check engine CHERY TIGGO 2009 Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine Ring End Gap
•Wipe the cylinder bore clean. Insert ring and push down with piston to ensure it is square in the bore. The ring
gap measurement must be made with the ring posi-
tioned at least 13 mm from bottom of cylinder bore
and below the bottom of the oil ring travel where
the cylinder bore has minimal wear. Check gap with
feeler gauge.
RING END GAP
DESCRIPTION SPECIFICATION LIMIT
First Ring 0.25 - 0.35 mm 0.8 mm
Second Ring 0.40 - 0.55 mm 0.8 mm
Oil Control Ring 0.10 - 0.40 mm 1.0 mm
Piston Pin Clearance
•Check the diameter of the piston pin bore.
• Check the outer diameter of the piston pin.
ENGINE UNIT REPAIR
BESM020052
BESM020053
02
02–225Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine •Check the inner diameter of connecting rod (small end).
PISTON PIN CLEARANCE
Piston and Piston Pin 0.002 - 0.013 mm
Assembly
Piston Pin Installation
•Measure the following dimensions of each piston
(1), piston pin (2) and connecting rod (3).
Length of piston pin in hole (A).
Width of pin sockets (B).
Length of piston pin (C).
Width of small end of connecting rod (D).
• Put measured sizes above into following formula to
calculate L.
L=[(A-C)-(B-D)] / 2
• After inserting the push rod of the special tool into piston pin, install pipe A in the top of the push rod.
• Install forward marks of piston and connecting rod in the same direction.
• Lubricate the external diameter of piston pin with engine oil.
• Through pipe A, insert the push rod, piston pin and pipe component into piston pin hole from the side with the
forward mark.
• Screw on guide block B into guide pipe A to gain clearance between guide block A (2) and guide block B (1)
equal to the value of Value L (L=[(A-C)-(B-D)] / 2)
plus 3 mm.
• Keep the forward mark of piston upward. Install piston and connecting rod in tool base of piston pin installer.
ENGINE UNIT REPAIR
BESM020054
LTSM020111
LTSM020112
02–226Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine •Using a press, press the piston pin (1) in under pressure. When the pressure is less than standard value,
replace piston pin and piston component and/or
replace connecting rod.standard value: 7,350-
17,200 Newtons
• Check to make sure the piston can rotate freely.
Piston Ring Installation
NOTE :
The compression rings have an identification mark (1)
on the top of the ring.
Piston Ring Identification Marks:
•No. 1 Ring - 1R
• No. 2 Ring - 2R
When installing piston ring, keep the mark upwards and
towards the top of piston.
• Size markings of pistons shown as the following:
SIZE IDENTIFICATION
Standard None
Increase 0.50 mm 50
Increase 1.00 mm 100
CAUTION:
Do not use a piston ring expander to install the oil control rings.
Oil Control Ring Installation
•Install the main ring of oil control ring into oil ring groove.
NOTE :
There is no difference between the upper and lower oil control rings.
ENGINE UNIT REPAIR
LTSM020113
LTSM020116
02
02–227Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 3. Using a hammer handle or similar tool, push thepiston 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.
4. Remove the connecting rod bearings. CAUTION: When removing the connecting rod
side bearings, note the installation position.
Keep them in the correct order.
Inspection
Bearing Radial Clearance
•Check the radial clearance of connecting rod bearing.
CONNECTING ROD RADIAL CLEARANCE
Radial Clearance 0.016 - 0.051 mm
Bearing Oil Clearance (Plastigauge)
•Check the oil clearance of the connecting rods and crankshaft.
Clean all engine oil off of the connecting rod bearing and the crankshaft journal.
Cut the plastigauge into lengths as wide as the crankshaft journal.
Lay the plastigauge across the crankshaft
journal.
Carefully install the connecting rod cap.
