load capacity CHERY TIGGO 2009 Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine HOW TO USE THIS MANUAL
Topics
This manual contains procedures for performing all required service operations.
The procedures are divided into three basic operations:
•Removal/Installation
• Disassembly/Assembly
• Inspection
Service Procedures
Most repair procedures begin with an illustration. It identifies the components, shows how the parts fit together and
describes visual part inspection. Removal & Installation procedures have written instructions.
Service procedures include the following elements:
•Detailed removal & installation instructions
• Integrated torque specifications
• Integrated illustrations
• Component specifications
Diagnostic Procedures
The diagnostic procedures are grouped into the following:
Diagnostic Trouble Codes (DTC)
•DTCs are important hints for repairing malfunctions that are difficult to simulate. Perform the specific DTC diag-
nostic inspection to quickly and accurately diagnose the malfunction.
Diagnostic Symptoms
• Symptom troubleshooting quickly determines the location of the malfunction according to symptom type.
Specifications
This manual contains specifications that are divided into the following groups:
•Torque specifications
• Clearance specifications
• Capacity specifications
01–2Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Specifications
Torque Specifications
DESCRIPTIONTORQUE (N·m)
Coolant Pump Mounting Bolts 14
Radiator Support Mounting Bolts 5
Coolant Fan Mounting Bolts 5
Thermostat Mounting Bolts 13
Fluid Specifications
DESCRIPTIONCAPACITY (L)
Cooling System 7.0
Special Tools
Cooling System Pressure Tester
GENERAL INFORMATION
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06–5Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 8. Install the wheel assembly and install the wheel mounting nuts.(Tighten: Wheel mounting nuts to 110 N·m)
Wheel Assembly
Description
Original equipment wheels are designed for operation up to the specified maximum vehicle capacity.
Inspect wheels for the following:
•Dents or cracks
• Damaged wheel bolt holes
• Air leaks from any area or surface of the rim
• Excessive run out
NOTE :
Do not attempt to repair a wheel by hammering, heating or welding.
NOTE :
The wheel nuts are designed for specific applications. Do not use replacement bolts with a different design or lesser
quality.
Removal & Installation
1. Raise and support the vehicle.
2. If the vehicle is equipped with wheel center caps that cover the wheel nuts, remove the cap with an appropriate removal tool utilizing the notch located between the wheel and the outer edge of the cap.
NOTE: Use care not to damage the finish on the wheel.
3. Remove the wheel mounting nuts (2) with a suit- able tool and remove the wheel assembly (1).
(Tighten: Wheel mounting nuts to 110 N·m)
4. Installation is in the reverse order of removal.
Wheel Balance
Description
Balance the wheel assembly as necessary following the wheel balancer manufacturer’s instructions.
• Road test the vehicle for at least 5 miles.
• If the vibration persists, continue with Diagnosis & Testing procedure.
NOTE :
• Balance equipment must be calibrated and maintained per equipment manufacturer’s specifications.
• Wheel weight must fit the rim.
ON-VEHICLE SERVICE
LTSM100053
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10–52Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Manual steering control of the vehicle can be maintained if power steering assist is lost. However, under this condi-
tion, steering effort is significantly increased.
WARNING!
Power steering fluid, engine parts and exhaust system may be extremely hot if engine has been running. Do not
start engine with any loose or disconnected hoses. Do not allow hoses to touch hot exhaust manifold or cata-
lyst. Fluid level should be checked with the engine off to prevent personal injury from moving parts.
Specifications
Fluid Specifications
DESCRIPTIONCAPACITY (L)
Power Steering Fluid (ATF III) 1.1
Special Tools
Steering Wheel Puller
Ball Joint Separator
CH-10002
GENERAL INFORMATION
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11 –3Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION
Description
The power steering pump is a constant flow rate and displacement vane type pump. The pump reservoir is detached
from the pump body. The pump is connected to the steering gear by the pressure and return lines.
Operation
The power steering pump is mounted to the engine and driven by the engine accessory drive belt. Power steering
fluid enters the pump from the reservoir. The power steering fluid is then trapped between the pump vanes and
moved to the high-pressure side of the pump creating a flow of steering fluid. The restriction of this flow by the
steering gear creates the pressure that provides the steering assist.
CAUTION:
•Operating the power steering with a low steering fluid level will damage the power steering sys-
tem.
• Holding the steering wheel in the full lock position for more than 3 seconds will damage the
power steering system.
