Technical Data of MK Series. ...................................... 2-1
Section 2 Vehicle System Configuration ........................................................................ 2-3
Section 3 Main Vehicle Test Technical Specification ...................................................... 2-5
Chapter 2 Usage and Maintenance of MK Series............................................................ 2-6
Section 1 Usage of MK Series ....................................................................................... 2-6
Section 2 Maintenance Category and Content of MK Sedan..........................................2-12
Section 3 Daily Maintenance of MK Sedan .................................................................... 2-18Part III EngineChapter 1 Engine Assembly............................................................................................... 3-1
Section 1 Engine Inspection ........................................................................................... 3-1
Section 2 Removal of the Engine Assembly from the Vehicle ....................................... 3-5
Section 3 Drive Belt Replacement .................................................................................. 3-7
Chapter 2 Engine Mechanical............................................................................................ 3-8
Section 1 Engine Components ....................................................................................... 3-8
Section 2 Throttle Body ..................................................................................................3-12
Section 3 Valve Clearance Adjustment .......................................................................... 3-14
Chapter 3 Fuel System....................................................................................................... 3-15
Section 1 Check Fuel System Pressure ......................................................................... 3-15
Section 2 Fuel Pump Inspection ..................................................................................... 3-16
Section 3 Fuel Pump Replacement ................................................................................ 3-17

2-85. Actions to ensure vehicle working condition and safe driving.
(1) To make sure of driving safety, execute the following inspections before driving.
a. Inspect fuel level, and add fuel when necessary.
b. Inspect illuminating lights, turning signal lights, braking signal lights to see if they work.
c.Check the position of rearview mirrors.
d.Check if breaking system functions well.
e.Check if glass of all the lights, windshield is clean.
(2) Regular inspection Perform the following regular inspections to ensure the vehicle work condition and
driving safety.
a. Check engine oil level. Park the vehicle on flat road; check the oil level with engine oil level indicator
at least 10 minutes after the engine is stopped. The oil level should be between the two marks. If it is
lower than "L" mark, add some oil; if it is higher than "F" mark, there is excessive oil, so release it.
Or investigate the cause of high oil level.
The volume between the lowest oil level ("L") and highest oil level ("F") is 1.4L.
b. Check engine coolant level. Check the level when the engine is cool. The coolant level should be between
LOW and FULL. If it is lower than "LOW", add coolant. If the coolant is much lower than Min (every
coolant fill is more than 1L) or the vehicle requires frequent fills,investigate if there is any problem with
the cooling system.
To keep the function of coolant, replace coolant every two years at the beginning of cold winter.
c. Check brake and clutch fluid level (sharing a reservoir). Brake fluid level should between the Max and
Min marks. And it is better to keep it close to the Max mark. Add fluid in time when there is not enough
fluid.
d. Check power steering fluid tank. The level should be between Max and Min marks. Refill when there
is not enough steering fluid to avoid pump stuck. It is strictly prohibited to run the vehicle without
steering fluid in any circumstances.
e. Check the charging status of battery and if the connection of battery wires is good.
f. Check tire status and pressure
g. Check the status of wipers.
(3) Observe warning lights and indicators on instrument panel.
a. There are various warning lights and indicators on the instrument panel of MK-1 sedans to indicate and
warn abnormal operations of engine, braking, and charging systems.
b. Pay attention to these lights when driving.When the warning lights or indicators are on,stop the vehicle,
check the vehicle and resolve the causes to make sure the vehicle works well or drives safely.
6. Correct ways to use new cars
Reliability and stability of components in new cars and recently repaired cars still need to be confirmed, and
relative parts are not broken-in, so they must be used carefully to ensure driving safety, to avoid abnormal damage,
and to extend the useful life of the car.
(1) Before driving inspection The following inspections must be performed on the new car to ensure car safety
and reliable operation:
a. Check if instrument panel, warning lights, and indicator, front and rear wiper and washer, and switches
work.
b. Check if the fastening of driveline, steering, suspension, wheels and other connection parts is good.Usage and Maintenance of MK Series - Usage of MK Series

