fuel CHERY TIGGO 2009 Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine 4.CHECK FUEL LEVEL SENSOR CIRCUIT FOR OPEN OR SHORT
• Turn ignition switch off.
• Disconnect the IC connector.
• Check harness for a short to ground.
FUEL LEVEL SENSOR
TERMINAL GROUND
1
Ground
• Check for continuity between the following terminals:
FUEL LEVEL
SENSOR
TERMINAL IC TERMINAL CONTINUITY
12
1Yes
• Continuity should exist.
• Check the harness for a short to power.
Is the check result normal?
Ye s>>Go to the next step.
No
>>Repair or replace the fuel level sensor supply circuit as necessary.
5.CHECK FUEL LEVEL SENSOR GROUND CIRCUIT
• Using a 12 V test light connected to battery (+), probe fuel level sensor ground circuit.
Does the test light illuminate brightly?
Ye s>>Go to the next step.
No
>>Repair or replace the fuel level sensor ground circuit for an open.
DIAGNOSIS & TESTING
15–82Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 6.CHECK FUEL LEVEL SENSOR RESISTANCE
• Turn ignition switch off.
• Check fuel level sensor as follows:
FUEL GAUGE POINTER
POSITION TANK (LITERS)SENDER RESISTANCE
(OHM) POINTER TOLERANCE
EMPTY 5283 ±3 °
RESERVE 11189 ±3 °
1/4 16.5 137±3 °
1/2 2889±3 °
3/4 39.5 62±3 °
FULL 5140±3 °
Is the check result normal?
Ye s>>Go to the next step.
No
>>Replace the fuel level sensor.
7.CHECK DTC
• With the X-431 scan tool, read IC DTCs.
• Refer to DTC Confirmation Procedure.
Is the DTC U0303 still present?
Ye s>>Replace the IC.
No
>>The system is now operating properly.
Reassemble the vehicle and verify the customers complaint is repaired.
DIAGNOSIS & TESTING
15
15–83Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine BODY EXTERIOR
BODY DIMENSIONS15-147
Description 15-147
Front Body Structure 15-148
Dimension of Engine Compartment
(Units: mm) 15-148
Front Structure 15-151
Dimension of Front Structure (Units:
mm) 15-151
Frame 15-153
Body Frame Dimensions (Units: mm) 15-153
Vehicle Clearance 15-154
Front View 15-154
Body 15-157
Side View 15-157
BUMPERS15-166
Front Bumper 15-166
Removal & Installation 15-166
DOORS15-167
Specification 15-167
Front Door 15-168
Removal & Installation 15-168
Disassembly 15-168
Assembly 15-172
Front Door Adjustment 15-172
Replacing Front Door Hinge 15-172
Rear Door 15-173
Removal & Installation 15-173
Disassembly 15-173
Assembly 15-174
Rear Door Adjustment 15-174
Replacing Rear Door Hinge 15-175
Back Cargo Door 15-175
Removal & Installation 15-175
Disassembly 15-175
Assembly 15-177
Back Cargo Door Adjustment 15-177
Replacing Rear Door Hinge 15-177
EXTERIOR LAMPS15-178
Description 15-178
Operation 15-178
Specification 15-178
Electrical Schematics 15-179
Front Combination Lamp Assembly 15-189
Removal & Installation 15-189
Headlamp Adjustment Procedure 15-190
Rear Combination Lamp Assembly 15-190
Removal & Installation 15-190Headlamp
15-191
Removal & Installation 15-191
Front Fog Lamp 15-192
Removal & Installation 15-192
Rear Fog Lamp 15-193
Removal & Installation 15-193
Tail/Backup/Stop Lamp 15-194
Removal & Installation 15-194
Turn Signal Lamp 15-195
Removal & Installation 15-195
High Mounted Stop Lamp 15-197
Removal & Installation 15-197
License Plate Lamp 15-197
Removal & Installation 15-197
FENDER15-199
Front Fender 15-199
Removal & Installation 15-199
FUEL DOOR15-200
Fuel Door 15-200
Removal & Installation 15-200
GRILLE15-201
Grille 15-201
Removal & Installation 15-201
HOOD15-202
Hood 15-202
Removal & Installation 15-202
Hood Adjustment 15-202
Hood Release Cable 15-203
Removal & Installation 15-203
LUGGAGE RACK15-204
Luggage Rack 15-204
Removal & Installation 15-204
SPARE TIRE SUPPORT15-205
Spare Tire Support 15-205
Removal & Installation 15-205
HORN15-206
Description 15-206
Operation 15-206
Electrical Schematics 15-207
Horn 15-208
Removal & Installation 15-208
15
15–145Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Cross section C3-C3, requirements for clearance and
levelness.
