air filter CHERY TIGGO 2009 Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine ENGINE
02
CONTENTSpage
1.6L & 1.8L Engine Mechanical ......................................................... 02-1
2.0L Engine Mechanical .............................................................. 02-76
2.4L Engine Mechanical ............................................................. 02-149
1.6L & 1.8L ENGINE MECHANICAL
GENERAL INFORMATION02-3
Description 02-3
Operation 02-3
Specifications 02-3
Special Tools 02-7
Lubrication System 02-10
DIAGNOSIS & TESTING02-13
Engine Performance Diagnostics 02-13
Engine Mechanical Diagnostics 02-14
Cylinder Compression Pressure Test 02-16
Cylinder Head Gasket Test 02-16
ON-VEHICLE SERVICE02-17
Accessory Drive Belt 02-17
Removal & Installation 02-17
Air Cleaner Element 02-18
Removal & Installation 02-18
Air Cleaner Housing 02-18
Removal & Installation 02-18
Cylinder Head Cover 02-19
Removal & Installation 02-19
Camshaft 02-20
Removal & Installation 02-20
Cylinder Head 02-23
Removal & Installation 02-23
Front Crankshaft Oil Seal 02-25
Removal & Installation 02-25 Rear Crankshaft Oil Seal
02-27
Removal & Installation 02-27
Engine Mounts 02-29
Removal & Installation - Left Mount 02-29
Removal & Installation - Right Mount 02-30
Removal & Installation - Front Mount 02-30
Removal & Installation - Rear Mount 02-31
Engine Assembly 02-31
Removal & Installation 02-31
Engine Timing Belt 02-38
Removal & Installation 02-38
Exhaust Manifold 02-41
Removal & Installation 02-41
Intake Manifold 02-43
Removal & Installation 02-43
Idler Pulley 02-45
Removal & Installation 02-45
Oil Filter 02-46
Removal & Installation 02-46
Oil Pan 02-47
Removal & Installation 02-47
Oil Pump 02-48
Removal & Installation 02-48
Oil Strainer 02-49
Removal & Installation 02-49
02
02–1Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine DIAGNOSIS & TESTING
Engine Performance Diagnostics
CONDITIONPOSSIBLE CAUSE CORRECTION
Engine Does Not Start 1. Weak battery.
2. Corroded or loose battery
connections.
3. Faulty starter.
4. Faulty coil(s) or control unit.
5. Incorrect spark plug gap.
6. Contamination in fuel system.
7. Faulty fuel pump.
8. Incorrect timing.1. Test battery. Charge or replace if
necessary.
2. Clean and tighten battery
connections. Apply a coat of light
mineral grease to terminals.
3. Test starting system. Check for
codes. (Refer to Appropriate
Diagnostic Information)
4. Test and replace if needed. (Refer
to Appropriate Diagnostic
Information)
5. Set gap.
6. Clean system and replace fuel
filter.
7. Test fuel pump and replace as
needed. (Refer to Appropriate
Diagnostic Information)
8. Check for a skipped timing belt.
Engine Stalls Or Idles Rough 1. Idle speed too low.
2. Incorrect fuel mixture.
3. Intake manifold leakage.
4. Faulty ignition coil(s).1. Test minimum air flow. (Refer to
Appropriate Diagnostic Information)
2. (Refer to Appropriate Diagnostic
Information)
3. Inspect intake manifold, manifold
gasket, and vacuum hoses.
4. Test and replace if necessary.
(Refer to Appropriate Diagnostic
Information)
Engine Loss Of Power 1. Dirty or incorrectly gapped spark
plugs.
2. Contamination in fuel system.
3. Faulty fuel pump.
4. Incorrect valve timing.
5. Leaking cylinder head gasket.
6. Low compression.
7. Burned, warped, excessive
clearance, or pitted valves.
8. Plugged or restricted exhaust
system.
9. Faulty ignition coil(s).
10. Burned spark plugs.1. Clean spark plugs and set gap.
2. Clean system and replace fuel
filter.
3. Test and replace if necessary.
(Refer to Appropriate Diagnostic
Information)
4. Correct valve timing.
5. Replace cylinder head gasket.
6. Test compression of each
cylinder.
7. Replace valves.
8. Perform exhaust restriction test.
Install new parts.
9. Test and replace if necessary.
(Refer to Appropriate Diagnostic
Information)
10. Replace spark plugs.
DIAGNOSIS & TESTING
02
02–13Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine CONDITIONPOSSIBLE CAUSE CORRECTION
Engine Miss On Acceleration 1. Dirty or incorrectly gapped spark
plugs.
