Geely CK 2009, CK 2007, CK 2008, CK 2010 User 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 Clearance Adjustment ...........................................................................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 Radiator Replacement.................................... 54

...............................................................................................52

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

..............................................................61

Chapter 9 General Engine Troubles and Their Troubleshooting ....................64

Section 1 Overview ........................................................................................................64

Section 2 General Engine Fault and T roubleshooting .......................................................64

Section 3 Engine Noise Diagnosis and T roubleshooting ................................................77

Chapter 10 Engine Management Unit..............................................................81

Section 1 System Description .........................................................................................81

Section 2 System Component and W orking Principle ......................................................82

Part II Chassis............................................................................85

Chapter 1 Transmission Control Device .........................................................85

Section 1 Transmission Control Device .........................................................................85

Section 2 Lever Type Transmission Control Device ......................................................85

Section 3 Cable T ype Transmissi on Control Module ......................................................87

Chapter 2 Accelerator Pedal............................................................................90

Section 1 Accelerator 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

Section 1 Propeller Shaft .................................................................................................. 97

Chapter 5 Front Suspension System ............................................................... 103

Section 1 Front Suspension System ................................................................................ 103

Section 2 Front Suspension ............................................................................................105

Section 3 Front Wheel Alignment .......................................................................................106

Section 4 Front Strut Assembly ....................................................................................... 107

Section 5 Lower Swing Arm Assembly ............................................................................ 110

Section 6 Front Stabilizer Bar and Link Rod Assembly .....................................................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 Strut Assembly .....................................................................119

Section 5 Rear stabilizer bar assembly, strut rod components ..........................................121

Section 6 Left & Right Trailing Rod Assembly .............................................................. 123

Section 7 No. 1 Transverse Arm Assembly .....................................................................124

Section 8 No. 2 Transverse Arm Assembly .....................................................................125

..................................................................................116

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

..........................................................136

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 Brake Assembly ..................................................................................... 144

Section 6 Rear Brake

Section 7 Brake Line ....................................................................................................... 151

.....................................................................................................147

Section 8 Parking Brake System ..................................................................................... 155

Part III Electrical Equipment

........................................................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 T able and Solution Pr ocedure ...........................................174

Section 3 Combination Meter .......................................................................................... 187

Chapter 4 Wiper and Washer System ...............................................................193

Section 1 Wiper and W asher System Inspection ............................................................ 193

Section 2 Replacement and Adjustment ............................................................................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 2 Audio System Connector Terminal Layout ...........................................................224

Section 3 Audio System Inspection ................................................................................. 225

Section 4 Audio and V ideo System Replacement ........................................................... 238

Chapter 7 SRS (Supplemental Restraint System).............................................242

Section 1 SRS-General Information .................................................................................242

Section 2 Troubleshooting ................................................................................................ 251

Section 3 Removal & Installation ................................................................................... 262

Chapter 8 MK-20 ABS System ........................................................................ 272

Section 1 ABS Diagnosis ................................................................................................. 272

Section 2 ABS 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 & W orking 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 7 A/C System Faults Check & Troubleshooting ................................................ 313

Chapter 2 Inside & outside Trim and Accessory................................................318

Section 1 Configuration Index ............................................................................................318

(I) Outside Trim And Front Accessory .................................................................................318

(II) Outside Trim and Rear Accessory .................................................................................319

(III) Front inside trim ..........................................................................................................320

(IV) Rear inside trim ............................................................................................................321

Section 2 Inside & Outside T rim and Accessories 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 and Adjustment ...................................................................331

(VII) Seat Belt .....................................................................................................................335

...............................................................................................326

(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

...........................................................................................................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 T ypical Technology Of Body Panel Repair ..................................................372

Section 3 Repair after Body Damage ..........................................................................372

Section 4 Features and Composition of Automobile Body ............................................. 377

Section 5 Painting Technique after Body Repair............................................................383

Section 6 Service Data For Body ................................................................................385

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

Water pump

generator

Power steering pump

crankshaft

Belt Looseness

Notice:

Check the belt deflection at the specified point See (Figure 1).

Measuring Point

Figure 1

Air condition

compressor

Fan Belt 7

Power steering Belt 5～66

A/C Belt 6. 5～78

Belt deflection See (Table 1)

Belt pressure : 98N

New Belt mm Old Belt mm

～

11.5

～

13.5

8 9

z Set tension to specified value when installing new belt. z Check the deflection to ensure it is below the specified value after the belt runs for over 5 minutes. z Reinstall the belt which has been running for over 5 minutes. The deflection of the old belt is regarded as

the standard for inspection.

z Check 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.

Ignition timing: MR479Q: 10 ± 2° BTDC (before top dead center) at idle MR479QA: 10 ± 2° BTDC at idle MR481QA: 10 ± 2° BTDC at idle

Figure 2

c) When fault diagnosis tester is not used

(1) Shorting fault diagnosis interface socket 13 (TC) terminal and 4(CG) terminal.

Notice:

z Ensure correct connection, otherwise the engine will be damaged. z Switch off all electrical appliance system. z Check 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) Remove timing light.

