CHERY TIGGO 2009 Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine DOORS
Specification
Torque Specifications
DESCRIPTIONTORQUE (N·m)
Left/Right Front Door Upper Hinge to Body Bolts 36 ± 4
Left/Right Front Door Upper Hinge to Door Bolts 36 ± 4
Left/Right Front Door Lower Hinge to Body Bolts 36 ± 4
Left/Right Front Door Lower Hinge to Door Bolts 36 ± 4
Left/Right Rear Door Upper Hinge to Body Bolts 36 ± 4
Left/Right Rear Door Upper Hinge to Door Bolts 36 ± 4
Left/Right Rear Door Lower Hinge to Body Bolts 36 ± 4
Left/Right Rear Door Lower Hinge to Door Bolts 36 ± 4
Back Door Upper Hinge to Body Bolts 36 ± 4
Back Door Upper Hinge to Door Bolts 50 ± 5
Back Door Lower Hinge to Body Bolts 35 ± 3
Back Door Lower Hinge to Door Bolts 50 ± 5
Left Hood Hinge to Body Bolts 23 ± 2
Left Hood Hinge to Hood Bolts 23 ± 2
Right Hood Hinge to Body Bolts 23 ± 2
Right Hood Hinge to Hood Bolts 23 ± 2
Rear Mounting Bracket of Front Fender to Body Bolts 10 ± 1
Left/Right Front Fender to Body Bolts 10 ± 1
Radiator Support to Body Bolts 10 ± 1
15
15–167Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Front Door
Removal & Installation
1. Disconnect the negative battery cable.
2. Disconnect the inner harness electrical connectoron the front door.
3. Remove the mounting bolts (1) from the front door hinge.
4. Remove the front door assembly.
5. Installation is in the reverse order of removal.
Disassembly
1. Turn the ignition switch off.
2. Using a small trim stick, remove the pull handle cover (1) from the pull handle (2).
DOORS
LTSM150111
LTSM150139
15–168Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 3. Remove the inner door handle mounting screw (1).
4. Remove the pull handle mounting screws (2).
5. Using a small trim stick, remove the inner doorhandle trim bezel (1).
6. Carefully pry the door trim panel clips from the door.
7. Disconnect the power window switch and the door lamp electrical connector.
8. Remove the door trim panel.
9. Disconnect the speaker connector (1).
10. Remove the inner door handle assembly mounting screw (2).
11. Disconnect the inner door handle cables (3).
12. Remove the protective film (4).
DOORS
LTSM150134
LTSM150140
LTSM150135
15
15–169Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 13. Temporarily connect the power window switch.
14. Turn the ignition switch on and use the power window switch to move the front door glass to a position so thedoor glass bolts can be removed.
15. Turn the ignition switch off and disconnect the power window switch.
16. Remove the two door glass mounting bolts (1). (Tighten: Door glass mounting bolts to 11 N·m)
NOTE: Properly support the door glass when
removing the mounting bolts. The door glass may
drop and be damaged.
17. Remove the door glass weatherstrip (1).
18. Lift the door glass and remove the door glass from the door.
NOTE: Take care not to damage the door glass.
19. Disconnect the power window motor electrical con- nector.
20. Remove the six power window regulator mounting bolts (1).
(Tighten: Power window regulator mounting bolts to
11 N·m)
21. Carefully remove the power window regulator.
22. Remove the power window motor from the regulator.
23. Remove three door lock assembly retaining bolts. (Tighten: Door lock assembly retaining bolts to9±1N·m)
DOORS
LTSM150116
LTSM150137 LTSM150117
15–170Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 24. Remove the internal unlock cable (1) and lockcable (2).
25. Remove the lock buckle with screwdriver. (Tighten: Lock buckle screws to 12 ± 2 N·m)
26. Remove the front door outside handle.
27. Remove the front door panel and then the protec- tive film.
28. Pry up on the cover (1) of the outside handle.
29. Remove the mounting bolts with hexagon spline wrench.
DOORS
LTSM150098
LTSM150114
15
15–171Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 30. Detach the lock from the linkage rod, remove thelock and the cover of left front door.
31. Remove the outside handle.
Assembly
Assemble is in the reverse order of disassembly
Front Door Adjustment
1. Adjust the door gap with a spacer gauge. •The gap of the upper section between the front door and the back door should be 5.5 ± 0.7 mm
• The gap of the outboard side should be 5.5 ± 0.7 mm
• The gap between the front door and pole A should be 6.5±1mm
• The gap of upper section between front door and back door should be 5.5 ± 0.7 mm
• The gap between the front/back door and the doorsill should be6±1mm
• The overall levelness when measured with a magnet should be 0-0.5 mm
2. Install the bolts (Part Number: T11-6101103, 2 pcs both upper and lower) into the body for 2-3 turns, tighten with pneumatic wrench. Torque: 35 ± 3 N·m.
