CHERY TIGGO 2009 Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine Rear Crankshaft Oil Seal GuideCH-20006
Front Crankshaft Seal InstallerCH-20007
Front Crankshaft Seal GuideCH-20008
Camshaft HolderCH-20010
Valve Seal Installer CH-20011
GENERAL INFORMATION
02–82Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Valve Stem Seal Installer GuideCH-20012
Valve Seal RemoverCH-20013
Valve Keeper Installer CH-20017
Valve Spring Compressor CH-20018
Crankshaft Belt Pulley Fixture CH-20019
GENERAL INFORMATION
02
02–83Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Engine Hoist
Flywheel FixtureCH-20043
Oil Filter Remover CH-10003
Lubrication System
The engine lubrication system operates as follows:
•Oil is drawn into the oil pump through the oil pump strainer tube in the sump of the oil pan.
• Oil is pumped through the oil filter on the cylinder block.
• Oil enters the main oil gallery where it is distributed to the crankshaft main journals and to the cylinder head.
• From the main journals, the oil is routed through cross-drilled passages in the crankshaft to lubricate the con-
necting rod bearings. Controlled leakage through the crankshaft main bearings and connecting rod bearings is
slung radially outward to cool and lubricate the cylinder walls as well as the entire connecting rod, piston and
piston ring assembly.
• The engine lubrication system is a full-flow filtration, pressure feed type. The oil pump body is mounted to the
engine block. The pump inner rotor is driven by the crankshaft.
Engine Oil Pressure Specifications
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
GENERAL INFORMATION
02–84Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Engine Lubrication System Exploded View
1 - Oil Dipstick
2 - Oil Dipstick Bolt
3 - Oil Dipstick Bracket
4 - Oil Dipstick Guide
5 - Crankshaft Rear Oil Seal
6 - O-Ring
7 - Oil Filter Bracket Gasket
8 - Oil Filter Bracket
9 - Pressure-Relief Plunger
10 - Flange Bolt
11 - Flange Bolt
12 - Oil Cooler
13 - Oil Filter Connector
14 - Oil Filter
15 - Dowel Pin16 - Oil Pan Bolt
17 - Oil Pan Bolt
18 - Oil Pan Bolt
19 - Oil Pan
20 - O-Ring
21 - O-Ring
22 - Oil Pump Strainer Bolt
23 - Oil Pump Strainer
24 - Baffle Plate
25 - O-Ring
26 - O-Ring
27 - Crankshaft Front Oil Seal
28 - Oil Pump Bolt
29 - Oil Pump Assembly
30 - Oil Pump Assembly Gasket
GENERAL INFORMATION
LTSM020161
02
02–85Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Engine Oil Flow Diagram
1 - Oil Pump Strainer
2 - Baffle Plate
3 - Oil Pan
4 - Oil Pump
5 - Turbocharger Inlet Oil Passage (if equipped)
6 - To Cylinder Head
7 - Oil Return Passage
8 - To Front Bearing Cap9 - To Middle Bearing Cap
10 - Oil Dipstick
11 - To Crankcase
12 - Crankcase Pipe
13 - Oil Filter Bracket
14 - Oil Pressure Switch
15 - Oil Cooler
16 - Oil Filter
GENERAL INFORMATION
BESM020088
02–86Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine DIAGNOSIS & TESTING
Engine Performance Diagnostics
CONDITIONPOSSIBLE CAUSE 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
02–87Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine CONDITIONPOSSIBLE CAUSE CORRECTION
Engine Miss On Acceleration 1. Dirty or incorrectly gapped spark
plugs.
2. Contamination in fuel system.
7. Burned, warped, excessive
clearance, or pitted valves.
4. Faulty ignition coil(s).1. Clean spark plugs and set gap.
2. Clean fuel system and replace
fuel filter.
3. Replace valves.
4. Test and replace if necessary.
(Refer to Appropriate Diagnostic
Information)
Engine Miss At High Speed 1. Dirty or incorrect spark plug gap.
