relay CHERY TIGGO 2009 Service Repair Manual

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
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01–17Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine How To Check Electrical Connectors
Many electrical problems are caused by faulty electrical connections or wiring. It is also possible for a sticking com-
ponent or relay to cause a problem. Before condemning a component or wiring assembly always, check the electrical
connectors for good continuity.
How To Probe Connectors
•Connector damage and an intermittent connection can result from improperly probing the connector during cir-
cuit checks.
• The probe of a DMM may not correctly fit the connector cavity. To correctly probe the connector, follow the pro-
cedures below using a “T” pin. For the best contact, grasp the “T” pin using an alligator clip.
Probing From Harness Side
•If the connector has a rear cover connector, remove the rear cover before probing the terminal.
• Do not probe waterproof connectors from the harness side. Damage to the seal between the wire and connec-
tor may result.
Probing From Terminal Side
•Female Terminal:
Do not insert any object into the female connector that is bigger than the male terminal.
• Male Terminal:
Carefully probe the contact surface of each terminal using a “T” pin. Do not bend terminal.
How To Check Proper Contact Spring Tension Of Terminal
•An enlarged contact spring of a terminal may create intermittent signals in the circuit.
• If an intermittent open circuit occurs, follow the procedure below to inspect for open wires and enlarged contact
spring of female terminal.
Use a male terminal which matches the female terminal.
Disconnect the suspected faulty connector and hold it terminal side up.
While holding the wire of the male terminal, attempt to insert the male terminal into the female terminal.
While moving the connector, check whether the male terminal can be easily inserted or not.
NOTE :
If the male terminal can be easily inserted into the female terminal, replace the female terminal.
DIAGNOSING ELECTRICAL FAILURES
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01–19Chery 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 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 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
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01–27Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine P0261 - Cylinder 1 Injector Circuit Low,
P0264 - Cylinder 2 Injector Circuit Low,
P0267 - Cylinder 3 Injector Circuit Low,
P0270 - Cylinder 4 Injector Circuit Low 03-157
P0262 - Cylinder 1 Injector Circuit High,
P0265 - Cylinder 2 Injector Circuit High,
P0268 - Cylinder 3 Injector Circuit High,
P0271 - Cylinder 4 Injector Circuit High 03-164
P0321 - Distributor Engine Speed In
Phase Circuit Performance 03-171
P0324 - Knock Control System Error 03-177
P0343 - Camshaft Position Sensor
Circuit High Input 03-181
P0444 - Evaporative Emission System
Purge Control Valve Circuit Open 03-187
P0506 - Idle Control System RPM
Lower Than Expected 03-191
P0601 - Internal Control Module
Memory Check Sum Error, P0604 -
Internal Controller Module Random
Access Memory (RAM) Error, P0605 -
Internal Controller Module ROM Test
Error, P0606 - ECM Processor 03-193
P0602 - ECM Programming Error 03-195
P0645 - A/C Clutch Relay Circuit 03-197
P1545 - Throttle Position Control
Malfunction 03-202
P2138 - Pedal Position Sensor
Performance 03-210
ON-VEHICLE SERVICE03-217
Engine Coolant Temperature (ECT)
Sensor 03-217
Description 03-217
Operation 03-217
Removal & Installation 03-217
Knock Sensor 03-218
Description 03-218
Operation 03-218
Removal & Installation 03-218
Oxygen Sensor 03-218
Description 03-218
Operation 03-218
Upstream Oxygen Sensor 03-219
Downstream Oxygen Sensor 03-219Removal & Installation - Upstream
Oxygen Sensor
03-219
Removal & Installation - Downstream
Oxygen Sensor 03-219
Crankshaft Position (CKP) Sensor 03-220
Description 03-220
Operation 03-220
Removal & Installation 03-220
Camshaft Position (CMP) Sensor 03-220
Description 03-220
Operation 03-221
Removal & Installation 03-221
Vehicle Speed Sensor 03-221
Description 03-221
Operation 03-221
Removal & Installation 03-221
Accelerator Sensor 03-221
Description 03-221
Operation 03-222
Removal & Installation 03-222
Manifold Absolute Pressure Sensor -
1.6L 03-222
Description 03-222
Operation 03-222
Removal & Installation 03-222
Air Flow Sensor - 1.8L 03-223
Description 03-223
Operation 03-223
Removal & Installation 03-223
Accelerator Pedal Position Sensor 03-224
Description 03-224
Operation 03-224
Removal & Installation 03-224
Electronic Throttle Control Actuator 03-225
Description 03-225
Operation 03-225
Removal & Installation 03-225
Engine Control Module (ECM) 03-226
Description 03-226
Operation 03-226
Removal & Installation 03-226
03–2Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION
Description
The Engine Control Module (ECM) consists of a microcomputer and electrical connectors containing circuits for signal
input, output, power supply and ground. The ECM controls the engine functions.
