ad blue CHERY TIGGO 2009 Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine NUMBERITEM DESCRIPTION
1 Power source This represents the condition when the system receives battery
positive voltage.
2 Fuse The single line represents that this is a fuse.
3 Current rating This represents the current rating of the fuse.
4 Fuse location This represents the location of the fuse in the Power Fuse Box or
Front Fuse and Relay Box.
5 Connectors This represents connector E-101 is female and connector C-101 is
male.
6 Terminal number This represents the terminal number of a connector.
7 Component name This represents the name of a component.
8 Connector number This represents the connector number.
The letter represents which harness the connector is located in.
9 SpliceThe shaded circle represents that the splice is always on the
vehicle.
10 Optional splice The open circle represents that the splice is optional depending on
vehicle application.
11 Option abbreviation This represents that the circuit is optional depending on vehicle
application.
12 Ground (GND) This represents the ground connection. (See Ground Distribution in
Section 16 Wiring).
Ground connector number has no view face.
13 Page crossing This arrow represents that the circuit continues to an adjacent page.
The
Acorresponds with the Aon the adjoining page of the
electrical schematic.
14 Data linkThis represents that the system branches to another system
identified by cell data code.
15 Option description This represents a description of the option abbreviation used on the
page.
16 Connector views This represents the connector information.
This component side is described by the connector symbols.
17 Connector color This shows a code for the color of the connector:
B = Black
W = White
R = Red
G = Green
L = Blue
Y = Yellow
BR = Brown
O = Orange
GR = Gray
18 Shielded line The line enclosed by broken line circle represents shielded wire.
19 Light-emitting diodes As an illumination tool, in the circuit and instrument cluster.
HOW TO READ ELECTRICAL SCHEMATICS
01–24Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine CONNECTING ROD AXIAL CLEARANCE
DESCRIPTION SPECIFICATION LIMIT
Connecting Rods 0.10 - 0.25 mm 0.4 mm
Connecting Rod Bearings
•Perform the following steps when replacing the connecting rod bearings:
Measure and record the External Diameter of
the connecting rod journals.
Use the connecting rod bearing identification table to locate the desired bearing.
• The bearing will have an identification mark (1) imprinted in the position as shown.
IDENTIFYING CONNECTING ROD BEARINGS
Internal Diameter of Connecting Rods (without bearing): 48.000 - 48.015 mm Crank Journal Connecting Rod Bearing
Group Identification
Color External
Diameter (mm) Identification
Number Identification
Color Thickness (mm)
1 Yellow 44.995 - 45.000 1 Yellow 1.487 - 1.491
2 None 44.985 - 44.995 2 None 1.491 - 1.495
3 White 44.980 - 44.985 3 Blue 1.495 - 1.499
NOTE :
As an example, if the measurement of the external diameter of the connecting rod journal is 44.996 mm, it will be
identified as Group 1 in the table. If the crankshaft has been replaced, check the identification color applied to the
new crankshaft journal. If the journal is yellow, the crankshaft bearing will be from Group 1, and the connecting rod
bearing will be identified as 1.
ENGINE UNIT REPAIR
LTSM020119
LTSM020181
02–232Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine •Identify the bearing markings (1) & (2) on the cylin-
der block.
• The bearing will have an identification mark (1)
imprinted in the position as shown.
IDENTIFYING CRANKSHAFT MAIN BEARINGS
Combination of Crankshaft Main Journal and Spindle Bore Identification
mark and color
of No. 1, 2, 4, 5 journal bearing Identification
mark and color
of No. 3 journal bearing
Crankshaft Main Journal
Identification
mark of spindle bore
Group Identification
Color External
Diameter (mm)
1 Yellow 56.994 - 57.000 0
Green Black
1 Yellow Green
2 None Yellow
2 None 56.988 - 56.994 0
Yellow Green
1 None Yellow
2 Blue None
3 White 56.982 - 56.988 0
None Yellow
1 Blue None
2 Red Blue
NOTE :
As an example, if the identification color of the crankshaft main journal is yellow and the identification mark of spindle
bore is “1”, choose the No. 1,2,4,5 bearing of which identification mark is “2” and identification color is “yellow” and
No.3 bearing of which identification mark is “1” and identification color is “green”.
