CHERY TIGGO 2009 Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine Special Tools
Flywheel Fixture09924 - 17810
Bearing Extractor 09917 - 58010
Input Shaft Bearing Mounting Device 09925 -98210
Clutch Pressure Plate InstallerCH-20014
GENERAL INFORMATION
08–318Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine CLUTCH ASSEMBLY SERVICE
Clutch and Pressure Plate
Removal & Installation
1. Remove the transaxle assembly (See Transaxle Assembly Removal & Installation in Section 08 Transaxle).
2. Remove the clutch pressure plate bolts (1).(Tighten: Clutch pressure plate bolts to 25 N·m)
3. Remove the modular clutch assembly.
4. Using special tool CH-20043 (1), hold the flywheel.
5. Remove the flywheel-to-crankshaft bolts (1) and remove flywheel assembly (if necessary for resur-
facing).
(Tighten: Flywheel-to-crankshaft bolts to 75 N·m)
BESM080046
LTSM080145
BESM020058
08
08–319Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 6. Remove the input shaft bearing using special tool09917-58010 (1) and spanner, as shown in the
figure.
Inspect
• Check the input shaft bearing to ensure it is able to rotate freely, replace the bearing if necessary.
• Measure the depth of the recesses of the clutch friction lining rivet head, i.e., the distance between rivet head
and friction lining surface (as shown in the figure).
If the depth of any hole comes to the limit, replace
friction lining assembly.
Standard: 1.2 mm
Limit: 0.5 mm
• Check clutch pressure plate diaphragm spring for irregular wear or damage.
• Check clutch pressure plate for wear or hot spots.
• If found abnormal, replace the clutch plate assembly. Never separate the clutch plate assembly into the dia-
phragm spring and clutch plate.
• Check the contact surface of the flywheel and friction lining for irregular wear or hot spots. Repair or replace if
necessary.
Installation
• Prior to assembling, check the flywheel surface and clutch plate surface to ensure they are clean and dry.
• Using special tools CH-30028 (1), install the input shaft bearing to the crankshaft (as shown in the figure). Align
the clutch friction lining assembly and flywheel cen-
ter using special tools (as shown in the figure), and
then install the clutch plate assembly and bolts,
Tighten the bolts to the specified torque. (Tighten:
Clutch pressure plate bolts to 25 N·m)
CLUTCH ASSEMBLY SERVICE
LTSM080146
LTSM080147
LTSM080148
08–320Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine NOTE :
When tightening the clutch pressure plate bolts (1),
tighten by hand until the friction lining assembly is prop-
erly aligned.
•Apply a thin layer of grease to the input shaft, and then assemble the transaxle and engine.
NOTE: Turn the splines when installing the transaxle input shaft into the clutch friction lining assembly until the
splines are engaged.
Clutch Pedal Height
Adjust the clutch pedal height using the adjusting bolts
(1) on the pedal bracket (3) in accordance with the fol-
lowing requirements. When the clutch pedal (4) is
approximately 8 mm higher than the brake pedal (5),
the clutch pedal height is normal.
Clutch Pedal Free Travel
Depress the clutch pedal (1) until the clutch resistance
can be felt. Stop accordingly and measure the distance
(clutch pedal free travel A). The free travel should be
within 15 - 25 mm.
After checking clutch pedal free travel, check the clutch
to ensure it is in normal working condition while the
engine is running.
CLUTCH ASSEMBLY SERVICE
LTSM080149
LTSM080150
LTSM080151
08
08–321Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Clutch Master Cylinder
Description
The clutch master cylinder mounts to the clutch pedal
and consists of a piston and cylinder housing, an actu-
ating push rod, and an interconnecting hydraulic line.
Fluid is supplied to the clutch master cylinder via the
brake fluid reservoir.
Operation
When the clutch pedal is depressed, the push rod moves the piston in the master cylinder, displacing fluid through
the hydraulic line and into the release bearing. The release bearing is extended and forces the fingers of the clutch
diaphragm springs to move. As the fingers move, they release the clamping pressure on the clutch disc between the
clutch pressure plate and the flywheel. The clutch becomes disengaged as this pressure is released. When the clutch
pedal is released, the system hydraulic pressure is released. This allows the force of the clutch diaphragm springs to
return themselves to their original position, re-clamping the clutch disc between the flywheel and the clutch pressure
plate. Also, the release bearing is forced to return, which reverses the movement of the hydraulic system and returns
the pedal to its original position against the up stop.
