CHERY TIGGO 2009 Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine Thermostat Inspection
1. Inspect the sealing surface of the thermostat (theseat should be tight at room temperature).
2. Inspect the opening temperature and maximum stroke of the thermostat.• Opening temperature of the thermostat is 87°
± 2°C
• Maximum stroke of the thermostat is 8 mm
• Full opening temperature of the thermostat is
104°C
3. Verify the thermostat closes 5°C lower than the opening temperature.
4. If the thermostat fails any of the inspection steps, replace the thermostat.
Coolant Pump
Removal & Installation - 1.6L & 1.8L & 2.0L
WARNING!
Always allow the engine to cool before opening the cooling system. Do not remove 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.
1. Drain the cooling system (See Cooling System Draining Procedure in Section 06 Cooling System).
2. Remove the timing belt (See Timing Belt Removal & Installation in Section 02 Engine).
3. Remove the coolant pump mounting bolts (1).(Tighten: Coolant pump mounting bolts to 15 N·m)
4. Remove the water pump and gasket.
5. Installation is in the reverse order of removal.
Installation Notes:
• Install a new coolant pump gasket during installa-
tion (1).
• Verify the cooling system is filled to proper
specifications.
ON-VEHICLE SERVICE
LTSM060014
BESM060001
BESM060002
06–16Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Removal & Installation - 2.4L
WARNING!
Always allow the engine to cool before opening the cooling system. Do not remove 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.
1. Drain the cooling system (See Cooling System Draining Procedure in Section 06 Cooling System).
2. Remove the accessory drive belt (See Accessory Drive Belt Removal & Installation in Section 02 Engine).
3. Remove the engine timing belt (See Engine Timing Belt Removal & Installation in Section 02 Engine).
4. Remove the upper balance shaft timing belt (See Upper Balance Shaft Timing Belt Removal & Installation inSection 02 Engine).
5. Remove the coolant pump mounting bolts (1). (Tighten: Coolant pump mounting bolts to 14 N·m)
6. Remove the coolant pump and gasket.
7. Installation is in the reverse order of removal.
Installation Notes:
• Install a new coolant pump gasket during installation.
• Verify the cooling system is filled to proper specifications.
Coolant Pump Inspection
Check coolant seal of the coolant pump for coolant leak. If coolant pump bearing is loose, replace the assembly.
Radiator
Description
The radiator is a cross-flow type (horizontal tubes) with design features that provide greater strength, as well as
sufficient heat transfer capabilities to keep the engine coolant within operating temperatures.
Operation
The radiator functions as a heat exchanger, using air flow across the exterior of the radiator tubes. Heat from the
coolant is then transferred from the radiator into the moving air.
Removal & Installation
WARNING!
Always allow the engine to cool before opening the cooling system. Do not remove 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.
ON-VEHICLE SERVICE
LTSM060003
06
06–17Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 1. Disconnect the negative battery cable.
2. Drain the cooling system (See Cooling System Draining Procedure in Section 06 Cooling System).
3. Disconnect the upper radiator hose from the radiator.
4. Disconnect the lower radiator hose from the radiator.
5. Disconnect the cooling fan electrical connectors.
6. Remove the cooling fan (See Cooling Fan Removal & Installation in Section 06 Cooling).
7. Remove the automatic transaxle fluid hose connecting bolts to radiator (only with 2.0L engine).
8. Remove the radiator support lever retaining bolts(1).
9. Remove the radiator support mounting bolts (1). (Tighten: Radiator support mounting bolts to 5 N·m)
10. Remove the radiator from the engine compartment.
11. Installation is in the reverse order of removal.
Installation Notes:
• Verify the cooling system is filled to proper
specifications.
Cooling Fan
Description
The radiator cooling fans are dual-speed electric motor driven fans. The radiator fan assembly includes two electric
motors, two five-blade fans, and a support shroud that is attached to the radiator. The radiator fans are serviced as
an assembly.
ON-VEHICLE SERVICE
LTSM060016
LTSM060004
06–18Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Operation
The radiator cooling fan operation is controlled by the Engine Control Module (ECM) and the fan relays, with inputs
from the following:
•Engine coolant temperature
• Automatic transaxle fluid temperature (with DP0 transaxle)
• A/C signal
Inspect the cooling fan for proper low speed and high speed operation:
• The low speed fan should be switched on at 98°C and switched off at 94°C.
• The high speed fan should be switched on at 105°C and switched off at 101°C.
• If the water temperature is greater than 101°C after the fan is switched off, the fan will continue to operate for
1 minute.
• If the water temperature is greater than 94°C after the fan is switched off, the fan will continue to operate for
0.5 minute.
• If the water temperature is less than 85°C after the fan is switched off, the fan will stop operating.
Removal & Installation
WARNING!
Always allow the engine to cool before opening the cooling system. Do not remove 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.
1. Disconnect the negative battery cable.
2. Drain the cooling system (See Cooling System Draining Procedure in Section 06 Cooling System).
3. Disconnect the upper radiator hose from the radiator.
4. Disconnect the cooling fan electrical connector and the cooling fan ground cable connected to the body.
5. Remove the cooling fan mounting bolts (1) to the
radiator.
