2008 GEELY CK Workshop Manual

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

2139. Install oil pipe and water hose
40. Install left & right propeller shaft
41. Install left & right front wheel
42. Check engine oil for leakage
43. Install all connected wire harnesses and the cables on engine and vehicle body

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

24(c) Loose installing bolt of the idler. See (Figure 52). Move the pulley to
its far left and tighten it temporarily.
(d) Remove the belt from the camshaft timing pulley.
Notice:
zHold the timing belt, the engagement of the crankshaft timing
pulley and timing belt will not move.
zBe careful not to drop anything into the timing belt cover.
zDo not let the belt contact oils, water or dirt.
Figure 53
22. Remove the camshaft and the timing pulley. See (Figure 53)
(a) Turn the camshaft hexagon head and loose pulley bolt.
(b) Remove pulley bolt and timing pulley.
23. Remove camshaft. See (Figure 54)
Because the camshaft end play is quite small, keep camshaft horizontal
when removing it.Take the following steps to avoid the damage:
(a) Remove the camshaft
(1) Turn the camshaft to access the hole of the counter gear installed on camshaft drive gear.
Hint: The intake camshaft lobe of Cylinder 1 and 3 can push up their
own valve tappet.
(2) Remove 2 bolts and bearing cap No. 1.
(3) Install the counter gear on the intake camshaft with the service
bolt onto the drive gear.
(4) Uniformly loose and detach 8 bearing cap bolts in several times
in the sequence shown in Figure 55.
(5) Remove 4 bearing caps and camshaft.
If the camshaft can not be kept horizontal, lift it vertically. Reinstall the
bearing cap with 2 bolts. Alternatively loose and detach the bearing cap
bolts and lift the camshaft gear. See (Figure 56)Figure 52
Figure 55
Figure 56 Figure 54

25 (b) Remove the counter gear of the camshaft.
(1) Clamp the camshaft's hexagon on the vise.
(2) Turn the counter gear cloclwise, Remove the service bolt.
(3) Remove the snap ring with a circlip pliers. See (Figure 57).
(4) Remove waved gasket, camshaft counter gear and the camshaft gear spring. See (Figure 58)
24. Remove and install spark plug hole gasket. See Provision 15 and 16, Section 3 Timing Belt
Replacement for detailed information. See (Figure 44, 45).
Figure 57
25. Install camshaft
(a) Install exhaust camshaft and turn camshaft counterclockwise to make the dowel pin cross the vertical
line a little. See (Figure 59).
(b) Apply grease to a new oil seal lip and install it into the oil seal. See (Figure 60).
Figure 59
(c) Install camshaft counter gear.
(1) Clamp the camshaft's hexagon head with a vise.
(2) Install camshaft gear spring, camshaft counter gear and waved washer. (Figure 61).
Hint: Align the pin on the gear to the spring end of the counter gear.
(3) Install the snap ring with a circlip plier.
(4) Turn the counter gear clockwise with the special tool. Align the
holes on the camshaft drive gear. Install the service bolt.Figrue 61Rotate
Figure 58
Figure 60