service CHERY TIGGO 2009 Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine 8. Remove the power steering pump inlet hose clamp(1), and then remove the pump inlet hose.
9. Remove the pump outlet pipe bolt (2).
10. Rotate the steering pump pulley until the bolt (1) access hole lines up with the bolt.
11. Remove the power steering pump retaining bolt. (Tighten: Power steering pump bolt to 20 - 30 N·m)
12. Remove the two bolts (1) on the other side of the power steering pump.
(Tighten: Power steering pump bolts to 20 - 30
N·m)
13. Remove the steering pump from the engine bracket.
14. Installation is in the reverse order of removal.
Installation Notes:
• Fill the power steering reservoir to the proper level.
• Check the system for leaks.
Power Steering Fluid Reservoir
Removal & Installation
1. Siphon as much steering fluid as possible from the power steering fluid reservoir.
ON-VEHICLE SERVICE
LTSM110032
LTSM110009
LTSM110010
11 –36Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 2. Remove the hose clamps (1) securing the returnhose and the supply hose to the steering fluid res-
ervoir fitting.
3. Slide the hose off the end of the reservoir fitting and remove the steering fluid reservoir.
4. Installation is in the reverse order of removal.
Installation Notes:
• Fill the power steering reservoir to the proper level.
• Check the system for leaks.
Power Steering Pressure and Return Lines - 1.6L & 1.8L & 2.0L
Removal & Installation
1. Siphon as much steering fluid as possible from the power steering fluid reservoir.
2. Remove the engine cover.
3. Remove the hose clamps securing the return hose and the supply hose to the steering fluid reservoir fitting.
4. Remove the high pressure (1) and low pressure
lines (2) from the power steering pump (drain
steering fluid from lines).
(Tighten: High pressure line to power steering
pump 40 - 50 N·m)
(Tighten: Low pressure line to power steering pump
40 - 50 N·m)
ON-VEHICLE SERVICE
LTSM110038
LTSM110039
BESM110011
11
11 –37Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 5. Remove the high pressure and low pressure lines(1) from the steering gear (drain steering fluid from
lines).
(Tighten: High pressure line to power steering
pump 27 - 33 N·m)
(Tighten: Low pressure line to power steering pump
27 - 33 N·m)
6. Remove the power steering line clamp bracket bolt (1) from the pressure and return lines.
(Tighten: Power steering line clamp bracket bolt to
10 N·m)
7. Remove the pressure and return lines.
8. Installation is in the reverse order of removal.
Installation Notes:
• Fill the power steering reservoir to the proper level.
• Check the system for leaks.
ON-VEHICLE SERVICE
LTSM110007
BESM110013
11 –38Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Power Steering Pressure and Return Lines - 2.4L
Removal & Installation
1. Siphon as much steering fluid as possible from the power steering fluid reservoir.
2. Remove the hose clamps (1) securing the returnhose and the supply hose to the steering fluid res-
ervoir fitting.
3. Remove the pressure and return hoses.
4. Disconnect the power steering switch electrical connector.
5. Remove the bolt (2) from the pressure line and remove the clamp (1) from the return hose.
ON-VEHICLE SERVICE
LTSM110038
LTSM110032
11
11 –39Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 6. Remove the high pressure and low pressure lines(1) from the steering gear.
(Tighten: High pressure line to steering gear
27 - 33 N·m)
(Tighten: Low pressure line to steering gear
27 - 33 N·m)
7. Installation is in the reverse order of removal.
Installation Notes:
• Fill the power steering reservoir to the proper level.
• Check the system for leaks.
