engine coolant CHERY TIGGO 2009 Service Owner's Manual

Downloaded from www.Manualslib.com manuals search engine Inspection
NOTE :
All measurements should be taken with the engine block at room temperature, 21°C.
Engine Block
•Clean cylinder block thoroughly and check all core hole plugs for evidence of leaking.
• Examine block and cylinder bores for cracks or fractures.
• Check block deck surfaces for flatness. Deck surface must be within service limit of 0.050 mm.
Cylinder Bore
• The cylinder walls should be checked for out-of-round and taper with cylinder indicator or equivalent. If the cyl-
inder walls are badly scuffed or scored, the cylinder block should be replaced, and new pistons and rings fitted.
• Measure the cylinder bore at three levels in directions X and Y. Top measurement should be 10 mm down and
bottom measurement should be 10 mm up from
bottom of bore.
CYLINDER BORE
All Cylinders 83.500 - 83.510 mm
Assembly
NOTE :
Cleanliness is extremely important during the engine assembly procedure. Any foreign material, including any mate-
rial created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause
engine failure.
NOTE :
Assemble all components in their original position.
1. Install the pistons to the connecting rods.
2. Using a piston ring expander, install the piston rings.
3. Assemble all components in the reverse order of disassembly.
ENGINE UNIT REPAIR
BESM020063
02–125Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Cylinder Head Gasket Test
•A cylinder head gasket leak can be located between adjacent cylinders, between a cylinder and the adjacent
water jacket or from an oil passage to the exterior of the engine.
• Possible indications of the cylinder head gasket leaking between adjacent cylinders are:
Loss of engine power
Engine misfiring
Poor fuel economy
• Possible indications of the cylinder head gasket leaking between a cylinder and an adjacent water jacket are:
Engine overheating
Loss of coolant
Excessive steam (white smoke) emitting from exhaust
Coolant foaming
Engine Oil Pressure Test
1. Check the engine oil level.
2. Disconnect the oil pressure switch electrical connector.
3. Remove the oil pressure switch.
4. Install the mechanical oil pressure gauge.
5. Start the engine and warm to normal operating temperature.
6. After the engine has been warmed up, check that the oil pressure is within the specifications. Standard Oil Pressure: At 750 ± 50 RPM: 0.8 MPa
7. Stop the engine.
8. Remove the oil pressure gauge.
9. Apply the specified sealant to the thread (1) of oil pressure switch.
10. Install the oil pressure switch (Tighten: Oil pres- sure switch to 10 ± 2 N·m).
DIAGNOSIS & TESTING
LTSM020146
02–166Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine ON-VEHICLE SERVICE
Accessory Drive Belt
Removal & Installation
WARNING!
Inspect the drive belt only when the engine is stopped.
1. Loosen the power steering pump adjustment bolt(1).
1 - Power Steering Pump
2 - Crankshaft Pulley
3 - Idler Pulley
4 - A/C Compressor5 - Coolant Pump Pulley
6 - Generator Pulley
7 - A/C Compressor Belt
8 - Generator Belt
LTSM020176
LTSM020185
02
02–167Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 8. Remove the cylinder head bolts in the sequenceshown.
9. Remove the cylinder head.
10. Remove the cylinder head gasket.
11. Inspect the cylinder head for warp using a straightedge and feeler gauge. Repair the cylinder head if necessary.
12. Installation is in the reverse order of removal.
Installation Notes:
• Ensure cylinder head bolt holes in the block are clean, dry (free of residual oil or coolant), and threads are not
damaged.
• Do not reuse the cylinder head bolts. The new bolts should be examined before use. If the bolts are stretched,
the bolts should be replaced.
• Position the new cylinder head gasket on the engine block with the part number facing up. Ensure gasket is
seated over the locating dowels in the block.
• Before installing the bolts, the threads should be lightly coated with engine oil.
• The cylinder head bolts should be installed and
torqued in the sequence shown.
• Tighten the cylinder head bolts in the following sequence.
1st Step: Tighten the bolt to 78 N·m
2nd Step: Completely loosen the bolt
3rd Step: Retighten the bolt to 20 N·m
4th Step: Tighten the bolt an additional 90°
5th Step: Finish tightening the bolt an addi-
tional 90°
ON-VEHICLE SERVICE
LTSM020237
LTSM020097
LTSM020098
02–176Chery 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 10.Disconnectandremovethefuelline(2)atthefuel
rail.
11.Removethefuelpressureregulatorretainingbolt
(1)andsetthefuelpressureregulatoraside.
(Tighten:Fuelpressureregulatorboltto9N·m)
12.Removetheairinlethoseandtheaircleanercase
assembly.