8. Check engine idle See (Figure 3) (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).

Table 2

MR479Q 800±50 (rpm) MR4 79QA 800±50 (rpm) MR 4 81QA 800±50 (rpm)

Notice:

z Check idle when cooling fan motor is disconnected.

Switch off all electrical accessories and A/C.

9. Check compression pressure See (Figure 4) (a) Engine switched off.

Techometer

Battery

Figure 3

(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.

Figure 4

The Min. compression pressure: 980 kPa The tolerance range of the cylinders pressure: 100 kPa Notice:

Ensure sufficient battery power and the engine speed is no less than 250 RPM (revolutions per minute).

z Check the compression pressure of other cylinders in the same way. z Complete 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:

z If the compression pressure is improved after filling oil, the piston ring or the cylinder may be abrased

or damaged.

z If 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:

Complete measurement within 3 minutes.

z z Test 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.

CO HC Problems Causes

1. F ault . I ncorrect ignition timing

Table 3

Normal

Low High

High High

Rough idleHigh

Rough idle

(Bla c k smoke

from exhaust

pipe)

. Fouled, s hor t ed or improperly cle ara nce of spar k plug

2. Incorrect valve clearance

3. Leaky inta ke & exhaus t valves

4. Leaky cylinders

1. Air leaks . PCV hoses, intake manifold . Throttle body . Brake booster circuit

2. L ean mixture gas caus ing misfire

1. Clogged air filter

2. C logged PCV valve

. Faulty ECU . Faulty fuel pre ssure regula t or . Faulty wa ter temperature sensor . Faulty air compressor . Faulty injectors . Faulty throttle position sensor

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 bolt A. 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) Adjust A/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 bolt A and then bolt B.

Figure 6Figure 5

Torque: Bolt A 18N. m Bolt B 58N. m

11. Check driving belt for distortion and tension

Figure 7

Section 3 Valve Clearance Adjustment

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).

Figure 8

(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.

Figure 9

5. Check valve clearance (cool). See (Table 5)

Table

Figure 10

Intake Valve mm Exha ust Valve mm

MR479Q 0.20 ± 0.05 0.30 ± 0.05 MR479Q A 0. 20 ± 0.05 0.30 ± 0.05 MR481Q A 0.20 ± 0.05 0.30 ± 0.05

(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 11

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.

Figure 12

Figure 13

(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 14

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.

Install Mark

March Mark

Timing Mark

Figure 15

Figure 16

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

Cam Lobe

Upward

7. Adjust exhaust valve clearance. See (Figure 17)

Remove adjust gasket.

Front

(1) Crank to keep the camshaft head upward.

Nick

(2) Face valve tappet nick to vehicle front. (3) Press valve tappet, put special tool between camshaft and valve tappet.

Figure 17

Hint:

z Lean the end with mark "9" into the position in (Figure 18).

Figure 18

(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.

T orque: 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

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

Radiator Assembly

MT: Clutch Release

Cylinder Assembly

Radiator Inlet Pipe

AT: Oil Cooler

Outlet

Pipe

Inlet

Pipe

Radiator Outlet Pipe

Starter Assembly

MT: Transmission Control Cable Assembly

AT: Transmission Control Cable Assembly

Battery

Front Exhaust

Pipe Assy.

Tail Pipe

Muffler

3-way catalytic converter

Figure 20

Component 2

Fan & Generator V-Belt

Vane-Type Pump V-Belt (V/ Power Steering)

V-Belt No.1

Right Engine Glove Compartment

Steering Column Hole Cover

Mounting Insulator

Door Assembly

Steering Column Assembly

Steering Column Hole Cover

One-off accessory

Front Shaft Hub Left Nut

Front exhauxt pipe assembly

Gasket

Figure 21

Left Engine Mounting Bracket

Left Front Speed Sensor

Gasket

Flywheel

Component 3

Clutch Disc

Clutch Release Fork

Clutch Cover

Clutch Release Bearing

Release Fork Support

Release Fork Boot

Figure 22

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

Figure 23

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 24

Figure 25 Figure 26

21. Remove radiator assembly

22. Remove engine V-belt

23. Remove No. 1 V- belt (A/C compressor to crankshaft pulley)

24. Remove generator assembly

25. Remove A/C compressor

26. Remove compressor installing No. 1 bracket. Remove 4 bolts and compressor installing No. 1 bracket.

27. Remove starter assembly

28. Remove power steering pump V- belt

29. Detach power steering pump assembly

30. Remove power steering pump, adjust the bracket

31. Detach manual transaxle assembly (Separate automatic transaxle assembly)

32. Detach clutch cover panel assembly.

33. Detach clutch pressure plate assembly.

34. Detach flywheel sub-assembly.

35. Remove engine rear end cover.

36. Remove injector assembly and remove intake manifold.

Remove 2 bolts and intake manifold support and remove 7 bolts, 2 nuts, intake manifold and gasket. See (Figure 27).

