ESP CHERY TIGGO 2009 Service User Guide

Downloaded from www.Manualslib.com manuals search engine WARNING!
Exhaust gases contain carbon monoxide which can be harmful to your health and are potentially lethal. Exhaust
system leaks should be repaired immediately. Never operate the engine in enclosed areas. Failure to follow
these instructions may result in personal injury or death.
Operation
In order to reduce vehicle emissions released by the engine, the catalytic converter is required to perform in all oper-
ating conditions. This reduction is especially beneficial during the cold start and warm up phases of operation, which
is when a majority of the tailpipe emissions occur on today’s vehicles because the catalytic converter has not yet
reached its operating temperature. The exhaust system channels exhaust gases from the engine and away from the
vehicle.
Specifications
Torque Specifications
DESCRIPTIONTORQUE (N·m)
Catalytic Converter Mounting Nuts 50
Exhaust Manifold Flange Bolts 49 ± 5
Muffler Mounting Nuts 50
GENERAL INFORMATION
07
07–3Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Operation
Automatic transaxle control is divided into the electronic and hydraulic transaxle control functions. While the elec-
tronic transaxle control is responsible for gear selection and for matching the pressures to the torque to be trans-
mitted, the transaxle’s power supply control occurs via hydraulic elements in the electro-hydraulic control module. The
fluid supply to the hydraulic elements, such as the torque converter, the shift elements and the hydraulic transaxle
control, is provided by way of a fluid pump connected to the torque converter.
The Transaxle Control Module (TCM) allows for the precise adaptation of pressures to the corresponding operating
conditions and to the engine output during the gearshift phase, resulting in a noticeable improvement in shift quality.
The engine speed limit can be reached in the individual gears at full throttle and kickdown. The shift range can be
changed in the forward gears while driving, but the TCM employs a downshift safeguard to prevent engine over
speed. The system offers the additional advantage of flexible adaptation to different vehicle and engine variants.
GENERAL INFORMATION
LTSM080154T
08–6Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Operation
The transaxle control is divided into the electronic and hydraulic transaxle control functions. While the electronic
transaxle control is responsible for gear selection and for matching the pressures to the torque to be transmitted, the
transaxle’s power supply control occurs via hydraulic elements in the electro-hydraulic control module. The fluid sup-
ply to the hydraulic elements, such as the torque converter, the shift elements and the hydraulic transaxle control, is
provided by way of a fluid pump connected to the torque converter.
The Transaxle Control Module (TCM) allows for the precise adaptation of pressures to the corresponding operating
conditions and to the engine output during the gearshift phase, resulting in a noticeable improvement in shift quality.
The engine speed limit can be reached in the individual gears at full throttle and kickdown. The shift range can be
changed in the forward gears while driving, but the TCM employs a downshift safeguard to prevent engine over
speed. The system offers the additional advantage of flexible adaptation to different vehicle and engine variants.
GENERAL INFORMATION
LTSM080154T
08
08–145Chery 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 10. Align the selector finger (1) and fork shaft springpin (2), install the spring pin of selector finger (as
shown by the arrow in the figure).
11. Tighten the interlock plate limit bolt (1) together with the shim to the housing (as shown in the fig-
ure). The tightening torque of the bolt is 30 N·m.
Check front end circular cylinder of the bolt to
ensure it is in the corresponding groove of selector
finger.
