tow CHERY TIGGO 2009 Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine 5. Remove the rear oil seal using a suitable tool.
6. Installation is in the reverse order of removal.
Installation Notes:
• When installing seal, lubricate seal guide with clean
engine oil.
• Position the seal over the rear crankshaft seal
guide.
• Use special tool CH-20005 (2) CH-20006 (1), to
install the rear crankshaft oil seal.
• Ensure that the lip of the seal is facing toward the
crankcase during installation.
ON-VEHICLE SERVICE
LTSM020217
02–28Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Installation Notes:
•When installing seal, lubricate seal guide with clean
engine oil.
• Position the seal over the rear crankshaft seal
guide.
• Use special tool CH-20005 (2) and CH-20006 (1),
to install the rear crankshaft oil seal.
• Ensure that the lip of the seal is facing toward the
crankcase during installation.
ON-VEHICLE SERVICE
LTSM020217
02
02–102Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine •Use special tool MD-998776 (2) and MD-990938 (1), to install the rear oil seal.
• Ensure that the lip of the seal is facing toward the
crankcase during installation.
Engine Mounts
Removal & Installation - Left Mount
NOTE :
The following special tools are required to perform the repair procedure:
•Engine Hoist
1. Disconnect the negative battery cable.
2. Remove the air cleaner housing. (See Air Cleaner Housing Removal & Installation in Section 02
Engine).
3. Support the engine with the engine hoist.
4. Remove the engine left mount retaining bolts (2) and remove the engine left mount bracket bolts (1).
(Tighten: Engine left mount bolts to 70 N·m)
5. Installation is in the reverse order of removal.
ON-VEHICLE SERVICE
LTSM020132
LTSM020156
02
02–181Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine •Using a press, press the piston pin (1) in under pressure. When the pressure is less than standard value,
replace piston pin and piston component and/or
replace connecting rod.standard value: 7,350-
17,200 Newtons
• Check to make sure the piston can rotate freely.
Piston Ring Installation
NOTE :
The compression rings have an identification mark (1)
on the top of the ring.
Piston Ring Identification Marks:
•No. 1 Ring - 1R
• No. 2 Ring - 2R
When installing piston ring, keep the mark upwards and
towards the top of piston.
• Size markings of pistons shown as the following:
SIZE IDENTIFICATION
Standard None
Increase 0.50 mm 50
Increase 1.00 mm 100
CAUTION:
Do not use a piston ring expander to install the oil control rings.
Oil Control Ring Installation
•Install the main ring of oil control ring into oil ring groove.
NOTE :
There is no difference between the upper and lower oil control rings.
ENGINE UNIT REPAIR
LTSM020113
LTSM020116
02
02–227Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine CONNECTING ROD BEARING OIL CLEARANCE
Standard Clearance 0.02 - 0.05 mm
Maximum Clearance 0.1 mm
Assembly
NOTE :
•The connecting rod bolts should NOT be reused.
• Before installing the NEW rod bolts, apply clean engine oil to the threads and under the bolt heads.
Piston and Connecting Rod
•Oil the piston rings and the side of the piston.
• Position the piston rings in the proper alignment
with the piston pin (2):
Top Ring (1)
Bottom Ring (3)
Oil Control Ring (4)
• Install protective coverings over the connecting rod
bolts.
• Rotate the crankshaft journal to the lowest position.
• Use a suitable piston ring compressor to insert the
piston and connecting rod assembly into cylinder.
• Make sure the forward mark on the top of the pis-
ton is facing the front of the engine (5).
• Using a suitable tool, tap the piston and connecting rod assembly into cylinder.
NOTE :
The piston direction mark (2) should point toward the
timing belt side (1).
• Check the axial clearance of the connecting rods.
ENGINE UNIT REPAIR
LTSM020117
LTSM020118
BESM020064
02
02–231Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine •Main bearing and thrust bearing installation.
Install the main bearings with oil grooves on
the cylinder block side.
Install the main bearings without oil grooves (2) on the bearing cap.
