suspension CHERY TIGGO 2009 Service Repair Manual

Downloaded from www.Manualslib.com manuals search engine 2009
CHERY
Tiggo
Service Manual
FOREWORD
This manual contains on-vehicle service
and diagnosis procedures for the Chery Tiggo.
A thorough familiarization with this manual
is important for proper repair and
maintenance. It should always be kept in a
handy place for quick and easy reference.
The contents of this manual, including
drawings and specifications, are the latest
available at the time of printing. As
modifications affecting repair or
maintenance occur, relevant information
supplementary to this volume will be made
available at Chery dealers. This manual
should be kept up-to-date.
Chery Automobile Company, Ltd. reserves the
right to alter the specifications and
contents of this manual without obligation
or advance notice.
All rights reserved. No part of this book
may be reproduced or used in any form or
by any means, electronic or mechanical—
including photocopying and recording and the
use of any kind of information storage and
retrieval system—without permission in
writing.
NOTE:
This Tiggo service manual only applies to the fol-
lowing engines and transaxles:
• 1.6L with M/T
• 1.8L with M/T
• 2.0L with A/T
• 2.4L with A/T
Chery Automobile Company, Ltd.Wuhu, Anhui Province, CHINA
CONTENTS
Title Section
GENERAL INFORMATION01
ENGINE02
ELECTRONIC ENGINE CONTROLS03
FUEL DELIVERY04
STARTING & CHARGING05
COOLING06
EXHAUST07
TRANSAXLE & TRANSFER CASE08
DRIVELINE & AXLE09
SUSPENSION10
STEERING11
BRAKES12
HEATING & AIR CONDITIONING13
RESTRAINTS14
BODY & ACCESSORIES15
WIRING16
ALPHABETICAL INDEXAI
© 2009 Chery Automobile Co., Ltd.
PRINTED NOVEMBER, 2009

Downloaded from www.Manualslib.com manuals search engine SERVICE MANUAL CHAPTERCOMPONENT / VEHICLE SYSTEM
08 - Transaxle & Transfer Case •
Transaxle Control Module (TCM)
• Automatic Transaxle Shifter Selector
• Automatic Transaxle Assembly
• Manual Transaxle Assembly
• Winter Mode Switch
• EPDE Solenoid Valve
• Backup Lamp Switch
• Integrated Torque Management (ITM) Control Module
09 - Driveline & Axle •None
10 - Suspension •None
11 - Steering •Power Steering Switch
12 - Brakes •
Antilock Brake System (ABS) Module
• Wheel Speed Sensors
• Brake Switch
• Parking Brake Switch
• Brake Fluid Level Switch
13 - Heating & Air Conditioning •
Manual Temperature Control System
• Blower Motor
• A/C Compressor
• Refrigerant Pressure Switch
14 - Restraints •
Restraints Control Module
• Seat Belt Buckle Switch
• Front Crash Sensors
• Driver Airbag
• Passenger Airbag
HOW TO LOCATE ELECTRICAL SCHEMATICS IN THE SERVICE MANUAL
01–26Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 33. Remove the left transaxle mount bolts (2) and thetransaxle mount bracket retaining bolts (1).
(Tighten: Left transaxle mount bolt to 70 N·m)
34. Using special tool CH-20001 (2), remove the three bolts (1) securing the right engine mount.
(Tighten: Engine right mount bolt to 70 N·m)
35. Verify all components between the engine and vehicle are disconnected.
36. Remove the front sub-frame (See Front Sub-Frame Removal & Installation in Section 10 Suspension).
37. Hoist the engine from vehicle.
CAUTION:
Verify all electrical connectors are disconnected prior to engine/transaxle removal.
38. Separate the engine and transaxle.
ON-VEHICLE SERVICE
LTSM020156
LTSM020218
02–36Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 32. Remove the left transaxle mount bolts (2) and thetransaxle mount bracket retaining bolts (1).
(Tighten: Left transaxle mount bolt to 70 N·m)
33. Using special tool CH-20001 (2), remove the three bolts (1) securing the right engine mount.
(Tighten: Engine right mount bolt to 70 N·m)
34. Verify all components between the engine and vehicle are disconnected.
35. Remove the front sub-frame (See Front Sub-Frame Removal & Installation in Section 10 Suspension).
36. Hoist the engine from vehicle.
CAUTION:
Verify all electrical connectors are disconnected prior to engine/transaxle removal.
