Geely CK Series 2007 Instruction manual

Table of Contents
Part I Engine ...........................................................................1
Chapter 1 Engine Assembly (MR479Q, MR479QA, MR481QA)...................1
Section 1 Routine Inspection.........................................................................................1
Section 2 Drive Belt Replacement ...............................................................................5
Section 3 Valve ClearanceAdjustment ...........................................................................6
Chapter 2 Engine Components Replacement
(MR479Q, MR479QA, MR481QA)................................................................10
Section 1 Engine Components ....................................................................................10
Section 2 Engine Components Replacement ............................................................13
Section 3 Timing Belt Replacement .........................................................................17
Section 4 Camshaft Replacement ............................................................................22
Section 5 Cylinder Head Gasket Replacement .........................................................28
Section 6 Oil Pump Oil Seal Replacement ................................................................33
Section 7 Engine Rear Oil Seal Replacement ............................................................34
Chapter 3 Lubrication System (MR479Q, MR479QA, MR481QA) ...............35
Section 1 Oil Pressure Gage Sensor Replacement ....................................................35
Section 2 Oil Pump Assembly Replacement ..............................................................36
Section 3 Oil Filter Replacement ................................................................................38
Section 4 Starter Replacement .................................................................................39
Section 5 Generator Replacement ............................................................................40
Chapter 4 Fuel System (MR7131A, MR7151A, MR7161A) ........................41
Section 1 Check Fuel System Pressure .....................................................................41
Section 2 Fuel Pump Inspection ...................................................................................42
Section 3 Fuel Injector Replacement .........................................................................43
Section 4 Fuel Pump Replacement ............................................................................45
Section 5 Fuel Emission Control System ....................................................................47
Section 6 Carbon Canister Replacement ....................................................................48
Chapter 5 Exhaust System (MR7131A, MR7151A, MR7161A) .................50

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

Section 1 Propeller Shaft .................................................................................................. 97
Chapter 5 Front Suspension System ............................................................... 103
Section 1 Front Suspension System ................................................................................ 103
Section 2 Front Suspension ............................................................................................105
Section 3 FrontWheelAlignment .......................................................................................106
Section 4 Front StrutAssembly ....................................................................................... 107
Section 5 Lower SwingArmAssembly ............................................................................ 110
Section 6 Front StabilizerBarand Link RodAssembly .....................................................113
Chapter 6 Rear Suspension System ................................................................116
Section 1 Rear Suspension System
Section 2 Rear Suspension ............................................................................................117
Section 3 Rear Wheel Alignment .................................................................................... 118
Section 4 Left & Right Rear StrutAssembly .....................................................................119
Section 5 Rear stabilizer bar assembly, strut rod components ..........................................121
Section 6 Left & Right Trailing Rod Assembly .............................................................. 123
Section 7 No. 1 TransverseArm Assembly ..................................................................... 124
Section 8 No. 2 TransverseArm Assembly ..................................................................... 125
Chapter 7 Wheel ................................................................................................126
Section 1 Tire Inspection ................................................................................................. 126
Section 2 Wheel Replacement ......................................................................................... 127
Chapter 8 Power Steering System .................................................................. 128
Section 1 Power Steering System .................................................................................... 128
Section 2 Steering Drive and Control Mechanism ......................................................... 130
Section 3 Steering Pipeline Component .......................................................................... 133
Section 4 Power Steering Gear Retaining Device
Chapter 9 Brake System .................................................................................. 139
Section 1 Brake System................................................................................................... 139
Section 2 Brake Fluid ....................................................................................................... 140
Section 3 Brake Pedal...................................................................................................... 141
Section 4 Vacuum Booster with Brake Master Cylinder Assembly ....................................143
Section 5 Front BrakeAssembly ..................................................................................... 144
Section 6 Rear Brake
Section 7 Brake Line ....................................................................................................... 151
..................................................................................116
.....................................................................................................147
..........................................................136

