2009 CHERY TIGGO engine

Downloaded from www.Manualslib.com manuals search engine EXHAUST
07
CONTENTSpage
Exhaust System ...................................................................... 07-1
EXHAUST SYSTEM
GENERAL INFORMATION07-2
Description 07-2
Operation 07-3
Specifications 07-3
DIAGNOSIS AND TESTING07-4
Exhaust System Diagnostic Chart 07-4
ON-VEHICLE SERVICE07-5
Exhaust Pipe Assembly 07-5
Removal & Installation - 1.6L & 1.8L &
2.0L 07-5 Removal & Installation - 2.4L 07-5
Muffler 07-6
Removal & Installation 07-6
Catalytic Converter 07-6
Description 07-6
Operation 07-6
Removal & Installation 07-7
07
07–1Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION
Description
The exhaust system provides an exit for exhaust gases and reduces engine noise by moving exhaust gases through
the three-way catalytic converter, a muffler inlet pipe and a muffler. Rubber exhaust hanger insulators attach the
exhaust system to the mounting hooks.
The exhaust system contains the following components:
•Catalytic converter assembly
• Muffler assembly
• Exhaust brackets with isolators bolted to the body
• Heated oxygen sensors mounted to the exhaust pipes
• Tailpipe assembly
1.6L & 1.8L & 2.0L Exhaust System
2.4L Exhaust System
LTSM070003
LTSM070004
07–2Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine WARNING!
Exhaust gases contain carbon monoxide which can be harmful to your health and are potentially lethal. Exhaust
system leaks should be repaired immediately. Never operate the engine in enclosed areas. Failure to follow
these instructions may result in personal injury or death.
Operation
In order to reduce vehicle emissions released by the engine, the catalytic converter is required to perform in all oper-
ating conditions. This reduction is especially beneficial during the cold start and warm up phases of operation, which
is when a majority of the tailpipe emissions occur on today’s vehicles because the catalytic converter has not yet
reached its operating temperature. The exhaust system channels exhaust gases from the engine and away from the
vehicle.
Specifications
Torque Specifications
DESCRIPTIONTORQUE (N·m)
Catalytic Converter Mounting Nuts 50
Exhaust Manifold Flange Bolts 49 ± 5
Muffler Mounting Nuts 50
GENERAL INFORMATION
07
07–3Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine DIAGNOSIS AND TESTING
Exhaust System Diagnostic Chart
CONDITIONPOSSIBLE CAUSES CORRECTION
Excessive Exhaust Noise · Leaks at pipe joints.
· Burned or blown out muffler.
· Burned or rusted-out exhaust pipe.
· Exhaust pipe leaking at manifold
flange.
· Exhaust manifold cracked or
broken.
· Leak between exhaust manifold
and cylinder head.
· Restriction in muffler or tailpipe.
· Exhaust system contacting body or
chassis.· Tighten clamps to specified torque
at leaking joints.
· Replace muffler assembly.
· Replace exhaust pipe.
· Tighten connection attaching nuts.
· Replace exhaust manifold.
· Tighten exhaust manifold to
cylinder head stud nuts or bolts.
· Remove restriction, if possible.
Replace muffler or tailpipe, as
necessary.
· Re-align exhaust system to clear
surrounding components.
Leaking Exhaust Gases · Leaks at pipe joints.· Tighten/replace clamps at leaking
joints.
Excessive Exhaust Temperature · Ignition timing incorrect.
· Poor fuel quality.
· Engine running rich.· Adjust the timing.
· Change and clean the fuel tank.
· Repair as needed.
07–4Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine ON-VEHICLE SERVICE
Exhaust Pipe Assembly
Removal & Installation - 1.6L & 1.8L & 2.0L
WARNING!
The normal operating temperature of the exhaust system is very high. Therefore, never work around, or attempt
to service any part of the exhaust system until it has cooled. Special care should be taken when working near
the catalytic converter. The temperature of the converter rises to a high level after a short period of engine oper-
ating time.
1. Raise and support the vehicle.
2. Remove the catalytic converter to exhaust manifoldbolts (1).
(Tighten: Exhaust manifold flange bolts to 49 ± 5
N·m)
3. Remove all the support isolators.
4. Remove the exhaust pipe assembly.
Removal & Installation - 2.4L
WARNING!
The normal operating temperature of the exhaust system is very high. Therefore, never work around, or attempt
to service any part of the exhaust system until it has cooled. Special care should be taken when working near
the catalytic converter. The temperature of the converter rises to a high level after a short period of engine oper-
ating time.
1. Raise and support the vehicle.
2. Remove the catalytic converter to exhaust manifold bolts (1).
(Tighten: Exhaust manifold flange bolts to 49 ± 5
N·m)
3. Remove all the support isolators.
4. Remove the exhaust pipe assembly.
LTSM070005
LTSM020189
07
07–5Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Muffler
Removal & Installation
WARNING!
The normal operating temperature of the exhaust system is very high. Therefore, never work around, or attempt
to service any part of the exhaust system until it has cooled. Special care should be taken when working near
the catalytic converter. The temperature of the converter rises to a high level after a short period of engine oper-
ating time.
