sensor CHERY TIGGO 2009 Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine Operating Components Condition
•Related Operating Components
RELATED OPERATING COMPONENT
GEARSHIFT LEVER
POSITION GEAR
RATIO ENGINE
START PARKING
MECHANISM DRIVE
LOCK
LOW
SPEED
CLUTCH (UD) REVERSE
GEAR
CLUTCH (REV) OVERSPEED
CLUTCH(OD) LOW
GEAR/
REVERSE GEAR
BRAKE (L/R) GEAR
2ND
BRAKE (2ND) ONE-
WAY
CLUTCH (OWC)
P Parking - Enabled -- - --
R Reverse
Gear 2.480 -
-- ---
N Neutral
Gear - Enabled -
-- ---
D Gear 1 2.842 -
--- *-
Gear 2 1.529 - ---- -
Gear 3 1.000 - --  ---
Gear 4 0.712 - --  - -
3 Gear 1 2.842 -
--- *-
Gear 2 1.529 - ---- -
Gear 3 1.000 - --  ---
2 Gear 1 2.842 -
--- *- 
Gear 21.529

- ---- -
L Gear 1 2.842 - --- --
* Low gear/reverse gear is applied when vehicle speed is lower than 10 km/h. Operating components
On Board Diagnostic Logic
•Self-diagnosis detection logic.
DTC NO. DTC DEFINITION DTC DETECTION
CONDITION DTC SET
CONDITION POSSIBLE CAUSES
43 Third gear, ratio out
of limits Vehicle is driving •
The Transaxle
Control Module
(TCM) will set this
DTC when the TCM
detected that 3rd
Gear Ratio Error is
already present. The
output shaft speed
signal is increased.
• If the DTC was
set 4 times, then the
A/T will be locked in
3rd gear (D gear). •
Input shaft speed
sensor
• Output shaft speed
sensor
• The retainer of
deceleration clutch
• Transfer case
driven and drive gear
• Overdrive clutch
system
• Low speed clutch
system
• Noise interference
DTC Confirmation Procedure:
Before performing the following procedure, confirm that battery voltage is more than 12 V.
• Connect the X-431 scan tool to the Data Link Connector (DLC) - use the most current software available.
• After connection, press POWER key to start X-431.
DIAGNOSIS & TESTING
08
08–219Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Operating Components Condition
•Related Operating Components
RELATED OPERATING COMPONENT
GEARSHIFT LEVER
POSITION GEAR
RATIO ENGINE
START PARKING
MECHANISM DRIVE
LOCK
LOW
SPEED
CLUTCH (UD) REVERSE
GEAR
CLUTCH (REV) OVERSPEED
CLUTCH(OD) LOW
GEAR/
REVERSE GEAR
BRAKE (L/R) GEAR
2ND
BRAKE (2ND) ONE-
WAY
CLUTCH (OWC)
P Parking - Enabled -- - --
R Reverse
Gear 2.480 -
-- ---
N Neutral
Gear - Enabled -
-- ---
D Gear 1 2.842 -
--- *-
Gear 2 1.529 - ---- -
Gear 3 1.000 - --  ---
Gear 4 0.712 - --  - -
3 Gear 1 2.842 -
--- *-
Gear 2 1.529 - ---- -
Gear 3 1.000 - --  ---
2 Gear 1 2.842 -
--- *- 
Gear 21.529

- ---- -
L Gear 1 2.842 - --- --
* Low gear/reverse gear is applied when vehicle speed is lower than 10 km/h. Operating components
On Board Diagnostic Logic
•Self-diagnosis detection logic.
DTC NO. DTC DEFINITION DTC DETECTION
CONDITION DTC SET
CONDITION POSSIBLE CAUSES
44 Fourth gear, ratio
out of limits Vehicle is driving •
The Transaxle
Control Module
(TCM) will set this
DTC when the TCM
detected that 4th
Gear Ratio Error is
already present. The
output shaft speed
signal is increased.
