2009 CHERY TIGGO timing belt

Downloaded from www.Manualslib.com manuals search engine Installation Notes:
•Oil pan sealing surfaces must be free of grease or oil.
• Install the four oil pan corner bolts in the sequence shown (1-2-3-4).
• Install the remaining oil pan bolts.
• Torque all the oil pan bolts to the proper
specification.
Oil Pump
Removal & Installation
1. Remove the accessory drive belt (See Accessory Drive Belt Removal & Installation in Section 02 Engine).
2. Remove the crankshaft vibration damper retaining
bolt (1).
(Tighten: Crankshaft vibration damper bolts to 25
N·m)
3. Remove the engine timing belt (See Engine Timing Belt Removal & Installation in Section 02 Engine).
4. Remove the crankshaft timing belt pulley bolt (2) from the crankshaft.
(Tighten: Crankshaft timing belt pulley bolt to
130 N·m and an additional 65°)
5. Remove the key-way from the crankshaft.
6. Using an appropriate tool, remove the front crank- shaft oil seal (1).
ON-VEHICLE SERVICE
VISM020013
BESM020055 LTSM020199
02–121Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 2.4L ENGINE MECHANICAL
GENERAL INFORMATION02-151
Description 02-151
Operation 02-151
Specifications 02-151
Special Tools 02-154
Lubrication System 02-160
DIAGNOSIS & TESTING02-163
Engine Performance Diagnostics 02-163
Engine Mechanical Diagnostics 02-164
Cylinder Compression Pressure Test 02-165
Cylinder Head Gasket Test 02-166
Engine Oil Pressure Test 02-166
ON-VEHICLE SERVICE02-167
Accessory Drive Belt 02-167
Removal & Installation 02-167
Air Cleaner Element 02-168
Removal & Installation 02-168
Air Cleaner Housing 02-169
Removal & Installation 02-169
Cylinder Head Cover 02-170
Removal & Installation 02-170
Camshaft 02-171
Removal & Installation 02-171
Cylinder Head 02-175
Removal & Installation 02-175
Front Crankshaft Oil Seal 02-177
Removal & Installation 02-177
Rear Crankshaft Oil Seal 02-179
Removal & Installation 02-179
Engine Mounts 02-181
Removal & Installation - Left Mount 02-181
Removal & Installation - Right Mount 02-182
Removal & Installation - Front Mount 02-182
Removal & Installation - Rear Mount 02-183
Engine Assembly 02-183
Removal & Installation 02-183
Engine Timing Belt 02-189
Removal & Installation 02-189
Inspection 02-194
Timing Belt Automatic Tensioner 02-196
Removal & Installation 02-196
Inspection 02-197
Upper Balance Shaft Timing Belt 02-198
Removal & Installation 02-198Exhaust Manifold
02-200
Removal & Installation 02-200
Intake Manifold 02-201
Removal & Installation 02-201
Upper Balance Shaft 02-204
Removal & Installation 02-204
Upper Balance Shaft Bearing
Replacement 02-207
Lower Balance Shaft 02-208
Removal & Installation 02-208
Lower Balance Shaft Bearing
Replacement 02-211
Oil Filter 02-212
Removal & Installation 02-212
Oil Pan 02-213
Removal & Installation 02-213
Oil Pump 02-215
Removal & Installation 02-215
Oil Strainer 02-216
Removal & Installation 02-216
ENGINE UNIT REPAIR02-217
Engine Block 02-217
Specifications 02-217
Disassembly 02-218
Inspection 02-220
Assembly 02-220
Pistons 02-221
Specifications 02-221
Disassembly 02-222
Inspection 02-224
Assembly 02-226
Connecting Rods 02-229
Specifications 02-229
Disassembly 02-229
Inspection 02-230
Assembly 02-231
Crankshaft 02-233
Specifications 02-233
Disassembly 02-234
Inspection 02-236
Assembly 02-237
02–149Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION
Description
The 2.4L in-line four cylinder engine has the following features:
•Single overhead camshaft
• Four valves per chamber cylinder head design
• Aluminum cylinder head
• Cast iron cylinder block
Operation
The 2.4L engine utilizes 4 valves-per-cylinder and a single-overhead-camshaft design. The engine uses an individual
coil ignition system and multi-point sequential injection. The cylinder block is made of cast iron and the bearing caps
are integrated into the lower cylinder block assembly. A cast iron oil pan is located at the bottom of the lower cylinder
block. The camshaft is mounted in the cylinder head and acts against the valve tappets to open and close the valves.
