Door CHERY TIGGO 2009 Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine VIN Identification Codes
The vehicle identification number (VIN) is a 17-digit combination of letters and numbers.
VIN DIGIT DESIGNATIONDEFINITION
1 World Manufacture Identifier
2 Brand Of The Vehicle
3 Vehicle Chassis Type
4 Transmission Type
5 Engine Type
6 Restraint System
7 Check Digit
8 Model Year
9 Assembly Plant
10 Production Sequence Number
• Digits #1, #2, #3 The first 3 vehicle identification number (VIN) positions are the world manufacturer identifier:
LV V represents Chery Automobile Co., Ltd.
• Digit #4 The fourth digit of the VIN code represents the brand of the vehicle:
The brand Cheryis represented by the letter D.
• Digit #5 The fifth digit of the VIN code represents the body configuration of the vehicle:
A represents three compartments, five-door, and 4X2.
B represents two compartments, five-door, and 4X2.
C represents three compartments, four-door, two-lid, and 4X2.
D represents two compartments, five-door, and 4X4.
• Digit #6 The sixth digit of the VIN code represents the type of transmission:
1 represents manual transmission.
2 represents automatic transmission.
• Digit #7 The seventh digit of the VIN code represents the type of engine:
1 represents electronically controlled gasoline engines 1.5L - 2.0L (excluding 2.0L) series.
2 represents engines smaller than 1.5L (excluding 1.5L).
4 represents 2.0L - 2.5L engines (excluding 2.5L).
VEHICLE IDENTIFICATION NUMBER (VIN)
PZSM020054
01
01–11Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine SERVICE MANUAL CHAPTERCOMPONENT / VEHICLE SYSTEM
15 - Body & Accessories •
Windshield Wiper Motor
• Windshield Washer Motor
• Rear Window Defroster
• Power Door Locks
• Power Windows
• Power Mirrors
• Sunroof Control Unit
• Radio
• Interior Lights
• Exterior Lights
• Oil Pressure Switch
• Warning Buzzer
• Body Control Module (BCM)
• Instrument Cluster
• Key Switch
• Power Outlet
• Data Link Connector
• Immobilizer Control Module
• Horn
16 - Wiring •
Power Distribution
• Front Fuse and Relay Box
• Power Fuse Box
• Ignition Switch
• Ground Distribution
Abbreviation List
TERM ABBREVIATION
Antilock Brake System ABS
Accelerator Sensor AES
Accelerator Pedal Position Sensor APS
Automatic Temperature Control ATC
Automatic Transaxle Fluid ATF
Body Control Module BCM
Brake Pressure Sensor BPS
Camshaft Position Sensor CMP
Clutch Pedal Position Switch CPP Switch
Crankshaft Position Sensor CKP
Data Link Connector DLC
Diagnostic Trouble Code DTC
Engine Control Module ECM
Engine Coolant Temperature ECT
Engine Speed RPM
Evaporative Emission EVAP
Evaporative Emission Canister EVAP Canister
Evaporative Emission System EVAP System
Exhaust Gas Recirculation Valve EGR Valve
HOW TO LOCATE ELECTRICAL SCHEMATICS IN THE SERVICE MANUAL
01
01–27Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine DIAGNOSIS & TESTING
Vehicle Inspection
Visual inspection of the vehicle is recommended prior to road testing or performing any other procedure. Raise the
vehicle on a suitable hoist.
Inspect the following:
•Inspect tires and wheels for damage, mud packing and unusual wear; correct as necessary.
• Check and adjust tire pressure to the pressure listed on the label attached to the driver’s door opening.
Tire and Wheel Vibration
Tire and wheel imbalance, runout and force variation can cause vehicles to exhibit steering wheel vibration.
NOTE :
Balance equipment must be calibrated and maintained per equipment manufacturer’s specifications.
Tire Wear Patterns
Tire wear patterns can be traced to the following tire conditions:
•Under inflation will cause wear on the shoulders of tire.
• Over inflation will cause wear at the center of tire.
• Excessive camber causes the tire to run at an angle to the road. One side of tread is then worn more than the
other.
• Excessive toe-in or toe-out causes wear on the tread edges and a feathered effect across the tread.
NOTE :
Tread wear indicators are molded into the bottom of the tread grooves. When tread depth is 1.6 mm, the tread wear
indicators will appear as a band. Tire replacement is necessary when indicators appear in two or more grooves, or
if localized balding occurs.
Wheel Out-Of-Round Inspection
• Raise vehicle and securely support it.
• Attach a dial indicator on the edge of the rim and measure its unevenness.
• Replace the rim if necessary.10
10–50Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION
Description
This vehicle is equipped with a common HVAC housing assembly. The system combines air conditioning, heating,
and ventilating capabilities in a single unit housing mounted under the instrument panel. The driver can choose the
following functions from HVAC control panel:
•The inside temperature
• The speed of the blower
• Five different modes of operation
• A/C compressor clutch operation
• Recirculation door position
NOTE :
To maintain the performance level of the heating, ventilation and air conditioning (HVAC) system, the engine cooling
system must be properly maintained. Any obstructions in front of the radiator or A/C condenser will reduce the per-
formance of the A/C and engine cooling systems.
