2008 GEELY MK Workshop Manual

General Information - Repair Instruction1-8 (5) Seat Belt Pretensioner
a. Never measure the resistance of the seat belt pretensioner. (This may cause the seat belt pretensioner to
activate, which is very dangerous.)
b. Never disassemble the seat belt pretensioner.
c. Never install the seat belt pretensioner in another vehicle.
d. Store the seat belt pretensioner where the ambient temperature remains below 80°C and away from
electrical noise without high humidity.
e. When using electric welding, first disconnect the connector (yellow color and 2 pins) before starting
work.
f. When disposing of a vehicle or the seat belt pretensioner alone, the seat belt pretensioner should be
activated before disposal. Perform the operation in a safe place away from electrical noise.
g. The seat belt pretensioner is hot after activation, so let it cool down sufficiently before the disposal.
However never apply water to the seat belt pretensioner.
h. There should be no oil or water on the seat belt, no cleanser should be used to wash it. d. Store the driver airbag assembly where the ambient temperature remains below 93°C , without
high humidity and away from electrical noise.
e. When using electric welding, first disconnect the airbag connector (yellow color and 2 pins) under the
steering column near the combination switch connector before starting work.
f. When disposing of a vehicle or the driver airbag assembly alone, the airbag should be deployed using an
SST before disposal. Perform the operation in a safe place away from electrical noise.
(4) Front Passenger Airbag Assembly
a. Always store a removed or new front passenger airbag assembly with the airbag rupture surface facing
up. Storing the airbag assembly with the airbag rupture surface facing down could cause a serious accident if the
airbag inflates.
b. Never measure the resistance of the airbag squib. (This may cause the airbag to deploy, which is very
dangerous.)
c. Grease should not be applied to the front passenger airbag assembly and the airbag door should not be
cleaned with detergents of any kind.
d. Store the airbag assembly where the ambient temperature remains below 93°C , without high humidity
and away from electrical noise.
e. When using electric welding, first disconnect the airbag connector (yellow color and 2 pins) installed on
the assembly before starting work.
f. When disposing of a vehicle or the airbag assembly alone, the airbag should be deployed using an SST
before disposal. Perform the operation in a safe place away from electrical noise.Correct
Wrong

General Information - Repair Instruction1-93. Electronic Control Device
(1) Removal of the battery terminal cable
a. Before performing electrical servicing, disconnect the nega-
tive (-) cable from the battery in order to avoid short for burnout.
b. When disconnecting the terminal cable, turn off the ignition
and light switches, loosen the cable nut and raise the cable straight
up without twisting or prying it.
c. When disconnecting the terminal cable from the battery, all
information stored in the clock, radio and DTC shall be deleted,
therefore, these information shall be checked before disconnection.
(2) Processing of Electronic Parts
a. Do not open the cover or case of the ECU unless absolutely
necessary. (If the IC terminals are touched, the IC may be destroyed
by static electricity.)
b. To pull apart electrical connectors, pull on the connector itself,
not the wires.
c. Be careful not to drop electrical components, such as ECU
or relays. If they are dropped on a hard floor, they should be replaced
and not reused.
d. When steam cleaning an engine, protect the electronic
components, air filter and emission-related components from water.
e. Never use an impact wrench to remove or install tempera-
ture switches or temperature sensors.
f. When checking continuity at the wire connector, insert the
tester probe carefully to prevent terminals from bending.
4. Remove and Installation of Engine Intake Parts
(1) If any metal scrap is mixed in the inlet pass, that may give
a bad effect to the engine.
(2) When removing and installing of the inlet system parts, close (6) Airbag ECU
a. Never reuse the airbag ECU involved in a collision when the SRS has deployed.
b. The connectors to the airbag sensor assembly should be connected or disconnected with the airbag ECU
mounted on the floor. If the connectors are connected or disconnected while the airbag ECU is not mounted to
the floor, it could cause undesired inflation of the supplemental restraint system.
c. Work must be started after 60 seconds from the time the ignition switch is turned to the "LOCK" position
and the negative (-) terminal cable is disconnected from the battery, even if only loosing the set bolts of the
airbag ECU.
(7) Wire Harness and Connector
The SRS wire harness is integrated with the instrument panel wire harness assembly. All the connectors in
the system are a standard yellow color. If the SRS wire harness becomes disconnected or the connector becomes
broken due to an accident, etc., repair or replace it.Negative(-)
Cable
Wrong

