service CHERY TIGGO 2009 Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine 5. Disconnect the electrical connectors (1) from thefuel injectors.
6. Remove the fuel line (2) from the fuel rail.
7. 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)
8. Remove the fuel injectors (1) from the fuel rail.
9. Installation is in the reverse order of removal.
Installation Notes:
• Coat the surface of the O-ring seals with clean engine oil before installing the fuel injector. Be careful not to
damage the O-ring seals when inserting the fuel injector into the fuel distribution tube.
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).
ON-VEHICLE SERVICE
BESM040003
BESM040005
LTSM02017304
04–21Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 4. Remove the fuel pressure regulator (See Fuel Pressure Regulator Removal & Installation in Section 04 FuelDelivery).
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. Remove the clamp holding the fuel injector to the fuel rail.
8. Remove the fuel injector from the fuel rail.
9. Installation is in the reverse order of removal.
Installation Notes:
• Install new seals on the fuel injector sealing surfaces.
Fuel Injector Inspection
1. Remove the fuel injector electrical connector.
2. Use a digital multimeter to measure the resistance between the two fuel injector pins (fuel injector side).
SPECIFICATION TEMPERATURE
11 - 1 3  20°C
ON-VEHICLE SERVICE
LTSM040005
04–22Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Fuel Pressure Regulator - With Mitsubishi 2.4L Engine
Description
The fuel pressure regulator is connected to the fuel rail. The fuel pressure regulator has a vacuum connection to it.
The fuel pressure regulator is used to regulate the fuel pressure in the fuel system.
NOTE :
The 2.4L is the ONLY engine that uses an external fuel pressure regulator.
Operation
The fuel pressure regulator is designed to keep the fuel pressure in the fuel system at a constant pressure. It does
this with a spring-loaded diaphragm that controls a valve. The valve, when opened by excessive pressure in the fuel
lines, uncovers a fuel line that returns excess fuel to the fuel tank. The vacuum connection is there to help reduce
emissions during deceleration. During deceleration, the vacuum connection serves to open the fuel return valve
wider, which reduces pressure in the system and prevents excess hydrocarbon emissions due to less fuel being
injected as a result of the lower pressure in the system.
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.
ON-VEHICLE SERVICE
LTSM040007
04
04–23Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 3. Disconnect the fuel return pipe (2).
4. Remove the fuel pressure regulator mounting bolts(1).
(Tighten: Fuel pressure regulator mounting bolts to
9 N·m)
5. Remove the fuel pressure regulator.
6. Installation is in the reverse order of removal.
Installation Notes:
• Install new seals on the fuel pressure regulator sealing surfaces.
• Coat the surface of the fuel pressure regulator O-ring seal with clean engine oil before assembly.
• While installing the fuel pressure regulator, ensure that the fuel pressure regulator rotates smoothly in the fuel
distribution tube. If it does not rotate smoothly, the O-ring seal may have been damaged. Remove the fuel
pressure regulator and inspect the O-ring seal for damage.
Fuel Pressure Regulator Inspection
1. Connect a fuel pressure gauge to the inlet fuel pipe.
2. Start and idle the engine (note the fuel pressure).
3. Increase the engine speed to 2500 RPM (note the fuel pressure).
SPECIFICATION PRESSURE
Idle 350 kPa
2500 RPM 350 kPa
ON-VEHICLE SERVICE
LTSM040006
04–24Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine STARTING & CHARGING
05
CONTENTSpage
Starting System ...................................................................... 05-1
Charging System .................................................................... 05-11
STARTING SYSTEM
GENERAL INFORMATION05-2
Description 05-2
Operation 05-3
Specifications 05-3
Special Tools 05-3
Electrical Schematics 05-4
DIAGNOSIS AND TESTING05-6
Starter Motor Bench Test 05-6
Starter Solenoid Test 05-6
ON-VEHICLE SERVICE05-7
Battery 05-7
Description 05-7
Operation 05-7
Removal & Installation 05-7 Positive Battery Cable
05-8
Removal & Installation 05-8
Negative Battery Cable 05-8
Removal & Installation 05-8
Battery Hold Down 05-8
Removal & Installation 05-8
Battery Tray 05-9
Removal & Installation 05-9
Starter Motor Assembly 05-9
Description 05-9
Operation 05-9
Removal & Installation - 1.6L & 1.8L &
2.0L 05-9
Removal & Installation - 2.4L 05-10
05
05–1Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine ON-VEHICLE SERVICE
Battery
Description
This vehicle is equipped with a single 12 V battery. All of the components of the battery system are located within the
engine compartment of the vehicle. The battery system for this vehicle contains the following components:
•Battery - The storage battery provides a reliable means of storing a renewable source of electrical energy within
the vehicle.
• Battery Cables - The battery cables connect the positive and negative charged battery terminal posts to the
vehicle electrical system.
• Battery Hold Down - The battery hold down hardware secures the battery in the battery tray.
• Battery Tray - The battery tray provides a secure mounting location in the vehicle for the battery and an anchor
point for the battery hold down hardware.