ENGINE UNIT REPAIR
LTSM020127
LTSM020181
02–238Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Hard Start / Long Crank / Erratic Start / Erratic Crank
The following conditions apply to this symptom:
•The engine cranks for an extended period of time.
• The engine starts hard during a long cranking time.
1.PRELIMINARY CHECKS
• Confirm that the correct starting procedure was used by the customer before proceeding with diagnosis.
• Carry out the following preliminary checks:
Vacuum leaks
Fuel quality (concerns such as correct octane, contamination, winter/summer blend)
Intake air system (tubes)
Air cleaner (restrictions)
Battery condition and starter current draw.
Are all checks OK?
Ye s>>Go to the next step.
No
>>Repair as necessary.
Verify the symptom no longer exists.
2.CHECK ECM DTC
• With scan tool X-431, select view DTC and data stream in ECM.
Are there any DTCs present?
Ye s>>See the Diagnostic Trouble Code (DTC) List.
Go to the specific diagnostic test to troubleshoot the DTC.
No
>>Go to the next step.
3.CHECK SECONDARY IGNITION SYSTEM
• Perform the following to test the secondary ignition system:
Disconnect the injector fuse.
Remove any of the 4 spark plugs.
Connect the spark plug to spark plug wire.
Ground the spark plug on the cylinder block.
Crank the engine to test the secondary ignition system with the spark plugs removed.
Is a strong blue spark visible at each spark plug while cranking the engine?
Ye s>>Go to the next step.
No
>>Check Camshaft Position (CMP) sensor signal at ECM.
If CMP sensor is OK, check the following:
Crankshaft Position (CKP) sensor malfunction
Faulty spark plug wires
Faulty spark plugs
ELECTRONIC ENGINE CONTROLS - 2.4L ENGINE SYMPTOM DIAGNOSIS
03
03–549Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 4.CHECK SECONDARY IGNITION SYSTEM
• Perform the following to test the secondary ignition system:
Disconnect the injector fuse.
Remove any of the 4 spark plugs.
Connect the spark plug to spark plug wire.
Ground the spark plug on the cylinder block.
Crank the engine to test the secondary ignition system with the spark plugs removed.
Is a strong blue spark visible at each spark plug while cranking the engine?
Ye s>>Go to the next step.
No
>>Check Camshaft Position (CMP) sensor signal at ECM.
If CMP sensor is OK, check the following:
Crankshaft Position (CKP) sensor malfunction
Spark plug wires
Spark plugs
5.CHECK INTAKE AIR SYSTEM
• Check for MAP/MAF sensor.
Is there any contamination?
Ye s>>Clean or replace the sensor.
No
>>Go to the next step.
6.CHECK EXHAUST SYSTEM
• Check the exhaust system for restrictions.
Is there a restriction in the exhaust system?
Ye s>>Repair as necessary.
No
>>Go to the next step.
7.CHECK BASE ENGINE CONCERNS
• Check for base engine concerns (such as improper compression, worn camshaft/valve train, gasket leaks).
Is a fault indicated?
Ye s>>Repair as necessary.
No
>>Go to the next step.
8.CHECK AUTOMATIC/MANUAL TRANSAXLE OPERATION
• Check the operation of the transaxle.
Is the transaxle operation normal?
Ye s>>Go to the next step.
No
>>Repair as necessary.
ELECTRONIC ENGINE CONTROLS - 2.4L ENGINE SYMPTOM DIAGNOSIS
03–554Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Back Fires
The following conditions apply to this symptom:
•The engine will back fire when operated.
