2008 GEELY MK ESP

Geely “MK” series sedans (JL7132U,JL7132HU,JL7152U,JL7152HU,JL7162U) are brand
new superior models developed by Geely Group who has fully proprietary intellectual property
rights. As a result of the three years of involvements and efforts of the experts from Geely Automo-
bile Research Institute, these sedans reach international leading level in model design, power,
sense of comfort, safety and manufacturing technology while featured in beautiful appearance,
economy, environment protection and safety. The meaning of MK implied that Geely Automobile
has a great development from caterpillar to butterfly. With respect to the power, Geely “MK” series
sedans are equipped with 1.3L, 1.5L, and 1.6L EFI engines developed and manufactured by Geely
itself, and has reached “Chinese III” (Euro III) emission standard.
This manual contains a detailed description of the structures and principles, servicing and adjustment,
removal, assembling technology and matching clearance of the parts of the Geely “MK” sedans
with torque information of the bolts and nuts as well as schematic diagram for special tool operation.
This manual also introduces the transmission control system of the automatic transmission models,
vehicle electric circuits and elaborates ABS system, SRS, BOSCH M7.9.7 electronic control fuel
injection and ignition system, rear parking radar, sound, air conditioning and onboard hands-free
phone system. You can refer to this manual for the information about the regular maintenance,
servicing, adjustment, troubleshooting, removal and installation procedure, specific operations of
the “MK” sedans.
This manual covers the matching relation among the engine assembly, transmission assembly and
the vehicle, but does not have the further description of the structures and principles of the engine
and transmission assemblies and their servicing process. You can refer to the service manuals
solely prepared for engine assembly and transmission assembly for these information.
All information in this manual is based on the latest products released at the time of publication of
this manual. However, the specifications and procedures may need to be modified, and the subse-
quent change will be revealed in later versions.
This manual is prepared by Geely Automobile Research Institute under the assistance of technical
staff from Zhejiang Geely Automobile Co., Ltd and Geely International Corporation. Readers
discovering during the use of this manual the errors and careless omissions due to limited skills of
the preparers and tight schedule are encouraged and pled to contact Geely International in time for
our timely correction of the mistakes.ForewordGeely International Corporation
Nov . 2007

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

2-15
VI. Table 2 Maintenance Timetable of Geely Freedom Cruiser SedanMaintain the vehicle when either mileage or time has reached maintenance requirements. User should keep
maintaining the vehicle to no less than 100000km. User can send the vehicle for inspection and repair in advance
if it has been through special conditions.SystemInspection itemX1000km
Year7.5 15 22.5 30 37.5 45 52.5 60 67.5 75
0.5 1 1.5 2 2.5 3 3.5 4 4.5 5Steering
SystemSteering-wheel Play,Fastening and abnormal noiseOperation
Oil Leak
FasteningFastening,abnormal noise and damage
Steering link,joint,rack and dust bootcrack and damage
Abnormal noise at a joint
Wheel adjustment
Left and right rotation angle
Trie pressure
Tire crack and damage
Tire thread and uneven wearMetal dust,stone and foreign materialLoose hub nut and boltFront wheel bearing abnormal noise
Rear wheel bearing abnormal noiseFree play
Operation
Oil leak and oil level
Operation system abnormal noise
Replace oil
Replace ATF
Oil leak and oil level
Joint fasteningUniversal joint,dust root crack and damageSpline abnormal noise
Universal joint abnormal nosie
Free play and Function
Function
Operating travel
FunctionParking brake cable fastening,abnormal noise and damageo......Inspect ......ReplaceTable 2 Drive
line
Drive
Train
Braking
SystemSteering
Wheel
Steering
Gear
Steering
Link and
Joint
Knuckle
Front
Wheel
Wheel
Clutch
ManualTransmissionAutomaticTransmissionDriveshaftBrake
Pedal
Parking
BrakeUsage and Maintenance of MK Series - Maintenance Category and Content of MK Sedano
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2-18Section 3 Daily Maintenance of MK SedanDaily maintenance means operation of vehicle regular inspection, cleaning, fastening, and refilling according to
vehicle usage and condition on the basis of regular maintenance to make sure the vehicle is at good status. Daily
maintenance can be performed by driver or professional automotive mechanics in daily use of vehicle. But some
of the items must be conducted by professional mechanics at service shops.
1. Maintenance of air cleaner
Air cleaner filters the air that is coming into engine for the first time. Dust and other dirt filtered out gathers in the
induction tube. Air cleaner filters a lot of dust and dirty, so it must be cleaned in time.
2. Maintenance of air filter
Air filter does not only filter the dust and dirt in the air, but also keeps smooth ventilation. Its status has great effects
on the fuel economy and power of the engine, so it must be checked and maintained in time.
Before it is time to replace air filter, maintain it. Remove the filter, knock it with hand or stick to get rid of dust
on the filter and remove dirt inside the filter cover according to the cleanness of the road that the vehicle usually
runs on.
ATTENTION: do not clean the filter with wet cloth. Fasten the filter well when installing it back.
3. Maintenance of battery
Battery is used to start the vehicle and supply power to electrical facilities. Its status directly affects the regular
usage of the vehicle, especially for vehicles equipped with electrical controlled facilities. Keeping the battery in
good technical status and connections is especially important. It is necessary to often perform the following
inspections and maintenance in regular usage:
(1) Clean the outside of battery Inspect if the battery case or cover surface is dirty or has dirt, oil, or other dirty
things regularly. Clean it and keep the surface dry to avoid electrical leak caused by cover deformation.
(2) Check battery connections Bad connection between battery electrode and cable results in low engine start
speed which makes it difficult to start the vehicle or the vehicle cannot be started because of low output voltage
from battery. Loose connection at battery end leads to damage of electrical components and loss of trouble code
and other information stored in RAM of the computer system as a result of low voltage. Therefore, it is necessary
to check if the connection of cables on the battery electrode is good. When it is found loose, it must be fastened.
If there is any rust, the cables must be loosened, washed clean and be connected again.
4. Maintenance of tires and wheels
(1) Keeping tires and wheels under good condition is very important to vehicle fuel consumption and driving
safety. Therefore, inspect and maintain the tires regularly. Every 10000 km, the wheels should be adjusted. Follow
the sequence in picture 3:
Judge if there is any hidden problems in vehicle chassis mechanism by observing wear in different places, andfinding out the hidden problems does not only help you to understand
the technical status of the vehicle, but also benefits driving safety.
a. Serious wear on both edges of tire tread, means tires often
work with low tire pressure.
b. Wear of middle of the tire tread is mainly because the tires
are used with high tire pressure.This kind of wear shortens
the useful life of tires, and may result in sudden flat tire
when the vehicle runs on uneven road surface or meets any
obstacles.Usage and Maintenance of MK Series - Daily Maintenance of MK Sedan

