CHERY TIGGO 2009 Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine ITEMSPECIFICATION (mm)
Valve Outer Diameter Intake Valve
5.98 ± 0.008
Exhaust Valve 5.96 ± 0.008
Valve Guide Inner Diameter Intake Valve
5.4 ± 0.1
Exhaust Valve 5.4 ± 0.1
Fringe Thickness On Top Of Valve Intake Valve
0.3 ± 0.15
Exhaust Valve 0.3 ± 0.15
Valve Tilt Angle Intake Valve
65°
Exhaust Valve 68°
Valve Height Intake Valve
107.998
Exhaust Valve 106.318
• Measure valve deflection.
VALVE DEFLECTION LIMIT (DIAL GAUGE READING)
Intake 0.02 mm
Exhaust 0.04 mm
• If it exceeds the limit, check valve to valve guide clearance.
Measure valve stem diameter and valve guide inner diameter.
Check that clearance is within specification.
If it exceeds the limit, replace valve or valve
guide.
VALVE TO VALVE GUIDE CLEARANCE STANDARD
Intake 0.012 - 0.043 mm
Exhaust 0.032 - 0.063 mm
Assembly
1. Install the valves into the cylinder head (larger diameter on intake side).
2. Install the valve springs.
3. Install the valve spring retainers.
CYLINDER HEAD UNIT REPAIR
BESM020073
02–72Chery Automobile Co., Ltd.

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
02–73Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 2. Remove the valve keeper (1), valve spring retainer(2).
3. Remove the valve springs (3) from the cylinder head.
Inspection
•Whenever valves have been removed for inspection, reconditioning or replacement, valve springs should be
tested for correct load.
• Discard the springs that do not meet specifications.
• The following specifications apply to both intake
and exhaust valve springs.
VALVE SPRING LENGTH/HEIGHT
Spring Free Length 47.7 mm
Spring Height At 620 Newtons Of Pressure 32.0 mm
If it is not within specifications, replace the valve spring.
CYLINDER HEAD UNIT REPAIR
VISM080040
BESM020072
02–74Chery 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 valve spring compressor CH-20018 (1), 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
BESM020067
02
02–75Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 2.0L ENGINE MECHANICAL
GENERAL INFORMATION02-77
Description 02-77
Operation 02-77
Specifications 02-77
Special Tools 02-81
Lubrication System 02-84
DIAGNOSIS & TESTING02-87
Engine Performance Diagnostics 02-87
Engine Mechanical Diagnostics 02-88
Cylinder Compression Pressure Test 02-90
Cylinder Head Gasket Test 02-90
ON-VEHICLE SERVICE02-91
Accessory Drive Belt 02-91
Removal & Installation 02-91
Air Cleaner Element 02-92
Removal & Installation 02-92
Air Cleaner Housing 02-93
Removal & Installation 02-93
Cylinder Head Cover 02-93
Removal & Installation 02-93
Camshaft 02-94
Removal & Installation 02-94
Cylinder Head 02-97
Removal & Installation 02-97
Front Crankshaft Oil Seal 02-99
Removal & Installation 02-99
Rear Crankshaft Oil Seal 02-100
Removal & Installation 02-100
Engine Mounts 02-103
Removal & Installation - Left Mount 02-103
Removal & Installation - Right Mount 02-104
Removal & Installation - Front Mount 02-104
Removal & Installation - Rear Mount 02-105
Engine Assembly 02-105
Removal & Installation 02-105
Engine Timing Belt 02-112
Removal & Installation 02-112
Exhaust Manifold 02-115
Removal & Installation 02-115
Intake Manifold 02-117
Removal & Installation 02-117
Idler Pulley 02-119
Removal & Installation 02-119
Oil Filter 02-119
Removal & Installation 02-119Oil Pan
02-120
Removal & Installation 02-120
Oil Pump 02-121
Removal & Installation 02-121
Oil Strainer 02-122
Removal & Installation 02-122
ENGINE UNIT REPAIR02-123
Engine Block 02-123
Specifications 02-123
Disassembly 02-123
Inspection 02-125
Assembly 02-125
Pistons 02-126
Specifications 02-126
Disassembly 02-127
Inspection 02-128
Assembly 02-130
Connecting Rods 02-131
Specifications 02-131
Disassembly 02-131
Inspection 02-132
Assembly 02-132
Crankshaft 02-133
Specifications 02-133
Disassembly 02-133
Inspection 02-134
Assembly 02-135
CYLINDER HEAD UNIT REPAIR02-136
Cylinder Head 02-136
Specifications 02-136
Disassembly 02-136
Inspection 02-138
Assembly 02-138
Camshaft 02-139
Specifications 02-139
Disassembly 02-140
Inspection 02-140
Assembly 02-142
Valve & Valve Guides 02-143
Specifications 02-143
Disassembly 02-143
Inspection 02-144
Assembly 02-145
Valve Springs 02-146
Specifications 02-146
Disassembly 02-146
Inspection 02-147
Assembly 02-148
02–76Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION
Description
The 2.0L in-line four cylinder engine has the following features:
•Dual overhead camshafts
• Four valves per cylinder
• Aluminum cylinder head
• Aluminum cylinder block
Operation
The 2.0L engine utilizes 4 valve-per-cylinders and a dual overhead camshaft design. The engine uses an individual
coil ignition system. The cylinder block is made of aluminum and the bearing caps are integrated into the lower cyl-
inder block assembly. An aluminum oil pan bolts to the bottom of the lower cylinder block. The camshafts are
mounted in the cylinder head and act against valve tappets to open and close the valves. The camshafts are driven
off the front of the cylinder head by one timing belt. The belt is driven by a sprocket that is located on the crankshaft.
