CHERY TIGGO 2009 Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine 2. Remove the accelerator cable retaining bolt from the intake manifold.(Tighten: Accelerator cable retaining bolt to 10 N·m)
3. Remove the PCV hose (1).
4. Disconnect the four fuel injector electrical connec- tors (1).
5. Loosen the clamp between the air intake hose and the air cleaner.
6. Loosen the clamp between the air intake hose and the throttle body and then remove the intake pipe.
7. Remove the fuel rail bracket bolts. (Tighten: Fuel rail bracket bolts to 11 N·m)
8. Remove the fuel rail with the fuel injectors and set aside.
9. Remove the fuel injector O-rings.
10. Remove the screws securing the vacuum valve bracket to the intake manifold.
11. Set aside the vacuum valve and pipe.
12. Disconnect the intake manifold electrical harness, and vacuum hose.
ON-VEHICLE SERVICE
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02–202Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 13. Remove the intake manifold bracket bolts (1).(Tighten: Intake manifold bracket bolts to
14 ± 1 N·m)
14. Remove the intake manifold retaining nuts. (Tighten: Intake manifold retaining nuts to 49 ± 5 N·m)
15. Remove the intake manifold from the cylinder head.
16. Remove and discard the intake manifold gasket.
17. Installation is in the reverse order of removal.
Installation Notes:
• Clean all surfaces of the manifold and cylinder head.
• Install a new intake manifold gasket during installation.
• Install new O-rings on the fuel injectors.
ON-VEHICLE SERVICE
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02–203Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Upper Balance Shaft
Removal & Installation
1 - Upper Balance Shaft Rear Bearing
2 - Upper Balance Shaft Front Bearing
3 - Upper Balance Shaft
4 - Oil Pressure Switch
5 - Front Cover Gasket
6 - Oil Pump Driven Gear
7 - Oil Pump Drive Gear
8 - Front Cover
9 - Upper Balance Shaft Oil Seal
10 - Crankshaft Front Oil seal
11 - Oil Filter Adapter Gasket
12 - Oil Filter Adapter13 - Pressure-Relief Valve
14 - Pressure Relief Spring
15 - Pressure-Relief Valve Seal
16 - Oil Filter
17 - Pressure Relief Valve Plug
18 - Plug
19 - Front Cover Bolt
20 - O-Ring
21 - Oil Pump Oil Seal
22 - Oil Pump Cover
23 - Lower Balance Shaft
24 - Lower Balance Shaft Rear Bearing
ON-VEHICLE SERVICE
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02–204Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine NOTE :
The following special tools are required to perform the repair procedure:
•MB-991603 - Balance Shaft Bearing Puller Limiter
• MD-998162 - Plug Spanner
• MD-998371 - Balance Shaft Bearing Puller
• MD-998372 - Balance Shaft Bearing Puller
• MD-998375 - Crankshaft Front Oil Seal Installer
• MD-998705 - Balance Shaft Bearing Installer
• MD-998727 - Oil Pan Remover
• MD-998783 - Plug Spanner Fixer
• MB-991828 - Oil Filter Wrench
• MB-991396 - Oil Filter Wrench
1. Remove the engine timing belt (See Engine Timing Belt Removal & Installation in Section 02 Engine).
2. Remove the upper balance shaft timing belt (See Upper Balance Shaft Timing Belt Removal & Installation in Section 02 Engine).
3. Raise and support the vehicle.
4. Loosen the oil drain plug and drain the oil.
5. Remove the oil pan retaining bolts. (Tighten: Oil pan bolts to 18 N·m)
6. Using special tool MD-998727 (1), remove the oil pan.
NOTE: Insert the special tool between cylinder
block and the oil pan. Do not use a screwdriver or
chisel, otherwise the edge of oil pan may be dis-
torted and oil leaks will occur.
7. Remove the oil strainer retaining bolts. (Tighten: Oil strainer bolts to 19 N·m)
8. Remove the oil strainer.
9. Remove the oil strainer gasket.
10. Secure the lower balance shaft. Remove the plug from the cylinder block and then insert a holder (1)
(8 mm diameter) into the hole.
NOTE: If the holder can be inserted more than 60
mm, then the timing marks are aligned. If the
holder could not be inserted more than 20-25 mm,
the lower balance shaft pulley should be rotated
one revolution and the timing marks should be then
be aligned. Keep the holder installed until the
installation of the timing belt is complete.
ON-VEHICLE SERVICE
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02–205Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 11. Remove the lower balance shaft bolt (1).(Tighten: Lower balance shaft bolt to 55 N·m)
12. Remove the lower balance shaft pulley.
13. Remove the crankshaft pulley bolt. (Tighten: Crankshaft pulley bolt to 120 N·m)
14. Using special tool MD-9988778 (1), remove the crankshaft pulley.
15. Using special tool MD-9988785 (1), lock the upper balance shaft pulley in place.
16. Remove the upper balance shaft pulley bolt. (Tighten: Upper balance shaft pulley bolt to 45
N·m)
17. Using special tool MD-9988778 (1), remove the upper balance shaft pulley.
18. Remove the front cover.
19. Remove the front cover gasket.
20. Remove the upper balance shaft.
21. Remove the upper balance shaft bearings (See Upper Balance Shaft Bearing Replacement in Sec-
tion 02 Engine).
