2008 GEELY MK Chapter 9

Table of ContentsTable of ContentsIPart I General InformationChapter 1 How to Use This Manual.................................................................................. 1-1
Chapter 2 Repair Instruction............................................................................................. 1-3Part II Vehicle Usage and MaintenanceChapter 1 Brief Introduction of Geely MK......................................................................... 2-1
Section 1 Major Functional and Technical Data of MK Series. ...................................... 2-1
Section 2 Vehicle System Configuration ........................................................................ 2-3
Section 3 Main Vehicle Test Technical Specification ...................................................... 2-5
Chapter 2 Usage and Maintenance of MK Series............................................................ 2-6
Section 1 Usage of MK Series ....................................................................................... 2-6
Section 2 Maintenance Category and Content of MK Sedan..........................................2-12
Section 3 Daily Maintenance of MK Sedan .................................................................... 2-18Part III EngineChapter 1 Engine Assembly............................................................................................... 3-1
Section 1 Engine Inspection ........................................................................................... 3-1
Section 2 Removal of the Engine Assembly from the Vehicle ....................................... 3-5
Section 3 Drive Belt Replacement .................................................................................. 3-7
Chapter 2 Engine Mechanical............................................................................................ 3-8
Section 1 Engine Components ....................................................................................... 3-8
Section 2 Throttle Body ..................................................................................................3-12
Section 3 Valve Clearance Adjustment .......................................................................... 3-14
Chapter 3 Fuel System....................................................................................................... 3-15
Section 1 Check Fuel System Pressure ......................................................................... 3-15
Section 2 Fuel Pump Inspection ..................................................................................... 3-16
Section 3 Fuel Pump Replacement ................................................................................ 3-17

Table of Contents II Section 4 Fuel Emission Control System ....................................................................... 3-18
Section 5 Carbon Canister Replacement ....................................................................... 3-19
Chapter 4 Exhaust System................................................................................................. 3-21
Chapter 5 Cooling System................................................................................................. 3-22
Section 1 System Inspection .......................................................................................... 3-22
Section 2 Radiator Replacement ................................................................................... 3-24
Chapter 6 Manual Transaxle Assembly............................................................................. 3-25
Section 1 Frequent Problem Diagnosis .......................................................................... 3-25
Section 2 Vehicle Speed Sensor Replacement ............................................................. 3-26
Section 3 Manual Transaxle Replacement ..................................................................... 3-27
Section 4 Transmission/Transaxle Case Oil Seal Replacement .................................... 3-28
Chapter 7 Automatic Transaxle Assembly........................................................................ 3-29
Section 1 Frequent Problems Diagnosis ........................................................................ 3-29
Section 2 Hydraulic Torque Converter and Transaxle .................................................... 3-30
Section 3 Differential Front Oil Seal (ATM) .................................................................... 3-33
Section 4 Neutral Switch Assembly ................................................................................ 3-35Part IV ChassisChapter 1 Transmission Control........................................................................................ 4-1
Section 1 Introduction of Transmission Control ............................................................. 4-1
Section 2 Cable Type Transmission Control .................................................................. 4-3
Section 3 Manual Transmission Shift Mechanism .......................................................... 4-5
Section 4 Automatic Transmission Shift Mechanism ...................................................... 4-7
Chapter 2 Accelerator Pedal Device................................................................................. 4-11
Section 1 Introduction of Accelerator Pedal ................................................................... 4-11
Chapter 3 Clutch Control System...................................................................................... 4-12
Section 1 Introduction of Clutch Centrol ......................................................................... 4-12
Section 2 Clutch Pedal ...................................................................................................4-13
Chapter 4 Propeller Shaft/Driveshaft................................................................................ 4-17
Section 1 Propeller Shaft, Driveshaft and Transaxle ..................................................... 4-17

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

Table of ContentsV Section 1 SRS General Information ............................................................................... 5-54
Chapter 7 Air Conditioning System................................................................................... 5-72
Section 1 General Information ........................................................................................ 5-72
Section 2 Refrigerant ...................................................................................................... 5-77
Section 3 A/C Operating Mechanism ............................................................................. 5-83
Section 4 Heater, Ventilation and Air Conditioning ........................................................ 5-86
Section 5 Layont of Air Conditioning Hose ..................................................................... 5-92
Section 6 Multi-wedge belt (Connecting Compressor and Crankshaft Pulley) .............. 5-93
Section 7 Compressor Assembly .................................................................................... 5-94
Section 8 Condenser Fan and Condenser Assembly .................................................... 5-96
Chapter 8 MK-60 ABS System........................................................................................... 5-99
Section 1 ABS Diagnosis ................................................................................................ 5-99
Section 2 ABS System Check ...................................................................................... 5-103
Section 3 Removal and Installation .............................................................................. 5-138
Section 2 Power Door Lock Control System ................................................................5-142Part 6 Interior & Exterior Trim and AccessoryChapter 1 Front Seat Assembly......................................................................................... 6-1
Chapter 2 Rear Row Seat Assembly................................................................................. 6-3
Chapter 3 Front Seat Belt................................................................................................... 6-5
Chapter 4 Rear Seat Belt.................................................................................................... 6-9
Chapter 5 Dashboard, Middle Console and Instrument Panel....................................... 6-11
Chapter 6 Windshield......................................................................................................... 6-16
Chapter 7 Rear Window Glass (with Defrosting Heater Wire)........................................ 6-20
Chapter 8 Side Inner Panel Trim........................................................................................ 6-22
Chapter 9 Roof Trim............................................................................................................ 6-25
Chapter 10 Front Door Interior Trim.................................................................................. 6-27
Chapter 11 Rear Door Interior Trim................................................................................... 6-30
Chapter 12 Front Bumper................................................................................................... 6-33
Chapter 13 Rear Bumper.................................................................................................... 6-35

