light CHERY TIGGO 2009 Service Owner's Manual

Downloaded from www.Manualslib.com manuals search engine 4. Using valve spring compressor CH-20018 (1), com-press the valve springs.
5. Install the valve keepers.
6. Strike the valve stem lightly with a plastic hammer after installation to verify proper assembly.
Valve Springs
Specifications
Valve Spring Specifications
DESCRIPTION SPECIFICATION (mm)
Spring Free Length 47.7
Spring Height At 620 Newtons Of Pressure 32.0
Disassembly
NOTE :
The following special tools are required to perform the repair procedure:
•CH-20011 - Valve Seal Installer
• CH-20012 - Valve Stem Seal Installer Guide
• CH-20013 - Valve Seal Remover
• CH-20017 - Valve Keeper Installer
• CH-20018 - Valve Spring Compressor
1. Using the special tool CH-20018 (1), compress the valve springs.
CYLINDER HEAD UNIT REPAIR
BESM020067
BESM020067
02
02–146Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Assembly
1. Install the valve springs.
2. Install the valve spring retainers.
3. Using a valve spring compressor CH-20018 (1),compress the valve springs.
4. Install the valve keepers.
5. Strike the valve stem lightly with a plastic hammer after installation to verify proper assembly.
CYLINDER HEAD UNIT REPAIR
BESM020067
02
02–148Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine DIAGNOSIS & TESTING
Engine Performance Diagnostics
CONDITIONPOSSIBLE CAUSES CORRECTION
Engine Does Not Start 1. Weak battery.
2. Corroded or loose battery
connections.
3. Faulty starter.
4. Faulty coil(s) or control unit.
5. Incorrect spark plug gap.
6. Contamination in fuel system.
7. Faulty fuel pump.
8. Incorrect timing.1. Test battery. Charge or replace if
necessary.
2. Clean and tighten battery
connections. Apply a coat of light
mineral grease to terminals.
3. Test starting system. Check for
codes. (Refer to Appropriate
Diagnostic Information)
4. Test and replace as needed.
(Refer to Appropriate Diagnostic
Information)
5. Set gap.
6. Clean system and replace fuel
filter.
7. Test fuel pump and replace as
needed. (Refer to Appropriate
Diagnostic Information)
8. Check for a skipped timing belt.
Engine Stalls Or Idles Rough 1. Idle speed too low.
2. Incorrect fuel mixture.
3. Intake manifold leakage.
4. Faulty ignition coil(s).1. Test minimum air flow. (Refer to
Appropriate Diagnostic Information)
2. (Refer to Appropriate Diagnostic
Information)
3. Inspect intake manifold, manifold
gasket, and vacuum hoses.
4. Test and replace if necessary.
(Refer to Appropriate Diagnostic
Information)
Engine Loss Of Power 1. Dirty or incorrectly gapped spark
plugs.
2. Contamination in fuel system.
3. Faulty fuel pump.
4. Incorrect valve timing.
5. Leaking cylinder head gasket.
6. Low compression.
7. Burned, warped, excessive
clearance, or pitted valves.
8. Plugged or restricted exhaust
system.
9. Faulty ignition coil(s).
10. Burned spark plugs.1. Clean spark plugs and set gap.
2. Clean system and replace fuel
filter.
3. Test and replace if necessary.
(Refer to Appropriate Diagnostic
Information)
4. Correct valve timing.
5. Replace cylinder head gasket.
6. Test compression of each
cylinder.
7. Replace valves.
8. Perform exhaust restriction test.
Install new parts.
9. Test and replace if necessary.
(Refer to Appropriate Diagnostic
Information)
10. Replace spark plugs.
DIAGNOSIS & TESTING
02
02–163Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 8. Remove the cylinder head bolts in the sequenceshown.
9. Remove the cylinder head.
10. Remove the cylinder head gasket.
11. Inspect the cylinder head for warp using a straightedge and feeler gauge. Repair the cylinder head if necessary.
12. Installation is in the reverse order of removal.
Installation Notes:
• Ensure cylinder head bolt holes in the block are clean, dry (free of residual oil or coolant), and threads are not
damaged.