The piston assembly is an aluminum piston with a cast iron connecting rod.
The aluminum cylinder head contains dual overhead camshafts with 4 valve-per-cylinder construction. The valves are
arranged in two in-line banks. The cylinder head incorporates powdered metal valve guides and seats. The cylinder
head is sealed to the block using a multi-layer steel head gasket and retaining bolts.
Specifications
2.0L Engine Specifications
DESCRIPTION SPECIFICATION
Type In-Line OHV, DOHC
Number of Cylinders 4
Compression Ratio 10:1
Compression Pressure 10 - 15 bar
Max. Compression Pressure Variation Between
Cylinders 25%
Stroke 90 mm
Bore 83.5 mm
Displacement 1971 cc
Firing Order 1-3-4-2
Mechanical Specifications
DESCRIPTIONITEMSTANDARD LIMIT
Engine Oil Pressure Lower Idle Speed (800 ±
50 RPM) 1.2 - 1.5 bar
-
High Idle Speed (2000 RPM) 3.2 - 3.5 bar
-
High Speed (4000 RPM) 3.7 ± 0.5 bar -
Engine Block Clearance Surface Distortion
-0.15 mm
Inner Diameter 83.500 - 83.510 mm -
Out-Of-Round -< 0.008 mm
Taper -< 0.01 mm
Piston Ring Groove
Clearance First Ring
0.04 - 0.08 mm -
Second Ring 0.0251 - 0.01 mm -
02
02–77Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine DESCRIPTIONITEMSTANDARD LIMIT
Piston Ring End Gap
Clearance First Ring
0.2 - 0.4 mm 0.8 mm
Second Ring 0.4 - 0.6 mm 1.0 mm
Piston To Piston Pin
Clearance -
0.002 - 0.013 mm -
Piston Diameter -83.451 - 83.469 mm -
Ring Groove Clearance First Ring
0.04 - 0.08 mm -
Second Ring 0.01 - 0.0251 mm -
Connecting Rod Radial
Clearance -
0.016 - 0.051 mm -
Connecting Rod Axial
Clearance -
0.002 - 0.013 mm -
Diameter Of Crankshaft
Main Journals -
53.981 - 54 mm -
Diameter Of Crankshaft
Rod Journals -
47.884 - 47.9 mm -
Out-Of-Round Maximum
Of Crankshaft Main
Journals -
-< 0.008 mm
Axial Clearance Of
Crankshaft -
0.07 - 0.265 mm -
Radial Clearance Of
Crankshaft -
0.0035 - 0.034 mm -
Coaxality Crankshaft Main
Journal -
-< 0.005 mm
Thrust Washer Thickness -2.4 - 2.405 mm -
Oil Clearance Of
Crankshaft Rod and Main
Journals -
0.022 mm 0.058 mm
Cylinder Head Flatness --< 0.04 mm
Intake Valve Deflection --< 0.02 mm
Exhaust Valve Deflection --< 0.04 mm
Spring Height -47.7 mm -
Spring Height At 620
Newtons Of Pressure -
32.0 mm -
Intake Cam Lobe Height -37.15 mm -
Exhaust Cam Lobe Height -37.05 mm -
Camshaft Journal #1 Outer
Diameter -
31.934 - 31.95 mm -
Camshaft Journal #2, #3,
#4, #5, Outer Diameter -
23.947 - 23.96 mm -
Camshaft Cam Bearing #1
Inner Diameter -
32 - 32.025 mm -
Camshaft Cam Bearing
#2, #3, #4, #5, Inner
Diameter -
24 - 24.021 mm -
Camshaft Journal #1
Clearance -
0.05 - 0.091 mm -
Camshaft Journal #2, #3,
#4, #5 Clearance -
0.04 - 0.074 mm -
GENERAL INFORMATION
02–78Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine DESCRIPTIONITEMSTANDARD LIMIT
Intake Camshaft Axial
