ESP GEELY CK 2008 User Guide

314Have a focus inspection on the following area:
a. Each pipe union joint and valve connection.
b. All hose, especially near the pipe union.
c. Compressor shaft seal, front and rear cover, gasket, oil fill plug.
d. Area on the surface of the condenser and evaporator that is scratched, bruised or damaged.
e. Expansion valve inlet and outlet connection and temperature sensor element and the welding position.
3. Check the Refrigerant
Observing from the sight glass, you may understand the refrigerant status and analyze the possible faults:
4. Check Other Parts
Other parts needed to be checked and their check points:Conditions obse rvedP ossible proble ms
Cle ar, no a ir bubble , A/C e mits c ool wind Re frige ra tion system is normal
Cle ar, no a ir bubble , A/C e mits warm wind Re frige ra nt le a ke d, the re is le aka ge in the syste m
Occ a tiona l a ir bubble . Expa nsion va lve is froste d There is wa te r mixe d in the re frigeration syste m
Occational air bubble. Insufficient refrigerant or air mixed in the system
Cle ar, the re is oil stripe on the gla ss Outle t is not c old, no refrige ra nt
Foamy and turbid Excessive freezing oilChecked PartCheck Points
The re sha ll be no dirt and rust on the radiator tha t hinde r the he at
exchange;
The ra dia tor surfa ce ha s no da mage , fissure a nd hidde n trouble tha t ma y
cause refrigerant leakage.
Elec tromagne tic Clutc hClutc h ope ration is norma l. Whe n switche d on, the c ompre ssor sha ll
operate, clutch can not slip.
Compre ssor Be lt Be lt te nsion of 250N is normal, belt is not broke n and dama ged.
WireThe electromagnetic clutch and blower power cable shall be not damaged
and overheated; the connection shall be reliable, and the protective
gromme t through the me tal plate sha ll be ke pt good a nd without da ma ge .
HoseRefrigerant hose and condenser pipe shall be secured and shall not be
dama ged by a pproac hing the othe r ove rhe ate d pa rts, moving pa rts a nd
sha rp parts. Eva pora tor Conde nse r

3302.Notice On Removing The Rear Bumper
(1) Pull the rear bumper out to separate it from the bumper rail.Warning
If only one side of the rear bumper is separated from the bumper rail, the bumper may drop and
result in body injury. Be careful not to make the bumper drop before separating the rear bumper
from the bumper rail.3.Notice On Installing The Rear Bumper(1) Press the rear bumper joint into the vehicle body to connect the rear bumper mounting bracket assembly
and the bumper rail.
(2) Insert the rear bumper end tab into the corresponding hole of the rear fender to flush with the outer
surface.

343(IX) A pillar inside trim and front door sillA pillar inside trim and front door sill diagram
A pillar inside trim and front door sill diagram
1. Right A Pillar Inside Trim 2. Left A Pillar Inside Trim 3. Right Front Door Sill
4. Left Front Door Sill5.D-Clip 6. Steel Clip7. Cross Slot Head Self-tapping Screw
1. Removal
1Remove the installed right front door sill, left front door sill self-tapping screw cross screwdriver;
2Use an opener to remove the right A pillar inside trim, A pillar inside trim, right front door sill, left frontdoor sill.
2. Installation
1 Install the right A pillar inside trim, A pillar inside trim, right front door sill , left front door sill to the
corresponding position with clip and steel clip;
2Fix the right front door sill , left front door sill with a tapping screw. 1 2
3
6
4 57

344(X) B pillar inside trimB pillar inside trim diagram:
B Pillar Inside Trim Diagram
1. Right B Pillar Upper Inside Trim 2. Left B Pillar Upper Inside Trim 3. Right Deflector
4. Left Deflector5. Right B Pillar Lower Inside Trim 6. Left B Pillar Lower Inside Trim
7. Right B Pillar Lower Inside Trim Sound Insulator 8. Left B Pillar Lower Inside Trim Sound Insulator
9. Cross Pan Head Tapping Screw10. Steel Clip
1.Removal
1Remove the installed left B pillar lower inside trim, right B pillar lower inside trim tapping screw with a
cross screwdriver;
2Remove the left B pillar lower inside trim, right B pillar lower inside trim with a opener ;
3Remove the seat belt swing ring;
4Remove the right B pillar upper inside trim, leftB pillar upper inside trim tapping screw with the cross
screwdriver;
5Remove the right B pillar upper inside trim, leftB pillar upper inside trim with a opener.
2.Installation
1Clip B pillar inside trim to the corresponding position with clip and steel clip in order;
2Fix the upper inside trim and lower inside trim to the vehicle body with a tapping screw.
2
453
1
6
10
8 79

