torque CHERY TIGGO 2009 Service Workshop Manual

Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION
Description
The electronic ignition system consists of the following components:
•Engine Control Module (ECM)
• Ignition Coil
• Spark Plugs
• Spark Plug Wires
• Camshaft Position (CMP) Sensor
• Crankshaft Position (CKP) Sensor
Operation
The ignition system utilizes a split ignition coil which supplies secondary voltage to two cylinders. When the ignition
coil discharges, two spark plugs fire at the same time. The Engine Control Module (ECM) uses inputs from the
Crankshaft Position (CKP) Sensor to determine the Top Dead Center (TDC) position of the piston for cylinder number
one, and the Camshaft Position (CMP) Sensor to determine which ignition coil to energize.
Specifications
Torque Specifications
DESCRIPTION TORQUE (N·m)
Spark Plugs 30
Ignition Coil Bolts 6
Spark Plug Specifications
DESCRIPTIONGAP
FR7DTC 0.7 mm - 1.1 mm
03–566Chery Automobile Co., Ltd.

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Torque Specifications
DESCRIPTIONTORQUE (N·m)
Vapor Canister Bolts 10
Special Tools
Diagnostic Scan Tool
X-431
Engine AnalyzerKES-200
GENERAL INFORMATION
03
03–583Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Operation
The fuel delivery system is enabled when it reaches the following conditions:
•Turn the ignition switch ON (engine off), the fuel delivery system is enabled for 3-6 seconds.
• The Engine Control Module (ECM) receives a Crankshaft Position (CKP) sensor signal.
The fuel injectors are a solenoid-operated valve that meter fuel flow to each cylinder. The fuel injectors are opened
and closed constantly during engine operation. The amount of fuel is controlled by the length of time the fuel injector
is held open. The fuel injectors are powered by a 12 V source and are controlled through the ground side of the
circuit by the ECM.
The fuel pump operation is defined in the fuel system control strategy and is controlled by the ECM.
Specifications
Torque Specifications
DESCRIPTION TORQUE (N·m)
Fuel Rail Bracket Bolts 11
Fuel Filter Mounting Bolts 10
EVAP Emissions Assembly
1 - Fuel Filter Assembly
2 - Fuel Delivery and Return Pipes
3 - EVAP Pipe I
4 - Fuel Delivery Pipe III
5 - Fuel Delivery Pipe IV
6 - Air Duct
7 - Fuel Delivery Pipe V
8 - Pipe Clamps9 - EVAP Hose V
10 - Fuel Delivery Hose
11 - Air Duct
12 - Canister Assembly
13 - Canister Bracket Assembly
14 - Bolt
15 - EVAP Hose I
GENERAL INFORMATION
LTSM040010
04–4Chery Automobile Co., Ltd.

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The battery, starting and charging systems operate in conjunction with one another, and must be tested as a com-
plete system. For correct operation of starting/charging systems, all components used in these 3 systems must per-
form within specifications. When attempting to diagnose any of these systems, it is important that you keep their
interdependency in mind. These components form two separate circuits, a high amperage circuit that feeds the
starter motor up to 150 amps, and a control circuit that operates on less than 20 amps.
Specifications
Torque Specifications
DESCRIPTIONTORQUE (N·m)
Starter Mounting Bolts 30
Battery Positive Cable Nut 15
Special Tools
Digital Multimeter
Fluke 15B & 17B
GENERAL INFORMATION
05
05–3Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Battery Tray
Removal & Installation
1. Disconnect the negative battery cable.
2. Disconnect the positive battery cable.
3. Remove the battery hold down.
4. Remove the battery.
5. Remove the three bolts (1) from the battery tray.
6. Lift the battery tray out of the engine compartmentand remove from the vehicle.
7. Installation is in the reverse order of removal.
Starter Motor Assembly
Description
The starter motor is mounted with two bolts to the transaxle housing and is located on the side of the engine. The
starter motor incorporates several features to create a reliable, efficient, compact, lightweight and powerful unit. The
electric motor of the starter features electromagnetic field coils wound around pole shoes, and brushes contact the
motor commutator. The starter motor is serviced only as a unit and cannot be repaired.
Operation
The starter motor is equipped with a planetary gear reduction system. The planetary gear reduction system consists
of a gear that is integral to the output end of the electric motor armature shaft that is in continual engagement with
a larger gear that is splined to the input end of the starter pinion gear shaft. This feature makes it possible to reduce
the dimensions of the starter. At the same time, it allows higher armature rotational speed and delivers increased
torque through the starter pinion gear to the starter ring gear.
Removal & Installation - 1.6L & 1.8L & 2.0L
1. Disconnect the negative battery cable.
2. Disconnect the electrical connector from the starter.
3. Remove the bolts connecting the engine oil dipstick to the cylinder block and intake manifold.
4. Remove the engine oil dipstick.
NOTE :
After removing the engine oil dipstick, you should immediately plug the hole in the cylinder block in order to prevent
any debris from entering the engine. 5. Remove the starter solenoid nut (1) from the starter.
(Tighten: Starter solenoid nut to 10 N·m)
ON-VEHICLE SERVICE
LTSM050002
BESM050004
05
05–9Chery Automobile Co., Ltd.

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Torque Specifications
DESCRIPTIONTORQUE (N·m)
Generator Cable Nut 13
Generator Mounting Bolts 30
Generator Adjustment Bracket Bolts 25
Special Tools
Digital Multimeter
Fluke 15B & 17B
GENERAL INFORMATION
05
05–13Chery Automobile Co., Ltd.

