Geely MK 2006, MK 2007, MK 2008, MK 2009, MK 2010 User Manual

...

Foreword

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 ef forts of the experts from Geely Automobile 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 . W ith 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 subsequent 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.

Geely International Corporation

Nov . 2007

Table of Contents

Part I General Information

Chapter 1 How to Use This Manual .................................................................................. 1-1

Chapter 2 Repair Instruction ............................................................................................. 1-3

Part II V ehicle Usage and Maintenance

Chapter 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.................................................................... 2-18

Part III Engine

Chapter 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

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

Table of Contents

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................................................................................ 3-35

Part IV Chassis

Chapter 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 Contents

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

III

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

Section 7 Rear Brake Drum............................................................................................ 4-99

Section 8 Parking Brake System.......................................................................................4-106

Table of Contents

Part V Electric System & Accessory

Chapter 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

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

Wiring diagram of Combination Instrument and Location of Multi-pin Plug-in Terminal

5-7

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 Contents

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 ................................................................ 5-142

Part 6 Interior & Exterior Trim and Accessory

Chapter 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 ........................................................................................................... 6-42

Table of Contents

Part 7 Body

Chapter 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.............................................................................. 7-36

Attachment: Body Key Dimensions Appendix: T orque Table of the Fasteners for Important Assembly

General Information - How to Use This Manual

1-1

Part 1 General Information

Chapter 1 How to Use This Manual

I. Instruction

1. General Information (1)This manual conform to the first part of GB/T1.1--2000 Standardization Guide: The structure and preparing 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 “Removal 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 shown in 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

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.

6. International System of Unit The Units given in this manual are primarily expressed according to the International System of Unit.

1-2

II. Vehicle Identification

1. Vehicle Identification Number (VIN): Vehicle Identification Number (VIN) is the legal identification of the vehicle which is printed on the middle of the engine compartment cowl (as shown in the illustration).

General Information - How to Use This Manual

VIN code position

2. VIN Code

4. VIN Code: on the left lower corner of the front windshield.

5. Engine Number: marked on the engine block as shown in the illustration

3. Ex-work Nameplate: on the middle of the engine compartment cowl

6. Transmission Mark: printed on the left side of the transmission

Mark position

I. Precautions

1. Basic Repair Hint (1)Operation Hint

General Information - Repair Instruction

Chapter 2 Repair Instruction

1-3

Vehicle Protection Appearance

Safe Operation

Removal and installation, disassemble and inspection

Prepare the tools and measuring instrument

Removed parts

Before 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.

1-4

(2)Lift and support the vehicle

Be careful to lift and support the vehicle. Make sure that the vehicle is appropriately supported.

(3)Precoated Parts

a. Precoated parts are bolts, nuts, etc. that are coated with a seal

lock adhesive at the factory.

b. If a precoated part is retightened, loosened or caused to move

in any way, it must be recoated with the specified adhesive.

c. When reusing precoated parts, clean off the old adhesive and dry with compressed air. Then apply the specified sealing adhesive to the bolt, nut or threads.

Notice: the torque should achieve the lower limit of the allowed torque range. d. The precoated parts should be kept intact for a period of time for induration based on the requirement of the sealing adhesive.

(4)Gasket If necessary, apply the sealant to the gasket to prevent disclosure. (5)Bolt, nut and screw Be careful to follow all torque specification and torque wrench should be used.

General Information - Repair Instruction

Sealing Adhesive

(6)Fuse When replacing fuses, be sure the new fuse has the correct amperage rating. Do not exceed the rating or use one with a lower rating.

Illustration Symbol Part Name

Equal Rated Ampere Value

Fuse

Medium Current

Fuse

High Current Fuse

General Information - Repair Instruction

(7)Clip The following illustration shows the typical removal and installation of the clip for body parts. Tip: If the clip is damaged during the operation, you have to replace it with a new one.

1-5

Illustration

Removal/installation

Protective Band

Screwdriver

Protective Band

Scraper

Clip Remover

Slip-joint Pliers

1-6

General Information - Repair Instruction

Illustration

Remove

Removal/installation

Install

2. For Vehicles Equipped With SRS Airbag and Seat Belt Pretensioner Tip: This is equipped with an SRS (Supplemental Restraint System), such as the driver airbag assembly, front passenger airbag assembly airbag ECU and seat belt pretensioner. Failure to carry out service operations in the correct sequence could cause the supplemental restraint system to unexpectedly deploy during servicing, possibly leading to a serious accident. Further, if a mistake is made in servicing the supplemental restraint system, it is possible the SRS may fail to operate when required. Before servicing (including removal or installation of parts, inspection or replacement), be sure to read the following items carefully, then follow the correct procedure described in this manual. (1) General Notice

a. Malfunction symptoms of the supplemental restraint system are difficult to confirm, so the diagnostic trouble codes become the most important source of information when troubleshooting. When troubleshooting the supplemental restraint system, always inspect the diagnostic trouble codes before disconnecting the battery.

b. Work must be started after 90 seconds from the time the ignition switch is turned to the "LOCK" position and the negative (-) terminal cable is disconnected from the battery. (The supplemental restraint system is equipped with a back--up power source so that if work is started within 90 seconds of disconnecting the negative (-) terminal cable from the battery, the SRS may deploy.) When the negative (-) terminal cable is disconnected from the battery, memory of the clock and audio systems will be cancelled. So before starting work, make a record of the contents memorized by the each memory system. Then when work is finished, reset the clock and audio systems as before. To avoid erasing the memory of each memory system, never use a backup power supply from another battery.

General Information - Repair Instruction

1-7

c. Even in cases of a minor collision where the SRS does not deploy, the driver airbag assembly, front passenger airbag assembly and seat belt pretensioner should be inspected.

e. Never use SRS parts from another vehicle. When replacing parts, replace them with new parts. f. Before repairs, remove the airbag ECU if shocks are likely to be applied to the sensor during repairs. g. Never disassemble and repair the airbag ECU assembly, driver airbag assembly, front passenger airbag assembly or seat belt pretensioner. h. If the airbag ECU assembly, driver airbag assembly, front passenger airbag assembly or seat belt pretensioner has been dropped, or if there are cracks, dents or other defects in the case, bracket or connector, replace them with new ones. i. Do not directly expose the airbag ECU assembly, driver airbag assembly, front passenger airbag assembly or seat belt pretensioner to hot air or flames. j. Use a volt/ohmmeter with high impedance (10 k ohm/ V minimum) for troubleshooting of the electrical circuit. Information labels are attached to the periphery of the SRS components. Follow the instructions on the notices.

After work on the supplemental restraint system is completed, check the SRS warning light

(2) Clock Spring (in combination switch) The steering wheel must be fitted correctly to the steering column with the clock spring at the neutral position, otherwise clock spring disconnection and other troubles may result.

Mark

(3) Driver Airbag Assembly a. When removing the driver airbag assembly or handling a new driver airbag assembly, it should be placed with the steering wheel top surface facing up. Storing the steering wheel with its top surface facing downward may lead to a serious accident if the airbag deploys for some reason. In addition do not store a driver airbag assembly on top of another one. b. Never measure the resistance of the airbag squib. (This may cause the airbag to deploy, which is very dangerous.) c. Grease should not be applied to the driver airbag assembly and the pad should not be cleaned with detergents of any kind.

Correct

Wrong

1-8

d. Store the driver airbag assembly where the ambient temperature remains below 93°C , without high humidity and away from electrical noise. e. When using electric welding, first disconnect the airbag connector (yellow color and 2 pins) under the steering column near the combination switch connector before starting work. f. When disposing of a vehicle or the driver airbag assembly alone, the airbag should be deployed using an SST before disposal. Perform the operation in a safe place away from electrical noise. (4) Front Passenger Airbag Assembly a. Always store a removed or new front passenger airbag assembly with the airbag rupture surface facing up. Storing the airbag assembly with the airbag rupture surface facing down could cause a serious accident if the airbag inflates. b. Never measure the resistance of the airbag squib. (This may cause the airbag to deploy, which is very dangerous.) c. Grease should not be applied to the front passenger airbag assembly and the airbag door should not be cleaned with detergents of any kind. d. Store the airbag assembly where the ambient temperature remains below 93°C , without high humidity and away from electrical noise. e. When using electric welding, first disconnect the airbag connector (yellow color and 2 pins) installed on the assembly before starting work. f. When disposing of a vehicle or the airbag assembly alone, the airbag should be deployed using an SST before disposal. Perform the operation in a safe place away from electrical noise.

General Information - Repair Instruction

Correct

(5) Seat Belt Pretensioner a. Never measure the resistance of the seat belt pretensioner. (This may cause the seat belt pretensioner to activate, which is very dangerous.) b. Never disassemble the seat belt pretensioner. c. Never install the seat belt pretensioner in another vehicle. d. Store the seat belt pretensioner where the ambient temperature remains below 80°C and away from electrical noise without high humidity. e. When using electric welding, first disconnect the connector (yellow color and 2 pins) before starting work. f. When disposing of a vehicle or the seat belt pretensioner alone, the seat belt pretensioner should be activated before disposal. Perform the operation in a safe place away from electrical noise. g. The seat belt pretensioner is hot after activation, so let it cool down sufficiently before the disposal. However never apply water to the seat belt pretensioner. h. There should be no oil or water on the seat belt, no cleanser should be used to wash it.

Wrong

General Information - Repair Instruction

1-9

(6) Airbag ECU a. Never reuse the airbag ECU involved in a collision when the SRS has deployed. b. The connectors to the airbag sensor assembly should be connected or disconnected with the airbag ECU mounted on the floor. If the connectors are connected or disconnected while the airbag ECU is not mounted to the floor, it could cause undesired inflation of the supplemental restraint system. c. Work must be started after 60 seconds from the time the ignition switch is turned to the "LOCK" position and the negative (-) terminal cable is disconnected from the battery, even if only loosing the set bolts of the airbag ECU. (7) Wire Harness and Connector The SRS wire harness is integrated with the instrument panel wire harness assembly. All the connectors in the system are a standard yellow color. If the SRS wire harness becomes disconnected or the connector becomes broken due to an accident, etc., repair or replace it.

3. Electronic Control Device (1) Removal of the battery terminal cable a. Before performing electrical servicing, disconnect the negative (-) cable from the battery in order to avoid short for burnout. b. When disconnecting the terminal cable, turn of f the ignition

Negative(-) Cable

and light switches, loosen the cable nut and raise the cable straight up without twisting or prying it. c. When disconnecting the terminal cable from the battery, all information stored in the clock, radio and DTC shall be deleted, therefore, these information shall be checked before disconnection. (2) Processing of Electronic Parts a. Do not open the cover or case of the ECU unless absolutely necessary. (If the IC terminals are touched, the IC may be destroyed by static electricity.) b. To pull apart electrical connectors, pull on the connector itself, not the wires. c. Be careful not to drop electrical components, such as ECU or relays. If they are dropped on a hard floor, they should be replaced and not reused. d. When steam cleaning an engine, protect the electronic

Wrong

components, air filter and emission-related components from water. e. Never use an impact wrench to remove or install temperature switches or temperature sensors. f. When checking continuity at the wire connector, insert the tester probe carefully to prevent terminals from bending.

4. Remove and Installation of Engine Intake Parts (1) If any metal scrap is mixed in the inlet pass, that may give a bad effect to the engine. (2) When removing and installing of the inlet system parts, close

1-10

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.

General Information - Repair Instruction

Steel Band Circlip

Clamp Trace

II. Vehicle Lift and Support Location

1. 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.

3.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 stopper only after the front wheels.

Rubber Suport

General Information - Repair Instruction

Jack Position

Center of Gravity of the Vehicle

1-11

Support Position Jack Lifting Position

(empty load)

4. Precautions for Use of Swing Arm Type Lift (1) follow the safe operation instruction described in this manual. (2) use bracket with rubber support as shown in the illustration. (3) make the center of gravity of the vehicle as close as possible to that of the lift ("L" should be smaller). (4) adjust the bracker height, level the vehicle, align the groove of the bracket with the safety stand support location. (5) the arm should be locked during the job (6) lift the vehicle until the tires become round.Swing the vehicle to make sure of stable vehicle.

5. Precautions for Use of Plate Type Lift (1) follow the safe operation instruction described in this manual. (2) use the support of the plate type lift. (3) make sure to secure the vehicle in the specified position.

Left and right set position

Front and rear set position

•

Place the vehicle over the center of the lift.

•

Align the cushion gum ends of the plate with the attachment

lower ends (A, C).

•

Align the attachment upper end (B) with the front jack supporting point.

1-12

General Information - Repair Instruction

(3)lift the vehicle until the tires become a little bit round. Swing the vehicle to make sure of stable vehicle.

Lift Center

Swing Arm Type Lifter

Plate T ype Lift

Cener of Gravity of the Vehicle (Empty Load)

Support

rubber support

Support Dimension

Vehicle Usage and Maintenance - Brief Introduction of Geely MK

Part II Vehicle Usage and Maintenance

Chapter 1 Brief Introduction of Geely MK

Section 1 Major Functional and Technical Data of MK Series.

