service CHERY TIGGO 2009 Service Manual PDF

Downloaded from www.Manualslib.com manuals search engine 25. Remove the catalytic converter to exhaust manifoldbolts (1).
26. Raise and support the vehicle.
27. Remove the front axle shaft (See Front Axle Shaft Removal & Installation in Section 09 Driveline & Axle).
28. Drain the engine oil.
29. Lower the vehicle and install engine lift chain hangers.
30. Remove the bolts (1) securing the front engine mount.
(Tighten: Engine front mount bolt to 60 N·m)
31. Remove the bolts (1) securing the rear engine mount.
(Tighten: Engine rear mount bolt to 60 N·m)
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02–109Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 32. Remove the left transaxle mount bolts (2) and thetransaxle mount bracket retaining bolts (1).
(Tighten: Left transaxle mount bolt to 70 N·m)
33. Using special tool CH-20001 (2), remove the three bolts (1) securing the right engine mount.
(Tighten: Engine right mount bolt to 70 N·m)
34. Verify all components between the engine and vehicle are disconnected.
35. Remove the front sub-frame (See Front Sub-Frame Removal & Installation in Section 10 Suspension).
36. Hoist the engine from vehicle.
CAUTION:
Verify all electrical connectors are disconnected prior to engine/transaxle removal.
37. Separate engine and transaxle.
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02–11 0Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 38. Remove the accessory drive belt (1) (See Acces-sory Drive Belt Removal & Installation in Section
02 Engine).
39. Remove the generator (1) from the bracket (See Generator Removal & Installation in Section 05
Starting & Charging).
40. Remove the A/C compressor pipe.
41. Remove the A/C compressor (2) (See A/C Com- pressor Removal & Installation in Section 13 Heat-
ing & Air Conditioning).
42. Remove the power steering pump (1) with piping connected and set aside with wire.
43. Installation is in the reverse order of removal.
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Downloaded from www.Manualslib.com manuals search engine Engine Timing Belt
Removal & Installation
NOTE :
The following special tools are required to perform the repair procedure:
•CH-20001 - Right Engine Mount Bolt Remover
• CH-20003 - Crankshaft Holder
• CH-20010 - Camshaft Holder
• Engine Hoist
1. Release the coolant system pressure.
WARNING!
Always allow the engine to cool before opening the cooling system. Do not loosen the coolant pressure relief
cap when the engine is operating or the cooling system is hot. The cooling system is under pressure; steam and
hot liquid can come out forcefully when the cap is loosened slightly. Failure to follow these instructions may
result in serious personal injury.
1 - Timing Belt Upper Cover Bolt
2 - Timing Belt Upper Cover
3 - Timing Belt Cover Gasket
4 - Timing Belt
5 - Timing Belt Touch Pulley
6 - Camshaft Bolt
7 - Camshaft
8 - Rear Timing Cover Bolt9 - Rear Timing Cover
10 - Idler Pulley
11 - Tensioner Pulley
12 - Tensioner Pulley Bolt
13 - Timing Belt Lower Cover
14 - Timing Belt Lower Cover Bolt
15 - Timing Belt Upper Cover Bolt
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02–11 2Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 2. Remove the coolant reservoir (1) and set aside.
3. Attach an engine hoist and support the engine using an engine hoist.
4. Using special tool CH-20001 (2), remove theengine right mount bolts (1) and bracket.
(Tighten: Engine right mount bolts to 70 N·m)
5. Remove the accessory drive belt (See Accessory Drive Belt Removal & Installation in Section 02 Engine).
6. Remove the crankshaft vibration damper bolts (1). (Tighten: Crankshaft vibration damper bolts to
25 N·m)
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Downloaded from www.Manualslib.com manuals search engine 7. Remove the timing belt upper cover (1) and timingbelt lower cover (2).
(Tighten: Timing belt upper cover bolts to 11 N·m)
(Tighten: Timing belt lower cover bolts to 11 N·m)
8. Remove the cylinder head cover (See Cylinder Head Cover Removal & Installation in Section 02 Engine).
9. Remove the plug in the cylinder block.
10. Using special tool CH-20003 (1), install the crank- shaft holder into the cylinder block and rotate the
crankshaft until the crankshaft tool completely
holds the crankshaft in place.
