width CHERY TIGGO 2009 Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine CONDITIONPOSSIBLE CAUSE CORRECTION
Oil Pressure Drop 1. Low oil level.
2. Faulty oil pressure sending unit.
3. Low oil pressure.
4. Clogged oil filter.
5. Thin or diluted oil.
6. Excessive bearing clearance.1. Check engine oil level.
2. Install new sending unit.
3. Check sending unit and main
bearing oil clearance.
4. Install new oil filter.
5. Change oil to correct viscosity.
6. Measure bearings for correct
clearance.
Oil Leaks 1. Misaligned or deteriorated
gaskets.
2. Loose fastener, broken or porous
metal part.
3. Misaligned or deteriorated cup or
threaded plug.1. Replace gasket.
2. Tighten, repair or replace the part.
3. Replace if necessary.
Oil Consumption Or Spark Plugs
Fouled 1. PCV system malfunction.
2. Worn, scuffed or broken rings.
3. Carbon in oil ring slots.
4. Rings fitted too tightly in grooves.
5. Worn valve guide(s).
6. Valve stem seal(s) worn or
damaged.1. Check system and repair if
necessary.
2. Hone cylinder bores. Install new
rings.
3. Install new rings.
4. Remove rings and check grooves.
If groove is not proper width, replace
piston.
5. Replace cylinder head.
6. Replace seal(s).
DIAGNOSIS & TESTING
02
02–15Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Inspection
•The crankshaft main journals should be checked for
excessive wear, roundness and scoring. Limits of
roundness on any crankshaft main journals should
be held to 0.008 mm. Limits of roundness on any
crankshaft rod journals should be held to 0.005
mm. DO NOT nick crank pin or bearing fillets. Lim-
its of out of round on any crankshaft journals
should be held to 0.005 mm.
• Check the axial clearance after installation. Stan-
dard of axial clearance should be 0.07 mm. Limits
of axial clearance should be held to 0.265 mm.
• Clean the journal and bearing.
• Install the crankshaft.
• Cut the plastic-gauge to the same width as the
bearing, and then put it onto the crankshaft journal
to make it parallel with the central line of the crank-
shaft.
• Install the main bearing cap carefully, and tighten
the bolts to the specified torque.
• Remove the main bearing cap.
• Measure the oil clearance with the plastic-gauge.
Standard oil clearance of crankshaft rod and
main journals should be 0.022 mm
Limits of oil clearance of crankshaft rod and main journals should be 0.058 mm
Standard oil clearance of crankshaft main journal
should be 0.022 mm. Limits of oil clearance of crank-
shaft main journal should be 0.058 mm.
ENGINE UNIT REPAIR
BESM020075
BESM020076
BESM020077
02
02–61Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine CONDITIONPOSSIBLE CAUSE CORRECTION
Oil Pressure Drop 1. Low oil level.
2. Faulty oil pressure sending unit.
3. Low oil pressure.
4. Clogged oil filter.
5. Thin or diluted oil.
6. Excessive bearing clearance.1. Check engine oil level.
2. Install new sending unit.
3. Check sending unit and main
bearing oil clearance.
4. Install new oil filter.
5. Change oil to correct viscosity.
6. Measure bearings for correct
clearance.
Oil Leaks 1. Misaligned or deteriorated
gaskets.
2. Loose fastener, broken or porous
metal part.
3. Misaligned or deteriorated cup or
threaded plug.1. Replace gasket.
2. Tighten, repair or replace the part.
3. Replace if necessary.
Oil Consumption Or Spark Plugs
Fouled 1. PCV system malfunction.
2. Worn, scuffed or broken rings.
3. Carbon in oil ring slots.
4. Rings fitted too tightly in grooves.
5. Worn valve guide(s).
6. Valve stem seal(s) worn or
damaged.1. Check system and repair if
necessary.
2. Hone cylinder bores. Install new
rings.
3. Install new rings.
4. Remove rings and check grooves.
If groove is not proper width, replace
piston.
5. Replace cylinder head.
6. Replace seal(s).
DIAGNOSIS & TESTING
02
02–89Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Inspection
•The crankshaft main journals should be checked for
excessive wear, roundness and scoring. Limits of
roundness on any crankshaft main journals should
be held to 0.008 mm. Limits of roundness on any
crankshaft rod journals should be held to 0.005
mm. DO NOT nick crank pin or bearing fillets. Lim-
its of out of round on any crankshaft journals
should be held to 0.005 mm.
• Check the axial clearance after installation. Stan-
dard of axial clearance should be 0.07 mm. Limits
of axial clearance should be held to 0.265 mm.
• Oil Clearance of crankshaft main journal
Clean the journal and bearing.
Install the crankshaft.
