service CHERY TIGGO 2009 Service Repair Manual

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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 GENERAL INFORMATION
01
CONTENTSpage
Service Information ................................................................... 01-1
Vehicle Information ................................................................... 01-9
Electrical Circuit Diagnosis Information ................................................. 01-15
Electrical Information ................................................................ 01-20
SERVICE INFORMATION
HOW TO USE THIS MANUAL01-2
Topics 01-2
Service Procedures 01-2
Diagnostic Procedures 01-2
Specifications 01-2
VEHICLE SERVICE PREPARATION01-3
Preparation For Vehicle Service 01-3
Tools and Testing Equipment 01-3
Special Tools 01-3
Disconnection of the Negative Battery
Cable 01-4
PROPER SERVICE PRACTICES01-5
Removal of Parts 01-5
Component Disassembly 01-5
Inspection of Parts 01-5
Arrangement of Parts 01-6
Cleaning of Parts 01-6
Component Reassembly 01-6
Adjustments 01-7
Rubber Parts and Rubber Tubing 01-7
Hose Clamps 01-8
Vise 01-8
Dynamometer 01-8
01
01–1Chery Automobile Co., Ltd.

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 VEHICLE SERVICE PREPARATION
Preparation For Vehicle Service
•Always be sure to cover fenders, seats and floor
areas before starting work.
Tools and Testing Equipment
•Be sure that all necessary tools and measuring
equipment are available before starting any work.
• Inspect the vehicle and reference any needed ser-
vice information before starting any work.
Special Tools
•Use special tools when they are required.
BESM010004
BESM010005
BESM010006T
01
01–3Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Disconnection of the Negative Battery Cable
•Before beginning any electrical work, turn the igni-
tion switch to LOCK, disconnect the negative bat-
tery cable and then wait two minutes to allow the
backup supply of the air bag diagnostic monitor unit
to deplete its stored power.
• Disconnecting the battery cable deletes the memo-
ries of the clock, audio and DTCs, etc. Therefore, it
is necessary to verify those memories before dis-
connecting the cable.
VEHICLE SERVICE PREPARATION
LTSM010002
01–4Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine PROPER SERVICE PRACTICES
Removal of Parts
•While correcting a problem, also try to determine its
cause. Begin work only after first determining which
parts and subassemblies must be removed and dis-
assembled for replacement or repair. After removing
the part, plug all holes and ports to prevent foreign
material from entering.
Component Disassembly
•If the disassembly procedure is complex requiring
many parts to be disassembled, make sure that all
parts are disassembled in a way that will not affect
their performance or external appearance. Identify
each part so reassembly can be performed easily
and efficiently.
Inspection of Parts
•When removed, inspect each part for possible mal-
function, deformation, damage or other problems.
BESM010007
BESM010008
BESM010009
01
01–5Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Arrangement of Parts
•All disassembled parts should be carefully arranged
for reassembly.
• Be sure to separate and identify the parts to be
replaced from those that will be reused.
Cleaning of Parts
•Carefully and thoroughly clean all parts to be
reused.
WARNING!
Using compressed air can cause dirt and other particles to fly out causing injury to the eyes. Wear protective
eyewear whenever using compressed air.
Component Reassembly
•Standard values, such as torques and certain
adjustments, must be strictly observed in the reas-
sembly of all parts. If removed, replace these parts
with new ones:
Oil seals
Gaskets
O-rings
Lock washers
Cotter pins
Nylon nuts
PROPER SERVICE PRACTICES
BESM010010
BESM010011
BESM010012
01–6Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine •Depending on location:
Apply sealant and gaskets, or both, to speci-
fied locations. When sealant is applied, install
parts before sealant hardens to prevent leaks.
Apply oil to the moving components of parts.
Apply specified oil or grease at the prescribed locations (such as oil seals) before reassembly.
reassembly.
Adjustments
• Use suitable gauges and testers when making
adjustments.
Rubber Parts and Rubber Tubing
•Prevent gasoline or oil from getting on rubber parts
or tubing.
PROPER SERVICE PRACTICES
BESM010013
BESM010014
BESM010015
01
01–7Chery Automobile Co., Ltd.

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 FASTENER USAGE
Fastener Usage
WARNING!
Use of an incorrect fastener may result in component damage. Failure to follow these instructions may result in
personal injury or death.
Fasteners and torque specification references in this Service Manual are identified in metric format.
During any maintenance or repair procedures, it is important to salvage all fasteners (nuts, bolts, etc.) for reassembly.
If the fastener is not salvageable, a fastener of equivalent specification must be used.
01–14Chery Automobile Co., Ltd.