engine overheat CHERY TIGGO 2009 Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine Cylinder Compression Pressure Test
•The result of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions.
• Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise
the indicated compression pressures may not be valid for diagnostic purposes.
Check engine oil level and add oil if necessary.
Disconnect the spark plug wires.
Remove all spark plugs from engine (as spark plugs are being removed, check electrodes for abnormal
firing indicators fouled, hot, oily, etc.).
Record cylinder number of each spark plug for future reference.
Disconnect fuel injector electrical connectors.
Be sure throttle blade is fully open during the compression check.
Insert compression pressure adaptor or the equivalent into each spark plug hole in cylinder head.
Crank engine until maximum pressure is reached on gauge. Record each cylinder pressure.
Compression should not be less than 1000 kPa and not vary more than 25 percent from cylinder to cylinder.
If one or more cylinders have abnormally low compression pressures, repeat the compression test.
If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem with the cylinder in question.
NOTE :
The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine
should not be disassembled to determine the cause of low compression unless some malfunction is present.
Cylinder Head Gasket Test
• A cylinder head gasket leak can be located between adjacent cylinders, between a cylinder and the adjacent
water jacket or from an oil passage to the exterior of the engine.
• Possible indications of the cylinder head gasket leaking between adjacent cylinders are:
Loss of engine power
Engine misfiring
Poor fuel economy
• Possible indications of the cylinder head gasket leaking between a cylinder and an adjacent water jacket are:
Engine overheating
Loss of coolant
Excessive steam (white smoke) emitting from exhaust
Coolant foaming
DIAGNOSIS & TESTING
02–16Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Cylinder Compression Pressure Test
•The result of a cylinder compression pressure test can be utilized to diagnose several engine malfunctions.
• Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise
the indicated compression pressures may not be valid for diagnostic purposes.
Check engine oil level and add oil if necessary.
Disconnect the spark plug wires.
Remove all spark plugs from engine (as spark plugs are being removed, check electrodes for abnormal
firing indicators fouled, hot, oily, etc.).
Record cylinder number of each spark plug for future reference.
Disconnect fuel injector electrical connectors.
Be sure throttle blade is fully open during the compression check.
Insert compression pressure adaptor or the equivalent into each spark plug hole in cylinder head.
Crank engine until maximum pressure is reached on gauge. Record each cylinder pressure.
Compression should not be less than 1000 kPa and not vary more than 25 percent from cylinder to cylinder.
If one or more cylinders have abnormally low compression pressures, repeat the compression test.
If the same cylinder or cylinders repeat an abnormally low reading on the second compression test, it could indicate the existence of a problem with the cylinder in question.
NOTE :
The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine
should not be disassembled to determine the cause of low compression unless some malfunction is present.
Cylinder Head Gasket Test
• A cylinder head gasket leak can be located between adjacent cylinders, between a cylinder and the adjacent
water jacket or from an oil passage to the exterior of the engine.
• Possible indications of the cylinder head gasket leaking between adjacent cylinders are:
Loss of engine power
Engine misfiring
Poor fuel economy
• Possible indications of the cylinder head gasket leaking between a cylinder and an adjacent water jacket are:
Engine overheating
Loss of coolant
Excessive steam (white smoke) emitting from exhaust
Coolant foaming
DIAGNOSIS & TESTING
02–90Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Cylinder Head Gasket Test
•A cylinder head gasket leak can be located between adjacent cylinders, between a cylinder and the adjacent
water jacket or from an oil passage to the exterior of the engine.
