engine GEELY CK 2008 Workshop Manual

Table of ContentsPart I Engine ...........................................................................1Chapter 1 Engine Assembly (MR479Q, MR479QA, MR481QA)...................1Section 1 Routine Inspection.........................................................................................1
Section 2 Drive Belt Replacement ...............................................................................5
Section 3 Valve Clearance Adjustment...........................................................................6Chapter 2 Engine Components Replacement
(MR479Q, MR479QA, MR481QA)................................................................10Section 1 Engine Components....................................................................................10
Section 2 Engine Components Replacement............................................................13
Section 3 Timing Belt Replacement.........................................................................17
Section 4 Camshaft Replacement............................................................................22
Section 5 Cylinder Head Gasket Replacement.........................................................28
Section 6 Oil Pump Oil Seal Replacement................................................................33
Section 7 Engine Rear Oil Seal Replacement............................................................34Chapter 3 Lubrication System (MR479Q, MR479QA, MR481QA)...............35Section 1 Oil Pressure Gage Sensor Replacement....................................................35
Section 2 Oil Pump Assembly Replacement..............................................................36
Section 3 Oil Filter Replacement................................................................................38
Section 4 Starter Replacement.................................................................................39
Section 5 Generator Replacement............................................................................40Chapter 4 Fuel System (MR7131A, MR7151A, MR7161A)........................41Section 1 Check Fuel System Pressure.....................................................................41
Section 2 Fuel Pump Inspection...................................................................................42
Section 3 Fuel Injector Replacement.........................................................................43
Section 4 Fuel Pump Replacement............................................................................45
Section 5 Fuel Emission Control System....................................................................47
Section 6 Carbon Canister Replacement....................................................................48Chapter 5 Exhaust System (MR7131A, MR7151A, MR7161A).................50

Chapter 6 Cooling System Inspection
(MR7131A, MR7151A, MR7161A).................................................................52Section 1 System Check
Section 2 Water Pump, Thermostat and Radiator Replacement.................................... 54Chapter 7 Clutch (MR7131A, MR7151A, MR7161A)....................................56Section 1 Clutch Replacement...................................................................................57Chapter 8 Maunal Transaxle Assembly
(MR7131A, MR7151A, MR7161A)................................................................59Section 1 Manual Transaxle Replacement..................................................................60
Section 2 Vehicle Speed Sensor Replacement
Section 3 Transmission Case Oil Seal..........................................................................62
Section 4 Transaxle Case Oil Seal Replacement........................................................63Chapter 9 General Engine Troubles and Their Troubleshooting....................64Section 1 Overview........................................................................................................64
Section 2 General Engine Fault and Troubleshooting.......................................................64
Section 3 Engine Noise Diagnosis and Troubleshooting................................................77Chapter 10 Engine Management Unit..............................................................81Section 1 System Description.........................................................................................81
Section 2 System Component and Working Principle......................................................82Part II Chassis............................................................................85Chapter 1 Transmission Control Device.........................................................85Section 1 Transmission Control Device.........................................................................85
Section 2 Lever Type Transmission Control Device......................................................85
Section 3 Cable Type Transmission Control Module......................................................87Chapter 2 Accelerator Pedal............................................................................90Section 1 Accelerator Pedal..........................................................................................90Chapter 3 Clutch Control System....................................................................91Section 1 Clutch Control System....................................................................................91
Section 2 Clutch Cable Control Mechanism.....................................................................91
Section 3 Clutch hydraulic Control Device.......................................................................94Chapter 4 Propeller Shaft...............................................................................97...............................................................................................52
..............................................................61

Section 3 Removal & Installation................................................................................... 262Chapter 8 MK-20 ABS System........................................................................ 2 7 2Section 1 ABS Diagnosis ................................................................................................. 272
Section 2 ABS System Check .......................................................................................... 276
Section 3 Removal and Installation................................................................................. 292Part IV Air Conditioner and Inside & Outside Trim ......................297Chapter 1 A/C System...................................................................................... 2 9 7Section 1 The Structure & Working Principle of Refrigeration System...............................297
Section 2 Heating System ................................................................................................ 299
Section 3 A/C controlling system.................................................................................... 302
Section 4 Service Caution & Notice................................................................................ 304
Section 5 The Refrigeration System Operation Procedure..............................................305
Section 6 Basic System .................................................................................................... 308
Section 7 A/C System Faults Check & Troubleshooting................................................ 313Chapter 2 Inside & outside Trim and Accessory................................................318Section 1 Configuration Index............................................................................................318(I) Outside Trim And Front Accessory.................................................................................318
(II) Outside Trim and Rear Accessory.................................................................................319
(III) Front inside trim..........................................................................................................320
(IV) Rear inside trim ............................................................................................................321Section 2 Inside & Outside Trim and Accessories Removal and Installation.......................322(I) Front Bumper..................................................................................................................322
(II) Engine Hood.................................................................................................................324
(III) Outside Rear View Mirror
(IV) Rear trunk Lid...............................................................................................................327
(V) Rear Bumper...................................................................................................................329
(VI) Seat Removal, Installation and Adjustment...................................................................331
(VII) Seat Belt.....................................................................................................................335
(VIII) Instrument panel and auxiliary console.....................................................................338
(IX) A pillar inside trim and front door sill ............................................................................343
(X) B pillar inside trim........................................................................................................344
(XI) Cpillar inside trim and rear door sill.............................................................................345
(XII) Roof inside trim
(XIII) Carpet and Heat Insulator.............................................................................................347 ...............................................................................................326
...........................................................................................................346

