service CHERY TIGGO 2009 Service Manual Online

Downloaded from www.Manualslib.com manuals search engine 16. Remove the bolts (2) & (3) securing the engine oildipstick to intake manifold. Remove the dipstick.
(Tighten: Dipstick bracket bolts to 11 N·m)
17. Disconnect the oil pressure switch connector (4).
18. Remove the nuts (1) securing the intake manifold to cylinder head.
(Tighten: Intake manifold nuts to 11 N·m)
NOTE: Replace the manifold gasket.
19. Installation is in the reverse order of removal.
Installation Notes:
• Clean all surfaces of manifold and cylinder head.
• Install a new intake manifold gasket during installation.
• Install new O-rings on the fuel injectors.
Idler Pulley
Removal & Installation
1. While using a suitable tool and securely holding the hexagonal portion of the drive belt tensioner, rotate the
pulley counterclockwise to loosen the drive belt.
WARNING!
Avoid placing hands near the drive belt tensioner while it is being held.
2. Remove the drive belt.
Upper Accessory Drive Belt Idler Pulley (1)
• Remove the bolt and the upper accessory drive
belt idler pulley.
(Tighten: Upper idler pulley bolt to 45 N·m)
Lower Accessory Drive Belt Idler Pulley (2)
• Remove the bolt and the lower accessory drive belt
idler pulley.
(Tighten: Lower idler pulley bolt to 45 N·m) 3. Installation is in the reverse order of removal.
Oil Filter
Removal & Installation
NOTE :
The following special tools are required to perform the repair procedure:
• CH-10003 - Oil Filter Remover
CAUTION:
When servicing the oil filter, avoid deforming the filter by installing the special tool against the
base of the filter.
ON-VEHICLE SERVICE
LTSM020223
LTSM020203
02–11 9Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine WARNING!
Prolonged and repeated contact with engine oil will harm your skin. If engine oil is spilled on your skin, wash it
off immediately with water. In addition, used engine oil contains potentially harmful contaminants which may
cause skin cancer. Always use adequate skin protection when performing vehicle service.
1. Using special tool CH-10003 oil filter remover,remove the oil filter (1).
(Tighten: Oil filter to 25 N·m)
CAUTION: When removing the oil filter, ensure
that the oil filter gasket is not stuck to the
engine. The oil filter gasket must be removed
from the engine before installing the new oil
filter.
2. Installation is in the reverse order of removal.
Installation Notes:
• Clean all surfaces, and verify the oil filter does not leak.
Oil Pan
Removal & Installation
1. Remove the oil dipstick.
2. Raise and support the vehicle.
3. Remove the oil pan drain plug and drain the
engine oil.
(Tighten: Oil pan drain plug to 40 N·m)
NOTE :
Do not pry on cylinder block to remove oil pan. 4. Remove oil pan bolts (1). (Tighten: Oil pan bolts to 18 N·m)
5. Using a putty knife, loosen seal around oil pan.
6. Remove the oil pan.
7. Installation is in the reverse order of removal.
ON-VEHICLE SERVICE
LTSM020206
LTSM020205
02
02–120Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Installation Notes:
•Oil pan sealing surfaces must be free of grease or oil.
• Install the four oil pan corner bolts in the sequence shown (1-2-3-4).
• Install the remaining oil pan bolts.
• Torque all the oil pan bolts to the proper
specification.
Oil Pump
Removal & Installation
1. Remove the accessory drive belt (See Accessory Drive Belt Removal & Installation in Section 02 Engine).
2. Remove the crankshaft vibration damper retaining
bolt (1).
(Tighten: Crankshaft vibration damper bolts to 25
N·m)
3. Remove the engine timing belt (See Engine Timing Belt Removal & Installation in Section 02 Engine).
4. Remove the crankshaft timing belt pulley bolt (2) from the crankshaft.
(Tighten: Crankshaft timing belt pulley bolt to
130 N·m and an additional 65°)
5. Remove the key-way from the crankshaft.
6. Using an appropriate tool, remove the front crank- shaft oil seal (1).
ON-VEHICLE SERVICE
VISM020013
BESM020055 LTSM020199
02–121Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 7. Remove the four oil pump bolts (1).(Tighten: Oil pump bolts to 11 N·m)
8. Remove the oil pump (2) using a suitable tool.
9. Remove the oil pump gasket (3).
10. Installation is in the reverse order of removal.
Installation Notes:
• Before installing, prime the new oil pump. Fill the oil pump with engine oil and rotate the oil pump.
• Replace the oil pump gasket.
Oil Strainer
Removal & Installation
1. Raise and support the vehicle.
2. Remove the oil pan (See Oil Pan Removal & Installation in Section 02 Engine).
3. Remove the oil strainer retaining bolts (1).
(Tighten: Oil strainer bolts to 18 N·m)
4. Carefully remove the oil strainer.
5. Installation is in the reverse order of removal.
Installation Notes:
• Install new O-rings on the oil strainer pipe.
ON-VEHICLE SERVICE
BESM020032
BESM020018
02
02–122Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Inspection
NOTE :
All measurements should be taken with the engine block at room temperature, 21°C.
Engine Block
•Clean cylinder block thoroughly and check all core hole plugs for evidence of leaking.
• Examine block and cylinder bores for cracks or fractures.
• Check block deck surfaces for flatness. Deck surface must be within service limit of 0.050 mm.
Cylinder Bore
• The cylinder walls should be checked for out-of-round and taper with cylinder indicator or equivalent. If the cyl-
inder walls are badly scuffed or scored, the cylinder block should be replaced, and new pistons and rings fitted.