37. Remove knock sensor

38. Remove water temperature gauge sensor

39. Remove crankshaft position sensor

40. Remove engine oil pressure switch

41. Remove water inlet hose housing

42. Remove water outlet hose joint

43. Detach exhaust manifold. See (Figure 28)

44. Remove engion oil filter sub-assembly

45. Remove ignition coil and high voltage cable

46. Install engine sub-assembly

47. Install ignition coil and high voltage cable

48. Install engine oil filter sub-assembly

49. Install exhaust manifold

Figure 27

(a) Install new gasket and exhaust manifold stay with

5 nuts, Torque: 34N. m

(b) Install exhaust manifold stay with two bolts.

Torque: 59N. m

Torque: 17N. m

Figure 28

50. Install water outlet hose joint. See (Figure 29, 30)

Figure 29

Figure 30

51. Install water inlet hose housing. See (Figure 31, 32)

Figure 31 Figure 32

52. Install engine oil pressure switch

53. Install crankshaft position sensor T orque: 9, 3N. m

54. Install water temperature gauge and water temperature sensor T orque: 15N. m

55. Install knock sensor Torque: 44N. M

56. Install intake manifold. See (Figure 33)

Install the intake manifold with new gasket with 7 bolts and 2 nuts. Uniformly tighten bolts and nuts in several time.

57. Install injector assembly

58. Install rear end cover

59. Install flywheel sub-assembly. See (Figure 34)

(a) Install flywheel to crankshaft. (b)Install and uniformly tighten and connect bolt as shown in the

figure. Torque: 78N. m

60. Install clutch assembly

61. Install flywheel and ring gear. See (Figure 35)

(a)Install the oil thrower, it’s chamfer side on crankshaft in

the axie direction.

(b) Install flywheel and ring gear on crankshaft.

Figure 33

Figure 34

the figure.

Torque: 64N. m

62. Install manual transaxle assembly

63. Install starter assembly

64. Install power steering pump bracket

65. Install power steering pump adjusting bracket with 2 bolts.

66. Connect power steering pump assembly

67. Install engine assembly and transaxle

68. Connect left, right, front and rear lower suspension arm sub-assembly

69. Connect left and right tie rod ball stud pin assembly

70. Connect left, right and front vehicle speed sensor (with ABS)

71. Install left & right nuts on the front shaft hub

72. Install front exhaust pipe assembly

73. Connect steering shaft assembly and steering column hole cover. See (Figure 36)

74. Connect wire harness

75. Install belt adjusting bracket of A/C compressor

76. Connect A/C compressor

77. Install generator assembly

78. Install A/C compressor to crankshaft pulleyV-belt

79. Install generator belt

80. Install engine assembly with transaxle

81. Install radiator assembly

82. Install throttle body assembly

83. Install fuel delivery pipe sub-assembly

84. Install battery

85. Install air filter assembly with hose

86. Install front wheel

87. Fill engine oil

88. Fill coolant

89. Check engine oil for leakage

90. Check engine coolant for leakage

Figure 35

91. Check fuel for leakage

92. Check idle and ignition timing

93. Check CO/HC

94. Check and adjust front wheel alignment

95. Check ABS vehicle speed sensor signal

Figure 36

Right Engine Mounting

Section 3 Timing Belt Replacement

Air Filter Assembly W/ Hose

Ventilation Pipe

Seal

Cylinder Head

Vane-Type Pump V-Belt V/ Power Steering

Cylinder Head Gasket

High Pressure Cable

Gasket

V-Belt No.1

Timing Chain Or Timing Belt Cover Assembly No. 2

Crankshaft Or Pulley

Cover Sub-Assembly

Timing Chain Timing Belt

Crankshaft Pulley

Cover Sub-Assembly

Fan & Generator V-Belt

Timing Belt

Timing Belt Guide

Fan Pulley

Generator Assembly

Figure 37

1. 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 38

Figure 39

Figure 40

Figure 41

20. 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.

Figure 43

Figure 44

(b) Check valve timing. Loose idler bolt.

(1) Turn crankshaft from TDC to BDC slowly.

Notice: Crank always in clockwise.

Figure 45

(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.

T orque: 37N. m

(4) Remove crankshaft pulley bolt.

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 .

Figure 46

(b) Install pulley bolt T orque: 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.

Figure 47

(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 hose

Figure 48

39. 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

Section 4 Camshaft Replacement

Air Filter Assembly W/ Hose

Vane-Type Pump V-Belt

V/ Power Steering

Fan & Generator V-Belt

V-Belt No.1

Cylinder Head

Crankshaft Bearing Cap

Crankshaft Timing Belt Washer

Crankshaft Counter Gear

Wave Gasket

Ventilation Pipe

Cylinder

Head Gasket

High Pressure Cable

Seal

Right Engine Mounting

Snap Ring

Camshaft Timing Pulley

Fan Pulley

Timing Belt Cover No. 2

Crankshaft Or Pulley Cover Sub-Assembly

Figure 49

Camshaft

Camshaft No. 2

Oil Seal

Generator Assembly

1. 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

Figure 50

Figure 51

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.

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