Removal & Installation
1. Disconnect hydraulic supply line to clutch mastercylinder (1) to completely drain clutch master cylin-
der and tubing.
2. Disconnect hydraulic line (1) and drain fluid into suitable container.
CLUTCH ASSEMBLY SERVICE
LTSM080196
LTSM080197
LTSM080191
08–322Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 3. Remove instrument panel lower trim panel (1) (SeeInstrument Panel Removal & Installation in Section
15 Body & Accessories).
4. Disconnect clutch master cylinder push-rod (1) from clutch pedal.
5. Remove hydraulic line from rail retainer.
6. Release master cylinder by rotating to disengage from pedal bracket assembly.
CAUTION:
Use care when removing clutch master cylinder from engine compartment. Aggressive handling
can result in a damaged hydraulic line and improper clutch release operation upon reassembly.
CAUTION:
Brake fluid will damage painted surfaces. If brake fluid is spilled on any painted surfaces, wash it
off immediately with water.
7. Remove the master cylinder assembly (1) from the mounting position and carefully maneuver the
hydraulic pipe from the engine compartment.
8. Installation is in the reverse order of removal.
CLUTCH ASSEMBLY SERVICE
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VISM080021
LTSM080197
08
08–323Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Clutch Slave Cylinder
Removal & Installation
NOTE :
After replacing the slave cylinder, it is necessary to make sure brake master cylinder fluid level is full and the res-
ervoir cap is installed tightly.1. Remove the clutch master cylinder outlet pipe (1) from the clutch slave cylinder.
(Tighten: Outlet pipe bolt to 17 ± 1 N·m)
2. Remove the clutch slave cylinder bolts (1) from the transaxle housing.
(Tighten: Clutch slave cylinder bolts to 11 ± 1 N·m)
3. Installation is in the reverse order of removal.
4. Bleed the hydraulic clutch (See Bleeding Hydraulic Clutch in Section 08 Transaxle). NOTE: Check pipes for leakage of brake fluid.
CLUTCH ASSEMBLY SERVICE
LTSM080191
LTSM080143
08–324Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Bleeding Hydraulic Clutch
Operation
1. Verify fluid level in brake master cylinder. Top offwith DOT 4 brake fluid as necessary. Leave cap
off.
2. Raise the vehicle on hoist.
3. Remove the bleed port protective cap and install a suitable size and length of clear hose to monitor and divert fluid into a suitable container.
4. Loosen the bleed port (1).
5. Actuate the clutch pedal until the brake master cylinder fluid drains from the bleed port.
6. Depress the clutch pedal, tighten the bleed port.
7. From driver’s seat, actuate the clutch pedal until the hydraulic clutch system has pressure.
8. Depress the clutch pedal, loosen the bleed port and bleed the brake master cylinder fluid.
9. Repeat steps 6 to 8 several times until there is no air in the hydraulic clutch system.
NOTE :
Do not allow clutch master cylinder to run dry while fluid exits bleed port.
10. Close the hydraulic bleed port, remove the drain hose and replace the dust cap on the bleed port.
11. Top off the brake master cylinder fluid level with DOT 4 brake fluid as necessary.
CAUTION:
During the bleeding process, make sure the brake master cylinder fluid is always full.
CLUTCH ASSEMBLY SERVICE
LTSM080195
LTSM020210
08
08–325Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine TRANSFER CASE (4X4)
GENERAL INFORMATION08-327
Description 08-327
Operation 08-327
ON-VEHICLE SERVICE08-328
Transfer Case 08-328
Removal & Installation 08-328
TRANSFER CASE UNIT REPAIR08-329
Transfer Case 08-329
Disassembly 08-329
Assembly 08-331
08–326Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION
Description
Transfer case is attached to the transaxle housing.
Operation
The transfer case transfers the torque output from the transaxle to the ITM controller.
1 - Transaxle Housing
2 - Rear Transaxle Cover3 - Axle Shaft Guide
4 - Front Different Housing
LTSM160007
08
08–327Chery Automobile Co., Ltd.