I. Vehicle performance and structural data

Table 1 vehicle data

2-1

Dimension

Number of passengers

Curb weight

Weight

Road

adaptability

Curb

Gross Vehicle W eight

Max turning angle of front wheel

Item

Length

Dimension

Axle

Wheelbase Front Suspension Rear suspension

Minimum turning diameter Minimum Ground Clearance Approach angle Deviation angle

Width Height Front Rear

Front Axle Rear Axle V ehicle Front Rear

Left: Inner/out

Right: inner/out

Unit

person

° °

JL7132U

JL7152U

1090(1040)

660(640) 430(400)

1460(1410)

780(760) 680(650)

JL7162U

4342 1692 1435 1450 1431 2502

848 992

10.4m 150mm

15°

20°

37.2°±2°/ 32°±2°

JL7132HU JL7152HU

1450(1455)

780(785)

1080

665 415

670

Wheel Positioning

Front wheel leaning angle Kingpin inward leaning angle Kingpin rearward leaning angle Left front wheel toe-in Rear wheel outward

° °

-0°30'±45' 10°0'±45'

2°0'±45'

1±2mm

-0°56'±45'

2-2

Brief Introduction of Geely MK - Major Functional and Technical Data of MK Series.

II. Introduction of major systems

Table 2 Models and technical data of major systems.

Engine

Transmission

Item Description

Unit

Drive Type

Model Type Bore Diameter Piston play

mm Displacement Compression Ratio Max Power Max Torque Idle Speed

kw/r/min

N.m/r/min

r/min

Ignition Sequence

minimum fuel consumption rate

Model 1st gear 2nd gear 3rd gear 4th gear

g/kw.h

JL7132U JL7152U JL7162U JL7132HU JL7152HU

›‹

Front Wheel Drive

MR479Q MR479QA MR481QA MR479Q MR479QA

In-line 4 cylinderIn-line 4 cylinder In-line 4 cylinder In-line 4 cylinder In-line 4 cylinder

78.7 78.7 81.0 78.7 78.7

69.0 77.0 77.0 69.0 77.0

1.342 1.498 1.587 1.342 1.498

9.3 : 1 9.8 : 1 9.6 : 1 9.3 : 1 9.8 : 1

63/6000 69/6000 78.7/6000 63/6000 69/6000

110/5200 128/3400 137/4400 110/5200 128/3400

800±50

800±50 800±50

800±50

1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2

259 279 269 259 279

JL-S160 JL-S160A JL-Z110 JL-Z130

3.182 3.087 3.087

1.895 1.634 1.634

1.250 1 1

0.909 / /

Clutch Type

Steering type Braking

system

suspension

Tire

Fuel Tank Capacity

Body structure

5th gear Reverse gear Final Drive Ratio

Model Booster type Front Rear Specification Tire pressure Wheel

KPa

0.703 / /

3.083 2.29 2.29

4.308 3.317 3.317

Single disc, Plate and dry Spring

Hydraulic Gear-rack

Hydraulic, X-type pipe

Vacuum booster, Front Wheel Disc, Rear Wheel Drum

McPherson suspension strut system

Twist beam independent suspension system

85/60R15(1175/65R14)

230(Front)/210(Rear)

Aluminum 15X6J (Iron 14X5 1/2JJ)

Unitary construction body

Brief Introduction of Geely MK - Vehicle Configuration

Table 3 Power Performance Parameter

No.

Item Name

Unit

JL7132U JL7152U JL7162U JL7132HU JL7152HU

2-3

Maximum vehicle speed Acceleration time within the fourth gear from 30km/h to 120km/h

Acceleration time from 0-100km/h

Minimum stable vehicle speed within the fourth gear

Maximum gradeability

Table 4 Economic Performance Parameter

No.

Fuel consumption at constant speed (60km/h)

Fuel consumption at constant speed (90km/h)

Coasting distance (fully loaded, initial speed 50km/h)

Item Name

Unit L/100km L/100km

Section 2 Vehicle Configuration

No.

1 2

Item Name

Body color

Type

Common color

Uncommon color

km/h



JL7132U JL7152U JL7162U

4.5

4.6 5.0

6.2

550

Standard Comfortable Luxury

Chinese red, snow mountain white, pearl black, sky blue, ribbon silver

Crystal diamond silver, golden sand green, pineapple yellow

155175165155



16.5

165

JL7132HU JL7152HU

4.7

6.3

550

6.66.2

550

5.1

6.7

550

3 4 5 6 7 8

9 10 11 12 13 14 15 16 17

Exterior device

Interior device

Front chromeplated trim molding Diamond-shape headlight Crystal diamond taillight Highly penetrable front fog light Green heat insulating four-door glass Scuff strip with same color as that of the body Aluminum alloy wheel rim Tire (185/60R15) (with spare tire) Retractive antenna (A pillar) Bumper with same color as that of the body Light color (T)deep color(S)mixed color(R)interior trim Central control panel

Firry red Firry red A/C outlet vent + trim ring Chromeplated inner handle Sun shade (with ticket folder) High-grade flannelette

Seat

Luxury leather

/ /

/ / / /

Titanium silver

Front seat headrest front and rear angle/height adjustable function

2-4

Brief Introduction of Geely MK - Vehicle Configuration

No.

20 21 22 23

25 26 27

29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50

Interior device

Electric device

Safety device

Item Name

Front seat back trash bag 6/4 split foldable rear seat Cable-controlled oil tank cap Cable-controlled trunk plastic leather Power window (with one-touch function) Remote control central door lock Power rearview mirror with turn signal light Smart remote control key (control the closure of the door and window and the delay of the vehicle lights) Adjustable intermittent wiper On-board handsfree handset Anti-clamp retractive power window Central pointer type instrument Temperature display Hi-fi CD audio MP3 function Speaker Freon-free A/C system Air cleaner ABS + EBD Driver side airbag Front passenger side airbag Telescopic steering column Front seat belt pretensioner /height adjustable Rear row triple-person seat belt Anti-glaze inner rearview mirror Anti-explosion and anti-leak plastic oil tank Rear windshield defroster function High-mounted stop light Four-door anti-impact beam Digital display rear parking radar

Adjustable steering wheel

Type

Follow me home light delay system

Standard Comfortable Luxury

Single Disc Single Disc 6 Discs

6 speakers (2 Tweeters) 6 speakers (2 Tweeters) 6 speakers (2 Tweeters)

Remark: - denote standard configuration Z - standard C - comfortable D - luxury S - dark interior trim

T - light colored interior trim R - mixed color

Brief Introduction of Geely MK - Main Vehicle Test Technical Specification

Section 3 Main Vehicle Test Technical Specification

2-5

Item

Inspection line items

Description 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 two rolling 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 by sliding 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 is

(0.6-0.8)H, H refers to the central height of headlamps.

-0°30'± 45' 10°0'± 45'

2°0'± 45'

-0°56'± 45'

60% (no load),

60% (no load, and full load)

20%(Front Axis),

24%(Rear Axis)

33.3 Km/h-42.1Km/h

Harsh brake at 50km/h. the stop distance is Rain test. 100 points is full mark. Minus one point for each

Specification

1±2

50% (full load)

20%

2 m/km

15000 cd

10cm/10m

19m

Regular quality inspection items

Emission

seepage. Minus 3 points for slow seepage 3 points, and minus 6 for a quick seepage. The limit of vehicle sealing is Check 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

nose

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)

Specification: GB18352.3-2005

93 points

Daily inspection and smell with

70°C

40°C

Inspect regularly

37.2°±2°/ 32°±2°

2-6

Usage and Maintenance of MK Series - Usage of MK Series

Chapter 2 Usage and Maintenance of MK Series

Section 1 Usage of MK Series

1. Instrument Panel Overview

1.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 Transmission Shift Lever

10.Parking Brake Control Lever

11.Engine Hood Release Handle

12.Power Window Lock

13.Power Door Lock Switch

1.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 Switch

Usage and Maintenance of MK Series - Usage of MK Series

2-7

2.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.

Move seat forward or backward angle

Adjust seat back angle

2-8

5. 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

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, vehicle

2-9

2-10

must be running at medium speed without load. Increase the speed and load gradually with the accumulation of breaking-in mileage. b. Because the brake plat is not broken in on a new vehicle,in order to ensure safety and reduce wear,avoid harsh brake, and brake for multiple times to break in the brake plate faster. c. It is better to avoid driving vehicle on steep roads or in bad conditions during breaking-in period. d. Pay special attention to engine coolant temperature meter and oil pressure meter.Check engine oil level frequently and make sure engine works in normal temperature and good lubrication. e. Maintain the vehicle strictly according to first-time maintenance requirements to bring the vehicle into normal usage life under good condition.

7.vehicle towing There are towing facilities both in the front and rear end of MK-1 sedan for towing other vehicles and being towed. To ensure safety, pay attention to the following instructions when towing. (1) Towing car Towing car should be started and shifted steadily.The speed should be no more than 40km/h. (2) Follow the instructions below when being towed:

a. Steering system of the vehicle being towed works well. b. Braking system of the vehicle being towed works well or it cannot be towed with a rope and must be towed with the towing shaft instead. c. Release park brake and shift the transmission to neutral gear when the vehicle is being towed. d. Turn the ignition switch to ACC to allow turning signal lights,braking indicator to be turned on when necessary. e. The towing rope must be tensioned in the towing process. f. If the purpose of towing is to start the engine, shift the transmission to the 2nd or 3rd gear to increase engine speed. It is good for starting the engine.

8. Instructions to save fuel when using the vehicle (1) Reasonable load Do not store useless articles in luggage compartment because they consumes fuel for nothing. (2) Correct driving style Instructions as follows:

a. When engine is started, do not heat it but press the accelerator pedal slightly, drive the vehicle slowly and accelerate gradually. b. Shift to higher gears when driving to allow the engine to work at appropriate engine speed and avoid running the engine at low or high speed. The engine speed should be higher than 2500r/min when driving, and higher than 3000r/min when up-shifting. c. Keep the vehicle speed stable, and avoid harsh acceleration and frequent braking. d. Pay attention to vehicle speed. Drive at high speed results in excessive fuel consumption.

(3) Organize vehicle usage well Pay attention to the following two instructions.

a. Organize vehicle usage time and avoid short trips. Because at the beginning when the vehicle is started (around 1km), the engine has not reached its efficiency point, and the fuel consumption doubles compared to regular.

b. Select a good driving route, avoid driving through the city or blocks with heavy traffic. (4) Keep the vehicle under good work condition Strictly follow instructions to maintain the vehicle to make sure the vehicle is under good technical working condition, and inspect and replace key parts that affect vehicle fuel consumptions. For example:

Usage and Maintenance of MK Series - Usage of MK Series

a. Keep air filter clean, Block of air filter affects engine air induction efficiency and increases fuel consumption. So it must be cleaned and replaced in time. b. Keep ignition system under good work condition. Bad connection or electricity leak of ignition coil and power distributor or inappropriate gap or carbon residue of spark plug decreases ignition power supply and efficiency, which leads to engine fuel consumption increase. So they need regular inspection and repair to keep their good work condition. c. Fuel feeding system works well. Often check if fuel feeder pipe leaks, and check if injectors and other parts perform well on regular basis (electrical injection engines). d. Keep regular tire pressure. If the tire pressure is not enough, vehicle rolling resistance increases and engine fuel consumption increases accordingly. So tire pressure must be checked on time (around once a week).

2-11

2-12

Usage and Maintenance of MK Series - Maintenance Category and Content of MK Sedan

Section 2 Maintenance Category and Content of MK Sedan

As the vehicle is being used, its technical performance changes as the mileage accumulates and being affected by various factors, which results in decrease of power, fuel economy, safety, and increase of emission pollutions, noise and incidents. So timely maintenance during vehicle usage eliminates potential risks and prevents incidents from happening, improves vehicle integrity and technical functionality, and prolongs useful life of the vehicle.

According to the vehicle technical requirements and usage history, maintenance of freedom Cruiser sedan can be classified into several categories.

I. first time maintenance

First time maintenance is also called breaking-in maintenance. It is performed when the vehicle mileage has accumulated to 1500~2500km in breaking-in period. First time maintenance must be conducted at the appointed service shops. It includes:

1. Check if there is any leak in engine, transmission, and differential. Fix if there is any.

2. Replace engine oil filter, engine oil and ATF for A/T.

3. Check the level of engine coolant, braking fluid, windshield washing fluid, power steering fluid and if there is any leak. Refill if the level is too low and repair if there is any leak.

4. Check if there is any damage in triangle arm and ball joint, connection ball joint, triangle arm flexible hinge, or the ball joint is loose. If there is, fix or replace it.

5. Check if the drive shaft dust cover is damaged. If there is, replace it.

6. Check if there is any leak in steering mechanism, or front and rear absorber and fix it there is any.

7. Check the tire pressure, front 230kpa, and rear 210kpa.

II. Regular maintenance

After first time maintenance, the vehicle is in regular usage life. During regular use, the vehicle needs to be maintained regularly according to the way it is used in.

