%27 GEELY CK 2008 User Guide

60Section 1 Manual Transaxle Replacement1. Open the engine hood
2. Remove the battery
3. Remove clutch cylinder sub-assembly. See (Figure 140)
4. Detach transmission shift cable assembly. See (Figure 141)
5. Remove the connector and turn on the back-up lamp switch connector.
6. Disconnect vehicle speed sensor
Disconnect vehicle speed sensor connector.
7. Detach the front exhaust pipe
8. Drain transmission oil
9. Detach left & right front wheel hub nut
10. Detach left & right front wheel speed sensor (ABS)
11. Detach front balance rod
12. Detach left & right tie-rod with ball stud pin
13. Detach front balance rod
14. Detach left & right lower swing arm
15. Detach left & right front propeller assembly
16. Hoist the engine from compartment. See "Provision 20, Section 2, Chapter 2"
17. Detach starter assembly
18. Detach engine mounting bracket
19. Detach manual transaxle assembly
20. Install engine mounting bracket
21. Install manual transaxle assembly
22. Connect engine vibration insulating cushions
23. Install starter assembly
24. Install left & right front propeller assembly
25. Connect left & right lower swing arm
26. Connect left & right tie-rod with ball stud pin
27. Connect front balance rod
28. Connect left & right front speed sensor (ABS)
29. Installleft & right front shaft nut
30. Install front exhaust pipe
31. Connect speedometer sensor connector.
32. Connect back-up lamp switch connector.
33. Connect transmission shift cable assembly. See (Figure 141)
34. Install clutch sub-pump assembly. See (Figure 140)Figure 140
Figure 141

10110. Remove the snap ring on the spline shaft end of the tripod constant velocity joint
Notice: Do not damage the snap ring, or it shall be replaced
11.Disassemble the Rzeppa Constant velocity universal joint boot Use screwdriver to loosen the
Rzeppa Constant velocity universal joint boot band, remove the boot
Notice: Replace the band if it is distorted
12. Disassemble the Rzeppa Constant velocity universal joint
(1) Remove the old grease
(2) Use the mark pen to make a matchmark on the inboard and outboard joint
Notice: Do not punch the marks
13. Installation is in the reverse order of removal procedure
Notice:
(1) Apply proper amount of long life grease as specified when assembling the tripod
velocity universal joint and Rzeppa Constant velocity universal joint, and then
assemble it according to the matchmark.(2) Keep both sides of the spline shaft clean, the boot intact and the band assembled into place(3) The tripod constant velocity joint spline shaft and the differential shall be assembled into place, with the snap ring opening facing down, use rubber hammer to tap it
appropriately when necessary
(4) Propeller shaft attaching nut torque: 145~155N.m, install the cotter pin
(5) Steering knuckle lower swing arm assembly ball stud pin retaining bolt and nut
torque: 80~90N.m
(6) Tie rod ball stud pin attaching nut torque:27~39N.m, install the cotter pin

127Section 2 Wheel ReplacementReplacement(1) Pry the edge of the wheel rim trim cover with screwdriver to remove the wheel rim trim cover
(2) Loose every tire nut with tire nut wrench.
(3) Four jacks support the vehicle body, two at each side as shown in the figure.
The jack should be near to the to-be-replaced wheel with solid base.
(4) Remove the wheel nut.
Caution:
(1) Make sure the parking brake control handle has been pulled up before jacking up the
vehicle
(2) Wheel nut torque : 95~115N.m
(3) Check the four wheel alignment when necessary

1327. Remove the combination switch assembly
(1) Remove 3 set screws.
(2) Disconnect headlamp dimmer switch and wiper and washer switch wire harness
(3) Remove the combination switch assembly
8. Disconnect the universal joint
Remove the locking bolt between the joint yoke and the power steering gear
9. Remove steering column assembly.
(1) Remove the wire harness connector on the steering column assembly
(2) Remove 2 bolts, 2 nuts and the steering column assembly
10. Remove ignition switch lock core assembly
(1) Remove the ignition switch wire harness
(2) Remove the screw, then remove the ignition switch assembly

