GEELY CK 2008 Repair Manual

447. Install fuel delivery pipe sub-assembly
(a) Install two washers in intake manifold. See (Figure 99).
(b) Install 4 injectors and fuel delivery pipe assembly into intake manifold .
(c) Temperarily install 2 bolts to attach the fuel delivery pipe to intake
manifold .
(d) Check injector for smooth rotation. See (Figure 100).
Hint: If injector doesn't rotate smoothly, replace O-ring with the injector
connector upward.
(e) Tighten the 2 bolts and attach the fuel delivery pipe to intake manifold
See (Figure 101).
Torque: 15N. m
Figure 100 Figure 101Figure 99 Washer
Rotate
Upward

45Section 4 Fuel Pump ReplacementFigure 102

461. Avoid fuel ejection
2. Disconnect fuel tank hose
3. Disconnect fuel tank return hose
4. Disconnect fuel tank gas exhaust hose
5. Detach fuel pump assembly with filter screen. See (Figure 103)
Using special tool, loose fuel tank cap. Be careful not to bend the fuel
level sensor arm when pulling out fuel pump.
6. Install fuel pump assembly. See (Figure 104). Replace ring seal .
Align the tab on the fuel pump to the notch on the fuel tank port. Tighten
the fuel tank cap with special tool.
Torque: 40N. m
7. Install fuel gas exhaust hose
(a) Install return hose;
(b) Install fuel hose;
(c) Check fuel for leakage.Figure 103
Figure 104New Washer

47Section 5 Fuel Emission Control System1. Check the operation when the fuel is cut off.
(a) Warm up the engine for at least 2500rpm. Using sound grade meter, check injector's noise when running.
See (Figure 105).
(b) The noise from the injector should stop immediately after loosing the throttle. Repeat for several times.
2. Check fuel vapor emission control system. See (Figure 106)
(a) Disconnect vacuum pipe after starting the engine.
(b) Select "ACTIVE TEST" and "PURGE VSV (Vacuum Solenoid Valve)" from the display on the fault
diagnosis tester. Confirm vacuum at VSV port.
(c) Connect the vacuum pipe after completing "ACTIVE TEST".
(d) After conducting "ECM DATA MONITOR"on the fault diagnosis tester, select "PURGE VSV" to
check operation.
(e) Start the vehicle after warming up the engine to confirm the VSV status is changed from disconnected to
connected. See (Figure 107).
3. Check the fill fuel port cap and gasket for distortion or damage. See (Figure 108)
Figure 105 Figure 106
Figure 107 Figure 108Sound Grade Meter
Gasket

Ohmmeter
No trggerOhmmeter
Trigger48Section 6 Carbon Canister Replacement1. Check and replace carbon canister
(a) Eye-inspect the carbon canister for crack or damage. See (Figure 109).
(b) Check the carbon canister's operation.
1. Plug the exhaust hole. See (Figure 110).
2. Blow air in through (4.71kpa, 48kgf/cm2) fuel tank hole when the exhaust
hole is closed. Check and ensure air is blew out from the blow purge hole.
Replace the carbon carnister if the operation is not as specified.
3. Blow air in through the fuel tank hole. Check and ensure air flows out from
the other hole without resistance.
Replace the carbon carnister if the operation is not as specified.
(c) Clean the carbon carnister: Plug the blowing tube, bleed air in through (4.71kpa,) fuel tank hole and goes
out from the exhaust port. See (Figure 111).
Figure 110 Figure 111
2. Vacuum Solenoid Valve (VSV)
(a) Using ohmmeter, check VSV open circuit. The resistance is 27-33¸ when the temperature is 20°. See
(Figure 112).
(b) Using ohmmeter, check VSV grounding. Replace VSV if it is continuity. See (Figure 113).Figure 112 Figure 113Figure 109Ω

Near cylinder head
Cleaning pipeNear the intake manifold49(3) Check VSV operation from hole E to F and that the air flow should be difficult. See (Figure 114).
3. PCV sub-assembly
It should be easy for air to pass through the cylinder head.
Notice:
zDo not suck air through valve.
zNever put any object into the valve. Replace PCV if the operation is
not as specified.
zBlow air in from the intake manifold side. Check that the air flow
should be difficult. Replace PCV if the operation is not as specified. See
(Figure 115).
Figure 115AirFigure 114

