CHERY TIGGO 2009 Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine 8. Remove the power steering pump inlet hose clamp(1), and then remove the pump inlet hose.
9. Remove the pump outlet pipe bolt (2).
10. Rotate the steering pump pulley until the bolt (1) access hole lines up with the bolt.
11. Remove the power steering pump retaining bolt. (Tighten: Power steering pump bolt to 20 - 30 N·m)
12. Remove the two bolts (1) on the other side of the power steering pump.
(Tighten: Power steering pump bolts to 20 - 30
N·m)
13. Remove the steering pump from the engine bracket.
14. Installation is in the reverse order of removal.
Installation Notes:
• Fill the power steering reservoir to the proper level.
• Check the system for leaks.
Power Steering Fluid Reservoir
Removal & Installation
1. Siphon as much steering fluid as possible from the power steering fluid reservoir.
ON-VEHICLE SERVICE
LTSM110032
LTSM110009
LTSM110010
11 –36Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 2. Remove the hose clamps (1) securing the returnhose and the supply hose to the steering fluid res-
ervoir fitting.
3. Slide the hose off the end of the reservoir fitting and remove the steering fluid reservoir.
4. Installation is in the reverse order of removal.
Installation Notes:
• Fill the power steering reservoir to the proper level.
• Check the system for leaks.
Power Steering Pressure and Return Lines - 1.6L & 1.8L & 2.0L
Removal & Installation
1. Siphon as much steering fluid as possible from the power steering fluid reservoir.
2. Remove the engine cover.
3. Remove the hose clamps securing the return hose and the supply hose to the steering fluid reservoir fitting.
4. Remove the high pressure (1) and low pressure
lines (2) from the power steering pump (drain
steering fluid from lines).
(Tighten: High pressure line to power steering
pump 40 - 50 N·m)
(Tighten: Low pressure line to power steering pump
40 - 50 N·m)
ON-VEHICLE SERVICE
LTSM110038
LTSM110039
BESM110011
11
11 –37Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 5. Remove the high pressure and low pressure lines(1) from the steering gear (drain steering fluid from
lines).
(Tighten: High pressure line to power steering
pump 27 - 33 N·m)
(Tighten: Low pressure line to power steering pump
27 - 33 N·m)
6. Remove the power steering line clamp bracket bolt (1) from the pressure and return lines.
(Tighten: Power steering line clamp bracket bolt to
10 N·m)
7. Remove the pressure and return lines.
8. Installation is in the reverse order of removal.
Installation Notes:
• Fill the power steering reservoir to the proper level.
• Check the system for leaks.
ON-VEHICLE SERVICE
LTSM110007
BESM110013
11 –38Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Power Steering Pressure and Return Lines - 2.4L
Removal & Installation
1. Siphon as much steering fluid as possible from the power steering fluid reservoir.
2. Remove the hose clamps (1) securing the returnhose and the supply hose to the steering fluid res-
ervoir fitting.
3. Remove the pressure and return hoses.
4. Disconnect the power steering switch electrical connector.
5. Remove the bolt (2) from the pressure line and remove the clamp (1) from the return hose.
ON-VEHICLE SERVICE
LTSM110038
LTSM110032
11
11 –39Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 6. Remove the high pressure and low pressure lines(1) from the steering gear.
(Tighten: High pressure line to steering gear
27 - 33 N·m)
(Tighten: Low pressure line to steering gear
27 - 33 N·m)
7. Installation is in the reverse order of removal.
Installation Notes:
• Fill the power steering reservoir to the proper level.
• Check the system for leaks.
ON-VEHICLE SERVICE
LTSM110007
11 –40Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine BRAKES
12
CONTENTSpage
Base Brakes ........................................................................\
. 12-1
Antilock Brakes ..................................................................... 12-34
Parking Brake ...................................................................... 12-79
BASE BRAKES
GENERAL INFORMATION12-2
Description 12-2
Operation 12-3
Specifications 12-4
Special Tools 12-5
Electrical Schematics 12-6
DIAGNOSIS & TESTING12-7
Diagnostic Help 12-7
Brake Noise 12-7
Braking Concerns 12-8
ON-VEHICLE SERVICE12-9
Brake Bleeding 12-9
Brake Bleeding Information 12-9
Brake Bleeding Procedure 12-9
Manual Brake Bleeding 12-9
Pressure Brake Bleeding 12-10
Master Cylinder - LHD 12-11
Description 12-11
Operation 12-11
Removal & Installation 12-11
Master Cylinder - RHD 12-12
Description 12-12
Operation 12-13
Removal & Installation 12-13
Power Brake Booster - LHD 12-14
Description 12-14
Operation 12-14
Removal & Installation 12-14
Power Brake Booster - RHD 12-16
Description 12-16
Operation 12-16
Removal & Installation 12-16Front Brake Caliper
12-18
Description 12-18
Operation 12-18
Removal & Installation 12-19
Rear Brake Caliper 12-19
Description 12-19
Operation 12-20
Removal & Installation 12-20
Front Brake Rotor 12-21
Removal & Installation 12-21
Inspection 12-21
Rear Brake Rotor 12-22
Removal & Installation 12-22
Inspection 12-22
Rear Brake Backing Plate 12-23
Removal & Installation 12-23
Front Brake Pads 12-24
Removal & Installation 12-24
Inspection 12-25
Rear Brake Pads 12-25
Removal & Installation 12-25
Inspection 12-26
UNIT REPAIR12-27
Front Brake Caliper 12-27
Disassemble 12-27
Inspection 12-28
Assemble 12-28
Rear Brake Caliper 12-30
Disassemble 12-30
Inspection 12-31
Assemble 12-32
12
12–1Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION
Description
Base Brakes
The base brake system consists of the following components:
•Brake pedal
• Power brake booster
• Master cylinder
• Brake tubes and hoses
• Disc brakes (front)
• Disc brakes (rear)
• Parking brake
• Parking brake shoes (rear)
Front Disc Brake
The front disc brake assembly consists of the following major components:
•Caliper
• Caliper adapter bracket
• Brake pads
• Rotor
1 - Front Wheel Knuckle
2 - Knuckle Hub Bearing
3 - Front Wheel Hub Assembly
4 - Dust Shield5 - Front Brake Rotor
6 - Brake Caliper Assembly
7 - Disc Brake Caliper and Rotor Assembly
LTSM120001
12–2Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Rear Disc Brake
The rear disc brake assembly consists of the following major components:
•Caliper
• Caliper adapter bracket
• Brake pads
• Rotor
• Parking brake shoes
CAUTION:
•Use DOT 4 brake fluid or equivalent from a tightly sealed container. Do not use petroleum-based
fluids, which will cause seal damage in the brake system.