The camshaft is driven off the front of the cylinder head by the timing belt. The belt is driven by a sprocket that is
located on the crankshaft. The piston assembly is an aluminum piston with a cast iron connecting rod.
The aluminum cylinder head contains a single overhead camshaft with 4 valves-per-cylinder construction. The valves
are arranged in two in-line banks. The cylinder head incorporates powdered metal valve guides and seats. The cyl-
inder head is sealed to the block using a multi-layer steel head gasket and retaining bolts.
Specifications
2.4L General Engine Specifications
DESCRIPTION SPECIFICATION
Type In-Line, OHV, SOHC
Number of Cylinders 4
Compression Ratio 9:1
Output Power (kw) 95 / 5500 RPM
Stroke 100 mm
Cylinder Diameter 86.5 mm
Displacement 2351 cc
Firing Order 1-3-4-2
Max Torque (N·m) 198.1
2.4L Mechanical Specifications
ITEMSTANDARD LIMIT
Engine Timing Belt Tensioner Arm Protrusion
12-
Tensioner Arm Depression (98-196 N) ≤1-
Camshaft Cam Height Air-In
37.5037.00
Air-Out 36.9936.49
Shaft Diameter 45.0-
Cylinder Head Lower Surface Flatness
0.030.2
Surface Grinding Limit* Total Grinding of Cylinder Block and Cylinder Head -
0.2
Full Height 119.9 - 120.1-
02–151Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Torque Specifications
CAUTION:
When torquing a fastener in two steps, DO NOT use a torque wrench for the second step.
DESCRIPTIONTORQUE (N·m)
Alternator Adjusting Bolt 10
Alternator Bracket Bolt 24
Alternator Center Nut 45
Camshaft Position Sensor Bracket 14
Camshaft Position Sensor 10
Camshaft Position Sensor Cylinder 22
Crank Belt Gear 25
Ignition Coil 10
Locking Bolt 22
Spark Piston 25
Water Pump Belt Gear 9
Timing Belt Automatic Tensioner Bolt 24
Belt Gear of Balance Axle 46
Central Belt Wheel Bolt 36
Lower Balance Shaft Bolt 55
Timing Belt Cover Bolts 11
Tensioner Wheel Bolt 49
Tensioner Arm Bolt 22
Tensioner Bracket 49
Timing Belt Indicator 09
Timing Belt Rear Cover 11
Upper Balance Shaft Tensioner Bolt 19
Camshaft Pulley Bolt 90
Crankshaft Pulley Bolt 120
Connecting Bolt of Outflow Pipe 20
EGR Valve 22
Exhaust Manifold Nut (M8) 30
Exhaust Manifold Nut (M10) 50
Fuel Pressure Regulator 9
Fuel Return Pipe 09
Injector and Distribution Pipe 12
Intake Manifold Bolt 20
Intake Manifold Bracket 14
Thermostat Housing Bolt 24
Water Pump Bolts 14
Rocker Cover Bolt 4
Rocker and Camshaft Assembly Bolt 32
Trust Bearing Cover Bolt 19
GENERAL INFORMATION
02–153Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Oil Filter WrenchMB-991828
Oil Filter WrenchMB-991396
Lubrication System
The engine lubrication system operates as follows:
• Oil is drawn into the oil pump through the oil pump strainer tube in the sump of the oil pan.
• Oil is pumped through the oil filter to the cylinder block.
• Oil enters the main oil gallery where it is distributed to the crankshaft main journals and to the cylinder head.
• From the main journals, the oil is routed through cross-drilled passages in the crankshaft to lubricate the con-
necting rod bearings. Controlled leakage through the crankshaft main bearings and connecting rod bearings is
slung radially outward to cool and lubricate the cylinder walls as well as the entire connecting rod, piston and
piston ring assembly.
• The lubrication system is a fully force-fed, full-flow filtration type. The oil pump is a gear type which is driven by
the crankshaft via the timing belt.
GENERAL INFORMATION
02
02–160Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine DIAGNOSIS & TESTING
Engine Performance Diagnostics
CONDITIONPOSSIBLE CAUSES CORRECTION
Engine Does Not Start 1. Weak battery.
2. Corroded or loose battery
connections.
3. Faulty starter.
4. Faulty coil(s) or control unit.
5. Incorrect spark plug gap.
6. Contamination in fuel system.
7. Faulty fuel pump.
8. Incorrect timing.1. Test battery. Charge or replace if
necessary.
2. Clean and tighten battery
connections. Apply a coat of light
mineral grease to terminals.