General Information - Repair Instruction1-103.Precautions for Use of Jack and Safety Stand
(1)always use the wheel stoppers when performing servicing on
level ground.
(2)use safety stand and rubber support as shown in the illustration.
(3)use the jack and safety stand to support specified location.
(4)When jacking up the front wheels of the vehicle, release the
park brake and place stoppers only behind the rear wheels. When
jacking up the rear wheels, place stoppers only before the front wheels.
(5)During the job, make sure to use safety stand instead of jack
only to support the vehicle.
(6)When only jacking up the front wheels or rear wheels, place
stoppers before or after the wheels touching the ground.
(7)when lowering the vehicle with its front wheels lifted, release
the park brake, and place the stopper only before the rear wheels.
When lowering the vehicle with its rear wheels lifted, place the stop-
per only after the front wheels. the opening of the removed inlet system parts and the engine with a
clean shop lag or gum tape.
(3)When installing the inlet system parts, check that there is no
mixing of a metal scrap.
5. Handling of Hose Clamp
(1)Before removing the hose, check the clamp position to re-tighten
it for sure.
(2)Replace a deformed or dented clamp with a new one.
(3)In case of reusing the hose, install the clamp on the hose where
it has a clamp track.
(4)For a steel band circlip, make it adjust by adding force to the
arrow mark direction after the installation.II. Vehicle Lift and Support Location1. Vehicle Conditions To Be Under Attention During Lift
(1)Generally speaking, when being lifted, the vehicle should be empty, do not lift the heavily loaded vehicles.
(2)When removing heavy parts such as engine and transmission, the center of gravity of the vehicle will move.
Place balance weight to prevent the vehicle from rolling or use special jack to support the vehicle.
2. Precautions for Use of Four-tappet Lift
(1)follow the safe operation instruction described in this manual.
(2)do not damage the tire or rim.
(3)use wheel stopper to retain the vehicle.Rubber SuportSteel Band Circlip
Clamp Trace

General Information - Repair Instruction1-114. Precautions for Use of Swing Arm Type Lift
(1) follow the safe operation instruction described in this manual.
(2) use bracket with rubber support as shown in the illustration.
(3) make the center of gravity of the vehicle as close as possible to that of the lift ("L" should be smaller).
(4) adjust the bracker height, level the vehicle, align the groove of the bracket with the safety stand
support location.
(5) the arm should be locked during the job
(6) lift the vehicle until the tires become round.Swing the vehicle to make sure of stable vehicle.
5. Precautions for Use of Plate Type Lift
(1) follow the safe operation instruction described in this manual.
(2) use the support of the plate type lift.
(3) make sure to secure the vehicle in the specified position. Left and right set position
Front and rear set position Place the vehicle over the center of the lift. Align the cushion gum ends of the plate with the attachment
lower ends (A, C). Align the attachment upper end (B) with the front jack supporting point.Support Position
Jack Lifting Position Jack Position
Center of Gravity of the Vehicle
(empty load)

Swing Arm Type LifterLift Center
Plate Type LiftGeneral Information - Repair Instruction1-12 (3)lift the vehicle until the tires become a little bit round. Swing the vehicle to make sure of stable vehicle.Cener of Gravity of the Vehicle
(Empty Load)rubber support
Support Dimension
Support

Part II Vehicle Usage and MaintenanceChapter 1 Brief Introduction of Geely MKSection 1 Major Functional and Technical Data of MK Series.I. Vehicle performance and structural data Table 1 vehicle dataVehicle Usage and Maintenance - Brief Introduction of Geely MK2-1JL7162U
JL7152U JL7132UUnit
mm
mm
person
kg
m
mm
°
mm Item ID
1
2
3
4
5DimensionDimension
Axle4342
1692
1435
1450
1431
2502
848
992
5
150mm
15°
20°
-0°30'±45'
1±2mmLength
Width
Height
Front
Rear
Wheelbase
Front Suspension
Rear suspension
Number of passengersWeightCurb weight
Front Axle
Rear Axle
Vehicle
Front
Rear CurbGross Vehicle
Weight
Road
adaptabilityMinimum turning diameter
Minimum Ground Clearance
Approach angle
Deviation angleWheel
Posi-
tioningLeft: Inner/out
Right: inner/outMax turning angleof front wheel
Front wheel leaning angle
Kingpin inward leaning angle
Kingpin rearward leaning angle
Left front wheel toe-in
Rear wheel outwardJL7132HU JL7152HU1090(1040)
660(640)
430(400)
1460(1410)
780(760)
680(650)1080
665
415
1450(1455)
780(785)
670 10.4m
°
°
°
°
°
°°37.2°±2°/ 32°±2°
37.2°±2°/ 32°±2°
2°0'±45' 10°0'±45'
-0°56'±45'