2. Contamination in fuel system.
7. Burned, warped, excessive
clearance, or pitted valves.
4. Faulty ignition coil(s).1. Clean spark plugs and set gap.
2. Clean fuel system and replace
fuel filter.
3. Replace valves.
4. Test and replace if necessary.
(Refer to Appropriate Diagnostic
Information)
Engine Miss At High Speed 1. Dirty or incorrect spark plug gap.
2. Faulty ignition coil(s).
3. Dirty fuel injector(s).
4. Contamination in fuel system.1. Clean spark plugs and set gap.
2. Test and replace if necessary.
(Refer to Appropriate Diagnostic
Information)
3. Test and replace if necessary.
(Refer to Appropriate Diagnostic
Information)
4. Clean system and replace fuel
filter.
Engine Mechanical Diagnostics
CONDITION
POSSIBLE CAUSE CORRECTION
Valve Train Noise 1. High or low oil level in crankcase.
2. Thin or diluted oil.
3. Thick oil.
4. Low oil pressure.
5. Worn cam lobe.
6. Worn valve guides.
7. Excessive runout of valve seats
on valve faces.1. Check and correct engine oil
level.
2. Change oil to correct viscosity.
3. Change engine oil and filter.
4. Check and correct engine oil
level.
5. Install new camshaft.
6. Replace cylinder head.
7. Grind valve seats and replace
valves.
Connecting Rod Noise 1. Insufficient oil supply.
2. Low oil pressure.
3. Thin or diluted oil.
4. Excessive bearing clearance.
5. Connecting rod journal out-of-
round.
6. Connecting rod out-of-round.
7. Misaligned connecting rods.
8. Connecting rod nuts loose.1. Check engine oil level.
2. Check engine oil level. Inspect oil
pump relief valve and spring.
3. Change oil to correct viscosity.
4. Measure bearings for correct
clearance. Repair if necessary.
5. Replace crankshaft or grind
surface.
6. Replace connecting rod.
7. Replace bent connecting rods.
8. Tighten the connecting rod nuts.
Main Bearing Noise 1. Insufficient oil supply.
2. Low oil pressure.
3. Thin or diluted oil.
4. Excessive bearing clearance.
5. Excessive end play.
6. Crankshaft journal out-of-round or
worn.
7. Loose flywheel or torque
converter.1. Check engine oil level.
2. Check engine oil level. Inspect oil
pump.
3. Change oil to correct viscosity.
4. Measure bearings for correct
clearance. Repair if necessary.
5. Check thrust bearing for wear on
flanges.
6. Replace crankshaft or grind
journals.
7. Tighten to correct torque.
DIAGNOSIS & TESTING
02–14Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine CONDITIONPOSSIBLE CAUSE CORRECTION
Oil Pressure Drop 1. Low oil level.
2. Faulty oil pressure sending unit.
3. Low oil pressure.
4. Clogged oil filter.
5. Thin or diluted oil.
6. Excessive bearing clearance.1. Check engine oil level.
2. Install new sending unit.
3. Check sending unit and main
bearing oil clearance.
4. Install new oil filter.
5. Change oil to correct viscosity.
6. Measure bearings for correct
clearance.
Oil Leaks 1. Misaligned or deteriorated
gaskets.
2. Loose fastener, broken or porous
metal part.
3. Misaligned or deteriorated cup or
threaded plug.1. Replace gasket.
2. Tighten, repair or replace the part.
3. Replace if necessary.
Oil Consumption Or Spark Plugs
Fouled 1. PCV system malfunction.
2. Worn, scuffed or broken rings.
3. Carbon in oil ring slots.
4. Rings fitted too tightly in grooves.
5. Worn valve guide(s).
6. Valve stem seal(s) worn or
damaged.1. Check system and repair if
necessary.
2. Hone cylinder bores. Install new
rings.
3. Install new rings.
4. Remove rings and check grooves.
If groove is not proper width, replace
piston.
5. Replace cylinder head.
6. Replace seal(s).
DIAGNOSIS & TESTING
02
02–15Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 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
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.
CAUTION:
When servicing the oil filter, install the special tool against the base of the filter to avoid deforming
the filter.
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 the surface, and verify the oil filter does not leak.