345(XI) Cpillar inside trim and rear door sillC pillar inside trim and rear door sill diagram:
C pillar inside trim& rear door sill diagramdiagram
1.Right C Pillar Upper Inside Trim 2.Left C Pillar Upper Inside Trim 3. Right C Pillar Upper Inside
Trim Sound Insulator 4. Left Sound Insulator 5. Right C Pillar Lower Inside Trim 6. Left C Pillar
Lower Inside Trim 7. Right Rear Door Sill 8. Left Rear Door Sill9. E-Clip10. Cross Pan
Head Self-tapping Screw 11. D-Clip
1. Removal
1Remove the installed door sill and C pillar lower inside trim tapping screw and E-clip with a cross
screwdriver;
2Remove C pillar upper inside trim with a opener ;
3Remove C pillar lower inside trim with a opener
2.Installation
1 Clip C pillar inside trim and rear door sill onto the corresponding position in order;
2Tap C pillar upper inside trim and C pillar lower inside trim lightly with a rubber hammer to ensure D-clip
clipped in the vehicle inner panel;
3Fix the rear door sill onto the vehicle body with a tapping screw.112 110843
57
96

346(XII) Roof inside trimRoof Inside Trim Diagram:
Roof inside trim diagram
1. Roof Inside Trim2. Left Sun Visor Bracket 3. Right Sun Visor Bracket 4. Cross Semi-
Countersunk Screw 5. Left Sun Visor Assembly 6. Right Sun Visor Assembly 7 . Cross
Counter Sunk Tapping Screw 8. Glass Box Assembly 9. Right Front Handle Assembly10. Left
Rear Handle Assembly11. Right Rear Handle Assembly12. E-Clip13. Roof Rear Heat Insulator
14. Roof Front Heat Insulator15. Cross Slot Head Screw
1. Removal
1Remove the safe handle, map lamp, left/right A pillar inside trim, left/right B pillar upper inside trim, left/
right C pillar upper inside trim;
2Remove the screw used to install left/right sun visor assembly with a cross screwdriver. Remove the left/
right sun visor assembly
3Remove the plastic clip used to install roof inside trimassembly with opener. Remove the lower dome
lamp connector and roof inside trimassembly.
2. Installation
1Install the dome lamp connector into the corresponding hole and clip the plastic clip onto the corresponding
hole in the vehicle body. Fix the roof inside trimassembly;
2Install the safe handle to the corresponding position on the trim board on the right front pillar with a
tapping screw and clip the safe handle cover;
3Install the left, right sun visor onto the roof inside trimassembly with a tapping screw and fix it to the
corresponding hole on the vehicle body;
4Install left/right A pillar inside trim, left/right B pillar upper inside trim, left/right C pillar upper inside trim. 2 13 4
5
6 7
8
9 10
11
12 13 1415

347(XIII) Carpet and Heat InsulatorCarpet and Heat Insulator Diagram
Carpet and Heat Insulator Diagram
1. Carpet 2. Cowl Lower Sound Insulator 3. Cowl Upper Sound Insulator 4 . Cowl Outer
Panel Heat Insulator 5. Foot Pedal 6. Cross Pan Head Screw 7. Floor Sound Insulator
1. Removal
1Remove the front and rear seats, left front door sill, right front door sill, right B pillar lower inside trim, left
B pillar lower inside trim, right rear door sill, left rear door sill, front and rear part of the auxiliary console;
2Remove the cross pan head screw and remove the foot pedal.
3Remove carpet and cowl lower sound insulator, cowl upper sound insulator, cowl outer panel heat insulator.
2. Installation
1Install the accelerator pedal assembly, brake and clutch pedal assembly, parking brake control mechanism
assembly onto the vehicle body;
2Install the carpet to the corresponding hole. Install both sides of the carpet under the left front door sill,
right front door sill, right B pillar lower inside trim, left B pillar lower inside trim, right rear door sill, left
rear door sill.1 27 3
4
65