1.Regular maintenance for vehicles used under extreme bad conditions. Any of the condition below is defined as extreme bad condition: (1) Frequent start. (2) Often drive the vehicle in dusty circumstances. (3) Drive the vehicle in hot areas (such as in summer in the south). (4) Often drive in cold areas (often runs short trips, engine temperate cannot reach regular work temperature). Vehicles ran under extreme bad conditions need to be maintained every 5000km.

2. Regular maintenance for vehicles Vehicles that have not been through extreme bad conditions need to be maintained every 7500km. Regular maintenance is required to be performed at Geely service shop, too. List of parts that need to be replaced regularly is in table 1. Maintenance timetable is in table2.

III. Geely maintenance program

Geely recommends following Geely maintenance program. The intervals of maintenance schedules are determined by mileage meter or time periods. Maintain the vehicle when either meets the schedule. For details, please refer to the schedule.

Usage and Maintenance of MK Series - Maintenance Category and Content of MK Sedan

For servicing items whose deadlines have expired, they should be maintained at the same intervals as before. The

intervals are recorded in maintenance schedule.

Rubber hoses

Used in cooling and heating system, braking and fuel-feeding systems should be inspected by qualified Geely

technicians according to Geely maintenance schedule.

There are all very important maintenance items. Hoses must be replaced immediately should there be any aging

or damage. Please pay attention, rubber hoses age as time goes by, and they may have problems of inflation, wear,

or crack.

Special Tips

If the vehicle is driven under one or more of the following circumstances, the maintenance items should be

carried out more frequently. See attached maintenance schedule.

A Road condition

1. drive on rough, muddy or skiddy roads

2. drive on dusty roads.

B driving condition

1. Repeat driving within 8km a few times, or when the outdoor temperature is below 0 degree centigrade.

2. Idle the car drive at a low speed for a long time, such as police car, taxi, or door to door delivery vehicles.

3. Continuously drive the car at high speed for more than 2 hours (80% of the max speed).

2-13

IV. Regular inspections

1. weekly schedule inspect engine oil level and cleanness inspect engine coolant level inspect brake fluid level inspect windshield wash fluid level inspect power steering fluid level

2. monthly inspections inspect water pump belt inspect electrolyte level in battery inspect tire air pressure and wear inspect steering wheel inspect brake inspect acceleration pedal

3. inspection when driving (low speed) inspect speed meter and water temperature check steering wheel power and if vehicle runs off-track check if the front wheels skid or swing

inspect if brake functions or if the vehicle runs off-track when brake is functioning

4. other inspection items

Eliminate problems immediately when there is anything abnormal

2-14

Usage and Maintenance of MK Series - Maintenance Category and Content of MK Sedan

V. Table 1 List of parts to be replaced regularly

System

Braking System

Driveline

Steering System

A/C System

Engine

Parts need to be replaced regularly

Brake master cylinder cup valve and dust cover

Brake master cylinder cup

Brake hose

Brake caliper valve

Brake booster rubber

Brake booster vacuum hose

Brake fluid

MT Transmission oil

AT Transmission oil

Steering fluid

Air Cleaner

Air c leaner f ilter

14 15 16 17 18 19

Lubricant

Oil filter Fuel filter Coolant All hoses Canister Timing belt

(API) SG or above

(Table 1)

Intervals

Every 2 years (or as required) Every 2 years (or as required) Every 2 years (or as required) Every 4 years (or as required) Every 2 years (or as required) Every 4 years (or as required) Every 2 years,or 40000km (or as required) Every 2 years,or 40000km (or as required) Every 2 years,or 40000km (or as required) Every 2 years,or 40000km (or as required) To be cleaned every 10,000km and changed every 30,000km (or as required) First 2500km or 2 months. Every 7500km or 6 months afterward (or as required) First 2500km or 2 months. Every 7500km or 6 months afterward (or as required) Every 5000km (or as required) Every 40000km (or as required) Every year (or as required) Every 2 years (or as required) Every 60000km (or as required) Every 120000km (or as required)

Wedge belt (including the power steering pump,

air conditioner compressor and generator belts)

PCV system

Spark plug

The intervals in the part list are for cars driven under normal condition. If the car is driven in special circumstances, the replacement can be advanced from the schedule above.

Every 50000km (or as required)

Every 20000km or 12 months (or as required) Every 20000km (or as required)

Usage and Maintenance of MK Series - Maintenance Category and Content of MK Sedan

2-15

VI. Table 2 Maintenance Timetable of Geely Freedom Cruiser Sedan

Maintain 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.

System Inspection item

Steering System

Drive line

Drive Train

Braking System

Steering Wheel

Steering Gear

Steering Link and Joint

Knuckle Front

Wheel

Clutch

Manual Transmission

Automatic Transmission

Driveshaft

Brake Pedal

Parking Brake

Steering-wheel Play,Fastening and abnormal noise Operation Oil Leak Fastening Fastening,abnormal noise and damage Steering link,joint,rack and dust boot crack and damage Abnormal noise at a joint Wheel adjustment Left and right rotation angle

Trie pressure

Tire crack and damage Tire thread and uneven wear Metal dust,stone and foreign material Loose hub nut and bolt Front wheel bearing abnormal noise Rear wheel bearing abnormal noise Free play Operation Oil leak and oil level Operation system abnormal noise Replace oil Replace ATF Oil leak and oil level Joint fastening Universal joint,dust root crack and damage Spline abnormal noise Universal joint abnormal nosie Free play and Function Function Operating travel Function Parking brake cable fastening,abnormal noise and damage

X1000km

Year

oooo

oooo oooo oooo

oooo

......Replace

ooo

o o

o o o

Table 2

o o

oo o

o o

oo oo oo

o o

oo oo

o oo

o oo o oo o oo

o oo

oo oo

oo oo oo

o oo

o oo o oo

......Inspect

7. 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 5

o o

o o o

o o

o o o

o o

o o o o o

o o

2-16

Usage and Maintenance of MK Series - Maintenance Category and Content of MK Sedan

......Inspect

......Replace

System Inspection item

Brake Booster

Brake reservoir level Function

Master brake cylinder,brake cylinder and brakecalipel

Braking System

Suspension System

Brake Drum and Shoe

Brake Disc and Brake Lining

Spring Attachment

and Joint Suspension

Arm and Shock Absorber

Clearance between brake drum and brake lining Brake shoe sliding part and brake lining wear Brake drum wear and damage Brake lining wear Brake disc wear and damage Damage Fastening and damage of attachment Abnormal noise at a joint Noise from joint,damage to arm and shock absorber fluid leak and damage Abnormal noise at fixture

Spark plug working status Lgnition time

Ignition System

Distributor air gap Electrical

System

Battery Wiring Harnee and Clip Lighting Comblned Instrument Horn,Wiper and

W asher

Distributor cap condition

Connection

Fastening and damage of joints

Function

X1000km

Year

Brake liguid leak

7. 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 5

o o oo

Function wear and damage

oo o oo

o oo o oo

o oo

o oo o oo

o oo

o o

oo o o

o o

oo o

o oo oo

ooo o oo

oo o o

ooo o oo

o o

Engine

Body and Accessory

Defrost and Power Door Lock

Starting performance,abnormal noise,

Engine General Status

Door and Trunk Lock Hood

Seat Others

idle and acceleration Valve clearance Oil leak

Function

o o oo

Lock Function Fastening abnormal noise and damage Seat and seat belt status Lubrication

o oo

Usage and Maintenance of MK Series - Maintenance Category and Content of MK Sedan

VII . Additional maintenance schedule Vehicles run in special circumstances require higher frequency of maintenance as listed below.

A-1: driving on bumpy, muddy or melted snow road.

Inspection of the brake friction wafer and braking drum

Inspection of the braking pad and braking disc

Inspection of the brake piping and hose

Inspection of the transmit shaft ball and joint and dust shield

Inspection of the drive shaft cover

Inspection of the steering wheel, connecting rod and steering gear

box oil Inspection of the front and rear suspension devices

Screwing down the bolts and nuts of the chassis and vehicle body

A-2: driving on dusty road

Replacement of engine oil

Replacement of engine oil filter

Inspection and replacement of air filter

Inspection of the brake friction wafer and braking drum

Inspection of the braking pad and braking disc

Replacement of the air conditioner filter

Every 5,000km (kilometer) or every 6 months Every 5,000km (kilometer) or every 6 months Every 2,500km (kilometer) or every 3 months Every 10,000 km (kilometer) or every 6 months Every 5,000km (kilometer) or every 3 months Every 10,000km (kilometer)

Every 10,000 km (kilometer) or every 6 months Every 5,000km (kilometer) or every 3 months Driving for 1000 km (kilometer) for the first time and then every 10,000 km or every 6 months Every 10,000 km (kilometer) or every 6 months Every 10,000 km (kilometer) or every 12 months Every 5,000km (kilometer) or every 3 months

Every 10,000 km (kilometer) or every 6 months Every 10,000 km (kilometer) or every 6 months

2-17

B-1: repeated short-distance driving and outer air temperature under zero within 8km (kilometer)

Replacement of engine oil

Replacement of engine oil filter

B-2: long-term empty run and / or long-distance driving with low speed, such as police wagon, taxi or automobile delivering goods to the customers etc

Inspection of the brake friction wafer and braking drum

Inspection of the braking pad and braking disc

B-3: continuous high-speed driving for more than 2 hours (80% of the maximum vehicle speed or above)

Replacement of driving axle oil of the manual transmission

Inspection or replacement of the driving axle fluid of the

automatic transmission

Every 2,500km (kilometer) or every 3 months Every 5,000km (kilometer) or every 6 months

Every 10,000 km (kilometer) or every 6 months Every 5,000km (kilometer) or every 3 months

Every 40,000km (kilometer) or every 48 months Every 40,000km (kilometer) or every 24 months

2-18

Usage and Maintenance of MK Series - Daily Maintenance of MK Sedan

Section 3 Daily Maintenance of MK Sedan

Daily 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, and finding 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

c. Wavy wear on the tread is related to its quality and positioning of the wheels. Find out the root cause

and eliminate any problems.

d. Serious wear on the outer side beside the tread of steering wheels means the wheel outward leaning angle

is too big; wear on the inner side beside the tread means the leaning angle is too small.

e. When the toe-in value is getting smaller, the wear on the outer side of tread is in shape of saws. On the contrary, when the inner side has the saw shape wear means the toe-in value is too big. (2) Maintenance

a. Keep the tire pressure to specified value under any circumstances. Measure the pressure on cold tire

b. Check tire pressure regularly, and remove any indented objects that may stick through the tires.

c. Avoid oil, gasoline, and brake fluid on tires.

d. When replaced with new tires, the wheels need to be balanced and adjusted again. Or the vehicle may shake when running at high speed and bear abnormal wear.

e. Do not mix tires of different structure, pattern, or brand on one vehicle. (3) Tire specification and pressure

Tire Specification Tire Pressure (KPa) Front Tire 185/60R15 84H or 175/65R14 82H 230 Rear Tire 185/60R15 84H or 175/65R14 82H 210

2-19

(4) Tire wear limits

When the wear limit mark on tire shows up as the tire wears, it must be replaced with new tires (wear limit mark indicates the thickness of tire pattern is 1.6mm).

5. Maintenance of wiper and washer Status of wiper and washer directly influences windshield and driver's view. So, pay attention to wipers and washers. (1) Wiper Check if the wiper blade has any damage, deformation, which affects windshield wiping quality and if the wiper works well. If wiper blade does not wipe well or the wiper does not work well, fix or replace it in time. (2) Washer Check washing fluid level in the tank, and refill when necessary. To get best washing effects, use specified washing fluid, refill slowly, and pay attention not to mix it with any dirt. Mix the washing fluid with some alcohol in winter to avoid freezing.

6. inspect and adjust headlamp Incorrect beam of the headlamps affects safety of driving in the dark. So they must be inspected regularly, and be adjusted when necessary.

7. Maintenance of inside the vehicle The major content of maintenance inside the vehicle is cleaning, to keep the vehicle clean and provide fresh and pleasant driving circumstance. The key points of indoor cleaning are: (1) Ways to remove stains Get rid of dust before trying to remove stains, and then apply appropriate cleansing, and wipe the stains off with clean, soft, and not too wet cloth repeatedly. (2) Cleansing It is better to remove stains on textile and man-made leather with hydro solvent made from soap fluid and surface active agent. Be careful to avoid using any cleansing because they may corrode the synthetic decoration materials more or less. Ball-pen and lipstick marks can be removed with alcohol, grease can be removed with low Ron value gasoline, and chocolate and sugar stains can be cleaned with ammonia spirit, asphalt must be cleaned with special cleansing.

2-20

(3) Long time exposure to sun damages interior. So it is better to use covers on upper seat backs, and rear separation board that are exposed to sun.