Install the two thrust bearings on crankshaft journal No. 3. Apply clean oil to the surface of
thrust bearing.
The grooved (1) side of the thrust bearing should face towards the crankshaft.
Main Bearing Caps and Bolts
• Install the main bearing caps with the arrow on the main caps (1) facing the front of the engine.
• Install the main bearing cap bolts in the sequence
shown.
• Torque the bearing cap bolts in the sequence
shown to 25 N·m.
• Tighten the main bearing cap bolts an additional 90°- 100° in the sequence shown.
CAUTION:
If the bolts are over tightened (exceed angle of
100°), loosen the bolts and restart the torque
sequence from Step 1
•After installing the main bearing caps, assure that the crankshaft rotates smoothly.
ENGINE UNIT REPAIR
LTSM020128
LTSM020129
LTSM020130
02
02–239Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine DIAGNOSIS & TESTING
Fuel Pressure Test
WARNING!
Fuel in the fuel system remains under high pressure, even when the engine is not running. Before servicing or
disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to
prevent accidental spraying of fuel (See Fuel Pressure Relief Procedure in Section 04 Fuel Delivery). Failure to
follow these instructions may result in serious personal injury or death.
Perform the following procedure to test for proper fuel pressure.
WARNING!
Wrap towels around hoses to catch any gasoline spillage.
1. Remove the protective cap and connect the fuel pressure gauge (2) to the fuel rail service test port pressurefitting (1) on the fuel rail (3).
2. Start and warm the engine and note the pressure gauge reading:
1.6L & 1.8L & 2.0L
• Fuel pressure at idle: 400-420 kPa (4.0 - 4.2 bar)
BESM030020
04–12Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Operation
The following are the details of the manual transaxle:
Neutral
Engine power is transmitted to the input shaft via the clutch assembly and the input shaft turns. Since no synchro-
nizers are engaged on either the input or output shafts, power is not transmitted to the output shafts, power is not
transmitted to the output shaft and the differential does not turn.
1st Gear
Engine power is transmitted to the input shaft via the clutch assembly and the input shaft turns. The input shaft first
gear is integral to the input shaft, and is in constant mesh with the intermediate shaft first speed gear. Because of
this constant mesh, the output shaft first speed gear freewheels until first gear is selected. As the gearshift lever is
moved to the first gear position, the 1-2 fork moves the 1-2 synchronizer sleeve towards first gear on the output
shaft. The synchronizer sleeve engages the first gear clutch teeth, engaging the gear to the output shaft, and allow-
ing power to transmit through the output shaft to the differential.
2nd Gear
Engine power is transmitted to the input shaft via the clutch assembly and the input shaft turns. The input shaft
second gear is integral to the input shaft, and is in constant mesh with the output shaft second speed gear. Because
of this constant mesh, the output shaft second speed gear freewheels until second gear is selected. As the gearshift
lever is moved to the second gear position, the 1-2 fork moves the 1-2 synchronizer sleeve towards second gear on
the output shaft. The synchronizer sleeve engages the second gear clutch teeth, engaging the gear to the output
shaft, and allowing power to transmit through the output shaft to the differential.
3rd Gear
Engine power is transmitted to the input shaft via the clutch assembly and the input shaft turns. The input shaft third
speed gear is in constant mesh with the output shaft 3-4 cluster gear which is fixed to the output shaft. Because of
this constant mesh, the input shaft third speed gear freewheels until third gear is selected. As the gearshift lever is
moved to the third gear position, the 3-4 fork moves the 3-4 synchronizer sleeve towards third gear on the input
shaft. The synchronizer sleeve engages the third gear clutch teeth, engaging the gear to the input shaft, and allowing
power to transmit through the output shaft to the differential.
