2008 GEELY MK Brake

Table of ContentsIII Section 2 Front Driveshaft .............................................................................................. 4-19
Section 3 Front Wheel Hub ............................................................................................ 4-30
Section 4 Rear Wheel Hub and Bearing Assembly ....................................................... 4-35
Chapter 5 Front Suspension System................................................................................ 4-38
Section 1 Front Suspension System .............................................................................. 4-38
Section 2 Front Suspension ........................................................................................... 4-40
Section 3 Front Wheel Alignment ................................................................................... 4-43
Section 4 Front Strut Assembly ...................................................................................... 4-46
Section 5 Front Lower Swing Arm Assembly ................................................................. 4-49
Section 6 Front Stabilizer Bar and Link Rod Assembly .................................................. 4-53
Chapter 6 Rear Suspension System................................................................................. 4-54
Section 1 Rear Suspension System ............................................................................... 4-54
Section 2 Rear Wheel Alignment ................................................................................... 4-56
Section 3 LH/RH Rear Suspension Coil Spring ............................................................. 4-57
Section 4 Rear Absorber Installation Assembly ............................................................. 4-60
Section 5 Rear Suspension Crossmember .................................................................... 4-62
Chapter 7 Wheel.................................................................................................................. 4-66
Section 1 Tire Inspection and Wheel Replacement ....................................................... 4-66
Chapter 8 Power Steering System.................................................................................... 4-67
Section 1 Power Steering System .................................................................................. 4-67
Section 2 Steering Drive and Control Mechanism ......................................................... 4-69
Section 3 Steering Pipeline Component ........................................................................ 4-73
Section 4 Power Steering Gear ...................................................................................... 4-75
Chapter 9 Brake System.................................................................................................... 4-79
Section 1 Brake System ................................................................................................. 4-79
Section 2 Brake Fluid ..................................................................................................... 4-81
Section 3 Brake Pedal ....................................................................................................4-82
Section 4 Brake Master Cylinder Assembly ................................................................... 4-85
Section 5 Vacuum Booster ............................................................................................. 4-91
Section 6 Front Brake Disc ............................................................................................. 4-94

Table of Contents IV Section 7 Rear Brake Drum ............................................................................................ 4-99
Section 8 Parking Brake System.......................................................................................4-106Part V Electric System & AccessoryChapter 1 Starting and Charging System......................................................................... 5-1
Section 1 Starting System (MR479Q, MR479QA, MR481QA) ...................................... 5-1
Section 2 Charging System (MR479Q, MR479QA, MR481QA) .................................... 5-3
Chapter 2 Combination Instrument System..................................................................... 5-7
Section 1 Wiring diagram of Combination Instrument and Location of Multi-pin Plug-in Terminal5-7
Section 2 Malfunction Symptom Table and Troubleshooting ......................................... 5-10
Chapter 3 Wiper and Washer System............................................................................... 5-21
Section 1 Wiper and Washer System Inspection ........................................................... 5-21
Section 2 Replacement and Adjustment ........................................................................ 5-23
Chapter 4 Light System...................................................................................................... 5-26
Section 1 Light System Introduction ............................................................................... 5-26
Section 2 Light System Malfunction Inspection ............................................................. 5-28
Section 3 Headlamp Replacement ................................................................................. 5-34
Section 4 Front Fog Lamp Replacement ...................................................................... 5-35
Section 5 Rear Combination Lamp Replacement .......................................................... 5-36
Section 6 High-mounted Stop light Replacement .......................................................... 5-36
Section 7 Front Reading Lamp Replacement ................................................................ 5-37
Section 8 Rear Reading Lamp Replacement ................................................................. 5-37
Section 9 License Plate Lamp Replacement ................................................................. 5-37
Chapter 5 Audio System..................................................................................................... 5-38
Section 1 Audio System Description .............................................................................. 5-38
Section 2 Audio System Connector Terminal Layout ..................................................... 5-40
Section 3 Audio System Inspection ................................................................................ 5-41
Section 4 Audio System Replacement ........................................................................... 5-52
Chapter 6 SRS (Supplemental Restraint System)............................................................ 5-54