(XIV) Rear trunk Inside Trim............................................................................348
(XV) Engine Hood Inside Trim...........................................................................349
(XVI) Door..............................................................................................................350Part V Body............................................................................359Chapter 1 General Information.....................................................................359Section 1 Body Structure..............................................................................................359Chapter 2 Body Repair..................................................................................369Section 1 Body Damage Forms and Requirements for Repair....................................369
Section 2 Typical Technology Of Body Panel Repair..................................................372
Section 3 Repair after Body Damage..........................................................................372
Section 4 Features and Composition of Automobile Body............................................. 377
Section 5 Painting Technique after Body Repair............................................................383
Section 6 Service Data For Body................................................................................385

1Part I EngineChapter 1 Engine Assembly
(MR479Q, MR479QA, MR481QA)Section 1 Routine Inspection1. Check coolant
2. Check engine oil
3. Check battery
4. Check air cleaner element assembly
5. Check spark plug
6. Check drive belt
Figure 1
Notice:
zCheck the belt deflection at the specified point See (Figure 1).
zSet tension to specified value when installing new belt.
zCheck the deflection to ensure it is below the specified value after the belt runs for over 5 minutes.
zReinstall the belt which has been running for over 5 minutes. The deflection of the old belt is regarded as
the standard for inspection.
zCheck V-belt for tension and distortion after the engine cranks for 2
turns.
7. Check ignition timing See (Figure 2)
a) Warm up the engine.
b) When using fault diagnosis tester
Connect fault diagnosis tester to fault diagnosis interface socket.
Ignition timing:
MR479Q: 10 ± 2° BTDC (before top dead center) at idle
MR479QA: 10 ± 2° BTDC at idle
MR481QA: 10 ± 2° BTDC at idleFigure 2New Belt mm Old Belt mm
Fan Belt 7～
13. 5
Power steering Belt 5～
66～
8
A/C Belt 6. 5
～78～
9 Belt deflection See (Table 1)
Be lt pre ssure : 98NBelt Looseness
Measuring PointWater pump
Power steering
crankshaftgenerator
Air condition
compressor pump11.5～
9

2c) When fault diagnosis tester is not used
(1) Shorting fault diagnosis interface socket 13 (TC) terminal and 4(CG) terminal.
Notice:
zEnsure correct connection, otherwise the engine will be damaged.
zSwitch off all electrical appliance system.
zCheck when disconnecting cooling fan motor.
(2) Using timing light to check ignition timing.
Ignition timing: 10 ± 2° BTDC at idle
Notice:
(1) Transmission shift lever should be in neutral position when checking ignition timing.
(2) Running engine at 1,000-1,300rpm for 5s and check at idle.
(3) Remove the tester on fault diagnosis socket.
(4) Ignition timing advance angle becomes larger when the engine roate speed is higher.
(5) Remove timing light.
8. Check engine idle See (Figure 3)
Notice:
zCheck idle when cooling fan motor is disconnected.
zSwitch off all electrical accessories and A/C.
9. Check compression pressure See (Figure 4)
(a) Engine switched off.
(b) Detach high voltage cable.
(c) Detach spark plug.
(d) Check the compression pressure in the cylinder.
(1) Insert pressure gauge into the hole of the spark plug.
(2) Throttle valve full open.
(3) Crank the engine, measure the compression pressure. MR479Q 800±50 (rpm)
MR479Q A 800±50 (rpm)
MR481Q A 800±50 (rpm)Table 2(a) Warm up the engine.
(b) Connect fault diagnosis tester to fault diagnosis interface socket.
(c) Connect tachometer testing pen to fault diagnosis socket terminal
9 when not using fault tester.
(d) Check idle See (Table 2).
Figure 4Figure 3Techometer
Battery