37. Separate engine and transaxle.
ON-VEHICLE SERVICE
LTSM020156
LTSM020218
02
02–11 0Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 17. Remove both front axle shafts (See Front Axle Shaft Removal & Installation in Section 09 Driveline & Axle).
18. Remove the engine undercover and splash shields.
19. Remove the engine to transaxle lower bolts.(Tighten: Engine to transaxle lower bolts to 80 N·m)
20. Remove the bolts that mount the side sill to vehicle body. (Tighten: Side sill to vehicle body bolts to 120 N·m)
21. Remove the front engine mount bolts (1). (Tighten: Front mount bolts to 60 N·m)
22. Remove the rear engine mount bolts (2) and the rear engine mount bracket bolts (1).
(Tighten: Rear mount bolts to 40 N·m)
23. Remove the sub-frame assembly (See Sub-Frame Assembly Removal & Installation in Section 10 Suspension).
24. Remove the engine to transaxle lower bolts. (Tighten: Transaxle mount bolts to 40 N·m)
25. Separate the transaxle from the engine and remove the transaxle from the vehicle.
WARNING!
Use a suitable jack to support the transaxle during removal.
26. Installation is in the reverse order of removal.
ON-VEHICLE SERVICE
BESM080035
LTSM020188
08–242Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine 20. Remove the rear engine mount bolts (2) and therear engine mount bracket bolts (1).
(Tighten: Rear mount bolts to 40 N·m)
21. Remove the sub-frame assembly (See Sub-Frame Assembly Removal & Installation in Section 10 Suspension).
22. Remove the engine to transaxle lower bolts (1). (Tighten: Transaxle mount bolts to 40 N·m)
23. Separate the transaxle from the engine and remove it from the vehicle.
WARNING!
Support the transaxle with a suitable jack while removing the transaxle.
24. Installation is in the reverse order of removal.
Installation Notes:
•Refill 2.2L transaxle fluid through the fill hole (1)
until the fluid starts to leak from the fill hole.
• After installation, check for any fluid leakage and
verify the transaxle fluid level is correct.
ON-VEHICLE SERVICE
LTSM020188
VISM080002
LTSM080189
08
08–263Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION
Description
This vehicle is equipped with unequal length half shafts, consisting of short left and long right half shafts. The half
shafts consist of a fixed Constant Velocity (CV) joint at the outboard end connected by a solid shaft to a plunging CV
joint on the inboard end. The inner CV joint has a splined end and is attached to the transaxle and is retained with
a snap ring. The outer joint has a splined connection to the wheel hub and is retained with a lock nut.
For further information on the front axle assembly see Front Sub-Frame Assembly Description & Operation in Section
10 Suspension.
Operation
The front axle transmits torque from the transaxle to the wheels. In order to allow vertical and horizontal movement
of the wheels, the axle shafts have plunging CV joints on the inboard ends of the axle shafts.