• Possible indications of the cylinder head gasket leaking between adjacent cylinders are:
Loss of engine power
Engine misfiring
Poor fuel economy
• Possible indications of the cylinder head gasket leaking between a cylinder and an adjacent water jacket are:
Engine overheating
Loss of coolant
Excessive steam (white smoke) emitting from exhaust
Coolant foaming
Engine Oil Pressure Test
1. Check the engine oil level.
2. Disconnect the oil pressure switch electrical connector.
3. Remove the oil pressure switch.
4. Install the mechanical oil pressure gauge.
5. Start the engine and warm to normal operating temperature.
6. After the engine has been warmed up, check that the oil pressure is within the specifications. Standard Oil Pressure: At 750 ± 50 RPM: 0.8 MPa
7. Stop the engine.
8. Remove the oil pressure gauge.
9. Apply the specified sealant to the thread (1) of oil pressure switch.
10. Install the oil pressure switch (Tighten: Oil pres- sure switch to 10 ± 2 N·m).
DIAGNOSIS & TESTING
LTSM020146
02–166Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Electronic Engine Control Input & Output Device Failure Modes
NUMBER ITEMFAILURE MODECORRECTION
1 CKP•
Engine is hard to start.
• The engine RPM will be limited after the engine starts.
• The highest RPM is less than 3800.
• Excessive exhaust emissions.
• No ignition signal to the ECM.
• The tachometer does not work.
• Rough engine operation. Replace
2 CMP•
The fuel injector ON time may vary from 720 degrees to 360
degrees.
• The sensor output is not correct, the MIL light will turn on
when with the second revolution after the engine starts.
• Engine is hard to start.
• The highest RPM is less than 4000. Replace
3 APPS•
The MIL light will turn on.
• Poor acceleration.
• The engine RPM will be limited after the engine starts. Replace
4 ECT•
Engine hard to start when cold.
• Engine hard to start when hot.
• Poor driving capability.
• If the sensor circuit is shorted to power, the engine will run
under the default values.
• The temperature gauge indicates too high.
• The temperature gauge indicates too low.
• The cooling fan operates continuously on high speed.
• The high temperature warning lamp will flash when the IP
indicates low temperature. Replace
5 MAF•
The cooling fan will operate for approximately 60 seconds on
high speed after the ignition switch is turned off.
• Poor acceleration.
• Poor driving capability. Replace
6 O2 Sensor •
Poor fuel economy.
• Excessive exhaust emissions.
• Sluggish acceleration.
• Poor driving capability. Replace
7 Knock Sensor •
The engine produces an engine knock.
• Overheated engine.
• Excessive exhaust emissions.
• Poor fuel economy.
• Lack of engine power.
• Internal engine damage. Replace
8 ECM•
Unstable engine idle.
• Poor acceleration.
• Unable to start.
• High engine idle.
• The engine exhaust exceeds emission standards.
• Engine is hard to start.
• Air conditioner does not operate.
• Fuel injector control failure.
• Engine stalls out. Replace
9 Ignition Coil •
Unstable idle.
• Lack of engine power.
• Poor fuel economy

.
• Excessive exhaust emissions.
• Weak spark. Replace
GENERAL INFORMATION
03–4Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Electronic Engine Control Input & Output Device Failure Modes
NUMBER ITEMFAILURE MODECORRECTION
1 CKP•
Engine is hard to start.
• The engine RPM will be limited after the engine starts.
• The highest RPM is less than 3800.
• Excessive exhaust emissions.
• No ignition signal to the ECM.
• The tachometer does not work.
• Rough engine operation. Replace
2 CMP•
The fuel injector ON time may vary from 720 degrees to 360
degrees.
• The sensor output is not correct, the MIL light will turn on
when with the second revolution after the engine starts.
• Engine is hard to start.
• The highest RPM is less than 4000. Replace
3 APPS•
The MIL light will turn on.
• Poor acceleration.
• The engine RPM will be limited after the engine starts. Replace
4 ECT•
Engine hard to start when cold.
• Engine hard to start when hot.
• Poor driving capability.
• If the sensor circuit is shorted to power, the engine will run
under the default values.
• The temperature gauge indicates too high.
• The temperature gauge indicates too low.
• The cooling fan operates continuously on high speed.
• The high temperature warning lamp will flash when the IP
indicates low temperature. Replace
5 MAF•
The cooling fan will operate for approximately 60 seconds on
high speed after the ignition switch is turned off.
• Poor acceleration.
• Poor driving capability. Replace
6O
2Senser •
Poor fuel economy.