349VTake out the rear trunk carpet, spare tire cover board and the rear trunk miscelleaneous box. Screw the
spare tire press plate assembly to take out the spare tire.
2. Installation
1Clip the rear trunk inside trim onto the corresponding hole in the reserve order of the removal;
2Install the right rear and left rear combination lamp access hole cover;
3Install the right and left speaker grill to the rear partition inside trim with a cross screwdriver;
4Install the rear partition inside trim to the vehicle body;
5Install the high mounted stop lamp and the C- pillar upper inside trim.(XV) Engine Hood Inside TrimEngine Hood Inside Trim Diagram:
Engine Hood Inside Trim
1. Engine Hood Inside Trim 2. E-Clip
1. Removal
1Open the engine hood and gas spring;
2Remove the clip and remove the engine hood inside trim
2. Installation
1Open the installed engine hood and gas spring;
2Align the corresponding hole position in the the engine hood inside trim and press the clip in by hand.
2 1

366II. Removable Sheet Metal Parts
(I) Engine Hood, Front Fender1. Engine hood is mainly used to protect the engine, meet the whole vehicle design, and make the mainte-
nance convenient. It also has an effect of isolating the engine noise. The engine hood has a double-insurance
lock system. The release of the first lock is controlled by the drawing cable that is under the instrument panel.
As to the release of the second lock, you should firstly release the first one and the hood will open, and then
move the hood lock hook. The double-insurance lock system is designed for safety, especially in the course
of running with a high-speed, to prevent the engine hood from being raised, which often causes traffic
accidents. The angle of the hood that is fully opened is 52°.As shown in Figure 5-8
Figure 5-8 Engine Hood Hinge
1Hinge Bracket 2 Hinge Arm 3 Pin Shaft(II) Front FenderThe matching relationship between the front fender and hood, front door is as shown in the Figure 5-9.
Figure 5-9 Section Around The Front Fender
A) The matching relationship with the hood (5mm ± 0.5mm)
B) The matching relationship with the front door (5mm ± 0.5mm) 13252
†while fully open
Engine Hood
outer plate
Engine Hood
inner plate
AEngine HoodFront fender
Front door
Front fender
B

372Section 2 Typical Technology Of Body Panel RepairThe flow line of the repair technology is as follows:Section 3 Repair after Body DamageBody repair methods include calibration, reshaping, strengthening, partial replacement and renewing of a
whole part. CO2 gas protecting welding should be adopted when welded.I. Reshaping1. Calibration
The deformation of the body is usually caused by an accident. You can calibrate it by propping to its former
location. When calibrating, impose force in the opposite direction of the outside force or deformation force.
Under the most circumstances, calibration in a cool status can be adopted. The internal stress can be re-
moved by partial heating. Then you can do some corresponding aging treatment.
It is better to use body calibration machine for car body calibration. Geometric dimension and tolerance can
be restored to the former standard. Power, economy and comfortableness can be assured.
The body repair begins with a process of preliminary calibration or rough calibration. The body deformation
can be removed by propping back to its former location. The angle of the applied force for propping back
should be almost the same with the outside force that causes damage. Reaction force should be imposed at
the back of the pulling action point to make the propping force adjustable. Inspect the deformation during the
process of propping back. Proper heating is applied on correspondent parts to remove internal stress.
2. Strengthening
When partial damage, break or crackle occur on structural components, strengthening is allowed, especially
to be applied in those parts where damage often occurs. Willful strengthening or repair welding should be
avoided, because it will affect the stressing status on body.
The main ways of strengthening are sleeving and bracket reinforcement.
3. Partial And Whole Part Replacement
The parts that are badly rusted should be partially replaced. What is broken and damaged should be replace
a new one. The post pillar is pressed and molded adopting thin sheet. Parts and components are brought from
manufacturers. When they are molded by you, material, section dimension, and thickness etc should accord
with their original design requirements. When the broken post pillar (incl. cross member) is wholly replaced,
the connection way must be the same with the original one.
Appearance assessment Disassembly Paint removal Appraisal
Panel repair
AssemblyPainting