brake GEELY CK 2008 Workshop Manual

Section 1 Propeller Shaft.................................................................................................. 97Chapter 5 Front Suspension System............................................................... 1 0 3Section 1 Front Suspension System................................................................................ 103
Section 2 Front Suspension............................................................................................105
Section 3 Front Wheel Alignment.......................................................................................106
Section 4 Front Strut Assembly....................................................................................... 107
Section 5 Lower Swing Arm Assembly............................................................................ 110
Section 6 Front Stabilizer Bar and Link Rod Assembly.....................................................113Chapter 6 Rear Suspension System................................................................116Section 1 Rear Suspension System
Section 2 Rear Suspension............................................................................................117
Section 3 Rear Wheel Alignment.................................................................................... 118
Section 4 Left & Right Rear Strut Assembly.....................................................................119
Section 5 Rear stabilizer bar assembly, strut rod components..........................................121
Section 6 Left & Right Trailing Rod Assembly.............................................................. 123
Section 7 No. 1 Transverse Arm Assembly..................................................................... 124
Section 8 No. 2 Transverse Arm Assembly..................................................................... 125Chapter 7 Wheel................................................................................................126Section 1 Tire Inspection................................................................................................. 126
Section 2 Wheel Replacement......................................................................................... 127Chapter 8 Power Steering System.................................................................. 1 2 8Section 1 Power Steering System.................................................................................... 128
Section 2 Steering Drive and Control Mechanism......................................................... 130
Section 3 Steering Pipeline Component.......................................................................... 133
Section 4 Power Steering Gear Retaining DeviceChapter 9 Brake System.................................................................................. 1 3 9Section 1 Brake System ................................................................................................... 139
Section 2 Brake Fluid....................................................................................................... 140
Section 3 Brake Pedal...................................................................................................... 141
Section 4 Vacuum Booster with Brake Master Cylinder Assembly....................................143
Section 5 Front Brake Assembly..................................................................................... 144
Section 6 Rear Brake
Section 7 Brake Line ....................................................................................................... 151..................................................................................116
.....................................................................................................147..........................................................136

Section 8 Parking Brake System..................................................................................... 155........................................................157Chapter 1 Survey................................................................................................157
Chapter 2 Starting and Charging System.........................................................161Section 1 Starting System (MR479Q MR479QA MR481QA)..........................................161
Section 2 Charging System (MR479Q, MR479QA, MR481QA).......................................164Chapter 3 Combination Meter System..............................................................171Section 1 Circuit Diagram of Combination Meter and Location of Multi-pin Plug-in
Terminal............................................................................................................................ 171
Section 2 Malfunction Symptom Table and Solution Procedure...........................................174
Section 3 Combination Meter.......................................................................................... 187Chapter 4 Wiper and Washer System...............................................................193Section 1 Wiper and Washer System Inspection............................................................ 193
Section 2 Replacement and Adjustment............................................................................196Chapter 5 Light System......................................................................................198Section 1 Survey of Light System......................................................................................198
Section 2 Light System Symptom Inspection.................................................................. 202
Section 3 Headlamp Replacement....................................................................................211
Section 4 Front Fog Lamp Replacement............................................................................215
Section 5 Rear Combination Lamp Replacement..............................................................217
Section 6 High Mounted Stop Lamp Replacement............................................................218
Section 7 Interior Dome Lamp Replacement.....................................................................219
Section 8 Rear Row Reading Lamp Replacement...........................................................220
Section 9 License Plate Lamp Replacement...................................................................220Chapter 6 Audio System......................................................................................221Section 1 Audio System Description.................................................................................221
Section 2 Audio System Connector Terminal Layout...........................................................224
Section 3 Audio System Inspection................................................................................. 225
Section 4 Audio and Video System Replacement........................................................... 238Chapter 7 SRS (Supplemental Restraint System).............................................242Section 1 SRS-General Information.................................................................................242
Section 2 Troubleshooting................................................................................................ 251Part III Electrical Equipment

4Table 3
CO HC Problems Causes
1. Fa ult
. Inc orre c t ignition timing
. Fouled, shorted or imprope rly cle aranc e of spa rk plug
2. Incorrect valve clearance
3. Le a ky inta ke & e xha ust valve s
4. Leaky cylinders
1. Air leaks
. PCV hoses, intake manifold
. Throttle body
. Brake booster circuit
2. Le a n mixture ga s c a using misfire
1. Clogged air filter
2. Clogge d P CV valve
. Faulty ECU
. Fa ulty fue l pre ssure regula tor
. Faulty water temperature sensor
. Faulty air compressor
. Faulty injectors
. Faulty throttle position sensor Normal
Low High
High HighRough idle
(Black smoke
from exhaust
pipe ) Rough idle Rough idle High

91Chapter 3 Clutch Control SystemSection 1 Clutch Control SystemClutch operating system descriptionThis model is equipped with hydraulic and cable clutch control system, respectively used for 1.3L engine
1.5L engine.PROBLEM SYMPTOMS TABLEUse the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.Section 2 Clutch Cable Control MechanismComponentsSympto m Sus pe cte d Are a
1. Clutc h pe da l position (Too low)
2. Control mec ha nism (Stagna tion)
3. Clutc h pe da l fre e stroke (too la rge)
C lut c h doe s not r e le a s e 1. H ydr a ulic pipe line ( A ir in line )
1. Control system (Incorrect assembly & adjustment)
2. Clutc h asse mbly (Fa ulty) Clutch noisyC lut c h s lipsConnect The
Clutch Fork Clutch Cable
Assmbly
Adjusting NutCowl Baffle
Clutch and Brake
Pedal Assembly

