2008 GEELY CK wheel

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

12Component 3Figure 22Flywheel
Clutch Disc
Clutch Cover
Clutch Release Bearing
Clutch Release Fork
Release Fork Support
Release Fork Boot

13Section 2 Engine Components Replacement1. Avoid gasoline ejection when work.
2. Drain the coolant to empty.
3. Remove air filter assembly with hose. See (Figure 23)
4. Remove battery
5. Remove fuel delivery pipe sub-assembly
6. Disconnect water hoses, disconnect heater outlet hose
from A/C hose.
7. Loose nut, remove accelerator control cable
8. Remove throttle body assembly
9. Remove power steering pump reservoir assembly
10. Remove front exhaust pipe assembly
11. Remove steering gear boot
12. Seperate steering column assembly. See (Figure 24)
13. Remove front wheel hub nut
14. Disconnect front wheel vehicle speed sensor (with ABS)
15. Detach steering tie rod ball stud pin assembly
16. Detach front lower swing arm sub-assembly
17. Detach front propeller assembly. See (Figure 25)
Detach front propeller from the shaft hub with plastic hammer.
18. Disconnect transmission shift cable or gear shift level assembly
19. Disconnect clutch cylinder assembly or disconnect clutch cable
20. Detach engine assembly and transaxle
(a) Hoisting engine ;
(b) Remove 3 bolts. Detach the right engine mounting bracket. See (Figure 26) ;
(c) Remove 1 bolt. Detach the left engine mounting bracket;
(d) Remove 1 bolt. Detach the rear engine mounting bracket;
(e) Remove engine and transaxle and put them on the pallet;
(f) Jack up the boday.Figure 23
Figure 24
Figure 25 Figure 26

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

1550. Install water outlet hose joint. See (Figure 29, 30)
Figure 29
51. Install water inlet hose housing. See (Figure 31, 32)
Figure 31 Figure 32
52. Install engine oil pressure switch
53. Install crankshaft position sensor
Torque: 9, 3N. m
54. Install water temperature gauge and water temperature sensor
Torque: 15N. m
55. Install knock sensor
Torque: 44N. M
56. Install intake manifold. See (Figure 33)
Install the intake manifold with new gasket with 7 bolts and 2
nuts. Uniformly tighten bolts and nuts in several time.
57. Install injector assembly
58. Install rear end cover
59. Install flywheel sub-assembly. See (Figure 34)
(a) Install flywheel to crankshaft.
(b)Install and uniformly tighten and connect bolt as shown in the
figure. Torque: 78N. m
60. Install clutch assembly
61. Install flywheel and ring gear. See (Figure 35)
(a)Install the oil thrower, it’s chamfer side on crankshaft in
the axie direction.
(b) Install flywheel and ring gear on crankshaft.Figure 33
Figure 34 Figure 30

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

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