8. Maintenance of body exterior Body exterior is to keep body cleanness and brightness to give the impression of beauty and comfort, and to avoid rust and abnormal paint peeling off. The key points of body maintenances are: (1) Wash body using the method below:

a. Wash the dirty things off the body by pressurized water, and then clean the body with soft cloth of sponge from up to down. b. Dry body surface with good white cloth. Apply brake pedal several times when driving after the car is washed to get rid of water in braking system. c. Do not wipe the body when it is dry. Do not clean paint surface and glass with gasoline,

coal oil, narkosid, strong lye or alcohol. (2) Cleaning windshield glass Do not use silicon-bronze radical products. To get better cleaning effects, use special glass cleanser. (3) Cleaning asphalt on the body Do not peel the asphalt off from body or bumper, but use special cleanser (4) Paint Scratches or slight damages can be fixed with special paint spray. It dries in the air. (5) Cleaning exterior decoration parts and aluminum parts. Wash with water with soap fluid or cleanser, and wash with clean water. To keep the gloss of painted surface, wax on the surface after it is dry. (6) Polish and wax the body paint polishing and waxing keeps the body bright and pretty, and protects the paint as well.

a. Polish in winter. Make sure the vehicle body is absolutely clean and dry before

polishing, polish with fluid or milky wax.

b. Vehicle body must be absolutely dry and clean before waxing. Use waxing tools (soft

table tissue or smooth cotton cloth) to cover the body paint surface evenly with wax.

Check if the vehicle body is covered by wax: spray some water onto the paint surface,

if water drops are formed, that surface is waxed, otherwise, clean the surface and wax

it again. Attention: do not wax under sun, or in cold weather. Attention

1) When using high pressure washing machine, do not point the washing sprayer to transmission, steering mechanism and other rubber protection parts, or exterior decoration parts, roof welding lines, heat radiator or engine compartment.

2) The bottom of vehicle body is made of anti-corrosion material,and has been through anti-corrosion process. After the vehicle has been running frequently on roads de-frozen with salt for some time, clean engine compartment and lower part of vehicle body and take some protection actions.

Usage and Maintenance of MK Series - Daily Maintenance of MK Sedan

Engine Engine Assembly

3-1

Part III Engine

Chpater 1 Engine Assembly

Information about engine accessories in MK-1 Car Maintenance Manual deals with only that concerned with a

complete car. Please refer to separated Maintenance Manual for information about the engine body. Engines

concerned are MR479Q, MR479QA and MR481QA.

Section 1 Engine Inspection

1. Check the engine oil

(1) Check the oil level.

(2) Start the engine, and reach warm-up temperature.

(3) Shut the engine down, wait for 3-5min, and check the oil level.

(4) Check whether the oil level is in within the range marked by the scale; if it is lower than the limit (mark

L), fill oil to mark F.

(5) Keep the oil clean without any coolant or petrol mixed in and with appropriate viscosity.

2. Change oil.

(1) Start the engine. When normal temperature is reached, shut down the engine.

(2) Open the oil cap, remove the oil drain plug, and drain the oil.

(3) Tighten the oil drain plug to a specified torque 54N.m.

(4) Fill fresh oil into the crank case with oil quantity 2.8L in case of the filter not changed, 3.0L in case of the

filter changed and 3.5L in case of the dry filter.

(5) Fit on the oil filling cap.

(6) Start the engine.

(7) Shut down the engine and check the oil quantity, and fill oil to the mark F on the oil scale if necessary.

3. Replace the oil filter.

(1) Remove the oil filter.

(2) Before mounting the oil filter, apply a small quantity of engine oil to the O-ring of the new oil filter.

(3) Tight the oil filter to a specified torque (12.7N.m).

(4) Start the engine, and check whether there is any leakage

(5) Shut down the engine, check the oil quantity and fill as required.

4. Oil selection

Oil over PAI SG grade is preferred.

SAE10W-30 or SAE10W-40 is preferred, and ASE5W-30 is used in cold region in the winter.

Note: For the best effect and the greatest safety, it is advisable to use the following lubrication oil.

a. Meet the requirements of API level.

b. Select proper SAE viscosity rating within expected ambient temperature.

The lubrication oil that can not meet the requirements of SAE viscosity and API label at the same time is not

allowed.

5. Check the coolant.

(1) After the engine is cooled down, remove the radiator cover.

3-2

Engine Assembly Engine Inspection

(2) Make sure that the coolant level is above the neck of the radiator. (3) Put the radiator cover in place, pressurize to 2.0Mpa, and keep the pressure for 1minute unless the coolant leaks. (Mount a tester on the radiator cover, start the engine, and then shut down under a pressure 2.0Mpa). (4) Check whether the coolant quantity in the dilatation can is between the mark "Low" and "Full".

(5) Check whether the radiator cover is clean; test whether the opening pressure of the main valve is 107.8KPa

with a radiator cover tester. The minimum opening pressure is 58.5KPa.

6. Check the battery. (1) The terminal voltage of the battery is 12.5-12.9V at 20°C, and charge when the voltage value is less than the specified value. Check whether the fusible cutout and the fuse are loose, corrosive or on.

7. Check the air filter. (1) Whether the cover, the case or the element of the filter is distorted, corroded or damaged. (2) Whether the air hose is damaged. (3) Whether the air chamber is distorted or damaged. (4) Whether the air filter element is blocked, polluted or damaged. If the filter element is blocked slightly, remove the dirt by blowing the element from above. (5) Whether there is any pollutant or dirt on the air filter support.

8. Check the spark plug. (1) Spark generation. a. Disconnect the coupling of the injector. b. Remove the spark plug from the secondary wire. c. Remove the spark plug. d. Connect the spark plug to the secondary wire. e. Ground the spark plug. f. Start the engine, and check whether spark is generated.

Prompt: The starting time is not more than 1-2s. (2) Clean the spark plug: The air pressure is not greater than 588kp and the time is not more than 20s. (3) Check whether the thread and the insulator of the spark plug are damaged. Replace if necessary. (4) Check the electrode gap of the spark plug: 0.8±0.1mm for MR479Q and MR479QA; 1±0.05mm for MR481QA.

9. Check the driving belt. Belt distortion (see Table 1): Belt pressure: 98N

Water pump

Alternator

Table

New belt mm Used belt mm

Generator drive belt 7~9 11.5-13.5

Power steering belt 5~6 6~8

Air conditioner belt 6.5~7 8~9

Power steering pump

Crank

Measure belt looseness

Note: Check the belt distortion at the specified point (see Figure 1-1).

When mounting a new belt, set the tensioning force to specified value.

After the belt has been operated more than 5 minutes, check and ensure the distortion not exceeding specified

Figure 1-1

value.

Compressor

Engine Assembly Engine Inspection

After the belt is re-mounted and operates more than 5 minutes, check the distortion based on old belt distortion.

Check the tensioning force and the distortion of the V-belt after the crankshaft of the engine has rotated 2

turns.

10. Check the ignition timing (see Figure 1-2). (1) Start the engine for warming up. (2) When using the portable tester:

Connect the portable tester to the fault diagnosis socket (DLC3). Ignition timing:

before the top dead center when idling.

10°±20'

Prompt:

Please refer to the operating manual of the portable tester for

Figure 1-2

detail.

(3) When not using the portable tester: a.Short the terminals 13(TC) and 4(CG) of the fault diagnosis socket(DLC3) with special service tool(SST). Attention:

Make sure to connect correctly, or else the engine can be damaged. Switch off all the electric systems. Check when the cooling fan motor is disconnected. b.Check the ignition timing with a timing light. Ignition timing: 10°±20' before the top dead center when idling. Note: (a) Check the ignition timing, and the transmission should be set to the neutral position. (b) Keep the engine speed at 1,000-1,300r/min for 5s and check when idling. (c) Remove the special tool on the fault diagnosis socket. (d) When the engine speed rises, the advance angle of ignition timing will increase. (e) Remove the timing light.

11. Check the engine idle (see Figure 1-3). (1) The engine warms up. (2) When using the portable tester: Connect the portable tester to the fault diagnosis socket (DLC3). Tip: Please refer to the operating manual of the portable tester for detail.

Tachometer

(3) When not using the portable tester: Connect the test pen of the tachometer to the terminal 9(TAC) of the fault diagnosis socket (DLC3) with special tool (SST). (see Figure 1-3). (4) Check the idling speed: 800±50r/min. Attention:

Check idle when the cooling fan motor is disconnected.

Switch off all the electric accessories and air conditioners.

Battery

Figure 1-3

3-3

3-4

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).

Engine Assembly Engine Inspection

Figure 1-4

Table 2

Cylinder 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.

Normal

Low

High

Engine Assembly Removal of the Engine Assembly from the Vehicle

High

Problems

Bad idle speed

Bad idle speed (HC reading fluctuates)

Bad idle speed (Black smoke exhausts)

Causes

1. Ignition fault: Incorrect ignition timing; Dirt, short circuit, or incorrect spark plug gap.

2. Incorrect valve gap.

3. Suction and exhaust valve leak.

4. Cylinder leaks.

1. Vacuum leaks. PCV pipe . manifold; Idle speed control valve; Brake booster pipeline.

2. Spark lacks since the mixed gas is too thin.

1. Air filter is blocked.

2. PCV valve is blocked.

3. EFI system fails. ECU fails. Pressure regulator of fuel oil is out of order. Water temperature sensor does not work. Suction pressure/temperature sensor fails. Injector fails. The throttle position sensor fails.

3-5

Table 3

Section 2 Removal of the Engine Assembly from the Vehicle

1. Avoid petrol overflowing (Disconnect from the fuel tank).

2. Remove the front wheel.

3. Discharge the coolant completely.

4. Remove the air filter assembly with hose (see Figure 1-5). (1) Disconnect the joint of the temperature sensor and the wire plug. (2) Disconnect the vent duct from the hose of the air filter. (3) Release the wire clip bolt on the air filter. (4) Disconnect the hose of the air filter from the throttle body. (5) Remove 3 bolts and the air filter assemblies.

5. Remove the battery.

6. Remove the fuel pipe sub-assembly.

7. Disconnect the water pipe; disconnect the water outlet pipe of the heater from the air conditioner pipe.

8. Release the nut and remove the accelerator control cable.

Figure 1-5

3-6

Engine Assembly Removal of the Engine Assembly from the Vehicle

9. Remove the oil tank assembly of the power steering pump (with power steering).

10. Remove the radiator assembly.

11. Disconnect the harness.

12. Disengage the steering column assembly.

13. Disengage No.2 steering countershaft assembly (see Figure 1-6). Remove the cover sheet of the steering column on the car body.

14. Remove the exhaust pipe assembly in the front.

15. Remove the nut on the front hub (Parts on the other side are

Mark

disassembled in the same way).

16. Disconnect the speed sensor on the front wheel (with ABS).

17. Disengage the ball assembly of the steering tie rod.

18. Disengage the front suspension arm sub-assembly.

19. Disengage the front drive shaft assembly (see Figure 1-7).

20. Disengage the front drive shaft from the hub with a plastic hammer.

21. Disconnect the shift cable or the tie-rod assembly of the transmission.

22. Disconnect the clutch wheel cylinder assembly or the clutch cable (M/T).

Figure 1-6

23. Remove the engine assembly together with the drive bridge: (1) Hoist the engine a bit with lifting equipment; (2) Remove 2 bolts, and disengage the right support of the engine (see Figure 1-8); (3) Remove 2 bolts, and disengage the left support of the engine; (4) Remove one bolt, 3 nuts and disengage the rear support of the engine;

(5) Remove the engine together with the drive bridge and place them on the floor; (6) Lift the body.

Figure 1-7

Figure 1-8

Engine Assembly Drive Belt Replacement

Section 3 Drive Belt Replacement

1. Remove the V-belt of the generator (see Figure 1-9). (1) Release bolts A and B. (2) Release the bolt C and remove the V-belt.

3-7

2. Remove the V-belt (from the air conditioner compressor to the crankshaft sheave (see Figure 1-10). (1) Release the nut A. (2) Release the bolt B, and remove the V-belt.

3. Remove the belt of the water pump. Release bolts A and B, and remove V-belt.

4. Mount the V-belt of the water pump. Mount the V-belt on the sheave briefly.

5. Adjust the V-belt of the steering pump (see Figure 1-11). (1) Adjust the tension of the power steering belt, and fasten the bolt B. (2) Fasten the bolt A. Torque: 39N.m

Figure 1-9

Figure 1-10

Figure 1-11

6. Mount No.1 V-belt (from the air conditioner compressor to the crankshaft sheave). (See Figure 1-10).

7. Adjust No.1 V-belt (from the air conditioner compressor to the crankshaft sheave). (1) Adjust the tension of the belt of the air conditioner by fastening the bolt B. (2) Fasten the nut A. Torque: 39N.m.

8. Mount the V-belt of the generator (see Figure 1-9).

9. Adjust the V-belt of the generator. Fasten the bolt A, and then the bolt B.

Torque: 18N.m for bolt A, 58N.m for bolt B.