1383. Loosen the union thread of the high and low pressure pipes on the steering gear assembly
4. Remove the boot band and No. 1, No. 2 boots
5. Disconnect the power steering gear assembly from the steering column
Remove the steering gear pinion shaft spline lock bolt on the universal joint yoke
6. Remove power steering gear assembly
Remove 4 steering gear assembly set bolts, remove the power steering gear assembly
7. Installation is in the reverse order of the removal
Notice:
(1) Insert the steering gear pinion shaft spline into the spline hole of the universal joint
yoke, make sure that the positions of the notch of the steering gear pinion shaft and the
lock bolt of the universal joint yoke are correct
(2) Secure the power steering gear with 4 bolts, torque: 63~93N.m
(3) Tighten the steering gear pinion shaft spline lock bolt on the universal joint yoke, torque:
22~34N.m
(4) Tighten the 4 set bolts of the boot band and boot torque: 16~26N.m
(5) Install the union thread of the power steering high and low pressure pipe to the power
steering gear, torque: 19~33N.m
(6) Connect the tie rod ball stud pin with the steering knuckle, make sure that the mating
surface of the tie rod ball stud pin and the steering knuckle is clean, tighten the slot nut,
torque: 27~39N.m. Install the cotter pin, make sure of the correct installation
(7) Add appropriate amount of specified power steering fluid, bleed the power steering sys-
tem
(8) Check the power steering pipeline system for leakage
(9) Check the front wheel alignment and front wheel left and right limit turn angle, adjust the
toe in if necessary and tighten the tie rod lock nut
(10)Check the position of the steering wheel. It is required that the steering wheel spokes
are basically symmetrical when the vehicle is driven straight ahead, reassemble the steering
wheel if necessary

163II. STARTER ASSEMBLY REPLACEMENT (MR479Q, MR479QA, MR481QA)1. REMOVE STARTER ASSEMBLY
(a) Disconnect the starter connector.
(b) Remove the nut, and disconnect the starter
cable.
(c) Remove the 2 bolts and the starter
assembly.
2. INSTALL STARTER ASSEMBLY
Install according to the inverted order of removal.
Torque:
Bolt 37N.m (378kgf.cm, 27ft.lbf)
Harness 9.8N.m(100kgf.cm, 7.0ft.lbf)

2272. The radio backlight does not light up with the illumination switch ON
Wiring Diagram
(1) Check radio assembly (TAIL)
Check the voltage between terminals under each operating condition as shown in the table below.
Standard:
Abnormal:Repair or replace wire harness and connector
Normal:Check and replace radio assemblyMain Fuse BoxRadio and CDFusible Link Box
BatteryLight
Control
Switch
BatteryTeste r Connec tion Condition Sta nda rd Sta tus
TAIL - GND Combined Switch (Light switc h) 10～
14V

2327. Poor sound quality only when playing tape
(1) Replace it with another tape and re-check
yReplace the faulty tape with working tape to see if the same fault will re-occur.
Standard: The fault is cleared
Normal:There is something wrong with the tape
Abnormal:Check for foreign object
(2) Check for foreign object
yCheck the radio assembly and the cassette player for foreign objects or defects.
Abnormal:Clean foreign objects
Normal:Clean the magnet head and check operation
(3) Magnet Head Cleaning
1Raise the cassette door with your finger. Next, using a pencil or similar object, push in the guide.
2Using a cleaning pen or cotton applicator soaked in cleaner, clean the magnet head surface, pinch rollers
and tape press wheel.
3Check if the same fault reoccurs.
Normal:The magnet head is dirty
Abnormal:Check and replace radio assembly
8. Tape jammed, malfunction with tape speed or auto-reverse
(1) Check for foreign objects
yCheck the radio assembly and tape player for foreign objects and defects
Standard: No foreign objects or defects
Abnormal:Clean foreign objects
Normal:Replace it with another tape and re-check
(2) Replace it with another tape and re-check
yReplace the faulty tape with working tape (less than 90min) to see if the same fault will re-occur.
Standard: The fault is cleared.
Normal:There is something wrong with the tape
Abnormal:Clean the head
(3) Clean the magnet head
1Raise the cassette door with your finger. Next, using a pencil or similar object, push in the guide.
2Using a cleaning pen or cotton applicator soaked in cleaner, clean the magnet head surface, pinch rollers
and capstans.
3Check if the same fault reoccurs.
Normal: The head is dirty
Abnormal: Check and replace radio assembly