12. Check the gearshift shaft to ensure it is able to rotate and perform axial movement freely.
13. Install air duct (1) and air duct cap (2). Apply seal- ant to the surface of the inserted part of air duct.
14. Install the backup light switch assembly (1). (Tighten: Backup light switch to 32 N·m)
ON-VEHICLE SERVICE
LTSM080094
LTSM080128
LTSM080134
LTSM080135
08
08–269Chery 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 INSTRUMENT CLUSTER15-52
Description 15-52
Operation 15-52
Specifications 15-53
Special Tools 15-53
Electrical Schematics 15-54
Instrument Cluster Connector Pin-Out
Table 15-62
DIAGNOSIS & TESTING15-64
Clearing Service Monitor Lamp 15-64
Diagnostic Help 15-64
Intermittent DTC Troubleshooting 15-64
Ground Inspection 15-64
Diagnostic Tools 15-65
Diagnostic Trouble Code (DTC) List 15-65
Instrument Cluster DTC List 15-65
Diagnostic Trouble Code (DTC) Tests 15-66
U029C - Battery Over Voltage Error,
U029C - Battery Under Voltage Error 15-66
U040F - Temperature Sensor Shorted
To Supply, U040F - Temperature
Sensor Shorted To Ground (With
Mitsubishi 2.4L Engine System) 15-72
U050F - EEPROM Checksum Error 15-77
U0303 - Fuel Sensor Open Circuit Or
Shorted To Supply, U0303 - Fuel
Sensor Short To Ground 15-79
ON-VEHICLE SERVICE15-84
Instrument Cluster 15-84
Removal & Installation 15-84
INTERIOR LAMPS15-85
Description 15-85
Operation 15-85
Electrical Schematics 15-86
Front Room Lamp 15-91
Removal & Installation 15-91
Middle/Rear Courtesy/Dome Lamp 15-91
Removal & Installation 15-91
Key Hole Lamp 15-92
Removal & Installation 15-92
POWER OUTLET15-93
Description 15-93
Operation 15-93
Electrical Schematics 15-94
Removal & Installation 15-95
POWER WINDOW15-96
Description 15-96
Operation 15-96
Electrical Schematics 15-97
Power Window Switch 15-100
Removal & Installation 15-100
Power Window Motor 15-100
Removal & Installation 15-100
Power Window Motor Inspection 15-103
SEATS15-104
General Information 15-104
Description 15-104
Operation 15-104
Electrical Schematics 15-105
Front Seat 15-106
Removal & Installation 15-106
Rear Seats 15-107
Removal & Installation 15-107
Heated Seat Switch 15-109
Removal & Installation 15-109
Heated Seat Element 15-109
Removal & Installation 15-109
IMMOBILIZER CONTROL MODULE15-110
Description 15-110
Operation 15-110
Electrical Schematics 15-111
Immobilizer Control Module Connector
Pin-Out Table 15-112
DIAGNOSIS & TESTING15-113
Diagnostic Help 15-113
Intermittent DTC Troubleshooting 15-113
Ground Inspection 15-113
Diagnostic Tools 15-113
Diagnostic Trouble Code (DTC) List 15-114
Immobilizer Control Module DTC List 15-114
Remote Keyless Entry (RKE)
Inoperative 15-115
No Response From Remote Keyless
Entry (RKE) Transmitter 15-115
15–2Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Diagnostic Trouble Code (DTC) Tests15-117
B1000 - ECU Defect: Internal Errors 15-117
B3042 - W-Line Short Circuit To
Ground, B3043 - W-Line Short Circuit
To Battery 15-121
B3050 - Relay External Line Short
Circuit To Ground Or Open Circuit,
Relay External Line Malfunction,
B3053 - Relay External Line Short
Circuit To Battery 15-126B3055 - No Transponder Modulation Or
No Transponder, B3056 - No
Transponder Fixed Code Programmed 15-132
B3060 - Unprogrammed Transponder
Fixed Code Received, B3061 -
Disturbed Or No Challenge/Response
Transponder Communication, B3077 -
Read-Only Transponder Detected
15-138
ON-VEHICLE SERVICE15-144
Immobilizer Control Module 15-144
Removal & Installation 15-144
BODY AND ACCESSORIES - BODY INTERIOR
15
15–3Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Diagnostic Trouble Code (DTC) List
Immobilizer Control Module DTC List
DTCDTC DEFINITION
B1000 ECU Defect, Internal Errors
B3040 Communication Error On W-Line, ECM Doesn’t Answer On Challenge Or Response
Requests
B3042 W-Line Short Circuit To Ground
B3043 W-Line Short Circuit To Battery
B3045 DWA Line Short Circuit To Ground Or Open Circuit, DWA Line Malfunction
B3048 DWA Line Short Circuit To Battery
B3050 Relay Extern Line Short Circuit To Ground Or Open Circuit, Relay Extern Line
Malfunction
B3053 Relay Extern Line Short Circuit To Battery
B3055 No Transponder Modulation Or No Transponder
B3056 No Transponder Fix Code Programmed
B3057 No Security Code Programmed
B3060 Unprogrammed Transponder Fix Code Received
B3061 Disturbed Or No Challenge / Response Transponder Communication
B3077 Read-Only Transponder Detected
DIAGNOSIS & TESTING
15–11 4Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Remote Keyless Entry (RKE) Inoperative
No Response From Remote Keyless Entry (RKE) Transmitter
1.CHECK BATTERY
• Check battery of the RKE transmitter.
Is the battery voltage of the RKE transmitter normal?
Ye s>>Go to the next step.
No
>>This concern has been caused by the transmitter battery.
Go to step 4.
2.CHECK THE IGNITION LOCK CYLINDER CONDITION
• Check the ignition lock cylinder for proper operation.
Is the check result normal?
Ye s>>Go to the next step.
No
>>Repair or replace the ignition lock cylinder key switch.
3.PERFORM THE RKE TRANSMITTER MATCH PROCEDURE
• Close all the doors.
• Insert the ignition key into the ignition switch which has lost synchronization in LOCK position.
• Press any button on the RKE transmitter within 5 seconds.
• Pull the ignition key out of the ignition switch.
• Try to operate the RKE transmitter.
Does the RKE transmitter operate properly?
Ye s>>Erase all codes before returning the vehicle to the customer.
No
>>Go to the next step.
DIAGNOSIS & TESTING
15
15–11 5Chery Automobile Co., Ltd.