light CHERY TIGGO 2009 Service User Guide

Downloaded from www.Manualslib.com manuals search engine Installation Notes:
•Clean all surfaces of manifold and cylinder head.
• Install a new exhaust manifold gasket during installation.
Intake Manifold
Removal & Installation
1. Disconnect the negative battery cable.
2. Remove the engine cover.
3. Drain the cooling system (See Cooling System Draining and Filling in Section 06 Cooling).
WARNING!
Always allow the engine to cool before opening the cooling system. Do not loosen the coolant pressure relief
cap when the engine is operating or the cooling system is hot. The cooling system is under pressure; steam and
hot liquid can come out forcefully when the cap is loosened slightly. Failure to follow these instructions may
result in serious personal injury.
4. Remove the coolant fan & radiator assembly (See Coolant Fan & Radiator Assembly Removal & Installation in
Section 06 Cooling).
1 - Fuel Rail Bolt
2 - Fuel Rail
3 - Electronic Throttle Control Actuator Bolt
4 - Electronic Throttle Control Actuator
5 - Electronic Throttle Control Actuator Gasket
6 - Air Intake Pressure Temperature Sensor Bolt7 - Air Intake Pressure Temperature Sensor
8 - Intake Manifold Bolt
9 - Intake Manifold
10 - Intake Manifold Bracket
11 - Intake Manifold Gasket
ON-VEHICLE SERVICE
LTSM020164
02
02–43Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 7. Using valve spring compressor CH-20018 (1), com-press the valve springs.
8. Install the valve keepers.
9. Strike the valve stem lightly with a plastic hammer after installation to verify proper assembly.
10. Install valve tappets in the head.
11. Install the camshafts.
Installation Notes:
• Coat the valve oil seal with engine oil.
Camshaft
Specifications
Camshaft Specifications
DESCRIPTION SPECIFICATION (mm)
Intake Cam Lobe Height 37.15
Exhaust Cam Lobe Height 37.05
Journal #1 Outer Diameter 31.934 - 31.95
Journal #2, #3, #4, #5, Outer Diameter 23.947 - 23.96
Cam Bearing #1 Inner Diameter 32 - 32.025
Cam Bearing #2, #3, #4, #5, Inner Diameter 24 - 24.021
Journal #1 Clearance 0.05 - 0.091
Journal #2, #3, #4, #5 Clearance 0.04 - 0.074
Intake Camshaft Axial Clearance 0.15 - 0.20
Exhaust Camshaft Axial Clearance 0.15 - 0.20
CYLINDER HEAD UNIT REPAIR
BESM020067
02–66Chery 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 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 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 7. Remove the cylinder head bolts in the ordershown.
8. Remove cylinder head gasket.
9. Installation is in the reverse order of removal.
Installation Notes:
• Ensure cylinder head bolt holes in the block are clean, dry (free of residual oil or coolant), and threads are not
damaged.
• The cylinder head bolts should not be reused. The new bolts should be examined before use. If the bolts are
stretched, the bolts should be replaced.
• Position the new cylinder head gasket on the engine block with the part number facing up. Ensure gasket is
seated over the locating dowels in the block.
• Before installing the bolts, the threads should be lightly coated with engine oil.
ON-VEHICLE SERVICE
BESM020065
02
02–98Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 6. Drain the cooling system (See Cooling SystemDraining and Filling in Section 06 Cooling).
WARNING!
Always allow the engine to cool before opening the cooling system. Do not loosen the coolant pressure relief
cap when the engine is operating or the cooling system is hot. The cooling system is under pressure; steam and
hot liquid can come out forcefully when the cap is loosened slightly. Failure to follow these instructions may
result in serious personal injury.
7. Remove the coolant fan & radiator assembly (See Coolant Fan & Radiator Assembly Removal & Installation inSection 06 Cooling).