• Excessive exhaust emissions.
• Sluggish acceleration.
• Poor driving capability. Replace
7 Knock Sensor •
The engine produces an engine knock.
• Overheated engine.
• Excessive exhaust emissions.
• Poor fuel economy.
• Lack of engine power.
• Internal engine damage. Replace
8 ECM•
Unstable engine idle.
• Poor acceleration.
• Unable to start.
• High engine idle.
• The engine exhaust exceeds emission standards.
• Engine is hard to start.
• Air conditioner does not operate.
• Fuel injector control failure.
• Engine stalls out. Replace
9 Ignition Coil •
Unstable idle.
• Lack of engine power.
• Poor fuel economy.
• Excessive exhaust emissions.
• Weak spark. Replace
GENERAL INFORMATION
03–230Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Electronic Engine Control Input & Output Device Failure Modes
NUMBER ITEMFAILURE MODECORRECTION
1 CKP•
Engine is hard to start.
• The engine RPM will be limited after the engine starts.
• The highest RPM is less than 3800.
• Excessive exhaust emissions.
• No ignition signal to the ECM.
• The tachometer does not work.
• Rough engine operation. Replace
2 CMP•
The fuel injector ON time may vary from 720 degrees to 360
degrees.
• The sensor output is not correct, the MIL light will turn on
when with the second revolution after the engine starts.
• Engine is hard to start.
• The highest RPM is less than 4000. Replace
3 APPS•
The MIL light will turn on.
• Poor acceleration.
• The engine RPM will be limited after the engine starts. Replace
4 ECT•
Engine hard to start when cold.
• Engine hard to start when hot.
• Poor driving capability.
• If the sensor circuit is shorted to power, the engine will run
under the default values.
• The temperature gauge indicates too high.
• The temperature gauge indicates too low.
• The cooling fan operates continuously on high speed.
• The high temperature warning lamp will flash when the IP
indicates low temperature. Replace
5 MAF•
The cooling fan will operate for approximately 60 seconds on
high speed after the ignition switch is turned off.
• Poor acceleration.
• Poor driving capability. Replace
6O
2Sensor •
Poor fuel economy.
• Excessive exhaust emissions.
• Sluggish acceleration.
• Poor driving capability. Replace
7 Knock Sensor •
The engine produces an engine knock.
• Overheated engine.
• Excessive exhaust emissions.
• Poor fuel economy.
• Lack of engine power.
• Internal engine damage. Replace
8 ECM•
Unstable engine idle.
• Poor acceleration.
• Unable to start.
• High engine idle.
• The engine exhaust exceeds emission standards.
• Engine is hard to start.
• Air conditioner does not operate.
• Fuel injector control failure.
• Engine stalls out. Replace
9 Ignition Coil •
Unstable idle.
• Lack of engine power.
• Poor fuel economy.
• Excessive exhaust emissions.
• Weak spark. Replace
GENERAL INFORMATION
03
03–443Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 4.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.
5.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.
6.CHECK ENGINE OVERHEATING
• Is the engine overheating (hot start concern only)?
For hot start concerns, does engine appear to be overheating?
Ye s>>Repair the engine cooling system.
No
>>Go to the next step.
7.CHECK POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM
• Remove the PCV valve and shake it.
Does PCV valve rattle?
Ye s>>Go to the next step.
No
>>Replace the PCV valve.
ELECTRONIC ENGINE CONTROLS - 2.4L ENGINE SYMPTOM DIAGNOSIS
03–550Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Fast Idle
The following conditions apply to this symptom:
•The engine idles at a higher than recommended speed.
1.VERIFY ENGINE OPERATES AT NORMAL OPERATING TEMPERATURE
• Check the engine operating temperature.
Does the engine appear to be either overheating or not reaching normal operating temperature?
Ye s>>Repair the engine cooling system.
No
>>Go to the next step.
2.PRELIMINARY CHECKS
• Carry out the following preliminary checks:
Vacuum leaks
Throttle plate and linkage
Intake air tube (leaks)
Correct sealing of intake manifold and components attached to intake air tube
Are all checks OK?
