CHERY TIGGO 2009 Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine 2.CHECK A/T RELAY SUPPLY VOLTAGE
• Turn ignition switch ON and then OFF.
• Check voltage between TCM terminals 2, 3 and ground.
• Turn ignition switch ON, battery voltage will exist.
• After turning ignition switch OFF, battery voltage will exist for a few seconds, then drop to approximately 0 V.
Is the check result normal?
Ye s>>Go to step 8.
No
>>Go to the next step.
3.CHECK A/T RELAY CONTROL VOLTAGE
• Turn ignition switch on.
• Check voltage between ECM terminal 63 and
ground.
• Voltage should be more than 12 V.
Is the check result normal?
Ye s>>Go to the next step.
No
>>Go to step 8.
4.CHECK A/T RELAY CONTROL VOLTAGE CIRCUIT
• Disconnect TCM harness connector.
• Disconnect front fuse and relay box harness connector H.
• Check harness continuity between TCM terminal 63 and front fuse and relay box terminal H6.
• Check harness continuity between front fuse and relay box terminal H10 and front fuse and ground.
• Check harness connector A-102, E-105, terminal 11.
• Continuity should exist.
• Check the harness for short to power or short to ground.
Is the check result normal?
Ye s>>Go to the next step.
No
>>Repair or replace the circuit for an open or short to ground or short to power in harness or connec-
tors.
DIAGNOSIS & TESTING
LTSMD080019
LTSMD080020
08–238Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 5.CHECK A/T RELAY SUPPLY CIRCUIT
• Check harness continuity between TCM terminal 2, 3 and front fuse and relay box terminal H9.
• Check for harness continuity between front fuse and relay box terminal H8 and G15.
• Check harness connector A-102, E-105, terminal 1.
• Continuity should exist.
• Check the harness for short to ground.
Is the check result normal?
Ye s>>Go to the next step.
No
>>Repair or replace the circuit for an open or short to ground in harness or connectors.
6.CHECK FUSE
• Disconnect Fuse 10 (30A) fuse from the front fuse and relay box.
• Check fuse 10 (30A).
Is the check result normal?
Ye s>>Go to the next step.
No
>>Replace fuse 10 (30A).
7.CHECK FRONT FUSE AND RELAY BOX
• Check front fuse and relay box.
Is the check result normal?
Ye s>>Go to the next step.
No
>>Replace front fuse and relay box.
8.CHECK DTC
• With the X-431 scan tool, read TCM DTCs.
• Refer to DTC Confirmation Procedure.
Is DTC 54 still present?
Ye s>>Replace the TCM.
No
>>The system is now operating properly.
Reassemble the vehicle and road test to verify the customers complaint is repaired.
DIAGNOSIS & TESTING
08
08–239Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine ON-VEHICLE SERVICE
F4A4 Automatic Transaxle Assembly
Removal & Installation
1. Raise and support the vehicle.
2. Disconnect the negative battery cable.
3. Remove the battery and battery tray (See Battery Removal & Installation in Section 05 Starting & Charging).
4. Remove the air cleaner and air duct assembly.
5. Drain the cooling system (See Cooling System Draining Procedure in Section 06 Cooling System).
6. Remove the base mounting bolts (1) of the aircleaner housing assembly.
7. Disconnect and remove the electrical connectors for the following components:• Output shaft sensor (1)
• Input shaft sensor (2)
• Electromagnetic valve switch connector (3)
• Gear switch connector (5)
8. Disconnect the transaxle fluid lines (6) using a suit- able tool.
9. Remove the shift cable (4) from the transaxle assembly.
10. Remove the starter motor (See Starter Removal & Installation in Section 05 Starting & Charging).
BESM080038
LTSM080153
08–240Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 11. Remove the bolts (1) attaching the drive plate tothe torque converter.
(Tighten: Drive plate bolts to 75 N·m)
12. Support the engine using an engine support fixture or suitable jack.
13. Remove the engine to transaxle upper bolts and remove the bracket. (Tighten: Engine to transaxle upper bolts to 80 N·m)
14. Remove transaxle mount nuts (2) and the transaxle mount bracket bolts (1).
(Tighten: Transaxle mount nuts to 120 N·m)
15. Raise the vehicle.
16. Remove the drain plug (1) and drain the transaxle fluid.
ON-VEHICLE SERVICE
BESM080058
LTSM020156
LTSM080190
08
08–241Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 17. Remove both front axle shafts (See Front Axle Shaft Removal & Installation in Section 09 Driveline & Axle).
