lock CHERY TIGGO 2009 Service Owner's Guide

Downloaded from www.Manualslib.com manuals search engine 4. Remove the connecting rod retaining bolts.
5. Remove the connecting rod bearing cap.
6. Using a hammer handle or similar tool, push theconnecting rod/piston assembly (1) out through the
top of the cylinder block.
7. Remove the connecting rod bearings (See Con- necting Rod Removal & Installation in Section 02
Engine).
CAUTION: When removing the connecting rod
side bearings, note the installation position.
Keep them in the correct order.
8. Installation is in the reverse order of removal.
ENGINE UNIT REPAIR
BESM020042
BESM020043
BESM020044
BESM020045
02
02–124Chery 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 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 Connecting Rods
Specifications
Torque Specifications
DESCRIPTIONTORQUE (N·m)
Connecting Rod Bolts 1st Step: Tighten bolts to 25 N·m
2nd Step: Tighten the connecting rod bolts an additional 90°
Clearance Specifications
DESCRIPTION SPECIFICATION (mm)
Connecting Rod Radial Clearance 0.016 - 0.051
Connecting Rod Axial Clearance 0.002 - 0.013
Disassembly
1. Remove the connecting rod cap bolts.
2. Remove the connecting rod bearing cap.
3. Using a hammer handle or similar tool, push the
piston and connecting rod assembly (1) out
through the cylinder head side of the engine block.
NOTE: Before removing the piston and connecting
rod assembly, check the connecting rod side
clearance.
ENGINE UNIT REPAIR
BESM020043
BESM020044
02–131Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Crankshaft
Specifications
Torque Specifications
DESCRIPTIONTORQUE (N·m)
Main Bearing Cap Bolts 1st Step: Tighten the bolt to 45 N·m
2nd Step: Tighten the bolt an additional 180°
Lower Cylinder Block Bolts 23
Clearance Specifications
DESCRIPTIONSPECIFICATION (mm)
Diameter of Crankshaft Main Journals 53.981 - 54
Diameter of Crankshaft Rod Journals 47.884 - 47.9
Out-of-Round Maximum of Crankshaft Main Journals 0.008
Axial Clearance of Crankshaft 0.07 - 0.265
Radial Clearance of Crankshaft 0.0035 - 0.034
Coaxality of Crankshaft Main Journals 0.05
Thrust Washer Thickness 2.4 - 2.405
Disassembly
1. Remove the front crankshaft oil seal (See Front Crankshaft Oil Seal Removal & Installation in Section 02
Engine).
2. Remove the rear crankshaft oil seal (See Rear Crankshaft Oil Seal Removal & Installation in Section 02 Engine).
3. Remove the pistons with connecting rod assemblies.
4. Remove the lower cylinder block bolts in the sequence shown.
NOTE: Before loosening the lower cylinder block
bolts, measure the crankshaft side clearance.
5. Remove the lower cylinder block.
6. Remove the crankshaft.
7. Remove the main bearings and thrust bearings from the cylinder block and lower cylinder block. NOTE: If reusing the bearings, identify and number the bearings so that they are assembled in the same position
and direction.
ENGINE UNIT REPAIR
BESM020074
02–133Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Assembly
1. Install the main bearings and thrust bearings to the upper cylinder block and lower cylinder block.NOTE: Identify and number the bearings, if reusing them, so that they are assembled in the same position and
direction.