10. Check distortion and tension of the driving belt.

3-8

Component View

Air filter assembly with hose

Engine Mechanical Engine Components

Chapter 2 Engine Mechanical

Section 1 Engine Components

Accelerator control cable assemble

Water inlet pipe of heater

Water outlet pipe of heater

Fuel oil sub-assembly

Upside of radiator support

Engine cover lock assembly

Radiator assembly

Clutch release assembly

Water inlet pipe of radiator

Water outlet pipe of radiator

Output pipe of oil cooler

Input pipe of oil cooler

Transmission control cable assembly

Starter assembly

Battery

Suitable for 1.5L/1.6L(Tight coupling)

Suitable for 1.3L/1.5L(Non-tight coupling)

Figure 2-1

Component View

Engine Mechanical Engine Components

3-9

V-belt of fan and generator

V-belt of vane pump (with power steering mechanism)

No.1 V -belt

Separator of the right engine support

Steering column cover

Glove case door

assembly Steering column assembly

Mounting support of the left engine

: Non-reusable parts

Left front drive shaft assembly

Front exhaust pipe assembly

Washer

Figure 2-2

Left front speed sensor (with ABS)

Left nut on the front hub

Washer

3-10

Component View

Engine Mechanical Engine Components

Fuel oil pipe subassembly

Fuel oil pipe clip

Secondary wire

Vent duct

Fastener of No.1 injector

Throttle assembly

adjusting support with power steering

Water temperature sensor

Crankshaft position sensor

O-ring

Injector

O-ring

Vane pump assembly with power steering

Washer

Pump support with power steering

Knock sensor

Suction manifold

Washer

Water inlet pipe housing

Water outlet pipe housing

No.1 heat shield of exhaust manifold

Bypass hose

Rear end housing

Hex. flange

M6¡Á50

bolt

Ignition coil

Ignition coil installation bracket

Bolt M8¡Á31

Generator assembly

No.1 support of compressor

Air conditioner compressor

Oil filter assembly

Washer

Exhaust manifold

Support of exhaust manifold

Figure 2-3

Component View

Support of the right engine

Engine Mechanical Engine Components

Air filter assembly with hose

V-belt of vane pump with power steering

Vent duct

Gasket

Cylinder head

3-11

Secondary wire

Washer

Washer of the cylinder head

No.1 V-belt

No.2 Timing belt hood

Crankshaft sheave

No.3 Timing belt hood

Timing belt guide pulley

No.1 Timing belt hood

V-belt of fan and generator

Timing belt

Fan sheave

Generator assembly

: Non-reusable parts

Figure 2-4

3-12

Component View

Engine Mechanical Throttle Body

Section 2 Throttle Body

Washer

Throttle body

Accelerator cable

Air filter case with pipe

: Non-reusable parts

Bypass hose

Vent duct

Idle control valve assembly

Throttle position sensor

Seal

Figure 2-5

Engine Mechanical Throttle Body

3-13

Dismounting/mounting and disassembly and assembly (see Figure 2-1~2-5).

1. Drain the coolant. Warning: Do not remove the radiator cover, liquid under pressure or steam (likely to eject) while the engine and the radiator are still hot in order to avoid scalding. (1) Remove the radiator cover. (2) Remove the plug of the radiator, and discharge the coolant.

2. Remove the cable of the accelerator. Release the nut and remove the cable of the accelerator.

3. Remove the air filter hood with hose. (1) Disconnect the connector and the wire fastening device of the suction temperature sensor. (2) Disconnect the vent duct from the air filter hose. (3) Release the clamping collar bolt of the air filter hose. (4) Release 2 clamps on the air filter hood. (5) Disconnect the air filter hose from the throttle body, and remove the air filter hood together with the hose.

4. Remove the throttle body assembly (see Fig. 2-6). (1) Disconnect the connector of the throttle position sensor. (2) Disconnect the connector of ISC valve.

(3) Remove 2 bolts and 2 nuts, and remove the throttle body from the suction manifold (see Fig. 2-7).

(4) Disconnect 2 bypass hoses, remove and check the throttle body (see Fig. 2-8). Check: a. Check whether the throttle shaft shakes. b. Check whether there is any block at each state. c. Check whether the throttle can open and close smoothly. d. Check whether there is a gap between the check screw and the rod of the throttle when the throttle is at CLOSE position. Attention: Do not adjust the check screw of the throttle. If the operation deviates from specifications, replace the throttle. (5) Remove the washer of the throttle body.

5. Dismantle throttle body idle speed control valve assembly. Detach 4 screws, idle speed control valve and washer.

6. Detach throttle position sensor Detach 2 screws and throttle position sensor.

Figure 2-6

Figure 2-7

Coolant Bypass Pipe

Figure 2-8

3-14

Engine Machinery Valve Clearance Adjustment

Section 3 Valve Clearance Adjustment

Adjust the throttle gap (see Figure 2-9). Calculate the thickness of new washer to allow the gap of the exhaust valve to reach a specified value. N=T+(A-0.2mm) Note: where, N -- Thickness of new washer T -- Thickness of the washer removed A -- Measured throttle gap Calculation formula of the suction valve is: N= T+(A-0.3mm). (1) Remove the adjusting washer. a. Rotate the crankshaft until the top of the cam is upwards. b. The nick of the valve tappet faces toward the front. c. Press the valve tappet down with a special tool, and place the tool between the camshaft and the valve tappet (see Figure 2-10). Tip:

Place one end, with a mark "9", of the special tool to the position

shown in Figure 1-24 a bit aslant.

If the special tool (B) is put into a deep position too much, it will be clipped by the washer. In order to avoid the special tool (B) being too hard to take out, put it into slowly by decreasing the inclination angle from the suction side.

It is difficult for the special tool (B) to insert due to the shape of the cam when inserting it from the suction side to the back side of No.3 cylinder (see Figure 2-10). When adjusting the washer, therefore, it is advisable to insert from the exhaust side. d. Press the valve tappet down alternately with the special tool (A) and (B) to check the throttle gap.

Camshaft Top

Notch

Figure 2-9

Figure 2-10

No.3 Cylinder back side

Vehicle Front

Notch

(2) Re-mount the adjusting washer. a. Mount a new adjusting washer on the valve tappet. b. Press the valve tappet down with the special tool (A), and remove the special tool (B). c. Re-check the throttle gap.

Notch

Figure 2-11

Fuel System Check Fuel System Pressure

3-15

Chapter 3 Fuel System

Section 1 Check Fuel System Pressure

On-board inspection

1. Check the operation of the fuel pump. (1) Connect the positive and the negative of the battery to appropriate connector sockets of the fuel pump (see Figure 3-1). Attention: Do not start the engine. If there is pressure present, you will hear that the fuel is flowing. If there is no pressure present, check the fusible cutout, fuse, EFI open-circuit relay, fuel pump, ECM (Electronic Control Module) and circuit joint. (2) Turn the ignition switch to "OFF".

2. Check the pressure of the fuel. (1) Check whether the battery voltage is more than 12V. (2) Disconnect the negative wiring cable from the battery. (3) Mount a pressure gauge on the fuel input pipe (see Figure 3-2). (4) Connect the negative terminal of the battery. (5) Measure the fuel pressure. Fuel oil pressure: 265-304kPa If the pressure is low, check the fuel pipe and connection, fuel pump, and fuel filter. If the pressure is too high, replace the regulator. (6) Start the engine. Measure the fuel pressure at idle speed. The fuel pressure is 265-304KPa. If the pressure is unsatisfactory, check

the fuel pump, pressure regulator, and injector, and replace if necessary. (7) After shutting down the engine, check the fuel pressure and keep the specified pressure for about 5 minutes. The fuel pressure is: 147KPa.

3. The fuel oil pressure regulator (DR) (see Figure 3-3). Mounting position: On the distributing pipe for fuel. Faults: Too low or too high fuel pressure, or hard to start. General causes: Using poor fuel for a long time results in: 1. strainer blocked; 2. serious leakage caused by particles and impurities.

Other reasons: Man-made mechanical damage, etc. Maintenance precautions: During maintenance: 1. Never impact the diaphragm element with high pressure gas; 2. Never clean it with aggressively corrosive liquid; 3. No distortion caused by external force. Easy measuring method: For the system with oil return, connect a pressure gauge for the fuel on the suction pipe, start the engine, and run at idle speed. Now, the fuel pressure in the engine should be about 260KPa; pull out the vacuum pipe of the fuel pressure regulator, and the pressure should be 300KPa approximately.

Battery

Figure 3-1

T conector

Hose

Fuel Inlet Pipe

Fuel Pipe Conector

Figure 3-2

Figure 3-3

3-16

Fuel System Fuel Pump Inspection

Section 2 Fuel Pump Inspection

1. Fuel pump (1) Check whether the resistance of the fuel pump is 0.2~3.0 ohm¸ at 20°C. If not, replace the fuel pump (see Figure 3-4). (2) Fuel oil pump running: Switch on the fuel pump with a battery and check. If the operation is unsatisfactory, replace the fuel pump or wires (see Figure 3-5). The test should be done within 10s to protect the coil from burning out.

2. Fuel injector assembly

Oil injecting quantity: 40~50cm Tolerance of each injector: not more than 10 cm3. If the fuel injecting quantity is not up to the specification, replace the injector. Check leakage: Under above conditions, disconnect the wire from the battery, the fuel should not drip one per minute.

/s.

Ohm

meter

Battery

Figure 3-4 Figure 3-5

Component View

Fuel return hose

Fuel System Fuel Pump Replacement

Section 3 Fuel Pump Replacement

Fuel tank cap

Fuel oil hose

Fuel pump with fuel sensor assembly

3-17

O-ring

Fuel tank assembly

Figure 3-6

Replace

1. Operations avoiding petrol overflowing.

2. Disconnect the fuel oil hose from the oil tank.

3. Disconnect the oil return hose from the oil tank.

4. Disconnect the vapor discharge pipe from the oil tank.

5. Remove the fuel oil pump assembly with a filter (see Figure 3-7) Loosen the oil tank cap with a tailored tool. Take care not to bend the arm of the oil quantity sensor when taking the fuel oil pump out

6. Mount the fuel oil pump assembly (see Figure 3-8).Replace the sealing ring. Align the boss on the oil pump with the nick on the oil tank port; tighten the oil tank cap with special tool.

Torque: 40N.m

7. Mount the vapor discharge pipe. (1) Mount the oil return hose; (2) Mount the fuel oil hose; (3) Check leakage of the fuel oil.

Figure 3-7

snap ring

Figure 3-8

3-18

Fuel System Fuel Emission Control System

Section 4 Fuel Emission Control System

On-board Inspection

1. Check the operation when disconnecting the fuel supply.

(1) Warm the engine up to 2,500r/min at least, and check the noise of the injector with a sound level meter (see Figure 3-9). (2) When the throttle releases, the noise from the injector should stop immediately; repeat several times.

2. Check the fuel vapor discharge control system (see Figure 3-10). (1) After starting the engine, disconnect the vacuum pipe. (2) Make sure that there is vacuum present at the canister control valve (TEV) port when selecting ”ACTIVE TEST" and "PURGE TEV" based on the display on the fault diagnosis instrument.

(3) After "ACTIVE TEST", connect the vacuum pipe.

(4) Carry out "ECM DATA MONITOR" on the fault diagnosis instrument, and then select "PURGE TEV" for operation inspection. (5) Start up the car after the engine warms up, and make sure the TEV ON from OFF (see Figure 3-11).

3. Check whether there is any distortion or damage on the filling cap and the washer (see Figure 3-12).

Sound level meter

Figure 3-9 Figure 3-10

Figure 3-11 Figure 3-12

Gasket

Fuel System Carbon Canister Replacement

Section 5 Carbon Canister Replacement

1. Check and replace the canister. (1) Check for crack or damage on the canister visually (see Figure 3-13). (2) Check the operation of the canister. a. Plug the discharge port (see Figure 3-14).

b. Blow air (4.71KPa, 48kgf/cm air should flow out from the exit port. If the operation is unsatisfactory, replace the canister. c.Blow air into the absorption port, the air should flow from other ports without any resistance. If the operation is unsatisfactory, replace the canister. (3) Clean the canister: Block the desorption port, blow air (4.71KPa, 48kgf/cm the air should flow from the discharge port (see Figure 3-15).

) into the absorption port when keeping the discharge port closed, and the

) into the absorption port, and

3-19

Absorption port

Discharge port

Exit port

Figure 3-13 Figure 3-15

Figure 3-14

Absorption port

Discharge port

Exit port

Plug up

2. Canister control valve (TEV) (see Figure 3-16) Mounting position: On the vacuum pipeline of the canister - suction manifold. Faults: Bad idle speed, malfunction, etc. General cause: Ingress of foreign materials into inside of the valve results in corrosion and Poor tightness. Maintenance precautions: During maintenance:

1. Air flowing direction must conform to specifications;

2. If the control valve fails due to black particles in the valve body, and it is necessary to replace the control valve, please check the condition of the canister;

3. Avoid liquid such as water and oil entering into the valve during maintaining as possible;

4. It is advisable to mount the canister control valve on the hose hanging in the air or fasten with soft rubber to avoid transmission of solid borne noise.

3-20

Fuel System Carbon Canister Replacement

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°C

Figure 3-16

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).

Cylinder head side

Cleaning pipe

Easy Hard

Manifold side

Figure 3-17

Component View

Front Muffer

Three-way Catalytic Converter

Exhaust System Exhaust System

Chapter IV Exhaust System

Suitable for 1.5L/1.6L(Tight coupling)

Center Muffer

Rear Muffer

Suitable for 1.3L/1.5L(Non-tight coupling)

Front Rubber Bracket

3-21

Rear Rubber Bracket

Figure 4-1

Replace

1. Remove the tail exhaust pipe assembly. Remove 2 bolts and the tail exhaust pipe assembly.

2. Remove the middle exhaust pipe assembly. Replace the exhaust system. Remove 2 bolts and the middle exhaust pipe assembly.

