belt CHERY TIGGO 2009 Service Repair Manual
[x] Cancel search | Manufacturer: CHERY, Model Year: 2009, Model line: TIGGO, Model: CHERY TIGGO 2009Pages: 1903, PDF Size: 33.38 MB
Page 13 of 1903
Downloaded from www.Manualslib.com manuals search engine •Digit #8 The eighth digit of the VIN code represents the restraint rystem:
A represents manual safety belts.
B represents manual safety belts plus air bags in the front row.
• Digit #9 The ninth digit of the VIN code is the check digit:
It is to check accuracy of VIN record, and is made out through computation after confirming the other six-
teen digits of the VIN.
• Digit #10 The tenth VIN position represents the model year code:
5 represents the year 2005.
• Digit #11 The eleventh VIN position represents the assembly plant code:
D represents the Chery Automobile Co., Ltd.
• Digits #12, #13, #14, #15, #16, #17 The last six VIN positions represent the production sequence number.
This represents the actual production number of the vehicle.
VEHICLE IDENTIFICATION NUMBER (VIN)
01–12Chery Automobile Co., Ltd.
Page 14 of 1903
Downloaded from www.Manualslib.com manuals search engine INTERNATIONAL SYMBOLS
International Symbols
The graphic symbols illustrated in the following International Control and Display Symbols chart are used to identify var-
ious instrument controls. The symbols correspond to the controls and displays that are located on the instrument panel.
International Control and Display Symbols
1 - High Beam
2 - Fog Lamps
3 - Headlamp, Parking Lamps, Panel Lamps
4 - Turn Signals
5 - Hazard Warning
6 - Front Windshield Washer
7 - Front Windshield Wiper
8 - Front Windshield Wiper and Washer
9 - Front Windshield Defroster
10 - Blower Motor Fan
11 - Rear Window Defroster
12 - Rear Window Wiper13 - Rear Window Washer
14 - Fuel
15 - Engine Coolant Temperature
16 - Battery Charging Condition
17 - Engine Oil
18 - Seat Belt
19 - Brake Failure
20 - Parking Brake
21 - Hood
22 - Trunk
23 - Horn
24 - Cigarette Lighter
BESM010003
01
01–13Chery Automobile Co., Ltd.
Page 27 of 1903
Downloaded from www.Manualslib.com manuals search engine SERVICE MANUAL CHAPTERCOMPONENT / VEHICLE SYSTEM
08 - Transaxle & Transfer Case •
Transaxle Control Module (TCM)
• Automatic Transaxle Shifter Selector
• Automatic Transaxle Assembly
• Manual Transaxle Assembly
• Winter Mode Switch
• EPDE Solenoid Valve
• Backup Lamp Switch
• Integrated Torque Management (ITM) Control Module
09 - Driveline & Axle •None
10 - Suspension •None
11 - Steering •Power Steering Switch
12 - Brakes •
Antilock Brake System (ABS) Module
• Wheel Speed Sensors
• Brake Switch
• Parking Brake Switch
• Brake Fluid Level Switch
13 - Heating & Air Conditioning •
Manual Temperature Control System
• Blower Motor
• A/C Compressor
• Refrigerant Pressure Switch
14 - Restraints •
Restraints Control Module
• Seat Belt Buckle Switch
• Front Crash Sensors
• Driver Airbag
• Passenger Airbag
HOW TO LOCATE ELECTRICAL SCHEMATICS IN THE SERVICE MANUAL
01–26Chery Automobile Co., Ltd.
Page 30 of 1903
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.
Page 32 of 1903
Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION
Description
The 1.6L & 1.8L in-line four cylinder engines have the following features:
•Dual overhead camshafts
• Four valves per cylinder
• Aluminum cylinder head
• Cast iron cylinder block (1.8L Engine)
• Aluminum cylinder block (1.6L Engine)
Operation
The 1.6L & 1.8L engines utilize 4 valve-per-cylinder and a dual overhead camshaft design. The engines use an indi-
vidual coil ignition system. The 1.6L engine uses an aluminum cylinder block, and the 1.8L engine is made of cast
iron. The bearing caps are integrated into the lower cylinder block assembly. An aluminum oil pan bolts to the bottom
of the lower cylinder block. The camshafts are mounted in the cylinder head and act against valve tappets to open
and close the valves. The camshafts are driven off the front of the cylinder head by one timing belt. The belt is driven
by a sprocket that is located on the crankshaft. The piston assembly is an aluminum piston with a cast iron con-
necting rod.
The aluminum cylinder head contains dual overhead camshafts with 4 valve-per-cylinder construction. The valves are
arranged in two in-line banks. The cylinder head incorporates powdered metal valve guides and seats. The cylinder
head is sealed to the block using a multi-layer steel head gasket and retaining bolts.
Specifications
1.6L Engine Specifications
DESCRIPTION SPECIFICATION
Type In-Line OHV, DOHC
Number of Cylinders 4
Compression Ratio 10.5:1
Compression Pressure 10 - 15 bar
Max. Compression Pressure Variation Between
Cylinders 25%
Stroke 77.5 mm
Bore 81 mm
Displacement 1597 cc
Firing Order 1-3-4-2
1.8L Engine Specifications
DESCRIPTIONSPECIFICATION
Type In-Line OHV, DOHC
Number of Cylinders 4
Compression Ratio 10.5:1
Compression Pressure 10 - 15 bar
Max. Compression Pressure Variation Between
Cylinders 25%
Stroke 89.5 mm
Bore 81 mm
Displacement 1845 cc
Firing Order 1-3-4-2
02
02–3Chery Automobile Co., Ltd.