13.Removetheacceleratorcableboltfromthecylinderhead.
14.Disconnectandremovethefollowingelectricalconnectors:
Coolanttemperaturesensor
Crankshaftpositionsensor
Camshaftpositionsensor
Ignitioncoil
Fourfuelinjectors
Airflowsensor
Canistersolenoidvalve
EGRcontrolsolenoidvalve
Throttlepositionsensor
A/Ccompressor
Oilpressuresensor
Powersteeringpumppressureswitch
Generator
Upstreamoxygensensor
Knocksensor
Idleaircontrolmotor
ON-VEHICLESERVICE
LTSM040006
LTSM020160
02–184CheryAutomobileCo.,Ltd.

Downloaded from www.Manualslib.com manuals search engine NOTE :
The following special tools are required to perform the repair procedure:
•MB-990767 - Timing Belt Spanner Wrench
• MD-998785 - Timing Belt Gear Holder
• MD-998767 - Automatic Tensioner Socket
1. 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.
2. Attach an engine hoist to the engine.
3. Raise the engine with the engine hoist, just enough to support the engine.
1 - Right Engine Mounting Bracket
2 - Spacer
3 - Upper Balance Shaft Pulley
4 - Upper Balance Shaft Timing Belt
5 - Upper Balance Shaft Timing Belt Tensioner
6 - Crankshaft Sensing Blade
7 - Upper Timing Belt Cover
8 - Lower Timing Belt Cover
9 - Timing Belt Automatic Tensioner
10 - Idler Pulley
11 - Crankshaft Bolt12 - Crankshaft Timing Belt Pulley
13 - Lower Balance Shaft Pulley
14 - Crankshaft Position Sensor
15 - Power Steering Bracket
16 - Timing Belt Rear Cover
17 - Timing Belt
18 - Camshaft Timing Pulley
19 - Camshaft Pulley Bolt
20 - Crankshaft Upper Balance Shaft Pulley
21 - Tensioner Arm
22 - Tensioner Pulley
ON-VEHICLE SERVICE
LTSM020048
02–190Chery 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 Inspection
NOTE :
All measurements should be taken with the engine block at room temperature, 21°C.
Engine Block
•Clean cylinder block thoroughly and check all core hole plugs for evidence of leaking.
• Examine block and cylinder bores for cracks or fractures.
• Check block deck surfaces for flatness. Deck surface must be within service limit of 0.050 mm.
Cylinder Bore
• The cylinder walls should be checked for out-of-round and taper with cylinder indicator or equivalent. If the cyl-
inder walls are badly scuffed or scored, the cylinder block should be replaced, and new pistons and rings fitted.
• Measure the cylinder bore at three levels in directions A and B. Top measurement should be 12 mm down and
bottom measurement should be 12 mm up from
bottom of bore.
CYLINDER BORE
Cylinder Size 86.50 - 86.53 mm
Cylinder Cylindrically ≤0.01 mm
Assembly
NOTE :
Cleanliness is extremely important during the engine assembly procedure. Any foreign material, including any mate-
rial created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause
engine failure.
NOTE :
Assemble all components in their original position.
1. Install the pistons to the connecting rods.
2. Using a piston ring expander, install the piston rings.
3. Assemble all components in the reverse order of disassembly.
ENGINE UNIT REPAIR
LTSM020126
02–220Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine CRANKSHAFT BEARING OIL CLEARANCE
Standard Clearance 0.02 - 0.04 mm
Maximum Clearance 0.1 mm
Crankshaft Main Journal Roundness
•The crankshaft main journals should be checked for
excessive wear, roundness and scoring. Limits of
roundness on any crankshaft main journals should
be held to 0.006 mm. Limits of roundness on any
crankshaft rod journals should be held to 0.006
mm. DO NOT nick crank pin or bearing fillets. Lim-
its of out of round on any crankshaft journals
should be held to 0.006 mm.
CRANKSHAFT MAIN JOURNALS
DESCRIPTION SPECIFICATION MAXIMUM LIMIT
Crankshaft Journal Roundness 0.006 mm0.006 mm
Assembly
NOTE :
Cleanliness is extremely important during the engine assembly procedure. Any foreign material, including any mate-
rial created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause
engine failure.
Before installing the main bearing bolts, clean the threads and oil the bolts with clean engine oil.
Crankshaft Main Bearings
•Perform the following when replacing the crankshaft main bearings:
Measure and record the external diameter of
the crankshaft main journals.
ENGINE UNIT REPAIR
BESM020075
LTSM020119
02
02–237Chery Automobile Co., Ltd.