8. Remove the starter motor wiring.
9. Relieve the fuel pressure (See Fuel Pressure Relief Procedure in Section 04 Fuel Delivery).
10. Disconnect and remove the fuel line at the fuel rail.
11. Remove the air inlet hose and the air cleaner case assembly.
NOTE: For 1.8L engine, disconnect the air flow
sensor electrical connector.
12. Remove the ground cable bolt from the cylinder head.
ON-VEHICLE SERVICE
LTSM020190
LTSM020226
02
02–106Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Engine Timing Belt
Removal & Installation
NOTE :
The following special tools are required to perform the repair procedure:
•CH-20001 - Right Engine Mount Bolt Remover
• CH-20003 - Crankshaft Holder
• CH-20010 - Camshaft Holder
• Engine Hoist
1. Release the coolant system pressure.
WARNING!
Always allow the engine to cool before opening the cooling system. Do not loosen the coolant pressure relief
cap when the engine is operating or the cooling system is hot. The cooling system is under pressure; steam and
hot liquid can come out forcefully when the cap is loosened slightly. Failure to follow these instructions may
result in serious personal injury.
1 - Timing Belt Upper Cover Bolt
2 - Timing Belt Upper Cover
3 - Timing Belt Cover Gasket
4 - Timing Belt
5 - Timing Belt Touch Pulley
6 - Camshaft Bolt
7 - Camshaft
8 - Rear Timing Cover Bolt9 - Rear Timing Cover
10 - Idler Pulley
11 - Tensioner Pulley
12 - Tensioner Pulley Bolt
13 - Timing Belt Lower Cover
14 - Timing Belt Lower Cover Bolt
15 - Timing Belt Upper Cover Bolt
ON-VEHICLE SERVICE
LTSM020162
02
02–11 2Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Installation Notes:
•Clean all surfaces of manifold and cylinder head.
• Install a new exhaust manifold gasket during installation.
Intake Manifold
Removal & Installation
1. Disconnect the negative battery cable.
2. Remove the engine cover.
3. Drain the cooling system (See Cooling System Draining and Filling in Section 06 Cooling).
WARNING!
Always allow the engine to cool before opening the cooling system. Do not loosen the coolant pressure relief
cap when the engine is operating or the cooling system is hot. The cooling system is under pressure; steam and
hot liquid can come out forcefully when the cap is loosened slightly. Failure to follow these instructions may
result in serious personal injury.
1 - Fuel Rail Bolt
2 - Fuel Rail
3 - Electronic Throttle Control Actuator Bolt
4 - Electronic Throttle Control Actuator
5 - Electronic Throttle Control Actuator Gasket
6 - Air Intake Pressure Temperature Sensor Bolt7 - Air Intake Pressure Temperature Sensor
8 - Intake Manifold Bolt
9 - Intake Manifold
10 - Intake Manifold Bracket
11 - Intake Manifold Gasket
ON-VEHICLE SERVICE
LTSM020164
02–11 7Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 7. Using a valve spring compressor CH-20018 (1),compress the valve springs.
8. Install the valve keepers.
9. Strike the valve stem lightly with a plastic hammer after installation to verify proper assembly.
10. Install valve tappets in the head.
11. Install the camshafts.
Installation Notes:
• Coat the valve oil seal with engine oil.
Camshaft
Specifications
Camshaft Specifications
DESCRIPTION SPECIFICATION (mm)
Intake Cam Lobe Height 37.15
Exhaust Cam Lobe Height 37.05
Journal #1 Outer Diameter 31.934 - 31.95
Journal #2, #3, #4, #5, Outer Diameter 23.947 - 23.96
Cam Bearing #1 Inner Diameter 32 - 32.025
Cam Bearing #2, #3, #4, #5, Inner Diameter 24 - 24.021
Journal #1 Clearance 0.05 - 0.091
Journal #2, #3, #4, #5 Clearance 0.04 - 0.074
Intake Camshaft Axial Clearance 0.15 - 0.20
Exhaust Camshaft Axial Clearance 0.15 - 0.20
CYLINDER HEAD UNIT REPAIR
BESM020067
02–139Chery Automobile Co., Ltd.