torque CHERY TIGGO 2009 Service Service Manual

Downloaded from www.Manualslib.com manuals search engine Connecting Rod Cap Nuts
•Apply engine oil to the connecting rod bolts.
• Install each connecting rod nut finger tight, then
alternately tighten each nut to assemble the cap
properly.
• Tighten the connecting rod nuts using the two step
torque-turn method:
1st Step: Tighten nuts to 20 N·m
2nd Step: Tighten the connecting rod nuts an
additional 90°- 100°
CAUTION:
If the nuts are over tightened (exceed angle of
100°), loosen the nuts and restart the torque
sequence from Step 1.
Crankshaft
Specifications
Torque Specifications
DESCRIPTION TORQUE (N·m)
Main Bearing Cap Bolts 1st Step: Tighten the bolts to 25 N·m
2nd Step: Tighten the bolts an additional 180°
Clearance Specifications
DESCRIPTION SPECIFICATION (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 Crankshaft Main Journal 0.05
Thrust Washer Thickness 2.4 - 2.405
ENGINE UNIT REPAIR
LTSM020120
02
02–233Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Inspection
Crankshaft Axial Clearance
•Check the axial clearance of the crankshaft.
CRANKSHAFT AXIAL CLEARANCE
DESCRIPTION SPECIFICATION MAXIMUM LIMIT
Crankshaft 0.05 - 0.18 mm 0.25 mm
Crankshaft Bearing Oil Clearance (Plastigauge)
•Check the oil clearance of the crankshaft.
Clean all engine oil off of the crankshaft jour-
nals.
Cut the plastigauge into lengths as wide as the crankshaft journal.
Lay the plastigauge across the crankshaft journal.
Carefully install the main bearing cap.
Torque the main bearing cap to the specified torque.
Carefully disassemble the main bearing cap.
Use the measuring rule imprinted on the plas- tigauge package to measure the width of the
widest part of the plastigauge.
ENGINE UNIT REPAIR
BESM020076
BESM020077
02–236Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine •Main bearing and thrust bearing installation.
Install the main bearings with oil grooves on
the cylinder block side.
Install the main bearings without oil grooves (2) on the bearing cap.
Install the two thrust bearings on crankshaft journal No. 3. Apply clean oil to the surface of
thrust bearing.
The grooved (1) side of the thrust bearing should face towards the crankshaft.
Main Bearing Caps and Bolts
• Install the main bearing caps with the arrow on the main caps (1) facing the front of the engine.
• Install the main bearing cap bolts in the sequence
shown.
• Torque the bearing cap bolts in the sequence
shown to 25 N·m.
• Tighten the main bearing cap bolts an additional 90°- 100° in the sequence shown.
CAUTION:
If the bolts are over tightened (exceed angle of
100°), loosen the bolts and restart the torque
sequence from Step 1
•After installing the main bearing caps, assure that the crankshaft rotates smoothly.
ENGINE UNIT REPAIR
LTSM020128
LTSM020129
LTSM020130
02
02–239Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine CYLINDER HEAD UNIT REPAIR
Cylinder Head
Specifications
Torque Specifications
DESCRIPTIONTORQUE (N·m)
Cylinder Head Bolts 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 additional 90°
Cylinder Head Cover Bolts 11 N·m
Clearance Specifications
DESCRIPTIONSPECIFICATION (mm)
Cylinder Head Flatness 0.03
Intake Valve Deflection 0.02
Exhaust Valve Deflection 0.04
Spring Height 51
Disassembly
NOTE :
The following special tools are required to perform the repair procedure:
•MD-998772 - Valve Spring Compressor
• MD-998774 - Valve Oil Seal Installer
NOTE :
Replacement cylinder head comes complete with valves, seals, springs, retainers, keepers, tappets, and camshafts. 1. Remove camshaft.
2. Using the special tool MD-998772 (1), compress the valve spring.
3. Remove the valve keeper, valve spring retainer and valve spring.
4. Push the valve stem from the cylinder head and remove the valve.
LTSM020092
02
02–241Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine NUMBER ITEMFAILURE MODECORRECTION
10 Fuel Injector •
Unstable idle.
• Lack of engine power.
• Poor acceleration.
• Engine will not start.
• Plugged injector. Replace
11 TPS•
Poor acceleration.
• The MIL light will turn on. Replace
12 EVAP•
The engine base fuel closed-loop control self-learning will be
shut off.
• The engine idle air control self-learning will be shut off.
• Unstable idle or high idle. Replace
13 Fuel Pump •
Noisy fuel pump operation.
• Poor acceleration.
• Engine will not start. Replace
14 MAP•
Poor acceleration.
• Unstable idle.
• Rough engine operation. Replace
15 IAT•
Intake air temperature will be equal to the coolant
temperature. Replace
16 Cooling Fan •
High engine temperature.
• Poor air conditioner performance. Replace
17 Accelerator
Sensor •
Misfire
• Poor driving capability.
