2008 GEELY CK clutch

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

141Section 3 Brake PedalComponents1. Vacuum Booster Assembly
2. Liner
3. Spacer
4. Torsion Spring
5. Brake Pedal Arm
6. Cushion Gasket
7. Brake Pedal MatReplacement:1. Separate the vacuum booster with brake master cylinder assembly
Remove the cotter pin, flat washer and pivot, separate the vacuum booster with brake master cylinder
assembly from the brake pedal
2. Remove the clutch and brake pedal assembly
(1) Remove 4 nuts connecting the vacuum booster with brake master cylinder assembly and brake
pedal support bracket.
(2) Remove 3 bolts connecting the clutch and brake pedal assembly and front cowl panel cross member.
Remove the clutch and brake pedal assembly.
3.Remove the brake pedal
Remove the bolt and nut, Torsion Spring, liner, brake pedal arm assembly , spacer
4. Remove the brake pedal arm assembly
Remove brake pedal mat and cushion gasket from the brake pedal arm.
5. The installation is in the reverse order of removal.
Notice:
(1) Apply No 3 molybdenum disulphide lithium base grease to the relatively moving faces.
(2) After assembling the brake pedal and the brake pedal support bracket, make sure the
brake pedal can turn freely.NutBoltBrake Pedal BracketBrake Pedal

161Chapter 2 Starting and Charging SystemSection 1 Starting System
(MR479Q MR479QA MR481QA)I. STARTER INSPECTIONNOTICE:
These tests must be done within 5 seconds to avoid burning out the coil.
1. INSPECT MAGNETIC SWITCH
(a) Use wire to connect the starter as shown.
(b) Connect the magnetic switch and the battery as
shown.
(c) Disconnect the magnet exciting coil from the
terminal A.
(d) Check if the clutch pinion gear is moving out.
If the clutch pinion gear is not moving out, replace
the magnetic switch.
(e) Connect the battery as shown above. Disconnect
the battery positive (+) from the terminal, to make the clutch pinion gear disengaged.
(f) Check if the clutch pinion gear has returned.
If the clutch pinion gear has not returned, replace
the magnetic switch.Terminal ABatteryBatteryDisconnect

1622. INSPECT STARTER NO-LOAD
(a) Connect the magnet exciting coil and the terminal.
(b) Connect the ammeter and the battery to the starter
as shown.
(c) Check that the starter rotates smoothly and steadily
with the clutch pinion gear moving out.
(d) Check that the ammeter shows the specified
current.
Specified current: 90 A or less at 11.5 V
if the current is not normal, replace the starter.
3. WIRING
(a) Check that the connecting wire between
the positive (+) and the starter is stable
and reliable, and the insulating bush is in
good condition, in order to avoid a fire
caused by electric spark.
(b) Check that there is continuity in the wire
and if the insulating bush is not damaged.
If the harness is damaged, replace it.AmmeterIgnition SwitchBattery Main Fuse BoxStarter

302Section 3 A/C controlling systemI. Introduction and CompositionIn order to ensure the effective opeation of the A/C system in any operating condition, some advanced
electric control devices are used to protect the A/C system in adverse engine operating condition.
The electrical control part consists of: A/C switch, relay, evaporator temperature sensor, water temperature
sensor, pressure switch, ECU...etc.
A/C system circuit diagram is shown in Figure 6.II. controlling system feature(1) The condenser fan's power is 90W;
(2) The performance of the condenser fan is controlled by ECU, pressure switch;
(3) Cut off the electrical power of the A/C compressor clutch when the water temperature reaches 109°C;
(4) Connect blower switch 9 to rotate the blower motor 6 to ensure A/C normal operation. Connect A/C
switch 10 to output A/C request signal to ECU.
(5) After ECU receives the request signal and the one from the evaporator temperature sensor 17, if the
engine is at idle, ECU first increases the engine speed to 950 ± 50r/min, lest the A/C operation enhance
the load and lower the engine speed or result in engine off. And then the ECU can respond. If the engine
is in accelerating condition, ECU does not respond immediately either, and respond 5 seconds later after
the end of the accelerating condition. ECU send out a A/C control signal from pin 22 to relay 7, command
the relay to suction in. With the low pressure switch 11 closed, the compressor 12 starts to work when the
magnetic clutch suction on. The condenser relay holds in and condenser blower 13 rotates. When high
pressure switch 15 is closed, have the relay 7 hold in and the water tank fan 14 rotates. When the water
temperature sensor 16's temperature is higher than 109°C, ECU shut off the output signal of the pin 22
and A/C stops operation.
(6) When the Refrigeration system pressure is over 1.7MPa, radiator fan will rotato. Disconnect A/C
compressor Refrigeration system power supply when the pressure is over 2.6MPa or less than 0.25MPa;