Check for the following after repair:
• Any scratches from reassembly
• Whether the bolts and nuts are assembled properly
• Whether the bolts and nuts are properly tightened
• Whether the gap and levelness between front door and back door is within the specifications
• Whether the edge height is 0-0.5 mm.
Replacing Front Door Hinge
1. Remove the front fender to gain access to the door hinge (See Fender Removal & Installation in Section 15
Body & Accessories).
2. Support the door.
3. Remove the four retaining bolts from the upper and lower hinges, and then remove the hinges.
DOORS
LTSM150120
15–172Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Rear Door
Removal & Installation
1. Disconnect the negative battery cable.
2. Disconnect the inner electrical harness connectoron the rear door.
3. Remove the mounting bolts (1) from the rear door hinge.
4. Remove the rear door assembly.
5. Installation is in the reverse order of removal.
Disassembly
1. Remove the bolts to remove the bezel for the inside door handle.
2. Pry out the window regulator switch and pull out the electrical harness.
3. Remove the door trim panel.
4. Remove the mounting bolts for the inside door handle to remove the handle.
5. Remove the protective film from the rear door.
6. Lower the glass to a proper position, remove the set bolts, move the glass to the bottom of the door, and then remove the door glass.
7. Remove the mounting bolts for the glass guide rail.
DOORS
LTSM150112
15
15–173Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 8. Remove the mounting bolts (1) from the windowregulator.
9. Remove the lock mounting screws with an internal spline socket.
10. Loosen the pull rod from the door handle, pull out the electrical harness, and then remove the lock.
11. Remove the rear door outside handle. •Remove the mounting bolts of the handle seat
with hexagon spline wrench from one side of
the shield.
12. Remove the handle seat. •Remove the outside handle.
13. Remove the weather strip from the door opening.
14. Disconnect the inner harness of the door from out- side.
Assembly
Assemble in the reverse order of disassembly.
Rear Door Adjustment
1. Adjust the door gap with a spacer gauge.•The gap between the rear door and the trian-
gle window should be 8 ± 1.5 mm
• The gap between the rear door and the side
fender should be6±1mm
• The gap between the rear door and the door-
sill should be6±1mm
• The overall levelness when measured with a
magnet should be 0-0.5 mm as shown by the
arrow
2. Install the nuts (Part Number: Q32008, 2 pcs both upper and lower) into the body for 2-3 turns,
tighten with pneumatic wrench. Torque: 35 ± 3
N·m.
Check for the following after repair:
• Any scratches from reassembly
• Whether the bolts and nuts are assembled properly
• Whether the bolts and nuts are properly tightened
• Whether the gap between rear door and side fender and the levelness are within the specifications
• Whether the edge of back door is 0-0.5 mm higher than the side fender.
DOORS
LTSM150118
LTSM150119
15–174Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Replacing Rear Door Hinge
1. Remove the door check bolts.
2. Support the door.
3. Remove the four retaining bolts from the upper and lower hinges, and then remove the hinges.
Back Cargo Door
Removal & Installation
1. Remove the two back cargo door bolts connecting the back door and hinge.(Tighten: Bolts connecting the back door and hinge to 50 ± 5 N·m)
(Tighten: Bolts connecting the hinge and body to 36 ± 4 N·m)
2. Disconnect the wiring harness electrical connector.
3. Remove the two mounting bolts (1) of the back cargo door stopper on body.
(Tighten: Bolts connecting the back cargo door
stopper bracket and body to 27 N·m)
4. Remove the back cargo door.
5. Installation is in the reverse order of removal.
Disassembly
1. Remove the back cargo door panel.
2. Remove the rear wiper motor (See Rear Wiper Motor Removal & Installation in Section 15 Body &
Accessories).
3. Remove the protective film from the back cargo door.
4. Remove mounting bolts, pull out the harness.
5. Remove the outside handle mounting bolts (1) from one side of the door panel.
DOORS
LTSM150113
LTSM150121
15
15–175Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 6. Remove the rod from the door handle from thedoor lock body, remove the outer handle of back
cargo door.
7. Remove the back cargo door lock.
8. Pull out the connector for the wiring harness.
9. Remove the lock.
10. Remove the high mounted stop lamp assembly (1).
11. Remove the rear fog lamp assembly.
12. Remove the spare tire support.
DOORS
LTSM150122
LTSM150123
15–176Chery Automobile Co., Ltd.