II. Introduction of major systems Table 2 Models and technical data of major systems.
JL7132U JL7152U JL7162U JL7132HU JL7152HU
4
MR479Q MR479QA MR481QA MR479Q MR479QAIn-line 4 cylinder In-line 4 cylinder In-line 4 cylinder In-line 4 cylinder In-line 4 cylinder78.7 78.7 81.0 78.7 78.7
69.0 77.0 77.0 69.0 77.0
1.342 1.498 1.587 1.342 1.498
9.3 : 1 9.8 : 19.6 : 19.3 : 1 9.8 : 1
63/6000 69/6000 78.7/6000 63/6000 69/6000
110/5200 128/3400 137/4400 110/5200 128/3400
800±50
1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
259 279 269 259 279
JL-S160 JL-S160A JL-Z110 JL-Z130
3.182 3.087 3.087
1.895 1.634 1.634
1.250 1 1
0.909 / /
0.703 / /
3.083 2.29 2.29
4.308 3.317 3.317
Hydraulic Gear-rack
Hydraulic, X-type pipe
Vacuum booster, Front Wheel Disc, Rear Wheel Drum
McPherson suspension strut system
Twist beam independent suspension system
85/60R15(1175/65R14)
230(Front)/210(Rear)
Aluminum 15X6J (Iron 14X5 1/2JJ)
45
Unitary construction body Unit
mm
mm
L
kw/r/min
N.
m/r/min
r/min
g/kw.
h
KPa
L Item Description
Drive Type ID
1
2
3
4
5
6
7
8
9
10EngineModel
Type
Bore Diameter
Piston play
DisplacementCompression RatioMax Power
Max Torque
Idle Speed
Ignition Sequenceminimum fuel consumption rateTransmission
Braking
system
suspension
Tire Clutch Type
Steering type
Model
Booster type
Front
Rear
Specification
Tire pressure
Wheel
Fuel Tank Capacity
Body structureSingle disc, Plate and dry SpringBrief Introduction of Geely MK - Major Functional and Technical Data of MK Series.2-2Model
1st gear
2nd gear
3rd gear
4th gear
5th gear
Reverse gearFinal Drive Ratio /Front Wheel Drive ›‹
2
800±50800±50
800±50
800±50

Table 3 Power Performance Parameter
Table 4 Economic Performance ParameterUnit
km/h
s
s
km/h
% Item Name
Maximum vehicle speedAcceleration time within the fourth gear from 30km/h to 120km/hAcceleration time from 0-100km/hMinimum stable vehicle speed within the fourth gearMaximum gradeability No.
1
2
3
4
5Unit
L/100km
L/100km
m Item Name
Fuel consumption at constant speed (60km/h)
Fuel consumption at constant speed (90km/h)Coasting distance (fully loaded, initial speed 50km/h)No.
1
2
3JL7132U JL7152U JL7162UJL7132HU JL7152HU


/JL7132U JL7152U JL7162UJL7132HU JL7152HU
4.5
550Brief Introduction of Geely MK - Vehicle Configuration2-3Section 2 Vehicle ConfigurationType
Common color
Uncommon color
Exterior
device
Seat Interior
deviceItem NameNo.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19Standard Comfortable Luxury
Firry red Firry red
Titanium silver Body colorChinese red, snow mountain white, pearl black, sky blue, ribbon silver
Crystal diamond silver, golden sand green, pineapple yellowFront chromeplated trim molding
Diamond-shape headlight
Crystal diamond taillight
Highly penetrable front fog light
Green heat insulating four-door glass
Scuff strip with same color as that of the body
Aluminum alloy wheel rim
Tire (185/60R15) (with spare tire)
Retractive antenna (A pillar)
Bumper with same color as that of the bodyLight color (T)deep color(S)mixed color(R)interior trimCentral control panel
A/C outlet vent + trim ring
Chromeplated inner handle
Sun shade (with ticket folder)
High-grade flannelette
Luxury leatherFront seat headrest front and rear angle/height adjustable function
/ /
20
2522
16.5 18
20165
33
28 30155 175 165 155
306.25.1
4.65.0
4.7
6.7
6.36.6 6.2
550 550
550 550 / /
/ / / /