battery CHERY TIGGO 2009 Service Owner's Manual

Downloaded from www.Manualslib.com manuals search engine DIAGNOSIS & TESTING
Engine Performance Diagnostics
CONDITIONPOSSIBLE CAUSES 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
02–163Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine CONDITIONPOSSIBLE CAUSES CORRECTION
Oil Pressure Drop 1. Low oil level.
2. Faulty oil pressure sending unit.
3. Low oil pressure.
4. Clogged oil filter.
5. Thin or diluted oil.
6. Excessive bearing clearance.1. Check engine oil level.
2. Install new sending unit.
3. Check sending unit and main
bearing oil clearance.
4. Install new oil filter.
5. Change oil to correct viscosity.
6. Measure bearings for correct
clearance.
Oil Leaks 1. Misaligned or deteriorated
gaskets.
2. Loose fastener, broken or porous
metal part.
3. Misaligned or deteriorated cup or
threaded plug.1. Replace gasket.
2. Tighten, repair or replace the part.
3. Replace if necessary.
Oil Consumption Or Spark Plugs
Fouled 1. PCV system malfunction.
2. Worn, scuffed or broken rings.
3. Carbon in oil ring slots.
4. Rings fitted too tightly in grooves.
5. Worn valve guide(s).
6. Valve stem seal(s) worn or
damaged.1. Check system and repair if
necessary.
2. Hone cylinder bores. Install new
rings.
3. Install new rings.
4. Remove rings and check grooves.
If groove is not proper width, replace
piston.
5. Replace cylinder head.
6. Replace seal(s).
Cylinder Compression Pressure Test
•
The result of a cylinder compression pressure test
can be utilized to diagnose several engine malfunc-
tions.
• Ensure the battery is completely charged and the
engine starter motor is in good operating condition.
Otherwise the indicated compression pressures
may not be valid for diagnostic purposes.
Check engine oil level and add oil if neces-
sary.
Disconnect the spark plug wires.
Remove all spark plugs from engine (as spark plugs are being removed, check electrodes for
abnormal firing indicators fouled, hot, oily,
etc.).
Record cylinder number of each spark plug for future reference.
Disconnect fuel injector electrical connectors.
Be sure throttle blade is fully open during the compression check.
Insert compression pressure adaptor or the equivalent into each spark plug hole in cylinder head.
Crank engine until maximum pressure is reached on gauge. Record each cylinder pressure.
Compression should not be less than 880 kPa and not vary more than 25 percent from cylinder to cylinder.
If one or more cylinders have abnormally low compression pressures, repeat the compression test.
If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem with the cylinder in question.
NOTE :
The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine
should not be disassembled to determine the cause of low compression unless some malfunction is present.
DIAGNOSIS & TESTING
LTSM020191
02
02–165Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Air Cleaner Housing
Removal & Installation
1. Disconnect the negative battery cable.
2. Disconnect the air flow sensor electrical connector.
3. Loosen the clamp between the air intake hose and the air cleaner.
4. Remove the retaining bolt (1), securing the aircleaner housing to its base.
(Tighten: Air cleaner housing retaining bolts to
10 N·m)
5. Remove the air cleaner housing.
6. Installation is in the reverse order of removal.
ON-VEHICLE SERVICE
LTSM020240
LTSM020160
02
02–169Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Cylinder Head Cover
Removal & Installation
1. Disconnect the negative battery cable.
2. Remove the accelerator cable bracket bolts (1).(Tighten: Accelerator cable bracket bolts to 10 N·m)
3. Remove the accelerator cable.
4. Remove the air flow hose clamp (2) and discon- nect the air flow hose.
5. Remove the spark plug wires (3) and set them aside (See Spark Plug Wire Removal & Installation
in Section 03 Electronic Engine Controls).
