2009 CHERY TIGGO radiator cap

Downloaded from www.Manualslib.com manuals search engine Cooling System Troubleshooting Chart
CONDITIONPOSSIBLE CAUSES CORRECTION
Loss of Coolant · Coolant hoses or tubes
· Hose clamps
· Coolant pump gasket
· Thermostat gasket
· Thermostat housing
· Radiator
· Coolant reservoir
· Pressure relief cap
· Coolant pump leaking
· Heater core
· Engine gaskets (may leak
internally or externally)
· Cylinder block core plugs· Replace coolant hoses or tubes
· Replace hose clamps
· Replace coolant pump gasket
· Replace thermostat gasket
· Repair/replace thermostat housing
· Repair/replace radiator
· Replace coolant reservoir
· Replace pressure relief cap
· Replace coolant pump
· Replace heater core
· Replace engine gaskets
· Replace cylinder block core plugs
Engine Overheats · Low coolant level
· External engine coolant leak
· Air lock in system
· Pressure relief cap installation
· Restricted airflow through the A/C
condenser/radiator
· Internal engine coolant leak
· Coolant condition/concentration
· Electric cooling fan
· Radiator
· Thermostat
· Engine coolant temperature
indicator gauge
· Heater core
· Coolant pump
· Coolant flow restriction· Add coolant as needed
· Repair engine coolant leak
· Bleed air from cooling system
· Ensure pressure relief cap is
installed correctly
· Remove restriction from the A/C
condenser/radiator
· Repair internal engine coolant leak
· Repair coolant condition/
concentration as needed
· Replace electric cooling fan(s)
· Repair/replace radiator
· Replace thermostat
· Verify engine coolant temperature
indicator gauge operation
· Replace heater core
· Replace coolant pump
· Repair cause of coolant flow
restriction
Engine Does Not Reach Normal
Operating Temperature · Thermostat
· Electric cooling fan always on
· Engine coolant temperature
indicator gauge· Replace thermostat
· Repair cause of electric cooling fan
always on
· Verify engine coolant temperature
indicator gauge operation
Electric Cooling Fan(s) Does Not
Operate · Fuse and Relay Box
· Wiring
· Relay(s)
· Fuse(s)
· Engine Control Module (ECM)
· Cooling fan motor(s)· Repair/replace Fuse and Relay
Box
· Repair wiring
· Replace relay(s)
· Replace fuse(s)
· Replace the ECM
· Replace cooling fan motor(s)
Electric Cooling Fan(s) On All The
Time · Wiring
· Relay(s)
· Engine Control Module (ECM)· Repair wiring
· Replace relay(s)
· Replace the ECM
DIAGNOSIS AND TESTING
06–12Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine ON-VEHICLE SERVICE
Cooling System Draining and Filling
Cooling System Draining Procedure
WARNING!
Never remove the pressure relief cap, under any conditions, while the engine is operating or hot. Failure to fol-
low these instructions could result in personal injury or damage to the cooling system or engine. To avoid hav-
ing scalding hot coolant or steam blow out of the cooling system, use extreme care when removing the pressure
relief cap. Wait until the engine has cooled, then wrap a thick cloth around the pressure relief cap and turn it
slowly one turn (counterclockwise). Step back while the pressure is released from the cooling system. When you
are certain all the pressure has been released, using a cloth turn and remove the pressure relief cap. Failure to
follow these instructions may result in serious personal injury.
Perform the following procedure when draining the cooling system.1. Do not remove the pressure cap first.
2. With the engine cold, remove the pressure cap.
3. Raise and support the vehicle and locate the radiator drain plug.
4. Attach one end of a hose to the drain plug (1). Put the other end into a clean container. Open the
drain plug and drain the coolant from the radiator.
5. Tighten the radiator drain plug.
Cooling System Filling Procedure
CAUTION:
Failure to purge air from the cooling system can result in an overheating condition and severe
engine damage.
LTSM060015
06
06–13Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Perform the following procedure when filling the cooling system.1. Fill the system using the proper mixture of anti- freeze/coolant and water. Fill the coolant recovery
reservoir to the MAXline and install the pressure
cap.
2. With the heater control in the HEAT position, start and operate the engine with coolant recovery reservoir cap in place.
3. Add coolant to the coolant recovery reservoir as necessary. Only add coolant to the coolant recovery reservoir when the engine is cold. Coolant level in a warm engine will be higher due to thermal expansion.
Thermostat
Description
The thermostat is located in the thermostat housing. The thermostat housing is located on the top of the engine
between the engine and the radiator.