3. Remove the front exhaust pipe assembly. Remove 2 bolts and the front exhaust pipe assembly.

4. Mount the front exhaust pipe assembly. Measure the free length of the spring with a slide caliper. Free length: 42mm

Mount the front exhaust pipe on the exhaust manifold with new washer. Notes:

Do not use the removed washer any more.

5. Mount the front exhaust pipe assembly. Torque: 43N.m

6. Mount the middle exhaust pipe assembly. Mount the middle exhaust pipe on the front exhaust pipe with new washer. Torque: 44N.m

7. Mount the tail exhaust pipe assembly. Mount the tail exhaust pipe on the middle exhaust pipe with new washer. (see Figure 4-2). Torque: 43N.m

8. Check exhaust leakage.

Figure 4-2

Tail pipe side

washer

3-22

Cooling System System Inspection

Chapter 5 Cooling System

Section 1 System Inspection

1. Check leakage in the cooling system (see Figure 5-1). (1) Fill coolant in the radiator, and mount the tester at the radiator cover port. (2) Start the engine. (3) Keep the pump pressure at 118KPa without drop. If the pressure drops,check whether there is any leakage at the port, radiator and water pump; if not, check the heating core, cylinder and cap.

2. Check the engine coolant quantity in the compensating tank. The coolant level should be between LOW and FULL.

3. Check the coolant quality. (1) Remove the radiator cover. Do not remove the radiator cover when the engine and the radiator are still hot in order to avoid scalding since the liquid vapor may inject. (2) Check whether there are excessive deposit and rust or sundries around the radiator cover. The coolant is not allowed to contact with oil. (3) Remount the radiator cover.

4. Thermostat Notes: The temperature indicated on the thermostat is marked as open temperature of the valve (see Figure 5-2). (1) Submerge the thermostat into water and heat gradually. (2) Check the open temperature of the valve. Open temperature of the valve: 80-84°C (3) Check the lift of the valve (see Figure 5-3 and Figure 5-4). Lift of the valve: 8mm or more at 95°C

Tester of radiator cap

Figure 5-1

Figure 5-2

8.0mm or more

Figure 5-3 Figure 5-4

(4) When the thermostat is at low temperature (lower than 77°C), the valve should close completely.

Cooling System System Inspection

5. Fan (1) At low temperature (lower than 83°C), check the operation of the cooling fan. a. The ignition switch is set to ON. b. The cooling fan should stop. c. Disconnect the connector of the water temperature sensor. (see Figure 5-5) d.Touch the ground with a wire. e.Check if the cooling fan rotates. f. Re-connect the connector of the water temperature sensor.

3-23

disconnect

Figure 5-5

(2) At high temperature (more than 93°C), check the operation of the fan (see Figure 5-6). a. Start the engine, and enable the coolant temperature higher than 93°C. b.Check whether the cooling fan rotates. If not, replace the water temperature switch.

(3) Check the cooling fan (see Figure 5-7). a. Disconnect the joint of the cooling fan. b. Connect the battery and the ammeter with the connector. c. The cooling fan should rotate stably and check the current readings. Standard current: 5.7-7.7A. d. Connect the connector of the cooling fan.

Above 93°C

Figure 5-6

Amper meter

Battery

Figure 5-7

3-24

Cooling System Radiator Replacement

Section 2 Radiator Replacement

1. Replace the radiator. (1) Open the radiator cover. (2) Open the water drain valve and discharge the coolant. (3) Disconnect the water inlet pipe of the radiator. (4) Disconnect the water outlet pipe of the radiator. (5) Disconnect the input pipe of the oil cooler of the automatic transmission (automatic transmission). (6) Disconnect the output pipe of the oil cooler of the automatic transmission (automatic transmission). (7) Remove 4 bolts of the radiator mounting support (see Figure 5-8).

Figure 5-8

(8)Remove the radiator assembly, remove 4 bolts, and separate the fan and the fan housing (see Figure 5-9).

Figure 5-9

(9) Mount the cooling fan assembly. a. Secure the compensating tank assembly on the cooling fan support with bolts; torque: 16 N.m. b. Mount the fan and the fan housing with 3 bolts; torque: 7.5N.m. c. Mount the cooling fan assembly on the radiator assembly with 3 bolts; torque: 16N.m. d. Connect the overflow pipe on the compensating tank assembly and the radiator assembly, and fasten with the elastic ring. e. Mount the radiator assembly in the reverse order of dismounting.

Chapter 6 Manual Transaxle Assembly

Component View

Manual Transaxle Assembly Frequent Pr oblem Diagnosis

Section 1 Frequent Problem Diagnosis

3-25

Starter Connector

Right front drive shaft assembly

Snap ring

Clutch Cylinder

Engine hood

Harness of starter

Starter assembly

Battery fixing bar

Control cable of transmission

Clamp

W asher

Battery support

Battery

Bottom board

Connector of odometer sensor

Rear Engine Vibration Absorber

Rear support of engine

5 Spead Manual Transmission (JL-S160/S160A)

Back-up lamp Connector

: Non-reusable parts

Filling plug

Washer

Left support of engine

figure 6-1

Snap ring

Clamp

Hub nut

Washer

Drain Plug

Left front drive shaft

Cotter pin

Ball tie-rod

3-26

Manual Transaxle Assembly Vehicle Speed Sensor Replacement

Table 6-1 Frequent problem diagnosis

Sympton

Vibration and noise

Oil leakage of the transmission

Hard to shift

Trip stop

Section 2 Vehicle Speed Sensor Replacement

Possible causes Transmission or the engine is suspended loosely or damaged; Axial gap is improper; Gear or bearing is worn or damaged; Unsatisfactory transmission oil is used or oil level is low; Engine idle is incorrect. The oil seal or the O-ring is damaged. The control cable is unqualified; Synchronizer is poorly contacted with gear or worn; Elasticity of the synchronous spring is insufficient; Unqualified transmission oil is used. Fork of the shift gear is worn or lifting spring is broken; Gap between the synchronizer bush and the sleeve spline is too large; Gear or bearing is worn or damaged.

1. Disengage the vehicle speed sensor (see Figure 6-2).

2. Remove the bolt and the vehicle speed sensor.

3. Mount the vehicle speed sensor (see Figure 6-3).

4. Connect the vehicle speed sensor.

Figure 6-2

Figure 6-3

Manual Transaxle Assembly Manual Transaxle Replacement

Section 3 Manual Transaxle Replacement

Replace

1. Open the engine cover.

2. Remove the battery.

3. Remove the clutch wheel cylinder assembly (see Figure 6-4).

4. Separate the transmission shift cable assembly (see Figure 6-5).

5. Disengage the joint of the backup lamp switch.

6. Disengage the speed sensor. Disengage the speed sensor joint.

7. Remove the forepart of the exhaust pipe.

8. Discharge the drive bridge oil.

9. Remove the nut on the left and the right front hub.

10. Disengage the speed sensor on the left and the right front wheel (ABS).

11. Disengage the front stabilizer bar.

12. Disengage the left and the right ball tie-rod.

13. Disengage the front stabilizer bar.

14. Disengage the left and the right lower cantilever.

15. Remove the left and the right front drive shaft assembly.

16. Hoist the engine from the machinery space according to "Point 24, Section 2, Chapter 1".

17. Remove the starter assembly.

18. Disengage the engine support.

19. Remove the manual drive bridge assembly.

20. Mount the engine support.

21. Mount the manual drive bridge assembly.

22. Couple the vibration insulating pad of the engine.

23. Mount the starter assembly.

24. Mount the left and the right front drive shaft assembly.

25. Connect the left and the right lower cantilever.

26. Connect the left and the right ball tie-rod.

27. Connect the front stabilizer bar.

28. Connect the left and the right front speed sensor (ABS).

29. Mount the left and the right front shaft nut.

30. Mount the fore part of the exhaust pipe.

31. Connect the joint of the odometer sensor.

32. Connect the joint of the back-up lamp switch.

33. Connect the transmission shift cable assembly (see Figure 6-5).

34. Mount the clutch wheel cylinder assembly (see Figure 6-4).

3-27

Figure 6-4

Figure 6-5

3-28

Manual Transaxle Assembly Transmission/Transaxle Case Oil Seal Replacement

Section 4 Transmission/Transaxle Case Oil Seal Replacement

I. Replace the oil seal of transmission housing

1. Remove the oil seal of the transmission housing (see Figure 6-6).

2. Mount the oil seal of the transmission housing (see Figure 6-7). Attention: Take care not to damage the lip surface of the oil seal.

II. Replace the Oil Seal of the Drive Bridge Housing

1. Remove the oil seal of the transaxle housing with special maintenance tool (see Figure 6-8).

Figure 6-6

Figure 6-7

2. Mount the oil seal of the transaxle housing (see Figure 6-9).

Figure 6-8

Figure 6-9

Automatic Transaxle Assembly Frequent Problems Diagnosis

Chapter 7 Automatic Transaxle Assembly

Section 1 Frequent Problems Diagnosis

Possible Cause

1. There is no scan information. (1)The diagnosis system fails. (2)The automatic transmission unit fails.

2. The engine can't start. (1)The engine system fails. (2)The fuel pump or torque meter fails.

3. The vehicle cant' runs forwards. (1)The circuit voltage is improper. (2)The rear clutch or single clutch fails. (3)The valve fails.

4. The vehicle can't run backwards. (1)The low speed brake or front clutch pressure is improper. (2)The front clutch or low speed reverse gear fails. (3)The valve fails.

5. The vehicle can't runs forwards or backwards. (1)The pressure deduction is improper or the transmission signal fails. (2)There is pressure in the oil pump or the valve body fails.

6. The engine stalls in gear shift. (1)The engine system or clutch torque meter fails. (2)The valve body or torque meter fails.

7. The vehicle vibrates and lasts for a long time when the gear is shifted from N to D. (1)The rear clutch fails. (2)The valve body clutch fails. (3)The restrictor switch fails.

8. The vehicle vibrates and lasts for a long time when the gear is shifted from N to R. (1)The front clutch pressure fails. (2)The front clutch or valve body fails. (3)The low speed reserve gear pressure or low speed reverse gear fails.

9. The vehicle vibrates and lasts for a long time when the gear is shifted from N to D/R. (1)The pressure reduction fails. (2)The oil pump fails. (3)The valve body fails.

10. The gear shift impacts. (1)The servo switch or restrictor position switch fails. (2)The pressure is decreases abnormally. (3)The clutch or brake fails.

11. All gear shift points are either too early or too late in the running status.

3-29

3-30

The valve body fails.

12. The vehicle shifts before or after some gear points in the running status. The vehicle switch or parking switch fails.

13. The vehicle has poor acceleration in running. (1)The clutch or brake fails. (2)The engine system fails.

14. The vehicle vibrates when it runs at a constant speed or accelerating speed. (1)The hydraulic torque clutch pressure or hydraulic torque meter fails. (2)The engine system or valve fails.

15. The acceleration switch system fails. (1)The acceleration switch or ignition switch fails. (2)The connector or automatic transmission control unit fails.

Automatic Transaxle Assembly Hydraulic Torque Converter and Transaxle

Section 2 Hydraulic Torque Converter and Transaxle

I. Automatic transmissions Removal

1. Put the select lever in "N" position

2. Remove 3 bolts of the flexibility plate (engine side)

3. Remove starter and 2 cooling hoses.

4. Disconnect neutral switch connector and odometer sensor.

5. Loosen the drain screw under the housing to bleed ATF and tighten the drain screw with sealing glue when assembling. Tightening torque is 29~35N.m

6. Loosen the locking bolt for select lever cable.

7. Remove Drive Shaft LH&RH, using plastic stopper in the oil sealing of differential.

8. Detach suspension bolts.

9. Separate transmission from engine after bolts between engine and transmission remove.

II. Automatic Transmission Installation

1. Check whether torque converter of the transmission is in the right position, the methods as follows: Check whether the distance from 3 anchor point of torque converter to front contact face of the transmission box A 28mm , If the space A<28 mm, try install again. The way to install is that left hand catch hold of the central anchor column of the converter and make it in alignment with input shaft as near as possible, push the torque converter in rotating way by right hand until it gets to the bottom to meet the requirement of A 28 mm. (See figure 7-1 and 2)

2. Install Flexibility plate and central plate on the crankshaft end face with 6 bolts in the direction of Figure 2. Tightening torque is 45~55 N.m. Turn the longer hole of the Flexibility plate to the lowest of the engine position in order to connect torque converter.

Automatic Transaxle Assembly Hydraulic Torque Converter and Transaxle

3-31

Front contact face

Figure 7-1

Torque converter anchor point

Central anchor column

Central plate

Torque converter

Figure 7-2

Flexible plate

Torque converter housing end

3. 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.

Figure 7-3

Figure 7-4

Figure 7-5

3-32

Automatic Transaxle Assembly Hydraulic Torque Converter and Transaxle

9. Put shift lever to "N" position, meanwhile, adjust the shift fork in neutral position. Connect shift cable with bracket and fix by fastening bolt. The tightening torque is 6.9~13.7 N.m (See figure 7-6).