Cross section C4-C4, requirements for clearance and
levelness.
Cross section C5-C5, requirements for clearance and
levelness.
1 - Side Wall2 - Rear Bumper
1 - Side Wall2 - Rear Headlight
1 - Fuel Tank Cover 2 - Side Wall
BODY DIMENSIONS
LTSM150023
LTSM150024
LTSM150025
15–162Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine FUEL DOOR
Fuel Door
Removal & Installation
1. Open the fuel door.
2. Remove the two fuel door retaining bolts (1).(Tighten: Fuel door bolts to 5 N·m)
3. Remove the fuel door.
4. Installation is in the reverse order of removal.
LTSM150128
15–200Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine A/1Power Fuse Box B3
B /1Power Fuse Box B3
C /1Power Fuse Box B3
D /1Power Fuse Box B4
E /1Power Fuse Box B4
E-001 B/81 ECM D2
E-002 B/25 ABS Hydraulic Control Module D2
E-003 B/4A/C Pressure Switch D2
E-004 W-O/4 Upstream Oxygen Sensor D3
E-005 W-O/4 Downstream Oxygen Sensor (With EOBD) D3
E-006 B/3Crankshaft Position Sensor C4
E-007 B/3Camshaft Position Sensor C4
E-008 B/3Generator C2
E-009 B/5Air Flow Sensor C4
E-010 B/2Fuel Injector No.1 C3
E-011 B/2Fuel Injector No.2 C3
E-012 B/2Fuel Injector No.3 C3
E-013 B/2Fuel Injector No.4 C4
E-014 B/1Power Steering Switch B2
E-015 B/2A/C Compressor B2
E-016 W/1 Oil Pressure Switch B2
E-017 B/3Knock Sensor B3
E-018 B/1Starter Motor B4
E-019 B/2Engine Coolant Temperature Sensor C4
E-020 B/4Ignition Coil C4
E-021 B/2Backup Lamp Switch C4
E-022 B/3Canister Control Valve C4
E-023 B/3Vehicle Speed Sensor D4
E-024 GR/2 Brake Fluid Level Switch D4
E-025 GR/5 Front Wiper Motor D4
E-026 B/2Siren D3
E-027 B/6Electronic Throttle Control Actuator B3
E-028 B/2Front Wheel Speed Sensor LH D5
E-029 B/2Front Wheel Speed Sensor RH D1
E-030 B/2Front Fog Lamp LH B5
E-033 B/4Manifold Absolute Pressure Sensor (With
1.6L Engine) C3
E-034 B/10 Front Combination Lamp LH C5
E-035 B/3Accelerator Sensor C2
E-038 B/3Side Turn Signal Lamp LH D5
E-039 B/2Side Turn Signal Lamp RH D1
E-040 B/2Front Fog Lamp RH B1
E-041 B/4Downstream Oxygen Sensor (Without
EOBD) D3
E-042 B/10 Front Combination Lamp RH C1
VEHICLE HARNESS ROUTING MAPS
16
16–49Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine E-001B/81 ECM D2
E-003 B/4A/C Pressure Switch D2
E-004 W-O/4 Upstream Oxygen Sensor D3
E-005 W-O/4 Downstream Oxygen Sensor (With EOBD) D3
E-006 B/3Crankshaft Position Sensor D4
E-007 B/3Camshaft Position Sensor C4
E-008 B/3Generator C2
E-009 B/5Air Flow Sensor C4
E-010 B/2Fuel Injector No.1 C2
E-011 B/2Fuel Injector No.2 C3
E-012 B/2Fuel Injector No.3 C3
E-013 B/2Fuel Injector No.4 C3
E-014 B/1Power Steering Switch B2
E-015 B/2A/C Compressor B2
E-016 B/1Oil Pressure Switch B2
E-017 B/3Knock Sensor C3
E-018 B/1Starter Motor C3
E-019 B/2Engine Coolant Temperature Sensor C4
E-020 B/4Ignition Coil C4
E-022 B/2Canister Control Valve C4
E-026 B/2Siren D3
E-027 B/6Electronic Throttle Control Actuator B3
E-033 B/4Manifold Absolute Pressure Sensor C3
E-036 GR/56 TCM (Transmission Control Module) D2
E-037 GR/33 A/T Assembly D4
E-041 B/4Downstream Oxygen Sensor (Without
EOBD) D3
E-043 B/2Fluid Cooler Flow Control Solenoid Valve D4
E-102 W/14 To C-102 E2
E-103 B/14 To C-103 E2
E-105 B/16 To A-102 D3
E-108 B/2To C-108 D2
E-207 -Ground D2
E-208 -Ground D2
VEHICLE HARNESS ROUTING MAPS
16–52Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine E-050B/4A/C Pressure Switch D2
E-051 W/26 ECM D2
E-052 W/16 ECM D2
E-053 W/12 ECM D2
E-054 W/22 ECM D2
E-055 GR/3 Camshaft Position Sensor D4
E-056 GR/3 Crankshaft Position Sensor D2
E-058 B/7Air Flow Sensor D4
E-059 GR/2 Fuel Injector No.1 C2