ON-VEHICLE SERVICE
LTSM020203
LTSM020206
02–46Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 2.0L ENGINE MECHANICAL
GENERAL INFORMATION02-77
Description 02-77
Operation 02-77
Specifications 02-77
Special Tools 02-81
Lubrication System 02-84
DIAGNOSIS & TESTING02-87
Engine Performance Diagnostics 02-87
Engine Mechanical Diagnostics 02-88
Cylinder Compression Pressure Test 02-90
Cylinder Head Gasket Test 02-90
ON-VEHICLE SERVICE02-91
Accessory Drive Belt 02-91
Removal & Installation 02-91
Air Cleaner Element 02-92
Removal & Installation 02-92
Air Cleaner Housing 02-93
Removal & Installation 02-93
Cylinder Head Cover 02-93
Removal & Installation 02-93
Camshaft 02-94
Removal & Installation 02-94
Cylinder Head 02-97
Removal & Installation 02-97
Front Crankshaft Oil Seal 02-99
Removal & Installation 02-99
Rear Crankshaft Oil Seal 02-100
Removal & Installation 02-100
Engine Mounts 02-103
Removal & Installation - Left Mount 02-103
Removal & Installation - Right Mount 02-104
Removal & Installation - Front Mount 02-104
Removal & Installation - Rear Mount 02-105
Engine Assembly 02-105
Removal & Installation 02-105
Engine Timing Belt 02-112
Removal & Installation 02-112
Exhaust Manifold 02-115
Removal & Installation 02-115
Intake Manifold 02-117
Removal & Installation 02-117
Idler Pulley 02-119
Removal & Installation 02-119
Oil Filter 02-119
Removal & Installation 02-119Oil Pan
02-120
Removal & Installation 02-120
Oil Pump 02-121
Removal & Installation 02-121
Oil Strainer 02-122
Removal & Installation 02-122
ENGINE UNIT REPAIR02-123
Engine Block 02-123
Specifications 02-123
Disassembly 02-123
Inspection 02-125
Assembly 02-125
Pistons 02-126
Specifications 02-126
Disassembly 02-127
Inspection 02-128
Assembly 02-130
Connecting Rods 02-131
Specifications 02-131
Disassembly 02-131
Inspection 02-132
Assembly 02-132
Crankshaft 02-133
Specifications 02-133
Disassembly 02-133
Inspection 02-134
Assembly 02-135
CYLINDER HEAD UNIT REPAIR02-136
Cylinder Head 02-136
Specifications 02-136
Disassembly 02-136
Inspection 02-138
Assembly 02-138
Camshaft 02-139
Specifications 02-139
Disassembly 02-140
Inspection 02-140
Assembly 02-142
Valve & Valve Guides 02-143
Specifications 02-143
Disassembly 02-143
Inspection 02-144
Assembly 02-145
Valve Springs 02-146
Specifications 02-146
Disassembly 02-146
Inspection 02-147
Assembly 02-148
02–76Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine DIAGNOSIS & TESTING
Engine Performance Diagnostics
CONDITIONPOSSIBLE CAUSE CORRECTION
Engine Does Not Start 1. Weak battery.
2. Corroded or loose battery
connections.
3. Faulty starter.
4. Faulty coil(s) or control unit.
5. Incorrect spark plug gap.
6. Contamination in fuel system.
7. Faulty fuel pump.
8. Incorrect timing.1. Test battery. Charge or replace if
necessary.
2. Clean and tighten battery
connections. Apply a coat of light
mineral grease to terminals.
3. Test starting system. Check for
codes. (Refer to Appropriate
Diagnostic Information)
4. Test and replace as needed.
(Refer to Appropriate Diagnostic
Information)
5. Set gap.
6. Clean system and replace fuel
filter.
7. Test fuel pump and replace as
needed. (Refer to Appropriate
Diagnostic Information)
8. Check for a skipped timing belt.
Engine Stalls Or Idles Rough 1. Idle speed too low.
2. Incorrect fuel mixture.
3. Intake manifold leakage.
4. Faulty ignition coil(s).1. Test minimum air flow. (Refer to
Appropriate Diagnostic Information)
2. (Refer to Appropriate Diagnostic
Information)
3. Inspect intake manifold, manifold
gasket, and vacuum hoses.
4. Test and replace if necessary.
(Refer to Appropriate Diagnostic
Information)
Engine Loss Of Power 1. Dirty or incorrectly gapped spark
plugs.
2. Contamination in fuel system.
3. Faulty fuel pump.
4. Incorrect valve timing.
5. Leaking cylinder head gasket.
6. Low compression.
7. Burned, warped, excessive
clearance, or pitted valves.
8. Plugged or restricted exhaust
system.
9. Faulty ignition coil(s).
10. Burned spark plugs.1. Clean spark plugs and set gap.
2. Clean system and replace fuel
filter.