• The engine back fire occurs at all operating parameters.
1.PRELIMINARY CHECKS
• Carry out the following preliminary checks:
Vacuum lines (check for damage and correct routing).
Spark plug wire routing (correct firing order).
Are all checks OK?
Ye s>>Go to the next step.
No
>>Repair as necessary.
Verify the symptom no longer exists.
2.CHECK ECM DTC
• Turn the ignition switch on.
• With the scan tool X-431, select view DTC and stream data in ECM.
Are there any DTCs present?
Ye s>>See the Diagnostic Trouble Code (DTC) List.
Go to the specific diagnostic test to troubleshoot the DTC.
No
>>Go to the next step.
3.CHECK SECONDARY IGNITION SYSTEM
• Perform the following to test the secondary ignition system:
Disconnect the injector fuse.
Remove any of the 4 spark plugs.
Connect the spark plug to spark plug wire.
Ground the spark plug on the cylinder block.
Crank the engine to test the secondary ignition system with the spark plugs removed.
Is a strong blue spark visible at each spark plug while cranking the engine?
Ye s>>Go to the next step.
No
>>Check Camshaft Position (CMP) sensor signal at ECM.
If CMP sensor is OK, check the following:
Crankshaft Position (CKP) sensor malfunction
Spark plug wires
Spark plugs
4.CHECK FUEL QUALITY
• Check fuel quality (concerns such as correct octane, contamination).
Is the fuel quality OK?
Ye s>>Go to the next step.
No
>>Repair as necessary.
Verify the symptom no longer exists.
ELECTRONIC ENGINE CONTROLS - 2.4L ENGINE SYMPTOM DIAGNOSIS
03–556Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 6.CHECK SECONDARY IGNITION SYSTEM
• Perform the following to test the secondary ignition system:
Disconnect the injector fuse.
Remove any of the 4 spark plugs.
Connect the spark plug to spark plug wire.
Ground the spark plug on the cylinder block.
Crank the engine to test the secondary ignition system with the spark plugs removed.
Is a strong blue spark visible at each spark plug while cranking the engine?
Ye s>>Go to the next step.
No
>>Check Camshaft Position (CMP) sensor signal at ECM.
If CMP sensor is OK, check the following:
Crankshaft Position (CKP) sensor malfunction
Spark plug wires
Spark plugs
7.CHECK FUEL SYSTEM PRESSURE
• Release the fuel system pressure (See Fuel Pressure Relief Procedure in Section 04 Fuel Delivery).
• Check fuel system pressure (See Fuel Pressure Test in Section 04 Fuel Delivery).
Is fuel pressure correct?
Ye s>>Go to the next step.
No
>>If the fuel pressure is greater than 400 kPa (4.0 bar):
Replace the fuel pressure regulator.
If the fuel pressure is less than 400 kPa (4.0 bar):
Check the fuel supply system for restrictions or leaks.
If no problems, repair or replace fuel filter, pressure regulator or fuel pump assembly.
8.CHECK EXHAUST SYSTEM
• Check the exhaust system for restrictions.
Is there a restriction in the exhaust system?
Ye s>>Repair as necessary.
No
>>Go to the next step.
9.CHECK PCV SYSTEM
• Check the Positive Crankcase Ventilation (PCV) system.
• Remove PCV valve and shake it.
Is PCV valve normal?
Ye s>>Go to the next step.
No
>>Replace the PCV valve.
ELECTRONIC ENGINE CONTROLS - 2.4L ENGINE SYMPTOM DIAGNOSIS
03–560Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Is the check result normal?
Ye s>>The condition that caused this DTC is intermittent (See Diagnostic Help in Section 08 Transaxle &
Transfer Case).
No
>>Go to the next step.
2.ACTUATE TEST
• With X-431, perform the solenoid actuate test.
• The solenoid should be heard.
Is the check result normal?
Ye s>>Go to step 7.
No
>>Go to the next step.