1. Raise and support the vehicle.
2. Remove the muffler mounting nuts (1).(Tighten: Muffler mounting nuts to 50 N·m)
3. Remove the support isolators (2).
4. Remove the muffler.
5. Clean the ends of the pipes and the muffler to ensure proper mating of all parts. Discard broken or worn isola- tors, rusted or overused clamps, supports, and attaching parts.
6. Installation is in the reverse order of removal.
Catalytic Converter
Description
The catalytic converter is attached to the exhaust manifold using fasteners and a gasket for sealing.
The catalytic converter plays a major role in the emission control system. The catalytic converter operates as a gas
reactor. Its catalytic function is to speed the heat-producing chemical reaction of components in the exhaust gases in
order to reduce air pollutants.
Operation
Catalyst operation is dependent on its ability to store and release the oxygen needed to complete the emissions-
reducing chemical reactions. As a catalyst deteriorates, its ability to store oxygen is reduced. Since the catalyst’s
ability to store oxygen is somewhat related to proper operation, oxygen storage can be used as an indicator of cat-
alyst performance.
CAUTION:
Unleaded gasoline must be used in order to avoid damaging the catalyst core.
ON-VEHICLE SERVICE
LTSM070002
07–6Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Removal & Installation
WARNING!
The normal operating temperature of the exhaust system is very high. Therefore, never work around or attempt
to service any part of the exhaust system until it has cooled. Special care should be taken when working near
the catalytic converter. The temperature of the converter rises to a high level after a short period of engine oper-
ating time.
1. Disconnect the negative battery cable.
2. Raise and support the vehicle.
3. Remove the catalytic converter mounting nuts (1)and gaskets.
(Tighten: Catalytic converter mounting nuts to 50
N·m)
4. Remove the catalytic converter.
5. Clean the ends of the pipes to ensure proper mat- ing of all parts. Discard broken or worn isolators,
rusted or overused clamps, supports, and attaching
parts.
6. Installation is in the reverse order of removal.
ON-VEHICLE SERVICE
LTSM07000107
07–7Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine TRANSAXLE & TRANSFER CASE
08
CONTENTSpage
DP0 Automatic Transaxle .............................................................. 08-1
F4A4 Automatic Transaxle ........................................................... 08-143
5-Speed Manual Transaxle ........................................................... 08-246
Front Differential ................................................................... 08-307
Clutch System ..................................................................... 08-316
Transfer Case (4x4) ................................................................. 08-326
DP0 AUTOMATIC TRANSAXLE
GENERAL INFORMATION08-3
Description 08-3
Operation 08-6
Specifications 08-7
Special Tools 08-8
Electrical Schematics 08-10
DP0 Transaxle Control Module (TCM)
Connector Pin-Out Table 08-18
DIAGNOSIS & TESTING08-19
Diagnostic Help 08-19
Intermittent DTC Troubleshooting 08-19
Ground Inspection 08-19
Diagnostic Tools 08-19
Diagnostic Trouble Code (DTC) List 08-20
DP0 Automatic Transaxle DTC List 08-20
Diagnostic Trouble Code (DTC) Tests 08-22
P0641 - Sensor Feed 08-22
P0657 - Solenoid Power Supply Circuit
Shorted To Voltage 08-28
P0657 - Solenoid Power Supply Circuit
Open 08-32
P0705 - Multi-Function Switch:
Prohibited Position 08-37
P0710 - Fluid Temperature Sensor 08-42
P0715 - Turbine Speed Sensor Affected
By Interference 08-46
P0730 - Ratio Of Transaxle Error 08-50
P0753 - Shift Solenoid Valve 1 (SSV1)
Open Circuit Or Short To Power Supply
Or Short To Ground 08-56 P0758 - Shift Solenoid Valve 2 (SSV2)
Open Circuit Or Short To Power Supply
Or Short To Ground 08-62
P0763 - Shift Solenoid Valve 3 (SSV3)
Short To Power Supply, P0763 - Shift
Solenoid Valve 3 (SSV3) Open Or
Short To Ground Circuit 08-68
P0768 - Shift Solenoid Valve 4 (SSV4)
Short To Power Supply, P0768 - Shift
Solenoid Valve 4 (SSV4) Open Or
Short To Ground Circuit 08-74
P0773 - Shift Solenoid Valve 5 (SSV5)
Short To Power Supply, P0773 - Shift
Solenoid Valve 5 (SSV5) Open Or
Short To Ground Circuit 08-81
P0775 - EVM (Modulation Solenoid
Valve) Open Circuit Or Short To
Ground, P0775 - EVM (Modulation
Solenoid Valve) Shorted To Voltage 08-87
P0795 - Torque Converter Lock
Solenoid Valve (EVLU) Open Circuit Or
Short To Ground, P0795 - Torque
Converter Lock Solenoid Valve (EVLU)
Short To Voltage 08-93
P0840 - Pressure Sensor 08-99
P1928 - Shift Lock Solenoid Valve
Circuit Shorted To Voltage 08-104
P1928 - Shift Lock Solenoid Valve
Open Circuit Or Short To Ground 08-109
P2709 - Shift Solenoid Valve 6 (SSV6)
Short To Power Supply 08-114
P2709 - Shift Solenoid Valve 6 (SSV6)
Open Circuit Or Short To Ground 08-119
08
08–1Chery Automobile Co., Ltd.