Specifications
Torque Specifications
DESCRIPTION TORQUE (N·m)
Power Steering Pressure Line To Steering Gear 27 - 33
Power Steering Return Line To Steering Gear 27 - 33
Power Steering Pressure Line To Power Steering Pump 40 - 50
Power Steering Pump Mounting Bolts 20 - 30
Pressure/Return Hose Routing Clamp Screws To Cross
Member 10-15
Fluid Specifications
DESCRIPTION
CAPACITY (L)
Power Steering Fluid (ATF III) 1.1
11 –32Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine DESCRIPTIONTORQUE (N·m)
Expansion Valve Bolts 10
Pipeline Stent 4
Refrigerant Lines To A/C Accumulator 6
Refrigerant Lines To A/C Compressor Bolt 30
Refrigerant Lines 10
Refrigerant Lines To A/C Evaporator Bolt 25
A/C Pressure Specifications
AMBIENT TEMPERATURE A/C HIGH SIDE PRESSURE A/C LOW SIDE PRESSURE
15.5°C 8.4 - 11.9 kgf/cm
2
120 - 170 psi 1.9 - 2.1 kgf/cm
2
28-31psi
21.1°C 10.5 - 17.5 kgf/cm
2
150 - 250 psi 1.9 - 2.1 kgf/cm
2
28-31psi
26.6°C 12.6 - 19.3 kgf/cm
2
180 - 275 psi 1.9 - 2.1 kgf/cm
2
28-31psi
32.2°C 14.0 - 21.8 kgf/cm
2
200 - 310 psi 1.9 - 2.1 kgf/cm
2
28-31psi
37.7°C 16.1 - 23 kgf/cm
2
230 - 330 psi 1.9 - 2.4 kgf/cm
2
28-35psi
43.3°C 18.9 - 25.3 kgf/cm
2
270 - 360 psi 1.9 - 2.6 kgf/cm
2
28-38psi
AMBIENT
TEMPERATURE VEHICLE SPEED A/C HIGH SIDE
PRESSURE A/C LOW SIDE
PRESSURE
35°C Idle Speed 1.4 - 1.8 MPa 0.26 - 0.33 MPa
30°C Idle Speed 1.3 - 1.8 MPa 0.26 - 0.33 MPa
A/C Refrigerant Charge Specifications
DESCRIPTION CAPACITY (g)
R-134a Refrigerant 700
Special Tools
Digital Multimeter
Fluke 15B & 17B
GENERAL INFORMATION
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13–5Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION
Description
The A/C refrigerant lines and pipes are used to carry the refrigerant between the various A/C system components.
Any kinks or sharp bends in the refrigerant lines and hoses will reduce the capacity of the entire A/C system and can
reduce the flow of refrigerant within the system.
Operation
High pressure is produced in a refrigerant system when the A/C compressor is operating. Extreme care must be
exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good
practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and
properly routed. Depending on vehicle, model and market application, refrigerant lines are connected to each other or
other A/C system components with block-type or quick-connect type fittings. To ensure the integrity of the refrigerant
system, O-rings and/or gaskets may be used to seal the refrigerant system connections. The refrigerant lines and
hoses cannot be repaired and must be replaced if leaking or damaged.
WARNING!
The A/C system contains refrigerant under high pressure. Repairs should only be performed by qualified service
personnel. Serious or fatal injury may result from improper service procedures.
If accidental A/C system discharge occurs, ventilate the work area before resuming service. Large amounts of
refrigerant released in a closed work area will displace the oxygen and cause suffocation and serious or fatal
injury.
CAUTION:
Never add R-12 to a refrigerant system designed to use R-134a. Do not use R-12 equipment or
parts on an R-134a A/C system. These refrigerants are not compatible and damage to the A/C sys-
tem will result.
CAUTION:
Never use R-12 refrigerant oil in an A/C system designed to use R-134a refrigerant oil. These refrig-
erant oils are not compatible and damage to the A/C system will result.
CAUTION:
Do not run the engine with a vacuum pump in operation or with a vacuum present within the A/C
system. Failure to follow this caution will result in serious A/C compressor damage.
CAUTION:
Do not overcharge the refrigerant system. Overcharging will cause excessive compressor head
pressure and can cause compressor noise and A/C system failure.
Specifications
Torque Specifications
DESCRIPTIONTORQUE (N·m)
A/C Compressor Bracket Bolts 40
A/C Compressor Line Bolts 20
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13–33Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine A/C Refrigerant Charge Specifications
DESCRIPTIONCAPACITY (kg)
R-134a Refrigerant 0.700
A/C Oil Specifications
DESCRIPTIONCAPACITY (ml)
Compressor 150
Condenser, Accumulator, Lines 15
Evaporator 30
Special Tools
Refrigerant Recovery/Recycling Station
GENERAL INFORMATION
13–34Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine ELECTRICAL REPAIR
Wire Repair
NOTE :
When splicing a wire, it is important that the correct gage be used.1. Remove one-half (1/2) inch of insulation from each wire that needs to be spliced.
2. Place a piece of adhesive lined heat shrink tubing on one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area.
3. Place the strands of wire overlapping each other inside of the splice clip.
4. Using a crimping tool, crimp the splice clip and wires together.
NOTE :
Do not use acid core solder when making wiring repairs. 5. Solder the connection together using a soldering iron and rosin core type solder only.
6. Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing.
Fuse Replacement
•When replacing a fuse, be sure to replace it with
one of the same capacity. If a fuse fails again, the
circuit probably has a short and the wiring should
be checked.
• Be sure the negative battery terminal is discon-
nected before replacing a main fuse.
• When replacing a pullout fuse, use the fuse puller.
BESM010025
16–8Chery Automobile Co., Ltd.