belt CHERY TIGGO 2009 Service Manual PDF

Downloaded from www.Manualslib.com manuals search engine •Using special tool MD-998767 (1) and a torque
wrench, adjust the timing belt tensioner.
• Measure distance “A” between the tensioner arm
and the automatic tensioner.
Standard distance is 3.84 mm
Inspection
1. Inspect the timing belt back rubber for signs ofaging and glistening.
ON-VEHICLE SERVICE
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02–194Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 2. Inspect the timing belt for the following:•Cracks in the back rubber (1).
• Cracks and stripping in the canvas (2).
• Cracks in the grooves (3).
• Cracks in the side of the belt (4).
3. Inspect the timing belt (1) for abnormal abrasion in the side of the belt (2).
4. Inspect the timing belt for abnormal abrasion (2) or teeth missing (1) from the belt.
ON-VEHICLE SERVICE
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02–195Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Timing Belt Automatic Tensioner
Removal & Installation
NOTE :
The following special tools are required to perform the repair procedure:
•MD-998767 - Automatic Tensioner Socket
1. Remove the engine timing belt (See Engine Timing Belt Removal & Installation in Section 02 Engine).
2. Remove the timing belt automatic tensioner bolts (1).
(Tighten: Timing belt automatic tensioner bolts to
24 N·m)
3. Installation is in the reverse order of removal.
Installation Notes:
• Perform the following to prepare the automatic tensioner for installation:
Slowly close the vise jaws until the rod hole
(1) and housing hole (2) are aligned.
Insert a steel wire (1.4 mm diameter) into the aligned hole.
Remove the automatic tensioner from the vise.
• The automatic tensioner is now ready to be installed on the engine.
ON-VEHICLE SERVICE
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02–196Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Upper Balance Shaft Timing Belt
Removal & Installation
NOTE :
The following special tools are required to perform the repair procedure:
•MD-998778 - Crankshaft Pulley Puller
• MD-998781 - Flywheel Holder
• MD-998785 - Upper Balance Shaft Pulley Holder
1. Remove the engine timing belt (See Engine Timing Belt Removal & Installation in Section 02 Engine).
2. Using special tool MD-998781 (1), attach the tool to the flywheel.
3. Remove the crankshaft pulley bolt. (Tighten: Crankshaft pulley bolt to 120 N·m)
4. Using special tool MD-998778 (1), remove the crankshaft pulley.
5. Remove the upper balance shaft timing belt. NOTE: Remember the rotation direction of the timing belt in order to avoid any error when reassembling.
6. Installation is in the reverse order of removal.
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02–198Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Installation Notes:
•Align the timing marks on the crankshaft pulley (2) and the upper balance shaft pulley with the timing marks on
the front engine cover (1).
• Make sure all timing marks are aligned properly.
• Install the timing belt.
• Make sure that the belt tensioner position is as
shown (3 & 4).
• While applying finger pressure to the belt tensioner in the direction of the arrow, tighten the tensioner bolt to 35
N·m.
CAUTION:
Do not allow the belt tensioner to move while tightening the bolt, if the tensioner moves it could
cause the belt to be overtightened.
•Ensure that the timing marks (1) have not moved, and are still in alignment.
• Press the center of the timing belt with an index
finger and measure the belt deflection (standard
deflection is 5-7 mm).
• If the belt deflection is not within specifications,
adjust if necessary.
• Reinstall the engine timing belt (See Engine Timing Belt Removal & Installation in Section 02 Engine).
ON-VEHICLE SERVICE
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02–199Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine NOTE :
The following special tools are required to perform the repair procedure:
•MB-991603 - Balance Shaft Bearing Puller Limiter
• MD-998162 - Plug Spanner
• MD-998371 - Balance Shaft Bearing Puller
• MD-998372 - Balance Shaft Bearing Puller
• MD-998375 - Crankshaft Front Oil Seal Installer
• MD-998705 - Balance Shaft Bearing Installer
• MD-998727 - Oil Pan Remover
• MD-998783 - Plug Spanner Fixer
• MB-991828 - Oil Filter Wrench
• MB-991396 - Oil Filter Wrench
1. Remove the engine timing belt (See Engine Timing Belt Removal & Installation in Section 02 Engine).
2. Remove the upper balance shaft timing belt (See Upper Balance Shaft Timing Belt Removal & Installation in Section 02 Engine).
3. Raise and support the vehicle.
4. Loosen the oil drain plug and drain the oil.
5. Remove the oil pan retaining bolts. (Tighten: Oil pan bolts to 18 N·m)
6. Using special tool MD-998727 (1), remove the oil pan.
NOTE: Insert the special tool between cylinder
block and the oil pan. Do not use a screwdriver or
chisel, otherwise the edge of oil pan may be dis-
torted and oil leaks will occur.
7. Remove the oil strainer retaining bolts. (Tighten: Oil strainer bolts to 19 N·m)
8. Remove the oil strainer.
9. Remove the oil strainer gasket.
10. Secure the lower balance shaft. Remove the plug from the cylinder block and then insert a holder (1)
(8 mm diameter) into the hole.
NOTE: If the holder can be inserted more than 60
mm, then the timing marks are aligned. If the
holder could not be inserted more than 20-25 mm,
the lower balance shaft pulley should be rotated
one revolution and the timing marks should be then
be aligned. Keep the holder installed until the
installation of the timing belt is complete.
