2008 GEELY MK brake fluid

Repair Repair the right side as the steps in the left side.
1. Check the thickness of the brake shoe lining.
Remove the hole plug, and check the thickness of the brake shoe
lining through the hole.
If the thickness is less than the minimum thickness, replace a new
brake shoe.
Minimum Thickness: 1.0mm
2. Remove the rear wheel.
3. Discharge the brake fluid.
Note:
Never spray the brake fluid on the paint surface, otherwise wash
it immediately.
4. Remove the rear brake drum.
(1) Loosen the parking brake rod, and remove the brake drum.
Tips: If the brake drum can't be removed easily, carry out the
following steps.
(2) Remove the hole plug, and insert a screwdriver through the
backboard to separate the brake automatic adjustment rod
and the adjustor.
(3) Rotate the adjustment wheel to reduce the length of the
adjustor with another screwdriver.
5. Check the inner diameter of the brake drum.
Measure the inner diameter of the brake drum with a brake drum
gauge or equivalent.
Standard Inner Diameter: 200.0mm
Maximum Inner Diameter: 201.0mm
6. Separate the left positioning post of the parking brake shoe.
Remove the extension spring from the front/rear brake shoe with
a special tool, and separate the left positioning post of the parking
brake shoe.
Note:
Be careful not to damage to the dust shield of the brake cylinder.
7. Remove the front brake shoe.
(1) Remove the end cap, set spring and pin with a special tool.
(2) Unfix the return spring, and remove the front brake shoe.
(3) Remove the left positioning post of the parking brake shoe.Brake System -Rear Brake Drum4-100Rotate

Brake System -Rear Brake Drum4-10213. Check the brake shoe and the brake shoe lining whether they
touch normally.
Mark the inner surface of the brake drum with chalk, joint and
abrade the brake shoe and the inner surface.
If the drum and the lining touch poorly, abrade the brake shoe or
replace a new one.
14. Remove the left front or top brake wheel cylinder.
(1) Unfix the brake oil pipe with a special tool, and collect the
brake fluid with a container.
(2) Remove the bolt and brake wheel cylinder.
15. Remove the brake cup.
(1) Remove the two dust shields from the brake cylinder.
(2) Remove the two pistons and springs.
(3) Remove the two brake cylinder caps from every piston.
16. Check the brake cylinder.
Check the cylinder wall and piston whether there is any rust or nick.
17. Remove the rear discharge screw plug of the brake drum.
18. Tighten the rear discharge screw plug of the brake drum
temporarily.
19. Install the brake wheel cylinder cup.
(1) Apply the lithium soap-base glycol lube on the two brake
wheel cylinder cups and the piston.
(2) Install two brake cylinder caps on every piston.
(3) Install the compression spring and the two pistons on the
brake wheel cylinder.
(4) Install two new dust shields on the brake wheel cylinder.
20. Install the left front or top brake cylinder.
(1) Install the brake cylinder with bolt.
Torque: 9.8N.m
(2) Connect the brake oil pipe with a special tool.
Torque: 15N.m
21. Apply the heat-resistant lube.
Apply the heat-resistant lube on the touch surface of the brake
backboard and the brake shoe.

Brake System -Rear Brake Drum4-105 (2) Measure the inner diameter of the brake drum and the
diameter of the brake shoe, and check the difference of them
whether it is a proper brake shoe clearance.
Brake Shoe Clearance: 0.3mm
Note:
Don't apply the oil or lube on the friction surface of the brake shoe
lining and brake drum.
30. Adjust the shoe clearance of the brake drum.
(1) Install two wheel hub nuts temporarily.
(2) Turn around eight teeth of the adjustor.
(3) Install the hole plug.
31. Install the rear brake drum sub-assembly.
32. Add the brake fluid to the storage tank.
33. Discharge the air in the master cylinder.
34. Discharge the air in the brake pipeline.
35. Check the level height in the storage tank.
36. Check the brake fluid whether there is any leakage.
37. Install the rear wheel.
Torque: 103N.m
38. Check the stroke of the parking brake extension rod.
39. Adjust he stroke of the parking brake extension rod.Extend

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

Suspected area
1. Wiring harness or connector
2. ECM
3. Combination instrument assy.
1. Wiring harness or connector
2. Alternator
3. Combination instrument assy.
1. Wiring harness or connector
2. Manual brake switch
3. Combination instrument assy.
1. Wiring harness or connector
2. Brake fluid level switch
3. Combination instrument assy.
1. Wiring harness or connector
2. ABS ECU or ABS warning lamp driving module
3. Combination instrument assy.
1. Wiring harness or connector
2. Airbag ECU controller
3. Combination instrument assy.
1. Wiring harness or connector
2. Airbag ECU controller
3. Combination instrument assy.
1. Wiring harness or connector
2. Front head light dimmer switch
3. Combination instrument assy.
1. Wiring harness or connector
2. Front head light dimmer switch
3. Combination instrument assy.
1. Wiring harness or connector
2. Rear defrost switch
3. Combination instrument assy. 8. Warning lamp fails
Symptom
Check that engine warning lamp does not
illuminate
Charge warning lamp does not illuminate
Park braking warning lamp does not
illuminate
Brake failure warning lamp does not
illuminate
ABS warning lamp does not illuminate
SRS warning lamp does not illuminate
Passenger's airbag indicator lamp does
not illuminate
High beam indicator lamp does not
illuminate
Rear foglight indicator lamp does not
illuminate
Rear defrost indicator lamp does not
illuminate5-16Combination Instrument System -Malfunction Symptom Table and Troubleshooting