• If the DTC was
set 4 times, then the
A/T will be locked in
3rd gear (D gear). •
Input shaft speed
sensor
• Output shaft speed
sensor
• The retainer of
deceleration clutch
• Transfer case
driven and drive gear
• Low speed clutch
system
• Overdrive clutch
system
• 2nd brake system
• Noise interference
DTC Confirmation Procedure:
Before performing the following procedure, confirm that battery voltage is more than 12 V.
• Connect the X-431 scan tool to the Data Link Connector (DLC) - use the most current software available.
DIAGNOSIS & TESTING
08
08–225Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Operating Components Condition
•Related Operating Components
RELATED OPERATING COMPONENT
GEARSHIFT LEVER
POSITION GEAR
RATIO ENGINE
START PARKING
MECHANISM DRIVE
LOCK
LOW
SPEED
CLUTCH (UD) REVERSE
GEAR
CLUTCH (REV) OVERSPEED
CLUTCH(OD) LOW
GEAR/
REVERSE GEAR
BRAKE (L/R) GEAR
2ND
BRAKE (2ND) ONE-
WAY
CLUTCH (OWC)
P Parking - Enabled -- - --
R Reverse
Gear 2.480 -
-- ---
N Neutral
Gear - Enabled -
-- ---
D Gear 1 2.842 -
--- *-
Gear 2 1.529 - ---- -
Gear 3 1.000 - --  ---
Gear 4 0.712 - --  - -
3 Gear 1 2.842 -
--- *-
Gear 2 1.529 - ---- -
Gear 3 1.000 - --  ---
2 Gear 1 2.842 -
--- *- 
Gear 21.529

- ---- -
L Gear 1 2.842 - --- --
* Low gear/reverse gear is applied when vehicle speed is lower than 10 km/h. Operating components
On Board Diagnostic Logic
•Self-diagnosis detection logic.
DTC NO. DTC DEFINITION DTC DETECTION
CONDITION DTC SET
CONDITION POSSIBLE CAUSES
46 Reverse gear, ratio
out of limits Vehicle is driving •
The Transaxle
Control Module
(TCM) will set this
DTC when the TCM
detected that
reverse Gear Ratio
Error is already
present. The output
shaft speed signal is
increased.
• If the DTC was
set 4 times, then the
A/T will be locked in
3rd gear (D gear). •
Input shaft speed
sensor
• Output shaft speed
sensor
• The retainer of
deceleration clutch
• Transfer case
driven and drive gear
• Reverse gear
clutch system
• low gear/reverse
gear brake (L/R)
system
• Noise interference
DTC Confirmation Procedure:
Before performing the following procedure, confirm that battery voltage is more than 12 V.
• Connect the X-431 scan tool to the Data Link Connector (DLC) - use the most current software available.
DIAGNOSIS & TESTING
08
08–231Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine On Board Diagnostic Logic
•Self-diagnosis detection logic.
DTC NO. DTC DEFINITION DTC DETECTION
CONDITION DTC SET
CONDITION POSSIBLE CAUSES
54 Electrical relay open
circuit Ignition switch on •
The Transaxle
Control Module
(TCM) will set this
DTC when the TCM
detected that the
A/T control voltage
is below 7 V.
• If the DTC was
set, then the A/T will
be locked in 3rd
gear (D gear) or
shifted to low gear
when in sports
mode. •
A/T control relay
• Harness or
connectors (The
sensor circuit is open
or shorted)
• TCM
DTC Confirmation Procedure:
Before performing the following procedure, confirm that battery voltage is more than 12 V.
• Connect the X-431 scan tool to the Data Link Connector (DLC) - use the most current software available.
• After connection, press POWER key to start X-431.
• Turn the ignition switch on.
• With the scan tool, view and erase stored DTCs in the TCM.
• Start engine and warm it to normal operating temperature.
• With the scan tool, select view DTC and data stream.
• If the DTC is detected, the DTC condition is current. Go to Diagnostic Procedure - Step 1.