(Tighten: Crankshaft holder to 28 N·m)
NOTE: The crankshaft holder will prevent the
crankshaft from rotating in either direction.
11. Using special tool CH-20010 (1), install the cam- shaft holder to hold the camshafts in place.
NOTE: The camshaft holder will prevent the cam-
shafts from rotating in either direction.
CAUTION: Rotating the camshafts or crankshaft with timing components loosened or removed can cause
serious damage to the valves or pistons.
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02–11 4Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 12. Loosen the bolt of the timing belt tensioner pulley(1), remove the pulley.
(Tighten: Timing belt tensioner pulley bolt to 30
N·m)
13. Remove the timing belt (3).
14. Installation is in the reverse order of removal.
Installation Notes:
• Install the timing belt and rotate the tensioner pul-
ley with an Allen wrench in order to apply tension
to the belt and align the finger pointer of the ten-
sioner to the middle of the U-slot opening. Tighten
the tensioner pulley bolt (1) to 30 N·m, then tighten
the intake and exhaust camshaft pulley bolts (2 &
4) to 120 N·m.
Exhaust Manifold
Removal & Installation
1. Remove the engine cover.
2. Remove the bolts (1) attaching the exhaust mani-
fold heat shield.
(Tighten: Exhaust manifold heat shield bolts to
15 N·m)
3. Remove the exhaust manifold heat shield.
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Downloaded from www.Manualslib.com manuals search engine 4. Remove the three bolts (1) securing the exhaustmanifold to the catalytic converter assembly.
5. Disconnect the catalytic converter assembly from the manifold.
6. Remove the exhaust manifold nuts (1). (Tighten: Exhaust manifold nuts to 25 N·m)
7. Remove the exhaust manifold.
8. Remove and discard manifold gasket (1).
9. Installation is in the reverse order of removal.
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02–11 6Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Installation Notes:
•Clean all surfaces of manifold and cylinder head.
• Install a new exhaust manifold gasket during installation.
Intake Manifold
Removal & Installation
1. Disconnect the negative battery cable.
2. Remove the engine cover.
3. Drain the cooling system (See Cooling System Draining and Filling in Section 06 Cooling).
WARNING!
Always allow the engine to cool before opening the cooling system. Do not loosen the coolant pressure relief
cap when the engine is operating or the cooling system is hot. The cooling system is under pressure; steam and
hot liquid can come out forcefully when the cap is loosened slightly. Failure to follow these instructions may
result in serious personal injury.
1 - Fuel Rail Bolt
2 - Fuel Rail
3 - Electronic Throttle Control Actuator Bolt
4 - Electronic Throttle Control Actuator
5 - Electronic Throttle Control Actuator Gasket
6 - Air Intake Pressure Temperature Sensor Bolt7 - Air Intake Pressure Temperature Sensor
8 - Intake Manifold Bolt
9 - Intake Manifold
10 - Intake Manifold Bracket
11 - Intake Manifold Gasket
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Downloaded from www.Manualslib.com manuals search engine 4. Disconnect the four fuel injector electrical connec-tors (1).
5. Disconnect the throttle body control electrical con- nector (2).
6. Disconnect the air flow sensor electrical connector (1).
7. Loosen the clamp between the air intake hose and the air cleaner.
8. Loosen the clamp between the air intake hose and the throttle body and then remove the intake pipe.
9. Loosen the clamp on the PCV hose and then disconnect the PCV hose.
10. Remove the fuel rail bracket bolts (1). (Tighten: Fuel rail bracket bolts to 11 N·m)
11. Remove the fuel rail with the fuel injectors and set aside.
12. Remove the fuel injector O-rings.
NOTE :
Install new O-rings on the fuel injectors.
13. Remove the screws securing the vacuum valve bracket to the intake manifold.
14. Set aside the vacuum valve and pipe.
15. Disconnect intake manifold electrical harness, and vacuum hose.
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