Section 8 Parking Brake System ..................................................................................... 155
........................................................157
Chapter 1 Survey................................................................................................157
Chapter 2 Starting and Charging System .........................................................161
Section 1 Starting System (MR479Q MR479QA MR481QA) ..........................................161
Section 2 Charging System (MR479Q,MR479QA, MR481QA) .......................................164
Chapter 3 Combination Meter System ..............................................................171
Section 1 Circuit Diagram of Combination Meter and Location of Multi-pin Plug-in
Terminal ............................................................................................................................ 171
Section 2 Malfunction Symptom Table and Solution Procedure ...........................................174
Section 3 Combination Meter .......................................................................................... 187
Chapter 4 Wiper and Washer System ...............................................................193
Section 1 Wiper and Washer System Inspection ............................................................ 193
Section 2 Replacement andAdjustment ............................................................................196
Chapter 5 Light System......................................................................................198
Section 1 Survey of Light System......................................................................................198
Section 2 Light System Symptom Inspection .................................................................. 202
Section 3 Headlamp Replacement ....................................................................................211
Section 4 Front Fog Lamp Replacement ............................................................................215
Section 5 Rear Combination Lamp Replacement ..............................................................217
Section 6 High Mounted Stop Lamp Replacement ............................................................218
Section 7 Interior Dome Lamp Replacement .....................................................................219
Section 8 Rear Row Reading Lamp Replacement ...........................................................220
Section 9 License Plate Lamp Replacement ...................................................................220
Chapter 6 Audio System......................................................................................221
Section 1 Audio System Description .................................................................................221
Section 2Audio System ConnectorTerminal Layout ...........................................................224
Section 3Audio System Inspection ................................................................................. 225
Section 4Audio and V ideo System Replacement ........................................................... 238
Chapter 7 SRS (Supplemental Restraint System).............................................242
Section 1 SRS-General Information .................................................................................242
Section 2 Troubleshooting ................................................................................................ 251
Part III Electrical Equipment

Section 3 Removal & Installation ................................................................................... 262
Chapter 8 MK-20 ABS System........................................................................ 272
Section 1 ABS Diagnosis ................................................................................................. 272
Section 2ABS System Check.......................................................................................... 276
Section 3 Removal and Installation ................................................................................. 292
Part IV Air Conditioner and Inside & Outside Trim ......................297
Chapter 1 A/C System ...................................................................................... 297
Section 1 The Structure & Working Principle of Refrigeration System ...............................297
Section 2 Heating System................................................................................................ 299
Section 3 A/C contr olling system .................................................................................... 302
Section 4 Service Caution & Notice ................................................................................ 304
Section 5 The Refrigeration System Operation Procedure ..............................................305
Section 6 Basic System.................................................................................................... 308
Section 7A/C System Faults Check & Troubleshooting ................................................ 313
Chapter 2 Inside & outside Trim and Accessory................................................318
Section 1 Configuration Index ............................................................................................318
(I) Outside Trim And FrontAccessory .................................................................................318
(II) Outside Trim and Rear Accessory .................................................................................319
(III) Front inside trim ..........................................................................................................320
(IV) Rear inside trim ............................................................................................................321
Section 2 Inside & Outside Trim andAccessories Removal and Installation .......................322
(I) Front Bumper ..................................................................................................................322
(II) Engine Hood .................................................................................................................324
(III) Outside Rear View Mirror
(IV) Rear trunk Lid ...............................................................................................................327
(V) Rear Bumper...................................................................................................................329
(VI) Seat Removal, Installation andAdjustment ...................................................................331
(VII) Seat Belt .....................................................................................................................335
(VIII) Instrument panel and auxiliary console .....................................................................338
(IX) A pillar inside trim and front door sill ............................................................................343
(X) B pillar inside trim ........................................................................................................344
(XI) Cpillar inside trim and rear door sill .............................................................................345
(XII) Roof inside trim
(XIII) Carpet and Heat Insulator.............................................................................................347
...............................................................................................326
...........................................................................................................346

(XIV) Rear trunk Inside Trim ............................................................................348
(XV) Engine Hood Inside Trim ...........................................................................349
(XVI) Door ..............................................................................................................350
Part V Body............................................................................359
Chapter 1 General Information .....................................................................359
Section 1 Body Structure ..............................................................................................359
Chapter 2 Body Repair..................................................................................369
Section 1 Body Damage Forms and Requirements for Repair ....................................369
Section 2 Typical Technology Of Body Panel Repair ..................................................372
Section 3 Repair after Body Damage ..........................................................................372
Section 4 Features and Composition ofAutomobile Body ............................................. 377
Section 5 Painting Technique after Body Repair............................................................383
Section 6 Service Data For Body ................................................................................385