5-209. Check park warning lamp
(1) Disconnect connector from park switch
(2) Turn ignition switch to ON, park brake warning lamp should go out.
(3) Use conductor to short connector terminal to ground, park brake warning lamp should illuminate.
10. Check park switch
(1) Disconnect connector from park switch
(2) Pull up manual brake, check whether its terminal is connected with ground
Pull up manual brake: on
Manual brake release: off
11. Brake fluid level warning lamp
(1) Disconnect connector from brake fluid level sensor
(2) Turn ignition switch to ON, brake fluid level warning lamp should go out.
(3) Use conductor to connect its connector terminal wiring harness terminals directly, brake fluid level
warning lamp should illuminate.
12. Check brake fluid level warning switch
(1) Remove tank cap
(2) Disconnect connector from tank
(3) Check whether terminals are connected.
Floater on top: off
(4) Use sucker to suck out liquid from tank
(5) Check whether terminals are connected.
Floater down: on state
(6) Pour liquid back into tank
13. Rear defrost indicator lamp
(1) Turn ignition switch to ON, and start up engine
(2) Push down defrost switch, now rear defrost indicator lamp should illuminate
(3) Turn ignition switch to OFF, rear defrost indicator lamp should go out
14. Rear foglight indicator lamp
When rear foglight illuminates, rear foglight indicator lamp should illuminate, now A5 terminal should be high
potential.
15. Safety belt warning indicator lamp
(1) Disconnect safety belt switch connector from driver side, now safety belt warning indicator lamp should
go out.
(2) Short connector terminal to ground, safety belt warning indicator lamp should illuminate.Combination Instrument System -Malfunction Symptom Table and Troubleshooting

Visually check whether Hydraulic coupler leaksScrew down pipe head as required Abnormal
Check worn condition of brake discReplace brake disc Abnormal
Check brake fluid level switchReplace brake fluid level switch Abnormal
Exhaust checkExhaust again Abnormal
Use fault diagnosis instrument hydraulic con-
trol unit for diagnosis
Check tightness of normally closed valve leakReplace HCU (hydraulic control unit) AbnormalUse fault diagnosis instrument hy-
draulic control unit for diagnostic
check of normally open valveReplace HCU(hydraulic control unit) AbnormalNormal
Normal
Normal
Normal
Normal
Use traditional method of non-ABS
vehicle to check booster and pedal
strokeMK-60 ABS system -ABS System Check5-112Travel of brake pedal is too long 4
[Description] Firstly visually check whether there is external leakage or
mechanical failure. Use exhaust method to check whether
there is air in the system. Use fault diagnosis instrument
hydraulic pressure unit functional testing to check whether
normally closed valve leaks.Possible cause

Brake fluid leaks

There is air in the system

Brake disc is worn severely

Brake fluid level switch
failsA very large force is needed to step on pedal 5
[Description] Use traditional method to check travel of booster and brake pedal.
Fault of normally open valve may be checked using fault diagnosis
instrument hydraulic pressure unit functional testingPossible cause

Booster has problem

Normally closed
valve has problem

ABS HECU assy.III. Replace hydraulic control unit1. Press lock catch on joint side, remove wire harness of pump motor.
2. Remove 4 screws as as shown in the figure, the removed old screws
can not be reused.
3. Separate hydraulic control unit HCU from electronic control unit
ECU.
4. Mount new hydraulic control unit HCU onto electronic control unit
ECU.
5. Use new screw to fix ECU onto HCU, tightening moment: 3-4N.m.
6. Insert motor wiring harness, note that lock catch must be in right
position.MK-60 ABS system -
Removal and Installation5-117Schematic diagram for removal of ABS HECU brake oil pipe5. When system is opened, don't use compressed air or move the vehicle.
6. After removing ABS assembly, use appropriate plugs to plug up hydraulic delivery outlets as soon as possible.
Remove other parts that might hinder work.
7. Please use HZY4 brake fluid, do not use mineral oil.
8. Use brake fluid to soak sealing member and Oring, do not use engine oil or brake ointment.
9. After repair, check whether function of routine brake system and ABS brake is reliable and normal or not.
10. Check whether there is any leakage at all Hydraulic couplers.II. Removal of HECU1. Turn off ignition switch and disconnect storage battery minus earth wire.
2. Remove wiring harness plug from ABS HECU assembly.
3. Step down the pedal >60mm, use pedal bracket to fix it, so master cylinder center valve will be turned off, when
system is opened, brake fluid will not flow out from outlet.
4. Put a clean pad under hydraulic controller.
5. Firstly remove brake hard tube (A, B) on HCU connecting with master cylinder, make sign. Plug up the outlet
with a plug immediately.
6. Remove brake pipe (1 - 4) to wheels and make sign. Plug up the outlet with a plug immediately.
7. Remove the screw cap fixing HECU onto the bracket.
8. Remove the entire HECU from bracket.