Chapter 4 Wheel suspensions
Contents
1. Fig 4 7 Front suspension exploded view 1 coil spring lower seat 2 lower control arm 3 lower arm shaft 4 lower control arm silent block 5 coil spring 6 upper seat 7 spring insulator gasket 8 com pression buffer 9 compression restrictor 10 suspension crossmember 11 lower control arm shaft bush 12 crossmember bracket 13 engine mounting bracket 14 spring upper mounting 15 shim 16 upper control arm shaft 17 upper control arm 18 recoil buffer bracket 19 recoil buffer 20 upper control arm silent block 21 balljoint 22 boot 23 body to tie rod mounting bracket 24 tie rod 25 shock absorber 26 securing clamp 27 rubber pad Note When removing the upper arm shaft note the amount and arrangement of washers between the upper arm shaft and the crossmember and also the number of shims between the crossmember and car body chassis arm so that at refitting all washers and shims will be properly replaced Disconnect the engine mounting rubber pads from the cross member brackets Place a hydraulic jack with a fixing tool under the suspension crossmember support the engine with arm 67 7820 9514 or hoist disconnect the recoil bumper bracket 47 and the cross member from the body chassis Remove the crossmember 1 in assembly with lower arms 4 The installation of suspension parts and units is done in reverse order The springs on the suspension should be2. balljoint Fig 4 13 Press fitting the lower control arm balljoint 1 tool 2 balljoint 3 cap 109 The lower arm The pressing out and press fitting of the joint can be carried out on a press using tool 67 7823 9526 and also with tool 67 7823 9517 fig 4 12 which is installed on the arm so that the head of the tool screw was directed inside Tighten the tool screw to press out the joint For press fitting insert the joint into the arm bezel and fit tool 67 7823 9517 fig 4 13 complete with cap 3 By tightening the fixture screw press fit the joint in the arm bezel Rear suspension The design of the rear suspension is shown on fig 4 14 Suspension removal and refitting Removal Lift the rear part of the vehicle and place it on sup ports Take off the rear wheels Disconnect the propeller shaft from the final drive gear flange Disconnect the hose of the brake hydraulic system from the steel tube on the axle and make arrangements to prevent liquid leaking from the brake system Disconnect the handbrake rear cable brackets from the body remove the front cable return spring and after undoing the locknut and the adjusting nut release the rear cable Disconnect from the bracket on the axle beam the tie rod 13 see fig 4 14 of the rear brake pressure regulator drive Disconnect the top ends of shock absorbers 25 Put under the rear axle beam a hydraulic jack Disconnect the longitudinal 3 an
3. installed only of one class class A not marked or has marks by white paint class B with black marks on the outer surface of the coils It is permissible to install springs of A class on the front suspen sion if B class springs are fitted on the rear suspension After reassembly and suspension refitting check the wheel alignment angles and toe in Suspension units dismantle and reassembly Dismantle f the suspension repair requires complete dis mantle of the units it is more convenient to begin directly on the vehicle after removing the crankcase protective plate and the splash guard Proceed as follows undo the upper balljoint 41 see fig 4 1 pin nut and remove the clips from hoses unbend the protective casing blades turn out the fastening bolt of the caliper carrier and move the whole assembly aside ATTENTION To avoid damaging the hoses do not leave the caliper to hang on hoses using tool 67 7823 9514 remove the hub cap and undo the wheel hub bearing nut 107 remove the front wheel hub in assembly with the brake disc using pusher 67 7823 9516 remove the front brake splash guard remove the front suspension shock absorber lower the suspension lower arm on a support and compress the suspension spring to fully unload the lower arm disconnect the balljoint housing from the suspension lower and upper control arms and remove the steering knuckle smoothly unload the suspension s
