2009 CHERY TIGGO fuel pressure

Downloaded from www.Manualslib.com manuals search engine ON-VEHICLE SERVICE
Engine Coolant Temperature (ECT) Sensor
Description
The Engine Coolant Temperature (ECT) Sensor is beside the thermostat. The ECT Sensor is a negative thermal
coefficient sensor.
Operation
The ECT sensor provides an input signal to the ECM. As temperature increases, resistance of the sensor decreases.
As coolant temperature varies, the ECT sensor resistance changes resulting in a different voltage value at the ECT
sensor signal circuit. The ECM uses the input to control air-fuel mixture, timing, and radiator fan on/off times.
Removal & Installation
1. Disconnect and isolate the negative battery cable.
2. Release the coolant system pressure.
WARNING!
Never remove the radiator pressure relief cap under any conditions while the engine is operating or hot. Failure
to follow these instructions could result in personal injury or damage to the cooling system or engine. To avoid
having scalding hot coolant or steam blow out of the cooling system, use extreme care when removing the pres-
sure 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, (with a cloth) turn and remove the pressure relief cap. Failure
to follow these instructions may result in serious personal injury.
3. Disconnect the coolant temperature sensor electrical connector.
CAUTION:
Remove the coolant temperature sensor when the engine is cold.
03
03–531Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Symptom Diagnostic Tests
General Troubleshooting Checks
•Confirm the engine trouble light is working properly.
• Confirm that there are no DTCs recorded with the X-431 Scan Tool.
• Confirm that the customer’s complaint is current, and the conditions that are causing the failure are present.
Visual Inspection
•Check the fuel system for any fuel leakage.
• Check the vacuum system for any broken, kinked or incorrectly linked vacuum pipes or hoses.
• Check the intake air pipe for being jammed, leaking, or damaged.
• Check the ignition system for any broken or aging spark plug wires and verify the engine firing order is correct.
• Check the engine ground cable and verify a clean and tight connection.
• Check the sensors and actuators electrical connectors and verify good contact and tight connection.
NOTE :
Repair any of the above conditions first before continuing with symptom diagnostics.
Diagnostic Help
• Confirm there are no current engine DTCs.
• Confirm that the failure exists and the customer complaint can be verified.
• Inspect the engine following the above steps and verify all engine features are operating properly.
• While servicing the vehicle, verify the service record, vehicle maintenance, engine compression pressures,
mechanical ignition timing and fuel conditions.
• If replacing the Engine Control Module (ECM), carry out the validation test. If the failure no longer exists, the
failure is in the ECM; if the failure still exists, reinstall the original ECM and repeat the diagnostic test.
Symptom Diagnostic Test List
SYMPTOM DEFINITION
Engine Cranks Normal But Will Not Start
Engine Will Not Crank
Hard Start / Long Crank Time
Fast Idle
Lack / Loss Of Power
Back Fires
Engine Poor Driveability
Low Idle / Stalls During Deceleration
Idle Speed Slow Return To Normal Idle
ELECTRONIC ENGINE CONTROLS - 2.4L ENGINE SYMPTOM DIAGNOSIS
03–544Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 4.CHECK FUEL SYSTEM PRESSURE
• Release the fuel system pressure (See Fuel Pressure Relief Procedure in Section 04 Fuel Delivery).
• Check fuel system pressure (See Fuel Pressure Test in Section 04 Fuel Delivery).
Is fuel pressure correct?
Ye s>>Go to the next step.
No
>>If the fuel pressure is greater than 400 kPa (4.0 bar):
Replace the fuel pressure regulator.
If the fuel pressure is less than 400 kPa (4.0 bar):
Check the fuel supply system for restrictions or leaks.
If no problems, repair or replace fuel filter, pressure regulator or fuel pump assembly.
5.CHECK EXHAUST SYSTEM
• Check the exhaust system for restrictions.
Is there a restriction in the exhaust system?
Ye s>>Repair as necessary.
No
>>Go to the next step.
6.CHECK ENGINE OVERHEATING
• Is the engine overheating (hot start concern only)?
For hot start concerns, does engine appear to be overheating?
Ye s>>Repair the engine cooling system.
No
>>Go to the next step.
