fuel CHERY TIGGO 2009 Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine 2009
CHERY
Tiggo
Service Manual
FOREWORD
This manual contains on-vehicle service
and diagnosis procedures for the Chery Tiggo.
A thorough familiarization with this manual
is important for proper repair and
maintenance. It should always be kept in a
handy place for quick and easy reference.
The contents of this manual, including
drawings and specifications, are the latest
available at the time of printing. As
modifications affecting repair or
maintenance occur, relevant information
supplementary to this volume will be made
available at Chery dealers. This manual
should be kept up-to-date.
Chery Automobile Company, Ltd. reserves the
right to alter the specifications and
contents of this manual without obligation
or advance notice.
All rights reserved. No part of this book
may be reproduced or used in any form or
by any means, electronic or mechanical—
including photocopying and recording and the
use of any kind of information storage and
retrieval system—without permission in
writing.
NOTE:
This Tiggo service manual only applies to the fol-
lowing engines and transaxles:
• 1.6L with M/T
• 1.8L with M/T
• 2.0L with A/T
• 2.4L with A/T
Chery Automobile Company, Ltd.Wuhu, Anhui Province, CHINA
CONTENTS
Title Section
GENERAL INFORMATION01
ENGINE02
ELECTRONIC ENGINE CONTROLS03
FUEL DELIVERY04
STARTING & CHARGING05
COOLING06
EXHAUST07
TRANSAXLE & TRANSFER CASE08
DRIVELINE & AXLE09
SUSPENSION10
STEERING11
BRAKES12
HEATING & AIR CONDITIONING13
RESTRAINTS14
BODY & ACCESSORIES15
WIRING16
ALPHABETICAL INDEXAI
© 2009 Chery Automobile Co., Ltd.
PRINTED NOVEMBER, 2009

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.

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 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.

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 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 7. Remove coolant reservoir (1).
8. Remove the coolant fan & radiator assembly (See Coolant Fan & Radiator Assembly Removal & Installation inSection 06 Cooling).
9. Remove the starter motor wiring.
10. Relieve the fuel pressure (See Fuel Pressure Relief Procedure in Section 04 Fuel Delivery).
11. Disconnect and remove the fuel line at the fuel rail.
12. Remove the air inlet hose and the air cleaner case assembly.
NOTE: For 1.8L engine, disconnect the air flow
sensor electrical connector.
13. Remove the ground cable bolt from the cylinder head.
ON-VEHICLE SERVICE
LTSM020190
LTSM020226
02–32Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 14.Disconnectandremovethefollowingelectricalconnectors:
€Coolanttemperaturesensor
€Camshaftpositionsensor
€Ignitioncoil
€Fourfuelinjectors
€Intakemanifoldairpressuresensor(1.6L)
€Airflowsensor(1.8L)
€Carboncanistersolenoidvalve
€Throttlebodycontrol
€A/Ccompressor
€Oilpressuresensor
€Powersteeringpumppressureswitch
€Generator
15.Removethepipefromthecanistercontrolvalve
(1).
16.Disconnecttheheaterhoses(1)onthevehicle.
17.Removethevacuumlinefromthebrakebooster
(2).
18.Removethedipstick.
19.Ifequippedwithamanualtransaxleremovethe
transaxleshiftcable(1).
ON-VEHICLESERVICE
LTSM020235
BESM020025
BESM080051
02
02–33CheryAutomobileCo.,Ltd.

Downloaded from www.Manualslib.com manuals search engine Installation Notes:
•Clean all surfaces of manifold and cylinder head.
• Install a new exhaust manifold gasket during installation.
Intake Manifold
Removal & Installation
1. Disconnect the negative battery cable.
2. Remove the engine cover.
3. Drain the cooling system (See Cooling System Draining and Filling in Section 06 Cooling).
WARNING!
Always allow the engine to cool before opening the cooling system. Do not loosen the coolant pressure relief
cap when the engine is operating or the cooling system is hot. The cooling system is under pressure; steam and
hot liquid can come out forcefully when the cap is loosened slightly. Failure to follow these instructions may
result in serious personal injury.
4. Remove the coolant fan & radiator assembly (See Coolant Fan & Radiator Assembly Removal & Installation in
Section 06 Cooling).
1 - Fuel Rail Bolt
2 - Fuel Rail
3 - Electronic Throttle Control Actuator Bolt
4 - Electronic Throttle Control Actuator
5 - Electronic Throttle Control Actuator Gasket
6 - Air Intake Pressure Temperature Sensor Bolt7 - Air Intake Pressure Temperature Sensor
8 - Intake Manifold Bolt
9 - Intake Manifold
10 - Intake Manifold Bracket
11 - Intake Manifold Gasket
ON-VEHICLE SERVICE
LTSM020164
02
02–43Chery Automobile Co., Ltd.