12. Check the compressing pressure (see Figure 1-4).
(1) Warm up and switch off the engine.
(2) Remove the secondary wire.
(3) Remove the spark plug.
(4) Check the compressing pressure in the cylinder.
a.Insert the pressure gauge into the spark plug bore.
b. Throttle widely opens.
c. Rotate the engine crankshaft and measure the compressing
pressure (see Table 2).Figure 1-4Table 2Cylinder compressing pressure (KPa)Pressure difference range of cylinders of this model (KPa)Minimum compressing pressure (KPa)MR479Q MR479QA MR481QA
1250 1320 1360
100
980
Attention:
The electric quantity in the battery should be always enough, and the engine speed should be not less than
250r/min.

Check the compressing pressure in other cylinders in the same way.
Measure as soon as possible.
(5) If the compressing pressure in more than one cylinder is relatively low, fill a bit engine oil to the cylinder
through the spark plug bore, and repeat step a to c to check.
Tip:

If the compressing pressure is increased after the oil is filled, the piston ring or the cylinder may be worn or
damaged.
If the pressure is still low, the valve may be jammed or badly sealed, or the washer may be leaked.
13. Check CO/HC.
(1) Start the engine.
(2) Keep the engine running at a speed of 2500 r/min for about 180s.
(3) During idling, insert the test bar of CO/HC instrument into the exhaust pipe about 40cm depth at least.
(4) Check the concentration of emission of CO/HC at idle speed and at a speed of 2500 r/min respectively.
Tip:

Measure within 3 minutes.
Test the concentration of emission and lambda value of CO/HC at idle speed and at a speed of 2500 r/min
respectively according to GB18352.3-2005 standard.
(5) If the concentration of CO/HC is not up to standard, carry out fault diagnosis by following the steps below.
(1) Check oxygen sensor.
(2) Refer to Table 3 to find possible causes, check and repair.Engine AssemblyEngine Inspection3-4 -

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 -

Figure 7-3Automatic Transaxle Assembly Hydraulic Torque Converter and Transaxle3-31Figure 7-5 Figure 7-4Figure 7-1
Figure 7-23. Install transmission in the engine, its way like manual transmission. The torque converter cannot be allowed to
move in axial motion during operating (The dimension of A keeps constant). Install starter in the transmission
housing.
4. Connect Flexibility plate with torque converter, using 3 special bolts. The way is as follows. First, assemble one
bolt in the torque converter by the longer hole of the Flexibility plate, and then rotate engine belt pulley to install
the other bolts, finally use torque spanner to tighten the bolts. Tightening torque is 40~50N.m.
5. Install suspension bolt and drive shaft LH&RH, the assembling way like manual transmission.
6. Connect two cooling pipes as showed in the figure 7-3 with the corresponding pipe of transmission with clip.
7. Connect the cable between bracket of throttle and transmission actuator.
8. Throttle valve cable adjustment as follows:
First, use pliers to clip the hexangular position under throttle valve cable.Turn 60°~90°counterclockwise,
and lift throttle valve cable to make throttle valve cable adjustable move to top position, and then turn back
60°~90° clockwise, meanwhile, make it lock (See figure 7-4). Finally put accelerator pedal to end position.
When throttle valve makes "ka-ka" sound, the distance under the throttle valve should meet B=2~8mm. If not,
try again until the gap B=2~8mm under the throttle valve (see figure 7-5), if gap B=2-8mm, throttle valve cable
adjustment is finished.Central
plateFlexible plate
Torque converter
housing end
Torque
converterFront contact face
Torque converter
anchor point
Central anchor col-
umn -

Part IV ChassisChapter 1 Transmission ControlSection 1 Introduction of Transmission ControlI. Description on Transmission ControlThis model is equipped with cable Transmission Controls, respectively used for 1.3L, 1.5L and 1.6L engine. Their
gears are: 5 forward gears + 1 reverse gear.II. Symptom TableUse the table below to help you find the cause of the problem. The numbers indicate the priority of the likely cause
of the problem. Check each part in order. If necessary, replace these parts.
Suspected Area
1. Transmission Control selector (position changing) cable
(improperly assembled)
2. Cable or shift lever (worn)
3. Cable assembly (incorrect)
4. Transmission (faulty)
1. Transmission control selector (position changing ) cable
(improperly assembled)
2. Cable or shift lever (worn)
3. Cable assembly (incorrect)
4. Transmission (faulty) Symptom
Transmission out of gear
Transmission shift difficultChassisTransmission Control4-1 -