service CHERY TIGGO 2009 Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION
Description
The generator is belt-driven by the engine. It is serviced only as a complete assembly. If the generator fails for any
reason, the entire assembly must be replaced. The generator produces DC voltage.
Operation
As the energized rotor begins to rotate within the generator, the spinning magnetic field induces a current into the
windings of the stator coil.
The Y-type stator winding connections deliver the induced AC current to 3 positive and 3 negative diodes for recti-
fication. From the diodes, rectified DC current is delivered to the vehicle’s electrical system through the generator,
battery, and ground terminals. 1.6L & 1.8L & 2.0L
2.4L
LTSM050009T
LTSM050008T
05–12Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine ON-VEHICLE SERVICE
Generator
Removal & Installation - 1.6L & 1.8L & 2.0L
1. Disconnect the negative battery cable.
2. Disconnect the generator electrical connector.
3. Remove the engine drive belt (See Drive Belt Removal & Installation in Section 02 Engine).
4. Remove the generator cable nut (1) connecting thepositive cable to the generator.
(Tighten: Generator cable nut to 13 N·m)
5. Remove two generator mounting bolts (1). (Tighten: Generator mounting bolts to 30 N·m)
6. Remove the generator from the engine.
7. Installation is in the reverse order of removal.
BESM050002
BESM050003
05
05–17Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Removal & Installation - 2.4L
1. Disconnect the negative battery cable.
2. Remove the engine drive belt (See Drive BeltRemoval & Installation in Section 02 Engine).
3. Remove the generator cable nut (1) connecting the positive cable to the generator.
(Tighten: Generator cable nut to 10 N·m)
4. Disconnect the electrical connector (2).
5. Remove the two generator adjustment bracket bolts (1).
(Tighten: Generator adjustment bracket bolts to
25 N·m)
6. Remove the generator from the engine.
7. Installation is in the reverse order of removal.
Generator Inspection
1. Start the engine. NOTE: If the battery warning lamp illuminates, there may be a problem with the charging system.
2. With the engine running, check the output voltage of the generator with a digital multimeter (note the voltage).
3. If the voltage is between 14.1 V - 14.7 V, the generator is good.
ON-VEHICLE SERVICE
LTSM050003
LTSM050004
05–18Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine COOLING
06
CONTENTSpage
Cooling System ...................................................................... 06-1
COOLING SYSTEM
GENERAL INFORMATION06-2
Description 06-2
Operation 06-4
Specifications 06-5
Special Tools 06-5
Electrical Schematics 06-6
DIAGNOSIS AND TESTING06-11
Cooling System Pressure Test 06-11
Cooling System Concentration Test 06-11
Cooling System Troubleshooting Chart 06-12
ON-VEHICLE SERVICE06-13
Cooling System Draining and Filling 06-13
Cooling System Draining Procedure 06-13
Cooling System Filling Procedure 06-13
Thermostat 06-14
Description 06-14
Operation 06-14 Removal & Installation - 1.6L & 1.8L &
2.0L 06-14
Removal & Installation - 2.4L 06-15
Thermostat Inspection 06-16
Coolant Pump 06-16
Removal & Installation - 1.6L & 1.8L &
2.0L 06-16
Removal & Installation - 2.4L 06-17
Coolant Pump Inspection 06-17
Radiator 06-17
Description 06-17
Operation 06-17
Removal & Installation 06-17
Cooling Fan 06-18
Description 06-18
Operation 06-19
Removal & Installation 06-19
Cooling Fan Inspection 06-19
06
06–1Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine ON-VEHICLE SERVICE
Cooling System Draining and Filling
Cooling System Draining Procedure
WARNING!
Never remove the pressure relief cap, under any conditions, while the engine is operating or hot. Failure to fol-
low these instructions could result in personal injury or damage to the cooling system or engine. To avoid hav-
ing scalding hot coolant or steam blow out of the cooling system, use extreme care when removing the pressure
relief cap. Wait until the engine has cooled, then wrap a thick cloth around the pressure relief cap and turn it
slowly one turn (counterclockwise). Step back while the pressure is released from the cooling system. When you
are certain all the pressure has been released, using a cloth turn and remove the pressure relief cap. Failure to
follow these instructions may result in serious personal injury.
Perform the following procedure when draining the cooling system.1. Do not remove the pressure cap first.
2. With the engine cold, remove the pressure cap.
3. Raise and support the vehicle and locate the radiator drain plug.
4. Attach one end of a hose to the drain plug (1). Put the other end into a clean container. Open the
drain plug and drain the coolant from the radiator.
5. Tighten the radiator drain plug.
Cooling System Filling Procedure
CAUTION:
Failure to purge air from the cooling system can result in an overheating condition and severe
engine damage.
LTSM060015
06
06–13Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Perform the following procedure when filling the cooling system.1. Fill the system using the proper mixture of anti- freeze/coolant and water. Fill the coolant recovery
reservoir to the MAXline and install the pressure
cap.
2. With the heater control in the HEAT position, start and operate the engine with coolant recovery reservoir cap in place.
3. Add coolant to the coolant recovery reservoir as necessary. Only add coolant to the coolant recovery reservoir when the engine is cold. Coolant level in a warm engine will be higher due to thermal expansion.
Thermostat
Description
The thermostat is located in the thermostat housing. The thermostat housing is located on the top of the engine
between the engine and the radiator.