10. Connect neutral switch connector.

11. Install odometer sensor (connect the sensor with the actuator of odometer in the transmission)

12. Fill in ATF.

Figure 7-6

"ATF " is the oil only for automatic transmission, its grade is DEXRONII or DEXRONIII. First, take dipstick out of automatic transmission and fill in 3 liter ATF from dipstick pipe. Put select lever to "P" position and start engine until AT temperature is up to 80°C, and then put select lever in "P" "R" "N" "D" "2" "L" and "L" "2" "D" "N" "R" "P" step by step. Insert and take out dipstick, wipe out the liquid in the dipstick. Repeat above-mentioned procedure without wiping to check oil level by dipstick. If oil level is between the third and fourth hole in the dipstick, the level is normal. Filling in oil is over and Insert dipstick tightly.

13. Wipe ATF in the A/T surface when filling.

14. A/T installation is completed.

III. Automatic Transmission Assembly JL-Z110 and JL-Z130

Central Plate

Throttle cable

Flexible Plate Set

Install in the engine

Hydraulic Torque Corverter

Dipsitick

Filling Pipe

Figure 7-7

Fluid Pan

Automatic Transaxle Assembly Differential Front Oil Seal (ATM) -

1. Check the hydraulic torque converter assembly. (1)Measure the status of the hydraulic torque converter. (2)Replace the ATF in the hydraulic torque converter. (3)Wash and check oil freezer and oil pipe. (4)Prevent the hydraulic torque converter being deformed and the oil pump gear being damaged.

2. Check the drive disc and gear ring. (1)Install a dial test indicator to measure the runout of the drive disc. (See Fig.7-8) (2)Check the damage of the gear ring. Maximum runout: 0.25mm If the runout is beyond the specified scope or the gear ring is damaged, replace the drive disc. Torque: 64N.m

3. Check the hydraulic torque converter. (See Fig.7-9) Install the hydraulic torque converter on the drive disc temporarily, and install a test indicator to measure the radial runout of the hydraulic torque converter bushing. Maximum radial runout: 0.20mm If the radial runout is beyond the specified scope, readjust the direction of installation. Notes: Mark the position of the torque converter to install it properly. Remove the hydraulic torque converter.

3-33

Figure 7-8

Figure 7-9

Section 3 Differential Front Oil Seal (ATM)

Replacement

1. Discharge the automatic transmission oil. (1) Remove the discharge plug and washer to discharge the ATF oil. (2) Install the discharge plug and new washer.

Torque: 25N.m

2. Remove the front wheel.

3. Remove the left/right front wheel hub nuts.

4. Unfix the front stabilizer bar.

5. Unfix #1 left/ring front suspension sub-assembly.

6. Unfix the left/right ball extension rod sub-assembly.

7. Unfix the left/right front axles.

8. Remove the differential front oil seal (on the transaxle housing).

3-34

Automatic Transaxle Assembly Differential Front Oil Seal (ATM)

9. Pull out oil seal (on the transaxle housing) with a special tool. (See Fig.7-10)

10. Remove the differential front oil seal on the transmission housing. Pull out the oil seal on the transmission housing with a special tool. (See Fig.7-11)

Figure 7-10

11. Install the differential front oil seal onto the transmission housing. (1) Install a new oil seal on the transmission housing with a special tool and hammer. (See Fig.7-12) (2) Apply MP lube on the flange of the oil seal.

12. Install the differential front oil seal onto the transmission housing. (1) Install a new oil seal onto the transmission housing with a special tool and hammer. (See Fig.7-13) (2) Apply MP lube on the flange of the oil seal.

Figure 7-11

Figure 7-12

Figure 7-13

13. Install all parts in the sequence of removal till the front wheel is installed, and then add transmission oil.

14. Check and adjust the alignment of the front wheel.

Automatic Transaxle Assembly Neutral Switch Assembly

Section 4 Neutral Switch Assembly

Replacement

1. Remove the lower engine mud baffle assembly.

2. Disconnect shift cable. (1) Detach the bolt and remove shift cable from the rocker arm.

(2) Detach E-shaped clip to remove shift cable from the

rocker arm.

3-35

3. Detach neutral switch assembly.

(1) Remove the connector from neutral switch. (2) Loosen nut and rocker arm. (3) Detach bolt to separate neutral switch.

4. Install neutral switch.

(1) Install neutral switch to the manual valve axle. (2) Install bolt temporarily. (3) Install neutral switch temporarily.

3-36

Automatic Transaxle Assembly Neutral Switch Assembly

(4) Turn the rocker arm to the end counterclockwise and rotate 2 teeth clockwise.

(5) Make the position of neutral switch parallel to the basic central line of neutral switch with a straight rule. (6) Keep this position and tighten the bolt.

Neutral Referenc line

(7) Tighten the shift rocker arm. (8) Connect the harness of neutral switch.

5. Install transmission cable (1) Put shift lever to "P" position, meanwhile, make neutral switch at "P" position. (2) Use a new E-shaped clip to fix shift cable on the bracket.

(3) Tighten the nut in the front of shift cable. Torque: 6.9 ~ 13.7 N.m

6. Check and adjust neutral switch. The display should be clear and correct.

7. Install the lower engine mud baffle.

Chassis Transmission Control

4-1

Part IV Chassis

Chapter 1 Transmission Control

Section 1 Introduction of Transmission Control

I. Description on Transmission Control

This 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 Table

Use 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.

Symptom

Transmission out of gear

Transmission shift difficult

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)

4-2

Component View

Transmission Control Introduction of Transmission Control

Floor gear shift lever handle

Gear shift lever shield

Control box decoration cover

Floor storage box

1 gear shift cable retainer

Snap Clip

12.0

E Clip

Speed changer control cable

Shift Bracket

Clip

Washer

E Clip

Clip

5.0

Control box hole

Control box rear part

12.0

Clip

Floor gear shift lever assembly

Washer

Shift Bracket

N•m : Specified torque

: Non-reusable parts

Clip

Transmission Control Cable Type Transmission Control

Section 2 Cable Type Transmission Control

Replacement

1. Remove the upper cover in dashboard panel.

2. Remove the lower cover in dashboard panel.

3. Remove the cup-holder in the middle console.

4. Loosen transmission control cover.

5. Remove the handle of the gear shift lever.

6. Remove the middle console body.

7. Remove the control cables assembly of the transmission.

(1) Remove the two cotter pins and unfix the head of the control

cables of the transmission (see the right figure).

(2) Remove the control cables assembly after loosening the shift

bracket with bolts.

4-3

(3) Remove the two cotter pins and two washers, and then unfix the two control cables from the manual transmission. (4) Remove the two spring clips and unfix the two control cables from the bracket.

(5) Remove the bolt and unfix the control cables.

(6) Remove the two bolts. (7) Pull the control cables out of the body. (8) Remove the retainer from the control cables.

4-4

8. Install the control cables assembly of the transmission. (1) Install the retainer on the control cables. (2) Push the control cables into the floor. (3) Install the control cables assembly with two bolts. Torque: 5.0N.m

(4) Connect the control cables assembly and fix the control cable with bolts. Torque: 5.0N.m

Transmission Control Cable Type Transmission Control

(5) Connect the ends of the two control cables, and then install two washers and two new spring clips. (6) Install two new spring clips on the cable bracket.

(7) Connect the control cables to gear shift lever. Note: Make sure the claws engage firmly.

(8) Connect the ends of the control cables to the gear shift lever selectively, and then install the cotter pin. Note: When connecting the control cables, the dents of their ends hall be made upwards. The cotter pins are inserted in a direction as shown in the figure. (9) Connect the ends of the gear shift cables to the gear shift lever assembly.

9. Install the middle console body.

10. Install the parking brake cover.

11. Install the handle of the gear shift lever.

12. Install the cup-holder.

13. Install the lower cover in dashboard panel.

14. Install the upper cover in dashboard panel.

Transmission Control Manual Transmission Shift Mechanism

Section 3 Manual Transmission Shift Mechanism

Replacement

1. Remove the upper cover in dashboard panel.

2. Remove the lower cover in dashboard panel.

3. Remove the cup-holder in the middle console.

4. Loosen transmission control cover.

5. Remove the handle of the gear shift lever.

6. Remove the middle console body.

7. Remove the control cables assembly of the transmission.

(1) Remove the two cotter pins and unfix the head of the control cables of the transmission

4-5

(2) Remove the spring clips and separate the control cables from the bracket.

8. Remove the four bolts and floor gear shift lever assembly.

9. Install the floor gear shift lever assembly.

Install the floor gear shift lever assembly with four bolts. Torque: 12N.m

4-6

10. Connect the control cables assembly. (1) Connect the control cables to floor gear shift lever assembly. Note: Make sure the spring clips engage firmly.

(2) Connect the ends of the control cables to the floor gear shift lever assembly, and then install the cotter pins. Note: When connecting the ends, the dents shall be made upwards. The cotter pins are inserted in a direction as shown in the figure. (3) Connect the ends of the gear shift cables to the floor gear shift lever assembly.

11. Install the middle console body.

12. Install the parking brake cover.

13. Install the handle of the gear shift lever.

14. Install the cup-holder.

15. Install the lower cover in dashboard panel.

16. Install the upper cover in dashboard panel.

Transmission Control Manual Transmission Shift Mechanism

Sawcat part

Transmission Control Automatic Transmission Shift Mechanism

Section 4 Automatic Transmission Shift Mechanism

Component View

E Clip

4-7

Console Panel Upper Cover Assembly

Console Panel Lower Cover Assembly

Cup Holder

Park Brake Cover Plate

E Clip

Console Assembly

Automatic Shifter Assembly

Specified Torque

E Clip

Key Retaining Cable

Shift Cable

4-8

Transmission Control Automatic Transmission Shift Mechanism

Component View

Automatic Shifter Panel

Automatic Shift Handle

Shift Lever Knob Cover

Spring

Inner Rod

Shift Lever Button

Spring

Dust-Proof Sliding Plate

Shift Lock Release Button

Cap

Bulb

Gear Range Indicator Wire Harness

Shift Lock Unit

Solenoid

Gear Range Display

Button Spring

Handle Connecting Rod

Shift Lever Support

Slot Pin

Key Retaining Cable Control Arm

Control Shaft

Shift Lever Sub-Assembly

Precoated Part

Shift Lock Control Arm

Transmission Control Automatic Transmission Shift Mechanism

Replacement

1. Remove CD cover

2. Remove console panel lower cover assembly

3. Remove cup holder

4. Remove console assembly

5. Remove key retaining cable.

(1) loosen the adjustment locking cap.

Tip:

Face the vehicle front and turn rotate it clockwise by 90°.

(2) Use screwdriver to remove the key retaining cable

6. Disconnect shift cable assembly

(1) Remove the nut, disconnect the shift cable from the shifter

assembly

4-9

(2) Use screwdriver to disconnect the shift cable from the shift lever tray.

7. Remove automatic shifter assembly

(1) Remove the four bolts. (2) Disconnect the two connectors. (3) Remove the shifter assembly.

4-10

Transmission Control Automatic Transmission Shift Mechanism

8. Install the automatic shifter assembly Install it in place in the reverse order of removal.

9. Check and adjust the shift lever position (1) Check that the starter works only when the shift lever is in P position, but doesn't work in other positions. (2) Move the shift lever, check whether the display of the gear range indicator is consistent with the actual gear

range. (3) Check that the key can be pulled out in P position. (4) Except the P position, the ignition key can not be turned to LOCK position with the shift lever in other

positions.

(5) Check that when shift release button is pressed down, the shift lever can be transferred to other positions

from the P position.

10. Adjustment

(1) When moving shift lever among the positions, make sure to

move the shift lever in a stable way, operate properly and the

positive display is correct.

Gear positions able to be operated without pressing down the

knob button are:

R N D,

L 2 D N Gear positions able to be operated only when the knob button is pressed down are: 2 L, N R P (2) Gear positions able to be operated only when the knob button is pressed down, the ignition switch is turned ON and the brake pedal is depressed are: P R

Depress the brake pedal, press down the shift lever knob button to shift the gear position. (ignition switch must be turned ON)

press the knob button to shift the gear position

Normal shift

(3) Start the engine, make sure the vehicle drives ahead when the shift lever is moved from N position to D position, and back up when the shift lever is set to R position.

Chapter 2 Accelerator Pedal Device

Section 1 Introduction of Accelerator Pedal

Component View

Accderator Pedal Rotation Assemloy

Accelerator Pedal Device Introduction of Accelerator Pedal

Hex. flange nut

22~29N .m

4-11

Accelerator pedal bracket assembly

Speaial Spring Clip

Lubrication bushing

Accelerator cable assembly

Accelerator cable

Replacement

1. Disconnect the accelerator cables. Loosen the accelerator cables and the bolts on the accelerator cable frame of the engine, and then disconnect the accelerator cables from the rocker of the motor restrictor.

2. Remove the accelerator pedal. (1)Remove the two bolts that connect the accelerator pedal and the body. (2)Disconnect the accelerator cables.

