GEELY MK 2008 Owners Manual

b. Tighten the lock nut.
Torque: 12N.m
c. Check the pedal's height after adjusting the pedal's free
travel.
(6) Check the clutch's separating point.
a. Tension the parking brake device and install a wheel
stopper.
b. Start the motor and make it run idly. c. DonÕt step the clutch pedal,and put the gear shift lever to the reverse gear slowly till the gears engage.
d. Step the clutch pedal down slowly,and measure the travel distance between the separating point to the
pedal travel end position.
Standard distance: 25mm or above (pedal travel end position to separating point)
If the distance doesn't meet standard, carry out the following steps:
Check the pedal's height.
Check the push par stroke and pedal's free travel.
Discharge the air in the clutch fluid pipe.
Check the clutch cover and clutch disc.
Check the pedal's travel.
Pedal travel: 120-130mmReplacement1. Remove the battery negative terminal.
2. Remove the upper cover in dashboard panel.
3. Remove the lower cover in dashboard panel.
4. Remove the pane of the control board.
5. Remove the clutch pedal spring.
6. Remove the U-connector with pin on the clutch master cylinder
push bar.
Remove the clips and pins.
7. Remove the clutch pedal bracket.
Remove the two nuts and bolts, and then remove the clutch pedal
bracket.
8. Remove the clutch pedal.
(1) Remove the bolts and nuts.
(2) Remove the clutch pedal from the clutch pedal bracket.Clutch Control SystemClutch Pedal4-1425mm or more
Separating point
Max. travel
end position -

Clutch Control SystemClutch Pedal4-159. Remove the clutch pedal gasket.
10. Remove the clutch pedal absorber.
Remove absorber from the clutch pedal.
11. Remove the clutch pedal bushing.
Remove the two bushings from the clutch pedal.
12. Remove the U-connector bushing on the clutch master cylinder's
push bar.
Remove the U-connector bushing from the clutch pedal with an
8mm hexagon wrench and hammer.
13. Install the U-connector bushing on the clutch master cylinder
push bar.
(1) Apply multi-function lube inside the new U-connector bushing.
(2) Install the U-connector bushing on the clutch pedal.
Tips: Install the U-connector bushing from the right side.
14. Install the clutch pedal bushing.
(1) Apply multi-function lube on both sides of the two new
bushings.
(2) Install the two bushings on the clutch pedal.
15. Install absorber on the clutch pedal.
Put absorber on the clutch pedal.
16. Install the clutch pedal.
Install the clutch pedal on the clutch pedal bracket with bolts and
nuts.
Torque: 37N.m
Tips: Install the bolts from the left side. -

Clutch Control SystemClutch Pedal4-1617. Install the clutch pedal bracket.
Install the clutch bracket with two bolts and nuts.
Torque: 12N.m
18. Install the U-connector with pin on the clutch master cylinder
push bar.
(1) Apply multi-function lube on the surfaces of the pin and the
U-connector bushing.
(2) Connect the U-connector to the clutch pedal with clip.
Tips: Install the pin from the right side.
(3) Install the clip on the pin.
19. Install the clutch pedal spring.
20. Check and adjust the clutch pedal.
21. Connect the battery negative terminal. -

Chapter 4 Propeller Shaft/DriveshaftSection 1 Propeller Shaft, Driveshaft and TransaxleI. Symptom Table The table below can help find the causes of the problem. The numbers indicate the priority of the causes of the
problem. Replace the parts if necessary.
Inspection Area
1. Wheel
2. Front wheel alignment
3. Rear wheel alignment
4. Front wheel hub bearing (worn)
5. Rear wheel hub bearing (worn)
6. Front shock absorber with coil spring
7. Steering linkage (loose or damaged)
8. Stabilizer bar
1. Wheel balance
2. Wheel hub bearing (worn)
3. Front shock absorber with coil spring
1. Outer joint (worn)
2. Inner joint (worn) Symptom
Deviation
Front wheel vibration
Noise (drive shaft)ReferenceII. On-board Inspection1. Check front wheel hub bearing
(1) Remove front wheel.
(2) Remove front brake caliper assembly.
(3) Remove front brake disc.
(4) Check the bearing backlash.
Set a dial indicator near the front wheel hub center to check
the backlash.
Maximum: 0.05mm
If the backlash exceeds the maximum value, replace the front
wheel hub bearing.
(5) Check the front wheel hub deviation
Using a dial indicator, check the deviation of the surface of the
wheel hub outside the hub bolt.
Maximum: 0.07mm
If the backlash exceeds the maximum value, replace the front
wheel hub subassembly.Propeller Shaft/DriveshaftPropeller Shaft, Driveshaft and Transaxle4-17 -