6. Remove the PCV tube (5).
7. Remove the cylinder head cover bolts (4). (Tighten: Cylinder head cover bolts to 11 N·m)
8. Remove the cylinder head cover from the cylinder head.
9. Remove the cylinder head cover gasket if necessary.
10. Installation is in the reverse order of removal.
NOTE :
Install a new cylinder head cover gasket during installation.
ON-VEHICLE SERVICE
LTSM020175
02–170Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine •Use special tool MD-998776 (2) and MD-990938 (1), to install the rear oil seal.
• Ensure that the lip of the seal is facing toward the
crankcase during installation.
Engine Mounts
Removal & Installation - Left Mount
NOTE :
The following special tools are required to perform the repair procedure:
•Engine Hoist
1. Disconnect the negative battery cable.
2. Remove the air cleaner housing. (See Air Cleaner Housing Removal & Installation in Section 02
Engine).
3. Support the engine with the engine hoist.
4. Remove the engine left mount retaining bolts (2) and remove the engine left mount bracket bolts (1).
(Tighten: Engine left mount bolts to 70 N·m)
5. Installation is in the reverse order of removal.
ON-VEHICLE SERVICE
LTSM020132
LTSM020156
02
02–181Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Removal & Installation - Right Mount
NOTE :
The following special tools are required to perform the repair procedure:
•Engine Hoist
1. Disconnect the negative battery cable.
2. Support the engine with the engine hoist.
3. Remove the engine right mount retaining bolts (2) and remove the engine right mount bracket bolts
(1).
(Tighten: Engine right mount bolts to 70 N·m)
4. Installation is in the reverse order of removal.
Removal & Installation - Front Mount
NOTE :
The following special tools are required to perform the
repair procedure:
• Engine Hoist
1. Disconnect the negative battery cable.
2. Support the engine with the engine hoist.
3. Remove the bolts (1) securing the front engine mount.
(Tighten: Engine front mount bolts to 60 N·m)
4. Installation is in the reverse order of removal.
ON-VEHICLE SERVICE
LTSM020155
BESM080035
02–182Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Removal & Installation - Rear Mount
NOTE :
The following special tools are required to perform the
repair procedure:
•Engine Hoist
1. Disconnect the negative battery cable.
2. Support the engine with the engine hoist.
3. Remove the engine rear mount retaining bolts (2) and remove the engine rear mount bracket bolts
(1).
(Tighten: Engine rear mount bolts to 60 N·m)
4. Installation is in the reverse order of removal.
Engine Assembly
Removal & Installation
NOTE :
The following special tools are required to perform the repair procedure:
• Engine Hoist
NOTE :
The engine is removed with the transaxle as an assembly. 1. Relieve the fuel pressure (See Fuel Pressure Relief Procedure in Section 04 Fuel Delivery).
2. Disconnect the negative battery cable.
3. Remove the battery, battery hold downs, and battery tray (See Battery Removal & Installation in Section 05 Starting & Charging).
4. Remove the hood.
5. Discharge air conditioning system (See A/C System Evacuation and Recharge in Section 13 Heating & Air Con- ditioning).
6. 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.
7. Remove the coolant fan & radiator assembly (See Coolant Fan & Radiator Assembly Removal & Installation in Section 06 Cooling).
8. Remove the starter motor wiring.
9. Remove the negative battery cable from the engine.
ON-VEHICLE SERVICE
LTSM020188
02
02–183Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 8. Installation is in the reverse order of removal.
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.
1 - Inlet Manifold Gasket
2 - Knock Sensor
3 - Coolant Hose
4 - Coolant Hose
5 - Coolant Temperature Sensor6 - Coolant Outlet Fitting
7 - Intake Manifold Support Bracket
8 - Intake Manifold
9 - Engine Hanger
ON-VEHICLE SERVICE
LTSM020178
02
02–201Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Hardware Requirements
The hardware configuration of X-431 is as follows:
Diagnostic Scan Tool Configuration
ITEM NAMEFUNCTION
1 X-431 Main Unit To Display Operational
Buttons, Test Results, Help
Information, etc.