4. mm and class B length is equal to or less than 192 mm The springs of A class can be not marked or have marks with white paint on the external side of coils spring of B class are marked with black paint On the front suspension the springs of the same class as those on the rear suspension should be installed As an excep tion when on the rear suspension the springs of B class are installed and there are no springs of the same class available for Fig 4 8 Inspecting the balljoint on fixture 02 8701 9502 1 balljoint 2 indicator 3 dynamometer 4 fixture 02 8701 9502 A method of checking the radial clearance B method of checking the axial clearance 6276H 640krc 278 Fig 4 9 Main parameters for checking the front suspension coil spring 108 Fig 4 10 Pressing out the upper control arm balljoint 1 control arm shaft 2 tool 67 7823 9527 3 balljoint 4 tool A 47045 the front suspension it is permissible to install the A class springs on the front suspension But you can not install the B class springs on the front suspension if the A class springs are installed on the rear suspension Inspect the gaskets and renew if they have damages Anti roll bar suspension arms steering knuckle Check the bar for deformations and ensure that the ends lie in one plane if deformation is insignificant the bar can be straightened at significant deformations renew the b
5. peeling from the metal fixture traces of grease leaks are permissible Check for wear of balljoint working surfaces by manually turning the ballpin No free play or pin jamming is allowed A more profound check of the balljoint radial and axial clear ances is carried out on fixture 02 8701 9502 Place the balljoint 1 fig 4 8 A in the fixture bezel and fix with screw Fit in the fix ture bracket indicator 2 so that the indicator leg will rest against the side surface of the balljoint housing the indicator arrow should point to zero Fit the dynamometer 3 in the fixture bezel and apply torque of 196 Nem 20 kgfem in both directions determine by indicator 2 the total radial clearance in the balljoint If it exceeds 0 7 mm renew the joint Make the similar check of the balljoint axial clearance previ ously having changed its fastening in the fixture as shown on fig 4 8 B The axial clearance in the joint should not exceed 0 7 mm Suspension springs Carefully examine the springs If any deformations affecting the spring efficiency will be found renew the springs To check the spring set down fully compress it three times The spring compression is made along the spring axis the bear ing surfaces should meet the vehicle suspension spring seats Then apply load of 6 276 N 640 kgf According to the spring length see fig 4 9 under the specified load the springs are divided into two classes class A length more than 192
6. rings and seals 25 The bearing outer rings are pressed off using washer 67 7853 9534 and press fit ted with tool 67 7853 9536 Mark the bearing rings so that to put them on former place when reassembling 105 a Fig 4 6 Front suspension on the vehicle rear view 1 lower control arm 2 crossmember 3 tie rod fastening bracket 4 anti roll bar to body securing bracket 5 tie rod 6 anti roll bar remove old greasing and wash with kerosine the inner cav ity of the steering knuckle the outer and inner cavities of the hub the CV join case tail and bearings fill 40 gr of fresh IUTON 24 in bearing cages spread even ly in the cavity of the steering knuckle between the bearings grease the splines of the joint casing tail fit the bearing inner rings the oil seal bush and press fit the sealings fit the steering knuckle on the joint case tail and connect the balljoint to the lower arm fix the shock absorber and attach the side tie rod of the steering mechanism to the steering knuckle arm fit the hub in assembly with brake disc on the joint case tail and establish the taper bush 21 turn the new adjusting nut and adjust the gaps in wheel hub bearings using tool 67 7853 9528 fit the wheel hub cap replace the brake caliper and the wheel Note In all cases when the nut is unscrewed from the tail of the outer joint case renew the nut or use one from another vehicle
7. vehicle rear part 4 4 Wheel alignment angles can not be adjusted 4 Replace shaft or arm wandering 1 Adjust pressure in tyres 2 Align wheels 3 Adjust bearing clearance 4 Replace deformed arms 5 Renew weak spring 6 Rectify fault 7 Replace worn tyres 8 Balance wheels 9 Straighten or replace suspension arms Shimmy Insufficient tyres pressure Excessive gap in front wheel hub bearings Shock absorbers do not work Loose fastening nuts on balljoint pins Misalignment of front wheels Worn arm shaft silent blocks Wheels are significantly out of balance Worn arm balljoints oo Ngoa AO N 1 Adjust pressure in tyres 2 Adjust clearance 3 Renew shock absorbers or repair 4 Tighten nuts 5 Align wheels 6 Renew silent blocks 7 Check and balance wheels 8 Replace joints Often stiffness in suspension Suspension springs set down Shock absorbers do not work Deformed front suspension arms 1 Renew springs 2 Renew shock absorbers or repair 3 Renew deformed arms Excessive gap in balljoints 1 Worn balljoint rubbing surfaces as a result of fouling due to leaks in shroud or its damage 100 1 Replace ball joint and boot Diagnosis Remedy Un even tyre tread wear 1 Excessive speed at cornering 2 Excessive wear of suspension joints and bushes 3 Wheels out of balance stains in regular intervals on tread outer path and on centra
8. worn or damaged rod and oil seal 4 Tighten nut 5 Renew or repair tank 6 Renew ring 7 Ensure required amount of liquid Insufficient shock absorber resistance at recoil stroke Leaking recoil valve or bypass valve Piston ring broken or stuck in flute Insufficient amount of liquid due to leak Scuffings on piston or cylinder Worn guide bush opening Impurities in liquid Recoil spring set down NO of WP 1 Renew damaged valve components or repair 2 Renew ring or rectify sticking 3 Renew damaged components and top up liquid 4 Renew damaged components and liquid 5 Replace guide bush 6 Wash all parts renew liquid 7 Replace spring Insufficient shock absorber resistance at compression stroke Compression valve leak Insufficient amount of liquid due to leak Worn guide bush and rod Impurities in liquid Worn or damaged compression valve discs aor woh 1 Renew damaged components or repair 2 Renew damaged components and top up liquid 3 Renew worn parts 4 Wash all parts renew liquid 5 Renew damaged components Shock absorber knock and squeak Worn rubber bushes in eyes Impact deformation of boot Insufficient amount of liquid due to leak Loose tank and piston fastening nuts Jammed rod due to deformation of cylinder tank or rod Loose shock absorber fastening nuts Damaged components of shock absorbers NO of WP 1 Renew bushes 2 Renew or repa
9. 67 7824 9513 002 to torque 68 6 88 2 Nem 7 9 kgfem Inspection of components Wash the metal components and dry wipe the rubber com ponents with clean cloth and wash in warm water Carefully inspect the components paying attention to the fol lowing the compression and feedback valve discs and the bypass valve plate should not be deformed the nonflatness of the bypass valve plate is allowed no more than 0 05 mm the working surfaces of the piston the piston ring the rod guide bush cylinder and the valve components should have no scuffings and dents that might affect normal operation of the shock absorber the recoil and compression valve springs should be tense enough and not damaged the compression valve discs should not be damaged and should have no significant wear it is recommended to renew the sealing at repair Replace all damaged components and start to reassemble the shock absorber 113
10. Balancing the wheels The wheels are balanced on special benches according to the instructions attached to the test bench The wheel out of bal ance is eliminated by balance weights which are fastened on the rim with special springs 106 Front suspension removal and refitting Place the vehicle on the lift or over an inspection pit set the parking brake open the hood and take out the spare wheel Place supports under rear wheels and take off front wheels Using remover 67 7824 9516 see fig 5 10 press out pins from the steering knuckle arms and draw aside the steering tie rods Disconnect the anti roll bar 6 fig 4 6 from the suspension lower arms Disconnect the tie rods 5 from body brackets and the cross member Disconnect the shock absorbers from the suspension lower arms Remove the engine crankcase protective plate and the splash guard Remove from each side the front brake caliper without dis connecting the brake hoses and suspend it so that the caliper will not hang on hoses Compress the suspension spring to completely unload the lower arm Disconnect from the lower arm the balljoint and take off the spring having smoothly unloaded it repeat the procedure for the other unit of the suspension Disconnect the upper arm shaft 49 see fig 4 1 from sus pension crossmember bracket 7 and remove the upper arm 46 in assembly with the steering knuckle wheel hub front brake and the outer joint case
11. Chapter 4 Wheel suspensions Fault diagnosis Diagnosis Remedy Noise and knock in susp 1 Faulty shock absorbers 2 Loose anti roll bar fastening bolts 3 Worn arm silent blocks 4 Loose shock absorber fastening or worn shock absorber eye rubber bushes 5 Worn arm balljoints 6 Excessive gap in wheel hub bearings 7 Wheels significantly out of balance 8 Deformed wheel discs 9 Set down or broken springs 10 Worn rear suspension bar rubber bushes 1 Knock in stiff suspension due to damaged buffers 12 Rear suspension stiffness due to rear axle overload 4 1 Deformed lower arm shaft or suspension arms Vehicle a Different pressure in tyres Misalignment of front wheels Wrong gap in front wheel bearings Deformed suspension arms Unequal tension of suspension springs Incomplete release of wheel brake mechanism Significant difference in tyres wear Front wheels significantly out of balance Displacement of rear axle due to deformation of rear suspension bar oo NDAN FW P ension at vehicle movement 1 Replace or repair shock absorbers 2 Tighten securing nuts and bolts in case of rubber pad wear replace 3 Renew silent blocks 4 Tighten fastening bolts and nuts renew bushes in shock absorber eyes 5 Renew ball joints 6 Adjust clearance or replace bearings 7 Balance wheels 8 Replace discs 9 Renew spring 10 Renew rubber bushes 1 Replace damaged buffers 2 Unload
12. aft 5 thrust washer 6 inner bush Fig 4 3 On vehicle check of the clearance in the suspension upper balljoint 1 upper control arm 2 indicator 3 upper balljoint housing 4 indicator fas tening bracket 5 control arm 6 dynamometer 7 block Front wheel camber If the camber angle differs from nor mal it should be adjusted by changing the amount of washers 50 see fig 4 1 between the upper arm shaft and crossmember bracket To reduce the camber angle remove the same amount of washers from both bolts and to increase add Front wheel toe in If the toe in differs from normal value it is necessary to slacken the fastening clamps on the side tie rods and using tool 67 7813 9504 identically turn both adjuster pins in opposite directions thus the pins are turned on or off and change the length of side tie rods After adjustment refit the fastening clamps with the slot fac ing back with allowable deviation downward by 60 to the hori zontal plane of the vehicle With the nuts tightened the clamp slot edges should not contact After toe in adjustment ensure that wheels and steering mechanism components do not hit the adjacent components of the suspension and car body To do this turn the wheels fully right and left until the steering pitman arm will rest against the steering mechanism housing fastening nuts Front wheel hub bearing gap check and adjustment To check the gap remove th
13. ar Carefully inspect and ensure that the suspension arms crossmember and steering knuckles are not deformed and have no cracks Renew the specified components in case of cracks and deformations Suspension crossmember Use tool 67 8732 9501 to check the geometrical parameters of the crossmember At significant deformations of the crossmember when it is impossible to adjust the front wheel alignment angle with washers and at satisfactory condition of all other elements renew the crossmember Silent blocks The criteria for renewal are described in chap ter Front suspension inspection Replacement of silent blocks The upper arm Between the eyes of the arm establish tool 67 7823 9527 on the shaft and place the arm on tool A 47045 fig 4 10 Press the arm shaft 1 with the punch to press out joint 3 from the aperture To press out the second joint turn over the arm and repeat the procedure The press fitting of upper arm joints is done with tool 67 7853 9519 fig 4 11 fixed in vice Fix the arm with shaft 1 in fixture 2 place the joint on the shaft and press fit in the arm bezel with tool 3 A 74177 1 Then repeat the above described opera tions to press fit the second joint on the other side of the arm Fig 4 11 Press fitting the upper control arm balljoint 1 control arm shaft 2 tool 67 7853 9519 3 fixture A 74177 1 Fig 4 12 Pressing out the lower control arm balljoint 1 tool 67 78223 9517 2
14. d 17 and transverse 24 arms from brackets on the body lower the jack and remove the axle Start to dismantle the suspension remove the shock absorbers from the brackets on the axle beam disconnect the longitudinal and transverse arms from the brackets on the axle beam The rear suspension components are shown on fig 4 15 The rear suspension refitting is carried out in reverse sequence On the rear suspension the springs of the same class as on the front suspension should be installed In exceptional cases if the springs of A class not marked or with marks by white paint on the external side of coils are installed on the front suspension and there are no springs of the same class available 12 13 14 15 16 17 18 25 24 23 Fig 4 14 Rear suspension i t 4 i t l 22 21 20 19 1 spacer sleeve 2 rubber bush 3 lower longitudinal arm 4 spring insulating gasket lower 5 spring seat lower 6 compression buffer 7 upper longitudinal arm securing bolt 8 upper longitudinal arm mounting bracket 9 suspension spring 10 upper spring seat 11 spring insulating gasket upper 12 spring mounting 13 rear brake pressure regulator operating rod link 14 shock absorber eye rubber bush 15 underbody crossmember 16 additional compression buffer 17 upper longitudinal arm 18 lower longitudinal arm mounting bracket 19 transverse arm to body mounting bracket 20 pressure re
15. e cap and slacken the wheel fas tening nut lift the front part of the vehicle rest it on a support and take off the front wheel Remove the front brake caliper with brake pads Do not allow the caliper to hang on high pressure hoses Fix tool 67 7834 9507 with indicator fig 4 4 on the steering knuckle so that the indicator leg will rest against the wheel hub as closely as possible to the adjusting nut Turn the hub in both directions and simultaneously move it with lever 67 7820 9521 along the steering knuckle shaft forward and backward Measure the size of shift gap by the indicator If the gap is more than 0 15 mm adjust it in the following order undo the adjusting nut from the outer joint housing tail fit a new or used but on other vehicle nut and tighten with torque to 19 6 Nem 2 kgfem simultaneously turning the hub in both directions 2 3 times for self setting the roller bearings slacken the adjusting nut and again tighten with torque to 6 86 Nem 0 7 kgfem make a mark B on the washer fig 4 5 then undo the nut by 20 25 until the first edge will meet the A mark fix the nut in this position by pressing the cups on the jour nal into the grooves on the outer joint race tail end After adjustment the bearing clearance should be within the limits of 0 01 0 07 mm Front wheel hub bearing renewing the greasing To renew the greasing do the following from both sides of the vehicle raise the
16. ers for checking the rear suspension spring 111 N i aA VEA oe BA i fr NY m_ Pr A P Ung K cylinder recoil valve discs 13 piston ring N m Fig 4 18 Front and rear suspension shock absorbers compression valve throttling disc 5 compression valve spring 6 compression valve holder 10 shock absorber piston 11 recoil valve cap 12 lower eye 2 compression valve body 3 compression valve discs 4 1 recoil valve spring recoil valve throttling disc 16 by pass valve cap recoil valve nut 9 8 15 7 compression valve cap recoil valve nut washer 17 by pass valve spring 18 restricting plate 19 tank 20 rod 21 26 rod oil seal 27 gasket 28 rod guard ring 29 tank nut 30 shock absorber eye 32 spring washer 33 washer 34 pad 35 distance sleeve 36 shock absorber casing 14 22 housing 23 rod guide sleeve 24 tank sealing ring 25 oil seal retainer front suspension shock absorber securing nut for top end upper 31 37 silent block 112 I ee ee ee ll Fig 4 19 Shock absorber operating curve force at recoil stroke Il force at compression stroke speed of 60 min rod stroke length of 80 mm for the front shock absorber and 100 mm for the rear one The curve of the diagram fig 4 19 should be smooth and in points of t
17. et The gap in the upper balljoints is checked in the following order place the vehicle on an even horizontal platform with hard surface lift the right left front part of the vehicle and take off the wheel put a 230 mm wooden pad under the lower arm which is closer to the ball pin and lower the vehicle on it ensure that resin does not come out from the runner chan nel of the upper ballpin housing if necessary smooth with a file to avoid errors when measuring fix tool indicator bracket 4 fig 4 3 on the top of stub axle place the indicator 2 in centre of the pin balljoint housing 3 sphere with small preliminary preload and then align the zero division of the scale with the arrow fix a fork lever 5 with length of 0 7 m on the front suspension upper arm using dynamometer 6 create load of 196 Nem 20 kgfem on the fork lever end 294 N in vertical direction first to press in and then to pull out the ball pin from the joint housing record the maximum deviations of the indicator arrow calculate the meaning of the clearance in the upper balljoint by summing the values of deviations from zero the total indicator readings should not exceed 0 8 mm 12 111098 Fig 4 1 Front suspension 1 front suspension crossmember 2 lower control arm shaft 3 lower arm silent block 4 lower control arm 5 lower control arm shims 6 lower control arm shaft bush 7 crossmember bracket 8 c
18. front part of the vehicle and take off the wheel unbend the edge of the brake front splash guard undo the fastening bolt of the brake pad carrier and remove the brake caliper from the brake disc by moving it aside Do not disconnect the brake hoses to avoid air penetration in the hydraulic system and do not leave the caliper to hang on the hoses Fig 4 4 Checking the axial gap in the front wheel hub bearings 1 indicator 2 fixture 67 7834 9507 3 lever 67 7820 9521 Fig 4 5 Tightening and adjusting the front wheel hub bearings A nut edge B mark on the nut use tool 67 7823 9514 to remove the wheel hub cap undo the adjusting nut and remove bush 21 see fig 4 1 carefully so that not to damage sealing 25 remove hub 19 in assembly with the brake disc put a support under the suspension lower arm 4 and slight ly lower the front part of the vehicle to compress spring 9 disconnect the lower balljoint 18 from the suspension arm disconnect the shock absorber 14 from the lower arm 4 and steering drive side tie rod from the steering knuckle shaft 29 move the front wheel drive shaft fully forward to the front axle by turning the steering knuckle 29 relatively the upper balljoint 41 remove the knuckle from the joint casing tail 23 using tool 67 7853 9535 with washer 67 7853 9540 press out from the cavity of the steering knuckle the inner rings of bear ings 27 with dismantling