3The Min. compression pressure: 980 kPa
The tolerance range of the cylinders pressure: 100 kPa
Notice:
zEnsure sufficient battery power and the engine speed is no less than 250 RPM (revolutions per minute).zCheck the compression pressure of other cylinders in the same way.
zComplete the measure as quick as possible.
(4) If the compression pressure in several cylinder is too low, fill some engine oil to the cylinder via the
hole of the spark plug. Check by repeating step 1-3.
Hint:
zIf the compression pressure is improved after filling oil, the piston ring or the cylinder may be abrased
or damaged.
zIf the pressure is still too low, the valve is stagnation or poor seal, or there is a leakage in gasket.
10. Check CO/HC
(a) Start engine.
(b) Running engine at 2500rpm for approximately 3 minutes.
(c) Insert CO/HC meter testing probe into tailpipe at least 40cm during idling.
(d) Check CO/HC concentration at idle and 2500rpm.
Hint:
zComplete measurement within 3 minutes.
zTest the CO/HC emission concentration at idle and 2500 rpm on QC/T630-1999 standard.
(e) Take the following steps to diagnose the fault if the CO/HC concentration does not comply with standard .
(1) Check the oxygen sensor operation.
(2) See (Table 3) for the possible cause and check and repair.

5Section 2 Drive Belt Replacement1. Disconnect all engine pipe hose and wire joint. Remove engine assembly from the engine
compartment, jack up the body, take out the engine assembly slowly (See Provision 20, Section
Two, Chapter Two for detailed information)
2. Remove generator V-belt See (Figure 5)
3. Remove No. 1 V-belt A/C compressor to crankshaft pulley
4. Remove water pump belt See (Figure 6)
5. Install water pump V-belt
6. Adjust V-belt of steering assisting pump
(a) Adjust power steering belt tension, tighten bolt B.
(b) Tighten bolt A.
Torque : 39N. m
7. Install V-belt A/C compressor No. 1 to crankshaft pulley
8. Adjust V-belt A/C compressor No. 1 to crankshaft pulley
(a) Adjust A/C belt tension by tightening bolt B.
(b) Tighten nut A.
Torque : 39N. m
9. Install Generator V-belt See (Figure 7)
10. Adjust Generator V-belt.
Tighten bolt A and then bolt B.
Torque: Bolt A 18N. m Bolt B 58N. m
11. Check driving belt for distortion and tension
Figure 7 Figure 6 Figure 5

8Notice:Due to the small end play on camshaft, the cylinder head may be damaged by the thrust force when removingit, it may stuck or damage camshaft. Take the following steps to avoid damage: (1) Turn the crankshaft pulley to make exhaust camshaft dowel pin is a bit higher than the cylinder head. See(Figure 15). (2) Align the matchmark on each gear to engage intake camshaft gear and exhaust camshaft gear. See(Figure 16).
(3) When the gears are engaged, install the intake camshaft bearing onto bearing journal.
Hint:
The intake camshaft lobe of cylinder 1 and 3 can jack up their own valve tappet.
(5) Install 4 bearing caps to the right position.
(6) Apply a light layer of engine oil on the thread and under the head of bearing cap bolts.
(7) Uniformly install and tighten 8 bearing cap bolts in several times, in the sequence shown in the figure.
Torque: 13N. m
(8) Remove service screw.
(9) Install the bearing cap No. 1. in the direction of the forward arrow mark.
(10)Apply a light layer of engine oil on the thread and under the head of bearing cap bolts.
(11)Alternatively tighten and install 2 bearing bolts.
Torque: 13N. m
7. Adjust exhaust valve clearance. See (Figure 17)
Remove adjust gasket.
(1) Crank to keep the camshaft head upward.
(2) Face valve tappet nick to vehicle front. (3) Press valve tappet, put special tool between camshaft and valve tappet.Hint:
zLean the end with mark "9" into the position in (Figure 18).Figure 15Install MarkTiming MarkMarch MarkCam LobeUpward
NickFrontFigure 17
Figure 18 Figure 16

9(4) Alternatively press valve tappet with the special tool (A) (B). Check
valve clearance. See (Figure 19).
8. Install cylinder head sub-assembly
(a) Remove all old gasket material.
(b) Apply the seal glue to the cylinder head.
(c) Connect wire harness and clip.
(d) Install gasket under of cylinder head.
(e) Install the cylinder head cover with 4 seal gaskets and 4 screw caps.
Torque: 7.8N. m
(f) Install 2 ventilation hoses to cylinder head cover.
(g) Connect generator wire joint.
(h) Connect generator wires.
(i) Connect oil pressure switch connector.
(j) Install wire clip.
(k) Connect A/C compressor switch connector.
9. Install electronic ignition coil and high voltage cable
10. Check engine oil for leakage
Figure 19