2008 GEELY MK ABS

Repair1. Discharge the brake fluid.
Note: Never spray the brake fluid on the paint surface, otherwise
wash it immediately.
2. Remove the brake master cylinder.
(1) Pull out the connector of the level alarm light switch.
(2) Slide the clip, and pull out #1 clutch storage tank pipe (manual
transaxle).
(3) Remove the two brake pipes from the brake master cylinder
with special tool.(with ABS)
(4) Remove the three brake pipes from the brake master cylinder
accessory with special tool. (without ABS)
(5) Remove the two lock nuts, and pull out the brake master
pump.
3. Remove the storage tank.
(1) Put the brake master cylinder on the bench clamp.
(2) Remove the pin from the brake master cylinder body with
punch and hammer.
(3) Pull out the Brake fluid reservoir.
(4) Remove the cover and strainer from the storage tank.
(5) Remove the storage tank and the two hole connectors.
4. Remove the brake master cylinder.
(1) Put the brake master cylinder on the bench clamp.
(2) Remove the O-ring.
(3) Push the piston with hand, and remove the snap ring with
snap ring pliers.Brake System -Brake Master Cylinder Assembly4-87With ABS:
Without ABS

(4) Push the piston with hand, and turn the cylinder body to
remove the straight pin. (with ABS)
(5) Push the piston with hand, and remove the piston bolt and
washer. (without ABS)
(6) Pull out #1 piston, piston guide block, spring, cup and washer
straightly.
Note: If angle appears in the pulling process, it may cause
damage to the cylinder wall.
(7) Put two blocks and cloth on the workbench. Put the flange of
the master cylinder against the block edge and knock it till #2
piston and spring get out of the cylinder.
Tips:Brake System -Brake Master Cylinder Assembly4-88 Make sure the distance (A) between the working cloth and the block's top is at least 100mm.
Note:
If angle appears in the pulling process, it may cause damage to the cylinder wall.
5. Check the brake master cylinder.
(1) Check the cylinder wall whether there is any rust or nick.
(2) Check the cylinder wall whether there is any abrasion or damage.
Note:
If necessary, clean or replace the brake master cylinder.
Tips:
Clean the assembled parts with compressed air.
6. Install the brake master cylinder.
(1) Fix the brake master cylinder on the bench clamp.
(2) Apply the lithium soap-base glycol lube on the rubber parts with arrow.
(3) Install # 2 and # 1 pistons, spring, piston guide block, cup and washer.
Note:
If angle appears in the installation process, it may cause damage to the cylinder wall. Be careful not to
damage the edge of the cup on the piston.

Brake System -Brake Master Cylinder Assembly4-89 (4) Push the piston, and install the straight pin on the cylinder
body. (with ABS)
(5) Push the piston, and install the new washer and piston bolt.
Torque: 10N.m
(6) Push the piston, and install the snap ring with snap ring pliers.
(7) Install the O-ring on the brake master cylinder.
7. Install the Brake fluid reservoir.
(1) Apply the lithium soap-base glycol lube on the Brake fluid reservoir connector, and install it on the brake
master scylinder.
(2) Install the pin on the brake master cylinder with punch and hammer.
8. Check and adjust the vacuum booster push bar.
(1) Install a special tool on the brake master cylinder,and lower
the special tool mandril till it touches the piston.
(2) Mark the mandril top surface of the special tool with chalk.
(3) Overturn the special tool, and leave a clearance between the
special tool and the vacuum booster.
Tips:
If there is clearance between the special tool body and the booster hull, it means that the clearance is
standard value. If there is no chalk trace on the booster push bar, it means that the clearance exceeds the
standard value.

Brake System -Brake Master Cylinder Assembly4-90 (4) Adjust the length of the vacuum booster push bar with the
special tool till the push bar touches the mandril head.
9. Install the brake master cylinder.
(1) Install the brake master cylinder on the booster with two bolts.
Torque: 13N.m
(2) Connect the two brake oil pipes to the brake master cylinder
with a special tool. (with ABS)
Torque: 15N.m
(3) Connect the three brake oil pipes to the brake master cylinder
with a special tool. (without ABS)
Torque: 15N.m
(4) Connect # 1 clutch storage tank oil pipe with clip. (Manual
transaxle type)
(5) Insert the brake fluid level alarm switch connector.
10. Add the brake fluid to the Brake fluid reservoir.
11. Discharge the air in the brake master cylinder.
12. Discharge the air in the brake pipeline.
13. Check the level height in the Brake fluid reservoir.
14. Check the brake fluid whether there is any leakage.With ABS:
Without ABS

19151915131515
Fluid level indicator lamp connectorVacuum booster assembly
Gasket25Clip26 Clip Master cylinder
Manual Transmission
#1 clutch fluid tank oil pipe
HECU assemblyClipSection 5 Vacuum BoosterComponent ViewBrake System -Vacuum Booster4-91Battery
#2 relay box, engine chamber
Return spring
Pin
Push bar
U-connector Without ABSVacuum tube
Non-reusable parts
Lithium soap base glycol lubeSpecified torque

Brake System -Vacuum Booster4-93Replacement1. Discharge the brake fluid.
Note:
Never spray the brake fluid on the paint surface, otherwise wash it immediately.
2. Unfix the clutch fluid tank pipe (manual transaxle).
3. Remove the brake master cylinder.
4. Remove the HECU assembly (with ABS).
5. Remove the vacuum booster.
(1) Unfix the vacuum tube from the brake booster.
(2) Remove the return spring, clip and pin.
(3) Remove the four nuts and U-clip.
(4) Pull out the vacuum booster and washer.
6. Install the vacuum booster.
(1) Install the vacuum booster and new washer.
(2) Install and fasten the vacuum booster nut.
Torque: 25N.m
(3) Install the return spring, clip and pin.
7. Install the vacuum booster push bar.
8. Install the brake actuator. (with ABS)
9. Install the brake master cylinder.
10. Connect the clutch fluid pipe.
11. Add the brake fluid to the reservoir.
12. Discharge the air in the brake master cylinder.
13. Discharge the air in the brake pipeline.
14. Check and adjust the height of the brake pedal.
15. Check the free stroke of the pedal.
16. Check the reserved distance of the pedal.
17. Discharge the air in the clutch tank pipe (manual transmission).
18. Check and adjust the clutch pedal (manual transmission).
19. Check the level height in the brake reservoir.
20. Check the brake fluid whether there is any leakage.
21. Check the clutch fluid whether there is any leakage (manual transmission).

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