• Do not reuse the cylinder head bolts. The new bolts should be examined before use. If the bolts are stretched,
the bolts should be replaced.
• Position the new cylinder head gasket on the engine block with the part number facing up. Ensure gasket is
seated over the locating dowels in the block.
• Before installing the bolts, the threads should be lightly coated with engine oil.
• The cylinder head bolts should be installed and
torqued in the sequence shown.
• Tighten the cylinder head bolts in the following sequence.
1st Step: Tighten the bolt to 78 N·m
2nd Step: Completely loosen the bolt
3rd Step: Retighten the bolt to 20 N·m
4th Step: Tighten the bolt an additional 90°
5th Step: Finish tightening the bolt an addi-
tional 90°
ON-VEHICLE SERVICE
LTSM020237
LTSM020097
LTSM020098
02–176Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Removal & Installation - Rear Mount
NOTE :
The following special tools are required to perform the
repair procedure:
•Engine Hoist
1. Disconnect the negative battery cable.
2. Support the engine with the engine hoist.
3. Remove the engine rear mount retaining bolts (2) and remove the engine rear mount bracket bolts
(1).
(Tighten: Engine rear mount bolts to 60 N·m)
4. Installation is in the reverse order of removal.
Engine Assembly
Removal & Installation
NOTE :
The following special tools are required to perform the repair procedure:
• Engine Hoist
NOTE :
The engine is removed with the transaxle as an assembly. 1. Relieve the fuel pressure (See Fuel Pressure Relief Procedure in Section 04 Fuel Delivery).
2. Disconnect the negative battery cable.
3. Remove the battery, battery hold downs, and battery tray (See Battery Removal & Installation in Section 05 Starting & Charging).
4. Remove the hood.
5. Discharge air conditioning system (See A/C System Evacuation and Recharge in Section 13 Heating & Air Con- ditioning).
6. Drain the cooling system (See Cooling System Draining and Filling in Section 06 Cooling).
WARNING!
Always allow the engine to cool before opening the cooling system. Do not loosen the coolant pressure relief
cap when the engine is operating or the cooling system is hot. The cooling system is under pressure; steam and
hot liquid can come out forcefully when the cap is loosened slightly. Failure to follow these instructions may
result in serious personal injury.
7. Remove the coolant fan & radiator assembly (See Coolant Fan & Radiator Assembly Removal & Installation in Section 06 Cooling).
8. Remove the starter motor wiring.
9. Remove the negative battery cable from the engine.
ON-VEHICLE SERVICE
LTSM020188
02
02–183Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine NOTE :
The following special tools are required to perform the repair procedure:
•MB-990767 - Timing Belt Spanner Wrench
• MD-998785 - Timing Belt Gear Holder
• MD-998767 - Automatic Tensioner Socket
1. Drain the cooling system (See Cooling System Draining and Filling in Section 06 Cooling).
WARNING!
Always allow the engine to cool before opening the cooling system. Do not loosen the coolant pressure relief
cap when the engine is operating or the cooling system is hot. The cooling system is under pressure; steam and
hot liquid can come out forcefully when the cap is loosened slightly. Failure to follow these instructions may
result in serious personal injury.
2. Attach an engine hoist to the engine.
3. Raise the engine with the engine hoist, just enough to support the engine.
1 - Right Engine Mounting Bracket
2 - Spacer
3 - Upper Balance Shaft Pulley
4 - Upper Balance Shaft Timing Belt
5 - Upper Balance Shaft Timing Belt Tensioner
6 - Crankshaft Sensing Blade
7 - Upper Timing Belt Cover
8 - Lower Timing Belt Cover
9 - Timing Belt Automatic Tensioner
10 - Idler Pulley
11 - Crankshaft Bolt12 - Crankshaft Timing Belt Pulley
13 - Lower Balance Shaft Pulley
14 - Crankshaft Position Sensor
15 - Power Steering Bracket
16 - Timing Belt Rear Cover
17 - Timing Belt
18 - Camshaft Timing Pulley
19 - Camshaft Pulley Bolt
20 - Crankshaft Upper Balance Shaft Pulley
21 - Tensioner Arm
22 - Tensioner Pulley
ON-VEHICLE SERVICE
LTSM020048
02–190Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 7. Using valve spring compressor MD-998772 (1),compress the valve springs.