4th Gear
Engine power is transmitted to the input shaft via the clutch assembly and the input shaft turns. The input shaft fourth
speed gear is in constant mesh with the output shaft 3-4 cluster gear which is fixed to the output shaft. Because of
this constant mesh, the input shaft fourth speed gear freewheels until fourth gear is selected. As the gearshift lever
is moved to the fourth gear position, the 3-4 fork moves the 3-4 synchronizer sleeve towards fourth gear on the input
shaft. The synchronizer sleeve engages the fourth gear clutch teeth, engaging the gear to the input shaft, and allow-
ing power to transmit through the output shaft to the differential.
5th Gear
Engine power is transmitted to the input shaft via the clutch assembly and the input shaft turns. The input shaft fifth
speed gear is pressed on to the input shaft, and is in constant mesh with the output shaft fifth speed gear. Because
of this constant mesh, the output shaft fifth speed gear freewheels until fifth gear is selected. As the gearshift lever
is moved to the fifth gear position, the 5-R fork moves the 5-R synchronizer sleeve towards the output shaft fifth
speed gear. The synchronizer sleeve engages the fifth gear clutch teeth, engaging the gear to the input shaft, and
allowing power to transmit through the output shaft to the differential.
Reverse Gear
Engine power is transmitted to the input shaft via the clutch assembly and the input shaft turns. The input shaft
reverse gear is integral to the input shaft, and is in constant mesh with the reverse idler gear. The reverse idler gear,
which reverses the rotation of the output shaft, is in constant mesh with the output shaft reverse gear. Because of
this constant mesh, the output shaft reverse gear freewheels until reverse gear is selected. As the gearshift lever is
moved to the reverse gear position, the 5-R fork moves the 5-R synchronizer sleeve towards the output shaft reverse
gear. The synchronizer sleeve engages the reverse gear clutch teeth, engaging the gear to the output shaft, and
allowing power to transmit through the output shaft to the differential.
GENERAL INFORMATION
08–250Chery 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 WARNING!
Do not remove the strut rod nut while the strut assembly is installed in the vehicle, or before the coil spring is
compressed with a spring compressor. The spring is held under high pressure and must be compressed before
the strut rod nut can be removed.
CAUTION:
At no time when servicing a vehicle can a sheet metal screw, bolt, or other metal fastener be
installed in the shock tower to replace the original plastic clamp. It may come in contact with the
strut or coil spring.
CAUTION:
The wheel bearing will be damaged if the vehicle is rolled with the axle shaft hub nut loose.
Operation
The front suspension utilizes a MacPherson strut system. This suspension system incorporates a strut assembly that
takes the place of the upper arm and ball joint. The strut performs the function of a shock absorber and is encom-
passed by a coil spring.
Specifications
Torque Specifications
DESCRIPTIONTORQUE (N·m)
Connecting Rod And Front Stabilizer Bar 40 - 50
Connect The Right And Left Assembly Of Front Drive
Shaft With Brake Disc 260 - 270
Control Arm And Sub-Frame 170 - 190
Connect Intermediate Propeller Shaft With Vehicle Body 58 - 68
Connecting Rod With Lower Suspension Lever 40 - 50
Connect Control Arm Knuckle Pin With Knuckle
Assembly 110 - 130
Connect Control Arm Knuckle Pin With Control Arm 140 - 160
Front Connecting Rod And Front Shock Absorber 40 - 50
Front Axle Shaft Nut 135
Fix Stabilizer Bar Clamp To Sub-Frame 22 - 28
Front Shock Absorber and Coil Spring 100 - 120
Front Suspension Strut And Vehicle Body 45 - 55
Front Suspension And Bracket 75 - 85
Insert From The Lower Part Of Sub-Frame, And The
Bolt Is On The Suspension. The Middle Part Shall Be
Clamped To The Main Longitudinal Beam Of Engine 110 - 130
1 - Front Lower Control Arm Ball Joint
2 - Front Lower Control Arm
3 - Steering Knuckle
4 - Front Strut Assembly
5 - Front Stabilizer Bar6 - Front Stabilizer Bar Bracket
7 - Front Stabilizer Bar Link
8 - Front Sub-Frame Assembly
9 - Side Member Assembly
GENERAL INFORMATION
LTSM100008
10–4Chery Automobile Co., Ltd.