2008 GEELY CK Workshop Manual

322Section 2 Inside & Outside Trim and Accessories Removal and
Installation(I) Front BumperThe structure is as shown in the figure below:
1. Front Bumper 2.Front Bumper Fixed Screw3.Secondary Bumper Assembly Upper Buckle and Plug
4.Mounting Plate Cross Head Counter Sunk Self-tapping Screw5.Mounting Plate Cross Head
Counter Sunk Self-tapping Screw 6.Front Bumper Mounting Bracket to Body Bolt 7.Front Bumper
Mounting Bracket Sub-assembly 8. Secondary Bumper Assembly9.Front Bumper Mounting
Bracket to Secondary Bumper Assembly Bolt 10.Front Bumper Cushion 11.Secondary Bumper
Assembly Lower Buckle and Plug 12.License Mounting Plate Assembly13.Secondary Bumper As-
sembly Lower Connecting Bolt 14.Front Bumper Mounting Plate Seat15.Mounting Plate Seat Bolt
16.Front Bumper Mounting Plate

3231. Front Bumper Removal and Installation
(1) Disconnect the negative (--) terminal cable from the battery. Disconnect fog lamp wire;
(2) Remove the mudguard skirt to front bumper clip;
(3) Remove the attaching bolt of the the front fender and panel and the front bumper sub-assembly;
(4) Remove the front bumper set screw and the clip. Remove the front bumper mounting plate and the
positioning screw of the seat;
(5) Remove the bolt which connecting front bumper mounting bracket with the vehicle body;
(6) Pull the front bumper assembly and the secondary bumper assembly together out of the vehicle body.
Separate the front bumper mounting bracket from the rail, front bumper mounting plate from the front
bumper mounting plate seat;
(7) Remove the front bumper mounting plate seat from the vehicle body;
(8) Remove the secondary bumper assembly and the front bumper mounting bracket sub-assembly;
(9) Remove front bumper mounting plate;
(11)Remove front bumper cushion. Remove the front license plate. Remove the mounting plate assembly;
(12)Remove fog lamp;
(13)The installation is in the reverse order of the removal.
2.Notice For Removal Of The Front Bumper
(1) Pull the front bumper to separate it from the bumper rail.
(2) Uniformly pull it by force to prevent the front bumper mounting plate and seat from damage.
Warning

324(II) Engine HoodEngine Hood Removal / Installation
For engine hood installation, see the figure
1. Removal
Warning
•It is dangerous to remove the engine hood without support. The engine hood may drop and
result in body injury. Work with at least one assistant when removing the engine hood and
should follow the procedures below:
1Disconnect windshield washer hose.
2Lift up the engine hood and support it with the spring brace;
3Remove 2 spring braces under the help of the assistant to prevent the engine hood from dropping down
and resulting in body injury;
4The assistant lifts the engine hood, removes the engine hood hinge bolt and the engine hood;
5Remove the ventilator louver and remove the hinge arm;
6Remove the hinge arm bracket attach bolt. Remove the hinge arm bracket from the body;
7Remove the engine hood lock;
8Remove the engine hood lock control cable.
2.Installation
1The installation is in the reverse order of the removal;
2Adjust the engine hood;Engine HoodGas Spring BraceEngine Hood Hinge Engine Hood Lock Control CableEngine Hood LockEngine Hood Installation Illustration

3253. Engine Hood Adjustment
Fix the engine hood to the engine hood hinge with bolts. the engine hood in vertical direction through the hinge
hole. Vertically adjust the front by adjusting the engine hood bumper and adjust the engine hood master lock
striker. The clearance tolerance is 1.0 mm-3.0 mm, while the flatness tolerance is 0 mm-1.0 mm.
(1) Open the engine hood
(2) Loose the bolt between the engine hood and the hinge
(3) Adjust the clearance between the engine hood and the front fender. Loose the bolt and move the engine
hood for adjustment.
(4) Close the engine hood
(5) Check for alignment
(6) Open the engine hood and adjust it as specified
(7) Adjust the engine hood bumper
(8) Check for alignment
(9) Adjust the engine hood master lock striker:
Loose 3 pin bolts on the engine hood lock. Move the engine hood lock for adjustment.
(10) Tighten the bolt between the engine and the hinge.
(11) Close the engine hood
4.Processing The Brace
Notice
•The air in the brace is of no color, no taste and no
poison.
(1) Wear the eye protection.
(2) Level the brace.
(3) Cut the brace with the hack saw as shown in the figure on
the right.
(4) Bleed the air from the brace
(5) Abandon the brace