Operation
The thermostat controls the operating temperature of the engine by controlling the amount of engine coolant flow to
the radiator. The thermostat opens when the engine coolant temperature is approximately 90°C. At this temperature,
engine coolant is allowed to flow to the radiator. The thermostat provides quick engine warm up and overall temper-
ature control. The thermostat begins to close below 90°C. The thermostat controls this by the use of a wax pellet
located in a sealed container at the spring end of the thermostat. When heated, the pellet expands and overcomes
the closing spring tension to force the valve to open, and when cooled, the pellet contracts and the closing spring
then forces the valve to close.
Removal & Installation - 1.6L & 1.8L & 2.0L
WARNING!
Always allow the engine to cool before opening the cooling system. Do not remove 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. Drain the cooling system (See Cooling System Draining Procedure in Section 06 Cooling System).
ON-VEHICLE SERVICE
LTSM060017
06–14Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Removal & Installation - 2.4L
WARNING!
Always allow the engine to cool before opening the cooling system. Do not remove 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. Drain the cooling system (See Cooling System Draining Procedure in Section 06 Cooling System).
2. Remove the accessory drive belt (See Accessory Drive Belt Removal & Installation in Section 02 Engine).
3. Remove the engine timing belt (See Engine Timing Belt Removal & Installation in Section 02 Engine).
4. Remove the upper balance shaft timing belt (See Upper Balance Shaft Timing Belt Removal & Installation inSection 02 Engine).
5. Remove the coolant pump mounting bolts (1). (Tighten: Coolant pump mounting bolts to 14 N·m)
6. Remove the coolant pump and gasket.
7. Installation is in the reverse order of removal.
Installation Notes:
• Install a new coolant pump gasket during installation.
• Verify the cooling system is filled to proper specifications.
Coolant Pump Inspection
Check coolant seal of the coolant pump for coolant leak. If coolant pump bearing is loose, replace the assembly.
Radiator
Description
The radiator is a cross-flow type (horizontal tubes) with design features that provide greater strength, as well as
sufficient heat transfer capabilities to keep the engine coolant within operating temperatures.
Operation
The radiator functions as a heat exchanger, using air flow across the exterior of the radiator tubes. Heat from the
coolant is then transferred from the radiator into the moving air.
Removal & Installation
WARNING!
Always allow the engine to cool before opening the cooling system. Do not remove 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
LTSM060003
06
06–17Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Operation
The radiator cooling fan operation is controlled by the Engine Control Module (ECM) and the fan relays, with inputs
from the following:
•Engine coolant temperature
• Automatic transaxle fluid temperature (with DP0 transaxle)
• A/C signal
Inspect the cooling fan for proper low speed and high speed operation:
• The low speed fan should be switched on at 98°C and switched off at 94°C.
• The high speed fan should be switched on at 105°C and switched off at 101°C.
• If the water temperature is greater than 101°C after the fan is switched off, the fan will continue to operate for
1 minute.
• If the water temperature is greater than 94°C after the fan is switched off, the fan will continue to operate for
0.5 minute.
• If the water temperature is less than 85°C after the fan is switched off, the fan will stop operating.
Removal & Installation
WARNING!
Always allow the engine to cool before opening the cooling system. Do not remove 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. Disconnect the negative battery cable.
2. Drain the cooling system (See Cooling System Draining Procedure in Section 06 Cooling System).
3. Disconnect the upper radiator hose from the radiator.
4. Disconnect the cooling fan electrical connector and the cooling fan ground cable connected to the body.
5. Remove the cooling fan mounting bolts (1) to the
radiator.
(Tighten: Cooling fan mounting bolts to 5 N·m)
6. Remove the radiator fan from the engine compartment.
7. Remove the cooling fan from its support, if necessary.
8. Installation is in the reverse order of removal.
Installation Notes:
• Verify the cooling system is filled to proper specifications.
Cooling Fan Inspection
1. Using the following table, apply battery voltage to the specified connector terminals.
2. Verify that the fan motor operates smoothly when voltage is applied.
3. If the test results are not as specified, replace the fan motor.
ON-VEHICLE SERVICE
LTSM060008
06
06–19Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION
Description
This vehicle is equipped with a common HVAC housing assembly. The system combines air conditioning, heating,
and ventilating capabilities in a single unit housing mounted under the instrument panel. The driver can choose the
following functions from HVAC control panel:
•The inside temperature
• The speed of the blower
• Five different modes of operation
• A/C compressor clutch operation
• Recirculation door position
NOTE :
To maintain the performance level of the heating, ventilation and air conditioning (HVAC) system, the engine cooling
system must be properly maintained. Any obstructions in front of the radiator or A/C condenser will reduce the per-
formance of the A/C and engine cooling systems.
13–2Chery Automobile Co., Ltd.