service CHERY TIGGO 2009 Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine Removal & Installation
1. Remove the EGR vacuum hose.
2. Remove the EGR valve retaining bolts (1).(Tighten: EGR valve retaining bolts to 25 N·m)
3. Installation is in the reverse order of removal.
ON-VEHICLE SERVICE
LTSM030015
03
03–589Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine FUEL DELIVERY
04
CONTENTSpage
Fuel Delivery System ................................................................. 04-1
FUEL DELIVERY SYSTEM
GENERAL INFORMATION04-2
Description 04-2
Operation 04-4
Specifications 04-4
Special Tools 04-5
Electrical Schematics 04-6
DIAGNOSIS & TESTING04-12
Fuel Pressure Test 04-12
ON-VEHICLE SERVICE04-15
Fuel Pressure Relief Procedure 04-15
Description 04-15
Fuel Pump 04-15
Description 04-15
Operation 04-15
Removal & Installation 04-15
Fuel Pump Inspection 04-17
Fuel Filter 04-18
Description 04-18
Operation 04-18 Removal & Installation 04-18
Fuel Injector Rail 04-19
Description 04-19
Operation 04-19
Removal & Installation - 1.6L & 1.8L &
2.0L 04-19
Removal & Installation - 2.4L 04-20
Fuel Injector 04-20
Description 04-20
Operation 04-20
Removal & Installation - 1.6L & 1.8L &
2.0L 04-20
Removal & Installation - 2.4L 04-21
Fuel Injector Inspection 04-22
Fuel Pressure Regulator - With
Mitsubishi 2.4L Engine 04-23
Description 04-23
Operation 04-23
Removal & Installation 04-23
Fuel Pressure Regulator Inspection 04-24
04
04–1Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine DIAGNOSIS & TESTING
Fuel Pressure Test
WARNING!
Fuel in the fuel system remains under high pressure, even when the engine is not running. Before servicing or
disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to
prevent accidental spraying of fuel (See Fuel Pressure Relief Procedure in Section 04 Fuel Delivery). Failure to
follow these instructions may result in serious personal injury or death.
Perform the following procedure to test for proper fuel pressure.
WARNING!
Wrap towels around hoses to catch any gasoline spillage.
1. Remove the protective cap and connect the fuel pressure gauge (2) to the fuel rail service test port pressurefitting (1) on the fuel rail (3).
2. Start and warm the engine and note the pressure gauge reading:
1.6L & 1.8L & 2.0L
• Fuel pressure at idle: 400-420 kPa (4.0 - 4.2 bar)
BESM030020
04–12Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 2.4L
•Fuel pressure at idle: 320-350 kPa (3.2 - 3.5 bar)
3. If engine runs, but pressure is below minimum pressure, check the following: a. Check for a kinked fuel supply line between the fuel rail and the fuel pump, repair if necessary.
b. Check the fuel filter for blockage, and replace the fuel filter if necessary (See Fuel Filter Removal & Installa-
tion in Section 04 Fuel Delivery).
c. Check the fuel pump, and replace if necessary (See Fuel Pump Removal & Installation in Section 04 Fuel
Delivery).
4. If operating pressure is above the maximum pressure, the electric fuel pump is OK, but fuel pressure regulator is defective. Replace the fuel pressure regulator (See Fuel Pump Removal & Installation in Section 04 Fuel
Delivery).
NOTE:
• The 1.6L & 1.8L & 2.0L fuel pressure regulator is integrated into the fuel pump assembly and is not serviced
separately.
• The 2.4L fuel pressure regulator is connected to the fuel rail, and is serviced separately.
5. Install the protective cap to the service test port pressure fitting (1) on the fuel rail.
Observe the following fuel pressures when testing:
FUEL PRESSURE - 1.6L & 1.8L & 2.0L
Key On 400 kPa (4.0 bar)
Engine Idle 400-420 kPa (4.0 - 4.2 bar)
Key Off 380 kPa (3.8 bar) in 10 minutes
FUEL PRESSURE - 2.4L
Key On 329 kPa (3.29 bar)
Engine Idle 320-350 kPa (3.2 - 3.5 bar)
Key Off 350 kPa (3.5 bar) in 10 minutes
Fuel System Troubleshooting Chart
CONDITIONPOSSIBLE CAUSES CORRECTION
No Start/Hard Start/Start and then
Stall · Contaminated fuel
· Low fuel pressure
· Restricted fuel filter
· Fuel pump relay inoperative
· Restricted or leaking fuel lines
· Fuel pressure regulator· Drain, flush and refill fuel system.