1
Part I Engine
Chapter 1 Engine Assembly
(MR479Q, MR479QA, MR481QA)
Section 1 Routine Inspection
1. Check coolant
2. Check engine oil
3. Check battery
4. Check air cleaner element assembly
5. Check spark plug
6. Check drive belt
Figure 1
Notice:
zCheck the belt deflection at the specified point See (Figure 1).
zSet tension to specified value when installing new belt.
zCheck the deflection to ensure it is below the specified value after the belt runs for over 5 minutes.
zReinstall the belt which has been running for over 5 minutes. The deflection of the old belt is regarded as
the standard for inspection.
zCheck V-belt for tension and distortion after the engine cranks for 2
turns.
7. Check ignition timing See (Figure 2)
a) Warm up the engine.
b) When using fault diagnosis tester
Connect fault diagnosis tester to fault diagnosis interface socket.
Ignitiontiming:
MR479Q: 10 ± 2° BTDC (before top dead center) at idle
MR479QA: 10 ± 2° BTDC at idle
MR481QA: 10 ± 2° BTDC at idle
Figure 2
New Belt mm Old Belt mm
Fan Belt 7～13.5
Power steering Belt 5～66
～8
A/C Belt 6. 5～78
～9
Belt deflection See (Table 1)
Belt pressure: 98N
Belt Looseness Measuring Point
Water pump
Power steering
crankshaft
generator
Air condition
compressor
pump 11.5 ～
9

2
c) When fault diagnosis tester is not used
(1) Shorting fault diagnosis interface socket 13 (TC) terminal and 4(CG) terminal.
Notice:
zEnsure correct connection, otherwise the engine will be damaged.
zSwitch off all electrical appliance system.
zCheck when disconnecting cooling fan motor.
(2) Using timing light to check ignition timing.
Ignition timing: 10 ± 2° BTDC at idle
Notice:
(1) Transmission shift lever should be in neutral position when checking ignition timing.
(2) Running engine at 1,000-1,300rpm for 5s and check at idle.
(3) Remove the tester on fault diagnosis socket.
(4) Ignition timing advance angle becomes larger when the engine roate speed is higher.
(5) Removetiming light.
8. Check engine idle See (Figure 3)
Notice:
zCheck idle when cooling fan motor is disconnected.
zSwitch off all electrical accessories and A/C.
9. Check compression pressure See (Figure 4)
(a) Engine switched off.
(b) Detach high voltage cable.
(c) Detach spark plug.
(d) Check the compression pressure in the cylinder.
(1) Insert pressure gauge into the hole of the spark plug.
(2) Throttle valve full open.
(3) Crank the engine, measure the compression pressure.
MR479Q 800±50 (rpm)
MR479QA 800±50 (rpm)
MR481QA 800±50 (rpm)
Table 2
(a) Warm up the engine.
(b) Connect fault diagnosis tester to fault diagnosis interface socket.
(c) Connect tachometer testing pen to fault diagnosis socket terminal
9 when not using fault tester.
(d) Check idle See (Table 2).
Figure 4
Figure 3
Techometer
Battery

3
The Min. compression pressure: 980 kPa
The tolerance range of the cylinders pressure: 100 kPa
Notice:
z Ensure sufficient battery power and the engine speed is no less than 250 RPM (revolutions per minute).
zCheck the compression pressure of other cylinders in the same way.
zComplete the measure as quick as possible.
(4) If the compression pressure in several cylinder is too low, fill some engine oil to the cylinder via the
hole of the spark plug. Check by repeating step 1-3.
Hint:
zIf the compression pressure is improved after filling oil, the piston ring or the cylinder may be abrased
or damaged.
zIf the pressure is still too low, the valve is stagnation or poor seal, or there is a leakage in gasket.
10. Check CO/HC
(a) Start engine.
(b) Running engine at 2500rpm for approximately 3 minutes.
(c) Insert CO/HC meter testing probe into tailpipe at least 40cm during idling.
(d) Check CO/HC concentration at idle and 2500rpm.
Hint:
zComplete measurement within 3 minutes.
zTest the CO/HC emission concentration at idle and 2500 rpm on QC/T630-1999 standard.
(e) Take the following steps to diagnose the fault if the CO/HC concentration does not comply with standard .
(1) Check the oxygen sensor operation.
(2) See (Table 3) for the possible cause and check and repair.

