boot CHERY TIGGO 2009 Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine •Shift cables
QR523 External View
1 - Transaxle Housing Assembly
2 - Bearing Cap Assembly
3 - Stud Bolt
4 - Gear-Shifting Mechanism Assembly5 - Release Fork Dust Boot
6 - Release Fork
7 - Clutch Housing Assembly
8 - Hydraulic Clutch Line Bracket
GENERAL INFORMATION
LTSM080021
08–248Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 1. Disconnect the negative battery cable.
2. Remove the air cleaner housing assembly.
3. Remove the two shift cables (1) from the transaxle.
4. Remove the shift cable clamp (1) from the shiftcable bracket.
5. Raise and support the vehicle.
1 - Backup Lamp Switch Assembly
2 - Limit Stop Screw-Interlocking Plate
3 - Plain Washer-Interlocking Plate Limit Stop Screw
4 - Bearing-Gear Shift Mechanism
5 - Lower Lining - Selector Lever
6 - Selector Lever Assembly
7 - Washer
8 - Bolt
9 - Upper Dust Boot - Selector Lever
10 - Nut
11 - Plain Washer-Gear Selecting Arm Nu
12 - Gear Shifting Arm Assembly
13 - Gear Shifting Drive Slider
14 - Dust Cap-Gear Shifting Shaft Fluid Seal
15 - Lower Dust Cap-Gear Selecting Arm
16 - Lower Bushing-Gear Selecting Arm17 - Gear Selecting Arm Assembly
18 - Upper Bushing-Gear Selecting Arm
19 - Baffle-Rear Neutral Position Return Spring
20 - Rear Neutral Retracting Spring
21 - Reverse Gear Lock Assembly
22 - Reverse Gear Lock Assembly Pin
23 - Selector Finger Pin
24 - Selector Finger
25 - Interlock Plate Assembly
26 - Front Neutral Retracting Spring Assembly
27 - Gearshift Shaft
28 - Retainer-Reverse Gear Lock
29 - Gear Shift Mechanism Housing
30 - Air Duct
31 - Air Duct Cap
32 - Bolt
ON-VEHICLE SERVICE
LTSM080087
BESM080051 VISM080026
08
08–265Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 6. Remove the gearshift knob.
7. Remove the gearshift boot from the lower console.
8. Apply the parking brake (apply parking brake han-dle to clear lower console upon removal).
9. Remove the lower console (See Lower Console Removal & Installation in Section 15 Body & Accessories).
10. Remove the clip on the gearshift mechanism and then remove the crossover cable and the selector
cable (1) from the gearshift mechanism.
11. Remove the four bolts (1) and then remove the gearshift mechanism from the bracket.
ON-VEHICLE SERVICE
VISM080017
VISM080018
BESM080054
BESM080053
08–266Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Assembly
1. Carefully press and fit two gear shift mechanism(1) & (2) bearings to the corresponding position on
the gear shift mechanism housing. The bearing (1)
should be pressed to the end, both end faces of
the bearing should align with the hole end faces of
the housing bearing. The side of the bearing with
letters should be placed outwards.
2. Press the air duct into the housing orifice to ensure the air duct is in the proper position.
3. Press and fit the fluid seal of the gearshift shaft into the fluid seal hole of the housing, ensure the fluid seal is pressed and fitted in position.
NOTE :
Apply transaxle fluid to the fluid lip seal. 4. Install the gearshift shaft through the fluid seal and into the housing of gear shift mechanism.
5. Following the direction of the arrow, install the rear neutral return spring stop, rear neutral return
spring, reverse gear lock assembly, selector finger
and interlock plate assembly, front neutral return
spring assembly onto the gearshift shaft (as shown
in the figure). Check the turn-down rims of rear
neutral return spring stop, and ensure they have
entered into corresponding vent groove of the
housing. One end of main body of reverse gear
lock with blind hole shall face rear neutral return
spring stop. And the small end face of front neutral
return spring assembly shall face towards selector
finger.
