oil GEELY MK 2008 Owner's Guide

2. Check the engine coolant quantity in the compensating tank.
The coolant level should be between LOW and FULL.
3. Check the coolant quality.
(1) Remove the radiator cover.
Do not remove the radiator cover when the engine and the radiator are still hot in order to avoid scalding
since the liquid vapor may inject.
(2) Check whether there are excessive deposit and rust or sundries around the radiator cover. The coolant is
not allowed to contact with oil.
(3) Remount the radiator cover.Chapter 5 Cooling SystemSection 1 System Inspection1. Check leakage in the cooling system (see Figure 5-1).
(1) Fill coolant in the radiator, and mount the tester at the radiator
cover port.
(2) Start the engine.
(3) Keep the pump pressure at 118KPa without drop. If the
pressure drops,check whether there is any leakage at the port,
radiator and water pump; if not, check the heating core,
cylinder and cap.Figure 5-1
Figure 5-2
Figure 5-3 Figure 5-4 (4) When the thermostat is at low temperature (lower than 77°C), the valve should close completely.Cooling SystemSystem Inspection3-224. Thermostat
Notes:
The temperature indicated on the thermostat is marked as open
temperature of the valve (see Figure 5-2).
(1) Submerge the thermostat into water and heat gradually.
(2) Check the open temperature of the valve.
Open temperature of the valve: 80-84°C
(3) Check the lift of the valve (see Figure 5-3 and Figure 5-4).
Lift of the valve: 8mm or more at 95°CTester of radiator cap
8.0mm or more -

Section 2 Radiator Replacement1. Replace the radiator.
(1) Open the radiator cover.
(2) Open the water drain valve and discharge the coolant.
(3) Disconnect the water inlet pipe of the radiator.
(4) Disconnect the water outlet pipe of the radiator.
(5) Disconnect the input pipe of the oil cooler of the automatic transmission (automatic transmission).
(6) Disconnect the output pipe of the oil cooler of the automatic transmission (automatic transmission).
(7) Remove 4 bolts of the radiator mounting support (see Figure 5-8).Figure 5-8
Figure 5-9Cooling SystemRadiator Replacement3-24 (8)Remove the radiator assembly, remove 4 bolts, and separate
the fan and the fan housing (see Figure 5-9).
(9) Mount the cooling fan assembly.
a. Secure the compensating tank assembly on the cooling fan support with bolts; torque: 16 N.m.
b. Mount the fan and the fan housing with 3 bolts; torque: 7.5N.m.
c. Mount the cooling fan assembly on the radiator assembly with 3 bolts; torque: 16N.m.
d. Connect the overflow pipe on the compensating tank assembly and the radiator assembly, and fasten
with the elastic ring.
e. Mount the radiator assembly in the reverse order of dismounting. -

Table 6-1 Frequent problem diagnosisPossible causes
Transmission or the engine is suspended loosely or damaged;
Axial gap is improper;
Gear or bearing is worn or damaged;
Unsatisfactory transmission oil is used or oil level is low;
Engine idle is incorrect.
The oil seal or the O-ring is damaged.
The control cable is unqualified;
Synchronizer is poorly contacted with gear or worn;
Elasticity of the synchronous spring is insufficient;
Unqualified transmission oil is used.
Fork of the shift gear is worn or lifting spring is broken;
Gap between the synchronizer bush and the sleeve spline is too large;
Gear or bearing is worn or damaged. Sympton
Vibration and noise
Oil leakage of the transmission
Hard to shift
Trip stopManual Transaxle Assembly Vehicle Speed Sensor Replacement3-261. Disengage the vehicle speed sensor (see Figure 6-2).
2. Remove the bolt and the vehicle speed sensor.
3. Mount the vehicle speed sensor (see Figure 6-3).
4. Connect the vehicle speed sensor.Section 2 Vehicle Speed Sensor ReplacementFigure 6-2
Figure 6-3 -

