timing 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

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

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

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

1920. Remove timing belt guide wheel
Hint:
(a) Mark on pulley and belt (in engine turning direction) if re-using timing belt (See Figure 42).
(b) Install bolt to the idler pulley. Move pulley to its far left and tighten it temperarily (See Figure 43).
21. Remove spark plug and gasket
Figure 42
22. Install spark plug and gasket
23. Put the piston in Cylinder 1 to TDC compression position.
See (Figure 44)
(a) Turn camshaft hexagon part. Align the mark "K" on the camshaft
timing pulley to the mark on the bearing cap.
(b) Using the crankshaft pulley bolt, turn the crankshaft, align the mark
on crankshaft timing pulley to the oil pump.
24. Install timing belt. See (Figure 45)
Notice: The engine must be cool.
(a) Install timing belt. Check the tension force between crankshaft timing
pulley and camshaft timing pulley.
Hint: Align the marks if re-using the timing belt when removing. The
engine's rotating direction should be the same with the arrow's when
installing belt.
(b) Check valve timing. Loose idler bolt.
(1) Turn crankshaft from TDC to BDC slowly.
Notice: Crank always in clockwise.
(2) Align each pulley to timing mark as shown in the figure. If the timing mark is not aligned,
remove timing belt and reinstall it.
(3) Tighten idler bolt.
Torque: 37N. m
(4) Remove crankshaft pulley bolt.Figure 44
Figure 45 Figure 43

20(c) Check timing belt for deflection
Check the belt distorn as shown in the figure.
Belt deflection:
20N: 5~6mm
Re-adjust the idler if the deflection does not comply with the regulation.
25. Install timing belt guide wheel. See (Figure 46)
Install guide, place the cup side outward.
26. Install timing belt cover sub-assembly
Torque: 9.3N. m
27. Install crankshaft gear or pulley cover sub-assembly
Torque: 9.3N. m
28. Install timing belt cover
Torque: 9.3N. m
29. Install crankshaft pulley. See (Figure 47)
(a) Align pulley lock key and pulley key groove. Install pulley.
(b) Install pulley bolt Torque: 127N. M
30. Install generator assembly
31. Install water pump pulley
32. Install power steering pump V-belt
33. Install A/C compressor fan to crankshaft pulleyV-belt
34. Install cylinder head cover sub-assembly.
(a) Wipe off all seal packing material.
(b) Apply the seal glue on cylinder head cover as shown in Figure 48.
(c) Install gasket onto cylinder head cover.
(d) Install cylinder head cover with 4 seal gaskets and 4 nuts.
Torque: 7.8N. M
(e) Install 2 ventilation hoses onto cylinder head cover.
(f) Install engine wire harness onto cylinder head cover.
(g) Connect generator wire joint.
(h) Connect generator wire.
(i) Connect oil pressure switch connector.
(j) Install wire clip.
(k) Connect A/C compressor switch connector.
35. Hoist the engine back into the compartment
36. Install left & right rear engine mounting brackets
37. Install ignition coil and high pressure cable
38. Install air filter assembly with hoseFigure 48Figure 46
Figure 47

22Section 4 Camshaft ReplacementFigure 49Vane-Type Pump V-Belt
V/ Power Steering
Fan & Generator V-BeltHigh Pressure CableVentilation Pipe
V-Belt No.1
Cylinder Head
Cylinder
Head Gasket
Crankshaft Bearing Cap
Crankshaft Timing Belt WasherCrankshaft Counter GearWave GasketSnap RingCamshaftCamshaft No. 2Oil Seal
Camshaft Timing Pulley
Fan PulleyGenerator AssemblyCrankshaft Or Pulley
Cover Sub-AssemblyTiming Belt
Cover No. 2Air Filter Assembly W/ HoseRight Engine MountingSeal

231. Disconnect all connected wire harnesses and the cable on the engine and the vehicle body
2. Remove air filter assembly with hose
3. Disconnect oil pipe and water hose
4. Loose positive and negative cables of the battery
5. Detach propeller shaft
6. Loose left & right rear engine mounting bracket after hoisting the engine.
7. Disconnect all other connectors between the engine and the vehicle body.
8. Remove engine per "Provison 20, Section 2, Chapter 2"
9. Remove A/C compressor to crankshaft pulleyV-belt
10. Remove power steering pump V- belt
11. Remove water pump fan pulley
12. Disconnect ignition coil and high voltage cables
13. Remove cylinder head cover sub-assembly
14. Remove generator assembly
15. Remove cylinder head cover sub-assembly
(a) Disconnect generator wire joint.
(b) Disconnect generator circuit
(c) Disconnect A/C compressor switch connector.
(e) Open wires clips.
(f) Disconnect wire harness from the cylinder head cover.
(g) Disconnect 2 ventilation PCV hoses from cylinder head cover.
(h) Remove 4 screws, 4 seal gaskets, cylinder head and gasket.
16. Remove generator assembly. See (Figure 50)
17. Remove timing belt cover
18. Remove crankshaft gear or pulley cover sub-assembly
19. Put the piston on Cylinder 1 to TDC compression position.
(a) Turn crankshaft pulley. Align its notch to the timing mark "O" on the
timing belt cover.
(b) Check if the mark "K" on camshaft timing pulley is aligned to the
timing mark on the bearing cap. Turn crankshaft 360° if not.
20. Remove ignition coil assembly
21. Remove timing belt. See (Figure 51)
(a) Mark on the timing belt and the camshaft pulley. The mark on the
timing belt to the timing belt cover No. 1 should match.
(b) Remove rubber gasket from timing belt cover.Figure 50
Figure 51