22. Installation is in the reverse order of removal.
ON-VEHICLE SERVICE
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02–206Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Upper Balance Shaft Bearing Replacement
1. Using special tool MB-991603 (2) and MD-998372(1), disassemble the upper balance shaft front and
rear bearing from the cylinder block.
NOTE :
Special tool MB-991603 should be installed on the front
of the cylinder block when disassembling the upper bal-
ance shaft rear bearing.
2. Using special tool MB-991603 (2) and MD-998705 (1), install the rear bearing (3).
NOTE :
There is NO oil hole in the rear bearing.
3. Using special tool MD-998705 (1), install the front bearing.
NOTE :
Align the oil holes in the front bearing and the cylinder
block.
ON-VEHICLE SERVICE
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02–207Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Lower Balance Shaft
Removal & Installation
1 - Upper Balance Shaft Rear Bearing
2 - Upper Balance Shaft Front Bearing
3 - Upper Balance Shaft
4 - Oil Pressure Switch
5 - Front Cover Gasket
6 - Oil Pump Driven Gear
7 - Oil Pump Drive Gear
8 - Front Cover
9 - Upper Balance Shaft Oil Seal
10 - Crankshaft Front Oil Seal
11 - Oil Filter Adapter Gasket
12 - Oil Filter Adapter13 - Pressure-Relief Valve
14 - Pressure Relief Spring
15 - Pressure-Relief Valve Seal
16 - Oil Filter
17 - Pressure Relief Valve Plug
18 - Plug
19 - Front Cover Bolt
20 - O-Ring
21 - Oil Pump Oil Seal
22 - Oil Pump Cover
23 - Lower Balance Shaft
24 - Lower Balance Shaft Rear Bearing
ON-VEHICLE SERVICE
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02–208Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine NOTE :
The following special tools are required to perform the repair procedure:
•MD-991603 - Balance Shaft Bearing Puller Limiter
• MD-998162 - Plug Spanner
• MD-998371 - Balance Shaft Bearing Puller
• MD-998372 - Balance Shaft Bearing Puller
• MD-998375 - Crankshaft Front Oil Seal Installer
• MD-998705 - Balance Shaft Bearing Installer
• MD-998727 - Oil Pan Remover
• MD-998783 - Plug Spanner Fixer
• MD-991828 - Oil Filter Wrench
• MD-991396 - Oil Filter Wrench
1. Raise and support the vehicle.
2. Loosen the oil drain plug and drain the oil.
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 in Section 02 Engine).
5. Remove the oil pan retaining bolts. (Tighten: Oil pan bolts to 18 N·m)
6. Using special tool MD-998727 (1), remove the oil pan.
NOTE: Insert the special tool between cylinder
block and the oil pan. Do not use a screwdriver or
chisel, otherwise the edge of oil pan may be dis-
torted and oil leaks will occur.
7. Remove the oil strainer retaining bolts. (Tighten: Oil strainer bolts to 19 N·m)
8. Remove the oil strainer.
9. Remove the oil strainer gasket.
10. Secure the lower balance shaft. Remove the plug from the cylinder block and then insert a holder (1)
(8 mm diameter) into the hole.
NOTE: If the holder can be inserted more than 60
mm, then the timing marks are aligned. If the
holder could not be inserted more than 20-25 mm,
the lower balance shaft pulley should be rotated
one revolution and the timing marks should be then
be aligned. Keep the holder installed until the
installation of the timing belt is complete.
ON-VEHICLE SERVICE
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02
02–209Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 11. Remove the lower balance shaft bolt (1).(Tighten: Lower balance shaft bolt to 55 N·m)
12. Remove the lower balance shaft pulley.
13. Remove the crankshaft pulley bolt. (Tighten: Crankshaft pulley bolt to 120 N·m)
14. Using special tool MD-9988778 (1), remove the crankshaft pulley.
15. Using special tool MD-9988785 (1), lock the upper balance shaft pulley in place.
16. Remove the upper balance shaft pulley bolt. (Tighten: Upper balance shaft pulley bolt to
45 N·m)
17. Using special tool MD-9988778 (1), remove the upper balance shaft pulley.
18. Remove the front cover.
19. Remove the front cover gasket.
20. Remove the lower balance shaft.
21. Remove the lower balance shaft bearings (See Lower Balance Shaft Bearing Replacement in Sec-
tion 02 Engine).
22. Installation is in the reverse order of removal.
ON-VEHICLE SERVICE
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02–210Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Lower Balance Shaft Bearing Replacement
1. Using special tool MD-998371 (1), remove thelower balance shaft front bearing from the cylinder
block.
2. Using special tool MD-998705 (1) MD-991603 (2), remove the lower balance shaft rear bearing from
the cylinder block.
3. Using special tool MD-998705 (2), install the rear bearing.
NOTE :
Align the oil holes (1) in the rear bearing and the cylin-
der block.
ON-VEHICLE SERVICE
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02–211Chery Automobile Co., Ltd.