The following are the input and output components monitored by the ECM. The monitored functions include compo-
nents from the engine, ignition, transaxle, air conditioning, or any other ECM supported subsystem.
ECM Inputs
•Brake Switch Sensor
• Refrigerant Pressure Sensor
• Camshaft Position (CMP) Sensor
• Crankshaft Position (CKP) Sensor
• Engine Coolant Temperature (ECT) Sensor
• Manifold Absolute Pressure (MAP) Sensor (1.6L)
• Air Flow Sensor (1.8L)
• Throttle Position Sensor (Integral with Electronic Throttle Control Actuator)
• Power Steering Switch
• Accelerator Pedal Position (APP) Sensor
• Knock Sensor
• Oxygen Sensor (Upstream & Downstream)
• Vehicle Speed Sensor
• Clutch Pedal Switch (Manual transaxle only)
ECM Outputs
• Canister Control Valve
• Fuel Injectors
• Fuel Pump Relay
• Electronic Throttle Control Actuator
• Ignition Coil
• A/C Compressor
• Cooling Fan
• Oxygen Sensor Heater (Upstream & Downstream)
Operation
The ECM monitors components and circuits, and tests them in various ways depending on the hardware, function,
and type of signal. For example, analog inputs, such as throttle position or engine coolant temperature are typically
checked for opens, shorts and out-of-range values. This type of monitoring is carried out continuously. Some digital
inputs like vehicle speed or crankshaft position rely on rationality checks - checking to see if the input value makes
sense at the current engine operating conditions. These types of tests may require monitoring several components
and can only be carried out under appropriate test conditions.
The ECM is a pre-programmed, microprocessor-based digital computer. It regulates ignition timing, air-fuel ratio,
emission control devices, charging system, certain transmission features, speed control, air conditioning compressor
clutch engagement and idle speed. The ECM can adapt its programming to meet changing operating conditions.
03
03–3Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine ECM Connector Pin-Out Table
ECM PIN-OUT TABLE
PINCIRCUIT IDENTIFICATION PINCIRCUIT IDENTIFICATION
1 (With EOBD)
42Intake Air Temperature Sensor
Upstream Oxygen Sensor Heater
(Without EOBD)
2 Ignition Coil 2 43-
3 GND (Ignition) 44Switched Supply Voltage
4 (With EOBD)
45Switched Supply Voltage
Downstream Oxygen Sensor Heater
(Without EOBD)
5 Ignition Coil 1 46Canister Control Valve
6 Injector 2 47Injector 4
7 Injector 3 48Upstream Oxygen Sensor Heater (With
EOBD)
(Without EOBD)
8 Engine Speed Output 49-
9 Coolant Temperature Output 50Fan Relay Control
10 Fuel Consumption Output 51GND (Signal)
11 EPC Lamp 52-
12 Continuous Supply Voltage 53GND (Signal)
13 Ignition Switch 54 Electronic Throttle Control Actuator
14 EMS Relay (Main Relay) 55Downstream Oxygen Sensor
15 Crankshaft Position Sensor 56-
16 Accelerator Position Sensor 57-
17 Sensor (GND) 58Brake Switch
18 Upstream Oxygen Sensor 59Vehicle Speed Sensor
19 Knock Sensor 1 60A/C Middle Pressure Switch
20 Knock Sensor 2 61GND (Power)
21 Brake Switch 62-
22 -63Switched Supply Voltage
23 Accelerator Sensor 64 Electronic Throttle Control Actuator
24 -65 Electronic Throttle Control Actuator
25 -66 Electronic Throttle Control Actuator