3. Test starting system. Check for
codes. (Refer to Appropriate
Diagnostic Information)
4. Test and replace as needed.
(Refer to Appropriate Diagnostic
Information)
5. Set gap.
6. Clean system and replace fuel
filter.
7. Test fuel pump and replace as
needed. (Refer to Appropriate
Diagnostic Information)
8. Check for a skipped timing belt.
Engine Stalls Or Idles Rough 1. Idle speed too low.
2. Incorrect fuel mixture.
3. Intake manifold leakage.
4. Faulty ignition coil(s).1. Test minimum air flow. (Refer to
Appropriate Diagnostic Information)
2. (Refer to Appropriate Diagnostic
Information)
3. Inspect intake manifold, manifold
gasket, and vacuum hoses.
4. Test and replace if necessary.
(Refer to Appropriate Diagnostic
Information)
Engine Loss Of Power 1. Dirty or incorrectly gapped spark
plugs.
2. Contamination in fuel system.
3. Faulty fuel pump.
4. Incorrect valve timing.
5. Leaking cylinder head gasket.
6. Low compression.
7. Burned, warped, excessive
clearance, or pitted valves.
8. Plugged or restricted exhaust
system.
9. Faulty ignition coil(s).
10. Burned spark plugs.1. Clean spark plugs and set gap.
2. Clean system and replace fuel
filter.
3. Test and replace if necessary.
(Refer to Appropriate Diagnostic
Information)
4. Correct valve timing.
5. Replace cylinder head gasket.
6. Test compression of each
cylinder.
7. Replace valves.
8. Perform exhaust restriction test.
Install new parts.
9. Test and replace if necessary.
(Refer to Appropriate Diagnostic
Information)
10. Replace spark plugs.
DIAGNOSIS & TESTING
02
02–163Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine •MD-998442 - Hydraulic Post Wiring
• MD-998713 - Camshaft Oil Seal Installer
• MD-998441 - Hydraulic Post Keeper
• MD-998440 - Leak Tester
1. Remove the accessory drive belt (See Accessory Drive Belt Removal & Installation in Section 02 Engine).
2. Remove the engine timing belt (See Engine Timing Belt Removal & Installation in Section 02 Engine).
3. Remove the cylinder head cover (See Cylinder Head Cover Removal & Installation in Section 02 Engine).
4. Using special tools MD-998719 (1) and MB-990767 (2) remove the camshaft timing belt pulley bolt.
(Tighten: Camshaft timing belt pulley bolt to
120 N·m)
5. Remove the camshaft timing belt pulley.
6. Remove the intake and exhaust rocker shaft assembly retaining bolts (2).
(Tighten: Rocker shaft assembly bolts to 32 N·m)
7. Remove the rocker arm and rocker shaft assem- blies.
CAUTION: Before disassembling the rocker arm
and rocker arm shaft assembly, install special
tool MD-998443 (1) as shown in the illustration
to prevent the hydraulic adjusters from drop-
ping into the cylinder head.
8. Remove the camshaft position sensor electrical connector.
9. Remove the camshaft position sensor. (See Camshaft Position Sensor Removal & Installation in Section 03 Elec- tronic Engine Controls).
10. Remove the camshaft thrust plate retaining bolt. (Tighten: Camshaft thrust plate bolt to 19 ± 3 N·m)
11. Remove the O-ring.
12. Remove the camshaft.
13. Installation is in the reverse order of removal.
ON-VEHICLE SERVICE
LTSM020056
LTSM020082
02–172Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Cylinder Head
Removal & Installation
1. Drain the cooling system (See Cooling System Draining and Filling in Section 06 Cooling).
2. Remove the engine timing belt (See Engine Timing Belt Removal & Installation in Section 02 Engine).
3. Remove the cylinder head cover (See Cylinder Head Cover Removal & Installation in Section 02 Engine).
4. Remove the camshafts (See Camshaft Removal & Installation in Section 02 Engine).
5. Remove the intake manifold (See Intake Manifold Removal & Installation in Section 02 Engine).
6. Remove the exhaust manifold (See Exhaust Manifold Removal & Installation in Section 02 Engine).
7. Remove the water pipe and thermostat assembly.
1 - Cylinder Head Bolt
2 - Valve Spring Locks
3 - Upper Valve Spring Retainer
4 - Valve Spring
5 - Valve Oil Seal6 - Lower Valve Spring Retainer
7 - Valve Guide
8 - Valve Seat
9 - Valve
10 - Cylinder Head
ON-VEHICLE SERVICE
LTSM020090
02
02–175Chery Automobile Co., Ltd.