92Adjustment1. Check and adjust clutch pedal height
The clutch pedal height should be 180~186 mm. Adjust the pedal by adjusting bolts.
2. Check and adjust clutch pedal stroke and free stroke
(1) The clutch pedal stroke: 134~142mm
(2) The clutch pedal free stroke: 10~30 mm
If the clutch pedal stroke and free stroke are not within specification, adjust it by adjusting the location of
the adjusting nut on the clutch cable. Re-adjust the clutch pedal height if necessary.
3. Check that the clutch pedal operates in flexible and reliable way
Notice:
(1) Make sure the clutch is fully applied and completely released when control the clutch
pedal.
(2) The clutch pedal must have certain free stroke. Otherwise, the full application of the
clutch may be impacted
(3) Tighten the lock nut after adjustmentConnect The
Clutch CableBushingBushingAdjusting BoltBrake Pedal Assembly Sleeve Clutch Pedal Torsion Spring Retainer Pedal MatClutch Pedal AssemblyClutch
Pedal
Bracket
AssemblyAdjusting Nut

94Section 3 Clutch hydraulic Control DeviceComponents
Clutch Sub-pump
Transmission Assembly
Reservoir
Cowl Baffle
Clutch And Brake Pedal Assembly
Clutch Master Cylinder
Clutch Master
Cylinder
Master Cylinder Bracket
Clamp Clamp
Connect The Pipe Assembly
Hose Union
Reservoir Hose 2Reservoir Hose 1
Clog Bolt
Rubber Washer
Union Nut
Hydraulic Hose
L Shaped Clip Plate L Shaped Clip Plate
Pivot

95Replacement1. Remove the reservoir hose 1 and reservoir hose 2
Notice: Clutch hydraulic control system and hydraulic
brake system share the reservoir. Prevent the brake
fluid from overflowing when removing the reservoir
hose.
2. Disconnect the connection with the pedal
Remove the lock pin, flat washer, pin shaft to separate the clutch hydraulic control master cylinder from
the clutch pedal
3. Remove the connecting pipe
Loose the threaded connector connecting pipe and the clutch master cylinder. Remove the connecting
pipe.
4. Remove the clutch pedal assembly
Remove the nuts, bolts, 2 bushing, sleeve, clutch pedal assembly
5. Remove the hydraulic hose
Loosen the union thread connecting clutch hydraulic hose and pipe. Remove E-shaped clip plate fixing
the both ends of the clutch hydraulic hose

966. Remove clutch hydraulic control master cylinder
Remove the 2 fixing bolts between the clutch hydraulic control master cylinder and the pedal bracket
7. Install and replace the parts in the reverse order of the above procedure
Notice:
(1) Be careful not to leak brake fluid onto other objects or paint surface. Clean it immedi-
ately to avoid damage.
(2) Do not damage the seal rubber when installing and removing the pipe and make sure the
installation is correct
(3) Clutch pedal set thread torque : 20~25N.m
(4) Clutch hydraulic control master cylinder set bolt torque : 20~25N.m
(5) Torque of the union thread connecting the pipe and clutch master cylinder:
12~16N.m
(6) Torque of the threaded connector connecting the clutch hydraulic hose and pipe:
12~16N.m
(7) Bleed the air in the clutch hydraulic control system
(8) Check the clutch hydraulic control system for leakage
(9) Check the clutch hydraulic control system for reliable working
(10)Check the brake fluid level. Fill the brake fluid of the same brand if necessary.
(11) Check the clutch pedal installation height stroke and free stroke
a . The clutch pedal installation height: 180~186 mm
b . The clutch pedal stroke: 134~142mm
c . The clutch pedal free stroke: 10~20 mm

99Service1. Remove the front wheel
2. Remove the ABS sensor signal wire
3. Remove the propeller shaft fixing nut
(1) Remove the cotter pin of the propeller shaft fixing nut
(2) loosen the propeller shaft fixing nut
4. Separate the steering tie rod
(1) Remove the cotter pin and the nut
(2) Separate the tie rod ball stud pin from the knuckle.
5. Detach the swing arm assembly.
(1) Remove the lower swing arm assembly ball stud pin lock bolt and nut on the knuckle
(2) Detach the lower swing arm assembly ball stud pin from the knuckle
6. Remove the constant velocity propeller shaft assembly Appropriately pull the brake outward, use a
rubber hammer or brass bar to tap the propeller shaft to remove itNotice: Actions shall be taken to prevent the propeller from being dropped off, do not damage
the boot and the oil seal7 Inspect the propeller shaft assembly
(1) Check the tripod constant velocity universal joint for looseness
(2) Check the sliding shaft for smooth movement

105Section 2 Front SuspensionComponents
LF Strut Assembly
Front
Brake Hose Clip
Connected to Brake
Connected
to Brake
LF Brake Assembly
Stabilizer Bar
Left Link Rod
Assembly
Left lower Swing
Arm Assembly
Lower Swing
Arm LF Bracket
Lower Swing Arm
RF Bracket
Front Stabilizer Bar Assembly
Stabilizer Bar
Right Link Rod Assembly
RF Brake Assembly
Connected to Brake
Clip
Front Brake Hose
RF Strut Assembly
Connected
to Brake
BodyBody
Right Lower
Swing Arm
Assembly
Lower Trailing
Arm Rear Elastic Hinge
Fixed to Shock
Absorber
ABS Sensor Wire Harness
Shock Absorber