Operation
The battery is designed to store electrical energy in a chemical form. When an electrical load is applied to the ter-
minals of the battery, an electrochemical reaction occurs. This reaction causes the battery to discharge electrical
current from its terminals. As the battery discharges, a gradual chemical change takes place within each cell. The
sulfuric acid in the electrolyte combines with the plate materials, causing both plates to slowly change to lead sulfate.
At the same time, oxygen from the positive plate material combines with hydrogen from the sulfuric acid, causing the
electrolyte to become mainly water. The chemical changes within the battery are caused by the movement of excess
or free electrons between the positive and negative plate groups. This movement of electrons produces a flow of
electrical current through the load device attached to the battery terminals.
Removal & Installation
1. Disconnect the negative battery cable.
2. Disconnect the positive battery cable.
3. Remove the battery hold down retaining nuts (1).
4. Remove the battery.
5. Installation is in the reverse order of removal.
LTSM050001
05
05–7Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Positive Battery Cable
Removal & Installation
1. Disconnect the negative battery cable.
2. Disconnect the positive battery cable.
3. Remove the battery cable from the B+ terminal of the generator.
4. Remove the battery cable from the B+ terminal of the starter motor.
5. One at a time, trace the battery cable retaining push pins, fasteners and routing clamps until the cables are freefrom the vehicle.
6. Remove the battery cable from the engine compartment.
7. Installation is in the reverse order of removal.
Negative Battery Cable
Removal & Installation
1. Disconnect the negative battery cable.
2. Remove the bolts securing the negative cable to the body ground and the transaxle.
3. One at a time, trace the battery cable retaining push pins, fasteners and routing clamps until the cables are free from the vehicle.
4. Remove the battery cable from the engine compartment.
5. Installation is in the reverse order of removal.
Battery Hold Down
Removal & Installation
1. Remove the retaining nuts (1).
2. Remove the battery hold down.
3. Installation is in the reverse order of removal.
ON-VEHICLE SERVICE
LTSM050001
05–8Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Battery Tray
Removal & Installation
1. Disconnect the negative battery cable.
2. Disconnect the positive battery cable.
3. Remove the battery hold down.
4. Remove the battery.
5. Remove the three bolts (1) from the battery tray.
6. Lift the battery tray out of the engine compartmentand remove from the vehicle.
7. Installation is in the reverse order of removal.
Starter Motor Assembly
Description
The starter motor is mounted with two bolts to the transaxle housing and is located on the side of the engine. The
starter motor incorporates several features to create a reliable, efficient, compact, lightweight and powerful unit. The
electric motor of the starter features electromagnetic field coils wound around pole shoes, and brushes contact the
motor commutator. The starter motor is serviced only as a unit and cannot be repaired.
Operation
The starter motor is equipped with a planetary gear reduction system. The planetary gear reduction system consists
of a gear that is integral to the output end of the electric motor armature shaft that is in continual engagement with
a larger gear that is splined to the input end of the starter pinion gear shaft. This feature makes it possible to reduce
the dimensions of the starter. At the same time, it allows higher armature rotational speed and delivers increased
torque through the starter pinion gear to the starter ring gear.
Removal & Installation - 1.6L & 1.8L & 2.0L
1. Disconnect the negative battery cable.
2. Disconnect the electrical connector from the starter.
3. Remove the bolts connecting the engine oil dipstick to the cylinder block and intake manifold.
4. Remove the engine oil dipstick.
NOTE :
After removing the engine oil dipstick, you should immediately plug the hole in the cylinder block in order to prevent
any debris from entering the engine. 5. Remove the starter solenoid nut (1) from the starter.
(Tighten: Starter solenoid nut to 10 N·m)
ON-VEHICLE SERVICE
LTSM050002
BESM050004
05
05–9Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 6. Remove the two starter mounting bolts (1) connect-ing the starter and transaxle.
(Tighten: Starter mounting bolts to 30 N·m)
7. Remove the starter from the engine.
8. Installation is in the reverse order of removal.
Removal & Installation - 2.4L
1. Disconnect the negative battery cable.
2. Remove the exhaust manifold (See Exhaust Manifold Removal & Installation in Section 02 Engine).
3. Disconnect the electrical connector from the starter.
4. Remove the starter solenoid nuts from the starter. (Tighten: Starter solenoid nuts to 10 N·m)
5. Remove the two starter mounting bolts (1) connecting the starter and transaxle. (Tighten: Starter mounting bolts to 30 N·m)
6. Remove the starter from the engine.
7. Installation is in the reverse order of removal.
ON-VEHICLE SERVICE
VISM050006
LTSM050005
05–10Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine CHARGING SYSTEM
GENERAL INFORMATION05-12
Description 05-12
Operation 05-12
Specifications 05-13
Special Tools 05-13
Electrical Schematics 05-14
DIAGNOSIS & TESTING05-16
Generator Noise 05-16
ON-VEHICLE SERVICE05-17
Generator 05-17
Removal & Installation - 1.6L & 1.8L &
2.0L 05-17
Removal & Installation - 2.4L 05-18
Generator Inspection 05-18
05
05–11Chery Automobile Co., Ltd.