2009 CHERY TIGGO light

Downloaded from www.Manualslib.com manuals search engine Removal & Installation - Rear Mount
NOTE :
The following special tools are required to perform the
repair procedure:
•Engine Hoist
1. Disconnect the negative battery cable.
2. Support the engine with the engine hoist.
3. Remove the engine rear mount retaining bolts (2) and remove the engine rear mount bracket bolts
(1).
(Tighten: Engine rear mount bolts to 60 N·m)
4. Installation is in the reverse order of removal.
Engine Assembly
Removal & Installation
NOTE :
The following special tools are required to perform the repair procedure:
• Engine Hoist
NOTE :
The engine is removed with the transaxle as an assembly. 1. Relieve the fuel pressure (See Fuel Pressure Relief Procedure in Section 04 Fuel Delivery).
2. Disconnect the negative battery cable.
3. Remove the battery, battery hold downs, and battery tray (See Battery Removal & Installation in Section 05 Starting & Charging).
4. Remove the hood.
5. Discharge air conditioning system (See A/C System Evacuation and Recharge in Section 13 Heating & Air Con- ditioning).
6. Drain the cooling system (See Cooling System Draining and Filling in Section 06 Cooling).
WARNING!
Always allow the engine to cool before opening the cooling system. Do not loosen 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.
7. Remove the coolant fan & radiator assembly (See Coolant Fan & Radiator Assembly Removal & Installation in Section 06 Cooling).
8. Remove the starter motor wiring.
9. Remove the negative battery cable from the engine.
ON-VEHICLE SERVICE
LTSM020188
02
02–183Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine NOTE :
The following special tools are required to perform the repair procedure:
•MB-990767 - Timing Belt Spanner Wrench
• MD-998785 - Timing Belt Gear Holder
• MD-998767 - Automatic Tensioner Socket
1. Drain the cooling system (See Cooling System Draining and Filling in Section 06 Cooling).
WARNING!
Always allow the engine to cool before opening the cooling system. Do not loosen 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.
2. Attach an engine hoist to the engine.
3. Raise the engine with the engine hoist, just enough to support the engine.
1 - Right Engine Mounting Bracket
2 - Spacer
3 - Upper Balance Shaft Pulley
4 - Upper Balance Shaft Timing Belt
5 - Upper Balance Shaft Timing Belt Tensioner
6 - Crankshaft Sensing Blade
7 - Upper Timing Belt Cover
8 - Lower Timing Belt Cover
9 - Timing Belt Automatic Tensioner
10 - Idler Pulley
11 - Crankshaft Bolt12 - Crankshaft Timing Belt Pulley
13 - Lower Balance Shaft Pulley
14 - Crankshaft Position Sensor
15 - Power Steering Bracket
16 - Timing Belt Rear Cover
17 - Timing Belt
18 - Camshaft Timing Pulley
19 - Camshaft Pulley Bolt
20 - Crankshaft Upper Balance Shaft Pulley
21 - Tensioner Arm
22 - Tensioner Pulley
ON-VEHICLE SERVICE
LTSM020048
02–190Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 7. Using valve spring compressor MD-998772 (1),compress the valve springs.
8. Install the valve keepers.
9. Strike the valve stem lightly with a plastic hammer after installation to verify proper assembly.
Camshaft
Specifications
Camshaft Specifications
DESCRIPTION SPECIFICATION MINIMUM LIMIT
Intake Cam Lobe Height 37.5 mm37 mm
Exhaust Cam Lobe Height 36.99 mm36.49 mm
CYLINDER HEAD UNIT REPAIR
LTSM020092
02
02–243Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine •Using special tool MD-998440 (1) (return leakage tester), install the hydraulic adjuster.
• After the plunger has moved slightly (0.2 - 0.5
mm), measure the time it takes to move an addi-
tional 1.0 mm. If the measurement value is not
within specifications, replace the hydraulic adjuster-
.Standard Value:4-20seconds/1 mm (applying
diesel oil of 15-20°C)
Rocker Arms
•Inspect the surface of the roller (2) on all rocker
arms. If there is any damage, the rocker arm
should be replaced.
• Inspect the roller for smooth operation. If the roller
does not revolve smoothly or is loose, the rocker
arm should be replaced.
• Inspect the internal diameter (1) of the rocker arms.
If there is any damage, the rocker arm should be
replaced.
Valve & Valve Guides
Specifications
Valve & Valve Guide Specifications
DESCRIPTION SPECIFICATION LIMIT
Intake Valve Deflection 0.02 mm0.02 mm
Exhaust Valve Deflection 0.04 mm0.04 mm
Intake Valve Clearance 0.020 - 0.050 mm0.10 mm
Exhaust Valve Clearance 0.030 - 0.070 mm0.15 mm
Intake Valve Edge Thickness 1.0 mm0.5 mm
Exhaust Valve Edge Thickness 1.2 mm0.7 mm
Intake Valve Height 112.30 mm111.80 mm
Exhaust Valve Height 114.11 mm113.61 mm
Intake Valve Guide Height 49.30 mm49.80 mm
Exhaust Valve Guide Height 49.30 mm49.80 mm
CYLINDER HEAD UNIT REPAIR
LTSM020159
LTSM020037
02–246Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine NOTE :
Before installing the valve seat, heat the cylinder head to the temperature of about 250°, or cool the valve seat in
liquid nitrogen in order to install the valve seat.