Cut the plastic-gauge to the same width as
the bearing, and then put it onto the crank-
shaft journal to make it parallel with the cen-
tral line of the crankshaft.
Install the main bearing cap carefully, and tighten the bolts to the specified torque.
Remove the main bearing cap.
Measure the oil clearance with the plastic- gauge.
Standard oil clearance of crankshaft main journal
should be 0.022 mm. Limits of oil clearance of crank-
shaft main journal should be 0.058 mm.
ENGINE UNIT REPAIR
BESM020075
BESM020076
BESM020077
02
02–134Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine CONDITIONPOSSIBLE CAUSES CORRECTION
Oil Pressure Drop 1. Low oil level.
2. Faulty oil pressure sending unit.
3. Low oil pressure.
4. Clogged oil filter.
5. Thin or diluted oil.
6. Excessive bearing clearance.1. Check engine oil level.
2. Install new sending unit.
3. Check sending unit and main
bearing oil clearance.
4. Install new oil filter.
5. Change oil to correct viscosity.
6. Measure bearings for correct
clearance.
Oil Leaks 1. Misaligned or deteriorated
gaskets.
2. Loose fastener, broken or porous
metal part.
3. Misaligned or deteriorated cup or
threaded plug.1. Replace gasket.
2. Tighten, repair or replace the part.
3. Replace if necessary.
Oil Consumption Or Spark Plugs
Fouled 1. PCV system malfunction.
2. Worn, scuffed or broken rings.
3. Carbon in oil ring slots.
4. Rings fitted too tightly in grooves.
5. Worn valve guide(s).
6. Valve stem seal(s) worn or
damaged.1. Check system and repair if
necessary.
2. Hone cylinder bores. Install new
rings.
3. Install new rings.
4. Remove rings and check grooves.
If groove is not proper width, replace
piston.
5. Replace cylinder head.
6. Replace seal(s).
Cylinder Compression Pressure Test
•
The result of a cylinder compression pressure test
can be utilized to diagnose several engine malfunc-
tions.
• Ensure the battery is completely charged and the
engine starter motor is in good operating condition.
Otherwise the indicated compression pressures
may not be valid for diagnostic purposes.
Check engine oil level and add oil if neces-
sary.
Disconnect the spark plug wires.
Remove all spark plugs from engine (as spark plugs are being removed, check electrodes for
abnormal firing indicators fouled, hot, oily,
etc.).
Record cylinder number of each spark plug for future reference.
Disconnect fuel injector electrical connectors.
Be sure throttle blade is fully open during the compression check.
Insert compression pressure adaptor or the equivalent into each spark plug hole in cylinder head.
Crank engine until maximum pressure is reached on gauge. Record each cylinder pressure.
Compression should not be less than 880 kPa and not vary more than 25 percent from cylinder to cylinder.
If one or more cylinders have abnormally low compression pressures, repeat the compression test.
If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem with the cylinder in question.
NOTE :
The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine
should not be disassembled to determine the cause of low compression unless some malfunction is present.
DIAGNOSIS & TESTING
LTSM020191
02
02–165Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine •Check the inner diameter of connecting rod (small end).
PISTON PIN CLEARANCE
Piston and Piston Pin 0.002 - 0.013 mm
Assembly
Piston Pin Installation
•Measure the following dimensions of each piston
(1), piston pin (2) and connecting rod (3).
Length of piston pin in hole (A).
Width of pin sockets (B).
Length of piston pin (C).
Width of small end of connecting rod (D).
• Put measured sizes above into following formula to
calculate L.
L=[(A-C)-(B-D)] / 2
• After inserting the push rod of the special tool into piston pin, install pipe A in the top of the push rod.
• Install forward marks of piston and connecting rod in the same direction.
• Lubricate the external diameter of piston pin with engine oil.
• Through pipe A, insert the push rod, piston pin and pipe component into piston pin hole from the side with the
forward mark.
• Screw on guide block B into guide pipe A to gain clearance between guide block A (2) and guide block B (1)
equal to the value of Value L (L=[(A-C)-(B-D)] / 2)
plus 3 mm.
• Keep the forward mark of piston upward. Install piston and connecting rod in tool base of piston pin installer.
ENGINE UNIT REPAIR
BESM020054
LTSM020111
LTSM020112
02–226Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 3. Using a hammer handle or similar tool, push thepiston and connecting rod assembly (1) out
through the cylinder head side of the engine block.
NOTE: Before removing the piston and connecting
rod assembly, check the connecting rod side
clearance.
4. Remove the connecting rod bearings. CAUTION: When removing the connecting rod
side bearings, note the installation position.
Keep them in the correct order.
Inspection
Bearing Radial Clearance
•Check the radial clearance of connecting rod bearing.