E-060 GR/2 Fuel Injector No.2 C3
E-061 GR/2 Fuel Injector No.3 C3
E-062 GR/2 Fuel Injector No.4 C3
E-064 B/6Idle Air Control Motor C3
E-065 B/1Oil Pressure Switch C3
E-066 BR/2 Knock Sensor C4
E-067 B/1Starter Motor C4
E-068 B/2Engine Coolant Temperature Sensor C4
E-069 GR/3 Ignition Coil 1 D2
E-070 GR/3 Ignition Coil 2 D4
E-071 GR/2 Canister Control Valve D3
E-072 BR/2 EGR Control Solenoid Valve D3
E-074 B/4Upstream Oxygen Sensor C4
E-076 B/4Throttle Position Sensor C4
E-077 W/26 TCM (Transmission Control Module) D1
E-078 W/16 TCM (Transmission Control Module) D1
E-079 W/22 TCM (Transmission Control Module) D1
E-081 GR/4 Generator C2
E-084 B/1Coolant Temperature Sensor (For
Instrument Cluster) D4
E-086 GR/10 A/T Assembly C4
E-087 GR/10 Gearshift Switch C4
E-088 B/3Input Shaft Sensor C4
E-089 GR/3 Output Shaft Sensor C4
E-102 W/14 To C-102 D2
E-103 B/14 To C-103 D2
E-105 B/16 To A-105 D2
E-207 -Ground C4
E-208 -Ground C4
VEHICLE HARNESS ROUTING MAPS
16–54Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine B-003GR/15 BCM (Body Control Module) D1
B-004 B/12 BCM (Body Control Module) D1
B-005 B/8BCM (Body Control Module) D1
B-006 B/10 Body Fuse And Relay Box (G) C2
B-008 W/1 Parking Brake Switch D2
B-011 B/4Downstream Oxygen Sensor (With
MITSUBISHI 2.4L Engine System) D2
B-012 W/2 Rear Power Outlet LH D5
B-017 L/6Driver Seat Assembly C2
B-018 L/6Heated Seat RH D2
B-019 W/6 Rear Combination Lamp LH D5
B-020 W/6 Rear Combination Lamp RH D4
B-021 W/2 Rear Wheel Speed Sensor LH D4
B-022 W/2 Rear Wheel Speed Sensor RH D3
B-023 B/3Decelerator Sensor D2
B-032a B/4Fuel Level Sensor And Fuel Pump (With
ACTECO Engine System) D3
B-032b B/4Fuel Level Sensor And Fuel Pump (With
MITSUBISHI 2.4L Engine System) D3
B-100 W/18 To D-100 C2
B-101 W/14 To D-101 C2
B-102 W/14 To G-100 D1
B-103 W/10 To G-101 D1
B-104 W/22 To C-104 C2
B-105 W/22 To C-105 D1
B-106 W/18 To A-103 E1
B-107 W/14 To I-100 C4
B-108 W/14 To H-100 D2
B-110 W/14 To L-100 D4
B-111 W/18 To E-104 E1
B-201 -Ground D1
B-202 -Ground D4
B-203 -Ground D2
B-204 -Ground D5
B-205 -Ground (With MITSUBISHI 2.4L Engine
System) D5
B-206 -Ground (With ACTECO Engine System) D4
VEHICLE HARNESS ROUTING MAPS
16–62Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Cooling System.............................6-1
Cooling System Draining and Filling, Cooling System . . . 6-13
Crankshaft Position (CKP) Sensor, 1.6L & 1.8L Engine Controls .......................... 3-220
Crankshaft Position (CKP) Sensor, 2.0L Engine Controls ............................... 3-430
Crankshaft Position (CKP) Sensor, 2.4L Engine Controls ............................... 3-542
Crankshaft, 1.6L & 1.8L Engine Mechanical .........2-60
Crankshaft, 2.0L Engine Mechanical ..............2-133
Crankshaft, 2.4L Engine Mechanical ..............2-233
Cylinder Head Cover, 1.6L & 1.8L Engine Mechanical . . . 2-19
Cylinder Head Cover, 2.0L Engine Mechanical ........2-93
Cylinder Head Cover, 2.4L Engine Mechanical .......2-170
Cylinder Head Unit Repair, 1.6L & 1.8L Engine Mechanical .............................. 2-63
Cylinder Head Unit Repair, 2.0L Engine Mechanical ....2-136
Cylinder Head Unit Repair, 2.4L Engine Mechanical ....2-241
Cylinder Head, 1.6L & 1.8L Engine Mechanical . . . 2-23, 2-63
Cylinder Head, 2.0L Engine Mechanical ........2-136, 2-97
Cylinder Head, 2.4L Engine Mechanical .......2-175, 2-241
D
Diagnosing Electrical Failures, Electrical Circuit Diagnosis
Information .............................. 1-16
Diagnosis & Testing, 1.6L & 1.8L Engine Controls .....3-22
Diagnosis & Testing, 1.6L & 1.8L Engine Mechanical . . . 2-13
