height CHERY TIGGO 2009 Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine Mechanical Specifications
DESCRIPTIONITEMSTANDARD LIMIT
Engine Oil Pressure Lower Idle Speed (800 ±
50 RPM) 1.2 - 1.5 bar
-
High Idle Speed (2000 RPM) 3.2 - 3.5 bar
-
High Speed (4000 RPM) 3.7 ± 0.5 bar -
Engine Block Clearance Surface Distortion
-0.15 mm
Inner Diameter 81.000 - 81.010 mm -
Out-Of-Round -< 0.008 mm
Taper -< 0.01 mm
Piston Ring Groove
Clearance First Ring
0.04 - 0.08 mm -
Second Ring 0.0251 - 0.01 mm -
Piston Ring End Gap
Clearance First Ring
0.2 - 0.4 mm 0.8 mm
Second Ring 0.4 - 0.6 mm 1.0 mm
Piston To Piston Pin
Clearance -
0.002 - 0.013 mm -
Piston Diameter -80.946 - 80.964 mm -
Ring Groove Clearance First Ring
0.04 - 0.08 mm -
Second Ring 0.01 - 0.0251 mm -
Connecting Rod Radial
Clearance -
0.016 - 0.051 mm -
Connecting Rod Axial
Clearance -
0.002 - 0.013 mm -
Diameter Of Crankshaft
Main Journals -
53.981 - 54 mm -
Diameter Of Crankshaft
Rod Journals -
47.884 - 47.9 mm -
Out-Of-Round Maximum
Of Crankshaft Main
Journals -
-< 0.008 mm
Axial Clearance Of
Crankshaft -
0.07 - 0.265 mm -
Radial Clearance Of
Crankshaft -
0.0035 - 0.034 mm -
Coaxality Crankshaft Main
Journal -
-< 0.005 mm
Thrust Washer Thickness -2.4 - 2.405 mm -
Oil Clearance Of
Crankshaft Rod and Main
Journals -
0.022 mm 0.058 mm
Cylinder Head Flatness --< 0.04 mm
Intake Valve Deflection --< 0.02 mm
Exhaust Valve Deflection --< 0.04 mm
Spring Height -47.7 mm -
Spring Height At 620
Newtons Of Pressure -
32.0 mm -
GENERAL INFORMATION
02–4Chery 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 CYLINDER HEAD UNIT REPAIR
Cylinder Head
Specifications
Torque Specifications
DESCRIPTIONTORQUE (N·m)
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°
Cylinder Head Cover Bolts 11
Clearance Specifications
DESCRIPTIONSPECIFICATION (mm)
Cylinder Head Flatness 0.04
Intake Valve Deflection 0.02
Exhaust Valve Deflection 0.04
Spring Height 47.7
Disassembly
NOTE :
The following special tools are required to perform the repair procedure:
•CH-20011 - Valve Seal Installer
• CH-20012 - Valve Stem Seal Installer Guide
• CH-20013 - Valve Seal Remover
• CH-20017 - Valve Keeper Installer
• CH-20018 - Valve Spring Compressor
NOTE :
Replacement cylinder head comes complete with valves, seals, springs, retainers, keepers, tappets, and camshafts. 1. Remove camshafts.
2. Remove the hydraulic tappet assembly (1).
BESM020071
02
02–63Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Inspection
•Cylinder head must be flat within 0.04 mm.
• Inspect camshaft bearing journals for scoring.
• Remove carbon and varnish deposits from inside of
valve guides with a valve guide cleaner.
• Verify the valve tappets move freely in their bores,
and that they have been rotating.
• Check the valve guide height.
Assembly
1. Install new valve guide if necessary.
2. Install new valve seat if necessary.
3. Using special tool CH-20011 (1) and CH-20012 (2),
install the new valve oil seal.
4. Install the valves into the cylinder head (larger diameter on intake side).
5. Install the valve springs.
6. Install the valve spring retainers.
CYLINDER HEAD UNIT REPAIR
BESM020068
LTSM020224
02
02–65Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 7. Using valve spring compressor CH-20018 (1), com-press the valve springs.
8. Install the valve keepers.
9. Strike the valve stem lightly with a plastic hammer after installation to verify proper assembly.
10. Install valve tappets in the head.
11. Install the camshafts.
Installation Notes:
• Coat the valve oil seal with engine oil.
Camshaft
Specifications
Camshaft Specifications
DESCRIPTION SPECIFICATION (mm)
Intake Cam Lobe Height 37.15
Exhaust Cam Lobe Height 37.05
Journal #1 Outer Diameter 31.934 - 31.95
Journal #2, #3, #4, #5, Outer Diameter 23.947 - 23.96
Cam Bearing #1 Inner Diameter 32 - 32.025
Cam Bearing #2, #3, #4, #5, Inner Diameter 24 - 24.021
Journal #1 Clearance 0.05 - 0.091
Journal #2, #3, #4, #5 Clearance 0.04 - 0.074
Intake Camshaft Axial Clearance 0.15 - 0.20
Exhaust Camshaft Axial Clearance 0.15 - 0.20
CYLINDER HEAD UNIT REPAIR
BESM020067
02–66Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Disassembly
1. Remove the camshaft bearing cap bolts.NOTE: Equally loosen camshaft bearing cap bolts
in several steps.