· Check fuel pump pressure.
· Replace fuel filter.
· Test fuel pump relay.
· Inspect/replace necessary fuel
line(s), perform fuel system air
purge.
· Inspect/replace the fuel pump if
necessary.
Stalls Under Aggressive Maneuvers/
Loss Of Fuel Pressure · Restricted or damaged fuel filter
· Contaminated fuel
· Damaged fuel tank· Replace fuel filter.
· Drain, flush and refill fuel system.
· Replace fuel tank.
Cannot Refill Fuel Tank/Excessive
Pressure in Fuel Tank When Cap is
Removed · Sticking or damaged fuel tank
fill/vent valve, hose or lines.
· Inspect, repair vent hose and lines,
replace fuel tank.
DIAGNOSIS & TESTING
04
04–13Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine ON-VEHICLE SERVICE
Fuel Pressure Relief Procedure
Description
WARNING!
Fuel in the fuel system remains under high pressure, even when the engine is not running. Before servicing or
disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to
prevent accidental spraying of fuel. Failure to follow these instructions may result in serious personal injury or
death.
Perform the following procedure to relieve fuel pressure from the fuel system:1. Remove the cover of the front fuse and relay box.
2. Identify and remove the fuel pump relay from the front fuse and relay box.
3. Start and run engine until it stalls.
4. Attempt to restart engine until it will no longer run.
5. Turn the ignition key to the OFF position.
Fuel Pump
Description
The fuel pump assembly contains the fuel pump motor and fuel level sensor.
Operation
The Engine Control Module (ECM) activates the fuel pump relay for several seconds after the ignition switch is
turned ON. When the relay is activated, it provides voltage to the fuel pump. When the ECM receives an engine
speed signal from the Crankshaft Position (CKP) sensor and a signal from the Immobilizer control module, the ECM
will energize the fuel pump relay.
NOTE :
• The electric fuel pump has different flow ratings based on engine requirements
• For service, the part number of the replacement fuel pump must be the equivalent of the original fuel pump
• Do not operate the fuel pump dry, this will damage the fuel pump
• Keep the fuel tank and pipeline clean, and replace the fuel filter if the fuel pump is replaced
Removal & Installation
WARNING!
Release fuel system pressure before servicing fuel system components. Service vehicles in well-ventilated areas
and avoid ignition sources. Never smoke while servicing the vehicle. This may result in personal injury or death.
NOTE :
The following special tool is required to perform the repair procedure:
•CH-20032 - Fuel Pump Remover
1. Release the fuel system pressure (See Fuel Pressure Relief Procedure in Section 04 Fuel Delivery).
2. Disconnect the negative battery cable.
3. Remove the rear seat cushion.
04
04–15Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 4. Remove the fuel pump cover (1).
5. Disconnect the fuel pump connector (3) and thefuel delivery hose (2) and fuel return hose (1).
6. Using special tool CH-20032, remove the fuel pump mounting cover (4).
7. Pull the fuel pump up and out of the fuel tank.
WARNING!
Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-
related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these
instructions may result in serious personal injury or death.
Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when
working on or near any fuel-related component. Highly flammable mixtures are always present and may be
ignited. Failure to follow these instructions may result in serious personal injury or death.
When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage.
Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instruc-
tions may result in serious personal injury or death.
NOTE :
Make sure not to spill fuel inside of the vehicle. 8. Tip the fuel pump on its side and drain the fuel from the fuel pump and remove the fuel pump from the vehicle. NOTE: To keep the fuel tank portion clean and to avoid damage and foreign materials, cover them completely
with plastic bags or something similar.
9. Remove and discard the seal from the fuel tank.
10. Installation is in the reverse order of removal.
Installation Notes:
• Install a new seal to the fuel pump sealing surface.
• Turn the ignition switch to ON (without starting the engine) to apply fuel pressure to the fuel system, then
check the connections for fuel leaks.
• Start the engine and let it idle and check for fuel leaks at the fuel system connections.
ON-VEHICLE SERVICE
LTSM040001
LTSM040002
04–16Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Fuel Pump Inspection
1. Using the following table, apply battery voltage to the specified connector terminals.
2. Check the fuel pump resistance.•Take out the fuel pump.
• Connect the digital multimeter to terminals 2 and 3. Check the fuel pump resistance.
• If the result is not as specified, replace the fuel pump.
3. Check fuel pump operation. •Remove the fuel pump.
• Apply battery voltage to terminals 2 and 3. Check that the pump operates within 10 seconds.
• If the pump does not operate, replace the fuel pump.