Ye s>>Go to the next step.
No
>>Repair as necessary.
Verify the symptom no longer exists.
3.CHECK ECM DTC
• Turn the ignition switch on.
• With the 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
>>See Diagnostic Help for additional information.
ELECTRONIC ENGINE CONTROLS - 2.4L ENGINE SYMPTOM DIAGNOSIS
03–552Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine The cooling system regulates engine operating temperature. It allows the engine to reach normal operating temper-
ature as soon as possible, maintains normal operating temperature and prevents overheating.
The cooling system also provides a means of heating the passenger compartment. The cooling system is pressurized
and uses a centrifugal water pump to circulate coolant throughout the system.
The cooling system consists of the following components:
•Radiator
• Coolant
• Coolant pump
• Electric cooling fans
• Electric cooling fans control module
• Thermostat
• Coolant reservoir
Thermostat Housing Assembly - 1.6L & 1.8L & 2.0L
1 - Gasket
2 - Coolant Temperature Sensor
3 - Thermostat Housing Assembly
4 - Thermostat Housing Mounting Bolts5 - Minor Cycle Water Hose
6 - Thermostat Housing Cover
7 - Thermostat Housing Cover Mounting Bolts
8 - Thermostat Assembly
GENERAL INFORMATION
LTSM060007
06
06–3Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Cooling System Troubleshooting Chart
CONDITIONPOSSIBLE CAUSES CORRECTION
Loss of Coolant · Coolant hoses or tubes
· Hose clamps
· Coolant pump gasket
· Thermostat gasket
· Thermostat housing
· Radiator
· Coolant reservoir
· Pressure relief cap
· Coolant pump leaking
· Heater core
· Engine gaskets (may leak
internally or externally)
· Cylinder block core plugs· Replace coolant hoses or tubes
· Replace hose clamps
· Replace coolant pump gasket
· Replace thermostat gasket
· Repair/replace thermostat housing
· Repair/replace radiator
· Replace coolant reservoir
· Replace pressure relief cap
· Replace coolant pump
· Replace heater core
· Replace engine gaskets
· Replace cylinder block core plugs
Engine Overheats · Low coolant level
· External engine coolant leak
· Air lock in system
· Pressure relief cap installation
· Restricted airflow through the A/C
condenser/radiator
· Internal engine coolant leak
· Coolant condition/concentration
· Electric cooling fan
· Radiator
· Thermostat
· Engine coolant temperature
indicator gauge
· Heater core
· Coolant pump
· Coolant flow restriction· Add coolant as needed
· Repair engine coolant leak
· Bleed air from cooling system
· Ensure pressure relief cap is
installed correctly
· Remove restriction from the A/C
condenser/radiator
· Repair internal engine coolant leak
· Repair coolant condition/
concentration as needed
· Replace electric cooling fan(s)
· Repair/replace radiator
· Replace thermostat
· Verify engine coolant temperature
indicator gauge operation
· Replace heater core
· Replace coolant pump
· Repair cause of coolant flow
restriction
Engine Does Not Reach Normal
Operating Temperature · Thermostat
· Electric cooling fan always on
· Engine coolant temperature
indicator gauge· Replace thermostat
· Repair cause of electric cooling fan
always on
· Verify engine coolant temperature
indicator gauge operation
Electric Cooling Fan(s) Does Not
Operate · Fuse and Relay Box
· Wiring
· Relay(s)
· Fuse(s)
· Engine Control Module (ECM)
· Cooling fan motor(s)· Repair/replace Fuse and Relay
Box
· Repair wiring
· Replace relay(s)
· Replace fuse(s)
· Replace the ECM
· Replace cooling fan motor(s)
Electric Cooling Fan(s) On All The
Time · Wiring
· Relay(s)
· Engine Control Module (ECM)· Repair wiring
· Replace relay(s)
· Replace the ECM
DIAGNOSIS AND TESTING
06–12Chery Automobile Co., Ltd.