light CHERY TIGGO 2009 Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine Hose Clamps
•When reinstalling, position the hose clamp in the
original location on the hose and squeeze the
clamp lightly with large pliers to ensure a good fit.
Vise
•When using a vise, put protective plates in the
jaws of the vise to prevent damage to parts.
Dynamometer
•When test-running a vehicle on a dynamometer:
Place a fan, preferably a vehicle-speed proportional type, in front of the vehicle.
Connect an exhaust gas ventilation unit.
WARNING!
Exhaust gases can injure or kill. They contain carbon monoxide (CO), which is colorless and odorless. Breathing
it can make you unconscious and can eventually poison you.
Cool the exhaust pipes with a fan.
Keep the area around the vehicle uncluttered.
Monitor the engine coolant temperature gauge.
PROPER SERVICE PRACTICES
BESM010016
BESM010017
01–8Chery Automobile Co., Ltd.

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 Sensors & Relays
•Gently apply a slight vibration to sensors and relays in the system you are inspecting. This test may indicate a
loose or poorly mounted sensor or relay.
Engine Compartment
• There are several reasons a vehicle or engine vibration could cause an electrical complaint. Some of the things
to check for are:
Connectors not fully seated.
Wiring harness not long enough and is being stressed due to engine vibrations or rocking.
Wires laying across brackets or moving components.
Loose, dirty or corroded ground wires.
Wires routed too close to hot components.
• To inspect components under the hood, start by verifying the integrity of the ground connections (See Ground
Inspection described later). First, verify that the system is properly grounded. Then check for any loose connec-
tions by gently shaking the wiring or components as previously explained. Using the wiring diagrams, inspect
the wiring for continuity.
Behind The Instrument Panel
• An improperly routed or improperly clamped harness can become pinched during accessory installation. Vehicle
vibration can aggravate a harness which is routed along a bracket or near a mounting screw.
• An unclamped or loose harness can cause wiring to be pinched by seat components (such as slide guides)
during vehicle vibration. If the wiring runs under seating areas, inspect wire routing for possible damage or
pinching.
Heat Sensitivity Test
The customer’s concern may occur during hot weather or after the vehicle has sat for a short time. In such cases you
will want to check for a heat sensitive condition.
To determine if an electrical component is heat sensitive, heat the component with a heat gun or equivalent.
CAUTION:
Do not heat components above 60°C (140°F).
If the incident occurs while heat testing the component, replace or properly insulate the component as needed.
Freezing Test
The customer may indicate the incident goes away after the vehicle warms up (winter time). The cause could be
related to water freezing somewhere in the wiring/electrical system. There are two methods to check for this:
•The first method is to arrange for the owner to leave the vehicle overnight. Make sure it will get cold enough to
duplicate the complaint. Leave the vehicle parked outside overnight. In the morning, do a quick and thorough
diagnosis of those electrical components which could be affected.
• The second method is to put the suspect component into a freezer long enough for any water to freeze. Rein-
stall the part into the vehicle and check for a reoccurrence of the incident. If it occurs, repair or replace the
component as needed.
Water Intrusion Test
The incident may occur only during high humidity or in rainy/snowy weather. In such cases the incident could be
caused by water intrusion on an electrical part. This can be simulated by soaking the car or running it through a car
wash.
Electrical Load Test
The incident may be electrical load sensitive. Perform diagnosis with all accessories (including A/C, rear window
defogger, radio, fog lamps) turned on.
Cold or Hot Starting Test
On some occasions an electrical incident may occur only when the vehicle is started cold, or it may occur when the
vehicle is restarted hot shortly after being turned off. In these cases you may have to keep the vehicle overnight to
make a proper diagnosis.
DIAGNOSING ELECTRICAL FAILURES
01
01–17Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Voltage Drop Test
Voltage drop tests are often used to find components or circuits which have excessive resistance. A voltage drop in
a circuit is caused by a resistance in the circuit during operation.
•Check the circuit using a Digital Multimeter (DMM).
• When measuring resistance with a DMM, remember that contact by a single strand of wire will give a reading
of 0 ohms. This would indicate a good circuit. When the circuit operates, this single strand of wire is not able
to carry the current. The single strand will have a high resistance to the current. This will be indicated as a
slight voltage drop.
• Unwanted resistance can be caused by the following:
Undersized wiring (single strand example)
Corrosion on switch contacts
Loose wire connections or splices
Precautions For Handling Control Modules and Electrical Components
•Never reverse polarity of battery terminals.
• Only install components specified for the vehicle.
• Before replacing the control module, check the input and output and functions of the components.
• When disconnecting components:
Do not apply excessive force when disconnecting a connector.
If a connector is installed by tightening bolts, loosen mounting bolt, then remove it by hand.
• When connecting components:
Before installing a connector, make sure the terminal is not bent or damaged, and then correctly connect it.
When installing a connector by tightening bolts, tighten the mounting bolt until the painted area of the con-
nector becomes even with the surface.
• Do not apply excessive shock to the control module by dropping or hitting it.