(Tighten: Cooling fan mounting bolts to 5 N·m)
6. Remove the radiator fan from the engine compartment.
7. Remove the cooling fan from its support, if necessary.
8. Installation is in the reverse order of removal.
Installation Notes:
• Verify the cooling system is filled to proper specifications.
Cooling Fan Inspection
1. Using the following table, apply battery voltage to the specified connector terminals.
2. Verify that the fan motor operates smoothly when voltage is applied.
3. If the test results are not as specified, replace the fan motor.
ON-VEHICLE SERVICE
LTSM060008
06
06–19Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine With 1.6L & 1.8L & 2.0L Engine
MEASURING CONDITION OPERATIONINSPECTION DIAGRAM
Battery positive (+) to
terminal – 1
Battery negative (-) to
terminal – 2 Turns smoothly
Battery positive (+) to
terminal – 1
Battery negative (-) to
terminal – 2Turns smoothly
ON-VEHICLE SERVICE
06–20Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine With 2.4L Engine
MEASURING CONDITION OPERATIONINSPECTION DIAGRAM
Battery positive (+) to
terminal – 4
Battery negative (-) to
terminal – 5 Turns smoothly
Battery positive (+) to
terminal – 6
Battery negative (-) to
terminal – 7Turns smoothly
ON-VEHICLE SERVICE
06
06–21Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine EXHAUST
07
CONTENTSpage
Exhaust System ...................................................................... 07-1
EXHAUST SYSTEM
GENERAL INFORMATION07-2
Description 07-2
Operation 07-3
Specifications 07-3
DIAGNOSIS AND TESTING07-4
Exhaust System Diagnostic Chart 07-4
ON-VEHICLE SERVICE07-5
Exhaust Pipe Assembly 07-5
Removal & Installation - 1.6L & 1.8L &
2.0L 07-5 Removal & Installation - 2.4L 07-5
Muffler 07-6
Removal & Installation 07-6
Catalytic Converter 07-6
Description 07-6
Operation 07-6
Removal & Installation 07-7
07
07–1Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION
Description
The exhaust system provides an exit for exhaust gases and reduces engine noise by moving exhaust gases through
the three-way catalytic converter, a muffler inlet pipe and a muffler. Rubber exhaust hanger insulators attach the
exhaust system to the mounting hooks.
The exhaust system contains the following components:
•Catalytic converter assembly
• Muffler assembly
• Exhaust brackets with isolators bolted to the body
• Heated oxygen sensors mounted to the exhaust pipes
• Tailpipe assembly
1.6L & 1.8L & 2.0L Exhaust System
2.4L Exhaust System
LTSM070003
LTSM070004
07–2Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine WARNING!
Exhaust gases contain carbon monoxide which can be harmful to your health and are potentially lethal. Exhaust
system leaks should be repaired immediately. Never operate the engine in enclosed areas. Failure to follow
these instructions may result in personal injury or death.
Operation
In order to reduce vehicle emissions released by the engine, the catalytic converter is required to perform in all oper-
ating conditions. This reduction is especially beneficial during the cold start and warm up phases of operation, which
is when a majority of the tailpipe emissions occur on today’s vehicles because the catalytic converter has not yet
reached its operating temperature. The exhaust system channels exhaust gases from the engine and away from the
vehicle.
Specifications
Torque Specifications
DESCRIPTIONTORQUE (N·m)
Catalytic Converter Mounting Nuts 50
Exhaust Manifold Flange Bolts 49 ± 5
Muffler Mounting Nuts 50
GENERAL INFORMATION
07
07–3Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine DIAGNOSIS AND TESTING
Exhaust System Diagnostic Chart
CONDITIONPOSSIBLE CAUSES CORRECTION
Excessive Exhaust Noise · Leaks at pipe joints.
· Burned or blown out muffler.
· Burned or rusted-out exhaust pipe.
· Exhaust pipe leaking at manifold
flange.
· Exhaust manifold cracked or
broken.
· Leak between exhaust manifold
and cylinder head.
· Restriction in muffler or tailpipe.
· Exhaust system contacting body or
chassis.· Tighten clamps to specified torque
at leaking joints.
· Replace muffler assembly.
· Replace exhaust pipe.
· Tighten connection attaching nuts.
· Replace exhaust manifold.
· Tighten exhaust manifold to
cylinder head stud nuts or bolts.
· Remove restriction, if possible.
Replace muffler or tailpipe, as
necessary.
· Re-align exhaust system to clear
surrounding components.
Leaking Exhaust Gases · Leaks at pipe joints.· Tighten/replace clamps at leaking
joints.
Excessive Exhaust Temperature · Ignition timing incorrect.
· Poor fuel quality.
· Engine running rich.· Adjust the timing.
· Change and clean the fuel tank.
· Repair as needed.
07–4Chery Automobile Co., Ltd.