ON-VEHICLE SERVICE
LTSM110007
11 –40Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine BRAKES
12
CONTENTSpage
Base Brakes ........................................................................\
. 12-1
Antilock Brakes ..................................................................... 12-34
Parking Brake ...................................................................... 12-79
BASE BRAKES
GENERAL INFORMATION12-2
Description 12-2
Operation 12-3
Specifications 12-4
Special Tools 12-5
Electrical Schematics 12-6
DIAGNOSIS & TESTING12-7
Diagnostic Help 12-7
Brake Noise 12-7
Braking Concerns 12-8
ON-VEHICLE SERVICE12-9
Brake Bleeding 12-9
Brake Bleeding Information 12-9
Brake Bleeding Procedure 12-9
Manual Brake Bleeding 12-9
Pressure Brake Bleeding 12-10
Master Cylinder - LHD 12-11
Description 12-11
Operation 12-11
Removal & Installation 12-11
Master Cylinder - RHD 12-12
Description 12-12
Operation 12-13
Removal & Installation 12-13
Power Brake Booster - LHD 12-14
Description 12-14
Operation 12-14
Removal & Installation 12-14
Power Brake Booster - RHD 12-16
Description 12-16
Operation 12-16
Removal & Installation 12-16Front Brake Caliper
12-18
Description 12-18
Operation 12-18
Removal & Installation 12-19
Rear Brake Caliper 12-19
Description 12-19
Operation 12-20
Removal & Installation 12-20
Front Brake Rotor 12-21
Removal & Installation 12-21
Inspection 12-21
Rear Brake Rotor 12-22
Removal & Installation 12-22
Inspection 12-22
Rear Brake Backing Plate 12-23
Removal & Installation 12-23
Front Brake Pads 12-24
Removal & Installation 12-24
Inspection 12-25
Rear Brake Pads 12-25
Removal & Installation 12-25
Inspection 12-26
UNIT REPAIR12-27
Front Brake Caliper 12-27
Disassemble 12-27
Inspection 12-28
Assemble 12-28
Rear Brake Caliper 12-30
Disassemble 12-30
Inspection 12-31
Assemble 12-32
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12–1Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Rear Disc Brake
The rear disc brake assembly consists of the following major components:
•Caliper
• Caliper adapter bracket
• Brake pads
• Rotor
• Parking brake shoes
CAUTION:
•Use DOT 4 brake fluid or equivalent from a tightly sealed container. Do not use petroleum-based
fluids, which will cause seal damage in the brake system.
• Brake fluid will damage painted surfaces. If brake fluid is spilled on any painted surfaces, wash
it off immediately with water.
• Never use gasoline, kerosene, alcohol, motor oil, transmission fluid, or any fluid containing min-
eral oil to clean system components. These fluids damage rubber cups and seals.
• During service procedures, grease or any other foreign material must be kept off the caliper
assembly, brake pads, brake rotor and external surfaces of the hub.
• When handling the brake rotor and caliper, be careful to avoid damaging the brake rotor and
caliper, and scratching or nicking the brake shoe lining.
Operation
Applying the brake pedal uses lever action to push a rod into the brake booster, which through the use of vacuum,
boosts the force of the rod and then transmits this force into the master cylinder. This produces hydraulic pressure in
the master cylinder. On vehicles not equipped with ABS, the hydraulic pressure is transmitted by brake fluid through
the brake tubes to the individual brake calipers or wheel cylinders. On vehicles equipped with ABS, the hydraulic
pressure is transmitted by brake fluid through the brake tubes to the ABS hydraulic control unit (HCU), which then
distributes that pressure to the individual brake calipers and wheel cylinders. The brake calipers use hydraulic pres-
sure to apply the brake pads. The application of the brake pads or shoes will cause the rotation of the wheels to slow
or stop depending on how much brake pressure is applied. The parking brakes carry out the same function except
that they are mechanically actuated by a cable that connects only to the rear brakes.
1 - Rear Hub Mounting Assembly
2 - Rear Brake Assembly
3 - Lock Nut
4 - Rear Wheel Hub Bearing Unit5 - Rear Brake Rotor
6 - Caliper Bolts
7 - Brake Caliper Assembly
7 - Disc Brake Caliper and Rotor Assembly
GENERAL INFORMATION
LTSM120002
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12–3Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine ON-VEHICLE SERVICE
Brake Bleeding
Brake Bleeding Information
WARNING!
When bleeding the brake system, wear safety glasses. A clear bleed tube must be attached to the bleeder
screws and submerged in a clear container filled partially with clean brake fluid. Direct the flow of brake fluid
away from yourself and the painted surfaces of the vehicle. Brake fluid at high pressure may come out of the
bleeder screws when opened.
CAUTION:
Before removing the master cylinder cap, wipe it clean to prevent dirt and other foreign matter
from dropping into the master cylinder reservoir. Use brake fluid or an equivalent from a fresh,
tightly sealed container. Brake fluid must conform to DOT 4 specifications.
NOTE :
During the brake bleeding procedure, be sure the brake fluid level remains close to theMAXlevel in the master
cylinder fluid reservoir. Check the fluid level periodically during the bleeding procedure and add brake fluid as
required.
NOTE :
Do not pump the brake pedal at any time while having a bleeder screw open during the bleeding process. This will
only increase the amount of air in the system and make additional bleeding necessary. Do not allow the master
cylinder reservoir to run out of brake fluid while bleeding the system. An empty reservoir will allow additional air into
the brake system. Check the fluid level frequently and add fluid as needed. The following wheel circuit sequence for
bleeding the brake hydraulic system should be used to ensure adequate removal of all trapped air from the hydraulic
system.
