2009 CHERY TIGGO Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine Timing Belt Automatic Tensioner
Removal & Installation
NOTE :
The following special tools are required to perform the repair procedure:
•MD-998767 - Automatic Tensioner Socket
1. Remove the engine timing belt (See Engine Timing Belt Removal & Installation in Section 02 Engine).
2. Remove the timing belt automatic tensioner bolts (1).
(Tighten: Timing belt automatic tensioner bolts to
24 N·m)
3. Installation is in the reverse order of removal.
Installation Notes:
• Perform the following to prepare the automatic tensioner for installation:
Slowly close the vise jaws until the rod hole
(1) and housing hole (2) are aligned.
Insert a steel wire (1.4 mm diameter) into the aligned hole.
Remove the automatic tensioner from the vise.
• The automatic tensioner is now ready to be installed on the engine.
ON-VEHICLE SERVICE
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02–196Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Inspection
1. Inspect the automatic tensioner for any leaks. Replace the tensioner if any leaks are found.
2. Inspect the automatic tensioner for signs of abra-sion at the end of the rod. Replace the tensioner if
any abrasions are found.
3. Inspect the length of the rod. If the rod length does not comply with the standard length, replace the
tensioner (standard rod length is 12 mm).
4. Using a calibrated force, press the end of the rod using 98 - 196 N·m and measure the rod displace-
ment. If the rod displacement is 1 mm larger than
the standard, replace the tensioner (standard mea-
surement is ≤1 mm).
5. Assemble the automatic tensioner with a soft jawed vise (1).
CAUTION: Use an appropriate pad (3) to protect
the tensioner bolt (2) from the jaws of the vise.
6. Rotate the handle of the vise to push the rod of the automatic tensioner into the tensioner. If the rod is
easy to push in, replace the automatic tensioner.
The rod should have some resistance when you
push the rod into the tensioner.
ON-VEHICLE SERVICE
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02
02–197Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Upper Balance Shaft Timing Belt
Removal & Installation
NOTE :
The following special tools are required to perform the repair procedure:
•MD-998778 - Crankshaft Pulley Puller
• MD-998781 - Flywheel Holder
• MD-998785 - Upper Balance Shaft Pulley Holder
1. Remove the engine timing belt (See Engine Timing Belt Removal & Installation in Section 02 Engine).
2. Using special tool MD-998781 (1), attach the tool to the flywheel.
3. Remove the crankshaft pulley bolt. (Tighten: Crankshaft pulley bolt to 120 N·m)
4. Using special tool MD-998778 (1), remove the crankshaft pulley.
5. Remove the upper balance shaft timing belt. NOTE: Remember the rotation direction of the timing belt in order to avoid any error when reassembling.
6. Installation is in the reverse order of removal.
ON-VEHICLE SERVICE
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02–198Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Installation Notes:
•Align the timing marks on the crankshaft pulley (2) and the upper balance shaft pulley with the timing marks on
the front engine cover (1).
• Make sure all timing marks are aligned properly.
• Install the timing belt.
• Make sure that the belt tensioner position is as
shown (3 & 4).
• While applying finger pressure to the belt tensioner in the direction of the arrow, tighten the tensioner bolt to 35
N·m.
CAUTION:
Do not allow the belt tensioner to move while tightening the bolt, if the tensioner moves it could
cause the belt to be overtightened.
•Ensure that the timing marks (1) have not moved, and are still in alignment.
• Press the center of the timing belt with an index
finger and measure the belt deflection (standard
deflection is 5-7 mm).
• If the belt deflection is not within specifications,
adjust if necessary.
• Reinstall the engine timing belt (See Engine Timing Belt Removal & Installation in Section 02 Engine).
ON-VEHICLE SERVICE
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02–199Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Exhaust Manifold
Removal & Installation
1. Remove the bolts attaching the exhaust manifold heat shield.(Tighten: Exhaust manifold heat shield bolts to 14 N·m)
2. Remove the exhaust manifold heat shield.
3. Remove the three bolts securing the exhaust manifold to the catalytic converter assembly. (Tighten: Exhaust manifold to catalytic converter bolts to 49 ± 5 N·m)
4. Disconnect the catalytic converter assembly from the manifold.
5. Remove the exhaust manifold nuts. (Tighten: Exhaust manifold nuts to 29 ± 3 N·m)
6. Remove the exhaust manifold from the cylinder head.
7. Remove and discard exhaust manifold gasket.
1 - Exhaust Manifold Heat Shield
2 - Engine Hanger
3 - Oxygen Sensor4 - Exhaust Manifold
5 - Exhaust Manifold Gasket
ON-VEHICLE SERVICE
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02–200Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 8. Installation is in the reverse order of removal.
Installation Notes:
• Clean all surfaces of manifold and cylinder head.
• Install a new exhaust manifold gasket during installation.
Intake Manifold
Removal & Installation
1. Disconnect the negative battery cable.
1 - Inlet Manifold Gasket
2 - Knock Sensor
3 - Coolant Hose
4 - Coolant Hose
5 - Coolant Temperature Sensor6 - Coolant Outlet Fitting
7 - Intake Manifold Support Bracket
8 - Intake Manifold
9 - Engine Hanger
ON-VEHICLE SERVICE
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02
02–201Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 2. Remove the accelerator cable retaining bolt from the intake manifold.(Tighten: Accelerator cable retaining bolt to 10 N·m)
3. Remove the PCV hose (1).
4. Disconnect the four fuel injector electrical connec- tors (1).
5. Loosen the clamp between the air intake hose and the air cleaner.
6. Loosen the clamp between the air intake hose and the throttle body and then remove the intake pipe.
7. Remove the fuel rail bracket bolts. (Tighten: Fuel rail bracket bolts to 11 N·m)
8. Remove the fuel rail with the fuel injectors and set aside.
9. Remove the fuel injector O-rings.
10. Remove the screws securing the vacuum valve bracket to the intake manifold.
11. Set aside the vacuum valve and pipe.
12. Disconnect the intake manifold electrical harness, and vacuum hose.
ON-VEHICLE SERVICE
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02–202Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 13. Remove the intake manifold bracket bolts (1).(Tighten: Intake manifold bracket bolts to
14 ± 1 N·m)
14. Remove the intake manifold retaining nuts. (Tighten: Intake manifold retaining nuts to 49 ± 5 N·m)
15. Remove the intake manifold from the cylinder head.
16. Remove and discard the intake manifold gasket.
17. Installation is in the reverse order of removal.
Installation Notes:
• Clean all surfaces of the manifold and cylinder head.
• Install a new intake manifold gasket during installation.
• Install new O-rings on the fuel injectors.
ON-VEHICLE SERVICE
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02
02–203Chery Automobile Co., Ltd.