2. Assemble the crankshaft and main bearings in the reverse order of disassembly.
ENGINE UNIT REPAIR
02–135Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 2.4L ENGINE MECHANICAL
GENERAL INFORMATION02-151
Description 02-151
Operation 02-151
Specifications 02-151
Special Tools 02-154
Lubrication System 02-160
DIAGNOSIS & TESTING02-163
Engine Performance Diagnostics 02-163
Engine Mechanical Diagnostics 02-164
Cylinder Compression Pressure Test 02-165
Cylinder Head Gasket Test 02-166
Engine Oil Pressure Test 02-166
ON-VEHICLE SERVICE02-167
Accessory Drive Belt 02-167
Removal & Installation 02-167
Air Cleaner Element 02-168
Removal & Installation 02-168
Air Cleaner Housing 02-169
Removal & Installation 02-169
Cylinder Head Cover 02-170
Removal & Installation 02-170
Camshaft 02-171
Removal & Installation 02-171
Cylinder Head 02-175
Removal & Installation 02-175
Front Crankshaft Oil Seal 02-177
Removal & Installation 02-177
Rear Crankshaft Oil Seal 02-179
Removal & Installation 02-179
Engine Mounts 02-181
Removal & Installation - Left Mount 02-181
Removal & Installation - Right Mount 02-182
Removal & Installation - Front Mount 02-182
Removal & Installation - Rear Mount 02-183
Engine Assembly 02-183
Removal & Installation 02-183
Engine Timing Belt 02-189
Removal & Installation 02-189
Inspection 02-194
Timing Belt Automatic Tensioner 02-196
Removal & Installation 02-196
Inspection 02-197
Upper Balance Shaft Timing Belt 02-198
Removal & Installation 02-198Exhaust Manifold
02-200
Removal & Installation 02-200
Intake Manifold 02-201
Removal & Installation 02-201
Upper Balance Shaft 02-204
Removal & Installation 02-204
Upper Balance Shaft Bearing
Replacement 02-207
Lower Balance Shaft 02-208
Removal & Installation 02-208
Lower Balance Shaft Bearing
Replacement 02-211
Oil Filter 02-212
Removal & Installation 02-212
Oil Pan 02-213
Removal & Installation 02-213
Oil Pump 02-215
Removal & Installation 02-215
Oil Strainer 02-216
Removal & Installation 02-216
ENGINE UNIT REPAIR02-217
Engine Block 02-217
Specifications 02-217
Disassembly 02-218
Inspection 02-220
Assembly 02-220
Pistons 02-221
Specifications 02-221
Disassembly 02-222
Inspection 02-224
Assembly 02-226
Connecting Rods 02-229
Specifications 02-229
Disassembly 02-229
Inspection 02-230
Assembly 02-231
Crankshaft 02-233
Specifications 02-233
Disassembly 02-234
Inspection 02-236
Assembly 02-237
02–149Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION
Description
The 2.4L in-line four cylinder engine has the following features:
•Single overhead camshaft
• Four valves per chamber cylinder head design
• Aluminum cylinder head
• Cast iron cylinder block
Operation
The 2.4L engine utilizes 4 valves-per-cylinder and a single-overhead-camshaft design. The engine uses an individual
coil ignition system and multi-point sequential injection. The cylinder block is made of cast iron and the bearing caps
are integrated into the lower cylinder block assembly. A cast iron oil pan is located at the bottom of the lower cylinder
block. The camshaft is mounted in the cylinder head and acts against the valve tappets to open and close the valves.
The camshaft is driven off the front of the cylinder head by the timing belt. The belt is driven by a sprocket that is
located on the crankshaft. The piston assembly is an aluminum piston with a cast iron connecting rod.
The aluminum cylinder head contains a single overhead camshaft with 4 valves-per-cylinder construction. The valves
are arranged in two in-line banks. The cylinder head incorporates powdered metal valve guides and seats. The cyl-
inder head is sealed to the block using a multi-layer steel head gasket and retaining bolts.
Specifications
2.4L General Engine Specifications
DESCRIPTION SPECIFICATION
Type In-Line, OHV, SOHC
Number of Cylinders 4
Compression Ratio 9:1
Output Power (kw) 95 / 5500 RPM
Stroke 100 mm
Cylinder Diameter 86.5 mm
Displacement 2351 cc
Firing Order 1-3-4-2
Max Torque (N·m) 198.1
2.4L Mechanical Specifications
ITEMSTANDARD LIMIT
Engine Timing Belt Tensioner Arm Protrusion
12-
Tensioner Arm Depression (98-196 N) ≤1-