6. Insert the gearshift shaft into the bearing.
7. Install the reverse gear limiter lock mechanism (1) (as shown in the figure).
(Tighten: Reverse gear limiter bolt to 22 N·m)
8. Install the gearshift fluid seal dust boot to the gearshift shaft fluid seal.
9. Install the gearshift lever assembly to the gearshift shaft, then press it in the pin hole of gearshift lever assembly, finally install the pin.
NOTE :
Neither end of the pin is allowed to protrude beyond the two end surfaces of the pin holes.
ON-VEHICLE SERVICE
LTSM080138
LTSM080139
LTSM080140
08–268Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine DIAGNOSIS & TESTING
Vehicle Inspection
Inspect the following for leaks or damage:
•Check for grease in the vicinity of the inboard tripod joint and outboard CV joint.
• Check the inner or outer joint seal boot or seal boot clamp for damage.
Noise Or Vibration On Turns
A clicking noise or a vibration in turns could be caused by one of the following conditions:
•Damaged outer CV joint or damaged CV seal boot or seal boot clamps.
• Damaged inner CV joint or damaged CV seal boot or seal boot clamps.
• Noise may also be caused by another component of the vehicle coming in contact with the half shafts.
NOTE :
If the CV seal boot is damaged, this will result in the loss and/or contamination of the joint grease, resulting in inad-
equate lubrication of the joint.
Clunking Noise During Acceleration
This noise may be a result of one of the following conditions:
• A torn seal boot on the inner or outer joint of the half shaft assembly.
• A loose or missing clamp on the inner or outer joint of the half shaft assembly.
• A damaged or worn half shaft CV joint.
Shudder Or Vibration During Acceleration
This problem could be a result of:
•A worn or damaged half shaft inner tripod joint.
• Improper wheel alignment.
Vibration At High Speeds
This problem could be a result of:
•Foreign material (mud, etc.) packed on the backside of the wheel(s).
• Out of balance tires or wheels.
• Improper tire or wheel runout.
09–4Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 7. Remove the bolts (1) connecting the steeringknuckle to the front strut assembly.
CAUTION:
When removing the front axle shaft, do not
subject the constant velocity joint to an exces-
sive angle. Also, be careful not to excessively
extend the slide joint.
8. Remove the front axle shaft from the transaxleusing a suitable tool.
9. Installation is in the reverse order of removal.
Installation Notes:
• Rotate the joint up/down, left/right, and in axial direction, check for any rough movement or significant loose-
ness.
• Check boot for cracks or other damage, and for grease leakage.
• If damaged, disassemble axle shaft to verify damage, and repair or replace as necessary.
ON-VEHICLE SERVICE
LTSM100041
09
09–7Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine DIAGNOSIS & TESTING
Vehicle Inspection
Inspect the rear axle for the following:
•Check the rear axle for loose bearings.
• Check the rear axle hub for any damage or excessive runout.
Shudder Or Vibration During Acceleration
This problem could be a result of:
•A worn or damaged half shaft inner tripod joint (4x4).
• Improper wheel alignment.
Vehicle Inspection
Inspect the following for leaks or damage:
•Check for grease in the vicinity of the inboard tripod joint and outboard CV joint (4x4).
• Check the inner or outer joint seal boot or seal boot clamp for damage (4x4).
Noise Or Vibration On Turns
A clicking noise or a vibration in turns could be caused by one of the following conditions:
•Damaged outer CV joint or damaged CV seal boot or seal boot clamps (4x4).
• Damaged inner CV joint or damaged CV seal boot or seal boot clamps (4x4).
• Noise may also be caused by another component of the vehicle coming in contact with the half shafts (4x4).
NOTE :
If the CV seal boot is damaged, this will result in the loss and/or contamination of the joint grease, resulting in inad-
equate lubrication of the joint.
Clunking Noise During Acceleration
This noise may be a result of one of the following conditions:
• A torn seal boot on the inner or outer joint of the half shaft assembly (4x4).
• A loose or missing clamp on the inner or outer joint of the half shaft assembly (4x4).
• A damaged or worn half shaft CV joint (4x4).
