service CHERY TIGGO 2009 Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine 4. Remove the engine right mount bolts (2) and theengine right mount bracket bolts (1).
(Tighten: Engine right mount bolts to 70 N·m)
5. Remove the accessory drive belts (See Accessory Drive Belt Removal & Installation in Section 02
Engine).
6. Remove the crankshaft vibration damper bolts (1). (Tighten: Crankshaft vibration damper bolts to
25 N·m)
7. Remove the timing belt upper cover. (Tighten: Timing belt upper cover bolts to 11 N·m)
8. Remove the timing belt lower cover. (Tighten: Timing belt lower cover bolts to 11 N·m)
9. Loosen the timing belt tensioning pulley bolt.
10. Remove the timing belt. NOTE: Remember the rotation direction of the timing belt in order to avoid any error when reassembling.
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Downloaded from www.Manualslib.com manuals search engine 11. Installation is in the reverse order of removal.
Installation Notes:
•Rotate the camshaft pulley and align the timing
marks (1) with the cylinder head cover.
• Rotate the crankshaft pulley and align the timing
marks (1) with the front cover.
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Downloaded from www.Manualslib.com manuals search engine •Rotate the lower balance shaft pulley and align the
timing marks (1) with the front cover.
• Remove the plug from the cylinder block and then
insert a holder (1) (8 mm diameter) into the hole.
NOTE :
If the holder can be inserted more than 60 mm, then the timing marks are aligned. If the holder could not be inserted
more than 20-25 mm, the lower balance shaft pulley should be rotated one revolution and the timing marks should
be then be aligned. Keep the holder installed until the installation of the timing belt is complete.
• Make sure all timing marks are aligned properly.
• Install the timing belt.
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Downloaded from www.Manualslib.com manuals search engine •Using special tool MD-998767 (1) and a torque
wrench, adjust the timing belt tensioner.
• Measure distance “A” between the tensioner arm
and the automatic tensioner.
Standard distance is 3.84 mm
Inspection
1. Inspect the timing belt back rubber for signs ofaging and glistening.
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Downloaded from www.Manualslib.com manuals search engine 2. Inspect the timing belt for the following:•Cracks in the back rubber (1).
• Cracks and stripping in the canvas (2).
• Cracks in the grooves (3).
• Cracks in the side of the belt (4).
3. Inspect the timing belt (1) for abnormal abrasion in the side of the belt (2).
4. Inspect the timing belt for abnormal abrasion (2) or teeth missing (1) from the belt.
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Downloaded from www.Manualslib.com manuals search engine Timing Belt Automatic Tensioner
Removal & Installation
NOTE :
The following special tools are required to perform the repair procedure:
•MD-998767 - Automatic Tensioner Socket
1. Remove the engine timing belt (See Engine Timing Belt Removal & Installation in Section 02 Engine).
2. Remove the timing belt automatic tensioner bolts (1).
(Tighten: Timing belt automatic tensioner bolts to
24 N·m)
3. Installation is in the reverse order of removal.
Installation Notes:
• Perform the following to prepare the automatic tensioner for installation:
Slowly close the vise jaws until the rod hole
(1) and housing hole (2) are aligned.
Insert a steel wire (1.4 mm diameter) into the aligned hole.
Remove the automatic tensioner from the vise.
• The automatic tensioner is now ready to be installed on the engine.
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Downloaded from www.Manualslib.com manuals search engine Inspection
1. Inspect the automatic tensioner for any leaks. Replace the tensioner if any leaks are found.
2. Inspect the automatic tensioner for signs of abra-sion at the end of the rod. Replace the tensioner if
any abrasions are found.
3. Inspect the length of the rod. If the rod length does not comply with the standard length, replace the
tensioner (standard rod length is 12 mm).
4. Using a calibrated force, press the end of the rod using 98 - 196 N·m and measure the rod displace-
ment. If the rod displacement is 1 mm larger than
the standard, replace the tensioner (standard mea-
surement is ≤1 mm).
5. Assemble the automatic tensioner with a soft jawed vise (1).
CAUTION: Use an appropriate pad (3) to protect
the tensioner bolt (2) from the jaws of the vise.
6. Rotate the handle of the vise to push the rod of the automatic tensioner into the tensioner. If the rod is
easy to push in, replace the automatic tensioner.
The rod should have some resistance when you
push the rod into the tensioner.
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Downloaded from www.Manualslib.com manuals search engine Upper Balance Shaft Timing Belt
Removal & Installation
NOTE :
The following special tools are required to perform the repair procedure:
•MD-998778 - Crankshaft Pulley Puller
• MD-998781 - Flywheel Holder
• MD-998785 - Upper Balance Shaft Pulley Holder
1. Remove the engine timing belt (See Engine Timing Belt Removal & Installation in Section 02 Engine).
2. Using special tool MD-998781 (1), attach the tool to the flywheel.
3. Remove the crankshaft pulley bolt. (Tighten: Crankshaft pulley bolt to 120 N·m)
4. Using special tool MD-998778 (1), remove the crankshaft pulley.
5. Remove the upper balance shaft timing belt. NOTE: Remember the rotation direction of the timing belt in order to avoid any error when reassembling.
6. Installation is in the reverse order of removal.
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Downloaded from www.Manualslib.com manuals search engine Installation Notes:
•Align the timing marks on the crankshaft pulley (2) and the upper balance shaft pulley with the timing marks on
the front engine cover (1).
• Make sure all timing marks are aligned properly.
• Install the timing belt.
• Make sure that the belt tensioner position is as
shown (3 & 4).
• While applying finger pressure to the belt tensioner in the direction of the arrow, tighten the tensioner bolt to 35
N·m.
CAUTION:
Do not allow the belt tensioner to move while tightening the bolt, if the tensioner moves it could
cause the belt to be overtightened.
•Ensure that the timing marks (1) have not moved, and are still in alignment.
• Press the center of the timing belt with an index
finger and measure the belt deflection (standard
deflection is 5-7 mm).
• If the belt deflection is not within specifications,
adjust if necessary.
• Reinstall the engine timing belt (See Engine Timing Belt Removal & Installation in Section 02 Engine).
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Downloaded from www.Manualslib.com manuals search engine Exhaust Manifold
Removal & Installation
1. Remove the bolts attaching the exhaust manifold heat shield.(Tighten: Exhaust manifold heat shield bolts to 14 N·m)
2. Remove the exhaust manifold heat shield.
3. Remove the three bolts securing the exhaust manifold to the catalytic converter assembly. (Tighten: Exhaust manifold to catalytic converter bolts to 49 ± 5 N·m)
4. Disconnect the catalytic converter assembly from the manifold.
5. Remove the exhaust manifold nuts. (Tighten: Exhaust manifold nuts to 29 ± 3 N·m)
6. Remove the exhaust manifold from the cylinder head.
7. Remove and discard exhaust manifold gasket.
1 - Exhaust Manifold Heat Shield
2 - Engine Hanger
3 - Oxygen Sensor4 - Exhaust Manifold
5 - Exhaust Manifold Gasket
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