4
Table 3
CO HC Problems Causes
1. Fault
. Incorrect ignition timing
. Fouled, shorted or improperly clearance of spark plug
2. Incorrect valve clearance
3. Leaky intake & exhaust valves
4. Leaky cylinders
1. Air leaks
. PCV hoses, intake manifold
. Throttle body
. Brake booster circuit
2. Lean mixture gas causing misfire
1. Clogged air filter
2. Clogged PCV valve
. Faulty ECU
. Faulty fuel pressure regulator
. Faulty water temperature sensor
. Faulty air compressor
. Faulty injectors
. Faulty throttle position sensor
Normal
Low High
High High
Rough idle
(Black smoke
from exhaust
pipe)
Rough idle
Rough idleHigh

5
Section 2 Drive Belt Replacement
1. Disconnect all engine pipe hose and wire joint. Remove engine assembly from the engine
compartment, jack up the body, take out the engine assembly slowly (See Provision 20, Section
Two, Chapter Two for detailed information)
2. Remove generator V-belt See (Figure 5)
3. Remove No. 1 V-belt A/C compressor to crankshaft pulley
4. Remove water pump belt See (Figure 6)
5. Install water pump V-belt
6. Adjust V-belt of steering assisting pump
(a) Adjust power steering belt tension, tighten bolt B.
(b) Tighten boltA.
Torque : 39N. m
7. Install V-belt A/C compressor No. 1 to crankshaft pulley
8. Adjust V-belt A/C compressor No. 1 to crankshaft pulley
(a) AdjustA/C belt tension by tightening bolt B.
(b) Tighten nut A.
Torque : 39N. m
9. Install Generator V-belt See (Figure 7)
10. Adjust Generator V-belt.
Tighten boltA and then bolt B.
Torque: BoltA 18N. m Bolt B 58N. m
11. Check driving belt for distortion and tension Figure 7
Figure 6Figure 5

6
Section 3 Valve ClearanceAdjustment
1. Remove right camshaft timing gear
2. Remove ignition coil and high voltage cable
3. Remove cylinder head cover sub-assembly See (Figure 8)
(a) Disconnect generator wire joint..
(b) Disconnect generator circuit.
(c) Disconnect oil pressure switch connector.
(d) Disconnect A/C compressor switch connector.
(e) Open the wire harness clip.
(f) Remove wire harness from cylinder head cover.
(g) Separate 2 ventilation hoses from cylinder head cover.
(h) Remove 4 screw nuts, 4 oil seal gaskets, cylinder head and gasket.
4. Adjust piston of Cylinder 1 to the compression position
(a) Turn crankshaft pulley, align notch to timing mark "0" on Cylinder 1. See (Figure 9).
(b) Align mark "K" on camshaft timing pulley to the timing mark on bearing cap. See (Figure 10) Crank 360°
if it is not aligned.
5. Check valve clearance (cool). See (Table 5)
(a) Turn the crankshaft pulley for 360°.Align notch to timing mark "0" on timing belt cover No. 1.
(b) Only check the valve as shown in the figure. Valve clearance measurement. See (Figure 11).
Figure 8
Figure 10
Intake Valve mm Exhaust Valve mm
MR479Q 0.20 ± 0.05 0.30 ± 0.05
MR479QA 0.20 ± 0.05 0.30 ± 0.05
MR481QA 0.20 ± 0.05 0.30 ± 0.05
Table 5
Figure 9

7
6. Adjust intake valve clearance
(a) Detach intake camshaft
Notice:
Because the camshaft end play is quite small, keep camshaft horizontal when removing it. If not, cylinder
head may be partially damaged by the thrust force£¬it may stuck or damage camshaft when turning crankshaft.
Take the following steps to avoid the damage:
(1) Turn the pulley to access the hole on the camshaft drive gear where the counter gear is installed. See
(Figure 12).
Hint:
The above condition allows the cylinders No. 1 and No. 3 of the intake camshaft to push up the valve tappet.
(2) Remove bolt and bearing cap No. 1.
(3) Install camshaft counter gear to drive gear with service bolt. See (Figure 13).
(4) Uniformly loose and remove 8 bearing cap bolts in several passes as
shown in the figure. See (Figure 14).
(5) Remove 4 bearing caps and camshafts.
Figure 11
Figure 14
Figure 12 Figure 13

8
Notice:
Due to the small end play on camshaft, the cylinder head may be damaged by the thrust force when removing
it, it may stuck or damage camshaft. Take the following steps to avoid damage:
(1) Turn the crankshaft pulley to make exhaust camshaft dowel pin is a bit higher than the cylinder head. See
(Figure 15).
(2) Align the matchmark on each gear to engage intake camshaft gear and exhaust camshaft gear. See
(Figure 16).
(3) When the gears are engaged, install the intake camshaft bearing onto bearing journal.
Hint:
The intake camshaft lobe of cylinder 1 and 3 can jack up their own valve tappet.
(5) Install 4 bearing caps to the right position.
(6) Apply a light layer of engine oil on the thread and under the head of bearing cap bolts.
(7) Uniformly install and tighten 8 bearing cap bolts in several times, in the sequence shown in the figure.
Torque: 13N. m
(8) Remove service screw.
(9) Install the bearing cap No. 1. in the direction of the forward arrow mark.
(10)Apply a light layer of engine oil on the thread and under the head of bearing cap bolts.
(11)Alternatively tighten and install 2 bearing bolts.
Torque: 13N. m
7. Adjust exhaust valve clearance. See (Figure 17)
Remove adjust gasket.
(1) Crank to keep the camshaft head upward.
(2) Face valve tappet nick to vehicle front.
(3) Press valve tappet, put special tool between camshaft and valve tappet.
Hint:
zLean the end with mark "9" into the position in (Figure 18).
Figure 15
Install Mark
Timing Mark
March Mark
Cam Lobe Upward
Nick
Front
Figure 17
Figure 18
Figure 16

