torque CHERY TIGGO 2009 Service Owners Manual

Downloaded from www.Manualslib.com manuals search engine MANUAL TRANSAXLE UNIT REPAIR
Transaxle
Specifications
Torque Specifications
DESCRIPTIONTORQUE (N·m)
Gear Shift Mechanism Housing Bolt 18
Gear Positions Self-Locking Bolt 35
Reverse Gear Bolt 20
Reverse Gear Cap Bolt 20
Rear Transaxle Bearing End-Plate Bolt 6.9
Transaxle To Clutch Housing Bolt 44
Bearing Input Shaft Bolt 18
Disassembly
1. Place the transaxle on a workbench.
2. Remove the clutch fork (2) and remove the release
bearing (1).
NOTE: The release bearing (1) is not serviceable.
3. Set the transaxle gear in the neutral position. Remove the gear shift mechanism housing retain-
ing bolts (1), and remove the gear shift mechanism
housing.
(Tighten: Gear shift mechanism housing bolts to
18 N·m)
LTSM020229
LTSM080119
08–270Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Inspection
1. Place a tin solder sheet (1) (approximate length is10 mm and diameter is 1.6 mm) on the specified
part of the transaxle housing, and then install the
differential outer bearing race.
2. Install the clutch housing, and tighten the bolts to the specified torque.
3. Replace the tin solder sheets with thicker tin solder sheets.
4. With a micrometer, measure the thickness (T) of the flattened tin solder sheet.• Select the thickness of the shim to be installed
according to the following equation.
Thickness of washer: (T + 0.005 mm) - (T +
0.11 mm)
5. Do not clean the release bearing.
6. Clean the sealing surface of all contaminates, remove all old sealant, and clean all bolt holes.
7. Check all parts for damage, replace any damaged parts if necessary.
8. Always align the bearing cap (1) with the shaft opening. Align the bearing collar to the bearing cap
opening (as the two circular rings indicate in the
figure).
MANUAL TRANSAXLE UNIT REPAIR
LTSM080026
LTSM080027
LTSM080131
08–274Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 9. Place the transaxle in the neutral position wheninstalling the self-locking bolts for the gear posi-
tions. The notches (1) of the shift fork guide block
should align in the same line.
10. Place the transaxle in the neutral position (1) when the gear shift mechanism housing assemble is in
the position of the selector finger in the gear shift
mechanism housing assembly shown in the figure.
11. Alternate tightening each bolt to the specified torque.
Assembly
1. Install the input shaft together with the output shaft.
2. Install the 5th-reverse gear shifting fork/fork stalk-5th-reverse gear fork/3rd-4th gear shifting fork/fork stalk–3rd- 4th fork.
3. Move the gear bushing-3rd-4th gear (1) and the gear bushing-5th-reverse gear (2) in the direction
shown in the figure.
MANUAL TRANSAXLE UNIT REPAIR
LTSM080132
LTSM080133
LTSM080028
08
08–275Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 8. Install the transaxle housing.
9. Applya1mmto1.2mmdiameter of sealant onthe specified position of the transaxle housing.
CAUTION:
The sealant line applied should be uniform and
continuous and without breaks.
10. Tighten the transaxle housing bolts to the specified torque.
11. Install the bottom transaxle cover.
12. Applya1mmto1.2mmdiameter of sealant on the specified position of the transaxle housing.
CAUTION:
The sealant line applied should be uniform and
continuous and without breaks.
13. Apply transaxle fluid to the O-ring of speed sensor.(Transaxle fluid: 75W-90)
MANUAL TRANSAXLE UNIT REPAIR
LTSM080032
LTSM080033
LTSM080034
08
08–277Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION
Description
The hydraulic clutch system consists of a clutch master
cylinder (2), slave cylinder (3), and an interconnecting
hydraulic fluid line. Hydraulic fluid is supplied by the
clutch system from the clutch master cylinder reservoir
(1).
Operation
The hydraulic clutch system is responsible for engaging and disengaging the clutch. Depressing the clutch pedal
develops fluid pressure in the clutch master cylinder. This pressure is transmitted to the integral release bearing
which is in contact with the pressure plate diaphragm spring. As additional force is applied, the bearing depresses the
diaphragm spring fingers inward on the fulcrums. The action moves the pressure plate rearward, relieving clamping
force on the clutch disc.
Specifications
Torque Specifications
DESCRIPTIONTORQUE (N·m)
Transaxle Mounting Bolts 6.9
Clutch Housing Mounting Bolts 44
Clutch Release Bearing Seat Retainer Mounting Bolts 9.8
Gear Shift Mechanism Assembly Mounting Bolts 18
Shift Gear Control Cable Bracket Mounting Bolts 18
Speedometer Gear Mounting Bolts 3.9
Final Drive Driven Gear Mounting Bolts 132
Back Up Lamp Switch 32
Idler Gear Assembly Mounting Bolt 48
Clutch Slave Cylinder Mounting Bolts 11 ± 1
LTSM080194
08
08–317Chery 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 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.

Downloaded from www.Manualslib.com manuals search engine 6. Remove the fluid seal of the input clutch.Pry out the fluid seal with a slotted screwdriver.
Assembly
1. Put a standard-sized 1.4 mm adjusting shim from the front bearing driven gear axle into the transfer case hous-ing. Press in the front outer bearing race of the driven gear axle, then the rear outer bearing race, and press the
front bearing of the driven gear axle into the driven gear axle; then put it into the collar and press in the rear
inner bearing race. Attach the locknut, and adjust the tightening torque of the driven gear by adjusting the locknut
until the driven gear axle can be driven with a torque of 1.0-1.5 N·m.