• Measure the cylinder bore at three levels in directions X and Y. Top measurement should be 10 mm down and
bottom measurement should be 10 mm up from
bottom of bore.
CYLINDER BORE
All Cylinders 83.500 - 83.510 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.
NOTE :
Assemble all components in their original position.
1. Install the pistons to the connecting rods.
2. Using a piston ring expander, install the piston rings.
3. Assemble all components in the reverse order of disassembly.
ENGINE UNIT REPAIR
BESM020063
02–125Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 2.4L ENGINE MECHANICAL
GENERAL INFORMATION02-151
Description 02-151
Operation 02-151
Specifications 02-151
Special Tools 02-154
Lubrication System 02-160
DIAGNOSIS & TESTING02-163
Engine Performance Diagnostics 02-163
Engine Mechanical Diagnostics 02-164
Cylinder Compression Pressure Test 02-165
Cylinder Head Gasket Test 02-166
Engine Oil Pressure Test 02-166
ON-VEHICLE SERVICE02-167
Accessory Drive Belt 02-167
Removal & Installation 02-167
Air Cleaner Element 02-168
Removal & Installation 02-168
Air Cleaner Housing 02-169
Removal & Installation 02-169
Cylinder Head Cover 02-170
Removal & Installation 02-170
Camshaft 02-171
Removal & Installation 02-171
Cylinder Head 02-175
Removal & Installation 02-175
Front Crankshaft Oil Seal 02-177
Removal & Installation 02-177
Rear Crankshaft Oil Seal 02-179
Removal & Installation 02-179
Engine Mounts 02-181
Removal & Installation - Left Mount 02-181
Removal & Installation - Right Mount 02-182
Removal & Installation - Front Mount 02-182
Removal & Installation - Rear Mount 02-183
Engine Assembly 02-183
Removal & Installation 02-183
Engine Timing Belt 02-189
Removal & Installation 02-189
Inspection 02-194
Timing Belt Automatic Tensioner 02-196
Removal & Installation 02-196
Inspection 02-197
Upper Balance Shaft Timing Belt 02-198
Removal & Installation 02-198Exhaust Manifold
02-200
Removal & Installation 02-200
Intake Manifold 02-201
Removal & Installation 02-201
Upper Balance Shaft 02-204
Removal & Installation 02-204
Upper Balance Shaft Bearing
Replacement 02-207
Lower Balance Shaft 02-208
Removal & Installation 02-208
Lower Balance Shaft Bearing
Replacement 02-211
Oil Filter 02-212
Removal & Installation 02-212
Oil Pan 02-213
Removal & Installation 02-213
Oil Pump 02-215
Removal & Installation 02-215
Oil Strainer 02-216
Removal & Installation 02-216
ENGINE UNIT REPAIR02-217
Engine Block 02-217
Specifications 02-217
Disassembly 02-218
Inspection 02-220
Assembly 02-220
Pistons 02-221
Specifications 02-221
Disassembly 02-222
Inspection 02-224
Assembly 02-226
Connecting Rods 02-229
Specifications 02-229
Disassembly 02-229
Inspection 02-230
Assembly 02-231
Crankshaft 02-233
Specifications 02-233
Disassembly 02-234
Inspection 02-236
Assembly 02-237
02–149Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine ON-VEHICLE SERVICE
Accessory Drive Belt
Removal & Installation
WARNING!
Inspect the drive belt only when the engine is stopped.
1. Loosen the power steering pump adjustment bolt(1).
1 - Power Steering Pump
2 - Crankshaft Pulley
3 - Idler Pulley
4 - A/C Compressor5 - Coolant Pump Pulley
6 - Generator Pulley
7 - A/C Compressor Belt
8 - Generator Belt
LTSM020176
LTSM020185
02
02–167Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 2. Remove the A/C compressor belt.
3. Loosen the generator adjustment bolts (1).
4. Remove the generator belt.
5. Installation is in the reverse order of removal.
Air Cleaner Element
Removal & Installation
1. Loosen the air cleaner case side clamps (1) andraise the air cleaner case (upper).
2. Remove the air cleaner element.
3. Installation is in the reverse order of removal.
ON-VEHICLE SERVICE
LTSM050004
LTSM020239
02–168Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Air Cleaner Housing
Removal & Installation
1. Disconnect the negative battery cable.
2. Disconnect the air flow sensor electrical connector.
3. Loosen the clamp between the air intake hose and the air cleaner.
4. Remove the retaining bolt (1), securing the aircleaner housing to its base.
(Tighten: Air cleaner housing retaining bolts to
10 N·m)
5. Remove the air cleaner housing.
6. Installation is in the reverse order of removal.
ON-VEHICLE SERVICE
LTSM020240
LTSM020160
02
02–169Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Cylinder Head Cover
Removal & Installation
1. Disconnect the negative battery cable.
2. Remove the accelerator cable bracket bolts (1).(Tighten: Accelerator cable bracket bolts to 10 N·m)
3. Remove the accelerator cable.
4. Remove the air flow hose clamp (2) and discon- nect the air flow hose.
5. Remove the spark plug wires (3) and set them aside (See Spark Plug Wire Removal & Installation
in Section 03 Electronic Engine Controls).
6. Remove the PCV tube (5).
7. Remove the cylinder head cover bolts (4). (Tighten: Cylinder head cover bolts to 11 N·m)
8. Remove the cylinder head cover from the cylinder head.
9. Remove the cylinder head cover gasket if necessary.
10. Installation is in the reverse order of removal.
NOTE :
Install a new cylinder head cover gasket during installation.
ON-VEHICLE SERVICE
LTSM020175
02–170Chery Automobile Co., Ltd.