2-13For servicing items whose deadlines have expired, they should be maintained at the same intervals as before. The
intervals are recorded in maintenance schedule.
Rubber hoses
Used in cooling and heating system, braking and fuel-feeding systems should be inspected by qualified Geely
technicians according to Geely maintenance schedule.
There are all very important maintenance items. Hoses must be replaced immediately should there be any aging
or damage. Please pay attention, rubber hoses age as time goes by, and they may have problems of inflation, wear,
or crack.
Special Tips
If the vehicle is driven under one or more of the following circumstances, the maintenance items should be
carried out more frequently. See attached maintenance schedule.
A Road condition
1. drive on rough, muddy or skiddy roads
2. drive on dusty roads.
B driving condition
1. Repeat driving within 8km a few times, or when the outdoor temperature is below 0 degree centigrade.
2. Idle the car drive at a low speed for a long time, such as police car, taxi, or door to door delivery vehicles.
3. Continuously drive the car at high speed for more than 2 hours (80% of the max speed).IV. Regular inspections1. weekly schedule

inspect engine oil level and cleanness
inspect engine coolant level
inspect brake fluid level

inspect windshield wash fluid level
inspect power steering fluid level
2. monthly inspections

inspect water pump belt
inspect electrolyte level in battery
inspect tire air pressure and wear

inspect steering wheel
inspect brake
inspect acceleration pedal
3. inspection when driving (low speed)

inspect speed meter and water temperature
check steering wheel power and if vehicle runs off-track

check if the front wheels skid or swing
inspect if brake functions or if the vehicle runs off-track when brake is functioning
4. other inspection items
Eliminate problems immediately when there is anything abnormalUsage and Maintenance of MK Series - Maintenance Category and Content of MK Sedan

2-14
V. Table 1 List of parts to be replaced regularlyThe intervals in the part list are for cars driven under normal condition. If the car is driven in special circumstances,
the replacement can be advanced from the schedule above.SystemParts need to be replaced regularly
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22Brake master cylinder cup valve and dust coverBrake master cylinder cup
Brake hose
Brake caliper valve
Brake booster rubber
Brake booster vacuum hose
Brake fluid
MT Transmission oil
AT Transmission oil
Steering fluid
Air Cleaner
Air c leaner f ilter
Lubricant
Oil filter
Fuel filter
Coolant
All hoses
Canister
Timing beltWedge belt (including the power steering pump,
air conditioner compressor and generator belts)PCV system
Spark plugEvery 2 years (or as required)
Every 2 years (or as required)
Every 2 years (or as required)
Every 4 years (or as required)
Every 2 years (or as required)
Every 4 years (or as required)
Every 2 years,or 40000km (or as required)
Every 2 years,or 40000km (or as required)
Every 2 years,or 40000km (or as required)
Every 2 years,or 40000km (or as required)
To be cleaned every 10,000km and changed
every 30,000km (or as required)
First 2500km or 2 months. Every 7500km or
6 months afterward (or as required)
First 2500km or 2 months. Every 7500km or
6 months afterward (or as required)
Every 5000km (or as required)
Every 40000km (or as required)
Every year (or as required)
Every 2 years (or as required)
Every 60000km (or as required)
Every 120000km (or as required)
Every 50000km (or as required)
Every 20000km or 12 months (or as required)
Every 20000km (or as required)Intervals
DrivelineSteering SystemBraking
SystemEngineA/C System
(API) SG or above(Table 1)Usage and Maintenance of MK Series - Maintenance Category and Content of MK Sedan

Component ViewFigure 2-3Engine MechanicalEngine Components3-10adjusting support
with power steering
Vane pump assembly with
power steering
Pump support with
power steeringHex. flange
bolt M6¡Á50
Ignition coil
Ignition coilinstallation bracket
Bolt M8¡Á31Fuel oil pipe subassembly
Fuel oil pipe clip
Vent ductSecondary wireBypass hose
Rear end housingWater outlet
pipe housing
No.1 heat shield of
exhaust manifoldOil filter assembly
Washer
Exhaust manifold
Support of exhaust
manifoldO-ring
Fastener of
No.1
injectorInjector
O-ring
Throttle assemblySuction manifold Washer
WasherKnock sensor
Water temperature sensorCrankshaft position sensorGenerator assemblyNo.1 support of compressor
Air conditioner compressorWater inlet pipe housing -