3. Remove the accelerator cables.

4. Install the accelerator cables and accelerator pedal assembly in a reverse order. Note: (1)The torque of the bolt is 20~25N.m. (2)Adjust the position of the accelerator cables properly to obtain a proper tension. (3)Check that the acceleration runs freely and reliably.

4-12

Clutch Control System Introduction of Clutch Centrol

Chapter 3 Clutch Control System

Section 1 Introduction of Clutch Centrol

I. Description

A hydraulic clutch control system is equipped which can be used in cars with various displacements (including

1.3L, 1.5L and1.6L).

II. Symptom Table

The table below lists the common symptoms and possible causes of the failures. The number means the possible sequence of the causes. Check the parts, and replace the corresponding parts if necessary.

Symptom

Clutch is trapped or shaken.

Clutch pedal is loosened.

Abnormal noise occurs.

Clutch skids.

Clutch can not be separated.

Suspected area

1. Engine fixture is loosened.

2. Clutch disc shakes seriously.

3. Clutch disc is contaminated by oil or wore down.

4. Torque spring of the clutch disc is damaged.

5. Clutch disc is hardened.

6. Diaphragm spring is not aligned on the top.

1. There is air in the clutch oil pipe.

2. Cup of the master cylinder is damaged.

3. Cup of the wheel cylinder is damaged.

1. Clutch release bearing is worn out, contaminated or damaged.

2. Torque spring of the clutch disc is damaged.

1. Clutch pedal has maladjusted free stroke.

2. Clutch disc is contaminated by oil.

3. Clutch disc is worn.

4. Diaphragm spring is damaged.

5. Platen is deformed.

6. Flywheel is deformed.

1. Clutch pedal has maladjusted free stroke.

2. There is air in the clutch oil pipe.

3. Cup of the master cylinder is damaged.

4. Cup of the wheel cylinder is damaged.

5. Clutch disc id deformed or wiggled.

6. Clutch disc is worn out.

7. Clutch disc is contaminated or burned out.

8. Clutch disc is contaminated by oil.

9. Clutch disc has no lube on its spline.

Component View

Clutch Control System Clutch Pedal

Section 2 Clutch Pedal

4-13

Hydranlic clutch hose

ÒLÓ Clip

Clutch hose Bracket

Bolt

Master cylinder Inlet hose

Sted Band Clamp

Master cylinder outtet pipeset

Clutch Peader Axis

N•m :Specified torque

Non-reusable parts Multi-function lube

Clip

Clutch pedal bushing

Clutch master cylinder cone U-connector bushing

Clutch pedal Transimissin Rod

Clutch pedal bracket

Hex. flange nut

Clutch pedal spring

Clutch pedal bushing

Absorber

Clutch pedal cover

Adjustment

1. Check and adjust the clutch pedal. (1) Lift the carpet on the floor. (2) Check the pedal’s height is proper. Pedal's height from oil felt: 134.3-144.3mm (3) Adjust the pedal's height. Loosen the lock nut, and turn the bolt till the correct pedal's height is reached, and then tighten the lock nut. Torque: 16N.m (4) Check whether the pedal's free travel and push bar travel are proper. a. Step the pedal down till a resistance appears. Pedal's free stroke: 5-15mm b. Step the pedal down lightly till the resistance increase a little. Push bar (on the pedals top) travel: 1.0-5.0mm (5) Adjust the pedal's free travel and push bar travel. a. Loosen the lock nut, and turn the push bar till the pedal's free travel and push bar travel are proper.

Pedal height

adjustment

Push travel & free travel adjustment point

Pedal free travel

Clutch

Travel

pedal

Pedal height

4-14

Clutch Control System Clutch Pedal

b. Tighten the lock nut.

25mm or more

Torque: 12N.m c. Check the pedal's height after adjusting the pedal's free travel. (6) Check the clutch's separating point. a. Tension the parking brake device and install a wheel stopper.

Max. travel end position

Separating point

b. Start the motor and make it run idly. c. DonÕt step the clutch pedal,and put the gear shift lever to the reverse gear slowly till the gears engage.

d. Step the clutch pedal down slowly,and measure the travel distance between the separating point to the pedal travel end position. Standard distance: 25mm or above (pedal travel end position to separating point) If the distance doesn't meet standard, carry out the following steps: Check the pedal's height.

Check the push par stroke and pedal's free travel. Discharge the air in the clutch fluid pipe. Check the clutch cover and clutch disc.

Check the pedal's travel. Pedal travel: 120-130mm

Replacement

1. Remove the battery negative terminal.

2. Remove the upper cover in dashboard panel.

3. Remove the lower cover in dashboard panel.

4. Remove the pane of the control board.

5. Remove the clutch pedal spring.

6. Remove the U-connector with pin on the clutch master cylinder push bar. Remove the clips and pins.

7. Remove the clutch pedal bracket. Remove the two nuts and bolts, and then remove the clutch pedal bracket.

8. Remove the clutch pedal. (1) Remove the bolts and nuts. (2) Remove the clutch pedal from the clutch pedal bracket.

Clutch Control System Clutch Pedal

9. Remove the clutch pedal gasket.

10. Remove the clutch pedal absorber. Remove absorber from the clutch pedal.

11. Remove the clutch pedal bushing. Remove the two bushings from the clutch pedal.

12. Remove the U-connector bushing on the clutch master cylinder's push bar. Remove the U-connector bushing from the clutch pedal with an 8mm hexagon wrench and hammer.

4-15

13. Install the U-connector bushing on the clutch master cylinder push bar. (1) Apply multi-function lube inside the new U-connector bushing. (2) Install the U-connector bushing on the clutch pedal. Tips: Install the U-connector bushing from the right side.

14. Install the clutch pedal bushing. (1) Apply multi-function lube on both sides of the two new bushings. (2) Install the two bushings on the clutch pedal.

15. Install absorber on the clutch pedal. Put absorber on the clutch pedal.

16. Install the clutch pedal. Install the clutch pedal on the clutch pedal bracket with bolts and nuts. Torque: 37N.m Tips: Install the bolts from the left side.

4-16

17. Install the clutch pedal bracket. Install the clutch bracket with two bolts and nuts. Torque: 12N.m

18. Install the U-connector with pin on the clutch master cylinder push bar. (1) Apply multi-function lube on the surfaces of the pin and the U-connector bushing. (2) Connect the U-connector to the clutch pedal with clip. Tips: Install the pin from the right side. (3) Install the clip on the pin.

19. Install the clutch pedal spring.

20. Check and adjust the clutch pedal.

21. Connect the battery negative terminal.

Clutch Control System Clutch Pedal

Propeller Shaft/Driveshaft Propeller Shaft, Driveshaft and Transaxle

4-17

Chapter 4 Propeller Shaft/Driveshaft

Section 1 Propeller Shaft, Driveshaft and Transaxle

I. Symptom Table

The table below can help find the causes of the problem. The numbers indicate the priority of the causes of the problem. Replace the parts if necessary.

Symptom

Deviation

Front wheel vibration

Noise (drive shaft)

1. Wheel

2. Front wheel alignment

3. Rear wheel alignment

4. Front wheel hub bearing (worn)

5. Rear wheel hub bearing (worn)

6. Front shock absorber with coil spring

7. Steering linkage (loose or damaged)

8. Stabilizer bar

1. Wheel balance

2. Wheel hub bearing (worn)

3. Front shock absorber with coil spring

1. Outer joint (worn)

2. Inner joint (worn)

Inspection Area

II. On-board Inspection

1. Check front wheel hub bearing (1) Remove front wheel. (2) Remove front brake caliper assembly. (3) Remove front brake disc. (4) Check the bearing backlash. Set a dial indicator near the front wheel hub center to check the backlash.

Maximum: 0.05mm If the backlash exceeds the maximum value, replace the front

wheel hub bearing.

Reference

(5) Check the front wheel hub deviation Using a dial indicator, check the deviation of the surface of the wheel hub outside the hub bolt.

Maximum: 0.07mm If the backlash exceeds the maximum value, replace the front

wheel hub subassembly.

4-18

(6) Install front brake disc. (7) Install front brake caliper assembly (8) Install font wheel. Torque: 103N.m

2. Check back wheel hub bearing (1) Remove rear wheel. (2) Remove rear brake drum subassembly. (3) Check bearing backlash. Set a dial indicator near the rear wheel hub center to check the backlash.

Maximum: 0.05mm If the backlash exceeds the maximum value, replace the rear

wheel hub and bearing assembly.

Propeller Shaft/Driveshaft Propeller Shaft, Driveshaft and Transaxle

(4) Check rear wheel hub deviation Using a dial indicator, check the deviation of the surface of the rear wheel hub inside the hub bolt.

Maximum: 0.07mm

If the backlash exceeds the maximum value, replace the rear wheel hub and bearing assembly. (5) Install rear brake subassembly (6) Install rear wheel Torque: 103N.m

Component View

Propeller Shaft/Driveshaft Front Driveshaft

Section 2 Front Driveshaft

right constant velocity drive

shaft assembly

4-19

with ABS LF vehicle speed sensor

brake hose

collar

gasket

snap ring

Tie rod left end assembly

snap ring

right constant velocity drive shaft assembly

front stabilizer bar

N.m :

specified torque

Non-reusable parts

cotter pin

gasket

collar

set nut

cotter pin

left lower swing arm

4-20

Component View

Propeller Shaft/Driveshaft Front Driveshaft

outboard rzeppa joint

outboard joint big clamp

outboard joint boot

outboard joint small clamp

inboard joint small clamp

inboard joint boot

RH:

right front drive shaft damper

drive shaft damper clamp

Non-reusable parts

inboard joint big clamp

tripod

retainer

tripod joint

Propeller Shaft/Driveshaft Front Driveshaft

Overhaul

1. Drain manual transmission oil (M/T transmission)

Torque: 39N.m

2. Drain automatic transmission oil (A/T transmission)

Torque: 25N.m

3. Remove front wheel

4. Remove engine bottom left shield (M/T transaxle)

5. Remove engine bottom right shield (M/T transaxle)

6. Remove engine bottom shield assembly (A/T transaxle)

7. Remove front wheel hub left bolt (1) Using a hammer and a drive shaft nut chisel, unstake the staked part of the left wheel hub nut. (2) While applying the brake pedal, remove the left wheel hub nut. Notice: the staked part of the nut should be fully unstaked, otherwise it may damage the thread of the drive shaft.

4-21

8. Remove left front vehicle speed sensor (with ABS) (1) Remove the bolt and clip, remove vehicle speed sensor and brake hose from left front shock absorber assembly.

(2) Remove the bolt, separate the left front vehicle speed sensor from steering knuckle.

9. Remove front stabilizer bar (1) Use a 10mm wrench to hold the bolt, remove the nut (2) Remove two collars, No.1 and No.2 gaskets, remove front stabilizer bar

4-22

10. Separate left lower swing arm assembly (1) Remove cotter pin and nut (2) On steering knuckle, remove the left lower swing arm assembly with ball joint puller.

11. Separate steering gear with tie rod assembly (1) Remove cotter pin and nut (2) On steering knuckle, remove the steering gear with tie rod assembly with ball joint puller.

Propeller Shaft/Driveshaft Front Driveshaft

12. Separate LF steering knuckle assembly Using a plastic hamper, separate left front drive shaft assembly from left front steering knuckle assembly Notice:

Do not damage the boot. With ABS:

Be careful not to damage the vehicle speed sensor rotor.

13. Remove left constant velocity drive shaft assembly Using a differential side gear shaft remover, remove the left constant velocity drive shaft assembly. Notice:

Do not damage the boot and oil seal. Be careful not to drop the drive shaft assembly.

14. Remove right constant velocity drive shaft assembly Using a brass bar and a hammer, remove the right constant velocity drive shaft assembly. Notice:

Do not damage the boot and oil seal. Be careful not to drop the drive shaft assembly.

Propeller Shaft/Driveshaft Front Driveshaft

15. Install LF steering knuckle assembly

Notice: The hub bearing could be damaged if it is subjected to the vehicle weight, such as when moving the vehicle with the drive shaft bearing removed. Therefore if it is absolutely necessary to place the vehicle weight on the hub bearing, first support it with the special service tool for front hub bearing.

16. Check left constant velocity drive shaft assembly

(1) Check the outboard joint for apparent looseness. (2) Check that the inboard joint slide smoothly. (3) Check the inboard joint for radial looseness. (4) Check the boot for damage. Notice: Place the drive shaft assembly on level surface during the inspection.

17. Remove inboard joint big clamp

Using a screw driver, loosen the inboard joint big clamp.

4-23

18. Remove inboard joint small clamp

Using a screw driver, loosen the inboard joint small clamp.

19. Separate inboard joint boot

Separate the outboard joint boot from the outboard Rzeppa joint assembly.

20. Remove left tripod joint assembly

(1) Wipe off the old grease from the tripod joint assembly. (2) Place the matchmarks between the tripod joint assembly and the outboard Rzeppa joint. Notice: Do not punch the matchmarks.

Mark

Geely MK 2006, MK 2007, MK 2008, MK 2009, MK 2010 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual