The brake system of the car needs to be checked carefully regarding damage of knots, the wrong assembly of knots or damage of details to system of brake pipelines and cylinders. At detection of malfunctions they have to be immediately eliminated. The system of production of the fulfilled gases, the stabilizer of cross stability and longitudinal levers of a back suspension bracket belong to knots and details of the car which because of the wrong assembly or shift can damage the brake system.

Fig. 11.6. Tank of the main brake cylinder

1. Turn off a cover of a tank of the main brake cylinder and close its dense tight cover (fig. 11.6).

2. Lift the car on the elevator and remove back wheels, having noted their situation.

3. Turn off самоконтрящуюся a nut of the tension device.

Fig. 11.7. Removal of a locking bracket

4. Remove a locking bracket (fig. 11.7) from a bar of the tension device.

5. Disconnect a cable from the tension device.

6. Take out a cable of the parking brake from the guides located on the body bottom tunnel, disconnect a plastic cover of a cable from a hook on the fuel tank and take aside the muffler.

7. Disconnect fastening of the muffler to the body bottom.

Fig. 11.8. Removal of brake hoses

8. Unscrew brake hoses from the brake pipeline at an arm of a back axis and remove locking brackets (fig. 11.8).

9. Take out hoses from an arm.

Fig. 11.9. Device for a hydraulic jack

10. Place the hydraulic jack supplied with a special nozzle under the longitudinal lever of a back axis and slightly raise an axis. The special device for a jack for simplification of assembly/dismantling has to be manufactured in a workshop according to the drawing in fig. 11.9. Notice that the size A has to correspond to the similar size of a jack from a car set.

11. Remove shock-absorbers.

12. If necessary, having used mount, release the shock-absorber from an arm of the longitudinal lever of a back suspension bracket.

13. Lower a jack.

Fig. 11.10. Removal of a spring of a back suspension bracket

14. Remove a spring of a back suspension bracket. If it is necessary, wring out a back suspension bracket, having placed mount in a shock-absorber arm, and get a spring of a back suspension bracket (fig. 11.10).

15. Remove the shock-absorber and a spring of a suspension bracket on the other side of the car.

Fig. 11.11. Removal of knot of a back suspension bracket

16. Place a jack under the middle of a back beam (fig. 11.11).

17. Turn off and remove fastening of a back beam to the car body bottom.

18. Lower a jack. Put a cable of the parking brake on the muffler.

Fig. 11.12. Knot of a back suspension bracket

1. Remove knot of a back suspension bracket from a hydraulic jack (two persons are necessary) and fix it in a vice with protective slips on sponges (fig. 11.12).

2. Unscrew the screw of fastening of the brake drum and remove the brake drum. If it is required, using the screw-driver, wring out the lever of brake shoes.

3. Take off a dustproof cap from a wheel nave.

4. Get the forelock from a nut of fastening of the hug bearing and turn off a nut.

5. Remove a nave from an axis.

6. Unbend brackets of fastening of the brake pipeline.

7. Turn off and remove brake boards from longitudinal levers of a back suspension bracket.

8. Turn off fastenings of the stabilizer of cross stability.

9. Remove the stabilizer from a back suspension bracket. If necessary use a drift to take out the stabilizer from a saddle on a back beam.

10. Disconnect fastening of a cable of the parking brake.

Fig. 11.13. Installation of the stabilizer of cross stability

1. Install the stabilizer in a new back beam and screw it, having tightened nuts the moment of 80 N • m (fig. 11.13).

2. Apply a thin film of the condensing lubricant on a back surface of a brake board.

3. Establish paper laying into place.

4. Apply a thin film of the blocking means interfering an otvorachivaniye of bolts on a carving of bolts.

Fig. 11.14. Installation of a brake board

5. Screw a brake board into place, tightening bolts the moment of 28 N • m (fig. 11.14).

6. Place the brake pipeline in brackets and clamp them.

7. Install the device of adjustment of brake shoes in extreme top situation.

8. Apply on a wheel axis lubricant in the field of a brake board.

Fig. 11.15. Installation of a nave of a back wheel

9. Establish a nave and a fixing washer on an axis and wrap a nut of fastening of the bearing the moment of 26 N • m (fig. 11.15).

10. Adjust a gap of the hug bearing of a back wheel.

11. Install brake drums and fix them by bolts.

1. Establish a back suspension bracket on a hydraulic jack (two persons are required).

2. Arrange a cable of the parking brake over the muffler.

3. Lift a back suspension bracket and attach it to the body bottom.

4. Arrange a hydraulic jack with special adaptation under one of longitudinal levers of a back suspension bracket and raise it a little.

5. Establish springs of a back suspension bracket with the lower rubber laying in the lower cups, having placed the top ends of a spring with support in the top cups in the body bottom.

6. Raise the suspension bracket lever a hydraulic jack a little more and insert the shock-absorber into an arm. If openings were not combined and the bolt is not inserted for combination of an opening, use a drift.

Fig. 11.16. Tightening of a bolt of fastening of the back shock-absorber

7. Tighten a bolt of fastening of the shock-absorber the moment of 70 N • m (fig. 11.16).

8. Lower a jack.

9. Insert brake hoses into a bracket on a beam of the back bridge and attach them.

10. Connect hoses to the brake pipeline.

11. Suspend the second section of an exhaust pipe on an arm on the body bottom.

12. Fix a brake cable according to the tags applied before removal on an arm of a beam of the back bridge, on an arm on the bottom of the fuel tank, on an arm of the bottom of a body and on the device of adjustment of a tension of a cable.

13. Lower the car a little and establish wheels.

1. At the released parking brake tighten an adjusting nut of the regulator of a tension of a cable from the moment of delay of rotation of wheels to their full stop.

2. Adjust a gap in bearings of naves of back wheels.

3. Lower the car and tighten bolts of fastening of knot of a back suspension bracket the moment of 90 N • m.

4. Having hung out the car on border height, insert a bolt of fastening of the longitudinal lever of a back suspension bracket to an arm of a body and tighten the moment 95 N • m. During tightening of a bolt on front seats freight on 70 kg has to settle down.

5. Adjust brakes of back wheels:

– remove air from the hydraulic drive of the brake system;

– check the brake system for existence of thinnesses;

– adjust the parking brake.

1. Lift the car on the elevator and you will hang out wheels.

2. Using a hydraulic jack with special adaptation, lift one lever of a back suspension bracket.

3. Turn out a bolt of fastening of the shock-absorber.

4. Lower a hydraulic jack a little to remove a spring of a back suspension bracket and both rubber laying.

5. Again raise the lever of a suspension bracket and install the shock-absorber.

6. Repeat these operations on the other side of the car.

7. Establish a hydraulic jack in the middle of a beam of the back bridge.

8. Remove brackets of fastening of brake hoses to the body bottom.

9. Place brake hoses and cables of the parking brake in bottom cavities.

10. Turn off fastenings of a back suspension bracket to the car bottom.

11. Take out fastening bolts from an arm.

12. If it is necessary, easily wring out a back axis the screw-driver.

Fig. 11.17. Installation of KM-452 adaptation under the car bottom

13. Lower a back suspension bracket a little and install KM-452-5 adaptation under the car bottom (fig. 11.17).

14. Attach KM-452 adaptation a bolt of fastening of a back suspension bracket to the car bottom.

Fig. 11.18. Use of a chisel for removal of a forward part of the plug

15. By means of a chisel get a forward part of the plug (fig. 11.18).

16. In order to avoid damage of knot of a back suspension bracket dull a chisel a little.

Fig. 11.19. Fastening of KM-452-1 and 452-2 devices to knot of a back suspension bracket

17. Attach KM-452-1 and 452-2 devices to knot of a back suspension bracket (fig. 11.19).

18. Make sure that KM-452-2 adaptation is installed correctly (an arrow in the drawing 11.19).

19. For simplification of a vypressovka of the hinge by means of the industrial fan warm up hot air a back axis in the location of the hinge to 50–70 °C.

       PREVENTION

Do not use for warming up sources with an open flame.

20. Rotating a six-sided nut, take the rubber-metal hinge from the lever of a back suspension bracket.

1. Before assembly cover the new hinge with a thin layer of safety lubricant.

Fig. 11.20. Installation of the hinge

2. Insert the hinge into the lever of a back suspension bracket (fig. 11.20).

3. Check correctness of installation of the hinge.

Fig. 11.21. Installation of the rubber-metal hinge of the lever of a back suspension bracket

4. Using KM-452-3 and KM-452-4 devices, press the hinge in the lever until the ledge of adaptation does not rest against the lever (fig. 11.21).

5. Remove KM-452-2 adaptation from an arm of a suspension bracket and establish on the other side of a suspension bracket beam.

6. Also replace with Vypressuyte the second rubber-metal hinge, repeating the procedure given above.

7. Lift a back suspension bracket a hydraulic jack and attach the lever a bolt to an arm in the bottom.

8. Lower a suspension bracket a hydraulic jack a little.

9. Establish a spring of a back suspension bracket.

10. Again lift a suspension bracket and install the shock-absorber.

11. Lower a suspension bracket a hydraulic jack and establish into place a spring and the shock-absorber of a back suspension bracket on the other side of the car as it was described above.

12. Lower the car.

Delay fastening of a back suspension bracket. For loading of the car during an inhaling put on forward sitting of two mechanics. Delay fastening of the lever of a suspension bracket to an arm the moment of 95 N • m.

1. Lift the car.

2. Remove a back wheel.

Fig. 11.22. Otzhatiye of the lever of blocks of the parking brake

3. Remove the brake drum. Turn out the adjusting screw and weaken cables of the parking brake by means of the adjustment device if it is necessary. The screw-driver wring out inside the lever of blocks of the parking brake (fig. 11.22).

4. Having hooked, take off a hug bearing cap.

5. Remove the forelock from a nut of fastening of the hug bearing and turn off a nut.

Fig. 11.23. Removal of a nave of a back suspension bracket

6. Remove a nave and a persistent washer from a nave (fig. 11.23).

7. Clear an axis of dirt and examine on existence of damages.

1. By means of KM-266-4 adaptation press an external ring of the external bearing in a nave against the stop.

2. By means of KM-266-4 adaptation press an external ring of the internal bearing in a nave against the stop.

Fig. 11.24. Press fitting of the internal conic bearing

3. Insert the internal conic bearing into a nave (fig. 11.24).

Fig. 11.25. Press fitting of a sealing ring

4. Having used the plug of the corresponding diameter, press the condensing ring in a nave (fig. 11.25).

5. Apply dense lubricant on a surface and in both bearings of naves of wheels, on the condensing surface of sealing rings and in a cavity of naves.

6. If necessary tighten the adjusting device.

7. Establish a nave with a persistent washer on a nave axis.

9. Screw a nut of fastening of the hug bearing.

10. Install the brake drum and tighten the adjusting screw of fastening of a drum the moment of 90 N • m.

11. Adjust a gap of hug bearings.

12. Lower the car.

13. Adjust brakes of back wheels.

14. If it is necessary, adjust the parking brake.

As the required operations are almost identical described in the head "A nave of a back wheel", the description only of additional operations is given below.

Fig. 11.26. Use of the screw-driver for removal of a sealing ring

1. Using the screw-driver as the lever, remove a sealing ring (fig. 11.26).

2. Take the internal conic bearing from a nave.

Fig. 11.27. Use of KM-266-2, KM-266-3 and KM-466-2 devices for a vypressovka of an external ring of the internal bearing from a nave

1. KM-266-2 and KM-266-3 devices together with KM-466-2 adaptation to a vypressuyta an external ring of the internal bearing from a nave (fig. 11.27).

2. KM-266-1 and KM-266-3 devices together with KM-466-2 adaptation to a vypressuyta an external ring of the external bearing from a nave.

1. Remove a nave of a back wheel.

Fig. 11.28. Use of the screw-driver for removal of a sealing ring

2. Using the screw-driver as the lever, remove a sealing ring (fig. 11.28).

Fig. 11.29. Press fitting of a sealing ring

1. Using the plug of suitable diameter, press a sealing ring in a nave (fig. 11.29).

2. Apply dense lubricant for bearings on the condensing edge of a ring.

3. Establish a nave.

1. Lift the car on the elevator.

2. By means of a hydraulic jack raise one longitudinal lever of a back suspension bracket a little. Use for this purpose the special adaptation manufactured in a workshop (see fig. 11.9).

Fig. 11.30. Otvorachivaniye of a bolt of fastening of the back shock-absorber

3. Turn off a bolt of fastening of the shock-absorber and take out it from an arm of the lever of a back suspension bracket (fig. 11.30). If necessary use mount.

4. Lower a hydraulic jack.

Fig. 11.31. Removal of a spring of a back suspension bracket

5. Take out a spring of a back suspension bracket together with the top laying from cups in the bottom of a body and on the lever of a back suspension bracket (fig. 11.31).

6. Remove the top laying with the compression course limiter from a spring.

Fig. 11.32. Installation of the limiter of the course of compression

1. Establish rubber laying with the course limiter on a back spring (fig. 11.32).

2. To establish a spring in plates of a suspension bracket for what mount wring out a bridge beam down and insert a spring.

3. By means of a hydraulic jack lift a beam of the bridge and install the shock-absorber.

4. Fix the shock-absorber by a bolt, having tightened its moment 70 N • m.

5. Similarly remove and establish a spring on the other side of the car.

6. Lower a hydraulic jack.

7. Lower the car.

Because of a design of a suspension bracket of the back bridge removal and installation of shock-absorbers can be made only serially. The procedure given below describes removal and installation of the shock-absorber on the one hand of the car. Removal and installation of the shock-absorber on the other hand is made similarly.

1. Take off a protective cap from the top part of the shock-absorber.

Fig. 11.33. Removal of a basic washer and pillow of the shock-absorber

2. Turn off a six-sided nut and remove a basic washer and a pillow of the shock-absorber (fig. 11.33).

3. Lift the car on the elevator.

4. Turn off a bolt of fastening of the shock-absorber to the lever of a back suspension bracket.

Fig. 11.34. Removal of the shock-absorber

5. Remove the shock-absorber from an arm (fig. 11.34). If necessary use mount.

Fig. 11.35. Installation of the shock-absorber

6. Install the new shock-absorber in an arm of the lever of a back suspension bracket (fig. 11.35). Installation of an eye of the shock-absorber in an arm can be made by means of a plastic kiyanka.

7. By means of a suitable drift combine a shock-absorber eye with an opening in a suspension bracket lever arm.

Fig. 11.36. Installation of a bolt of fastening of the shock-absorber by means of a kiyanka

8. Easy blows of a plastic kiyanka insert against the stop a bolt of fastening of the shock-absorber into an arm opening (fig. 11.36).

9. Tighten a bolt the moment of an inhaling of 70 N • m.

10. Partially lower the car.

1. Insert top the end of the shock-absorber with the buffer and a washer into an arch.

2. Make sure that the washer of the shock-absorber is located correctly.

3. Lower the car.

4. Establish a shock-absorber pillow, a basic washer and screw a nut.

Fig. 11.37. Tightening of a nut of fastening of the top end of the shock-absorber

5. Tighten a nut the moment of an inhaling of 18 - 20 N • m (fig. 11.37).

6. Dress a protective cap on the top end of the shock-absorber.

Fig. 11.38. Removal of a basic washer and pillow of the shock-absorber

1. Turn off a six-sided nut and remove a basic washer and a pillow of the shock-absorber (fig. 11.38).

2. Raise the car a little.

       PREVENTION

Do not lift the car too highly, otherwise the spring of a suspension bracket will leave a plate in the body bottom.

1. Pull for the shock-absorber down and remove a rubber pillow.

Fig. 11.39. Installation of a rubber pillow of the shock-absorber

2. Install a new pillow on the shock-absorber (fig. 11.39).

3. Lower the car.

4. Install a pillow and a basic washer on the shock-absorber.

5. Tighten a nut the moment of 18-20 N • m.

1. Lift the car.

2. Remove one back wheel.

Fig. 11.40. Otvorachivaniye of bolts of fastening of the stabilizer of cross stability

3. Turn off bolts of fastening of the stabilizer on both sides of a back beam (fig. 11.40).

4. Remove rubber laying from knot of a back suspension bracket.

1. Shift the stabilizer towards the removed wheel and remove it from a back beam.

Fig. 11.41. Installation of the stabilizer of cross stability

2. Install the stabilizer on a back beam and fix by bolts, having tightened their moment 80 N • m (fig. 11.41).

3. Apply liquid soap solution on rubber laying and insert it into knot of a back suspension bracket.

4. Establish a back wheel.

5. Fix a wheel by bolts, having tightened their moment 90 N • m.

6. Lower the car.

Fastening of a back suspension bracket to the body bottom........ 105 N • m

Koronchaty nut of fastening of the hug bearing of a back wheel........ 25 N • m

Fastening of the stabilizer of cross resistance to a back beam........ 80 N • m

Bolt of fastening of the shock-absorber to an arm......... 70 N • m

Bolts of fastening of back wheels......... 90 N • m

Fastening of an axis of a back wheel to the lever of a back suspension bracket......... 70 N • m

Nuts of connections of pipelines of the brake system......... 3 N • m