ON-VEHICLE SERVICE
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02–205Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine NOTE :
The following special tools are required to perform the repair procedure:
•MD-991603 - Balance Shaft Bearing Puller Limiter
• MD-998162 - Plug Spanner
• MD-998371 - Balance Shaft Bearing Puller
• MD-998372 - Balance Shaft Bearing Puller
• MD-998375 - Crankshaft Front Oil Seal Installer
• MD-998705 - Balance Shaft Bearing Installer
• MD-998727 - Oil Pan Remover
• MD-998783 - Plug Spanner Fixer
• MD-991828 - Oil Filter Wrench
• MD-991396 - Oil Filter Wrench
1. Raise and support the vehicle.
2. Loosen the oil drain plug and drain the oil.
3. Remove the engine timing belt (See Engine Timing Belt Removal & Installation in Section 02 Engine).
4. Remove the upper balance shaft timing belt (See Upper Balance Shaft Timing Belt Removal & Installation in Section 02 Engine).
5. Remove the oil pan retaining bolts. (Tighten: Oil pan bolts to 18 N·m)
6. Using special tool MD-998727 (1), remove the oil pan.
NOTE: Insert the special tool between cylinder
block and the oil pan. Do not use a screwdriver or
chisel, otherwise the edge of oil pan may be dis-
torted and oil leaks will occur.
7. Remove the oil strainer retaining bolts. (Tighten: Oil strainer bolts to 19 N·m)
8. Remove the oil strainer.
9. Remove the oil strainer gasket.
10. Secure the lower balance shaft. Remove the plug from the cylinder block and then insert a holder (1)
(8 mm diameter) into the hole.
NOTE: If the holder can be inserted more than 60
mm, then the timing marks are aligned. If the
holder could not be inserted more than 20-25 mm,
the lower balance shaft pulley should be rotated
one revolution and the timing marks should be then
be aligned. Keep the holder installed until the
installation of the timing belt is complete.
ON-VEHICLE SERVICE
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02–209Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Oil Pump
Removal & Installation
1. Remove the engine timing belt (See Engine Timing Belt Removal & Installation in Section 02 Engine).
2. Remove the upper balance shaft timing belt (See Upper Balance Shaft Timing Belt Removal & Installation inSection 02 Engine).
3. Remove the oil filter.
4. Remove the oil filter adapter. (Tighten: oil filter adapter bolts to 11 N·m)
5. Remove the engine front cover.
6. Remove the oil pump drive gear and the driven gear.
7. Remove the oil pump rear cover.
8. Installation is in the reverse order of removal.
Installation Notes:
• Before installing the new oil pump, prime the oil pump by filling the oil pump with engine oil and rotate the oil
pump.
• Align the oil pump timing marks (1).
• Check oil pump side clearance.
1 - Engine Front Cover
2 - Oil Pump Driving Gear
3 - Oil Pump Driven Gear
4 - Oil Pump Rear Cover5 - Oil Pan
6 - Oil Strainer
7 - Oil Filter
8 - Oil Filter Adapter
ON-VEHICLE SERVICE
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02–215Chery 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
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02–231Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 13.CHECK THE CAMSHAFT AND CAMSHAFT SIGNAL PLATE
• Remove the cylinder head cover and timing belt cover (See Timing Belt Removal & Installation in Section 02
Engine).
• Check the installed clearance (See CMP Sensor Removal & Installation in Section 03 Electronic Engine Con-
trols).
• 0.8 - 1.2 mm should exist.
• Check the camshaft and camshaft signal plate for any condition that would result in an incorrect signal, such as
damage, become flexible, foreign material when rotate the camshaft.
Were any problems found?
Ye s>>Remove debris and clean the signal plate of camshaft rear end or replace camshaft.
Reinstall CMP sensor.
No
>>Go to step 16.
14.CHECK THE CRANKSHAFT AND CRANKSHAFT SIGNAL PLATE
• Check the installed clearance (See CKP Sensor Removal & Installation in Section 08 Transaxle & Transfer
Case).
• 0.8 - 1.2 mm should exist.
• Check the crankshaft and crankshaft signal plate for any condition that would result in an incorrect signal, such
as damage, become flexible, foreign material when rotate the crankshaft.
Were any problems found?
Ye s>>Remove debris and clean the signal plate of crankshaft rear end or replace crankshaft.
Reinstall the CKP sensor.
No
>>Go to the next step.
15.CHECK THE TIMING
• Check the timing for misalignment.
Is the timing misaligned?
Ye s>>Align the engine timing belt (See Timing Belt Removal & Installation in Section 02 Engine).
No
>>Go to the next step.
16.CHECK DTC
• With the X-431 scan tool, read ECM DTCs.
• Refer to DTC Confirmation Procedure.
Is DTC P0016 still present?
Ye s>>Replace the ECM.
NOTE : The Immobilizer control module must be matched to the new ECM (See ECM Removal & Instal-
lation in Section 03 Electronic Engine Controls).
No
>>The system is now operating properly.
Reassemble the vehicle and road test to verify the customers complaint is repaired.
DIAGNOSIS & TESTING
03–44Chery Automobile Co., Ltd.