• Brake fluid will damage painted surfaces. If brake fluid is spilled on any painted surfaces, wash
it off immediately with water.
• Never use gasoline, kerosene, alcohol, motor oil, transmission fluid, or any fluid containing min-
eral oil to clean system components. These fluids damage rubber cups and seals.
• During service procedures, grease or any other foreign material must be kept off the caliper
assembly, brake pads, brake rotor and external surfaces of the hub.
• When handling the brake rotor and caliper, be careful to avoid damaging the brake rotor and
caliper, and scratching or nicking the brake shoe lining.
Operation
Applying the brake pedal uses lever action to push a rod into the brake booster, which through the use of vacuum,
boosts the force of the rod and then transmits this force into the master cylinder. This produces hydraulic pressure in
the master cylinder. On vehicles not equipped with ABS, the hydraulic pressure is transmitted by brake fluid through
the brake tubes to the individual brake calipers or wheel cylinders. On vehicles equipped with ABS, the hydraulic
pressure is transmitted by brake fluid through the brake tubes to the ABS hydraulic control unit (HCU), which then
distributes that pressure to the individual brake calipers and wheel cylinders. The brake calipers use hydraulic pres-
sure to apply the brake pads. The application of the brake pads or shoes will cause the rotation of the wheels to slow
or stop depending on how much brake pressure is applied. The parking brakes carry out the same function except
that they are mechanically actuated by a cable that connects only to the rear brakes.
1 - Rear Hub Mounting Assembly
2 - Rear Brake Assembly
3 - Lock Nut
4 - Rear Wheel Hub Bearing Unit5 - Rear Brake Rotor
6 - Caliper Bolts
7 - Brake Caliper Assembly
7 - Disc Brake Caliper and Rotor Assembly
GENERAL INFORMATION
LTSM120002
12
12–3Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Specifications
Torque Specifications
DESCRIPTIONTORQUE (N·m)
Dust Shield Bolts 6.5 - 8.5
Locating Screws (Brake Rotor) 6 - 12
Brake Flex Hose Fitting - Front Caliper 19
Brake Flex Hose Banjo Bolt - Rear Caliper 20
Brake Pedal/Booster Mounting Nuts 25
Brake Tube Nuts 10
Disc Brake Caliper Adapter Bracket (To Knuckle) - Front 63
Disc Brake Caliper Adapter Bracket (To Support) - Rear 63
Disc Brake Caliper Guide Pin Bolts - Front 31 - 38
Disc Brake Caliper Guide Pin Bolts - Rear 23
Disc Brake Caliper Bleeder Screw 9 - 11
Fluid Reservoir Mounting Screw 11
Master Cylinder Mounting Nuts 23
Parking Brake Lever Mounting Nuts 6 - 12
Rear Brake Backing Plate Bolts 20
Wheel Mounting Nuts 110
Rotor Specifications
BRAKE ROTORROTOR
THICKNESS MINIMUM ROTOR
THICKNESS ROTOR DIAMETER ROTOR RUNOUT
Front Rotor 25 mm23 mm265 mm 0.1 mm
Rear Rotor 9 mm7 mm303 mm 0.1 mm
Brake Pad/Lining Specifications
Front Brake
APPLICATION SPECIFICATION (mm)
Brake Caliper Piston Diameter 57
Brake Rotor Diameter 265
Brake Rotor Thickness (New) 25
Min. Thickness Of Brake Rotor 23
Maximum Rotor Runout 0.1
Front Brake Pad Thickness (New) 17.8
Min. Thickness Of Front Brake Pad 7
GENERAL INFORMATION
12–4Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Rear Brake
APPLICATIONSPECIFICATION (mm)
Brake Rotor Diameter 303
Brake Rotor Thickness (New) 9
Min. Thickness Of Brake Rotor 7
Rear Brake Pad Thickness (New) 15
Min. Thickness Of Rear Brake Pad 7
Thickness Of Parking Brake Lining 2.5
Min. Thickness Of Parking Brake Lining 1.5
Special Tools
Dial Indicator
Digital Multimeter
Fluke 15B & 17B
GENERAL INFORMATION
12
12–5Chery Automobile Co., Ltd.