2008 GEELY CK oil type

Chapter 6 Cooling System Inspection
(MR7131A, MR7151A, MR7161A).................................................................52Section 1 System Check
Section 2 Water Pump, Thermostat and Radiator Replacement.................................... 54Chapter 7 Clutch (MR7131A, MR7151A, MR7161A)....................................56Section 1 Clutch Replacement...................................................................................57Chapter 8 Maunal Transaxle Assembly
(MR7131A, MR7151A, MR7161A)................................................................59Section 1 Manual Transaxle Replacement..................................................................60
Section 2 Vehicle Speed Sensor Replacement
Section 3 Transmission Case Oil Seal..........................................................................62
Section 4 Transaxle Case Oil Seal Replacement........................................................63Chapter 9 General Engine Troubles and Their Troubleshooting....................64Section 1 Overview........................................................................................................64
Section 2 General Engine Fault and Troubleshooting.......................................................64
Section 3 Engine Noise Diagnosis and Troubleshooting................................................77Chapter 10 Engine Management Unit..............................................................81Section 1 System Description.........................................................................................81
Section 2 System Component and Working Principle......................................................82Part II Chassis............................................................................85Chapter 1 Transmission Control Device.........................................................85Section 1 Transmission Control Device.........................................................................85
Section 2 Lever Type Transmission Control Device......................................................85
Section 3 Cable Type Transmission Control Module......................................................87Chapter 2 Accelerator Pedal............................................................................90Section 1 Accelerator Pedal..........................................................................................90Chapter 3 Clutch Control System....................................................................91Section 1 Clutch Control System....................................................................................91
Section 2 Clutch Cable Control Mechanism.....................................................................91
Section 3 Clutch hydraulic Control Device.......................................................................94Chapter 4 Propeller Shaft...............................................................................97...............................................................................................52
..............................................................61

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

103Chapter 5 Front Suspension SystemSection 1 Front Suspension SystemDescription on front suspension structure
This model uses strut swing arm independent suspension with stabilizer bar.
The shock absorber upper end is flexibly connected to the body through the shock absorber mounting seat,
the lower end is rigidly connected to the steering knuckle. The coil spring encloses the shock absorber (coil
spring geometrical axial line does not coincide with that of the shock absorber piston rod), and is supported
between the upper and lower spring seats.
Both ends of the stabilizer bar are connected to the shock absorber through the strut bar ball pin and the
intermediate part is supported on the lower front body by the rubber bushing and support frame.
The front cushion sleeves the shock absorber piston rod head to restrict the wheel jump limit position and
plays the role of buffer.
The thrust ball bearing, installed between the spring upper seat and the shock absorber mount, is used for the
relative rotation upon steering of the shock absorber rigidly connected to the steering knuckle to the shock
absorber mount flexibly connected to the body.
"L" type lower swing arm is secured to the lower engine compartment with the press plate through elastic
rubber bushing and hinge, and its outer end is connected to the steering knuckle through the ball stud pin
which is attached to the lower swing arm by 3 high intension bolts. The ball stud pin can be removed and
replaced when it is worn.
The ball seat material is saturated polyester containing oil, featured in comparatively high intensity and
wearability and good self-lubrication performance. Proper amount of grease has been added during the
assembly and there is no need for additional filling during the normal operation.
See the table for the front suspension technical parametersItem Parameter Item Parameter
shoc k a bsorbe r ope ra ting
cylinder diameter /mm￠
50 Wheel camber 0°±30′
shoc k a bsorbe r piston rod
diameter /mm￠
20 Wheel toe-in/mm 0±3
shoc k a bsorbe r stroke /mm 175 Kingpin inc lina tion 12°14′
Ca ste r of kin pin 2°23′
Remark: the wheel alignment parameter in the table is at free load.