Torque the connecting rod cap nuts to 20 N·m
Carefully disassemble the connecting rod 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
BESM020044
BESM020045
LTSM020122
02–230Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine CONNECTING ROD BEARING OIL CLEARANCE
Standard Clearance 0.02 - 0.05 mm
Maximum Clearance 0.1 mm
Assembly
NOTE :
•The connecting rod bolts should NOT be reused.
• Before installing the NEW rod bolts, apply clean engine oil to the threads and under the bolt heads.
Piston and Connecting Rod
•Oil the piston rings and the side of the piston.
• Position the piston rings in the proper alignment
with the piston pin (2):
Top Ring (1)
Bottom Ring (3)
Oil Control Ring (4)
• Install protective coverings over the connecting rod
bolts.
• Rotate the crankshaft journal to the lowest position.
• Use a suitable piston ring compressor to insert the
piston and connecting rod assembly into cylinder.
• Make sure the forward mark on the top of the pis-
ton is facing the front of the engine (5).
• Using a suitable tool, tap the piston and connecting rod assembly into cylinder.
NOTE :
The piston direction mark (2) should point toward the
timing belt side (1).
• Check the axial clearance of the connecting rods.
ENGINE UNIT REPAIR
LTSM020117
LTSM020118
BESM020064
02
02–231Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine CONNECTING ROD AXIAL CLEARANCE
DESCRIPTION SPECIFICATION LIMIT
Connecting Rods 0.10 - 0.25 mm 0.4 mm
Connecting Rod Bearings
•Perform the following steps when replacing the connecting rod bearings:
Measure and record the External Diameter of
the connecting rod journals.
Use the connecting rod bearing identification table to locate the desired bearing.
• The bearing will have an identification mark (1) imprinted in the position as shown.
IDENTIFYING CONNECTING ROD BEARINGS
Internal Diameter of Connecting Rods (without bearing): 48.000 - 48.015 mm Crank Journal Connecting Rod Bearing
Group Identification
Color External
Diameter (mm) Identification
Number Identification
Color Thickness (mm)
1 Yellow 44.995 - 45.000 1 Yellow 1.487 - 1.491
2 None 44.985 - 44.995 2 None 1.491 - 1.495
3 White 44.980 - 44.985 3 Blue 1.495 - 1.499
NOTE :
As an example, if the measurement of the external diameter of the connecting rod journal is 44.996 mm, it will be
identified as Group 1 in the table. If the crankshaft has been replaced, check the identification color applied to the
new crankshaft journal. If the journal is yellow, the crankshaft bearing will be from Group 1, and the connecting rod
bearing will be identified as 1.
ENGINE UNIT REPAIR
LTSM020119
LTSM020181
02–232Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 3. Remove the connecting rod cap nuts.
4. Remove the connecting rod bearing cap.
5. Using a hammer handle or similar tool, push thepiston 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.
6. Remove the connecting rod bearings. CAUTION: When removing the connecting rod
side bearings, note the installation position.
Keep them in the correct order.
ENGINE UNIT REPAIR
BESM020042
BESM020043
BESM020044
BESM020045
02
02–235Chery 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 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.

Downloaded from www.Manualslib.com manuals search engine 5. Using special tool CH-20013 (1), Remove the valveoil seal.
6. Remove the valve guide.
7. Remove the spark plugs.
Inspection
• Cylinder head must be flat within 0.03 mm.
• Inspect camshaft bearing journals for scoring.
• Remove carbon and varnish deposits from inside of
valve guides with a valve guide cleaner.
• Check the valve guide height.
Assembly
1. Install new valve guide if necessary.
2. Install new valve seat if necessary.
3. Using special tool MD-998774 (1), install the new
valve oil seal.
4. Install the valves into the cylinder head (larger diameter on intake side).
5. Install the valve springs.
6. Install the valve spring retainers.
CYLINDER HEAD UNIT REPAIR
LTSM020225
BESM020068 LTSM020094
02–242Chery Automobile Co., Ltd.