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Torque Specifications
DESCRIPTIONTORQUE (N·m)
Coolant Pump Mounting Bolts 14
Radiator Support Mounting Bolts 5
Coolant Fan Mounting Bolts 5
Thermostat Mounting Bolts 13
Fluid Specifications
DESCRIPTIONCAPACITY (L)
Cooling System 7.0
Special Tools
Cooling System Pressure Tester
GENERAL INFORMATION
06
06–5Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine WARNING!
Exhaust gases contain carbon monoxide which can be harmful to your health and are potentially lethal. Exhaust
system leaks should be repaired immediately. Never operate the engine in enclosed areas. Failure to follow
these instructions may result in personal injury or death.
Operation
In order to reduce vehicle emissions released by the engine, the catalytic converter is required to perform in all oper-
ating conditions. This reduction is especially beneficial during the cold start and warm up phases of operation, which
is when a majority of the tailpipe emissions occur on today’s vehicles because the catalytic converter has not yet
reached its operating temperature. The exhaust system channels exhaust gases from the engine and away from the
vehicle.
Specifications
Torque Specifications
DESCRIPTIONTORQUE (N·m)
Catalytic Converter Mounting Nuts 50
Exhaust Manifold Flange Bolts 49 ± 5
Muffler Mounting Nuts 50
GENERAL INFORMATION
07
07–3Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine DIAGNOSIS AND TESTING
Exhaust System Diagnostic Chart
CONDITIONPOSSIBLE CAUSES CORRECTION
Excessive Exhaust Noise · Leaks at pipe joints.
· Burned or blown out muffler.
· Burned or rusted-out exhaust pipe.
· Exhaust pipe leaking at manifold
flange.
· Exhaust manifold cracked or
broken.
· Leak between exhaust manifold
and cylinder head.
· Restriction in muffler or tailpipe.
· Exhaust system contacting body or
chassis.· Tighten clamps to specified torque
at leaking joints.
· Replace muffler assembly.
· Replace exhaust pipe.
· Tighten connection attaching nuts.
· Replace exhaust manifold.
· Tighten exhaust manifold to
cylinder head stud nuts or bolts.
· Remove restriction, if possible.
Replace muffler or tailpipe, as
necessary.
· Re-align exhaust system to clear
surrounding components.
Leaking Exhaust Gases · Leaks at pipe joints.· Tighten/replace clamps at leaking
joints.
Excessive Exhaust Temperature · Ignition timing incorrect.
· Poor fuel quality.
· Engine running rich.· Adjust the timing.
· Change and clean the fuel tank.
· Repair as needed.
07–4Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine TRANSAXLE & TRANSFER CASE
08
CONTENTSpage
DP0 Automatic Transaxle .............................................................. 08-1
F4A4 Automatic Transaxle ........................................................... 08-143
5-Speed Manual Transaxle ........................................................... 08-246
Front Differential ................................................................... 08-307
Clutch System ..................................................................... 08-316
Transfer Case (4x4) ................................................................. 08-326
DP0 AUTOMATIC TRANSAXLE
GENERAL INFORMATION08-3
Description 08-3
Operation 08-6
Specifications 08-7
Special Tools 08-8
Electrical Schematics 08-10
DP0 Transaxle Control Module (TCM)
Connector Pin-Out Table 08-18
DIAGNOSIS & TESTING08-19
Diagnostic Help 08-19
Intermittent DTC Troubleshooting 08-19
Ground Inspection 08-19
Diagnostic Tools 08-19
Diagnostic Trouble Code (DTC) List 08-20
DP0 Automatic Transaxle DTC List 08-20
Diagnostic Trouble Code (DTC) Tests 08-22
P0641 - Sensor Feed 08-22
P0657 - Solenoid Power Supply Circuit
Shorted To Voltage 08-28
P0657 - Solenoid Power Supply Circuit
Open 08-32
P0705 - Multi-Function Switch:
Prohibited Position 08-37
P0710 - Fluid Temperature Sensor 08-42
P0715 - Turbine Speed Sensor Affected
By Interference 08-46
P0730 - Ratio Of Transaxle Error 08-50
P0753 - Shift Solenoid Valve 1 (SSV1)
Open Circuit Or Short To Power Supply
Or Short To Ground 08-56 P0758 - Shift Solenoid Valve 2 (SSV2)
Open Circuit Or Short To Power Supply
Or Short To Ground 08-62
P0763 - Shift Solenoid Valve 3 (SSV3)
Short To Power Supply, P0763 - Shift
Solenoid Valve 3 (SSV3) Open Or
Short To Ground Circuit 08-68
P0768 - Shift Solenoid Valve 4 (SSV4)
Short To Power Supply, P0768 - Shift
Solenoid Valve 4 (SSV4) Open Or
Short To Ground Circuit 08-74
P0773 - Shift Solenoid Valve 5 (SSV5)
Short To Power Supply, P0773 - Shift
Solenoid Valve 5 (SSV5) Open Or
Short To Ground Circuit 08-81
P0775 - EVM (Modulation Solenoid
Valve) Open Circuit Or Short To
Ground, P0775 - EVM (Modulation
Solenoid Valve) Shorted To Voltage 08-87
P0795 - Torque Converter Lock
Solenoid Valve (EVLU) Open Circuit Or
Short To Ground, P0795 - Torque
Converter Lock Solenoid Valve (EVLU)
Short To Voltage 08-93
P0840 - Pressure Sensor 08-99
P1928 - Shift Lock Solenoid Valve
Circuit Shorted To Voltage 08-104
P1928 - Shift Lock Solenoid Valve
Open Circuit Or Short To Ground 08-109
P2709 - Shift Solenoid Valve 6 (SSV6)
Short To Power Supply 08-114
P2709 - Shift Solenoid Valve 6 (SSV6)
Open Circuit Or Short To Ground 08-119
08
08–1Chery Automobile Co., Ltd.