303Figure 6 A/C System Electrical Appliance DiagramIII. Protecting Device1. Low temperature protection
Evaporator temperature sensor, when the sensed temperature is lower than 3°C, the compressor clutch
is de-energized and stops operation.
2. High temperature protection
Water temperature sensor, when the sensed water temperature reaches 109°C, the compressor clutch is
de-energized and stops operation.
3. Low pressure protection
When pressure sensed by the pressure switch is lower than 0.25MPa, the compressor clutch is de-
energized and stops operation.
4. Voltage protection
When the pressure sensed by the pressure switch reaches 1.7MPa, radiator fan rotates.
5. High pressure protection
When the pressure sensed by the pressure switch reaches 2.6MPa, the compressor clutch is de-energized
and stops operation.
6. Normal pressure
When system pressure reaches 0.25MPa~2.4MPa, control the A/C idle speed. Color of wire:R-Red Bl-Blue Y-Yellow Lg-Light green Br-Brown B-Black P-Pink G-Green W-White Gr-Gray
1. Battery 2. Main Fuse Box 3. Alternator 4. Ignition Switch 5. Idle Rise Valve 6. Blower 7. Relay
8. Blower Regulating Resistance 9. Blower Switch 10. A/C Switch 11. A/C Low Pressure Switch
12. Compressor 13. Condensor Fan 14. Radiator Fan 15. A/C High Pressure Switch
16. Water Temperature Sensor 17. Evaporator Temperature Sensor 18. Electronic Wind Door Actuator Switch
19. Electronic Wind Door Actuator 20. Revolution Sensor 21. Engine ECU

3104. A/C Compressor Removal / Installation1. Disconnect the negative (--) terminal cable from the battery.
2. Drain the refrigerant from the system.
3. Detach the radiator.
4. Loose the drive belt and then remove the drive belt.Notice:•If anything moisture or any foreign matter enters into the Refrigeration system for circulation,
the cooling performance of the Refrigeration system will obviously deteriorate with abnormal
noise. Plug the port immediately after removing any cooling circulation component to prevent
anything moistur or any foreign matter from entering the circulation.5. Remove the compressor inlet and outlet pipe.
6. Removemagnetic clutch connector.
7. Remove the compressor.
8. The installation is in the reverse order of the removal.
9. Adjust the drive belt.
10. Check the Refrigeration system performance.5. The Condenser Removal / Installation1. Disconnect the negative (--) terminal cable from the battery.
2. Drain the refrigerant from the system.Notice:•If anything moisture or any foreign matter enters into the Refrigeration system for circulation,
the cooling performance of the Refrigeration system will obviously deteriorate with abnormal
noise. Plug the port immediately after removing any cooling circulation component to prevent
anything moistur or any foreign matter from entering the circulation.3. Remove the condenser inlet and outlet pipeline to prevent the compressor oil from splashing.
4. Remove condenser fan connector.
5. Remove the engine hood lock.
6. Remove the engine hood lock support brace.
7. Remove the condenser.
8. The installation is in the reverse order of the removal.
9. Check the Refrigeration system performance.The Condenser Installation Description:1. When installing the new condenser, it is recommended to fill certain SW-100 compressor oil into the
refrigerant circuit.Refill: (approximate)
20ml{20 cc }

314Have a focus inspection on the following area:
a. Each pipe union joint and valve connection.
b. All hose, especially near the pipe union.
c. Compressor shaft seal, front and rear cover, gasket, oil fill plug.
d. Area on the surface of the condenser and evaporator that is scratched, bruised or damaged.
e. Expansion valve inlet and outlet connection and temperature sensor element and the welding position.
3. Check the Refrigerant
Observing from the sight glass, you may understand the refrigerant status and analyze the possible faults:
4. Check Other Parts
Other parts needed to be checked and their check points:Conditions obse rvedP ossible proble ms
Cle ar, no a ir bubble , A/C e mits c ool wind Re frige ra tion system is normal
Cle ar, no a ir bubble , A/C e mits warm wind Re frige ra nt le a ke d, the re is le aka ge in the syste m
Occ a tiona l a ir bubble . Expa nsion va lve is froste d There is wa te r mixe d in the re frigeration syste m
Occational air bubble. Insufficient refrigerant or air mixed in the system
Cle ar, the re is oil stripe on the gla ss Outle t is not c old, no refrige ra nt
Foamy and turbid Excessive freezing oilChecked PartCheck Points
The re sha ll be no dirt and rust on the radiator tha t hinde r the he at
exchange;
The ra dia tor surfa ce ha s no da mage , fissure a nd hidde n trouble tha t ma y
cause refrigerant leakage.
Elec tromagne tic Clutc hClutc h ope ration is norma l. Whe n switche d on, the c ompre ssor sha ll
operate, clutch can not slip.
Compre ssor Be lt Be lt te nsion of 250N is normal, belt is not broke n and dama ged.
WireThe electromagnetic clutch and blower power cable shall be not damaged
and overheated; the connection shall be reliable, and the protective
gromme t through the me tal plate sha ll be ke pt good a nd without da ma ge .
HoseRefrigerant hose and condenser pipe shall be secured and shall not be
dama ged by a pproac hing the othe r ove rhe ate d pa rts, moving pa rts a nd
sha rp parts. Eva pora tor Conde nse r