Clearance -
0.15 - 0.20 mm -
Exhaust Camshaft Axial
Clearance -
0.15 - 0.20 mm -
Intake Valve Guide
Clearance -
0.012 - 0.043 mm -
Exhaust Valve Guide
Clearance -
0.032 - 0.063 mm -
Valve Outer Diameter Intake Valve
5.98 ± 0.008 mm -
Exhaust Valve 5.96 ± 0.008 mm -
Valve Guide Inner
Diameter Intake Valve
5.4 ± 0.1 mm -
Exhaust Valve 5.4 ± 0.1 mm -
Fringe Thickness On Top
Of Valve Intake Valve
0.3 ± 0.15 mm -
Exhaust Valve 0.3 ± 0.15 mm -
Valve Tilt Angle Intake Valve
65°-
Exhaust Valve 68°-
Valve Height Intake Valve
107.998 mm -
Exhaust Valve 106.318 mm -
Torque Specifications
CAUTION:
When torquing a fastener in two steps, DO NOT use a torque wrench for the second step.
DESCRIPTION TORQUE (N·m)
Accessory Drive Belt Tensioner Pulley Bolt 35
Camshaft Bearing Cap Bolts 11
Clutch Pressure Plate Bolts 25
Connecting Rod Cap Bolts 1st Step: Tighten the bolt to 25 N·m
2nd Step: Tighten the bolt an additional 90°
Crankshaft Holder 28
Crankshaft Main Bearing Cap Bolts 1st Step: Tighten the bolt to 45 N·m
2nd Step: Tighten the bolt an additional 180°
Crankshaft Timing Belt Pulley Bolt 1st Step: Tighten the bolt to 130 N·m
2nd Step: Tighten the bolt an additional 65°
Crankshaft Vibration Damper Bolts 25
Cylinder Head Cover Bolts 11
Cylinder Head Bolts 1st Step: Tighten the bolt to 40 ± 5 N·m
2nd Step: Tighten the bolt an additional 90 ± 5° 3rd Step: Tighten the bolt an additional 90 ± 5°
Dipstick Bracket Bolts 11
Drive Plate Bolts (automatic transaxle) 75
Engine Left Mount Bolt 70
Engine Right Mount Bolt 70
Engine Front Mount Bolt 60
Engine Rear Mount Bolt 60
GENERAL INFORMATION
02
02–79Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine DESCRIPTIONTORQUE (N·m)
Engine To Transaxle Bolts 80
Exhaust Manifold Nuts 25
Exhaust Manifold Heat Shield Bolts 15
Exhaust Camshaft Timing Belt Pulley Bolt 120
Flywheel Bolts (manual transaxle) 75
Fuel Rail Bracket Bolts 11
Idler Pulley Bolt 40
Intake Camshaft Timing Belt Pulley Bolt 120
Intake Manifold Bolts 10
Intake Manifold Nuts 11
Intake Manifold Bracket Bolts 25
Lower Idler Pulley Bolt 45
Lower Cylinder Block Bolts 23
Oil Filter 25
Oil Pan Bolts 18
Oil Drain Plug 40
Oil Strainer Bolts 18
Oil Pump Bolts 11
(Apply with Loctite 5910 Thread-Locker)
Rear Timing Cover Bolts 7
Timing Belt Upper Cover Bolts 11
Timing Belt Lower Cover Bolts 11
Timing Belt Tensioner Assembly 27
Timing Belt Tensioner Pulley Bolt 30
Throttle Body Bolts 11
Upper Idler Pulley Bolt 45
GENERAL INFORMATION
02–80Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Special Tools
Right Engine Mount Bolt RemoverCH-20001
Camshaft Seal InstallerCH-20002
Crankshaft HolderCH-20003
Valve Spring Compressor Adaptor CH-20004
Rear Crankshaft Oil Seal InstallerCH-20005
GENERAL INFORMATION
02
02–81Chery Automobile Co., Ltd.