2009 CHERY TIGGO gas type

Downloaded from www.Manualslib.com manuals search engine Hose Clamps
•When reinstalling, position the hose clamp in the
original location on the hose and squeeze the
clamp lightly with large pliers to ensure a good fit.
Vise
•When using a vise, put protective plates in the
jaws of the vise to prevent damage to parts.
Dynamometer
•When test-running a vehicle on a dynamometer:
Place a fan, preferably a vehicle-speed proportional type, in front of the vehicle.
Connect an exhaust gas ventilation unit.
WARNING!
Exhaust gases can injure or kill. They contain carbon monoxide (CO), which is colorless and odorless. Breathing
it can make you unconscious and can eventually poison you.
Cool the exhaust pipes with a fan.
Keep the area around the vehicle uncluttered.
Monitor the engine coolant temperature gauge.
PROPER SERVICE PRACTICES
BESM010016
BESM010017
01–8Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine VIN Identification Codes
The vehicle identification number (VIN) is a 17-digit combination of letters and numbers.
VIN DIGIT DESIGNATIONDEFINITION
1 World Manufacture Identifier
2 Brand Of The Vehicle
3 Vehicle Chassis Type
4 Transmission Type
5 Engine Type
6 Restraint System
7 Check Digit
8 Model Year
9 Assembly Plant
10 Production Sequence Number
• Digits #1, #2, #3 The first 3 vehicle identification number (VIN) positions are the world manufacturer identifier:
LV V represents Chery Automobile Co., Ltd.
• Digit #4 The fourth digit of the VIN code represents the brand of the vehicle:
The brand Cheryis represented by the letter D.
• Digit #5 The fifth digit of the VIN code represents the body configuration of the vehicle:
A represents three compartments, five-door, and 4X2.
B represents two compartments, five-door, and 4X2.
C represents three compartments, four-door, two-lid, and 4X2.
D represents two compartments, five-door, and 4X4.
• Digit #6 The sixth digit of the VIN code represents the type of transmission:
1 represents manual transmission.
2 represents automatic transmission.
• Digit #7 The seventh digit of the VIN code represents the type of engine:
1 represents electronically controlled gasoline engines 1.5L - 2.0L (excluding 2.0L) series.
2 represents engines smaller than 1.5L (excluding 1.5L).
4 represents 2.0L - 2.5L engines (excluding 2.5L).
VEHICLE IDENTIFICATION NUMBER (VIN)
PZSM020054
01
01–11Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION
Description
The 1.6L & 1.8L in-line four cylinder engines have the following features:
•Dual overhead camshafts
• Four valves per cylinder
• Aluminum cylinder head
• Cast iron cylinder block (1.8L Engine)
• Aluminum cylinder block (1.6L Engine)
Operation
The 1.6L & 1.8L engines utilize 4 valve-per-cylinder and a dual overhead camshaft design. The engines use an indi-
vidual coil ignition system. The 1.6L engine uses an aluminum cylinder block, and the 1.8L engine is made of cast
iron. The bearing caps are integrated into the lower cylinder block assembly. An aluminum oil pan bolts to the bottom
of the lower cylinder block. The camshafts are mounted in the cylinder head and act against valve tappets to open
and close the valves. The camshafts are driven off the front of the cylinder head by one 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 con-
necting rod.
The aluminum cylinder head contains dual overhead camshafts with 4 valve-per-cylinder construction. The valves are
arranged in two in-line banks. The cylinder head incorporates powdered metal valve guides and seats. The cylinder
head is sealed to the block using a multi-layer steel head gasket and retaining bolts.
Specifications
1.6L Engine Specifications
DESCRIPTION SPECIFICATION
Type In-Line OHV, DOHC
Number of Cylinders 4
Compression Ratio 10.5:1
Compression Pressure 10 - 15 bar
Max. Compression Pressure Variation Between
Cylinders 25%
Stroke 77.5 mm
Bore 81 mm
Displacement 1597 cc
Firing Order 1-3-4-2
1.8L Engine Specifications
DESCRIPTIONSPECIFICATION
Type In-Line OHV, DOHC
Number of Cylinders 4
Compression Ratio 10.5:1
Compression Pressure 10 - 15 bar
Max. Compression Pressure Variation Between
Cylinders 25%
Stroke 89.5 mm
Bore 81 mm
Displacement 1845 cc
Firing Order 1-3-4-2
02
02–3Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION
Description
The 2.0L in-line four cylinder engine has the following features:
•Dual overhead camshafts
• Four valves per cylinder
• Aluminum cylinder head
• Aluminum cylinder block
Operation
The 2.0L engine utilizes 4 valve-per-cylinders and a dual overhead camshaft design. The engine uses an individual
coil ignition system. The cylinder block is made of aluminum and the bearing caps are integrated into the lower cyl-
inder block assembly. An aluminum oil pan bolts to the bottom of the lower cylinder block. The camshafts are
mounted in the cylinder head and act against valve tappets to open and close the valves. The camshafts are driven
off the front of the cylinder head by one 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 dual overhead camshafts with 4 valve-per-cylinder construction. The valves are
arranged in two in-line banks. The cylinder head incorporates powdered metal valve guides and seats. The cylinder
head is sealed to the block using a multi-layer steel head gasket and retaining bolts.