Specifications
Torque Specifications
DESCRIPTIONTORQUE (N·m)
Front Stabilizer Bar to Stabilizer Bar Link Nuts 40 - 50
Control Arm Knuckle Pin With Knuckle Assembly 110 - 130
Control Arm to Sub-Frame Bolt 170 - 190
Stabilizer Bar Link to Lower Suspension Lever 40 - 50
Front Axle
1 - Front Stabilizer Bar
2 - Right Front Stabilizer Bar Link
3 - Rear Rubber Bushing
4 - Right Control Arm
5 - Sub-Frame Assembly
6 - Longitudinal Beam7 - Front Rubber Bushing
8 - Left Control Arm
9 - Control Arm Knuckle Pin
10 - Left Front Stabilizer Bar Link
11 - Stabilizer Bar
12 - Rubber Support
LTSM090004
09–2Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine DESCRIPTIONTORQUE (N·m)
Right and Left Front Drive Shaft Nuts 260 - 280
Control Arm Knuckle Pin With Control Arm 140 - 160
Front Connecting Rod and Front Shock Absorber 40 - 50
Stabilizer Bar Clamp to Sub-Frame 22 - 28
Rear Rubber Buffer Assembly to Vehicle Body 22 - 28
Front Axle Hub Nut 135
Front Suspension Strut to Vehicle Body 45 - 55
Front Suspension And Bracket 75 - 85
Lower Sub-Frame Insert to Suspension Bolt 110 - 130
Longitudinal Beam to Vehicle (Front) Body Bolt 74 - 86
Upper Link to Trailing Arm Bolt 100 - 120
One On Each Side To Connect Upper Link With Rear
Sub-Frame 80 - 101
One On Each Side To Connect Lower Control Arm With
Trailing Arm 100 - 120
Steering Knuckle and Suspension Strut 110 - 130
Soft Gasket and Bracket of Front Suspension 75 - 85
Tie Rod to Steering Knuckle Nut 35 - 45
Sub-Frame and Gasket Of Vehicle (Front) Body 170 - 190
Sub-Frame and Longitudinal Beam Assembly Bolts 75 - 85
Steering Gear to Sub-Frame Bolts 75 - 85
Wheel Mounting Nut \
\
11 0
Special Tools
Ball Joint Separator CH-10002
Bearing Puller
GENERAL INFORMATION
09
09–3Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine GENERAL INFORMATION
Description
The rear axle utilizes an independent design. This suspension system incorporates a separate wheel knuckle for
each wheel and allows the wheels to react to road imperfections independent of each other. This independent action
offers improved isolation from the effects of jounce and rebound.
The rear axle consists of the following components:
•Wheel Hub
• Wheel Studs
• Wheel Bearing
• Rear Trailing Arm
For further information on the rear axle assembly see Rear Suspension Description & Operation in Section 10 Sus-
pension.
Operation
The rear axle utilizes a sealed wheel bearing housed in the rear knuckle assembly. Rear Axle
1 - Rear Sub-Frame Assembly
2 - Rear Suspension Upper Link
3 - Left Rear Shock Absorber Mounting Bracket
4 - Left Brake Line Bracket
5 - Left Rear Trailing Arm
6 - Rear Stabilizer Bar
7 - Left Rear Lower Control Arm8 - Left and Right Stabilizer Bar Links
9 - Right Rear Connecting Rod
10 - Right Rear Lower Control Arm
11 - Rubber Support Seat
12 - Rear Stabilizer Bar
13 - Rubber Bushing
14 - Right Rear Trailing Arm
LTSM090005
09
09–9Chery Automobile Co., Ltd.

Downloaded from www.Manualslib.com manuals search engine Specifications
Torque Specifications
DESCRIPTIONTORQUE (N·m)
Rear Stabilizer Bar Link 40 - 50
Rear Shock Absorber to Mounting Bracket Bolts 40 - 50
Rear Axle Front Suspension to Rear Driving Axle Bolts 75 - 85
Rear Axle Front Suspension to Rear Sub-Frame Bolts 115 - 125
Left and Right Rear Half-Shaft to Disc Brake Nut 260 - 270
Left and Right Rear Half-Shaft to Axle Output Flange
Bolts 40
Intermediate Drive Shaft to Rear Axle Flange Bolts 59 - 71
Rear Axle Rear Suspension Mount Assembly to Rear
Axle Bolt 75-85
Rear Axle Rear Suspension Mount to Vehicle Body Bolt 75 - 85
Rear Rubber Buffer to Vehicle Body Bolts 22 - 28
Upper Link to Rear Sub-Frame Bolts 100 - 120
Lower Control Arm to Rear Sub-Frame Bolts 100 - 120
Rear Trailing Arm to Vehicle Body Bolts 140 - 160
Rear Suspension to Bracket Bolts 115 - 125
Rear Suspension, Longitudinal Beam of Engine to
Sub-Frame Bolts 75-85
Rear Stabilizer Bar Clamp to Vehicle Body Bolts 22 - 28
Rear Trailing Arm to Vehicle Body Bolts 140 - 160
Rear Cover of Control Arm to Sub-Frame Bolts 170 - 190
Soft Gasket to Bracket Of Rear Suspension Bolts 110 - 130
Sub-Frame And Gasket Of Vehicle (Rear) Body Bolts 170 - 190
Wheel Mounting Nut \
\
11 0
Special Tools
Bearing Puller
GENERAL INFORMATION
09–10Chery Automobile Co., Ltd.