Camshaft Cam Height Air-In
37.5037.00
Air-Out 36.9936.49
Shaft Diameter 45.0-
Cylinder Head Lower Surface Flatness
0.030.2
Surface Grinding Limit* Total Grinding of Cylinder Block and Cylinder Head -
0.2
Full Height 119.9 - 120.1-
02–151Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine ITEMSTANDARD LIMIT
Valve Edge Thickness
Air-In
1.00.5
Air-Out 1.20.7
Valve Rod Diameter 6.0-
Crest Clearance Between Valve Rod and Guide Air-In
0.02 - 0.05 0.10
Air-Out 0.03 - 0.07 0.15
Inclination Angle 45° - 45.5°-
Height Air-In
112.30 111.80
Air-Out 114.11113.61
Valve Spring Free Height
51.050.0
Pre-Loading Force/Operation Height km/mm 27.2/44.2-
Center Line ≤2°≤4°
Valve Guide Valve Margin
0.9 - 1.3-
Internal Diameter 6.0-
External Diameter 11.0-
Depression Depth 14.0-
Valve Stem Height 49.349.8
Engine Oil Pump Side Clearance Driving Gear 0.08 - 0.14
-
Driven Gear 0.06 - 0.12 -
Piston Piston Clearance 0.02 - 0.04-
Piston Ring Lateral Clearance
No.1 Ring 0.02 - 0.06
0.1
No.2 Ring 0.02 - 0.06 0.1
End Clearance No.1 Ring 0.25 - 0.35
0.8
No.2 Ring 0.40 - 0.55 0.8
Oil Ring 0.10 - 0.40 1.0
Piston Pin External Diameter
22.0-
Depressing Force (Kg) 755 - 1750-
Depressing Force (Kg) Room
Temperature -
Connecting Rod Big End Clearance 0.10 - 0.250.4
Crankshaft Axial Clearance
0.05 - 0.180.25
Main Journal Diameter 57-
Connecting Journal Diameter 45-
Main Journal Oil Clearance 0.02 - 0.040.1
Cylinder Block Upper Surface Flatness
0.050.1
Upper Surface Grinding Limit -*0.2
Cylinders Cylinder Out-of-Round 0.01-
Cylinder Head Replacement Valve Guides
0.25 O.S. 11.25 - 11.27
-
0.50 O.S. 11.50 - 11.52 -
Intake Valve Replacement Valve Seats 0.30 O.S. 34.435 -34.455
-
0.60 O.S. 34.735 - 34.755 -
Exhaust Valve Replacement Valve Seats 0.30 O.S. 31.935 - 31.955
-
0.60 O.S. 32.235 - 32.255 -
GENERAL INFORMATION
02
02–152Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Torque Specifications
CAUTION:
When torquing a fastener in two steps, DO NOT use a torque wrench for the second step.
DESCRIPTIONTORQUE (N·m)
Alternator Adjusting Bolt 10
Alternator Bracket Bolt 24
Alternator Center Nut 45
Camshaft Position Sensor Bracket 14
Camshaft Position Sensor 10
Camshaft Position Sensor Cylinder 22
Crank Belt Gear 25
Ignition Coil 10
Locking Bolt 22
Spark Piston 25
Water Pump Belt Gear 9
Timing Belt Automatic Tensioner Bolt 24
Belt Gear of Balance Axle 46
Central Belt Wheel Bolt 36
Lower Balance Shaft Bolt 55
Timing Belt Cover Bolts 11
Tensioner Wheel Bolt 49
Tensioner Arm Bolt 22
Tensioner Bracket 49
Timing Belt Indicator 09
Timing Belt Rear Cover 11
Upper Balance Shaft Tensioner Bolt 19
Camshaft Pulley Bolt 90
Crankshaft Pulley Bolt 120
Connecting Bolt of Outflow Pipe 20
EGR Valve 22
Exhaust Manifold Nut (M8) 30
Exhaust Manifold Nut (M10) 50
Fuel Pressure Regulator 9
Fuel Return Pipe 09
Injector and Distribution Pipe 12
Intake Manifold Bolt 20
Intake Manifold Bracket 14
Thermostat Housing Bolt 24
Water Pump Bolts 14
Rocker Cover Bolt 4
Rocker and Camshaft Assembly Bolt 32
Trust Bearing Cover Bolt 19
GENERAL INFORMATION
02–153Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Oil Filter WrenchMB-991828
Oil Filter WrenchMB-991396
Lubrication System
The engine lubrication system operates as follows:
• Oil is drawn into the oil pump through the oil pump strainer tube in the sump of the oil pan.
• Oil is pumped through the oil filter to the cylinder block.
• Oil enters the main oil gallery where it is distributed to the crankshaft main journals and to the cylinder head.
• From the main journals, the oil is routed through cross-drilled passages in the crankshaft to lubricate the con-
necting rod bearings. Controlled leakage through the crankshaft main bearings and connecting rod bearings is
slung radially outward to cool and lubricate the cylinder walls as well as the entire connecting rod, piston and
piston ring assembly.
• The lubrication system is a fully force-fed, full-flow filtration type. The oil pump is a gear type which is driven by
the crankshaft via the timing belt.
GENERAL INFORMATION
02
02–160Chery Automobile Co., Ltd.