8. Install the valve keepers.
9. Strike the valve stem lightly with a plastic hammer after installation to verify proper assembly.
Camshaft
Specifications
Camshaft Specifications
DESCRIPTION SPECIFICATION MINIMUM LIMIT
Intake Cam Lobe Height 37.5 mm37 mm
Exhaust Cam Lobe Height 36.99 mm36.49 mm
CYLINDER HEAD UNIT REPAIR
LTSM020092
02
02–243Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine •Using special tool MD-998440 (1) (return leakage tester), install the hydraulic adjuster.
• After the plunger has moved slightly (0.2 - 0.5
mm), measure the time it takes to move an addi-
tional 1.0 mm. If the measurement value is not
within specifications, replace the hydraulic adjuster-
.Standard Value:4-20seconds/1 mm (applying
diesel oil of 15-20°C)
Rocker Arms
•Inspect the surface of the roller (2) on all rocker
arms. If there is any damage, the rocker arm
should be replaced.
• Inspect the roller for smooth operation. If the roller
does not revolve smoothly or is loose, the rocker
arm should be replaced.
• Inspect the internal diameter (1) of the rocker arms.
If there is any damage, the rocker arm should be
replaced.
Valve & Valve Guides
Specifications
Valve & Valve Guide Specifications
DESCRIPTION SPECIFICATION LIMIT
Intake Valve Deflection 0.02 mm0.02 mm
Exhaust Valve Deflection 0.04 mm0.04 mm
Intake Valve Clearance 0.020 - 0.050 mm0.10 mm
Exhaust Valve Clearance 0.030 - 0.070 mm0.15 mm
Intake Valve Edge Thickness 1.0 mm0.5 mm
Exhaust Valve Edge Thickness 1.2 mm0.7 mm
Intake Valve Height 112.30 mm111.80 mm
Exhaust Valve Height 114.11 mm113.61 mm
Intake Valve Guide Height 49.30 mm49.80 mm
Exhaust Valve Guide Height 49.30 mm49.80 mm
CYLINDER HEAD UNIT REPAIR
LTSM020159
LTSM020037
02–246Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine NOTE :
Before installing the valve seat, heat the cylinder head to the temperature of about 250°, or cool the valve seat in
liquid nitrogen in order to install the valve seat.
•Machine the new valve seat and valve to proper specifications.
Assembly
1. Install the valves into the cylinder head (larger diameter on intake side).
2. Using special tool MD-998774, install the new valve oil seal.
3. Install the valve springs.
4. Install the valve spring retainers.
5. Using valve spring compressor MD-998772 (1),
compress the valve springs.
6. Install the valve keepers.
7. Strike the valve stem lightly with a plastic hammer after installation to verify proper assembly.
Valve Springs
Specifications
Valve Spring Specifications
DESCRIPTION SPECIFICATION LIMIT
Spring Free Length 51.0 mm50.0 mm
Spring Center Line ≤2.0° ≤4.0°
CYLINDER HEAD UNIT REPAIR
LTSM020092
02–252Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine •Check the valve spring center line. Discard the springs that do not meet specifications.
• The following specifications apply to both intake
and exhaust valve springs.
VALVE SPRING CENTER LINE
DESCRIPTION SPECIFICATION LIMIT
Spring Center Line ≤2.0° ≤4.0°
Assembly
1. Install the valve springs (2).
2. Install the valve spring retainers (1).
3. Using valve spring compressor MD - 998772, com-
press the valve springs.
4. Install the valve keepers.
5. Strike the valve stem lightly with a plastic hammer after installation to verify proper assembly.
CYLINDER HEAD UNIT REPAIR
LTSM020100
LTSM020039
02
02–255Chery Automobile Co., Ltd.