50Chapter 5 Exhaust System
(MR7131A, MR7151A, MR7161A)Component1Figure 116

511. Detach tail exhaust pipe assembly
Remove 2 bolts and the tail exhaust pipe assembly.
2. Remove intermediate exhaust pipe assembly
Replace exhaust system
Detach 2 bolts and intermediate exhaust pipe assembly.
3. Detach front exhaust pipe assembly
Remove 2 bolts and front exhaust pipe assembly.
4. Install front exhaust pipe assembly
Using vernier calipers, measure the free length of the spring.
Free length: 42mm
Using the new gasket, install the front exhaust pipe to the exhaust manifold.
Notice:
zDo not use removed gasket any more.
5. Install front exhaust pipe assembly.
Torque: 43N. m
6. Install intermediate exhaust pipe assembly
Using the new gasket, install the intermediate exhaust pipe to the front exhaust pipe.
Torque: 44N. m
7. Install tail exhaust pipe assembly
Using the new gasket, install the tail exhaust pipe to the intermediate
exhaust pipe. See (Figure 117).
Torque: 43N. m
8. Check exhaust for leakage
Figure 117Tail Pipe side
Washer

52Chapter 6 Cooling System Inspection
(MR7131A, MR7151A, MR7161A)Section 1 System Check1. Check the cooling system for leakage. See (Figure 118)
(a) Fill coolant into radiator. Install the tester onto the radiator cap port.
(b) Start engine.
(c) The water pump pressure is 118Kpa. Check the pressure and ensure the
pressure will not drop. If the pressure drops, check the port, radiator and
water pump for leakage. If there is no leakage, check the heat exchanger,
cylinder block and cylinder head.
2. Check the engine coolant level in the reservoir.
The coolant level should be between low and full marks.
3. Check coolant quality
(a) Remove radiator cap.
To avoid being scalded, do not remove radiator cap while the engine and
radiator are still hot, as fluid and steam can be sprayed under pressure.
(b) There should not be excessive deposits of rust or scale around the radiator,
and the coolant should be free from oil.
(c) Reinstall the radiator cap.
4. Thermostat
Hint:
The thermostat temp indicates the valve opening temperature.
See (Figure 119).
(a) Immerse the thermostat in water and gradually heat the water.
(b) Check the valve opening temperature. Valve opening temperature: 80 -- 84°C
(c) Check the valve lift. See (Figure 120, Figure 121). Valve lift: 8mm or mor at
95°C
(d) Check the thermostat is fully closed when the thermostat is at low temperature
( 77°C).
5. Radiator cap valve
Standard opening pressure: 93-123kpa
Minimum opening pressure: 78kpa
If the opening pressure is less thanminimum, replace the radiator cap.Figure 118
Figure 119
Figure 120
Figure 121 Radiator Cap Tester8.0mm or
More ≤

536. Fan
(1) Check the cooling fan operation with low temperature (Lower than
83°C)
(a) Turn the ignition switch to “ON” position.
(b) Check that the cooling fan stops.
(c) Pull out the water temperature sensor connector. See (Figure
122)
(d) Connect the water temperature sensor to car body with the
wire and ground the wire.
(e) Check the cooling fan operation.
(f) Insert water temperature sensor connector.> 93°C
See (Figure 123)
(a) Start engine and make the coolant temp. higher than 93°C.
(b) Check that the cooling fan turns.
Replace it with water temperature switch if it doesn't run)
(3) Check the cooling fan. See (Figure 124)
(a) Disconnect the cooling fan connector.
(b) Connect the battery and ammeter to the connector.
(c) Check that the cooling fan rotates smoothly and check
the reading on the ammeter.
Standard amperage: 5.7 - 7.7A
(d) Reconnect the cooling fan connector.Disconnest
Figure 123
Figure 124 Figure 122
(2) Check the cooling fan operation with high temperature (over 93°C)Battery Amperometer