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

Section 3 Main Vehicle Test Technical SpecificationDescription
Front wheel outward leaning angle
Kingpin inward leaning angle
Kingpin rearward leaning angle
Left front wheel toe-in (mm)
Rear wheel outward leaning angle
% of braking total power vs. gross vehicle weight
% of front wheel braking power vs. front axle load
% of gap between left and right wheel brake power vs. the
greater braking power of them tworolling resistance of each wheel should not be larger than the axle load by
parking brake total power should be lighter than the test vehicle weight bysliding distance of front/rear wheels
when vehicle speed meter shows 40km/h, vehicle speed
monitor indicates
brightness of left/right headlamps
tolerance of close lamps is
tolerance of distant lamps isHarsh brake at 50km/h. the stop distance is
Rain test. 100 points is full mark. Minus one point for each
seepage. Minus 3 points for slow seepage 3 points, and minus
6 for a quick seepage. The limit of vehicle sealing isCheck leaks of the vehicle. When vehicle has run 50km, stop it and
inspect for leaks. Check if there is oil/water marks at static joints,
or if there is oil/water drops dripping down at dynamic joints
10min after the vehicle is stopped, there is a leak; if there is oil/
water marks/drops, but it does not drip down, there is seepage.Measure the temperature of transmission oil inspection hole.
Usually it is not higher than ambient temperature.
Check the surface temperature of wheel trim column. Usually
it is no higher than ambient temperature.
vehicle should be slightly steering insufficient i.e. driving on
a circle with same steering wheel angle, and accelerate from
low to high speed, the diameter of the circle increases gradually.
Maximum front wheel turning angle (inner/outer)ItemSpecification: GB18352.3-2005Brief Introduction of Geely MK - Main Vehicle Test Technical Specification2-5Inspection
line itemsRegular
quality
inspection
itemsSpecification
-0°30'± 45'
10°0'± 45'
2°0'± 45'
1±2
-0°56'± 45'
60% (no load, and full load)
20%(Front Axis),
24%(Rear Axis)
5%
20%
2 m/km
33.3 Km/h-42.1Km/h
15000 cd
(0.6-0.8)H, H refers to the central
height of headlamps.
10cm/10m19m
93 points
Daily inspection and smell with
nose
70°C
40°C
Inspect regularly
37.2°±2°/ 32°±2°Emission60% (no load),
50% (full load)

Chapter 2 Usage and Maintenance of MK SeriesSection 1 Usage of MK Series1. Instrument Panel Overview1.Instrument Panel Outlet Vent
2. Instrument Panel
3.Upper Glove Compartment
(Front Passenger Airbag Cover)
4.Sunshade
5.Dome Light And Sunroof
Switch
6.Inside Rearview Mirror
7.Glove Box
8. Power Window Regulator
Switch
9. Manual Transmission Shift
Lever Or Automatic Transmis-
sion Shift Lever
10.Parking Brake Control Lever
11.Engine Hood Release Handle
12.Power Window Lock
13.Power Door Lock Switch1.Left Combination Switch
2.Right Combination Switch
3.Display
4.Audio
5.Short-Distance Odometer
Adjustment Button
6.Instrument Panel Brightness
Adjustment Switch
7.Hazard Warning Light
8.A/C Control Panel
9.Ash Tray
10.Defroster Switch
11.Cigarette Lighter
12.”A/C“ Switch
13.Ignition Switch
14.Tilt Steering Adjustment
Handle
15.Theft-Deterrent Indicator
16.Power Outside Rearview
Mirror Control SwitchUsage and Maintenance of MK Series - Usage of MK Series2-6