3. Test and replace if necessary.
(Refer to Appropriate Diagnostic
Information)
4. Correct valve timing.
5. Replace cylinder head gasket.
6. Test compression of each
cylinder.
7. Replace valves.
8. Perform exhaust restriction test.
Install new parts.
9. Test and replace if necessary.
(Refer to Appropriate Diagnostic
Information)
10. Replace spark plugs.
DIAGNOSIS & TESTING
02
02–87Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine CONDITIONPOSSIBLE CAUSE CORRECTION
Engine Miss On Acceleration 1. Dirty or incorrectly gapped spark
plugs.
2. Contamination in fuel system.
7. Burned, warped, excessive
clearance, or pitted valves.
4. Faulty ignition coil(s).1. Clean spark plugs and set gap.
2. Clean fuel system and replace
fuel filter.
3. Replace valves.
4. Test and replace if necessary.
(Refer to Appropriate Diagnostic
Information)
Engine Miss At High Speed 1. Dirty or incorrect spark plug gap.
2. Faulty ignition coil(s).
3. Dirty fuel injector(s).
4. Contamination in fuel system.1. Clean spark plugs and set gap.
2. Test and replace if necessary.
(Refer to Appropriate Diagnostic
Information)
3. Test and replace if necessary.
(Refer to Appropriate Diagnostic
Information)
4. Clean system and replace fuel
filter.
Engine Mechanical Diagnostics
CONDITION
POSSIBLE CAUSE CORRECTION
Valve Train Noise 1. High or low oil level in crankcase.
2. Thin or diluted oil.
3. Thick oil.
4. Low oil pressure.
5. Worn cam lobe.
6. Worn valve guides.
7. Excessive runout of valve seats
on valve faces.1. Check and correct engine oil
level.
2. Change oil to correct viscosity.
3. Change engine oil and filter.
4. Check and correct engine oil
level.
5. Install new camshaft.
6. Replace cylinder head.
7. Grind valve seats and replace
valves.
Connecting Rod Noise 1. Insufficient oil supply.
2. Low oil pressure.
3. Thin or diluted oil.
4. Excessive bearing clearance.
5. Connecting rod journal out-of-
round.
6. Connecting rod out-of-round.
7. Misaligned connecting rods.
8. Connecting rod nuts loose.1. Check engine oil level.
2. Check engine oil level. Inspect oil
pump relief valve and spring.
3. Change oil to correct viscosity.
4. Measure bearings for correct
clearance. Repair if necessary.
5. Replace crankshaft or grind
surface.
6. Replace connecting rod.
7. Replace bent connecting rods.
8. Tighten the connecting rod nuts.
Main Bearing Noise 1. Insufficient oil supply.
2. Low oil pressure.
3. Thin or diluted oil.
4. Excessive bearing clearance.
5. Excessive end play.
6. Crankshaft journal out-of-round or
worn.
7. Loose flywheel or torque
converter.1. Check engine oil level.
2. Check engine oil level. Inspect oil
pump.
3. Change oil to correct viscosity.
4. Measure bearings for correct
clearance. Repair if necessary.
5. Check thrust bearing for wear on
flanges.
6. Replace crankshaft or grind
journals.
7. Tighten to correct torque.
DIAGNOSIS & TESTING
02–88Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine CONDITIONPOSSIBLE CAUSE CORRECTION
Oil Pressure Drop 1. Low oil level.
2. Faulty oil pressure sending unit.
3. Low oil pressure.
4. Clogged oil filter.
5. Thin or diluted oil.
6. Excessive bearing clearance.1. Check engine oil level.
2. Install new sending unit.
3. Check sending unit and main
bearing oil clearance.
4. Install new oil filter.
5. Change oil to correct viscosity.
6. Measure bearings for correct
clearance.
Oil Leaks 1. Misaligned or deteriorated
gaskets.
2. Loose fastener, broken or porous
metal part.
3. Misaligned or deteriorated cup or
threaded plug.1. Replace gasket.
2. Tighten, repair or replace the part.
3. Replace if necessary.
Oil Consumption Or Spark Plugs
Fouled 1. PCV system malfunction.
2. Worn, scuffed or broken rings.
3. Carbon in oil ring slots.
4. Rings fitted too tightly in grooves.
5. Worn valve guide(s).
6. Valve stem seal(s) worn or
damaged.1. Check system and repair if
necessary.
2. Hone cylinder bores. Install new
rings.
3. Install new rings.
4. Remove rings and check grooves.
If groove is not proper width, replace
piston.
5. Replace cylinder head.
6. Replace seal(s).
DIAGNOSIS & TESTING
02
02–89Chery Automobile Co., Ltd.

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.