2009 CHERY TIGGO light

Downloaded from www.Manualslib.com manuals search engine Diagnostic Scan Tool Configuration
ITEM NAMEDESCRIPTION
1 X-431 Main Unit To Display Operational
Buttons, Test Results, Help
Information, etc.
2 Mini-Printer To Print Test Results.
(Optional)
3 CF Card To Store Diagnostic Software
and Data
4 USB Cable To Connect CF Card
Reader/Writer and Computer
5 CF Card
Reader/Writer To Read or Write Data On
The CF Card
6 Mitsubishi-12+16
Pin Connector To Diagnose Mitsubishi
Electronic Control Systems
On Chery B11 Series
7 Fiat-3 Pin
Connector To Diagnose Vehicles With
Fiat-3 Pin Diagnostic
ConnectorITEM NAME
DESCRIPTION
8 Smart OBDII-16
Pin Connector To Diagnose Other Systems
Of Vehicle With OBDII-16
Pin Diagnostic Connector
9 Power Cord To Connect AC 100 - 240 V
Outlet and Power Adapter
10 Cigarette Lighter
Cable To Get Power From Vehicle
Cigarette Lighter
11 Battery Cable
W/Two Clips To Get Power From Vehicle
Battery
12 Power Adapter To Convert 100 - 240 V AC
Power Into 12 V DC Power
13 Main Cable To Connect The Diagnostic
Connector and Smartbox
14 Smartbox To Perform Vehicle
Diagnosis
DIAGNOSIS & TESTING
BESM030003
03–460Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Check reference values between ECM terminals and ground under the following conditions:
ECM TERMINAL NO.ITEMTEST METHOD DATA (DC VOLTAGE)
62 Knock sensor•
Test Method 1: Knock at
cylinder with rubber
hammer
• Test Method 2: Knock at
sensor slightly Output signal voltage
should exist.
On Board Diagnostic Logic
• Self-diagnosis detection logic.
DTC NO. DTC DEFINITION DTC DETECTION
CONDITION POSSIBLE CAUSE
31 Knock sensorAn excessive voltage from
the sensor is sent to ECM. •
Knock sensor
• Harness or connectors
• ECM
DTC Confirmation Procedure:
Before performing the following procedure, confirm that battery voltage is more than 12 V.
• Turn ignition switch off.
• Connect the X-431 scan tool to the Data Link Connector (DLC) - use the most current software available.
• Turn ignition switch on.
• With the scan tool, record and erase stored DTCs in the ECM.
• Run engine for a while then select view DTC.
• If DTC is detected, go to Diagnostic Procedure - Step 1.
• If the DTC is not detected, the DTC condition is intermittent (See Diagnosis & Testing Diagnostic Help in Sec-
tion 03 Electronic Engine Controls).
NOTE :
Before performing the following procedure, make sure that the ECM ground connection is in good condition.
NOTE :
While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit
and component information.
Diagnostic Procedure
1.CHECK GROUND CONNECTION
• Turn ignition switch off.
• Loosen and retighten ground screws on the body (See Ground Inspection in Section 03 Electronic Engine Con-
trols).
• Inspect the ground connection E-208 (See Vehicle Wiring Harness Layout - Engine Room Harness (With Mit-
subishi 2.4L Engine) in Section 16 Wiring).
Is the ground connections OK?
Ye s>>Go to the next step.
No
>>Repair or replace ground connection.
DIAGNOSIS & TESTING
03–516Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 5.CHECK KNOCK SENSOR SIGNAL
• Connect knock sensor (1) connector.
• Set multimeter to voltage range.
• Check knock sensor (1) output signal as table
shown.
CHECK OUTPUT SIGNAL
KNOCK SENSOR TERMINAL NO. TEST METHODDATA (AVERAGE DC VOLTAGE)
1&2 •
Test Method 1: Knock at cylinder
with rubber hammer. Output signal voltage should exist.
• Test Method 2: Knock at sensor
slightly.
• Output signal voltage should exist.
Is the check result normal?
Ye s>>Go to the next step.
No
>>Replace knock sensor.
6.CHECK DTC
• With the X-431 scan tool, read ECM DTCs.
• Refer to DTC Confirmation Procedure.
Is DTC 31 still present?
Ye s>>Replace the ECM.
No
>>The system is now operating properly.
Reassemble the vehicle and road test to verify the customers complaint is repaired.
DIAGNOSIS & TESTING
LTSM030011
03–518Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine The oxygen sensors are equipped with a heating element that keeps the sensors at proper operating temperature
during all operating modes. Maintaining correct sensor temperature at all times allows the system to enter into closed
loop operation sooner. Also, it allows the system to remain in closed loop operation during periods of extended idle.
Upstream Oxygen Sensor
The input from the upstream heated oxygen sensor tells the Engine Control Module (ECM) the oxygen content of the
exhaust gas. Based on this input, the ECM fine tunes the air-fuel ratio by adjusting injector pulse width.
Downstream Oxygen Sensor
The downstream heated oxygen sensor signal is used to detect catalytic convertor deterioration. As the convertor
deteriorates, the signal from the downstream sensor begins to match the upstream sensor signal except for a slight
time delay. By comparing the downstream heated oxygen sensor signal to the signal from the upstream sensor, the
ECM calculates catalytic convertor efficiency. This calculation is also used to establish the upstream O2 goal voltage
(switching point).