7.CHECK POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM
• Remove the PCV valve and shake it.
Does PCV valve rattle?
Ye s>>Go to the next step.
No
>>Replace the PCV valve.
ELECTRONIC ENGINE CONTROLS - 2.4L ENGINE SYMPTOM DIAGNOSIS
03–550Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Lack / Loss Of Power
The following conditions apply to this symptom:
•The engine has poor performance.
• The engine has poor acceleration.
1.PRELIMINARY CHECKS
• Verify symptom is reported under normal driving conditions without excessive engine/vehicle load conditions.
• Carry out the following preliminary checks:
Fuel quality
Vacuum lines (check for damage and correct routing)
Intake air system (check for damaged tubes and dirty air filter)
Vehicle wiring (disconnected, corroded/damaged)
Throttle linkage
Radiator (obstructed)
Transaxle
NOTE :
Be aware of the over RPM limiting functions of the ECM.
Are all checks OK?
Ye s>>Go to the next step.
No
>>Repair as necessary.
Verify the symptom no longer exists.
2.CHECK ECM DTC
• Turn ignition switch on.
• With the scan tool X-431, read the DTC.
Do any DTC displayed on the scan tool?
Ye s>>See the Diagnostic Trouble Code (DTC) List.
Go to the specific diagnostic test to troubleshoot the DTC.
No
>>Go to the next step.
3.CHECK FUEL SYSTEM PRESSURE
• Release the fuel system pressure (See Fuel Pressure Relief Procedure in Section 04 Fuel Delivery).
• Check fuel system pressure (See Fuel Pressure Test in Section 04 Fuel Delivery).
Is fuel pressure correct?
Ye s>>Go to the next step.
No
>>If the fuel pressure is greater than 400 kPa (4.0 bar):
Replace the fuel pressure regulator.
If the fuel pressure is less than 400 kPa (4.0 bar):
Check the fuel supply system for restrictions or leaks.
If no problems, repair or replace fuel filter, pressure regulator or fuel pump assembly.
ELECTRONIC ENGINE CONTROLS - 2.4L ENGINE SYMPTOM DIAGNOSIS
03
03–553Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 5.CHECK KNOCK SENSOR
• Check knock sensor.
Is the check result normal?
Ye s>>Go to the next step.
No
>>Repair as necessary.
Verify the symptom no longer exists.
6.CHECK TIMING
• Check for the timing misalignment.
Is the check result normal?
Ye s>>Go to the next step.
No
>>Align the engine timing belt (See Engine Timing Belt Removal & Installation in Section 02 Engine).
7.CHECK FUEL SYSTEM PRESSURE
• Release the fuel system pressure (See Fuel Pressure Relief Procedure in Section 04 Fuel Delivery).
• Check fuel system pressure (See Fuel Pressure Test in Section 04 Fuel Delivery).
Is fuel pressure correct?
Ye s>>Go to the next step.
No
>>If the fuel pressure is greater than 400 kPa (4.0 bar):
Replace the fuel pressure regulator.
If the fuel pressure is less than 400 kPa (4.0 bar):
Check the fuel supply system for restrictions or leaks.
If no problems, repair or replace fuel filter, pressure regulator or fuel pump assembly.
8.CHECK FOR BASE ENGINE CONCERNS
• Check for base engine concerns (such as improper cylinder compression, worn camshaft/valve train, gasket
leaks).
Is a fault indicated?
Ye s>>Repair as necessary.
No
>>See Diagnostic Help for additional information.
ELECTRONIC ENGINE CONTROLS - 2.4L ENGINE SYMPTOM DIAGNOSIS
03
03–557Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 6.CHECK SECONDARY IGNITION SYSTEM
• Perform the following to test the secondary ignition system:
Disconnect the injector fuse.
Remove any of the 4 spark plugs.
Connect the spark plug to spark plug wire.
Ground the spark plug on the cylinder block.
Crank the engine to test the secondary ignition system with the spark plugs removed.
Is a strong blue spark visible at each spark plug while cranking the engine?
Ye s>>Go to the next step.
No
>>Check Camshaft Position (CMP) sensor signal at ECM.