• Be careful to prevent condensation in the control module due to rapid temperature changes and do not let
water or rain get on it. If water is found in the control unit, dry it fully and then install it in the vehicle.
• Be careful not to let oil get on the control module connector.
• Avoid cleaning the control module with volatile oil.
• When using a DMM, be careful not to let the test probes touch each other causing a short circuit. Prevent the
power transistor in the control module from being
shorted to damaging battery voltage.
• When checking input and output signals of the con-
trol module, use the specified test adapter (if
applicable).
DIAGNOSING ELECTRICAL FAILURES
LTSMD030028
01–18Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine NUMBERITEM DESCRIPTION
1 Power source This represents the condition when the system receives battery
positive voltage.
2 Fuse The single line represents that this is a fuse.
3 Current rating This represents the current rating of the fuse.
4 Fuse location This represents the location of the fuse in the Power Fuse Box or
Front Fuse and Relay Box.
5 Connectors This represents connector E-101 is female and connector C-101 is
male.
6 Terminal number This represents the terminal number of a connector.
7 Component name This represents the name of a component.
8 Connector number This represents the connector number.
The letter represents which harness the connector is located in.
9 SpliceThe shaded circle represents that the splice is always on the
vehicle.
10 Optional splice The open circle represents that the splice is optional depending on
vehicle application.
11 Option abbreviation This represents that the circuit is optional depending on vehicle
application.
12 Ground (GND) This represents the ground connection. (See Ground Distribution in
Section 16 Wiring).
Ground connector number has no view face.
13 Page crossing This arrow represents that the circuit continues to an adjacent page.
The
Acorresponds with the Aon the adjoining page of the
electrical schematic.
14 Data linkThis represents that the system branches to another system
identified by cell data code.
15 Option description This represents a description of the option abbreviation used on the
page.
16 Connector views This represents the connector information.
This component side is described by the connector symbols.
17 Connector color This shows a code for the color of the connector:
B = Black
W = White
R = Red
G = Green
L = Blue
Y = Yellow
BR = Brown
O = Orange
GR = Gray
18 Shielded line The line enclosed by broken line circle represents shielded wire.
19 Light-emitting diodes As an illumination tool, in the circuit and instrument cluster.
HOW TO READ ELECTRICAL SCHEMATICS
01–24Chery 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 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 7. Remove the cylinder head bolts in the ordershown.
8. Remove cylinder head gasket.
9. Installation is in the reverse order of removal.
Installation Notes:
• Ensure cylinder head bolt holes in the block are clean, dry (free of residual oil or coolant), and threads are not
damaged.
• The cylinder head bolts should not be reused. The new bolts should be examined before use. If the bolts are
stretched, the bolts should be replaced.
• Position the new cylinder head gasket on the engine block with the part number facing up. Ensure gasket is
seated over the locating dowels in the block.
• Before installing the bolts, the threads should be lightly coated with engine oil.
ON-VEHICLE SERVICE
BESM020065
02
02–24Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Removal & Installation - Rear Mount
NOTE :
The following special tools are required to perform the
repair procedure:
•Engine Hoist
1. Disconnect the negative battery cable.
2. Support the engine with the engine hoist.
3. Remove the engine rear mount retaining bolts (2) and remove the engine rear mount bracket bolts
(1).
(Tighten: Engine rear mount bolts to 60 N·m)
4. Installation is in the reverse order of removal.
Engine Assembly
Removal & Installation
NOTE :
The following special tools are required to perform the repair procedure:
• CH-20001 - Right Engine Mount Bolt Remover
• Engine Hoist
NOTE :
The engine is removed with the transaxle as an assembly. 1. Remove the vehicle hood.
2. Remove the negative battery cable from the engine.
3. Remove the engine cover.
4. Remove the battery, battery hold downs, and battery tray (See Battery Removal & Installation in Section 05 Starting & Charging).
5. Discharge air conditioning system (See A/C System Evacuation and Recharge in Section 13 Heating & Air Con- ditioning).
6. 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.
ON-VEHICLE SERVICE
LTSM020188
02
02–31Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Engine Timing Belt
Removal & Installation
NOTE :
The following special tools are required to perform the repair procedure:
•CH-20001 - Right Engine Mount Bolt Remover
• CH-20003 - Crankshaft Holder
• CH-20010 - Camshaft Holder
• Engine Hoist
1. Release the coolant system pressure.
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.
1 - Timing Belt Upper Cover Bolt
2 - Timing Belt Upper Cover
3 - Timing Belt Cover Gasket
4 - Timing Belt
5 - Timing Belt Touch Pulley
6 - Camshaft Bolt
7 - Camshaft
8 - Rear Timing Cover Bolt9 - Rear Timing Cover
10 - Idler Pulley
11 - Tensioner Pulley
12 - Tensioner Pulley Bolt
13 - Timing Belt Lower Cover
14 - Timing Belt Lower Cover Bolt
15 - Timing Belt Upper Cover Bolt
ON-VEHICLE SERVICE
LTSM020162
02–38Chery Automobile Co., Ltd.