clutch CHERY TIGGO 2009 Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine HOW TO LOCATE ELECTRICAL SCHEMATICS IN THESERVICE MANUAL
Electrical Schematic Index
The following table shows where to locate a specific electrical schematic for a vehicle component or system. The
electrical schematics are found throughout the service manual and are easily identified by their components or vehi-
cle systems.
NOTE :
Some service manual chapters DO NOT contain electrical schematics, and will be identified as Nonein the Com-
ponent/Vehicle System column.
SERVICE MANUAL CHAPTER COMPONENT / VEHICLE SYSTEM
01 - General Information •None
02 - Engine •None
03 - Electronic Engine Controls •
Engine Control Module (ECM)
• Engine Coolant Temperature Sensor
• Knock Sensor
• Upstream Oxygen Sensor
• Downstream Oxygen Sensor
• Crankshaft Position Sensor
• Camshaft Position Sensor
• Ignition Coil
• Canister Control Valve
• Front Fuse and Relay Box
• A/C Compressor
• Immobilizer Control Module
• Fuel Injectors
• Manifold Absolute Pressure Sensor (1.6L Only)
• Accelerator Pedal Position Sensor
• Vehicle Speed Sensor
• Throttle Pedal Position Sensor
• Power Steering Switch
• Clutch Pedal Switch (if equipped)
• Electronic Throttle Control Actuator
04 - Fuel Delivery •
Fuel Injectors
• Fuel Level Sensor and Fuel Pump
05 - Starting & Charging •
Starter Motor
• Ignition Switch
• Clutch Pedal Switch (if equipped)
• Generator
06 - Cooling System •Cooling Fan
07 - Exhaust •None
01
01–25Chery 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 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.

Downloaded from www.Manualslib.com manuals search engine Rear Crankshaft Oil Seal
Removal & Installation
NOTE :
The following special tools are required to perform the repair procedure:
•CH-20005 - Rear Crankshaft Oil Seal Installer
• CH-20006 - Rear Crankshaft Oil Seal Guide
• CH-20043 - Flywheel Fixture
1. Remove the transaxle assembly (See Transaxle Assembly Removal & Installation in Section 08 Transaxle & Transfer Case).
2. Using special tool CH-20043 (1), hold the flywheel.
3. Remove the clutch pressure plate retaining bolts (1) and then remove the clutch pressure plate.
(Tighten: Clutch pressure plate bolts to 25 N·m)
4. Remove the flywheel bolts (1) and then remove the flywheel.
(Tighten: Flywheel bolts to 75 N·m)
ON-VEHICLE SERVICE
LTSM080145
BESM080046
BESM020058
02
02–27Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 20. If equipped with an automatic transaxle, removethe transaxle shift cable (1) and the transaxle shift
cable clamp (2).
21. Remove the hydraulic pipe from the clutch slave cylinder.
22. Remove the A/C compressor line bolt (1) from the A/C compressor.
(Tighten: A/C compressor line bolts to 20 N·m)
NOTE: After removing the A/C lines, plug the A/C
lines to prevent any debris from entering the A/C
system.
23. Remove the high pressure line (1) and low pres- sure line (2) from the power steering pump (drain
fluid from lines).
(Tighten: High pressure line to power steering
pump 40 ± 5 N·m)
(Tighten: Low pressure line to power steering pump
40 ± 5 N·m)
24. Remove the exhaust manifold heat shield bolts (1) and then remove heat shield.
(Tighten: Exhaust manifold heat shield bolts to 15
N·m)
25. Disconnect the upstream and downstream oxygen sensor connectors.
ON-VEHICLE SERVICE
LTSM080186
VISM130017
BESM110011
BESM020078
02–34Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine DESCRIPTIONITEMSTANDARD LIMIT
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 bolt to 25 N·m
2nd Step: Tighten the bolt an additional 90°
Crankshaft Holder 28
Crankshaft Main Bearing Cap Bolts 1st Step: Tighten the bolt to 45 N·m
2nd Step: Tighten the bolt an additional 180°
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
GENERAL INFORMATION
02
02–79Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 3. If equipped with manual transaxle, remove clutchpressure plate retaining bolts (1) and remove the
clutch pressure plate.
(Tighten: Clutch pressure plate bolts to 25 N·m)
4. If equipped with manual transaxle, remove the fly- wheel bolts (1) and then remove the flywheel.
(Tighten: Flywheel bolts to 75 N·m)
5. If equipped with automatic transaxle, remove the drive plate retaining bolts (1) and then remove
drive plate.
(Tighten: Drive plate bolts to 75 N·m)
6. Remove the rear oil seal using a suitable tool.
7. Installation is in the reverse order of removal.
ON-VEHICLE SERVICE
BESM080046
BESM020058
BESM020031
02–101Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 13.Disconnectandremovethefollowingelectricalconnectors:
€Coolanttemperaturesensor
€Camshaftpositionsensor
€Ignitioncoil
€Fourfuelinjectors
€Intakemanifoldairpressuresensor(1.6L)
€Airflowsensor(1.8L)
€Carboncanistersolenoidvalve
€Throttlebodycontrol
€A/Ccompressor
€Oilpressuresensor
€Powersteeringpumppressureswitch
€Generator
14.Removethepipefromthecanistercontrolvalve
(1).
15.Disconnecttheheaterhoses(1)onthevehicle.
16.Removethevacuumlinefromthebrakebooster
(2).