19. gulator 21 pressure regulator operating rod 22 bush clamp 23 arm bush 24 transverse arm 25 shock absorber 110 for the rear suspension it is permissible to install the B class springs with black marking If on the front suspension the springs of B class are installed the rear suspension should be fit ted with B class springs only To avoid damage and excessive tightening of control arm rubber bushes and shock absorbers load the rear part of the vehicle so that distance X mea sured from the axle beam to the body chassis arm in 100 mm from the cross bar bracket fig 4 16 will make 152 mm use a dynamometer to tighten the nuts on fastening bolts of the longi tudinal and cross bars and the shock absorbers fastening pins on the axle beam and car body Inspection Before inspection thoroughly wash all components Protect the rubber components bushes and protective cov ers from solvents Springs Check the tension characteristic of the spring on control points fig 4 17 previously having depressed it to bring the coils in contact Note According to length under load of 3432 N 350 kgf the springs are divided into two classes class A length more than 278 mm and class B length equal to or less than 278 mm The springs of A class can be not marked or have marks with white paint on the external side of coils and class B marked with black paint on the external side of the coils Check for s
20. ir boot 3 Renew damaged components and top up liquid 4 Tighten nuts 5 Renew damaged components or repair 6 Tighten nuts 7 Renew damaged components 101 Diagnosis Remedy Excessive wear of tyre tread 1 High driving speed 2 Heavy vehicle acceleration 3 Often braking 4 Wrong wheel alignment angles 5 Excessive clearance in front wheel hub bearings 6 Vehicle overload 7 Recommended rearrangement of wheels was not carried out 1 Choose speed according to road conditions 2 Avoid sharp acceleration 3 Use brakes correctly 4 Adjust wheel alignment angles 5 Adjust clearance 6 Avoid vehicle overload 7 Rearrange wheels on vehicle according to service manual Tyres squeal at cornering 1 Abnormal tyre pressure 2 Wrong wheel alignment angle 3 Deformed suspension arms crossmember or body front elements Front suspension The design of the front suspension is shown on fig 4 1 Suspension components inspection At each maintenance and repair it is necessary to inspect the protective covers of suspension balljoints paying special atten tion to any possible mechanical damages It is necessary to check the suspension components for traces of hitting the road obstacles or car body for cracks on the suspension components deformations of lower arm shaft crossmember or suspension arms and elements of body front and also to check the condition of balljoints and silent blocks The deforma
21. l path when driving with a disbalanced wheel for a long time 4 Uneven wheel braking 5 Shock absorbers do not work 6 Wheel camber misalignment wear of tread inner path 7 Low tyre pressure large wear on tread edge 8 Excessive tyre pressure large wear in tread middle part 9 Low front wheel toe in wear of tread inner path 10 Excessive front wheel toe in wear of tread outer path 1 Low down speed 2 Repair suspension 3 Balance wheels 4 Adjust braking system 5 Renew shock absorbers or repair 6 Align wheel camber 7 Adjust to normal pressure 8 Adjust to normal pressure 9 Adjust wheel toe in 10 Adjust wheel toe in Wheel runout 1 Wheel out of balance uneven tread wear displacement of balance weights and tyres at installation deformed rim damaged tyres 2 Excessive gap in wheel hub bearings 1 Do the following balance or replace wheels balance wheels rectify rim or replace balance wheels replace tyre and balance wheels 2 Adjust clearance Liquid leak from shock absorber 1 Wear or destruction of rod sealing Foreign particles on sealing surfaces Dent risks scuffings on rod complete wear of chrome coating Loose tank nut Tank damage in zone of sealing ring Shrinkage or damage of tank sealing ring Excessive amount of liquid in shock absorber NOOO fF W MN 1 Replace oil seal 2 Wash shock absorber components renew or filter liquid 3 Renew