2. Remove the camshaft bearing caps and place them in proper order. NOTE: The camshaft bearing caps are marked for identification.
3. Remove the camshafts and then remove the camshaft seals.
Inspection
• Measure the camshaft cam lobe height.
• If wear is beyond the limit, replace the camshaft.
CAMSHAFT CAM LOBE HEIGHT
Intake Cam Lobe Height 37.15 mm
Exhaust Cam Lobe Height 37.05 mm
CYLINDER HEAD UNIT REPAIR
BESM020035
BESM020037
02
02–67Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine ITEMSPECIFICATION (mm)
Valve Outer Diameter Intake Valve
5.98 ± 0.008
Exhaust Valve 5.96 ± 0.008
Valve Guide Inner Diameter Intake Valve
5.4 ± 0.1
Exhaust Valve 5.4 ± 0.1
Fringe Thickness On Top Of Valve Intake Valve
0.3 ± 0.15
Exhaust Valve 0.3 ± 0.15
Valve Tilt Angle Intake Valve
65°
Exhaust Valve 68°
Valve Height Intake Valve
107.998
Exhaust Valve 106.318
• Measure valve deflection.
VALVE DEFLECTION LIMIT (DIAL GAUGE READING)
Intake 0.02 mm
Exhaust 0.04 mm
• If it exceeds the limit, check valve to valve guide clearance.
Measure valve stem diameter and valve guide inner diameter.
Check that clearance is within specification.
If it exceeds the limit, replace valve or valve
guide.
VALVE TO VALVE GUIDE CLEARANCE STANDARD
Intake 0.012 - 0.043 mm
Exhaust 0.032 - 0.063 mm
Assembly
1. Install the valves into the cylinder head (larger diameter on intake side).
2. Install the valve springs.
3. Install the valve spring retainers.
CYLINDER HEAD UNIT REPAIR
BESM020073
02–72Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 4. Using valve spring compressor CH-20018 (1), com-press the valve springs.
5. Install the valve keepers.
6. Strike the valve stem lightly with a plastic hammer after installation to verify proper assembly.
Valve Springs
Specifications
Valve Spring Specifications
DESCRIPTION SPECIFICATION (mm)
Spring Free Length 47.7
Spring Height At 620 Newtons Of Pressure 32.0
Disassembly
NOTE :
The following special tools are required to perform the repair procedure:
•CH-20011 - Valve Seal Installer
• CH-20012 - Valve Stem Seal Installer Guide
• CH-20013 - Valve Seal Remover
• CH-20017 - Valve Keeper Installer
• CH-20018 - Valve Spring Compressor
1. Using the special tool CH-20018 (1), compress the valve springs.
CYLINDER HEAD UNIT REPAIR
BESM020067
BESM020067
02
02–73Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 2. Remove the valve keeper (1), valve spring retainer(2).
3. Remove the valve springs (3) from the cylinder head.
Inspection
•Whenever valves have been removed for inspection, reconditioning or replacement, valve springs should be
tested for correct load.
• Discard the springs that do not meet specifications.
• The following specifications apply to both intake
and exhaust valve springs.
VALVE SPRING LENGTH/HEIGHT
Spring Free Length 47.7 mm
Spring Height At 620 Newtons Of Pressure 32.0 mm
If it is not within specifications, replace the valve spring.
CYLINDER HEAD UNIT REPAIR
VISM080040
BESM020072
02–74Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine DESCRIPTIONITEMSTANDARD LIMIT
Piston Ring End Gap
Clearance First Ring
0.2 - 0.4 mm 0.8 mm
Second Ring 0.4 - 0.6 mm 1.0 mm
Piston To Piston Pin
Clearance -
0.002 - 0.013 mm -
Piston Diameter -83.451 - 83.469 mm -
Ring Groove Clearance First Ring
0.04 - 0.08 mm -
Second Ring 0.01 - 0.0251 mm -
Connecting Rod Radial
Clearance -
0.016 - 0.051 mm -
Connecting Rod Axial
Clearance -
0.002 - 0.013 mm -
Diameter Of Crankshaft
Main Journals -
53.981 - 54 mm -
Diameter Of Crankshaft
Rod Journals -
47.884 - 47.9 mm -
Out-Of-Round Maximum
Of Crankshaft Main
Journals -
-< 0.008 mm
Axial Clearance Of
Crankshaft -
0.07 - 0.265 mm -
Radial Clearance Of
Crankshaft -
0.0035 - 0.034 mm -
Coaxality Crankshaft Main
Journal -
-< 0.005 mm
Thrust Washer Thickness -2.4 - 2.405 mm -
Oil Clearance Of
Crankshaft Rod and Main
Journals -
0.022 mm 0.058 mm
Cylinder Head Flatness --< 0.04 mm
Intake Valve Deflection --< 0.02 mm
Exhaust Valve Deflection --< 0.04 mm
Spring Height -47.7 mm -
Spring Height At 620
Newtons Of Pressure -
32.0 mm -
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 -
GENERAL INFORMATION
02–78Chery Automobile Co., Ltd.