2008 GEELY CK Workshop Manual

26(d) Install intake camshaft.
(1) Make the exhaust camshaft dowel pin a bit higher than the top of the cylinder head.
(2) Apply grease to camshaft's contact surface.
(3) Install intake camshaft gear to exhaust camshaft gear ,
Align the matchmarks on each gear. See (Figure 62).
(4) Check the timing marks on the camshaft gear for
alignment.See (Figure 63).
Hint: Matchmark is on the top.
26. Adjust valve clearance
27. Install camshaft timing pulley
Turn the camshaft's hexagon head. Tighten the timing pulley bolt. See (Figure 64).
Torque: 59N. M
Figure 63
Figure 65
28. Install the timing belt
(a) Align the marks on timing belt and the one on camshaft timing pulley.
(b) Install timing belt. Check tension force between the crankshaft timing pulleys. See (Figure 65).
29. Check valve timing
(a) Loose idler bolt.
(b) Turn crankshaft from TDC clockwise for 2 cycles.
(c) Check and align each pully to the timing mark as shown in Figure 66. Remove timing belt and reinstall it
if not.
30. Install crankshaft gear or pulley cover sub-assembly
Torque: 9.3N. mFigure 62 Install Mark
Timing MarkInstall Mark
Install Mark
Timing Mark
5-6mm Figure 64
Figure 66

2731. Install timing belt cover
Torque: 9.3N. m
32. Install generator assembly
33. Install right engine mounting bracket. See (Figure 67)
34. Install cylinder head cover sub-assembly
(a) Install 2 ventilation PCV hoses to the cylinder head cover.
(b) Connect the generator wire.
(c) Install the wire clip.
(d) Connect A/C compressor switch connector.
35. Install water pump pulley
36. Install power steering pump V-belt
37. Install A/C compressor to crankshaft pulleyV-belt
38. Install generator V-belt
39. Install left & right rear mounting bracket of engine.
40. Install ignition coil and high voltage cable
41. Hoist the engine back into the compartment
42. Install propeller shaft
43. Install air filter assembly with hose
44. Install oil pipe and water hoses
45. Install left and right front tires.
46. Check engine oil for leakage
47. Install all the wire harnesses and the cables on the engine connected to car bodyFigure 67

28Section 5 Cylinder Head Gasket ReplacementComponent 1Figure 68Vane Pump Assembly V/ Power Steering
Throttle Body AssemblyGasketDipstick
Inlet Pipe
Gasket
Wire HarnessO-RingTiming Chain Or Timing Belt Cover No. 2
Crankshaft Or Pulley Cover Sub-AssemblyFan PulleyFuel Delivery Pipe No.1

29Component 2Figure 69High Pressure Cable
Ventilation Pipe
Seal
Cylinder Head Cover Camshaft Camshaft Bearing CapOil SealCamshaft Timing Pulley
Cylinder Head Sub-Assembly
Cylinder
Head GasketCylinder Head
Cover Gasket Camshaft
No.2
Exhaust Manifold
Insulator No. 1
Gasket
Exhaust Manifold
Manifold Mounting

30Component 3Figure 70Air Filter Assembly W/ HoseEngine Hood
Right Wiper Arm
Left Wiper Arm
Right Scuttle Ventilation Grille
Left Scuttle Ventilation Grille Right Engine Mounting Bracket
Generator
AssemblyAccelerator Cable AssemblyWiper Arm Subassembly
EFI Fuel Hose Clamp
Fuel Pipe Sub-Assembly
Heater Outlet Hose A
Radiator Outlet Hose Radiator Inlet HoseHeater Inlet Hose
Vane-Type Pump
V-Belt V/ Power Steering
V-Belt No.1Fan & Generator V-Belt

31Replacement1. Disconnect all the wire harnesses and the cables on the engine connected to the car body.
2. Detach 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. Detach front exhaust pipe assembly
6. Loose engine left & right rear brackets after hoisting the engine.
7. Disconnect all the other connectors between the engine and the car body.
8. See "Provision 20, Section 2, Chapter 2". Lift the car body and take out the engine assembly.
9. Remove A/C compressor to the crankshaft pulleyV-belt.
10. Remove power steering pump V-belt.
11. Detach water pump fan pulley.
12. Disconnect ignition coil and high voltage cable.
13. Detach cylinder head cover sub-assembly.
14. Detach generator assembly.
15. Detach the camshaft.
16. Detach the throttle body assembly
17. Detach intake manifold stay No. 2.
18. Take out the dipstick
19. Detach No. 1 fuel delivery pipe
20. Detach the wire harness.
21. Detach the steering assisting pump assembly
22. Detach exhaust manifold. See (Figure 71)
23. Pry cylinder head from the dowel pin on the cylinder block.
See (Figure 72)
24. Remove the cylinder head gasket.
25. Install cylinder head gasket
26. Install cylinder head sub-assembly
27. Install exhaust pipe assembly.
(a) Install the new gasket and exhaust manifold with 5
bolts. Torque: 34N. m
(b) Install exhaust manifold stay with 2 bolts.
(c) Install upper heat shield with 4 bolts
Torque: 17N. mFigure 71
Figure 72

3228. Install power steering adjusting pole
29. Install power steering pump assembly
30. Install wire harness.
31. Install No. 1 fuel delivery pipe
32. Set the new gasket on cylinder head with flange upward. Install water inlet hose. See
(Figure 73)
33. Install manifold stay No. 2
34. Connect front exhaust pipe assembly
35. Install throttle body assembly
36. Install camshaft
37. Install engine cylinder head cover
38. Hoist the engine back to the compartment.
39. Install engine right left and rear brackets
40. Install propeller shaft
41. Install ignition coil and high pressure cables. Install air filter assembly with hose
42. Install oil pipe and water hose
43. Install left & right front tire
44. Install all the wire harnesses and cables on the engine connected to car body
45. Check compression pressure
46. Check CO/HC. Check idle and ignition timingFigure 73

33Section 6 Oil Pump Oil Seal Replacement1. Pry with 2 screwdrivers. Detach crankshaft timing pulley.
See (Figure 74)
2. Remove oil pump oil seal. See (Figure 75)
(a) Using a knife, cut off oil seal lip.
(b) Using a screwdriver, pry out the oil seal.
3. Install oil pump oil seal. See (Figure 76)
(a) Smear grease to a new oil seal lip.
(b) on the oil seal with hammer until the edge of the oil pump
case is filled with the seal packing.
4. Install crankshaft timing pulley. See (Figure 77)
(a) Align pulley set key to the key groove.
(b) Place the flange face inward. Install timing pulley.
5. Install timing belt
6. Check engine oil for leakage
Figure 76 Figure 74
Figure 75
Figure 77