Shudder Or Vibration During Acceleration
This problem could be a result of:
•A worn or damaged half shaft inner tripod joint (4x4).
• Improper wheel alignment.
Vibration At High Speeds
This problem could be a result of:
•Foreign material (mud, etc.) packed on the backside of the wheel(s).
• Out of balance tires or wheels.
• Improper tire or wheel runout.
Visual Inspection For Fluid Leaks (4x4)
This problem could be a result of:
•Where seals are used: There should be no appearance of fluid leakage or abnormal abrasions.
• Where sealant is applied: There should be no appearance of fluid leakage or fluid seepage.
• Where attaching bolts are used, fluid-fill and fluid-draining plugs are used: There should be no appearance of
fluid leakage, fluid seepage or loose bolts.
• The housing: There should be no appearance of fluid leakage or fluid seepage.
09
09–11Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine •Drill a hole to discharge the gas (fluid) in the strut assembly cylinder (Drill a hole in the cylinder body according
to the figure to discharge the gas).
Assembly
1. Replace all necessary parts prior to reassembly:
1. Cushion Pad
2. Dust Boot
3. Cushion Block
4. Upper Spring Seat
5.

Upper Spring Mount
2. Mount the new strut assembly into the fixture.
3. Insert the coil spring

into the spring compressor.
4. Compress the coil spring to a distance of ≤120 mm
between the two clamps.
UNIT REPAIR
LTSM100012
LTSM100016
LTSM100017
LTSM100018
10
10–23Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine ON-VEHICLE SERVICE
Front Wheel Alignment
Front Wheel Alignment Specifications
NOTE :
If the vehicle has been in an accident causing the front axle components to be damaged, the damaged components
must be replaced before performing a front wheel alignment.
FRONT WHEEL ALIGNMENT
FRONT WHEEL ALIGNMENT PREFERRED SETTINGACCEPTABLE RANGE
Camber -51’+9’ to -1°51’
Caster +2°50’+3°30’ to +2°5’
Inclination +11°30’+12°15’ to +10°45’
Toe-Individual 0’+5’ to -5’
Front Axle Toe-In Adjustment
CAUTION:
Do not twist the inner tie rod steering gear boot (bellows) while turning the inner tie rod during
front toe-in adjustment. It may be necessary to remove the clamp where the boot meets the inner
tie rod.
1. Loosen the tie rod adjusting jam nut (1).
(Tighten: Tie rod adjusting jam nut to 35 ± 3 N·m)
2. Grasp the inner tie rod shaft (2) and adjust the tie rod end until the front toe-in is set to the proper
specification.
3. Make sure the inner tie rod steering gear boot is not twisted. If removed, reinstall the clamp where the boot meets the inner tie rod.
4. Remove the alignment equipment.
5. Lower vehicle and jounce the front and rear of the vehicle.
Front Camber Adjustment
NOTE :
The front axle camber can not be adjusted. Replace the relative components if necessary.
BESM100031
10–44Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine ON-VEHICLE SERVICE
Steering Gear - LHD
Removal & Installation
NOTE :
The following special tools are required to perform the repair procedure:
•CH-10002 - Ball Joint Separator
1. Siphon out as much power steering fluid as possible from the reservoir.
WARNING!
Prolonged and repeated contact with power steering fluid will damage skin. If steering fluid is spilled on your
skin, wash it off immediately with water.
2. Remove the wheel mounting nuts and wheel assemblies from both sides of the vehicle. (Tighten: Wheel mounting nuts to 110 N·m)
3. Remove the return hose clamp (1) from the steer- ing liquid reservoir and insert the end of the hose
into a container.
4. Start the engine and turn the steering wheel from lock-to-lock until all power steering fluid has been drained from the system.
5. Stop the engine.
6. Raise and support the vehicle.
1 - Steering Gear Inlet/Outlet Pipe
2 - Dust Boot
3 - Steering Gear Lock Nut4 - Steering Gear Retaining Hole
5 - Clamp
6 - Tie Rod Lock Nut
LTSM110036
LTSM110042
11
11 –21Chery Automobile Co., Ltd.