326(III) Outside Rear View MirrorAttach the outside rear view mirror to the left and right doors. Integrate the outside rear view mirror with the
body smoothly using specially designed rubber bushing to make it a whole. The forward and rearward folding
of the rear view mirror will not be affected after being knocked. It is also a major way to reduce the whole
vehicle's air resistance coefficient.
Attach the lens to the plate with double sided adhesive tape. The plate is connected to the rear view mirror
case with the ball hinge to prevent fragment from splashing when it is broken, which may result in injury and
it is convenient to replace the broken lens. Pry the plate from the ball socket with the tool when the lens is
broken for replacement and press the new one into the ball socket. The case overturn force is designed to be
30N, enabling it liable to overturn when impacted by person or object and hence reducing the mutual damage.
The adjust handle of the outside rear view mirror is designed to be built in the vehicle to facilitate the
operator's direction adjustment. The optional flat mirror is generally selected for driver side to ensure the
sense of reality and distance. Spherical mirror is used for front passenger side to enlarge the rear field of
vision. In addition, outside rear view mirror has also the feature of electrical heating and defogging.
Notice
When folding the outside rear view mirror, be careful not to put your finger between the outside
rear view mirror and the mirror foot to avoid being crushed!Replace the Rear View MirrorRemoval
1. Remove battery negative cable.
2. Remove the inside trim.
3. Disconnect electric outside rear view mirror connector.
4. Remove screw and outside rear view mirror retaining clip.
5. Remove electric outside rear view mirror.
6. The installation is in the reverse order of the removal.Installation1. Position the rear view mirror on the door
2. Tighten the screw from left lower side screw clockwise
Tighten
Tighten the outer rear view mirror screw to 1.5 N.M¡«2 N.M
3. Install rear view mirror inside trim cover
4. Install rear view mirror inner adjust handle

327(IV) Rear trunk LidComponent View:
1.Rear trunk Lid Hinge Pin 2.Rear trunk Lid Hinge Retainer3.Rear trunk Lid Hinge Retainer
Mounting Nut4.Rear trunk Door Hinge Cushion 5.Rear trunk Lid Outer Panel And Reinforcement
Assembly 6.Geely Logo7.Rear License Plate Assembly8.Rear License Plate Assembly
Mounting Nut9.Rear trunk Lid Weatherstrip10.Rear trunk Lid inside Trim Board 11.Rear
trunk Lid Cushion12.Rear trunk Door Lock Cylinder Assembly 13.Rear trunk Lid inside Trim Board Clip
14.Rear trunk Lid Hinge Attaching Bolt 15.Rear trunk Door Lock Cable Assembly16.Rear
trunk Door Oil Filler Cable Assembly 17.Rear trunk Lid Hinge 18.Rear trunk Lid Spring

3281.Rear trunk Lid Removal/Installation
Warning
It is dangerous to remove the rear trunk lid spring before supporting the rear trunk lid. The rear
trunk lid may drop and result in body injury. Fully open the rear trunk lid, support the rear trunk
lid before removing the brace.
Remove rear trunk lid under the help of the assistant.(1) Disconnect the negative (--) terminal cable from the battery;
(2) Disconnect rear trunk wire harness connector. Pull the rear trunk lid wire harness out from the rear
trunk;
(3) Remove rear trunk door lock cylinder assembly. Pull out the rear trunk door lock cable;
(4) Remove rear trunk lid spring;
(5) Remove rear trunk lid hinge connecting bolt. Remove the rear trunk lid;
(6) Remove rear trunk lid hinge seat mounting nut. Remove the rear trunk lid hinge seat and the rear trunk lid
hinge
(7) Remove rear trunk door oil filler cable assembly;
(8) Remove cushion;
(9) Remove rear trunk lid hinge pin. Remove rear trunk lid hinge from the bracket;
(10) Remove rear trunk lid weatherstrip;
(11) Remove rear trunk lid inside trim board clip, Remove rear trunk lid inside trim board;
(12) Remove rear license plate assembly mounting nut , Remove rear license plate assembly;
(13) The installation is in the reverse order of the removal.;
(14) Adjust the rear trunk lid. (See rear trunk lid adjustment)2.Rear trunk Lid Adjustment(1) Measure the clearance and height between the rear trunk lid and vehicle body.
(2) Loose the rear trunk lid hinge mounting bolt or the rear trunk latch mounting screw and reinstall the rear
trunk lid if it is not as specified.
Clearance
a: 3.74mm
b: 1.0mm
c: 4.0mm
(3) Tighten the rear trunk lid hinge bolt;
(4) Close the rear trunk lid

329(V) Rear BumperThe structure diagram is shown as the figure below:
1.Cross Pan Head Tapping Screw And Big Washer Set2.Cross Pan Head Screw (GB973 M6X16)
3.Cross Pan Head Screw (GB973 M6X16) 4.Rear Bumper5.Clip6.Rear Bumper Reinforce-
ment Assembly 7.Rear Bumper Mounting Bracket Assembly8.Hexigon Bolt and Spring Washer
Set 9.Hexigon Bolt Spring and Flat Gasket Set
1.Rear Bumper Removal/Installation
(1) Disconnect the negative (--) terminal cable from the battery.
(2) Remove the cross pan head tapping screw and big washer set.
(3) Remove 4 hexagon bolt on the mounting bracket.
(4) Remove 2 cross pan head screw (GB973 M6X16)
(5) Pull the rear bumper out from the body.
(6) Remove the cross pan head screw (GB973 M6X16) and hexagon bolt spring and flat gasketset. Remove
the rear bumper mounting bracket assembly.
(7) The installation is in the reverse order of the removal.