Removal & Installation - Upstream Oxygen Sensor
1. Disconnect the negative battery cable.
2. Disconnect the oxygen sensor electrical connector.
CAUTION:
Remove the oxygen sensor after the exhaust pipe has cooled.
3. Remove the upstream oxygen sensor (1).(Tighten: Upstream oxygen sensor to 45 N·m)
4. Installation is in the reverse order of removal.
Installation Notes:
• Before installing the oxygen sensor, coat the threads with rust inhibiting lubricant.
ON-VEHICLE SERVICE
LTSM030004
03–534Chery 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 GENERAL INFORMATION
Description
The fuel system consists of a fuel tank with a reservoir, fuel pump, fuel filter, fuel delivery line, fuel rail, fuel rail pulse
damper and fuel injectors. The Engine Control Module (ECM) controls the fuel system based on signal inputs. The
immobilizer module signals the ECM to activate the fuel system. If the ECM does not receive the proper signal from
the immobilizer module, the ECM will not allow the fuel system to operate.
•The ACTECO engine utilizes a returnless fuel delivery system.
• The MITSUBISHI engine utilizes a fuel return fuel delivery system.
WARNING!
Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related
component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instruc-
tions may result in serious personal injury.
Fuel Filler Assembly
1 - Fuel Filler Cap Assembly
2 - Fuel Filler Shield
3 - Fuel Filler Tube Assembly
4 - Bolt
5 - Hose Clamp
6 - Fuel Filler Hose
7 - Fuel Filler Air Hose8 - Fuel Tank Assembly
9 - Electric Fuel Pump Assembly
10 - Fuel Delivery Pipe Assembly
11 - Fuel Return Pipe Assembly
12 - Hose Clamp
13 - Bolt
LTSM040008
04–2Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 4. Remove the fuel pump cover (1).
5. Disconnect the fuel pump connector (3) and thefuel delivery hose (2) and fuel return hose (1).
6. Using special tool CH-20032, remove the fuel pump mounting cover (4).
7. Pull the fuel pump up and out of the fuel tank.
WARNING!
Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-
related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these
instructions may result in serious personal injury or death.
Do not carry personal electronic devices such as cell phones, pagers or audio equipment of any type when
working on or near any fuel-related component. Highly flammable mixtures are always present and may be
ignited. Failure to follow these instructions may result in serious personal injury or death.
When handling fuel, always observe fuel handling precautions and be prepared in the event of fuel spillage.
Spilled fuel may be ignited by hot vehicle components or other ignition sources. Failure to follow these instruc-
tions may result in serious personal injury or death.
NOTE :
Make sure not to spill fuel inside of the vehicle. 8. Tip the fuel pump on its side and drain the fuel from the fuel pump and remove the fuel pump from the vehicle. NOTE: To keep the fuel tank portion clean and to avoid damage and foreign materials, cover them completely
with plastic bags or something similar.
9. Remove and discard the seal from the fuel tank.
10. Installation is in the reverse order of removal.
Installation Notes:
• Install a new seal to the fuel pump sealing surface.
• Turn the ignition switch to ON (without starting the engine) to apply fuel pressure to the fuel system, then
check the connections for fuel leaks.
• Start the engine and let it idle and check for fuel leaks at the fuel system connections.
ON-VEHICLE SERVICE
LTSM040001
LTSM040002
04–16Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Battery Tray
Removal & Installation
1. Disconnect the negative battery cable.
2. Disconnect the positive battery cable.
3. Remove the battery hold down.
4. Remove the battery.
5. Remove the three bolts (1) from the battery tray.
6. Lift the battery tray out of the engine compartmentand remove from the vehicle.
7. Installation is in the reverse order of removal.
Starter Motor Assembly
Description
The starter motor is mounted with two bolts to the transaxle housing and is located on the side of the engine. The
starter motor incorporates several features to create a reliable, efficient, compact, lightweight and powerful unit. The
electric motor of the starter features electromagnetic field coils wound around pole shoes, and brushes contact the
motor commutator. The starter motor is serviced only as a unit and cannot be repaired.
Operation
The starter motor is equipped with a planetary gear reduction system. The planetary gear reduction system consists
of a gear that is integral to the output end of the electric motor armature shaft that is in continual engagement with
a larger gear that is splined to the input end of the starter pinion gear shaft. This feature makes it possible to reduce
the dimensions of the starter. At the same time, it allows higher armature rotational speed and delivers increased
torque through the starter pinion gear to the starter ring gear.
Removal & Installation - 1.6L & 1.8L & 2.0L
1. Disconnect the negative battery cable.
2. Disconnect the electrical connector from the starter.
3. Remove the bolts connecting the engine oil dipstick to the cylinder block and intake manifold.
4. Remove the engine oil dipstick.
NOTE :
After removing the engine oil dipstick, you should immediately plug the hole in the cylinder block in order to prevent
any debris from entering the engine. 5. Remove the starter solenoid nut (1) from the starter.
(Tighten: Starter solenoid nut to 10 N·m)
ON-VEHICLE SERVICE
LTSM050002
BESM050004
05
05–9Chery Automobile Co., Ltd.