17.Removethedipstick.
18.Ifequippedwithamanualtransaxleremovethe
transaxleshiftcable(1).
19.Removethehydraulicpipefromtheclutchslave
cylinder.
ON-VEHICLESERVICE
LTSM020235
BESM020025
BESM080051
02–107CheryAutomobileCo.,Ltd.

Downloaded from www.Manualslib.com manuals search engine P0261 - Cylinder 1 Injector Circuit Low,
P0264 - Cylinder 2 Injector Circuit Low,
P0267 - Cylinder 3 Injector Circuit Low,
P0270 - Cylinder 4 Injector Circuit Low 03-157
P0262 - Cylinder 1 Injector Circuit High,
P0265 - Cylinder 2 Injector Circuit High,
P0268 - Cylinder 3 Injector Circuit High,
P0271 - Cylinder 4 Injector Circuit High 03-164
P0321 - Distributor Engine Speed In
Phase Circuit Performance 03-171
P0324 - Knock Control System Error 03-177
P0343 - Camshaft Position Sensor
Circuit High Input 03-181
P0444 - Evaporative Emission System
Purge Control Valve Circuit Open 03-187
P0506 - Idle Control System RPM
Lower Than Expected 03-191
P0601 - Internal Control Module
Memory Check Sum Error, P0604 -
Internal Controller Module Random
Access Memory (RAM) Error, P0605 -
Internal Controller Module ROM Test
Error, P0606 - ECM Processor 03-193
P0602 - ECM Programming Error 03-195
P0645 - A/C Clutch Relay Circuit 03-197
P1545 - Throttle Position Control
Malfunction 03-202
P2138 - Pedal Position Sensor
Performance 03-210
ON-VEHICLE SERVICE03-217
Engine Coolant Temperature (ECT)
Sensor 03-217
Description 03-217
Operation 03-217
Removal & Installation 03-217
Knock Sensor 03-218
Description 03-218
Operation 03-218
Removal & Installation 03-218
Oxygen Sensor 03-218
Description 03-218
Operation 03-218
Upstream Oxygen Sensor 03-219
Downstream Oxygen Sensor 03-219Removal & Installation - Upstream
Oxygen Sensor
03-219
Removal & Installation - Downstream
Oxygen Sensor 03-219
Crankshaft Position (CKP) Sensor 03-220
Description 03-220
Operation 03-220
Removal & Installation 03-220
Camshaft Position (CMP) Sensor 03-220
Description 03-220
Operation 03-221
Removal & Installation 03-221
Vehicle Speed Sensor 03-221
Description 03-221
Operation 03-221
Removal & Installation 03-221
Accelerator Sensor 03-221
Description 03-221
Operation 03-222
Removal & Installation 03-222
Manifold Absolute Pressure Sensor -
1.6L 03-222
Description 03-222
Operation 03-222
Removal & Installation 03-222
Air Flow Sensor - 1.8L 03-223
Description 03-223
Operation 03-223
Removal & Installation 03-223
Accelerator Pedal Position Sensor 03-224
Description 03-224
Operation 03-224
Removal & Installation 03-224
Electronic Throttle Control Actuator 03-225
Description 03-225
Operation 03-225
Removal & Installation 03-225
Engine Control Module (ECM) 03-226
Description 03-226
Operation 03-226
Removal & Installation 03-226
03–2Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION
Description
The Engine Control Module (ECM) consists of a microcomputer and electrical connectors containing circuits for signal
input, output, power supply and ground. The ECM controls the engine functions.
The following are the input and output components monitored by the ECM. The monitored functions include compo-
nents from the engine, ignition, transaxle, air conditioning, or any other ECM supported subsystem.
ECM Inputs
•Brake Switch Sensor
• Refrigerant Pressure Sensor
• Camshaft Position (CMP) Sensor
• Crankshaft Position (CKP) Sensor
• Engine Coolant Temperature (ECT) Sensor
• Manifold Absolute Pressure (MAP) Sensor (1.6L)
• Air Flow Sensor (1.8L)
• Throttle Position Sensor (Integral with Electronic Throttle Control Actuator)
• Power Steering Switch
• Accelerator Pedal Position (APP) Sensor
• Knock Sensor
• Oxygen Sensor (Upstream & Downstream)
• Vehicle Speed Sensor
• Clutch Pedal Switch (Manual transaxle only)
ECM Outputs
• Canister Control Valve
• Fuel Injectors
• Fuel Pump Relay
• Electronic Throttle Control Actuator
• Ignition Coil
• A/C Compressor
• Cooling Fan
• Oxygen Sensor Heater (Upstream & Downstream)
Operation
The ECM monitors components and circuits, and tests them in various ways depending on the hardware, function,
and type of signal. For example, analog inputs, such as throttle position or engine coolant temperature are typically
checked for opens, shorts and out-of-range values. This type of monitoring is carried out continuously. Some digital
inputs like vehicle speed or crankshaft position rely on rationality checks - checking to see if the input value makes
sense at the current engine operating conditions. These types of tests may require monitoring several components
and can only be carried out under appropriate test conditions.
The ECM is a pre-programmed, microprocessor-based digital computer. It regulates ignition timing, air-fuel ratio,
emission control devices, charging system, certain transmission features, speed control, air conditioning compressor
clutch engagement and idle speed. The ECM can adapt its programming to meet changing operating conditions.
03
03–3Chery Automobile Co., Ltd.