13–2Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine DIAGNOSIS & TESTING
A/C System Performance
The ambient air temperature must be a minimum of 21°C for this test.1. Connect a manifold gauge set.
2. Set the A/C Heater mode control switch knob in the Panel position, the temperature control knob in the full cool position, the A/C button in the On position, and the blower motor switch knob in the highest speed position.
3. Start the engine and hold the idle at 2,000 RPM with the compressor clutch engaged.
4. The engine should be at operating temperature. The doors and windows must be open.
5. Insert a thermometer in the driver side center A/C (panel) outlet. Operate the engine for five minutes.
6. The compressor clutch may cycle, depending upon the ambient temperature and humidity.
7. With the compressor clutch engaged, record the discharge air temperature and the compressor discharge pres- sure.
8. Compare the discharge air temperature to the performance temperature and pressure chart.
NOTE :
The discharge air temperatures will be lower if the humidity is less than the percentages shown.
TEMPERATURE AND PRESSURE
Ambient Air
Temperature and
Humidity 21°C ( 80%
humidity) 27°C ( 80%
humidity) 32°C ( 80%
humidity) 38°C ( 50%
humidity) 43°C ( 20%
humidity)
Air Temperature
at Center Panel
Outlet 10 - 13°C 14 - 17°C 15 - 18°C 17 - 20°C 14 - 17°C
Evaporator Inlet
Pressure at
Charge Port 241 - 276 kPa 262 - 290 kPa 269 - 296 kPa 275 - 303 kPa 262 - 290 kPa
Compressor
Discharge
Pressure 1241 - 1792 kPa 1380 - 1930 kPa 1380 - 1930 kPa 1655 - 2206 kPa 1567 - 2068 kPa
A/C System Troubleshooting Chart
CONDITION
POSSIBLE CAUSES CORRECTION
Rapid Compressor Clutch Cycling
(ten or more cycles per minute) · Low refrigerant system charge.· Test the A/C system for leaks.
Repair, evacuate and charge the
refrigerant system, if required.
Equal Pressures, But The
Compressor Clutch Does Not
Engage · No refrigerant in the refrigerant
system.
· Faulty A/C compressor clutch coil.
· Faulty A/C pressure switch.
· Faulty A/C heater control module.
· Faulty A/C fuse.
· Faulty A/C compressor relay.
· Faulty Evaporator temperature
sensor.· Test the A/C system for leaks.
Repair, evacuate and charge the
A/C, if required.
· Test the compressor clutch coil and
replace, if required.
· Test the A/C high pressure switch
and replace, if required.
· Test the A/C heater control module
and replace, if required.
· Test A/C fuse and replace.
· Test A/C compressor relay and
replace, if required.
· Test evaporator temperature sensor
and replace if required.
13–12Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine CONDITIONPOSSIBLE CAUSES CORRECTION
Normal Pressures, But A/C
Performance Test Air Temperatures
At Center Panel Outlet Are Too High · Excessive refrigerant oil in system.
· Blend door inoperative or sealing
improperly.
· Blend door actuator faulty or
inoperative.· Recover the refrigerant from the
refrigerant system and inspect the
refrigerant oil content. Restore the
refrigerant oil to the proper level, if
required.
· Inspect the blend door for proper
operation and sealing. Repair if
required.
· Replace if faulty.
The Low Side Pressure Is Normal
Or Slightly Low, And The High Side
Pressure Is Too Low · Low refrigerant system charge.
· Refrigerant flow through the
accumulator is restricted.
· Refrigerant flow through the
evaporator is restricted.
· Faulty compressor.· Test the refrigerant system for
leaks. Repair, evacuate and charge
the refrigerant system, if required.
· Replace the restricted accumulator,
if required.
· Replace the restricted evaporator
coil, if required.
· Replace the compressor, if
required.
The Low Side Pressure Is Normal
Or Slightly High, And The High Side
Pressure Is Too High · Condenser air flow restricted.
· Inoperative cooling fan.
· Refrigerant system overcharged.
· Air in the refrigerant system.
· Engine overheating.· Check the condenser for damaged
fins, foreign objects obstructing air
flow through the condenser fins, and
missing or improperly installed air
seals. Clean, repair, or replace
components as required.
· Test the cooling fan and replace, if
required.
· Recover the refrigerant from the
refrigerant system. Charge the
refrigerant system to the proper
level, if required.
· Test the refrigerant system for
leaks. Repair, evacuate and charge
the refrigerant system, if required.
· Test the cooling system and repair
as necessary.
The Low Side Pressure Is Too High,
And The High Side Pressure Is Too
Low · Accessory drive belt slipping.