If CMP sensor is OK, check the following:
Crankshaft Position (CKP) sensor malfunction
Spark plug wires
Spark plugs
7.CHECK FUEL SYSTEM PRESSURE
• Release the fuel system pressure (See Fuel Pressure Relief Procedure in Section 04 Fuel Delivery).
• Check fuel system pressure (See Fuel Pressure Test in Section 04 Fuel Delivery).
Is fuel pressure correct?
Ye s>>Go to the next step.
No
>>If the fuel pressure is greater than 400 kPa (4.0 bar):
Replace the fuel pressure regulator.
If the fuel pressure is less than 400 kPa (4.0 bar):
Check the fuel supply system for restrictions or leaks.
If no problems, repair or replace fuel filter, pressure regulator or fuel pump assembly.
8.CHECK EXHAUST SYSTEM
• Check the exhaust system for restrictions.
Is there a restriction in the exhaust system?
Ye s>>Repair as necessary.
No
>>Go to the next step.
9.CHECK PCV SYSTEM
• Check the Positive Crankcase Ventilation (PCV) system.
• Remove PCV valve and shake it.
Is PCV valve normal?
Ye s>>Go to the next step.
No
>>Replace the PCV valve.
ELECTRONIC ENGINE CONTROLS - 2.4L ENGINE SYMPTOM DIAGNOSIS
03–560Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 5.CHECK CLUTCH OPERATION CONDITION
• Check clutch operation condition.
Is the transaxle clutch operation normal?
Ye s>>Go to the next step.
No
>>Repair as necessary.
6.CHECK A/C SYSTEM OPERATION
• Start engine.
• Cycle A/C switch from on to off (verify A/C clutch engages condition).
• Check the A/C system operation.
Does the A/C system operate normally?
Ye s>>Go to the next step.
No
>>Repair as necessary.
7.CHECK FUEL SYSTEM PRESSURE
• Release the fuel system pressure (See Fuel Pressure Relief Procedure in Section 04 Fuel Delivery).
• Check fuel system pressure (See Fuel Pressure Test in Section 04 Fuel Delivery).
Is fuel pressure correct?
Ye s>>Go to the next step.
No
>>If the fuel pressure is greater than 400 kPa (4.0 bar):
Replace the fuel pressure regulator.
If the fuel pressure is less than 400 kPa (4.0 bar):
Check the fuel supply system for restrictions or leaks.
If no problems, repair or replace fuel filter, pressure regulator or fuel pump assembly.
8.CHECK FOR BASE ENGINE CONCERNS
• Check for base engine concerns (such as improper compression, worn camshaft/valve train, gasket leaks).
Is a fault indicated?
Ye s>>Repair as necessary.
No
>>See Diagnostic Help for additional information.
ELECTRONIC ENGINE CONTROLS - 2.4L ENGINE SYMPTOM DIAGNOSIS
03
03–563Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine FUEL DELIVERY
04
CONTENTSpage
Fuel Delivery System ................................................................. 04-1
FUEL DELIVERY SYSTEM
GENERAL INFORMATION04-2
Description 04-2
Operation 04-4
Specifications 04-4
Special Tools 04-5
Electrical Schematics 04-6
DIAGNOSIS & TESTING04-12
Fuel Pressure Test 04-12
ON-VEHICLE SERVICE04-15
Fuel Pressure Relief Procedure 04-15
Description 04-15
Fuel Pump 04-15
Description 04-15
Operation 04-15
Removal & Installation 04-15
Fuel Pump Inspection 04-17
Fuel Filter 04-18
Description 04-18
Operation 04-18 Removal & Installation 04-18
Fuel Injector Rail 04-19
Description 04-19
Operation 04-19
Removal & Installation - 1.6L & 1.8L &
2.0L 04-19
Removal & Installation - 2.4L 04-20
Fuel Injector 04-20
Description 04-20
Operation 04-20
Removal & Installation - 1.6L & 1.8L &
2.0L 04-20
Removal & Installation - 2.4L 04-21
Fuel Injector Inspection 04-22
Fuel Pressure Regulator - With
Mitsubishi 2.4L Engine 04-23
Description 04-23
Operation 04-23
Removal & Installation 04-23
Fuel Pressure Regulator Inspection 04-24
04
04–1Chery Automobile Co., Ltd.