2435. Servicing operation shall be carried out 60s after the negative
(-) terminal cable is disconnected from the battery. In addition,
the disconnected negative (-) terminal cable shall be protected
with insulating tape for insulation.
In order to deploy an airbag within a certain time period after the
battery is disconnected, condenser in the ECU shall retain some
electrical energy. Otherwise, it could lead to a serious accident
because of the unexpected deployment of airbag.
6. During spray paint work, ECU, airbag assembly, clock spring
assembly, etc shall be removed and kept in place to avoid the effects of overheat. (Over 93¡æ)
7. When the SRS is serviced, a diagnostic scan meter is used to clear the DTC to enable the normal work of
the warning light.1 1 D AB Lo D r iv er a ir b ag , lo w p o s it io n
13 (Option) PAB Hi Passenger airbag, high position
14 (Option) PAB Lo Passenger airbag, low position
20Passenger Airbag Deactivation
Indic atorPassenger airbag deac tivation indic ator light
27PPD/ Passenger Airbag
Deac tivation Sw itch, HighPassenger airbag deac tivation sw itc h, high position
30 Crash Output Crash outputInsulating TapeBatteryCableDriver Side
Warning LampPassenger Side
Warning LampDriver Seat Inflation
Element & AirbagCrash Sensor &
Diagnostic ModuleFront/RH Inflation
Element & Airbag

246 The transmit of the DTCs are carried out in the way that the SRS ECU (HAE2.5) via serial data interface
of the maintenance procedures assign the codes to the diagnostic detector.23 C ommunication trouble Y e s
24 Inte rna l trouble (se e the follow ing ta ble )No (replace SRS ECU (HAE2.5))
25PADS （
passenger airbag deactivation
sw itch）
, connected to power source or open
circuitYes
26PADS （
passenger airbag deactivation
sw itch）
, ground or short c irc uitYes
27 PADS (passenger airbag switch), trouble Yes
28 C ra sh output pin, ground Y e s
29C ra sh output pin, short c irc uite d to pow e r
sourceYes
30PADI (passenger airbag deactivation switch
indic ator light) error, c onnected to pow er source
or light bulb short c irc uitYes
31PADI (passenger airbag deactivation switch
indic a tor light) e rror, ground or ope n c irc uitYes
32 Se a t be lt pre te nsione r se pa ra te ignition Y e s, up to 5 time s
33Se a t be lt pre te nsione r se pa ra te ignition for 6
time sNo (replace SRS ECU (HAE2.5))No. Trouble De sc ription DTC
1 Ignition c irc uit 1 (drive r a irba g), high re sistanc e or ope n circ uit B1 346
2 Ignition c irc uit 1 (drive r a irba g), low re sista nc e or short c irc uit B1 347
3 Ignition c irc uit 1 (drive r a irba g), groundB1 348
4 Ignition c irc uit 1 (drive r a irba g), c onne cte d to powe r sourc e B1 349
5 Ignition c irc uit 2 (pa sse nge r a irbag), high re sista nc e or ope n c ircuit B1 352
6 Ignition c irc uit 2 (pa sse nge r a irbag), low resista nce or short c irc uit B1 353
7 Ignition c irc uit 2 (pa sse nge r a irbag), groundB1 354
8 Ignition circuit 2 (passenger airbag), connected to power source B1 355
9 Ignition c irc uit 3 (drive r se a t belt pre te nsione r), high re sista nc e or ope n c ircuit B1 361
10 Ignition c irc uit 3 (drive r se a t belt pre te nsione r), low resista nce or short c irc uit B1 362
11 Ignition c irc uit 3 (drive r se a t belt pre te nsione r), ground B1 363
12 Ignition c irc uit 3 (drive r se a t belt pre te nsione r), c onne c t to power sourc e B1 364
13Ignition c ircuit 4 (passe nger se a t be lt pre tensione r), high re sista nc e or open
circuitB1 367 Diagnostic DTCs