CONNECTING ROD RADIAL CLEARANCE
Radial Clearance 0.016 - 0.051 mm
Bearing Oil Clearance (Plastigauge)
•Check the oil clearance of the connecting rods and crankshaft.
Clean all engine oil off of the connecting rod bearing and the crankshaft journal.
Cut the plastigauge into lengths as wide as the crankshaft journal.
Lay the plastigauge across the crankshaft
journal.
Carefully install the connecting rod cap.
Torque the connecting rod cap nuts to 20 N·m
Carefully disassemble the connecting rod cap.
Use the measuring rule imprinted on the plas- tigauge package to measure the width of the
widest part of the plastigauge.
ENGINE UNIT REPAIR
BESM020044
BESM020045
LTSM020122
02–230Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Inspection
Crankshaft Axial Clearance
•Check the axial clearance of the crankshaft.
CRANKSHAFT AXIAL CLEARANCE
DESCRIPTION SPECIFICATION MAXIMUM LIMIT
Crankshaft 0.05 - 0.18 mm 0.25 mm
Crankshaft Bearing Oil Clearance (Plastigauge)
•Check the oil clearance of the crankshaft.
Clean all engine oil off of the crankshaft jour-
nals.
Cut the plastigauge into lengths as wide as the crankshaft journal.
Lay the plastigauge across the crankshaft journal.
Carefully install the main bearing cap.
Torque the main bearing cap to the specified torque.
Carefully disassemble the main bearing cap.
Use the measuring rule imprinted on the plas- tigauge package to measure the width of the
widest part of the plastigauge.
ENGINE UNIT REPAIR
BESM020076
BESM020077
02–236Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine •Install the new valve guide from the top of the cylinder head as shown in the illustration.
Intake valve guide length: 45.5 mm
Exhaust valve guide length: 50.5 mm
CAUTION:
The intake and exhaust valves are different
lengths, use care when replacing the valve
guides to install the correct valve guide.
•Install the valve guide to the specified height (1) of
14 mm.
• After installing the valve guide, insert the new valve and check for smooth movement.
Valve Seats
•Before machining the valve seat, check the clear-
ance between the valve guide and the valve stem.
If the clearance is excessive, repair the valve and
valve guide if necessary before machining the valve
seat.
• Repair the width and angle of the valve seat until
the valve seat meets specified values.
• After repairing the valve seat, use valve lapping
compound to lap the valves and seats in pairs.
Valve Seat Replacement
•Cut out a portion of the original valve seat and
remove the valve seat from the cylinder head.
• Select the replacement valve seat according to the
outer diameter of the enlarged valve seat.
REPLACEMENT VALVE SEAT SIZES
Intake valve seat Enlargement size 0.30 mm
34.435 - 34.455 mm
Enlargement size 0.60 mm 34.735 - 34.755 mm
Exhaust valve seat Enlargement size 0.30 mm
31.935 - 31.955 mm
Enlargement size 0.60 mm 32.235 - 32.255 mm
CYLINDER HEAD UNIT REPAIR
LTSM020106
LTSM020103
LTSM020104
02
02–251Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Upstream Oxygen Sensor
The input from the upstream heated oxygen sensor tells the Engine Control Module (ECM) the oxygen content of the
exhaust gas. Based on this input, the ECM fine tunes the air-fuel ratio by adjusting injector pulse width.
Downstream Oxygen Sensor
The downstream heated oxygen sensor signal is used to detect catalytic convertor deterioration. As the convertor
deteriorates, the signal from the downstream sensor begins to match the upstream sensor signal except for a slight
time delay. By comparing the downstream heated oxygen sensor signal to the signal from the upstream sensor, the
ECM calculates catalytic convertor efficiency. This calculation is also used to establish the upstream O2 goal voltage
(switching point).
Removal & Installation - Upstream Oxygen Sensor
1. Disconnect the negative battery cable.
2. Disconnect the oxygen sensor electrical connector.
CAUTION:
Remove the oxygen sensor after the exhaust pipe has cooled.
3. Remove the upstream oxygen sensor (1).(Tighten: Upstream oxygen sensor to 45 N·m)
4. Installation is in the reverse order of removal.
Installation Notes:
• Before installing the oxygen sensor, coat the threads with rust inhibiting lubricant.
Removal & Installation - Downstream Oxygen Sensor
1. Disconnect the negative battery cable.
2. Disconnect the oxygen sensor electrical connector.
CAUTION:
Remove the oxygen sensor after the exhaust pipe has cooled.
3. Remove the downstream oxygen sensor (2).
(Tighten: Downstream oxygen sensor to 45 N·m)
ON-VEHICLE SERVICE
BESM030017
BESM030017
03
03–219Chery Automobile Co., Ltd.