26 -67 Electronic Throttle Control Actuator
27 Injector 1 68Fan Relay Control 2
28 Downstream Oxygen Sensor Heater
(With EOBD) 69Air Compressor Relay
(Without EOBD)
29 -70Fuel Pump Relay
30 -71Diagnostic Link K
31 MIL Lamp 72-
32 Regulated Sensor Supply 3 73Regulated Sensor Supply 2
33 Regulated Sensor Supply 1 74Clutch Pedal Switch
34 Crankshaft Position Sensor 75A/C Stand By
GENERAL INFORMATION
03–20Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine DTCDTC DEFINITION
P0605 Internal Control Module ROM Test Error
P0606 ECM Processor
P0627 Fuel PumpAControl Circuit/Open
P0628 Fuel PumpAControl Circuit Low
P0629 Fuel PumpAControl Circuit High
P0645 A/C Clutch Relay Circuit
P0646 A/C Clutch Relay Control Circuit Low
P0647 A/C Clutch Relay Control Circuit High
P0650 Malfunction Indicator Lamp Control Circuit
P0688 EMC/ECM Power Relay Sense Circuit Open
P0691 Cooling Fan 1 Control Circuit Low
P0692 Cooling Fan 1 Control Circuit High
P0693 Cooling Fan 2 Control Circuit Low
P0694 Cooling Fan 2 Control Circuit High
P0700 Transmission Control System Malfunction
P0704 Clutch Switch Input Circuit
P1297 Manufacturer Controlled Computer And Auxiliary Outputs
P1336 Engine Torque Control Adaptation at Limit
P1545 Throttle Position Control Malfunction
P1558 Throttle Actuator Electrical Malfunction
P1559 Idle Speed Control Throttle Position Adaptation Malfunction
P1564 Idle Speed Control Throttle Position Low Voltage During Adaptation
P1565 Idle Speed Control Throttle Position Lower Limit not Attained
P1568 Idle Speed Control Throttle Position Mechanical Malfunction
P1579 Idle Speed Control Throttle Position Adaptation Not Started
P1604 Internal Control Module Driver Error
P1610 Manufacture Controlled Computer and Auxiliary Outputs
P1611 Manufacture Controlled Computer and Auxiliary Outputs
P1612 Manufacture Controlled Computer and Auxiliary Outputs
P1613 Manufacture Controlled Computer and Auxiliary Outputs
P1614 Manufacture Controlled Computer and Auxiliary Outputs
P1651 Manufacture Controlled Computer and Auxiliary Outputs
P2106 Throttle Actuator Control System Forced Limited Power
P2122 Throttle/Pedal Position Sensor/Switch D Circuit Low Input
P2123 Throttle/Pedal Position Sensor/Switch D Circuit High Input
P2127 Throttle/Pedal Position Sensor/Switch E Circuit Low Input
P2128 Throttle/Pedal Position Sensor/Switch E Circuit High Input
P2138 Accelerator Pedal Position Sensor Signal Correlation Error
P2177 System Too Lean off Idle
P2178 System Too Rich off Idle
P2187 System Too Lean at Idle
P2188 System Too Rich at Idle
P2195 O
2Sensor Signal Stuck Lean; Bank 1 Sensor 1
DIAGNOSIS & TESTING
03–26Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine CheckreferencevaluesbetweenECMterminalsandgroundunderthefollowingconditions:
ECMTERMINALNO.ITEMCONDITIONDATA(DCVOLTAGE)
12ContinuousSupply
Voltage- Voltage(11-14V)
13IgnitionSwitch€Ignitionswitch:ON Voltage(11-14V)
€Ignitionswitch:OFF Approximately0V
14EMSRelay(MainRelay)
€Ignitionswitch:OFF
€Morethanafew
secondsafterturning
ignitionswitchOFF
Voltage(11-14V)
44
45SwitchedSupplyVoltage
(SSV)€Ignitionswitch:ON Voltage (11 - 14 V)
63
DIAGNOSIS&TESTING
03
03–29CheryAutomobileCo.,Ltd.