• If the DTC is not detected, the DTC condition is intermittent (See Diagnostic Help and Intermittent DTC Trou-
bleshooting in Section 08 Transaxle & Transfer Case for more information).
NOTE :
While performing electrical diagnosis & testing, always refer to the electrical schematics for specific circuit
and component information.
Diagnostic Procedure
1.CHECK GROUND CONNECTION
• Turn ignition switch off.
• Loosen and retighten ground screws on the body (See Ground Inspection in Section 12 Brakes).
• Inspect the ground connection C-201 mounting position (See Vehicle Wiring Harness Layout - Main Harness in
Section 16 Wiring).
Are the ground connections OK?
Ye s>>Go to the next step.
No
>>Repair or replace the ground connections.
DIAGNOSIS & TESTING
08
08–237Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine ON-VEHICLE SERVICE
F4A4 Automatic Transaxle Assembly
Removal & Installation
1. Raise and support the vehicle.
2. Disconnect the negative battery cable.
3. Remove the battery and battery tray (See Battery Removal & Installation in Section 05 Starting & Charging).
4. Remove the air cleaner and air duct assembly.
5. Drain the cooling system (See Cooling System Draining Procedure in Section 06 Cooling System).
6. Remove the base mounting bolts (1) of the aircleaner housing assembly.
7. Disconnect and remove the electrical connectors for the following components:• Output shaft sensor (1)
• Input shaft sensor (2)
• Electromagnetic valve switch connector (3)
• Gear switch connector (5)
8. Disconnect the transaxle fluid lines (6) using a suit- able tool.
9. Remove the shift cable (4) from the transaxle assembly.
10. Remove the starter motor (See Starter Removal & Installation in Section 05 Starting & Charging).
BESM080038
LTSM080153
08–240Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine ON-VEHICLE SERVICE
Manual Transaxle Assembly
Removal & Installation
NOTE :
The following special tools are required to perform the repair procedure:
•MB-990938 - Handle
• MB-990935 - Installer Connector
1. Raise and support the vehicle.
2. Disconnect the negative battery cable.
3. Remove the battery and battery tray (See Battery Removal & Installation in Section 05 Starting & Charging).
4. Remove air cleaner and air duct.
5. Drain the cooling system (See Cooling System Draining Procedure in Section 06 Cooling System).
6. Remove the base mounting of the air cleaner housing assembly.
7. Remove the backup lamp switch (2) and vehicle speed sensor (1).
LTSM020226
LTSM030029
08–260Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 8. Install the transaxle housing.
9. Applya1mmto1.2mmdiameter of sealant onthe specified position of the transaxle housing.
CAUTION:
The sealant line applied should be uniform and
continuous and without breaks.
10. Tighten the transaxle housing bolts to the specified torque.
11. Install the bottom transaxle cover.
12. Applya1mmto1.2mmdiameter of sealant on the specified position of the transaxle housing.
CAUTION:
The sealant line applied should be uniform and
continuous and without breaks.
13. Apply transaxle fluid to the O-ring of speed sensor.(Transaxle fluid: 75W-90)
MANUAL TRANSAXLE UNIT REPAIR
LTSM080032
LTSM080033
LTSM080034
08
08–277Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 14. Install the vehicle speed sensor.
15. Install the gear shifting arm assembly. Apply lubri-cating fluid on the contact surface of the gear shift-
ing drive slider and the gear shifting arm assembly.
(The specified lubricating fluid: Mobilux Ep2)
STATUS OF SWITCH CIRCUIT
Pressed Off
Released On
16. Inspect the backup lamp switch. Inspect the switch for broken terminal or an open circuit.
Input Shaft
Specifications
Clearance Specifications
SYNCHRONIZER RING VALUE OF A (mm)WEARING LIMIT
1st-2nd Gear 1.10 - 1.170.05 mm
3rd-4th Gear 1.35 - 1.900.05 mm
5th Gear 1.10 - 1.170.05 mm
MANUAL TRANSAXLE UNIT REPAIR
LTSM080035
LTSM080036
08–278Chery 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.