Chapter 3 Fuel SystemSection 1 Check Fuel System PressureOn-board inspection
1. Check the operation of the fuel pump.
(1) Connect the positive and the negative of the battery to
appropriate connector sockets of the fuel pump (see Figure 3-1).
Attention: Do not start the engine.
If there is pressure present, you will hear that the fuel is flowing.
If there is no pressure present, check the fusible cutout, fuse, EFI
open-circuit relay, fuel pump, ECM (Electronic Control Module) and
circuit joint.
(2) Turn the ignition switch to "OFF".
2. Check the pressure of the fuel.
(1) Check whether the battery voltage is more than 12V.
(2) Disconnect the negative wiring cable from the battery.
(3) Mount a pressure gauge on the fuel input pipe
(see Figure 3-2).
(4) Connect the negative terminal of the battery.
(5) Measure the fuel pressure.
Fuel oil pressure: 265-304kPa
If the pressure is low, check the fuel pipe and connection,
fuel pump, and fuel filter. If the pressure is too high,
replace the regulator.
(6) Start the engine. Measure the fuel pressure at idle speed. The
fuel pressure is 265-304KPa. If the pressure is unsatisfactory, checkFigure 3-1
Figure 3-3 Figure 3-2Fuel SystemCheck Fuel System Pressure3-15the fuel pump, pressure regulator, and injector, and replace if necessary.
(7) After shutting down the engine, check the fuel pressure and
keep the specified pressure for about 5 minutes. The fuel pressure is:
147KPa.
3. The fuel oil pressure regulator (DR) (see Figure 3-3).
Mounting position: On the distributing pipe for fuel.
Faults: Too low or too high fuel pressure, or hard to start.
General causes: Using poor fuel for a long time results in: 1.
strainer blocked; 2. serious leakage caused by particles and impurities.
Other reasons: Man-made mechanical damage, etc.
Maintenance precautions: During maintenance: 1. Never impact the diaphragm element with high pressure
gas; 2. Never clean it with aggressively corrosive liquid; 3. No distortion caused by external force.
Easy measuring method: For the system with oil return, connect a pressure gauge for the fuel on the suction
pipe, start the engine, and run at idle speed. Now, the fuel pressure in the engine should be about 260KPa; pull out
the vacuum pipe of the fuel pressure regulator, and the pressure should be 300KPa approximately.Battery
T conector
Hose
Hose
Fuel Inlet Pipe
Fuel Pipe
Conector -

Section 2 Fuel Pump Inspection1. Fuel pump (1) Check whether the resistance of the fuel pump is 0.2~3.0 ohm¸ at 20°C. If not, replace the fuel pump (see Figure3-4).
(2) Fuel oil pump running:
Switch on the fuel pump with a battery and check. If the operation is unsatisfactory, replace the fuel pump or
wires (see Figure 3-5).
The test should be done within 10s to protect the coil from burning out.
2. Fuel injector assembly
Oil injecting quantity: 40~50cm3/s.
Tolerance of each injector: not more than 10 cm3.
If the fuel injecting quantity is not up to the specification, replace the injector.
Check leakage: Under above conditions, disconnect the wire from the battery, the fuel should not drip one per
minute.Figure 3-4 Figure 3-5BatteryOhm
meterFuel SystemFuel Pump Inspection3-16 -

Section 3 Fuel Pump ReplacementComponent ViewFigure 3-6Replace1. Operations avoiding petrol overflowing.
2. Disconnect the fuel oil hose from the oil tank.
3. Disconnect the oil return hose from the oil tank.
4. Disconnect the vapor discharge pipe from the oil tank.
5. Remove the fuel oil pump assembly with a filter (see Figure 3-7)
Loosen the oil tank cap with a tailored tool. Take care not to bend
the arm of the oil quantity sensor when taking the fuel oil pump out
6. Mount the fuel oil pump assembly (see Figure 3-8).Replace the
sealing ring. Align the boss on the oil pump with the nick on the oil
tank port; tighten the oil tank cap with special tool.
Torque: 40N.m
7. Mount the vapor discharge pipe.
(1) Mount the oil return hose;
(2) Mount the fuel oil hose;
(3) Check leakage of the fuel oil.Figure 3-7
Figure 3-8Fuel SystemFuel Pump Replacement3-17Fuel tank cap
Fuel pump with fuel sensor as-
sembly
O-ring
Fuel tank assembly Fuel return hoseFuel oil hose
snap ring -