292Section 3 Removal and InstallationI.Precautions for Removal1. Use the scan meter to locate the fault causes before proceeding to service.
2. wipe the surface clean with the cleaning agent without mineral oil before service; be careful to keep it
clean during service, only the lint-free cloth can be used to wipe the removed parts.
3. Only the original spare part can be used, and the package of the new spare part shall not be removed until
the installation.
4. Return liquid pump motor and the HCU is a type of integral structure and can not be separated.
5. When the system is opened, do not use compressed air or move the vehicle.
6. Use proper plug to clog each hydraulic outlet as soon as the ABS assembly is removed.
7. Remove other components that may interfere.
8. Please use the DOT 4 brake fluid, do not use the mineral oil.
9. Use the brake fluid to immerse the seal and the O ring, do not use the engine oil or brake grease.
10. After service, check the regular brake system and ABS brake function for normal and reliable operation.
11. Check all hydraulic pipe union for leakage.II. HECU Removal1. Turn off the ignition switch and disconnect the battery negative ground cable.
2. Remove the wire connector from the ABS HECU assembly.
3. Depress the brake pedal >60mm and hold it with the pedal retainer to close the master cylinder center
valve so that the brake fluid will not flow out from the outlet when the system is opened.
4. Put a clean cushion under the hydraulic regulator.
5. Remove the brake pipe (A, B) on the HCU connected to the master cylinder and place the mark, then
use a plug to clog the outlet immediately.
6. Remove the brake fluid pipe(1-4) leading to the wheels, then use a plug to clog the outlet immediately.
7. Remove the nut attaching the HECU to the bracket.

304Section 4 Service Caution & NoticeI. Service CautionRefrigerant Treatment
•During the treatment, the operator shall be careful not to inhale A/C refrigerant or lubricant vapor. Long-
term exposure to the A/C environment will cause the operator's eye, nose and throat liable to stimulation.
In addition, based on the consideration on the environment influence, when discharging the HFC-134a
from the A/C system, we suggest using the recyclable and rechargeable devices. If sudden system fault
occurs, it is recommended to place the device on a ventilated place before starting service.
•For HFC-134a service equipment, it is recommended not to perform the pressurization check or leakage
inspection. If these mixture combust, it may result in severe human injury or property loss.
•Please be noticed not to let the refrigerant leak near the spark or other hot objects. If the refrigerant gas
contacts the spark or similar heat source (e.g. cigarette or heater), it may generate poisonous gas. The
refrigerant is extremely liable to leakage during the transportation. In this case, please eliminate or remove
the heat source mentioned above and keep good ventilation.
•It is very dangerous to handle the liquid refrigerant. Only a drop of refrigerant can result in local frostbite
on skin if dropped on the skin of the operator. Therefore, it is specified that the operator shall always
wear glove and eye protection during the handling of the liquid refrigerant. If liquid refrigerant gets in
your eyes or on your skin, Wash the area with much cool water. Go immediately to hospital for professional
treatment.
Refrigerant Preservation
• Refrigerant preservation container is a high pressure resistant equipment. If it is put in hot treatment, the
explosion may arise, and the resulting metal fragments and the splashed liquid refrigerant will result in
severe human injury. It is recommended to preserve the refrigerant below 40°C.II. Service NoticeInsufficient Refrigerant Handling
•If the refrigerant is founded to be insufficient during the fault diagnosis, it is recommended not to add
refrigerant because of the following facts: the pressure readings indicated by different pressure gauge
are different, thus you will be unable to determine the exact amount of the refrigerant to be added, and
excessive or insufficient refrigerant may cause a series of chained negative effects such as damaged
refrigerant circulation parts or deteriorated refrigeration effect. Therefore, if the refrigerant is found to
be insufficient, it is recommended to drain the refrigerant from the refrigerant circulation pipeline and fill
specified amount of the refrigerant.
Compressor Oil Handling
•For this type of vehicle, it is recommended to use SW-100 type compressor oil. Use of PAG compressor
oil other than the SW-100 type may cause the A/C compressor to be damaged.
•During the operation, please be noticed not to splash the SW-100 type compressor oil onto the vehicle
surface. Therefore, if this happens, please wipe it off immediately, otherwise the compressor oil will
damage the paint on the vehicle surface.