Operation
The thermostat controls the operating temperature of the engine by controlling the amount of engine coolant flow to
the radiator. The thermostat opens when the engine coolant temperature is approximately 90°C. At this temperature,
engine coolant is allowed to flow to the radiator. The thermostat provides quick engine warm up and overall temper-
ature control. The thermostat begins to close below 90°C. The thermostat controls this by the use of a wax pellet
located in a sealed container at the spring end of the thermostat. When heated, the pellet expands and overcomes
the closing spring tension to force the valve to open, and when cooled, the pellet contracts and the closing spring
then forces the valve to close.
Removal & Installation - 1.6L & 1.8L & 2.0L
WARNING!
Always allow the engine to cool before opening the cooling system. Do not remove 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. Drain the cooling system (See Cooling System Draining Procedure in Section 06 Cooling System).
ON-VEHICLE SERVICE
LTSM060017
06–14Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 2. Remove the thermostat mounting bolts (1).(Tighten: Thermostat mounting bolts to 15 N·m)
3. Remove the thermostat and gasket.
4. Installation is in the reverse order of removal.
Installation Notes:
• Install a new thermostat gasket during installation.
• Verify the cooling system is filled to proper specifications.
Removal & Installation - 2.4L
WARNING!
Always allow the engine to cool before opening the cooling system. Do not remove 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. Drain the cooling system (See Cooling System Draining Procedure in Section 06 Cooling System).
2. Remove the thermostat mounting bolts (1).
(Tighten: Thermostat mounting bolts to 13 N·m)
3. Remove the thermostat and gasket.
4. Installation is in the reverse order of removal.
Installation Notes:
• Install a new thermostat gasket during installation.
• Verify the cooling system is filled to proper
specifications.
ON-VEHICLE SERVICE
LTSM060001
LTSM060009
06
06–15Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Thermostat Inspection
1. Inspect the sealing surface of the thermostat (theseat should be tight at room temperature).
2. Inspect the opening temperature and maximum stroke of the thermostat.• Opening temperature of the thermostat is 87°
± 2°C
• Maximum stroke of the thermostat is 8 mm
• Full opening temperature of the thermostat is
104°C
3. Verify the thermostat closes 5°C lower than the opening temperature.
4. If the thermostat fails any of the inspection steps, replace the thermostat.
Coolant Pump
Removal & Installation - 1.6L & 1.8L & 2.0L
WARNING!
Always allow the engine to cool before opening the cooling system. Do not remove 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. Drain the cooling system (See Cooling System Draining Procedure in Section 06 Cooling System).
2. Remove the timing belt (See Timing Belt Removal & Installation in Section 02 Engine).
3. Remove the coolant pump mounting bolts (1).(Tighten: Coolant pump mounting bolts to 15 N·m)
4. Remove the water pump and gasket.
5. Installation is in the reverse order of removal.
Installation Notes:
• Install a new coolant pump gasket during installa-
tion (1).
• Verify the cooling system is filled to proper
specifications.
ON-VEHICLE SERVICE
LTSM060014
BESM060001
BESM060002
06–16Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Removal & Installation - 2.4L
WARNING!
Always allow the engine to cool before opening the cooling system. Do not remove 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. Drain the cooling system (See Cooling System Draining Procedure in Section 06 Cooling System).
2. Remove the accessory drive belt (See Accessory Drive Belt Removal & Installation in Section 02 Engine).
3. Remove the engine timing belt (See Engine Timing Belt Removal & Installation in Section 02 Engine).
4. Remove the upper balance shaft timing belt (See Upper Balance Shaft Timing Belt Removal & Installation inSection 02 Engine).
5. Remove the coolant pump mounting bolts (1). (Tighten: Coolant pump mounting bolts to 14 N·m)
6. Remove the coolant pump and gasket.
7. Installation is in the reverse order of removal.
Installation Notes:
• Install a new coolant pump gasket during installation.
• Verify the cooling system is filled to proper specifications.
Coolant Pump Inspection
Check coolant seal of the coolant pump for coolant leak. If coolant pump bearing is loose, replace the assembly.
Radiator
Description
The radiator is a cross-flow type (horizontal tubes) with design features that provide greater strength, as well as
sufficient heat transfer capabilities to keep the engine coolant within operating temperatures.
Operation
The radiator functions as a heat exchanger, using air flow across the exterior of the radiator tubes. Heat from the
coolant is then transferred from the radiator into the moving air.
Removal & Installation
WARNING!
Always allow the engine to cool before opening the cooling system. Do not remove 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.
ON-VEHICLE SERVICE
LTSM060003
06
06–17Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 1. Disconnect the negative battery cable.
2. Drain the cooling system (See Cooling System Draining Procedure in Section 06 Cooling System).
3. Disconnect the upper radiator hose from the radiator.
4. Disconnect the lower radiator hose from the radiator.
5. Disconnect the cooling fan electrical connectors.
6. Remove the cooling fan (See Cooling Fan Removal & Installation in Section 06 Cooling).
7. Remove the automatic transaxle fluid hose connecting bolts to radiator (only with 2.0L engine).
8. Remove the radiator support lever retaining bolts(1).
9. Remove the radiator support mounting bolts (1). (Tighten: Radiator support mounting bolts to 5 N·m)
10. Remove the radiator from the engine compartment.
11. Installation is in the reverse order of removal.
Installation Notes:
• Verify the cooling system is filled to proper
specifications.
Cooling Fan
Description
The radiator cooling fans are dual-speed electric motor driven fans. The radiator fan assembly includes two electric
motors, two five-blade fans, and a support shroud that is attached to the radiator. The radiator fans are serviced as
an assembly.
ON-VEHICLE SERVICE
LTSM060016
LTSM060004
06–18Chery Automobile Co., Ltd.