Brake Bleeding Procedure
The following wheel circuit sequence for bleeding the brake hydraulic system should be used to ensure adequate
removal of all trapped air from the hydraulic system:
• Left rear wheel
• Right front wheel
• Right rear wheel
• Left front wheel
Manual Brake Bleeding
NOTE :
To bleed the brakes manually, the aid of a helper will be required.
Fill the brake master cylinder reservoir to the proper level with brake fluid.
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12–9Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine NOTE :
Never allow the brake master cylinder to empty of brake fluid while bleeding the brake system.
Attach a clear plastic hose to the bleeder screw and
feed the hose into a clear jar containing enough fresh
brake fluid to submerge the end of the hose.
1. Turn the ignition switch off.
2. Have a helper pump the brake pedal three or four times and hold it in the down position.
3. With the pedal in the down position, open the bleeder screw at least one full turn.
4. Once the brake pedal has dropped, close the bleeder screw. After the bleeder screw is closed, release thebrake pedal.
5. Repeat the above steps until all trapped air is removed from that wheel circuit (usually four or five times).
6. Bleed the remaining wheel circuits in the same manner until all air is removed from the brake system. Monitor the fluid level in the master cylinder reservoir to make sure it does not go dry.
7. Check and adjust brake fluid level to the MAXmark.
8. Check the brake pedal travel. If pedal travel is excessive or has not been improved, some air may still be trapped in the system. Re-bleed the brakes as necessary.
9. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct.
Pressure Brake Bleeding
NOTE :
Follow pressure bleeder manufacturer’s instructions for use of pressure bleeding equipment.
Fill the brake master cylinder reservoir to the proper level with brake fluid.
Attach the pressure bleeding equipment to the master cylinder.
NOTE :
Never allow the brake master cylinder to empty of brake fluid while bleeding the brake system.
Attach a clear plastic hose to the bleeder screw and
feed the hose into a clear jar containing enough fresh
brake fluid to submerge the end of the hose.
1. Turn the ignition switch off.
2. Open the bleeder screw at least one full turn or more to obtain a steady stream of brake fluid.
3. After approximately 120-240 ml of fluid has been bled through the brake circuit and an air-free flow is main- tained in the clear plastic hose and jar, close the bleeder screw.
4. Repeat this procedure at all the remaining bleeder screws.
5. Check and adjust brake fluid level to the MAXmark on the reservoir.
ON-VEHICLE SERVICE
BESM120001
BESM120001
12–10Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 6. Check the brake pedal travel. If pedal travel is excessive or has not been improved, some air may still betrapped in the system. Re-bleed the brakes as necessary.
7. Test drive the vehicle to verify the brakes are operating properly and pedal feel is correct.
Master Cylinder - LHD
Description
The master cylinder body is an anodized aluminum casting. It is located at the left side of the engine room. It has a
machined bore to accept the master cylinder pistons and also has threaded ports with seats for hydraulic brake tube
connections. The master cylinder has the brake fluid reservoir mounted on top of it and supplies brake fluid to the
master cylinder as required. On manual transaxle equipped vehicles, the brake fluid reservoir also feeds the clutch
hydraulic circuit. The reservoir is made of clear plastic and it houses the brake fluid level switch.
Operation
When the brake pedal is pressed, the master cylinder pistons apply brake pressure through the chassis brake tubes
to each brake assembly. The brake fluid reservoir supplies the brake hydraulic system with the necessary fluid to
operate properly.
Removal & Installation
CAUTION:
The vacuum in the power brake booster must be pumped down before removing the master cyl-
inder to avoid damaging the master cylinder and to prevent the booster from sucking in any con-
tamination. This can be done by pumping the brake pedal while the engine is not running until a
firm brake pedal is achieved.
1. Turn the ignition switch off.
2. Siphon out as much brake fluid as possible from the master cylinder.
3. With the engine off, pump the brake pedal 4-5 strokes until the pedal feel is firm.
4. Disconnect the negative battery cable.
5. Disconnect the brake fluid level switch electrical connector in the master cylinder brake fluid reservoir.
6. Disconnect the brake tubes (1) at the master cylin- der outlet ports. Install plugs at all of the open
brake tube outlets on the master cylinder.
(Tighten: Brake tube nuts to 10 N·m)
ON-VEHICLE SERVICE
BESM120006
12
12–11Chery Automobile Co., Ltd.