Figure 6-5Manual Transaxle Assembly Manual Transaxle Replacement3-27Section 3 Manual Transaxle ReplacementReplace1. Open the engine cover.
2. Remove the battery.
3. Remove the clutch wheel cylinder assembly (see Figure 6-4).
4. Separate the transmission shift cable assembly (see Figure 6-5).
5. Disengage the joint of the backup lamp switch.
6. Disengage the speed sensor.
Disengage the speed sensor joint.
7. Remove the forepart of the exhaust pipe.
8. Discharge the drive bridge oil.
9. Remove the nut on the left and the right front hub.
10. Disengage the speed sensor on the left and the right front wheel
(ABS).
11. Disengage the front stabilizer bar.
12. Disengage the left and the right ball tie-rod.
13. Disengage the front stabilizer bar.
14. Disengage the left and the right lower cantilever.
15. Remove the left and the right front drive shaft assembly.
16. Hoist the engine from the machinery space according to "Point
24, Section 2, Chapter 1".
17. Remove the starter assembly.
18. Disengage the engine support.
19. Remove the manual drive bridge assembly.
20. Mount the engine support.
21. Mount the manual drive bridge assembly.
22. Couple the vibration insulating pad of the engine.
23. Mount the starter assembly.
24. Mount the left and the right front drive shaft assembly.
25. Connect the left and the right lower cantilever.
26. Connect the left and the right ball tie-rod.
27. Connect the front stabilizer bar.
28. Connect the left and the right front speed sensor (ABS).
29. Mount the left and the right front shaft nut.
30. Mount the fore part of the exhaust pipe.
31. Connect the joint of the odometer sensor.
32. Connect the joint of the back-up lamp switch.
33. Connect the transmission shift cable assembly (see Figure 6-5).
34. Mount the clutch wheel cylinder assembly (see Figure 6-4).Figure 6-4 -

I. Replace the oil seal of transmission housing1. Remove the oil seal of the transmission housing (see Figure 6-6).
2. Mount the oil seal of the transmission housing (see Figure 6-7).
Attention:
Take care not to damage the lip surface of the oil seal.II. Replace the Oil Seal of the Drive Bridge Housing1. Remove the oil seal of the transaxle housing with special
maintenance tool (see Figure 6-8).
2. Mount the oil seal of the transaxle housing (see Figure 6-9).Section 4 Transmission/Transaxle Case Oil Seal ReplacementFigure 6-6
Figure 6-7Figure 6-8
Figure 6-9Manual Transaxle Assembly Transmission/Transaxle Case Oil Seal Replacement3-28 -

Chapter 7 Automatic Transaxle AssemblySection 1 Frequent Problems DiagnosisPossible Cause1. There is no scan information.
(1)The diagnosis system fails.
(2)The automatic transmission unit fails.
2. The engine can't start.
(1)The engine system fails.
(2)The fuel pump or torque meter fails.
3. The vehicle cant' runs forwards.
(1)The circuit voltage is improper.
(2)The rear clutch or single clutch fails.
(3)The valve fails.
4. The vehicle can't run backwards.
(1)The low speed brake or front clutch pressure is improper.
(2)The front clutch or low speed reverse gear fails.
(3)The valve fails.
5. The vehicle can't runs forwards or backwards.
(1)The pressure deduction is improper or the transmission signal fails.
(2)There is pressure in the oil pump or the valve body fails.
6. The engine stalls in gear shift.
(1)The engine system or clutch torque meter fails.
(2)The valve body or torque meter fails.
7. The vehicle vibrates and lasts for a long time when the gear is shifted from N to D.
(1)The rear clutch fails.
(2)The valve body clutch fails.
(3)The restrictor switch fails.
8. The vehicle vibrates and lasts for a long time when the gear is shifted from N to R.
(1)The front clutch pressure fails.
(2)The front clutch or valve body fails.
(3)The low speed reserve gear pressure or low speed reverse gear fails.
9. The vehicle vibrates and lasts for a long time when the gear is shifted from N to D/R.
(1)The pressure reduction fails.
(2)The oil pump fails.
(3)The valve body fails.
10. The gear shift impacts.
(1)The servo switch or restrictor position switch fails.
(2)The pressure is decreases abnormally.
(3)The clutch or brake fails.
11. All gear shift points are either too early or too late in the running status.Automatic Transaxle Assembly Frequent Problems Diagnosis3-29 -

The valve body fails.
12. The vehicle shifts before or after some gear points in the running status.
The vehicle switch or parking switch fails.
13. The vehicle has poor acceleration in running.
(1)The clutch or brake fails.
(2)The engine system fails.
14. The vehicle vibrates when it runs at a constant speed or accelerating speed.
(1)The hydraulic torque clutch pressure or hydraulic torque meter fails.
(2)The engine system or valve fails.
15. The acceleration switch system fails.
(1)The acceleration switch or ignition switch fails.
(2)The connector or automatic transmission control unit fails.I. Automatic transmissions Removal1. Put the select lever in "N" position
2. Remove 3 bolts of the flexibility plate (engine side)
3. Remove starter and 2 cooling hoses.
4. Disconnect neutral switch connector and odometer sensor.
5. Loosen the drain screw under the housing to bleed ATF and tighten the drain screw with sealing glue when
assembling. Tightening torque is 29~35N.m
6. Loosen the locking bolt for select lever cable.
7. Remove Drive Shaft LH&RH, using plastic stopper in the oil sealing of differential.
8. Detach suspension bolts.
9. Separate transmission from engine after bolts between engine and transmission remove.II. Automatic Transmission Installation1. Check whether torque converter of the transmission is in the right position, the methods as follows:
Check whether the distance from 3 anchor point of torque converter to front contact face of the transmission
box A 28mm , If the space A<28 mm, try install again. The way to install is that left hand catch hold of the
central anchor column of the converter and make it in alignment with input shaft as near as possible, push the torque
converter in rotating way by right hand until it gets to the bottom to meet the requirement of A 28 mm. (See
figure 7-1 and 2)
2. Install Flexibility plate and central plate on the crankshaft end face with 6 bolts in the direction of Figure 2.
Tightening torque is 45~55 N.m. Turn the longer hole of the Flexibility plate to the lowest of the engine position
in order to connect torque converter.Section 2 Hydraulic Torque Converter and TransaxleAutomatic Transaxle Assembly Hydraulic Torque Converter and Transaxle3-30 -