Diagnosis & Testing, 2.0L Engine Controls .........3-247
Diagnosis & Testing, 2.0L Engine Mechanical ........2-87
Diagnosis & Testing, 2.4L Engine Controls .........3-458
Diagnosis & Testing, 2.4L Engine Mechanical .......2-163
Diagnosis & Testing, 5-Speed Manual Transaxle ......8-259
Diagnosis & Testing, Air Distribution .............13-28
Diagnosis & Testing, Airbag System ...............14-8
Diagnosis & Testing, Alignment .................10-42
Diagnosis & Testing, Antilock Brakes .............12-45
Diagnosis & Testing, Base Brakes ................12-7
Diagnosis & Testing, Body Exterior ..............15-228
Diagnosis & Testing, Body Interior .........15-113, 15-64
Diagnosis & Testing, Charging System .............5-16
Diagnosis & Testing, DP0 Automatic Transaxle .......8-19
Diagnosis & Testing, Drive Shaft (4x4) .............9-26
Diagnosis & Testing, F4A4 Automatic Transaxle ......8-158
Diagnosis & Testing, Front Axle ..................9-4
Diagnosis & Testing, Front Suspension .............10-6
Diagnosis & Testing, Fuel Delivery System ..........4-12
Diagnosis & Testing, Manual Temperature Control ....13-12 Diagnosis & Testing, Parking Brake
..............12-82
Diagnosis & Testing, Power Steering Pump .........11-33
Diagnosis & Testing, Rear Axle ..................9-11
Diagnosis & Testing, Rear Suspension ............10-29
Diagnosis & Testing, Steering Column ............11-11
Diagnosis & Testing, Steering Gear ..............11-20
Diagnosis & Testing, Steering System .............11-4
Diagnosis & Testing, System Plumbing ............13-35
Diagnosis & Testing, Wheels and Tires ............10-50
Diagnosis and Testing, Cooling System .............6-11
Diagnosis and Testing, Exhaust System .............7-4
Diagnosis and Testing, Starting System .............5-6
Diagnostic Help, Antilock Brakes ................12-45
Diagnostic Trouble Code (DTC) List, Airbag System ....14-9
Diagnostic Trouble Code (DTC)

List, Antilock Brakes . . . 12-46
Diagnostic Trouble Code (DTC) List, Body Interior .......................... 15-114, 15-65
Diagnostic Trouble Code (DTC) List, DP0 Automatic Transaxle ................................ 8-20
Diagnostic Trouble Code (DTC) List, F4A4 Automatic Transaxle ............................... 8-159
Diagnostic Trouble Code (DTC) Tests, 1.6L & 1.8L Engine Controls ........................... 3-35
Diagnostic Trouble Code (DTC) Tests, 2.0L Engine Controls ............................... 3-261
Diagnostic Trouble Code (DTC) Tests, 2.4L Engine Controls ............................... 3-469
Diagnostic Trouble Code (DTC) Tests, Airbag System . . 14-11
Diagnostic Trouble Code (DTC) Tests, Antilock Brakes . . 12-47
Diagnostic Trouble Code (DTC) Tests, Body Interior .......................... 15-117, 15-66
Diagnostic Trouble Code (DTC) Tests, DP0 Automatic Transaxle ................................ 8-22
Diagnostic Trouble Code (DTC) Tests, F4A4 Automatic Trans- axle .................................. 8-160
Differential Carrier, Front Differential ..............8-312
Differential Unit Repair, Front Differential ...........8-312
Door Lock Assembly, Body Interior ..............15-35
Door Lock Switch, Body Interior ................15-35
Door Locks, Body Interior ..................... 15-29
Doors, Body Exterior ....................... 15-167
DP0 Automatic Transaxle .......................8-1
DPO Automatic Transaxle Assembly, DP0 Automatic Transaxle ............................... 8-136
Drive Shaft (4x4) ........................... 9-24
Driver Side Airbag, Airbag System ...............14-46
INDEX
AI-2