2008 GEELY MK fuel

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 -

Section 4 Fuel Emission Control SystemOn-board Inspection1. Check the operation when disconnecting the fuel supply.
(1) Warm the engine up to 2,500r/min at least, and check the noise of the injector with a sound level meter
(see Figure 3-9).
(2) When the throttle releases, the noise from the injector should stop immediately; repeat several times.
2. Check the fuel vapor discharge control system (see Figure 3-10).
(1) After starting the engine, disconnect the vacuum pipe.
(2) Make sure that there is vacuum present at the canister control valve (TEV) port when selecting ”ACTIVE
TEST" and "PURGE TEV" based on the display on the fault diagnosis instrument.
(3) After "ACTIVE TEST", connect the vacuum pipe.
(4) Carry out "ECM DATA MONITOR" on the fault diagnosis instrument, and then select "PURGE TEV"
for operation inspection.
(5) Start up the car after the engine warms up, and make sure the TEV ON from OFF (see Figure 3-11).
3. Check whether there is any distortion or damage on the filling cap and the washer (see Figure 3-12).Figure 3-9 Figure 3-10Fuel SystemFuel Emission Control System3-18Figure 3-11 Figure 3-12Sound level meter
Gasket -

Section 5 Carbon Canister Replacement1. Check and replace the canister.
(1) Check for crack or damage on the canister visually (see Figure 3-13).
(2) Check the operation of the canister.
a. Plug the discharge port (see Figure 3-14).
b. Blow air (4.71KPa, 48kgf/cm2) into the absorption port when keeping the discharge port closed, and the
air should flow out from the exit port.
If the operation is unsatisfactory, replace the canister.
c.Blow air into the absorption port, the air should flow from other ports without any resistance.
If the operation is unsatisfactory, replace the canister.
(3) Clean the canister: Block the desorption port, blow air (4.71KPa, 48kgf/cm2) into the absorption port, and
the air should flow from the discharge port (see Figure 3-15).Fuel SystemCarbon Canister Replacement3-192. Canister control valve (TEV) (see Figure 3-16)
Mounting position: On the vacuum pipeline of the canister - suction manifold.
Faults: Bad idle speed, malfunction, etc.
General cause: Ingress of foreign materials into inside of the valve results in corrosion and Poor tightness.
Maintenance precautions: During maintenance:
1. Air flowing direction must conform to specifications;
2. If the control valve fails due to black particles in the valve body, and it is necessary to replace the control
valve, please check the condition of the canister;
3. Avoid liquid such as water and oil entering into the valve during maintaining as possible;
4. It is advisable to mount the canister control valve on the hose hanging in the air or fasten with soft rubber
to avoid transmission of solid borne noise.Figure 3-13Figure 3-15 Absorption port
Discharge port
Exit port
Plug upFigure 3-14Absorption port
Discharge port
Exit port -

3. Vent valve (PCV) sub-assembly
Air should flow through the cylinder cap side freely.
Attention:

Do not suction air through the valve.
Never put anything into the valve. If the operation is unsatisfactory, replace PCV.

Blow air into from the suction side, and the air should be hard to flow through. If the operation is
unsatisfactory, replace PCV (see Figure 3-17).Figure 3-17Fuel SystemCarbon Canister Replacement3-20Figure 3-16 Easy measuring method: (disconnect the connector) Set the digital multi-meter to ohm position, with two leads
connecting to two pins of the canister control valve respectively, rated resistance 22-30 ohm at 20°CEasy HardCylinder head sideManifold side
Cleaning pipe -

Chapter 7 Automatic Transaxle AssemblySection 1 Frequent Problems DiagnosisPossible Cause1. There is no scan information.
(1)The diagnosis system fails.
(2)The automatic transmission unit fails.
2. The engine can't start.
(1)The engine system fails.
(2)The fuel pump or torque meter fails.
3. The vehicle cant' runs forwards.
(1)The circuit voltage is improper.
(2)The rear clutch or single clutch fails.
(3)The valve fails.
4. The vehicle can't run backwards.
(1)The low speed brake or front clutch pressure is improper.
(2)The front clutch or low speed reverse gear fails.
(3)The valve fails.
5. The vehicle can't runs forwards or backwards.
(1)The pressure deduction is improper or the transmission signal fails.
(2)There is pressure in the oil pump or the valve body fails.
6. The engine stalls in gear shift.
(1)The engine system or clutch torque meter fails.
(2)The valve body or torque meter fails.
7. The vehicle vibrates and lasts for a long time when the gear is shifted from N to D.
(1)The rear clutch fails.
(2)The valve body clutch fails.
(3)The restrictor switch fails.
8. The vehicle vibrates and lasts for a long time when the gear is shifted from N to R.
(1)The front clutch pressure fails.
(2)The front clutch or valve body fails.
(3)The low speed reserve gear pressure or low speed reverse gear fails.
9. The vehicle vibrates and lasts for a long time when the gear is shifted from N to D/R.
(1)The pressure reduction fails.
(2)The oil pump fails.
(3)The valve body fails.
10. The gear shift impacts.
(1)The servo switch or restrictor position switch fails.
(2)The pressure is decreases abnormally.
(3)The clutch or brake fails.
11. All gear shift points are either too early or too late in the running status.Automatic Transaxle Assembly Frequent Problems Diagnosis3-29 -

3. Definition of multi-pin plug-in unit terminal
1. Prompt:
R- red Bl- blue Y - yellow B- black P- pink G- green W- white
O- orange Gr - gray Br- brown V- purple Lg- olive drab
The first letter indicates primary color
The second letter indicates stripe colorTerminal
number1 MIL C 10 NA
2 Engine oil pressure switch YG 1 P
3 Brake fluid GR 2 R
4 Park G 3 N
5 Right turn light GB 4 D
6NA 52
7 EBD 6 L
8 Charge WR 7
9NA 8NA
10 NA 9 Sidelight GW
11 Safety belt YR 10 Start BR
12 NA 11 B+
13 Engine GY 12IG ( + ) Y
14 Safety gasbag RY 13 GND
15 NA 14 NA
16 IG ( + ) 15Speed sensor earthing B
1 NA 16 Speed signal input YR
2 Left turn light GW 17 Speed sensor power supply RY
3 High beam (+) RB 18 Key (ODO/TRIP) G
4 High beam (-) RW 19 Key (adjust brightness) YG
5 Foglight Gr 20 Key COM B
6 Rear defrost YB 21 Fuel gauge V
7 NA 22 ABS R
8 NA 23 Tachometer BBL
9 Door-lock warning lamp RBL 24 Coolant temperature gauge YWA
BCCombination Instrument System -Wiring diagram of Combination Instrument and Location of Multi-pin Plug-in Terminal5-9Definition of terminalConductor
ColorTerminal
numberDefinition of terminalConductor
Color