service CHERY TIGGO 2009 Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine 12. Remove the selector cable clamps (1) and bracketretaining bolts (2).
13. Remove the gear selector & shifter assembly.
14. Installation is in the reverse order of removal.
NOTE :
Selector cable can be adjusted with the adjusting bolt (1). Adjust bolts as needed to obtain proper cable adjustment.
Disassembly
1. Drive out the locking selector finger (1) pin follow- ing the direction as shown in the diagram.
2. Drive out the locking pin (2) reverse gear lock assembly pin.
3. Remove all of the components from shaft.
4. Thoroughly clean and check all parts, replace any worn parts as necessary.
ON-VEHICLE SERVICE
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08–267Chery 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
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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
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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)
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Downloaded from www.Manualslib.com manuals search engine 4. Gear Hub and Hub of Synchronizer•Assemble the gear bushing together with the
gear hub of synchronizer, and then inspect for
smooth operation without lockup.
• Inspect the front/rear of the interior surface of
the gear bushing for any damage.
• Inspect the synchronizer springs for any weak
springs or damage.
NOTE: If it is necessary to replace the gear
bushing and gear hub of the synchronizer,
they are only serviced as a complete set.
5. 3rd-4th Driven Gear •Inspect the gear surface of the skew gear and
clutch gear (1) for any damage.
• Inspect the conical surface of the synchronizer
(2) for thickening, damage or wear.
• Inspect the internal diameter of the front/rear
surface of the gear.
MANUAL TRANSAXLE UNIT REPAIR
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Downloaded from www.Manualslib.com manuals search engine CLUTCH SYSTEM
GENERAL INFORMATION08-317
Description 08-317
Operation 08-317
Specifications 08-317
Special Tools 08-318
CLUTCH ASSEMBLY SERVICE08-319
Clutch and Pressure Plate 08-319
Removal & Installation 08-319
Clutch Pedal Height 08-321Clutch Pedal Free Travel
08-321
Clutch Master Cylinder 08-322
Description 08-322
Operation 08-322
Removal & Installation 08-322
Clutch Slave Cylinder 08-324
Removal & Installation 08-324
Bleeding Hydraulic Clutch 08-325
Operation 08-325
08–316Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine CLUTCH ASSEMBLY SERVICE
Clutch and Pressure Plate
Removal & Installation
1. Remove the transaxle assembly (See Transaxle Assembly Removal & Installation in Section 08 Transaxle).
2. Remove the clutch pressure plate bolts (1).(Tighten: Clutch pressure plate bolts to 25 N·m)
3. Remove the modular clutch assembly.
4. Using special tool CH-20043 (1), hold the flywheel.
5. Remove the flywheel-to-crankshaft bolts (1) and remove flywheel assembly (if necessary for resur-
facing).
(Tighten: Flywheel-to-crankshaft bolts to 75 N·m)
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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
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Downloaded from www.Manualslib.com manuals search engine NOTE :
When tightening the clutch pressure plate bolts (1),
tighten by hand until the friction lining assembly is prop-
erly aligned.
•Apply a thin layer of grease to the input shaft, and then assemble the transaxle and engine.
NOTE: Turn the splines when installing the transaxle input shaft into the clutch friction lining assembly until the
splines are engaged.
Clutch Pedal Height
Adjust the clutch pedal height using the adjusting bolts
(1) on the pedal bracket (3) in accordance with the fol-
lowing requirements. When the clutch pedal (4) is
approximately 8 mm higher than the brake pedal (5),
the clutch pedal height is normal.
Clutch Pedal Free Travel
Depress the clutch pedal (1) until the clutch resistance
can be felt. Stop accordingly and measure the distance
(clutch pedal free travel A). The free travel should be
within 15 - 25 mm.
After checking clutch pedal free travel, check the clutch
to ensure it is in normal working condition while the
engine is running.
CLUTCH ASSEMBLY SERVICE
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Downloaded from www.Manualslib.com manuals search engine Clutch Master Cylinder
Description
The clutch master cylinder mounts to the clutch pedal
and consists of a piston and cylinder housing, an actu-
ating push rod, and an interconnecting hydraulic line.
Fluid is supplied to the clutch master cylinder via the
brake fluid reservoir.
Operation
When the clutch pedal is depressed, the push rod moves the piston in the master cylinder, displacing fluid through
the hydraulic line and into the release bearing. The release bearing is extended and forces the fingers of the clutch
diaphragm springs to move. As the fingers move, they release the clamping pressure on the clutch disc between the
clutch pressure plate and the flywheel. The clutch becomes disengaged as this pressure is released. When the clutch
pedal is released, the system hydraulic pressure is released. This allows the force of the clutch diaphragm springs to
return themselves to their original position, re-clamping the clutch disc between the flywheel and the clutch pressure
plate. Also, the release bearing is forced to return, which reverses the movement of the hydraulic system and returns
the pedal to its original position against the up stop.
Removal & Installation
1. Disconnect hydraulic supply line to clutch mastercylinder (1) to completely drain clutch master cylin-
der and tubing.
2. Disconnect hydraulic line (1) and drain fluid into suitable container.
CLUTCH ASSEMBLY SERVICE
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