Specifications
2.0L Engine Specifications
DESCRIPTION SPECIFICATION
Type In-Line OHV, DOHC
Number of Cylinders 4
Compression Ratio 10:1
Compression Pressure 10 - 15 bar
Max. Compression Pressure Variation Between
Cylinders 25%
Stroke 90 mm
Bore 83.5 mm
Displacement 1971 cc
Firing Order 1-3-4-2
Mechanical Specifications
DESCRIPTIONITEMSTANDARD LIMIT
Engine Oil Pressure Lower Idle Speed (800 ±
50 RPM) 1.2 - 1.5 bar
-
High Idle Speed (2000 RPM) 3.2 - 3.5 bar
-
High Speed (4000 RPM) 3.7 ± 0.5 bar -
Engine Block Clearance Surface Distortion
-0.15 mm
Inner Diameter 83.500 - 83.510 mm -
Out-Of-Round -< 0.008 mm
Taper -< 0.01 mm
Piston Ring Groove
Clearance First Ring
0.04 - 0.08 mm -
Second Ring 0.0251 - 0.01 mm -
02
02–77Chery 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 Removal & Installation - 2.4L
WARNING!
Always allow the engine to cool before opening the cooling system. Do not remove 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.
1. Drain the cooling system (See Cooling System Draining Procedure in Section 06 Cooling System).
2. Remove the accessory drive belt (See Accessory Drive Belt Removal & Installation in Section 02 Engine).
3. Remove the engine timing belt (See Engine Timing Belt Removal & Installation in Section 02 Engine).
4. Remove the upper balance shaft timing belt (See Upper Balance Shaft Timing Belt Removal & Installation inSection 02 Engine).
5. Remove the coolant pump mounting bolts (1). (Tighten: Coolant pump mounting bolts to 14 N·m)
6. Remove the coolant pump and gasket.
7. Installation is in the reverse order of removal.
Installation Notes:
• Install a new coolant pump gasket during installation.
• Verify the cooling system is filled to proper specifications.
Coolant Pump Inspection
Check coolant seal of the coolant pump for coolant leak. If coolant pump bearing is loose, replace the assembly.
Radiator
Description
The radiator is a cross-flow type (horizontal tubes) with design features that provide greater strength, as well as
sufficient heat transfer capabilities to keep the engine coolant within operating temperatures.
Operation
The radiator functions as a heat exchanger, using air flow across the exterior of the radiator tubes. Heat from the
coolant is then transferred from the radiator into the moving air.
Removal & Installation
WARNING!
Always allow the engine to cool before opening the cooling system. Do not remove 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.
ON-VEHICLE SERVICE
LTSM060003
06
06–17Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Front Strut Assembly
Description
A MacPherson type strut assembly is used in place of the traditional front suspension upper control arm and upper
ball joint. The bottom of the strut mounts directly to the steering knuckle using two attaching bolts and nuts going
through the strut clevis bracket and steering knuckle. The top of the strut mounts directly to the strut tower of the
vehicle using the three threaded studs on the strut assembly’s upper mount.
1 - Strut Cover
2 - Nut
3 - Upper Strut Mount
4 - Bearing Gasket
5 - Spring Upper Tray6 - Dust Cover
7 - Cushion Block
8 - Shock Absorber Assembly
9 - Lower Rubber Ring
10 - Coil Spring
ON-VEHICLE SERVICE
LTSM100009
10
10–13Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Front Brake Caliper
Description
The calipers are a single piston type. The calipers are free to slide laterally on the anchor, this allows continuous
compensation for lining wear. The calipers are directly bolted to the wheel hub with mounting bolts. The brake rotor
dust shield is mounted to the hub.
Operation
When the brakes are applied, fluid pressure is exerted against the caliper piston. The fluid pressure is exerted
equally and in all directions. This means pressure exerted against the caliper piston and within the caliper bores will
be equal. Fluid pressure applied to the pistons is transmitted directly to the inboard brake pad. This forces the pad
1 - Locating Guide Rod 5 - Lining Damper
2 - Dust Cap 6 - Brake Caliper Bracket
3 - Brake Gasket7 - Brake Caliper Body
Connecting Bolt
4 - Brake Lining Assembly 8 - Bleeding Screw9 - Dust Cover 12 - Piston
10 - Brake Caliper 13 - Piston Seal
11 - Piston Dust Cap 14 - Brake Caliper Bracket
Bolt
ON-VEHICLE SERVICE
LTSM120007
12–18Chery Automobile Co., Ltd.