service CHERY TIGGO 2009 Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine 3. Remove instrument panel lower trim panel (1) (SeeInstrument Panel Removal & Installation in Section
15 Body & Accessories).
4. Disconnect clutch master cylinder push-rod (1) from clutch pedal.
5. Remove hydraulic line from rail retainer.
6. Release master cylinder by rotating to disengage from pedal bracket assembly.
CAUTION:
Use care when removing clutch master cylinder from engine compartment. Aggressive handling
can result in a damaged hydraulic line and improper clutch release operation upon reassembly.
CAUTION:
Brake fluid will damage painted surfaces. If brake fluid is spilled on any painted surfaces, wash it
off immediately with water.
7. Remove the master cylinder assembly (1) from the mounting position and carefully maneuver the
hydraulic pipe from the engine compartment.
8. Installation is in the reverse order of removal.
CLUTCH ASSEMBLY SERVICE
LTSM150089
VISM080021
LTSM080197
08
08–323Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Clutch Slave Cylinder
Removal & Installation
NOTE :
After replacing the slave cylinder, it is necessary to make sure brake master cylinder fluid level is full and the res-
ervoir cap is installed tightly.1. Remove the clutch master cylinder outlet pipe (1) from the clutch slave cylinder.
(Tighten: Outlet pipe bolt to 17 ± 1 N·m)
2. Remove the clutch slave cylinder bolts (1) from the transaxle housing.
(Tighten: Clutch slave cylinder bolts to 11 ± 1 N·m)
3. Installation is in the reverse order of removal.
4. Bleed the hydraulic clutch (See Bleeding Hydraulic Clutch in Section 08 Transaxle). NOTE: Check pipes for leakage of brake fluid.
CLUTCH ASSEMBLY SERVICE
LTSM080191
LTSM080143
08–324Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Bleeding Hydraulic Clutch
Operation
1. Verify fluid level in brake master cylinder. Top offwith DOT 4 brake fluid as necessary. Leave cap
off.
2. Raise the vehicle on hoist.
3. Remove the bleed port protective cap and install a suitable size and length of clear hose to monitor and divert fluid into a suitable container.
4. Loosen the bleed port (1).
5. Actuate the clutch pedal until the brake master cylinder fluid drains from the bleed port.
6. Depress the clutch pedal, tighten the bleed port.
7. From driver’s seat, actuate the clutch pedal until the hydraulic clutch system has pressure.
8. Depress the clutch pedal, loosen the bleed port and bleed the brake master cylinder fluid.
9. Repeat steps 6 to 8 several times until there is no air in the hydraulic clutch system.
NOTE :
Do not allow clutch master cylinder to run dry while fluid exits bleed port.
10. Close the hydraulic bleed port, remove the drain hose and replace the dust cap on the bleed port.
11. Top off the brake master cylinder fluid level with DOT 4 brake fluid as necessary.
CAUTION:
During the bleeding process, make sure the brake master cylinder fluid is always full.
CLUTCH ASSEMBLY SERVICE
LTSM080195
LTSM020210
08
08–325Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine TRANSFER CASE (4X4)
GENERAL INFORMATION08-327
Description 08-327
Operation 08-327
ON-VEHICLE SERVICE08-328
Transfer Case 08-328
Removal & Installation 08-328
TRANSFER CASE UNIT REPAIR08-329
Transfer Case 08-329
Disassembly 08-329
Assembly 08-331
08–326Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine ON-VEHICLE SERVICE
Transfer Case
Removal & Installation
1. Drain the gear fluid from the transfer case.•Fluid-filling plug (1)
• Fluid-limiting plug (2)
• Fluid-drain plug (3)
2. Remove the front intermediate drive shaft assembly.
3. Remove the sub-frame assembly.
4. Remove the left and right front axle shaft mounting bolts (1).
5. Remove the transaxle and transfer case assembly (See Transaxle Assembly Removal & Installation in Section 08 Transaxle).
6. Remove the transfer case from the transaxle (8 bolts). (Tighten: Transaxle and transfer case bolts to 80 N·m)
7. Installation is in the reverse order of removal.
LTSM160011
LTSM160012
08–328Chery 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 ON-VEHICLE SERVICE
Front Hub and Bearing
Removal & Installation
NOTE :
The following special tools are required to perform the repair procedure:
•Bearing Puller
1. Raise and support the vehicle.
2. Remove the wheel mounting nuts and the tire and wheel assembly. (Tighten: Wheel mounting nuts to 110 N·m)
3. Remove the front axle hub nut (1) from the front knuckle.
(Tighten: Front axle hub nut to 135 N·m)
4. Remove the front brake rotor (See Front Brake Rotor Removal & Installation in Section 12 Brakes).
5. Remove the wheel speed sensor mounting bolt (1), then remove the wheel speed sensor.
6. Using the bearing puller, remove the wheel hub bearing from the knuckle.
7. Installation is in the reverse order of removal.
LTSM090006
LTSM100045
LTSM090003
09
09–5Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Front Axle Shaft
Removal & Installation
1. Raise and support the vehicle.
2. Remove the wheel mounting nuts and the tire and wheel assembly.(Tighten: Wheel mounting nuts to 110 N·m)
3. Remove the front axle hub nut (1) from the front knuckle.
(Tighten: Front axle hub nut to 135 N·m)
4. Remove the wheel speed sensor bolt (1), then remove wheel speed sensor.
5. Remove the brake caliper adapter to steering knuckle mounting bolts. (Tighten: Brake caliper adapter mounting bolts to 85 N·m)
6. Remove the brake caliper adapter (with the brake caliper still attached).
1 - Left Half Shaft2 - Right Half Shaft
ON-VEHICLE SERVICE
LTSM090002
LTSM090006
LTSM100045
09–6Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 7. Remove the bolts (1) connecting the steeringknuckle to the front strut assembly.
CAUTION:
When removing the front axle shaft, do not
subject the constant velocity joint to an exces-
sive angle. Also, be careful not to excessively
extend the slide joint.
8. Remove the front axle shaft from the transaxleusing a suitable tool.
9. Installation is in the reverse order of removal.
Installation Notes:
• Rotate the joint up/down, left/right, and in axial direction, check for any rough movement or significant loose-
ness.
• Check boot for cracks or other damage, and for grease leakage.
• If damaged, disassemble axle shaft to verify damage, and repair or replace as necessary.
ON-VEHICLE SERVICE
LTSM100041
09
09–7Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine REAR AXLE
GENERAL INFORMATION09-9
Description 09-9
Operation 09-9
Specifications 09-10
Special Tools 09-10
DIAGNOSIS & TESTING09-11
Vehicle Inspection 09-11
Shudder Or Vibration During Acceleration 09-11
Vehicle Inspection 09-11
Noise Or Vibration On Turns 09-11
Clunking Noise During Acceleration 09-11Shudder Or Vibration During Acceleration 09-11
Vibration At High Speeds
09-11
Visual Inspection For Fluid Leaks (4x4) 09-11
ON-VEHICLE SERVICE09-12
Rear Hub and Bearing 09-12
Removal & Installation 09-12
Rear Axle Assembly (4x4) 09-13
Description 09-13
Operation 09-14
Removal & Installation 09-1409-15
09–8Chery Automobile Co., Ltd.