· Faulty compressor.· Inspect the accessory drive belt
condition and tension. Tighten or
replace the accessory drive belt, if
required.
· Replace the compressor, if
required.
The Low Side Pressure Is Too Low,
And The High Side Pressure Is Too
High · Restricted refrigerant flow through
the refrigerant lines.
· Restricted refrigerant flow through
the A/C accumulator.
· Restricted refrigerant flow through
the condenser.
· Faulty A/C expansion valve.· Inspect the refrigerant lines for
kinks, tight bends or improper
routing. Correct the routing or
replace the refrigerant line, if
required.
· Replace the accumulator if
restricted.
· Replace the restricted condenser, if
required.
· Test A/C expansion valve and
replace, if required.
DIAGNOSIS & TESTING
13
13–13Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Heater Performance
Engine coolant is delivered to the heater core through heater hoses. With the engine idling at normal operating tem-
perature, set the temperature control knob in the full hot position, the mode control switch knob in the floor heat
position, and the blower motor switch knob in the highest speed position. Using a test thermometer, check the tem-
perature of the air being discharged at the HVAC housing floor outlets. Compare the test thermometer reading to the
heater performance chart.
HEATER PERFORMANCE
Ambient Air
Temperature 15.5°C (60°F) 21.1°C (70°F) 26.6°C (80°F) 32.2°C (90°F)
Minimum Air
Temperature at Floor
Outlet 62.2°C (144°F) 63.8°C (147°F) 65.5°C (150°F) 67.2°C (153°F)
Both of the heater hoses should be hot to the touch. The coolant return heater hose should be slightly cooler than
the coolant supply heater hose. If the return hose is much cooler than the supply hose, locate and repair the engine
coolant flow obstruction in the cooling system.
Obstructed Coolant Flow
Possible locations or causes of obstructed coolant flow:
• Pinched or kinked heater hoses.
• Improper heater hose routing.
• Plugged heater hoses or supply and return ports at the cooling system connections.
• A plugged heater core.
Mechanical Problems
Possible locations or causes of insufficient heat:
•An obstructed cowl air intake.
• Obstructed heater system outlets.
• A blend door not functioning properly.
• Trapped air in system.
Temperature Control
If the heater outlet air temperature cannot be adjusted with the temperature control knob(s) on the A/C heater control
panel, the following could require service:
•The A/C heater control panel.
• The blend door.
• The blend door cable.
• Improper engine coolant temperature.
DIAGNOSIS & TESTING
13–14Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 6. Loosen the two blend door and mode door controlcables (1).
7. Remove the manual temperature control module.
8. Installation is in the reverse order of removal.
Blower Motor Resistor
Removal & Installation
WARNING!
The blower motor resistor may get very hot during normal operation. If the blower motor was turned on prior to
servicing the blower motor resistor, wait five minutes to allow the blower motor resistors to cool before per-
forming diagnosis or service. Failure to take this precaution can result in possible personal injury.
CAUTION:
DONT operate the blower motor with the blower motor resistor removed from the circuit. Failure to
take this precaution can result in vehicle damage.
1. Disconnect the negative battery cable.
2. Remove the glove box (See Instrument Panel Removal & Installation in Section 15 Body & Accessories).
3. Disconnect the blower motor resistor electrical connector.
ON-VEHICLE SERVICE
LTSM130001
13–16Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine SYSTEM CONTROLS
GENERAL INFORMATION13-19
Description 13-19
Operation 13-21
Specifications 13-23
Special Tools 13-23ON-VEHICLE SERVICE13-24
Recirculation Door Actuator 13-24
Removal & Installation 13-24
13–18Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 1 - Inlet Shell Shield
2 - Inlets Shrouds
3 - Bolt (M6)
4 - Inlet Shell Assembly
5 - Recirculation Door Actuator
6 - Mixed Door Lever
7 - Defrost Door Lever
8 - Water Hose Clamp
9 - Blower Control Dial
10 - Defrost Door Linkage
11 - Mode Door Dial
12 - Plastic Washer
13 - Mode Door Dial Linkage
14 - Mode Door Dial Lever
15 - Evaporator Assembly
16 - HVAC Control Panel
17 - Temperature Control Dial Cable
18 - Mode Door Cable
19 - Outlet Assembly
20 - Clamp21 - Left Outlet
22 - Right Outlet
23 - Evaporator Assembly Upper Cover
24 - Drain Inner Hose Assembly
25 - Rubber Drain Inside Hose
26 - Rubber Drain Outside Hose
27 - Evaporator Assembly Lower Cover
28 - Evaporator Core
29 - Sealed Gasket
30 - Sponge
31 - Expansion Valve
32 - Blower Motor Resistor
33 - Blower Motor
34 - HVAC Filter
35 - Heater Core
36 - HVAC Control Panel Bolt
37 - HVAC Control Panel
38 - Clamp
39 - Water Hose Sealed Gasket
40 - Sponge
GENERAL INFORMATION
LTSM130019
13–20Chery Automobile Co., Ltd.