Adjust seat back angle
Move seat forward or backward angleUsage and Maintenance of MK Series - Usage of MK Series2-7212.How to use ignition switch
(1) LOCK when key is at this position, it can be pulled out and inserted in easily. The function of this position
is to lock steering wheel. If the key cannot be turned from LOCK to ACC, please rotate the steering wheel slightly
while turning the ignition key.
(2) ACC radio and cigarette lighter is turned on when key is at this position.
(3) ON when key is at this position, the following indicator is on: battery charging, ABS, brake fluid level,
park brake, engine coolant temperature, engine MIL, airbag oil pressure.
(4) START Turn the key to this position to start the engine. When engine is started, release the key
immediately. It returns to ON automatically. When engine is on, do not turn the key to this position.
Notice:
(1) Do not pull the key out or turn it to LOCK before the car is fully stopped, or there will be dangers caused
by locking steering wheel or disabling some safety functions.
(2) It is prohibited to drive the car with engine turned off to ensure functioning of braking and steering booster.
(3) Do not let the key stay at ON for a long time when engine is off, or the battery fully discharged.
(4) Shift to neutral gear before ignition key is switched to START.
(5) Turn the steering wheel lightly after the car is fully stopped to make sure it is locked.
3.Unlock Steering Wheel
How to unlock steering wheel: insert ignition key, turn the steering wheel lightly and switch the ignition key.
Steering wheel is unlocked.
4.Adjust seat position
Seat back angle and cushion angle of front seats in MK-1 sedan can be adjusted.
(1) Adjust seat back angle
Turn around adjusting handle, and adjust seat back to appro
priate position.
(2) Move seat forward or backward
Steps:
a. pull adjusting handler up
b. Move the seat forward or backward, and adjust the seat to
appropriate position.
c. Put the handler down and move the seat again till it is
locked.
Attention: adjust the seat only when the car is fully stopped
to ensure safety.
(3) Front head rest can be adjusted in two ways.
Push the head rest from back to front, there are three fixed
positions to lock.If pushed over the final locking position,the
head rest can return to the original position after hand
withdraws.
(4) Fold Rear Row Seat
The seat back can be tilted forward so that the trunk will be
used to the last degree.
a. Remove the head rest
b. Unlock the seatback and fold it down.
Split seatback can be folded separately on demand.

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

2-9 c. Check levels of braking fluid, engine coolant, engine oil, transmission oil, power steering fluid, and
washing fluid to see if there is any leaking.
d. Inspect if brake pedal, clutch pedal, accelerator pedal, transmission shifter, steering wheel, choke are
loose or stuck. The free travel of clutch pedal is 5~15mm, the free travel of brake pedal is 1~6mm and
the free play of steering wheel is less than 30mm(measurement point at margin of steering wheel). if it
is out of this normal range, the clutch needs to be tuned.
e. Inspect if the connection of battery, lamps and signal lights are normal, and if the wire routing and
position are correct and not loose.
f. Inspect if the tire pressure is correct.
(2) On-road inspection If the inspection result of the above items is good, start the engine and test the car on
road, and perform the following inspections.
a. Acceleration pedal, see if the operation is smooth and if it is loose.
b. Clutch, see if there is any stuck or abnormal noise, and slip when driving.
c. Transmission,check if shifting is smooth,or rough and wrong shifting.Inspect if the display of A/T
shift lever is normal.
d. Steering, check if steering is light and smooth, and if the steering wheel turns back after steering.
e. Brake pedal, apply brake pedal to check if the braking functions well when vehicle speed is at
40km/h and if the vehicle runs off track.
f. Park brake, when parking brake handler is pulled, there should be 6~9 clicking sounds. Pull park brake
when vehicle is running at the speed of 20km/h and transmission is at neutral gear to see if it brakes.
g. Vehicle speed meter, observe the vehicle speed meter while driving. When speed changes, check if the
indicator is moving steadily or shakes.
h. Heating and air-conditioning.Try every control button to see if both heating and cooling system work
well.
i. Abnormal noise, listen carefully to see if there is any abnormal noise from engine, drive line system or
any other parts of the vehicle at a steady speed and during accelerating, and decelerating.
(3) Inspection after test ride check if there is anything abnormal in the vehicle while driving and conduct the
following inspections after the vehicle is parked.
a. Check electrical fan When engine coolant temperature is beyond 92.5°C, the radiator fan should be
running; When A/C is on and the pressure of refrigerant is more than 1.5 cooling ton, air conditioning
cooling fan should be running.
b. Check headlamp, method: park the car 5m away from the inspection surface (inspection board, curtain,
or wall) to the front bumper, and check if the beam from headlamp is good. The upper level if headlamp
should be 540mm above the ground, and the distance between headlamps on the two sides is 900mm.
c. Inspect engine idle speed,idle speed of hot engine is 800r/min±50r/min,when A/C compressor works,
the idle speed should be 900r/min±50r/min. If idle speed is abnormal, adjust the idle speed adjust
ment screw to adjust it.
(4) Usage of new cars in breaking-in period Follow the instructions below in the first 1500~2500km breaking
mileage to avoid wear and abnormal damage in breaking-in period, and to improve vehicle performance, fuel
economy and to extend vehicle useful life.
a. Drive steadily during breaking-in; do not accelerate harshly to avoid running engine at high speed.
Engine should not exceed 4500r/min in any gears. Especially at the early stage of breaking-in, vehicleUsage and Maintenance of MK Series - Usage of MK Series