9. Put shift lever to "N" position, meanwhile, adjust the shift fork in
neutral position. Connect shift cable with bracket and fix by fastening
bolt. The tightening torque is 6.9~13.7 N.m (See figure 7-6).
10. Connect neutral switch connector.
11. Install odometer sensor (connect the sensor with the actuator of
odometer in the transmission)Figure 7-712. Fill in ATF.
"ATF " is the oil only for automatic transmission, its grade is DEXRONII or DEXRONIII. First, take
dipstick out of automatic transmission and fill in 3 liter ATF from dipstick pipe. Put select lever to "P" position
and start engine until AT temperature is up to 80°C, and then put select lever in "P" "R" "N" "D"
"2" "L" and "L" "2" "D" "N" "R" "P" step by step. Insert and take out dipstick,
wipe out the liquid in the dipstick. Repeat above-mentioned procedure without wiping to check oil level by
dipstick. If oil level is between the third and fourth hole in the dipstick, the level is normal. Filling in oil is over
and Insert dipstick tightly.
13. Wipe ATF in the A/T surface when filling.
14. A/T installation is completed.3-32Install in the engineCentral PlateFlexible Plate SetThrottle cableDipsitickFilling
PipeFluid Pan Hydraulic Torque
CorverterIII. Automatic Transmission Assembly JL-Z110 and JL-Z130Figure 7-6Automatic Transaxle Assembly Hydraulic Torque Converter and Transaxle -

Figure 7-93-33Replacement1. Discharge the automatic transmission oil.
(1) Remove the discharge plug and washer to discharge the ATF oil.
(2) Install the discharge plug and new washer.
Torque: 25N.m
2. Remove the front wheel.
3. Remove the left/right front wheel hub nuts.
4. Unfix the front stabilizer bar.
5. Unfix #1 left/ring front suspension sub-assembly.
6. Unfix the left/right ball extension rod sub-assembly.
7. Unfix the left/right front axles.
8. Remove the differential front oil seal (on the transaxle housing).Section 3 Differential Front Oil Seal (ATM)1. Check the hydraulic torque converter assembly.
(1)Measure the status of the hydraulic torque converter.
(2)Replace the ATF in the hydraulic torque converter.
(3)Wash and check oil freezer and oil pipe.
(4)Prevent the hydraulic torque converter being deformed and
the oil pump gear being damaged.
2. Check the drive disc and gear ring.
(1)Install a dial test indicator to measure the runout of the drive
disc. (See Fig.7-8)
(2)Check the damage of the gear ring.
Maximum runout: 0.25mm
If the runout is beyond the specified scope or the gear ring is
damaged, replace the drive disc.
Torque: 64N.m
3. Check the hydraulic torque converter. (See Fig.7-9)
Install the hydraulic torque converter on the drive disc temporarily,
and install a test indicator to measure the radial runout of the
hydraulic torque converter bushing.
Maximum radial runout: 0.20mm
If the radial runout is beyond the specified scope, readjust the
direction of installation.
Notes:
Mark the position of the torque converter to install it properly.
Remove the hydraulic torque converter.Figure 7-8Automatic Transaxle Assembly Differential Front Oil Seal (ATM) -

9. Pull out oil seal (on the transaxle housing) with a special tool.
(See Fig.7-10)
10. Remove the differential front oil seal on the transmission housing.
Pull out the oil seal on the transmission housing with a special
tool. (See Fig.7-11)
11. Install the differential front oil seal onto the transmission housing.
(1) Install a new oil seal on the transmission housing with a
special tool and hammer. (See Fig.7-12)
(2) Apply MP lube on the flange of the oil seal.
12. Install the differential front oil seal onto the transmission housing.
(1) Install a new oil seal onto the transmission housing with a
special tool and hammer. (See Fig.7-13)
(2) Apply MP lube on the flange of the oil seal.Figure 7-10
Figure 7-11
Figure 7-12Figure 7-13Automatic Transaxle Assembly Differential Front Oil Seal (ATM)3-3413. Install all parts in the sequence of removal till the front wheel is installed, and then add transmission oil.
14. Check and adjust the alignment of the front wheel. -