Page 34 of 1903
Downloaded from www.Manualslib.com manuals search engine DESCRIPTIONITEMSTANDARD LIMIT
Intake Cam Lobe Height -37.15 mm -
Exhaust Cam Lobe Height -37.05 mm -
Camshaft Journal #1 Outer
Diameter -
31.934 - 31.95 mm -
Camshaft Journal #2, #3,
#4, #5, Outer Diameter -
23.947 - 23.96 mm -
Camshaft Cam Bearing #1
Inner Diameter -
32 - 32.025 mm -
Camshaft Cam Bearing
#2, #3, #4, #5, Inner
Diameter -
24 - 24.021 mm -
Camshaft Journal #1
Clearance -
0.05 - 0.091 mm -
Camshaft Journal #2, #3,
#4, #5 Clearance -
0.04 - 0.074 mm -
Intake Camshaft Axial
Clearance -
0.15 - 0.20 mm -
Exhaust Camshaft Axial
Clearance -
0.15 - 0.20 mm -
Intake Valve Guide
Clearance -
0.012 - 0.043 mm -
Exhaust Valve Guide
Clearance -
0.032 - 0.063 mm -
Valve Outer Diameter Intake Valve
5.98 ± 0.008 mm -
Exhaust Valve 5.96 ± 0.008 mm -
Valve Guide Inner
Diameter Intake Valve
5.4 ± 0.1 mm -
Exhaust Valve 5.4 ± 0.1 mm -
Fringe Thickness On Top
Of Valve Intake Valve
0.3 ± 0.15 mm -
Exhaust Valve 0.3 ± 0.15 mm -
Valve Tilt Angle Intake Valve
65°-
Exhaust Valve 68°-
Valve Height Intake Valve
107.998 mm -
Exhaust Valve 106.318 mm -
Torque Specifications
CAUTION:
When torquing a fastener in two steps, DO NOT use a torque wrench for the second step.
DESCRIPTION TORQUE (N·m)
Accessory Drive Belt Tensioner Pulley Bolt 35
Camshaft Bearing Cap Bolts 11
Clutch Pressure Plate Bolts 25
Connecting Rod Cap Bolts 1st Step: Tighten the bolts to 25 N·m
2nd Step: Tighten the bolts an additional 90°
Crankshaft Holder 28
Crankshaft Main Bearing Cap Bolts 1st Step: Tighten the bolts to 45 N·m
2nd Step: Tighten the bolts an additional 180°
GENERAL INFORMATION
02
02–5Chery Automobile Co., Ltd.
Page 35 of 1903
Downloaded from www.Manualslib.com manuals search engine DESCRIPTIONTORQUE (N·m)
Crankshaft Timing Belt Pulley Bolt 1st Step: Tighten the bolt to 130 N·m
2nd Step: Tighten the bolt an additional 65°
Crankshaft Vibration Damper Bolts 25
Cylinder Head Cover Bolts 11
Cylinder Head Bolts 1st Step: Tighten the bolt to 40 ± 5 N·m
2nd Step: Tighten the bolt an additional 90 ± 5° 3rd Step: Tighten the bolt an additional 90 ± 5°
Dipstick Bracket Bolts 11
Drive Plate Bolts (automatic transaxle) 75
Engine Left Mount Bolt 70
Engine Right Mount Bolt 70
Engine Front Mount Bolt 60
Engine Rear Mount Bolt 60
Engine To Transaxle Bolts 80
Exhaust Manifold Nuts 25
Exhaust Manifold Heat Shield Bolts 15
Exhaust Camshaft Timing Belt Pulley Bolt 120
Flywheel Bolts (manual transaxle) 75
Fuel Rail Bracket Bolts 11
Idler Pulley Bolt 40
Intake Camshaft Timing Belt Pulley Bolt 120
Intake Manifold Bolts 10
Intake Manifold Nuts 11
Intake Manifold Bracket Bolts 25
Lower Idler Pulley Bolt 45
Lower Cylinder Block Bolts 23
Oil Filter 25
Oil Pan Bolts 18
Oil Drain Plug 40
Oil Strainer Bolts 18
Oil Pump Bolts 11
(Apply with Loctite 5910 Thread-Locker)
Rear Timing Cover Bolts 7
Timing Belt Upper Cover Bolts 11
Timing Belt Lower Cover Bolts 11
Timing Belt Tensioner Assembly 27
Timing Belt Tensioner Pulley Bolt 30
Throttle Body Bolts 11
Upper Idler Pulley Bolt 45
GENERAL INFORMATION
02–6Chery Automobile Co., Ltd.
Page 38 of 1903
Downloaded from www.Manualslib.com manuals search engine Valve Stem Seal Installer GuideCH-20012
Valve Seal RemoverCH-20013
Valve Keeper Installer CH-20017
Valve Spring Compressor CH-20018
Crankshaft Belt Pulley Fixture CH-20019
GENERAL INFORMATION
02
02–9Chery Automobile Co., Ltd.
Page 42 of 1903
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.
Page 46 of 1903
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. While using a suitable tool and securely holding the hexagonal portion of the drive belt tensioner, rotate thepulley counterclockwise to loosen the drive belt.
WARNING!
Avoid placing hands near the drive belt tensioner while it is being held.
1 - Drive Belt
2 - Generator Bolt
3 - Tensioner Pulley Bolt
4 - Tensioner
5 - Compressor
6 - Generator
7 - Idler Pulley
8 - Generator Bracket
9 - Generator Bracket Bolt10 - Generator Bracket Bolts
11 - Power Steering Pump Bolt
12 - Power Steering Pump Bolt
13 - Power Steering Pump Bolt
14 - Power Steering Pump Bracket
15 - Power Steering Pump Bracket Bolts
16 - Power Steering Pump
17 - Idler Pulley
18 - Compressor Bolts
LTSM020163
02
02–17Chery Automobile Co., Ltd.