2009 CHERY TIGGO timing belt

Downloaded from www.Manualslib.com manuals search engine ENGINE
02
CONTENTSpage
1.6L & 1.8L Engine Mechanical ......................................................... 02-1
2.0L Engine Mechanical .............................................................. 02-76
2.4L Engine Mechanical ............................................................. 02-149
1.6L & 1.8L ENGINE MECHANICAL
GENERAL INFORMATION02-3
Description 02-3
Operation 02-3
Specifications 02-3
Special Tools 02-7
Lubrication System 02-10
DIAGNOSIS & TESTING02-13
Engine Performance Diagnostics 02-13
Engine Mechanical Diagnostics 02-14
Cylinder Compression Pressure Test 02-16
Cylinder Head Gasket Test 02-16
ON-VEHICLE SERVICE02-17
Accessory Drive Belt 02-17
Removal & Installation 02-17
Air Cleaner Element 02-18
Removal & Installation 02-18
Air Cleaner Housing 02-18
Removal & Installation 02-18
Cylinder Head Cover 02-19
Removal & Installation 02-19
Camshaft 02-20
Removal & Installation 02-20
Cylinder Head 02-23
Removal & Installation 02-23
Front Crankshaft Oil Seal 02-25
Removal & Installation 02-25 Rear Crankshaft Oil Seal
02-27
Removal & Installation 02-27
Engine Mounts 02-29
Removal & Installation - Left Mount 02-29
Removal & Installation - Right Mount 02-30
Removal & Installation - Front Mount 02-30
Removal & Installation - Rear Mount 02-31
Engine Assembly 02-31
Removal & Installation 02-31
Engine Timing Belt 02-38
Removal & Installation 02-38
Exhaust Manifold 02-41
Removal & Installation 02-41
Intake Manifold 02-43
Removal & Installation 02-43
Idler Pulley 02-45
Removal & Installation 02-45
Oil Filter 02-46
Removal & Installation 02-46
Oil Pan 02-47
Removal & Installation 02-47
Oil Pump 02-48
Removal & Installation 02-48
Oil Strainer 02-49
Removal & Installation 02-49
02
02–1Chery 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 DESCRIPTIONTORQUE (N·m)
Crankshaft Timing Belt Pulley Bolt 1st Step: Tighten the bolt to 130 N·m
2nd Step: Tighten the bolt an additional 65°
Crankshaft Vibration Damper Bolts 25
Cylinder Head Cover Bolts 11
Cylinder Head Bolts 1st Step: Tighten the bolt to 40 ± 5 N·m
2nd Step: Tighten the bolt an additional 90 ± 5° 3rd Step: Tighten the bolt an additional 90 ± 5°
Dipstick Bracket Bolts 11
Drive Plate Bolts (automatic transaxle) 75
Engine Left Mount Bolt 70
Engine Right Mount Bolt 70
Engine Front Mount Bolt 60
Engine Rear Mount Bolt 60
Engine To Transaxle Bolts 80
Exhaust Manifold Nuts 25
Exhaust Manifold Heat Shield Bolts 15
Exhaust Camshaft Timing Belt Pulley Bolt 120
Flywheel Bolts (manual transaxle) 75
Fuel Rail Bracket Bolts 11
Idler Pulley Bolt 40
Intake Camshaft Timing Belt Pulley Bolt 120
Intake Manifold Bolts 10
Intake Manifold Nuts 11
Intake Manifold Bracket Bolts 25
Lower Idler Pulley Bolt 45
Lower Cylinder Block Bolts 23
Oil Filter 25
Oil Pan Bolts 18
Oil Drain Plug 40
Oil Strainer Bolts 18
Oil Pump Bolts 11
(Apply with Loctite 5910 Thread-Locker)
Rear Timing Cover Bolts 7
Timing Belt Upper Cover Bolts 11
Timing Belt Lower Cover Bolts 11
Timing Belt Tensioner Assembly 27
Timing Belt Tensioner Pulley Bolt 30
Throttle Body Bolts 11
Upper Idler Pulley Bolt 45
GENERAL INFORMATION
02–6Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine DIAGNOSIS & TESTING
Engine Performance Diagnostics
CONDITIONPOSSIBLE CAUSE 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 if 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
02–13Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 8. Remove the cylinder head cover bolts (1).(Tighten: Cylinder head cover bolts to 11 N·m)
9. Remove the cylinder head cover (2) from the cyl- inder head.
10. Remove the cylinder head cover gasket (3).
11. Installation is in the reverse order of removal.
NOTE :
Install a new cylinder head cover gasket during
installation.
Camshaft
Removal & Installation
NOTE :
The following special tools are required to perform the repair procedure:
• CH-20002 - Camshaft Seal Installer
• CH-20010 - Camshaft Holder
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. Remove the intake or exhaust camshaft timing belt pulley. (Tighten: Camshaft timing belt pulley bolt to 120 N·m)
ON-VEHICLE SERVICE
LTSM020198
02
02–20Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Cylinder Head
Removal & Installation
NOTE :
Replacement cylinder head comes complete with valves, seals, springs, retainers, keepers, and camshafts.1. Remove engine timing belt (See Engine Timing Belt Removal & Installation in Section 02 Engine).
2. Remove the cylinder head cover (See Cylinder Head Cover Removal & Installation in Section 02 Engine).
3. Remove the camshafts (See Camshaft Removal & Installation in Section 02 Engine).
4. Remove intake manifold (See Intake Manifold Removal & Installation in Section 02 Engine).
5. Remove exhaust manifold (See Exhaust Manifold Removal & Installation in Section 02 Engine).
6. Remove water pipe and thermostat assembly.
1 - Rocker Arms
2 - Hydraulic Tappets
3 - Valve Keepers
4 - Valve Spring Upper Retainers5 - Valve Springs
6 - Valve Oil Seals
7 - Valve Spring Lower Retainers
8 - Valves
ON-VEHICLE SERVICE
LTSM020167
02–23Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine •Install the cylinder head bolts in the order shown.
• Torque the cylinder head bolts in the following three
step sequence:
1st Step: Tighten the bolt to 40±5N·m
2nd Step: Tighten the bolt an additional 90 ±
5°
3rd Step: Tighten the bolt an additional 90 ± 5°
Front Crankshaft Oil Seal
Removal & Installation
NOTE :
The following special tools are required to perform the repair procedure:
• CH-20007 - Front Crankshaft Seal Installer
• CH-20008 - Front Crankshaft Seal Guide
• CH-20019 - Crankshaft Belt Pulley Fixture
1. Remove the accessory drive belt (See Accessory Drive Belt Removal & Installation in Section 02 Engine).
2. Remove the crankshaft vibration damper bolts (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).
ON-VEHICLE SERVICE
LTSM020236
BESM020055
02
02–25Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search 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. Use an appropriate tool and remove the front crankshaft oil seal (1).
CAUTION:
Be careful not to damage the front cover seal
surface while removing the seal.
7. Installation is in the reverse order of removal.
Installation Notes:
• Lubricate the new front seal with engine oil prior to assembly.
• Use the front crankshaft seal installer CH-20008 (1), to install the new seal.
ON-VEHICLE SERVICE
LTSM020199
LTSM020216
02–26Chery Automobile Co., Ltd.