belt 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

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

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

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

6Section 3 Valve Clearance Adjustment1. Remove right camshaft timing gear
2. Remove ignition coil and high voltage cable
3. Remove cylinder head cover sub-assembly See (Figure 8)
(a) Disconnect generator wire joint..
(b) Disconnect generator circuit.
(c) Disconnect oil pressure switch connector.
(d) Disconnect A/C compressor switch connector.
(e) Open the wire harness clip.
(f) Remove wire harness from cylinder head cover.
(g) Separate 2 ventilation hoses from cylinder head cover.
(h) Remove 4 screw nuts, 4 oil seal gaskets, cylinder head and gasket.
4. Adjust piston of Cylinder 1 to the compression position
(a) Turn crankshaft pulley, align notch to timing mark "0" on Cylinder 1. See (Figure 9).
(b) Align mark "K" on camshaft timing pulley to the timing mark on bearing cap. See (Figure 10) Crank 360°
if it is not aligned.
5. Check valve clearance (cool). See (Table 5)
(a) Turn the crankshaft pulley for 360°. Align notch to timing mark "0" on timing belt cover No. 1.
(b) Only check the valve as shown in the figure. Valve clearance measurement. See (Figure 11). Figure 8
Figure 10Intake Valve mm Exha ust Valve mm
MR479Q 0.20 ± 0.05 0.30 ± 0.05
MR479QA 0.20 ± 0.05 0.30 ± 0.05
MR481QA 0.20 ± 0.05 0.30 ± 0.05Table5Figure 9

11Component 2Figure 21Fan & Generator V-Belt
Vane-Type Pump V-Belt (V/ Power Steering)
V-Belt No.1Right Engine
Mounting InsulatorDoor AssemblySteering Column
AssemblyFront Shaft Hub Left NutLeft Front Speed Sensor Left Engine Mounting Bracket Steering Column Hole CoverHole Cover Steering Column Glove Compartment Front exhauxt pipe assembly
GasketGasket
One-off accessory

1421. Remove radiator assembly
22. Remove engine V-belt
23. Remove No. 1 V- belt (A/C compressor to crankshaft pulley)
24. Remove generator assembly
25. Remove A/C compressor
26. Remove compressor installing No. 1 bracket. Remove 4 bolts and compressor installing No.
1 bracket.
27. Remove starter assembly
28. Remove power steering pump V- belt
29. Detach power steering pump assembly
30. Remove power steering pump, adjust the bracket
31. Detach manual transaxle assembly (Separate automatic transaxle assembly)
32. Detach clutch cover panel assembly.
33. Detach clutch pressure plate assembly.
34. Detach flywheel sub-assembly.
35. Remove engine rear end cover.
36. Remove injector assembly and remove intake manifold.
Remove 2 bolts and intake manifold support and remove 7 bolts,
2 nuts, intake manifold and gasket. See (Figure 27).
37. Remove knock sensor
38. Remove water temperature gauge sensor
39. Remove crankshaft position sensor
40. Remove engine oil pressure switch
41. Remove water inlet hose housing
42. Remove water outlet hose joint
43. Detach exhaust manifold. See (Figure 28)
44. Remove engion oil filter sub-assembly
45. Remove ignition coil and high voltage cable
46. Install engine sub-assembly
47. Install ignition coil and high voltage cable
48. Install engine oil filter sub-assembly
49. Install exhaust manifold
(a) Install new gasket and exhaust manifold stay with
5 nuts, Torque: 34N. m
(b) Install exhaust manifold stay with two bolts.
Torque: 59N. m
(c) Install upper heat shield with 4 bolts.Torque: 17N. mFigure 27
Figure 28

16(c) Install and uniformly tighten connecting bolt in the sequence shown inthe figure.
Torque: 64N. m
62. Install manual transaxle assembly
63. Install starter assembly
64. Install power steering pump bracket
65. Install power steering pump adjusting bracket with 2 bolts.
66. Connect power steering pump assembly
67. Install engine assembly and transaxle
68. Connect left, right, front and rear lower suspension arm sub-assembly
69. Connect left and right tie rod ball stud pin assembly
70. Connect left, right and front vehicle speed sensor (with ABS)
71. Install left & right nuts on the front shaft hub
72. Install front exhaust pipe assembly
73. Connect steering shaft assembly and steering column hole cover. See (Figure 36)
74. Connect wire harness
75. Install belt adjusting bracket of A/C compressor
76. Connect A/C compressor
77. Install generator assembly
78. Install A/C compressor to crankshaft pulleyV-belt
79. Install generator belt
80. Install engine assembly with transaxle
81. Install radiator assembly
82. Install throttle body assembly
83. Install fuel delivery pipe sub-assembly
84. Install battery
85. Install air filter assembly with hose
86. Install front wheel
87. Fill engine oil
88. Fill coolant
89. Check engine oil for leakage
90. Check engine coolant for leakage
91. Check fuel for leakage
92. Check idle and ignition timing
93. Check CO/HC
94. Check and adjust front wheel alignment
95. Check ABS vehicle speed sensor signalFigure 35
Figure 36

17Section 3 Timing Belt ReplacementFigure 37Air Filter Assembly W/ HoseHigh Pressure CableVentilation PipeSeal
Cylinder Head
Right Engine Mounting
Fan & Generator V-Belt
V-Belt No.1Cylinder Head GasketGasket
Timing Chain Or Timing Belt Cover Assembly No. 2
Crankshaft Or Pulley
Cover Sub-Assembly
Crankshaft PulleyTiming Belt Guide
Timing Chain Timing Belt
Cover Sub-Assembly
Generator Assembly Timing Belt
Fan Pulley Vane-Type Pump V-Belt V/ Power Steering

181. Disconnect engine from all the wire harnesses and cables connected to body.
2. Remove air filter assembly with hose. See (Figure 38)
3. Disconnect oil pipe and water hoses
4. Loose positive and negative cables on battery
5. Detach propeller shaft
6. Loose engine left & right rear brackets after hoisting engine
7. Disconnect all the connectors of engine and the body
8. Remove engine per "Provision 20, Section 2, Chapter 2"
9. Remove A/C compressor to crankshaft pulley V-belt
10. Remove power steering pump V-belt
11. Remove water pump fan pulley
12. Remove high pressure cable.
13. Remove cylinder head cover sub-assembly
14. Remove generator assembly. See (Figure 39)
15. Put the piston in Cylinder 1 to TDC compression position
(a)Turn crankshaft pulley to align its notch to the timing mark "0"
on the timing belt cover. See (Figure 40).
(b) Check if the "K" mark on camshaft timing pulley and the timing mark
on the bearing cap are aligned. Crank the crankshaft for 360 degrees
if not. See (Figure 41).
16. Remove crankshaft pulley
17. Remove timing belt cover
18. Remove crankshaft gear or pulley cover sub-assembly
19. Remove timing belt cover sub-assembly
Figure 40 Figure 39 Figure 38
Figure 41