•Machine the new valve seat and valve to proper specifications.
Assembly
1. Install the valves into the cylinder head (larger diameter on intake side).
2. Using special tool MD-998774, install the new valve oil seal.
3. Install the valve springs.
4. Install the valve spring retainers.
5. Using valve spring compressor MD-998772 (1),
compress the valve springs.
6. Install the valve keepers.
7. Strike the valve stem lightly with a plastic hammer after installation to verify proper assembly.
Valve Springs
Specifications
Valve Spring Specifications
DESCRIPTION SPECIFICATION LIMIT
Spring Free Length 51.0 mm50.0 mm
Spring Center Line ≤2.0° ≤4.0°
CYLINDER HEAD UNIT REPAIR
LTSM020092
02–252Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine •Check the valve spring center line. Discard the springs that do not meet specifications.
• The following specifications apply to both intake
and exhaust valve springs.
VALVE SPRING CENTER LINE
DESCRIPTION SPECIFICATION LIMIT
Spring Center Line ≤2.0° ≤4.0°
Assembly
1. Install the valve springs (2).
2. Install the valve spring retainers (1).
3. Using valve spring compressor MD - 998772, com-
press the valve springs.
4. Install the valve keepers.
5. Strike the valve stem lightly with a plastic hammer after installation to verify proper assembly.
CYLINDER HEAD UNIT REPAIR
LTSM020100
LTSM020039
02
02–255Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Electronic Engine Control Input & Output Device Failure Modes
NUMBER ITEMFAILURE MODECORRECTION
1 CKP•
Engine is hard to start.
• The engine RPM will be limited after the engine starts.
• The highest RPM is less than 3800.
• Excessive exhaust emissions.
• No ignition signal to the ECM.
• The tachometer does not work.
• Rough engine operation. Replace
2 CMP•
The fuel injector ON time may vary from 720 degrees to 360
degrees.
• The sensor output is not correct, the MIL light will turn on
when with the second revolution after the engine starts.
• Engine is hard to start.
• The highest RPM is less than 4000. Replace
3 APPS•
The MIL light will turn on.
• Poor acceleration.
• The engine RPM will be limited after the engine starts. Replace
4 ECT•
Engine hard to start when cold.
• Engine hard to start when hot.
• Poor driving capability.
• If the sensor circuit is shorted to power, the engine will run
under the default values.
• The temperature gauge indicates too high.
• The temperature gauge indicates too low.
• The cooling fan operates continuously on high speed.
• The high temperature warning lamp will flash when the IP
indicates low temperature. Replace
5 MAF•
The cooling fan will operate for approximately 60 seconds on
high speed after the ignition switch is turned off.
• Poor acceleration.
• Poor driving capability. Replace
6 O2 Sensor •
Poor fuel economy.
• Excessive exhaust emissions.
• Sluggish acceleration.
• Poor driving capability. Replace
7 Knock Sensor •
The engine produces an engine knock.
• Overheated engine.
• Excessive exhaust emissions.
• Poor fuel economy.
• Lack of engine power.
• Internal engine damage. Replace
8 ECM•
Unstable engine idle.
• Poor acceleration.
• Unable to start.
• High engine idle.
• The engine exhaust exceeds emission standards.
• Engine is hard to start.
• Air conditioner does not operate.
• Fuel injector control failure.
• Engine stalls out. Replace
9 Ignition Coil •
Unstable idle.
• Lack of engine power.
• Poor fuel economy

.
• Excessive exhaust emissions.
• Weak spark. Replace
GENERAL INFORMATION
03–4Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine NUMBER ITEMFAILURE MODECORRECTION
10 Fuel Injector •
Unstable idle.
• Lack of engine power.
• Poor acceleration.
• Engine will not start.
• Plugged injector. Replace
11 TPS•
Poor acceleration.
• The MIL light will turn on. Replace
12 EVAP•
The engine base fuel closed-loop control self-learning will be
shut off.
• The engine idle air control self-learning will be shut off.
• Unstable idle or high idle. Replace
13 Fuel Pump •
Noisy fuel pump operation.
• Poor acceleration.
• Engine will not start. Replace
14 MAP•
Poor acceleration.
• Unstable idle.
• Rough engine operation. Replace
15 IAT•
Intake air temperature will be equal to the coolant
temperature. Replace
16 Cooling Fan •
High engine temperature.
• Poor air conditioner performance. Replace
17 Accelerator
Sensor •
Misfire
• Poor driving capability.
• Rough engine operation. Replace
Specifications
Torque Specifications
DESCRIPTION
TORQUE (N·m)
Engine Coolant Temperature (ECT) Sensor 20
Knock Sensor 20
Oxygen Sensors 45
Crankshaft Position (CKP) Sensor 10
Camshaft Position (CMP) Sensor 7
Air Flow Sensor Bolts 5
Engine Control Module (ECM) Bolts 10
Accelerator Pedal Position (APP) Sensor 11
Electronic Throttle Control Actuator 10
Vehicle Speed Sensor 10
Manifold Absolute Pressure (MAP) Sensor 6
GENERAL INFORMATION
03
03–5Chery Automobile Co., Ltd.