NOTE:
• These tests must be completed within 10 seconds to prevent the coil from burning out.
• Keep the fuel pump as far away from the battery as possible.
• Always switch the voltage on and off on the battery side, not on the fuel pump side.
MEASURING CONDITION SPECIFICATION INSPECTION DIAGRAM
Digital Multimeter Positive
(+) to terminal – 2
Digital Multimeter Negative
(-) to terminal – 3 < 130

Battery positive (+) to
terminal – 2
Battery negative (-) to
terminal – 3 8-16V
ON-VEHICLE SERVICE
04
04–17Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Fuel Filter
Description
The fuel filter consists of a housing with an integrated filter element.
Operation
The fuel flows through the filter from the outside to the inside. As a result, any impurities are trapped inside the filter.
Removal & Installation
WARNING!
Release fuel system pressure before servicing fuel system components. Service vehicles in well-ventilated areas
and avoid ignition sources. Never smoke while servicing the vehicle. This may result in personal injury or death.
1. Release the fuel system pressure (See Fuel Pressure Relief Procedure in Section 04 Fuel Delivery).
2. Disconnect the negative battery cable.
3. Remove the fuel delivery hose (1), fuel outlet hose(2) and the ground wire (3).
4. Remove the fuel filter.
5. Installation is in the reverse order of removal.
Installation Notes:
• Verify there are no leaks at the fuel line connec-
tions of the fuel filter.
ON-VEHICLE SERVICE
LTSM040003
04–18Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Fuel Injector Rail
Description
The fuel rail is used to mount the fuel injectors to the engine and it is mounted to the intake manifold.
Operation
The fuel rail supplies the necessary fuel to each individual fuel injector and is located above the intake manifold and
fuel injectors.
Removal & Installation - 1.6L & 1.8L & 2.0L
WARNING!
Release fuel system pressure before servicing fuel system components. Service vehicles in well-ventilated areas
and avoid ignition sources. Never smoke while servicing the vehicle. This may result in personal injury or death.
1. Release the fuel system pressure (See Fuel Pressure Relief Procedure in Section 04 Fuel Delivery).
2. Disconnect the negative battery cable.
3. Remove the engine cover.
4. Disconnect the electrical connectors (1) from thefuel injectors.
5. Remove the fuel line (2) from the fuel rail.
6. Remove the two fuel rail (4) bracket bolts (3) that mount the fuel rail to the intake manifold.
(Tighten: Fuel rail bracket bolts to 11 N·m)
7. Remove the fuel rail with the four fuel injectors (1).
8. Installation is in the reverse order of removal.
Installation Notes:
• Install new seals on the fuel injector sealing
surfaces.
ON-VEHICLE SERVICE
BESM040003
BESM040005
04
04–19Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Removal & Installation - 2.4L
WARNING!
Release fuel system pressure before servicing fuel system components. Service vehicles in well-ventilated areas
and avoid ignition sources. Never smoke while servicing the vehicle. This may result in personal injury or death.
1. Release the fuel system pressure (See Fuel Pressure Relief Procedure in Section 04 Fuel Delivery).
2. Disconnect the negative battery cable.
3. Disconnect four fuel injector electrical connectors(1).
4. Remove the fuel pressure regulator (See Fuel Pressure Regulator Removal & Installation in Section 04 Fuel Delivery).
5. Remove the two fuel rail mounting bolts. (Tighten: Fuel rail mounting bolts to 12 N·m)
6. Remove the fuel rail with the four fuel injectors.
7. Installation is in the reverse order of removal.
Installation Notes:
• Install new seals on the fuel injector sealing surfaces.
Fuel Injector
Description
The fuel injectors are positioned in the intake manifold with the nozzle ends directly above the intake valve port.
Operation
Injector operation is controlled by a ground path provided for each injector by the Engine Control Module (ECM).
Injector on-time (pulse-width) is variable, and is determined by the ECM. Based on the engine operating conditions,
the ECM will control injector pulse-width operation to obtain optimum performance.
Removal & Installation - 1.6L & 1.8L & 2.0L
WARNING!
Release fuel system pressure before servicing fuel system components. Service vehicles in well ventilated areas
and avoid ignition sources. Never smoke while servicing the vehicle. This may result in personal injury or death.
1. Release the fuel system pressure (See Fuel Pressure Relief Procedure in Section 04 Fuel Delivery).
2. Disconnect the negative battery cable.
3. Remove the engine cover.
4. Remove the ground cable on the cylinder head.
ON-VEHICLE SERVICE
LTSM020173
04–20Chery Automobile Co., Ltd.