3.CHECK REVERSE/LOW GEAR ELECTRO-MAGNETIC VALVE
• Turn the ignition switch off.
• Disconnect A/T assembly connector.
NUMBER SOLENOID WIRE COLOR
1 Low Speed
Electro-Magnetic Valve (UD) White / Red
2 2nd Gear
Electro-Magnetic Valve (2nd) Yellow / Red
3 Damp clutch
system control
Electro-Magnetic Valve (DCC) Brown / Yellow
4 Overdrive
Electro-Magnetic Valve (OD) Blue / Yellow
5 Low/reverse
Gear Electro-
Magnetic Valve (L/R) Black / Red
DIAGNOSIS & TESTING
08
08–179Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 3.CHECK LOW SPEED ELECTRO-MAGNETIC VALVE
• Stop vehicle and turn ignition switch off.
• Disconnect A/T assembly connector.
NUMBER SOLENOID WIRE COLOR
1 Low Speed
Electro-Magnetic Valve (UD) White / Red
2 2nd Gear
Electro-Magnetic Valve (2nd) Yellow / Red
3 Damp clutch
system control
Electro-Magnetic Valve (DCC) Brown / Yellow
4 Overdrive
Electro-Magnetic Valve (OD) Blue / Yellow
5 Low/reverse
Gear Electro-
Magnetic Valve (L/R) Black / Red
• Check UD solenoid resistance as shown in the following table:
A/T
ASSEMBLY TERMINAL LOW/
REVERSE GEAR
ELECTRO-
MAGNETIC VA LV E(L/R) OVERDRIVE
ELECTRO-
MAGNETIC VA LV E(OD) 2ND GEAR
ELECTRO-
MAGNETIC VA LV E(2ND) LOW
SPEED
ELECTRO-
MAGNETIC VA LV E(UD)
7-10 6-10 4-9 3-9
Resistance (23°C) 7.3 - 0.69

Is the check result normal?
Ye s>>Replace the low speed Electro-Magnetic Valve with a known good one.
With X-431, perform the solenoid actuate test.
If the solenoid can be heard, the system is normal.
If the solenoid can’t be heard, go to the next step.
No
>>Replace the damaged low speed Electro-Magnetic Valve.
DIAGNOSIS & TESTING
08
08–185Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 3.CHECK 2ND GEAR ELECTRO-MAGNETIC VALVE
• Stop vehicle and turn ignition switch off.
• Disconnect A/T assembly connector.
NUMBER SOLENOID WIRE COLOR
1 Low Speed
Electro-Magnetic Valve (UD) White / Red
2 2nd Gear
Electro-Magnetic Valve (2nd) Yellow / Red
3 Damp clutch
system control
Electro-Magnetic Valve (DCC) Brown / Yellow
4 Overdrive
Electro-Magnetic Valve (OD) Blue / Yellow
5 Low/reverse
Gear Electro-
Magnetic Valve (L/R) Black / Red
• Check 2nd solenoid resistance as shown in the following table:
A/T
ASSEMBLY TERMINAL LOW/
REVERSE GEAR
ELECTRO-
MAGNETIC VA LV E(L/R) OVERDRIVE
ELECTRO-
MAGNETIC VA LV E(OD) 2ND GEAR
ELECTRO-
MAGNETIC VA LV E(2ND) LOW
SPEED
ELECTRO-
MAGNETIC VA LV E(UD)
7-10 6-10 4-9 3-9
Resistance (23°C) 7.3 - 0.69

Is the check result normal?
Ye s>>Replace the 2nd gear Electro-Magnetic Valve with a known good one.
With X-431, perform the solenoid actuate test.
If the solenoid can be heard, the system is normal.
If the solenoid can’t be heard, go to the next step.
No
>>Replace the damaged 2nd gear Electro-Magnetic Valve.
DIAGNOSIS & TESTING
08
08–191Chery Automobile Co., Ltd.