305•Compared with the early used mineral oil, the SW-100 type compressor oil is of comparatively high
moisture absorption performance. If you mix the moisture object with the SW-100 type compressor oil, it
will damage the Refrigeration system. Therefore, after treating the compressor oil or removing the
refrigeration system components, the lid shall be covered immediately to prevent the SW-100 type
compressor oil from absorbing the moisture.Section 5 The Refrigeration System Operation ProcedureI. Refill RefrigerantNotice:•During the filling of refrigerant into the refrigeration system, be careful that it is required to
have the professionals operate under the specified standard and procedure, otherwise it will
reduce the A/C efficiency greatly and even damage the refrigeration system components.
Refill the HFC-134a refrigerant
Refill Preparation1. Install the inflating equipment.
2. Connect the low pressure tube to the low pressure
refill valve.
3. Connect the high pressure tube to the high pressure
refill valve.
4. Connect the intermediate tube to the vacuum pump.Vacuumization:1. Open all valves.Notice:•Close all valves of the manifold gauge immediately after the vacuum pump stops operation. If
the valve is still open after the vacuum pump stops operation, then the vacuum pump oil will
return to refrigerant circulation loop and reduce the A/C efficiency.2. Start the vacuum pump and run it for 15min.
3. Check if the readings at high and low sides of the manifold gauge fall within the range of -101 kPa{-760
mmHg }. Close the valves of the manifold gauge.Check the air tightness:1. Stop the vacuum pump and have it wait for 5min.
2. Check the high pressure side of the manifold gauge and the reading at the low pressure side.
•Check for leakage if the reading changes and vacuumize it again.
•Refill the new HRC-134a refrigerant if the reading doesn't change.To low pressure fill valveLow Pressure GaugeHigh Pressure
GaugeConnect the high
pressure refill valveLow Pressure TubeHigh Pressure TubeLow Pressure
Manual ValveHigh Pressure
Manual ValveVacuum PumpIntermediate Tube
Refrigerant Steel Jar

311Check the condenser1. Check for crack, damage or oil leakage.
•Replace the condenser if any of the above-mentioned faults occurs.
2. Check if the fin area is blocked by dust.
•Clean it if it is blocked.
3. Check if the fin area bends.
•If the fin area bends, level it with a flat head screwdriver.6. Refrigeration Pipeline Removal / Installation1. Remove battery.
2. Drain the refrigerant from the system.
3. Remove air filter.
4. Remove the clamp.
5. Remove the compressor inlet hose.
6. Remove the compressor outlet hose.
7. Remove liquid pipe I.
8. Remove pressure switch connector.
9. Remove the pipe clamp.
10. Remove liquid pipe II.
11. The installation is in the reverse order of the removal.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.
Introduction Of The Refrigeration Pipeline Removal:
Nuts union type:Loose the nuts with 2 wrenches and then remove the refrigeration pipe (or the hose).Slider joint type:Clip the slider block recess end with pliers or the similar tool and remove the attaching bolt or screw cap.

312Introduction Of The Refrigeration Pipeline Installation:
1. It is recommended to fill some SW-100 compressor oil into the refrigerating circulation when installing a
new refrigeration pipe or cooling hose.
Refill: (approximate)
5ml{5 cc}: Refrigeration pipe
10ml{10 cc}: Condenser hose
2. Fill compressor oil to O-ring and other connecting points.
3. Tighten the connecting points.
Nuts union or slider joint type:
1. Tighten the nuts or the bolts of the connectiong
points by hand.
2. Tighten the connecting points with specified
torque wrench. It is connected with nuts. Tighten
the nuts with a wrench or a torque wrench.
3. Clip the slider block recess with pliers or other
similar tool and clamp the pipe used to connect
slider block. Tighten the bolt or the nuts at the
connecting points with a torque wrench.
7. A/C control panel removal / installation:
1. Disconnect the negative (--) terminal cable from the battery.
2. Remove the auxiliary console.
3. Disconnect the hot and cold air cable and airflow allocating cable.
4. Remove A/C control panel.
5. Disconnect blower switch connector.
6. Remove the lighting wire harness connector.
7. Remove the inside and outside circulation switch connector.
8. The installation is in the reverse order of the removal.Slider BuldgeSlider RecessionTorque Wrench