18. Remove the engine undercover and splash shields.
19. Remove the engine to transaxle lower bolts.(Tighten: Engine to transaxle lower bolts to 80 N·m)
20. Remove the bolts that mount the side sill to vehicle body. (Tighten: Side sill to vehicle body bolts to 120 N·m)
21. Remove the front engine mount bolts (1). (Tighten: Front mount bolts to 60 N·m)
22. Remove the rear engine mount bolts (2) and the rear engine mount bracket bolts (1).
(Tighten: Rear mount bolts to 40 N·m)
23. Remove the sub-frame assembly (See Sub-Frame Assembly Removal & Installation in Section 10 Suspension).
24. Remove the engine to transaxle lower bolts. (Tighten: Transaxle mount bolts to 40 N·m)
25. Separate the transaxle from the engine and remove the transaxle from the vehicle.
WARNING!
Use a suitable jack to support the transaxle during removal.
26. Installation is in the reverse order of removal.
ON-VEHICLE SERVICE
BESM080035
LTSM020188
08–242Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Installation Notes:
•Check the transaxle fluid level.
Drive the vehicle until the ATF reaches oper-
ating temperature (70° - 80°C).
Park the vehicle on level ground.
Shift the gear selector lever to all gear posi- tions once, then shift to gear “N”.
Clean and check the outside of the dipstick and remove the dipstick to check the fluid
level.
Check if the transmission fluid level is within the HOT marking of the dipstick. If lower than
the HOT marking, refill the transaxle until the
fluid level is above the HOT marking.
• After installation, check for any fluid leakage and
verify the transaxle fluid level is correct. Refill the
transaxle fluid through the fill hole (1) shown in the
figure.
Automatic Shifter Selector
Removal & Installation
1. Raise and support the vehicle.
2. Disconnect the negative battery cable.
3. Remove the air cleaner and air duct assembly.
4. Remove the base mounting of the air cleaner housing assembly.
ON-VEHICLE SERVICE
LTSM080185
08
08–243Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 5. Remove the shift cable adjusting bolt (1) from thetransaxle gearshift switch.
6. Remove the gearshift knob (1).
7. Remove the gearshift cover (2) from the lower console.
8. Apply the parking brake (apply parking brake handle to clear lower console during removal).
9. Remove the lower console (See Lower Console Removal & Installation in Section 15 Body & Accessories).
10. Remove the shift cable from the gearshift mechanism.
11. Disconnect the electrical connector (2).
12. Remove the four bolts (1) and then remove the gearshift mechanism from the bracket.
ON-VEHICLE SERVICE
LTSM080167
BESM080049
LTSM080182
08–244Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 13. Installation is in the reverse order of removal.
NOTE :
If the battery has low voltage, press the release switch
(1) to move the gearshift lever.
ON-VEHICLE SERVICE
LTSM080187
08
08–245Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 5-SPEED MANUAL TRANSAXLE
GENERAL INFORMATION08-247
Description 08-247
Operation 08-250
Specifications 08-251
Special Tools 08-253
DIAGNOSIS & TESTING08-259
Abnormal Noise 08-259
Symptom Diagnostics 08-259
ON-VEHICLE SERVICE08-260
Manual Transaxle Assembly 08-260
Removal & Installation 08-260
Gear Selector & Shifter Assembly 08-264
Removal & Installation 08-264
Disassembly 08-267
Assembly 08-268
MANUAL TRANSAXLE UNIT REPAIR08-270
Transaxle 08-270
Specifications 08-270
Disassembly 08-270
Inspection 08-274
Assembly 08-275
Input Shaft 08-278
Specifications 08-278Disassemble
08-279
Assemble 08-281
Inspection 08-285
Output Shaft 08-287
Disassemble 08-287
Assemble 08-290
Output Gear For Reverse Gear 08-296
Disassemble 08-296
Inspection 08-296
5th-Reverse Gear Shift Fork 08-297
Disassemble 08-297
Assemble 08-298
3rd-4th Gear Shift Fork 08-298
Disassemble 08-298
Assemble 08-299
1st-2nd Gear Shift Fork 08-299
Disassemble 08-299
Assembly 08-300
Transaxle Clutch Housing Assembly 08-301
Disassemble 08-301
Assembly 08-303
Transaxle Main Housing Assembly 08-305
Assembly 08-305
08–246Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION
Description
The QR523 five-speed transaxle is a constant-mesh manual transaxle that is synchronized in all gear ranges, includ-
ing reverse.
The transaxle consists of three major sub-assemblies:
•Input shaft
• Output shaft
• Differential transaxle assembly
The transaxle shift system consists of the following components:
• Mechanical shift cover
• Shift rails
• Shift forks
08
08–247Chery Automobile Co., Ltd.