Chapter 14 Outside Rearview Mirror................................................................................. 6-37
Chapter 15 Door Protecting Stripe.................................................................................... 6-38
Chapter 16 Carpet and Insulator....................................................................................... 6-39
Chapter 17 Moonroof Assembly (Optional)...................................................................... 6-40
Chapter 18 Plug List........................................................................................................... 6-42Part 7 BodyChapter 1 Survey................................................................................................................ 7-1
Section 1 Body Structure ................................................................................................ 7-1
Chapter 2 Body Repair....................................................................................................... 7-9
Section 1 Body Damage Forms and Requirements for Repair ...................................... 7-9
Section 2 Typical Technique of Body Panel Repair ....................................................... 7-16
Section 3 Repair After Body Damage ............................................................................ 7-16
Section 4 Features and Composition of Automobile Body ............................................ 7-24
Section 5 Painting Techniques After Body Repair ......................................................... 7-35
Section 6 Service Data For for Body .............................................................................. 7-36Attachment: Body Key Dimensions
Appendix: Torque Table of the Fasteners for Important AssemblyTable of Contents VI

General Information - How to Use This Manual1-1Part 1 General InformationChapter 1 How to Use This ManualI. Instruction1. General Information
(1)This manual conform to the first part of GB/T1.1--2000 Standardization Guide: The structure and prepar-
ing rule of the standard.
(2)Generally, the repairing job can be divided into the following 3 procedures:
1. Diagnosis
2. Removal and installation, replacement, disassembly and inspection, adjustment
3. Final inspection
(3) The first procedure “Diagnosis” (the details refers to each section or chapter) and second procedure “Re-
moval and installation, replacement, disassembly and inspection, adjustment” are scattered in the chapters and
sections, and this manual omits the third procedure “Final inspection”.
(4) This manual does not include the following basic operations which are imperative in real scenarios.
operate the jack or lifter
b. clean the removed parts if necessary.
c. inspect the appearance
2. Preparation
SST (Special Service Tools) and SSM (Special Service Materials) may be required and correctly used based
on the repairing condition, make sure the job procedure is followed.
3. Repair Procedure
(1) The disassembly illustration is placed under the title.
(2) The illustration shows the disassembly of the parts to help you understand the assembly of the parts. (3) Non-reusable parts need to be coated with grease, and the precoated parts and torque are specially shownin the disassembly illustration.
(4) Sometimes, the illustrations of the similar model are used where there may be some details differently
from the actual vehicle.
(5)The operational procedure is described in the following ways:
a. The illustration shows what to do and where to do it.
b. The task heading tells what to do.
c.The detailed text tells how to perform the task and gives other information such as specifications and
warnings.
4. Specification
Specifications are presented in bold type throughout the manual.
5.Term Definition
6. International System of Unit
The Units given in this manual are primarily expressed according to the International System of Unit.Caution indicates there is a possibility of injury to you or other people.
Notice indicates the possibility of damage to the components being repaired.
Tip provides additional information to help you perform the repair efficiently.a.

General Information - Repair Instruction1-3Chapter 2 Repair InstructionI. Precautions1. Basic Repair Hint
(1)Operation HintVehicle Protection
Appearance
Safe Operation
Removal and
installation, disas-
semble and inspection
Prepare the tools and
measuring instrument
Removed partsBefore the work, place radiator fascia cloth, fender cloth, seat cover and mat.
Always wear clean uniform
Make sure to wear the helmet and safety shoe
when more than 2 persons work together, be sure to pay mutual attention to the safety.
when it is required to run the engine, you have to pay attention to the ventilation of the workshop.
When handling the high-temperature, rotating, moving and vibrating parts, be careful not to be scalded
or hurt.
When lifting the vehicle, safety stand should be used to support the specified position.
When lifting the vehicle, safety devices should be used.
The diagnosis requires full understanding of the trouble and effective operation.
Before the parts are removed, check the assembly for distortion and damage.
The diagnosis requires full understanding of the trouble and effective operation.
Before the parts are removed, check the assembly for distortion and damage.
If the structure is complicated, notes or marks should made to avoid mistake and impact of the part
function.
If needed, clean the removed parts and reassemble them after careful inspection.
Before the work, prepare the tool fixture, special tools, instrument, oil, workshop cloth and required
parts for replacement.
arrange the removed parts in correct sequence, do not confuse or contaminate them.
For non-reusable parts such as gasket, O ring and self-locking nut, replace them with new ones in
accordance with the instruction described in this manual.
Pick up replaced parts, put them in the containers, and show them to the customers.2
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