2 Mini-Printer To Print Test Results.
(Optional)
3 CF Card To Store Diagnostic Software
and Data
4 USB Cable To Connect CF Card
Reader/Writer and Computer
5 CF Card
Reader/Writer To Read or Write Data On
The CF Card
6 Mitsubishi-12+16
Pin Connector To Diagnose Mitsubishi
Electronic Control Systems
On Chery B11 Series
7 Fiat-3 Pin
Connector To Diagnose Vehicles With
Fiat-3 Pin Diagnostic
ConnectorITEM NAME
FUNCTION
8 Smart OBDII-16
Pin Connector To Diagnose Other Systems
Of Vehicle With OBDII-16
Pin Diagnostic Connector
9 Power Cord To Connect AC 100 - 240 V
Outlet and Power Adapter
10 Cigarette Lighter
Cable To Get Power From Vehicle
Cigarette Lighter
11 Battery Cable
W/Two Clips To Get Power From Vehicle
Battery
12 Power Adapter To Convert 100 - 240 V AC
Power Into 12 V DC Power
13 Main Cable To Connect The Diagnostic
Connector and Smartbox
14 Smartbox To Perform Vehicle
Diagnosis
GENERAL INFORMATION
BESM030003
03–8Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Electronic Throttle Control Actuator Self-Learning Operation Introduction
EPC Lamp Control Strategy
The Electronic Pedal Control (EPC) lamp will be on for a few seconds and turn off after the ignition switch is turned
on and the engine is not running. After the engine started, the EPC lamp will go off if the DTC is not existent in ECM.
If the internal self-check failed, the EPC lamp will continue to light.
Electronic Throttle Control Actuator Self-Learning Condition
•Engine stopped and the ignition switch on.
• Vehicle speed is 0 km/h.
• The Engine Coolant Temperature (ECT) is between 5.25°C and 100.5°C.
• The intake air temperature is more than 5.25°C.
• The accelerator pedal fully released.
• Battery voltage is more than 12 V.
Electronic Throttle Control Actuator Self-Learning Operating Procedure
Turn the ignition switch on for 10 seconds, then turn the ignition switch off. During the procedure, do not operate any
other components.
Self-Learning Components
Perform the self-learning process when the following repairs have been made:
•Replaced the ECM
• ECM which was disconnected and reconnected
• Replaced the Accelerator Pedal
• Replaced the Electronic Throttle Control Actuator
Self-Learning Operating Procedure
Turn the ignition switch on for 10 seconds, then turn the ignition switch off. During the procedure, do not operate any
other components.
Self-Learning Condition
The self-learning condition as the Electronic Throttle Control Actuator Self-Learning Condition.
CAUTION:
Ensure that the Electronic Throttle Control Actuator self-learning process lasts for at least 10 sec-
onds according to the Electronic Throttle Control Actuator self-learning condition. If the self-learn-
ing process fails, the engine can’t be started or the EPC lamp will be on. If this condition occurs,
perform the Self-Learning operating again after the DTCs be erased in ECM.
Diagnostic Trouble Code (DTC) List
DTC DTC DEFINITION
P000A ACamshaft Position Slow Response
P000B BCamshaft Position Slow Response
P0010 ACamshaft Position Actuator Circuit/Open
P0011 ACamshaft Position - Timing Over - Advanced or System Performance
P0012 ACamshaft Position - Timing Over - Retarded
P0013 BCamshaft Position - Actual Circuit/Open
P0014 BCamshaft Position - Timing Over - Advanced or System Performance
P0015 BCamshaft Position - Timing Over - Retarded
P0016 Crankshaft - Camshaft Position Correlation
P0030 O
2Sensor Heater Control Circuit (Bank 1 Sensor 1)
P0031 O
2Sensor Heater Control Circuit (Bank 1 Sensor 1) Low
DIAGNOSIS & TESTING
03
03–23Chery Automobile Co., Ltd.