2. Faulty ignition coil(s).
3. Dirty fuel injector(s).
4. Contamination in fuel system.1. Clean spark plugs and set gap.
2. Test and replace if necessary.
(Refer to Appropriate Diagnostic
Information)
3. Test and replace if necessary.
(Refer to Appropriate Diagnostic
Information)
4. Clean system and replace fuel
filter.
Engine Mechanical Diagnostics
CONDITION
POSSIBLE CAUSE CORRECTION
Valve Train Noise 1. High or low oil level in crankcase.
2. Thin or diluted oil.
3. Thick oil.
4. Low oil pressure.
5. Worn cam lobe.
6. Worn valve guides.
7. Excessive runout of valve seats
on valve faces.1. Check and correct engine oil
level.
2. Change oil to correct viscosity.
3. Change engine oil and filter.
4. Check and correct engine oil
level.
5. Install new camshaft.
6. Replace cylinder head.
7. Grind valve seats and replace
valves.
Connecting Rod Noise 1. Insufficient oil supply.
2. Low oil pressure.
3. Thin or diluted oil.
4. Excessive bearing clearance.
5. Connecting rod journal out-of-
round.
6. Connecting rod out-of-round.
7. Misaligned connecting rods.
8. Connecting rod nuts loose.1. Check engine oil level.
2. Check engine oil level. Inspect oil
pump relief valve and spring.
3. Change oil to correct viscosity.
4. Measure bearings for correct
clearance. Repair if necessary.
5. Replace crankshaft or grind
surface.
6. Replace connecting rod.
7. Replace bent connecting rods.
8. Tighten the connecting rod nuts.
Main Bearing Noise 1. Insufficient oil supply.
2. Low oil pressure.
3. Thin or diluted oil.
4. Excessive bearing clearance.
5. Excessive end play.
6. Crankshaft journal out-of-round or
worn.
7. Loose flywheel or torque
converter.1. Check engine oil level.
2. Check engine oil level. Inspect oil
pump.
3. Change oil to correct viscosity.
4. Measure bearings for correct
clearance. Repair if necessary.
5. Check thrust bearing for wear on
flanges.
6. Replace crankshaft or grind
journals.
7. Tighten to correct torque.
DIAGNOSIS & TESTING
02–88Chery 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 Cylinder Compression Pressure Test
•The result of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions.
• 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 necessary.
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 1000 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.
Cylinder Head Gasket Test
• A cylinder head gasket leak can be located between adjacent cylinders, between a cylinder and the adjacent
water jacket or from an oil passage to the exterior of the engine.
• Possible indications of the cylinder head gasket leaking between adjacent cylinders are:
Loss of engine power
Engine misfiring
Poor fuel economy
• Possible indications of the cylinder head gasket leaking between a cylinder and an adjacent water jacket are:
Engine overheating
Loss of coolant
Excessive steam (white smoke) emitting from exhaust
Coolant foaming
DIAGNOSIS & TESTING
02–90Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine ON-VEHICLE SERVICE
Accessory Drive Belt
Removal & Installation
WARNING!
Inspect the drive belt only when the engine is stopped.
1. While using a suitable tool and securely holding the hexagonal portion of the drive belt tensioner, rotate thepulley counterclockwise to loosen the drive belt.
WARNING!
Avoid placing hands near the drive belt tensioner while it is being held.
1 - Drive Belt
2 - Generator Bolt
3 - Tensioner Pulley Bolt
4 - Tensioner
5 - Compressor
6 - Generator
7 - Idler Pulley
8 - Generator Bracket
9 - Generator Bracket Bolt10 - Generator Bracket Bolt
11 - Power Steering Pump Bolt
12 - Power Steering Pump Bolt
13 - Power Steering Pump Bolt
14 - Power Steering Pump Bracket
15 - Power Steering Pump Bracket Bolt
16 - Power Steering Pump
17 - Idler Pulley
18 - Compressor Bolt
LTSM020163
02
02–91Chery Automobile Co., Ltd.