• Rough engine operation. Replace
Specifications
Torque Specifications
DESCRIPTION
TORQUE (N·m)
Engine Coolant Temperature (ECT) Sensor 20
Knock Sensor 20
Oxygen Sensors 45
Crankshaft Position (CKP) Sensor 10
Camshaft Position (CMP) Sensor 7
Air Flow Sensor Bolts 5
Engine Control Module (ECM) Bolts 10
Accelerator Pedal Position (APP) Sensor 11
Electronic Throttle Control Actuator 10
Vehicle Speed Sensor 10
Manifold Absolute Pressure (MAP) Sensor 6
GENERAL INFORMATION
03
03–5Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine DTCDTC DEFINITION
P0605 Internal Control Module ROM Test Error
P0606 ECM Processor
P0627 Fuel PumpAControl Circuit/Open
P0628 Fuel PumpAControl Circuit Low
P0629 Fuel PumpAControl Circuit High
P0645 A/C Clutch Relay Circuit
P0646 A/C Clutch Relay Control Circuit Low
P0647 A/C Clutch Relay Control Circuit High
P0650 Malfunction Indicator Lamp Control Circuit
P0688 EMC/ECM Power Relay Sense Circuit Open
P0691 Cooling Fan 1 Control Circuit Low
P0692 Cooling Fan 1 Control Circuit High
P0693 Cooling Fan 2 Control Circuit Low
P0694 Cooling Fan 2 Control Circuit High
P0700 Transmission Control System Malfunction
P0704 Clutch Switch Input Circuit
P1297 Manufacturer Controlled Computer And Auxiliary Outputs
P1336 Engine Torque Control Adaptation at Limit
P1545 Throttle Position Control Malfunction
P1558 Throttle Actuator Electrical Malfunction
P1559 Idle Speed Control Throttle Position Adaptation Malfunction
P1564 Idle Speed Control Throttle Position Low Voltage During Adaptation
P1565 Idle Speed Control Throttle Position Lower Limit not Attained
P1568 Idle Speed Control Throttle Position Mechanical Malfunction
P1579 Idle Speed Control Throttle Position Adaptation Not Started
P1604 Internal Control Module Driver Error
P1610 Manufacture Controlled Computer and Auxiliary Outputs
P1611 Manufacture Controlled Computer and Auxiliary Outputs
P1612 Manufacture Controlled Computer and Auxiliary Outputs
P1613 Manufacture Controlled Computer and Auxiliary Outputs
P1614 Manufacture Controlled Computer and Auxiliary Outputs
P1651 Manufacture Controlled Computer and Auxiliary Outputs
P2106 Throttle Actuator Control System Forced Limited Power
P2122 Throttle/Pedal Position Sensor/Switch D Circuit Low Input
P2123 Throttle/Pedal Position Sensor/Switch D Circuit High Input
P2127 Throttle/Pedal Position Sensor/Switch E Circuit Low Input
P2128 Throttle/Pedal Position Sensor/Switch E Circuit High Input
P2138 Accelerator Pedal Position Sensor Signal Correlation Error
P2177 System Too Lean off Idle
P2178 System Too Rich off Idle
P2187 System Too Lean at Idle
P2188 System Too Rich at Idle
P2195 O
2Sensor Signal Stuck Lean; Bank 1 Sensor 1
DIAGNOSIS & TESTING
03–26Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine NUMBER ITEMFAILURE MODECORRECTION
10 Fuel Injector •
Unstable idle.
• Lack of engine power.
• Poor acceleration.
• Engine will not start.
• Plugged injector. Replace
11 TPS•
Poor acceleration.
• The MIL light will turn on. Replace
12 EVAP•
The engine base fuel closed-loop control self-learning will be
shut off.
• The engine idle air control self-learning will be shut off.
• Unstable idle or high idle. Replace
13 Fuel Pump •
Noisy fuel pump operation.
• Poor acceleration.
• Engine will not start. Replace
14 MAP•
Poor acceleration.
• Unstable idle.
• Rough engine operation. Replace
15 IAT•
Intake air temperature will be equal to the coolant
temperature. Replace
16 Cooling Fan •
High engine temperature.
• Poor air conditioner performance. Replace
17 Accelerator
Sensor •
Misfire
• Poor driving capability.