9
(4) Alternatively press valve tappet with the special tool (A) (B). Check
valve clearance. See (Figure 19).
8. Install cylinder head sub-assembly
(a) Remove all old gasket material.
(b) Apply the seal glue to the cylinder head.
(c) Connect wire harness and clip.
(d) Install gasket under of cylinder head.
(e) Install the cylinder head cover with 4 seal gaskets and 4 screw caps.
Torque: 7.8N. m
(f) Install 2 ventilation hoses to cylinder head cover.
(g) Connect generator wire joint.
(h) Connect generator wires.
(i) Connect oil pressure switch connector.
(j) Install wire clip.
(k) Connect A/C compressor switch connector.
9. Install electronic ignition coil and high voltage cable
10. Check engine oil for leakage Figure 19

10
Chapter 2 Engine Components Replacement
(MR479Q, MR479QA, MR481QA)
Section 1 Engine Components
Component 1
Air Filter Assembly W/ Hose
Accelerator Control
Cable Assembly
Heater Inlet Hose
Heater Outlet Hose
Fuel Sub-Assembly
Efi Fuel Pipe Clamp
MT:
Transmission
Control Cable
Assembly
AT:
Transmission Control Cable Assembly
MT:
Clutch Release
Cylinder Assembly
Radiator Outlet Pipe
Radiator Inlet Pipe
Starter Assembly
AT: Oil Cooler
Outlet
Pipe
AT: Oil Cooler
Inlet
Pipe
Radiator Assembly Battery
Front Exhaust
Pipe Assy. 3-way catalytic
converter
Muffler
Tail Pipe
Figure 20

11
Component 2
Figure 21
Fan & Generator V-Belt Vane-Type Pump V-Belt (V/ Power Steering)
V-Belt No.1
Right Engine
Mounting Insulator
Door Assembly
Steering Column
Assembly
Front Shaft Hub Left Nut
Left Front Speed Sensor
Left Engine Mounting Bracket
Steering Column Hole Cover
Hole Cover
Steering Column
Glove Compartment
Front exhauxt pipe assembly
Gasket
Gasket
One-off accessory

12
Component 3
Figure 22
Flywheel
Clutch Disc Clutch Cover
Clutch Release Bearing
Clutch Release Fork
Release Fork Support
Release Fork Boot

13
Section 2 Engine Components Replacement
1. Avoid gasoline ejection when work.
2. Drain the coolant to empty.
3. Remove air filter assembly with hose. See (Figure 23)
4. Remove battery
5. Remove fuel delivery pipe sub-assembly
6. Disconnect water hoses, disconnect heater outlet hose
from A/C hose.
7. Loose nut, remove accelerator control cable
8. Remove throttle body assembly
9. Remove power steering pump reservoir assembly
10. Remove front exhaust pipe assembly
11. Remove steering gear boot
12. Seperate steering column assembly. See (Figure 24)
13. Remove front wheel hub nut
14. Disconnect front wheel vehicle speed sensor (with ABS)
15. Detach steering tie rod ball stud pin assembly
16. Detach front lower swing arm sub-assembly
17. Detach front propeller assembly. See (Figure 25)
Detach front propeller from the shaft hub with plastic hammer.
18. Disconnect transmission shift cable or gear shift level assembly
19. Disconnect clutch cylinder assembly or disconnect clutch cable
20. Detach engine assembly and transaxle
(a) Hoisting engine ;
(b) Remove 3 bolts. Detach the right engine mounting bracket. See (Figure 26) ;
(c) Remove 1 bolt. Detach the left engine mounting bracket;
(d) Remove 1 bolt. Detach the rear engine mounting bracket;
(e) Remove engine and transaxle and put them on the pallet;
(f) Jack up the boday.
Figure 23
Figure 24
Figure 25 Figure 26