2. Assemble the flange axle. Link the drive gear ring of the transfer case to the flange axle with a mounting bolt, tighten the bolt to 110 N·m.
Install the bearing to the left of the flange axle and the bearing to the left of the right bearing seat.
3. Choose the 2.4 mm standard-sized adjusting shim for the left bearing for the flange axle. Put the adjusting shim for the right bearing for the flange axle, the outer bearing race to the left of the flange axle and the flange axle
into the transfer case.
Measure the distance (A) from the contact surface of the right bearing seat and the transfer case to the right
bearing seat and the left bearing’s right end surface.
Measure the distance (B) from the contact surface of the right bearing seat and the transfer case to the place
where the right and left bearings on the right bearing seat.
4. Calculate the thickness value of the adjusting gasket S = A - B.
5. Select the adjusting gasket: S + (0.05 - 0.10) mm.
6. Assembly of the right bearing seat. Assemble the right bearing to the right bearing seat, install the retainer ring of the right bearing to the right
bearing seat, install the fluid seals to the left and right of the right bearing seat, install the O-ring and link the
right bearing seat to the transfer case housing with the bolt. Tighten the bolt to 35 N·m. The subassembly should
be able to rotate with 3.0-5.0 N·m torque.
7. Adjust the hypoid gear engagement: first, spread red lead powder on the teeth of the driven bevel gear so that there will appear red prints on both working sides of the gear teeth of the driving bevel gear when turning it by
hand. If the gear pattern prints on both engaging sides of the drive gear ring is higher than the center of the gear
height near to the small end and occupy over 60% of the gear tooth width, then the pattern is correct; and the
backlash between various gear teeth should fall between 0.13 mm and 0.18 mm.
A: If the clearance between one lateral side of a tooth and that of the adjacent tooth are not correct, choose
bearing shims to the left and right of the flange axle, repeat procedures 3, 4 and 5 to measure the clearance
between one lateral side of a tooth and that of the adjacent tooth on the hypoid gear until the adjustment is
correct.
B: If the gear pattern print leans to the tooth tip, replace the adjusting shim from the front bearing of the driven
gear to a thicker 1 mm; If the gear pattern print leans to the tooth root, then get the adjusting shim of the front
bearing of driven gear axle needs to be subtracted by 1 mm. Examine the gear pattern print, repeat procedures
3, 4, 5, 6, and 7 until the gear pattern is correct.
8. Assemble the transfer case front shell, and tighten to 35 N·m.
9. Assemble the transfer case small rear housing onto the transfer case, and tighten to 35 N·m.
10. Assemble the input clutch fluid seal, O-ring, retainer ring and the input clutch; install the transfer case onto the transaxle and tighten to 80 N·m.
NOTE: When assembling bearings and fluid seals, it is necessary to apply lubricating grease. The sealing sur-
face of the housing must have sealant applied.
TRANSFER CASE UNIT REPAIR
LTSM160019
08
08–331Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine DRIVELINE & AXLE
09
CONTENTSpage
Front Axle ........................................................................\
.. 09-1
Rear Axle ........................................................................\
... 09-8
Interactive Torque Management (ITM) System (4x4) .......................................09-16
Drive Shaft (4x4) .................................................................... 09-24
FRONT AXLE
GENERAL INFORMATION09-2
Description 09-2
Operation 09-2
Specifications 09-2
Special Tools 09-3
DIAGNOSIS & TESTING09-4
Vehicle Inspection 09-4
Noise Or Vibration On Turns 09-4
Clunking Noise During Acceleration 09-4 Shudder Or Vibration During Acceleration 09-4
Vibration At High Speeds 09-4
ON-VEHICLE SERVICE09-5
Front Hub and Bearing 09-5
Removal & Installation 09-5
Front Axle Shaft 09-6
Removal & Installation 09-6
09
09–1Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION
Description
This vehicle is equipped with unequal length half shafts, consisting of short left and long right half shafts. The half
shafts consist of a fixed Constant Velocity (CV) joint at the outboard end connected by a solid shaft to a plunging CV
joint on the inboard end. The inner CV joint has a splined end and is attached to the transaxle and is retained with
a snap ring. The outer joint has a splined connection to the wheel hub and is retained with a lock nut.
For further information on the front axle assembly see Front Sub-Frame Assembly Description & Operation in Section
10 Suspension.
Operation
The front axle transmits torque from the transaxle to the wheels. In order to allow vertical and horizontal movement
of the wheels, the axle shafts have plunging CV joints on the inboard ends of the axle shafts.
Specifications
Torque Specifications
DESCRIPTIONTORQUE (N·m)
Front Stabilizer Bar to Stabilizer Bar Link Nuts 40 - 50
Control Arm Knuckle Pin With Knuckle Assembly 110 - 130
Control Arm to Sub-Frame Bolt 170 - 190
Stabilizer Bar Link to Lower Suspension Lever 40 - 50
Front Axle
1 - Front Stabilizer Bar
2 - Right Front Stabilizer Bar Link
3 - Rear Rubber Bushing
4 - Right Control Arm
5 - Sub-Frame Assembly
6 - Longitudinal Beam7 - Front Rubber Bushing
8 - Left Control Arm
9 - Control Arm Knuckle Pin
10 - Left Front Stabilizer Bar Link
11 - Stabilizer Bar
12 - Rubber Support
LTSM090004
09–2Chery Automobile Co., Ltd.