(6) Install front brake disc.
(7) Install front brake caliper assembly
(8) Install font wheel.
Torque: 103N.m
2. Check back wheel hub bearing
(1) Remove rear wheel.
(2) Remove rear brake drum subassembly.
(3) Check bearing backlash.
Set a dial indicator near the rear wheel hub center to check the
backlash.
Maximum: 0.05mm
If the backlash exceeds the maximum value, replace the rear
wheel hub and bearing assembly.
(4) Check rear wheel hub deviation
Using a dial indicator, check the deviation of the surface of
the rear wheel hub inside the hub bolt.
Maximum: 0.07mm
If the backlash exceeds the maximum value, replace the rear
wheel hub and bearing assembly.
(5) Install rear brake subassembly
(6) Install rear wheel
Torque: 103N.mPropeller Shaft/DriveshaftPropeller Shaft, Driveshaft and Transaxle4-18 -

Section 2 Front DriveshaftComponent Viewsnap ring
snap ring
set nutPropeller Shaft/DriveshaftFront Driveshaft4-19right constant velocity drive
shaft assembly
right constant velocity drive
shaft assembly
Tie rod left end assembly
cotter pin
left lower swing arm collar gasket collar
gasket with ABS LF vehicle speed sensor
brake hose
front stabilizer bar
cotter pin
specified torqueN.
m :
Non-reusable parts -

tripod jointPropeller Shaft/DriveshaftFront Driveshaft4-20outboard rzeppa joint
outboard joint big clamp
outboard joint boot
outboard joint small clamp
drive shaft damper clamp
right front drive
shaft damper
inboard joint small clamp
inboard joint boot
inboard joint big clamp
tripod
retainerComponent ViewRH:
Non-reusable parts -

Overhaul1. Drain manual transmission oil (M/T transmission)
Torque: 39N.m
2. Drain automatic transmission oil (A/T transmission)
Torque: 25N.m
3. Remove front wheel
4. Remove engine bottom left shield (M/T transaxle)
5. Remove engine bottom right shield (M/T transaxle)
6. Remove engine bottom shield assembly (A/T transaxle)
7. Remove front wheel hub left bolt
(1) Using a hammer and a drive shaft nut chisel, unstake the
staked part of the left wheel hub nut.
(2) While applying the brake pedal, remove the left wheel hub
nut.
Notice: the staked part of the nut should be fully unstaked,
otherwise it may damage the thread of the drive shaft.
8. Remove left front vehicle speed sensor (with ABS)
(1) Remove the bolt and clip, remove vehicle speed sensor and
brake hose from left front shock absorber assembly.
(2) Remove the bolt, separate the left front vehicle speed sensor
from steering knuckle.
9. Remove front stabilizer bar
(1) Use a 10mm wrench to hold the bolt, remove the nut
(2) Remove two collars, No.1 and No.2 gaskets, remove front
stabilizer barPropeller Shaft/DriveshaftFront Driveshaft4-21 -

10. Separate left lower swing arm assembly
(1) Remove cotter pin and nut
(2) On steering knuckle, remove the left lower swing arm
assembly with ball joint puller.
11. Separate steering gear with tie rod assembly
(1) Remove cotter pin and nut
(2) On steering knuckle, remove the steering gear with tie rod
assembly with ball joint puller.Propeller Shaft/DriveshaftFront Driveshaft4-2212. Separate LF steering knuckle assembly
Using a plastic hamper, separate left front drive shaft assembly from left front steering knuckle assembly
Notice:

Do not damage the boot.

With ABS:
Be careful not to damage the vehicle speed sensor rotor.
13. Remove left constant velocity drive shaft assembly
Using a differential side gear shaft remover, remove the left
constant velocity drive shaft assembly.
Notice:

Do not damage the boot and oil seal.
Be careful not to drop the drive shaft assembly.
14. Remove right constant velocity drive shaft assembly
Using a brass bar and a hammer, remove the right constant
velocity drive shaft assembly.
Notice:
Do not damage the boot and oil seal.
Be careful not to drop the drive shaft assembly. -

15. Install LF steering knuckle assembly
Notice:
The hub bearing could be damaged if it is subjected to the vehicle
weight, such as when moving the vehicle with the drive shaft
bearing removed.
Therefore if it is absolutely necessary to place the vehicle weight
on the hub bearing, first support it with the special service tool for
front hub bearing.
16. Check left constant velocity drive shaft assembly
(1) Check the outboard joint for apparent looseness.
(2) Check that the inboard joint slide smoothly.
(3) Check the inboard joint for radial looseness.
(4) Check the boot for damage.
Notice:
Place the drive shaft assembly on level surface during the
inspection.
17. Remove inboard joint big clamp
Using a screw driver, loosen the inboard joint big clamp.
18. Remove inboard joint small clamp
Using a screw driver, loosen the inboard joint small clamp.
19. Separate inboard joint boot
Separate the outboard joint boot from the outboard Rzeppa joint
assembly.
20. Remove left tripod joint assembly
(1) Wipe off the old grease from the tripod joint assembly.
(2) Place the matchmarks between the tripod joint assembly and
the outboard Rzeppa joint.
Notice:
Do not punch the matchmarks.Propeller Shaft/DriveshaftFront Driveshaft4-23Mark -