• Rough engine operation. Replace
Specifications
Torque Specifications
DESCRIPTION
TORQUE (N·m)
Engine Coolant Temperature Sensor 20
Knock Sensor 20
Oxygen Sensors 45
Crankshaft Position Sensor 10
Camshaft Position Sensor 7
Air Flow Sensor 5
Engine Control Module 10
Accelerator Pedal Position Sensor 11
Electronic Throttle Control Actuator 10
Vehicle Speed Sensor 10
GENERAL INFORMATION
03
03–231Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine DTCDTC DEFINITION
P0537 A/C Evaporator Temperature Sensor Circuit Low
P0538 A/C Evaporator Temperature Sensor Circuit High
P0560 System Voltage Malfunction
P0562 System Voltage Low Voltage
P0563 System Voltage High Voltage
P0571 Brake SwitchACircuit
P0601 Internal Control Module EEPROM Error
P0602 Control Module Programming Error
P0604 Internal Control Module Random Access Memory (RAM) Error
P0605 Internal Control Module ROM Test Error
P0606 ECM Processor
P0627 Fuel PumpAControl Circuit Open
P0628 Fuel PumpAControl Circuit Low
P0629 Fuel PumpAControl Circuit High
P0645 A/C Clutch Relay Circuit
P0646 A/C Clutch Relay Control Circuit Low
P0647 A/C Clutch Relay Control Circuit High
P0650 Malfunction Indicator Lamp Control Circuit
P0688 EMC/ECM Power Relay Sense Circuit Open
P0691 Cooling Fan 1 Control Circuit Low
P0692 Cooling Fan 1 Control Circuit High
P0693 Cooling Fan 2 Control Circuit Low
P0694 Cooling Fan 2 Control Circuit High
P0700 Transmission Control System Malfunction
P0704 Clutch Switch Input Circuit
P1297 Manufacturer Controlled Computer And Auxiliary Outputs
P1336 Engine Torque Control Adaptation at Limit
P1545 Throttle Position Control Malfunction
P1558 Throttle Actuator Electrical Malfunction
P1559 Idle Speed Control Throttle Position Adaptation Malfunction
P1564 Idle Speed Control Throttle Position Low Voltage during Adaptation
P1565 Idle Speed Control Throttle Position Lower Limit not Attained
P1568 Idle Speed Control Throttle Position Mechanical Malfunction
P1579 Idle Speed Control Throttle Position Adaptation not Started
P1604 Internal Control Module Driver Error
P1610 Manufacture Controlled Computer and Auxiliary Outputs
P1611 Manufacture Controlled Computer and Auxiliary Outputs
P1612 Manufacture Controlled Computer and Auxiliary Outputs
P1613 Manufacture Controlled Computer and Auxiliary Outputs
P1614 Manufacture Controlled Computer and Auxiliary Outputs
P1651 Manufacture Controlled Computer and Auxiliary Outputs
P2106 Throttle Actuator Control System Forced Limited Power
P2122 Throttle/Pedal Position Sensor/Switch D Circuit Low Input
DIAGNOSIS & TESTING
03–252Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine NUMBER ITEMFAILURE MODECORRECTION
10 Fuel Injector •
Unstable idle.
• Lack of engine power.
• Poor acceleration.
• Engine will not start.
• Plugged injector. Replace
11 TPS•
Poor acceleration.
• The MIL light will turn on. Replace
12 EVAP•
The engine base fuel closed-loop control self-learning will be
shut off.
• The engine idle air control self-learning will be shut off.
• Unstable idle or high idle. Replace
13 Fuel Pump •
Noisy fuel pump operation.
• Poor acceleration.
• Engine will not start. Replace
14 MAP•
Poor acceleration.
• Unstable idle.
• Rough engine operation. Replace
15 IAT•
Intake air temperature will be equal to the coolant
temperature. Replace
16 Cooling Fan •
High engine temperature.
• Poor air conditioner performance. Replace
17 Accelerator
Sensor •
Misfire
• Poor driving capability.
• Rough engine operation. Replace
Specifications
Torque Specifications
DESCRIPTION
TORQUE (N·m)
Engine Coolant Temperature Sensor 20
Knock Sensor 20
Oxygen Sensors 45
Crankshaft Position Sensor 20
Camshaft Position Sensor 10
Air Flow Sensor 8
Engine Control Module 10
Electronic Throttle Control Actuator 10
Vehicle Speed Sensor 10
Coolant Temperature Sensor (For Instrument Cluster) 14
GENERAL INFORMATION
03–444Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Idle Speed Slow Return To Normal Idle
The following conditions apply to this symptom:
•Slow return to idle.
1.PRELIMINARY CHECKS
• Carry out the following preliminary checks:
Vacuum leaks
Intake air system
Throttle body
Are all checks OK?
Ye s>>Go to the next step.
No
>>Repair as necessary.
Verify the symptom no longer exists.
2.CHECK ECM DTC
• Turn the ignition switch on.
• With the scan tool X-431, read the DTC.
Are there any DTCs present?
Ye s>>Repair as necessary.
No
>>Go to the next step.
3.CHECK PCV VALVE
• Remove Positive Crankcase Ventilation (PCV) valve and shake it.
Does PCV valve rattle?
Ye s>>Install PCV valve, go to the next step.
No
>>Replace the PCV valve.
4.CHECK PCV SYSTEM
• Start engine and bring to normal operating temperature. Disconnect crankcase ventilation hose from PCV valve.
Place a stiff piece of paper over the hose. Wait 1 minute.
Does vacuum hold paper in place?
Ye s>>Verify test results. If OK, see diagnostic index to repair any additional symptom.
No
>>Check for vacuum leaks, obstructions in the PCV system, oil cap, PCV valve, rocker cover bolt
torque/gasket leak. Repair as necessary.
ELECTRONIC ENGINE CONTROLS - 2.4L ENGINE SYMPTOM DIAGNOSIS
03–564Chery Automobile Co., Ltd.