22. oil spring lower seat 9 coil spring 10 compression buffer mounting strut 11 compression buffer 12 compression restrictor 13 shock absorber mounting bracket lower 14 shock absorber 15 anti roll bar 16 rubber pad 17 anti roll bar securing clamp 18 lower balljoint 19 wheel hub 20 wheel and brake disc securing bolt 21 taper bush 22 cap 23 outer CV joint housing tail 24 oil seal bush 25 oil seal 26 splash guard ring 27 wheel hub bearings 28 wheel disc 29 steering knuckle 30 front brake splash guard 31 ballpin 32 boot 33 bearing 34 ballpin liner race 35 ballpin bearing housing 36 anti roll bar securing plate 37 washers 38 tie rod 39 tie rod mounting bracket 40 body chassis arm 41 upper ball joint 42 shock absorber rod mounting pad 43 shock absorber rod 44 washer 45 shock absorber mounting bracket 46 upper control arm 47 recoil buffer bracket 48 recoil buffer 49 upper arm shaft 50 shims 51 upper arm shaft securing bolts 52 suspension spring mounting upper 53 suspension spring seat upper 54 spring sealing gasket 55 crossmem ber to tie rod securing bracket 56 thrust washer 57 balljoint rubber bush 58 balljoint sleeve outer 59 balljoint sleeve inner 60 balljoint thrust washer Front wheel alignment angle Table 4 1 cnacxing and adjustment Front wheel alignment angle parameters The check and adj
23. pring and take it off using pusher 67 7823 9515 knock out the shaft and discon nect the suspension lower arm from the crossmember disconnect the upper arm shaft from the crossmember and remove the shaft in assembly with the control arm Note Before removing the upper and lower arm shafts count the amount of washers on each end of the lower arm shaft and on the fastening bolts of the upper arm shaft so that to refit them in former places remove the recoil bumper bracket and the crossmember as described above using puller 67 7824 9516 press out the balljoint pins from the steering knuckle The front suspension components are shown on fig 4 7 The reassembly of suspension units is carried out in reverse sequence When reassembling the wheel hub grease the bearing cages with JINTOJI 24 and put a thin layer in the cav ity of the steering knuckle between the bearings in the amount of 40 gr in each knuckle When refitting the crossmember tie rods the inner nut should be tightened until the clearance between the washer and the bracket 3 see fig 4 6 will be taken up and the outer one with torque specified in the appendix To avoid wrong force distribution in silent blocks the arm shaft nuts should be tightened under vehicle static load of 3140N 320 kgf Then check and adjust the wheel alignment angles and toe in Inspection Balljoint Ensure the integrity of the balljoint boots no breaks cracks rubber
24. pring deformation If the spring tension does not correspond to the data on fig 4 17 or the deformation can affect spring efficiency renew it Inspect the spring rubber gaskets if necessary renew Arms Check for arm deformation straighten if possible cracks on rear axle beam brackets and body overhaul the brackets in case of cracks the arm joint rubber bushes if necessary renew using a set of fixtures 67 7820 9517 Shock absorbers The design of shock absorbers of front and rear suspensions is shown on fig 4 18 Shock absorbers bench test To test the efficiency of the shock absorber make an oper ating diagram check on a dynamometer bench The working diagram is made according to the instruction attached to the test bench after no less than 5 working cycles at the shock absorber liquid temperature of 2045 C the flywheel Fig 4 15 Rear suspension exploded view 1 lower longitudinal arm 2 rubber bush 3 bracket 4 spacer sleeve 5 upper longitudinal arm 6 additional compression buffer 7 spring 8 spring seat upper 9 compression buffer 10 spring insulating gasket upper 11 shock absorber 12 spring insulating gasket lower 13 transverse arm Fig 4 16 Rear suspension mounting 1 chassis arm 2 transverse arm bracket 3 rear axle beam X 152 mm 3432H 350krc 434 278 eS a Fig 4 17 Main paramet
25. ransition from the recoil stroke to the compression stroke without areas parallel to zero line Evaluation of diagram results The resistance of recoil and compression strokes is defined by the peaks of the appropriate diagrams The highest point of the recoil stroke curve with the scale of 1 mm 47 N 4 8 kgf should be on the A distance from the zero line and equal to 25 32 mm for front shock absorbers 23 5 30 5 mm for the rear ones The highest point of the compression stroke curve with the same scale should be on the B distance from the zero line and equal to 3 5 6 5 mm for front shock absorbers 4 5 7 5 for the rear ones The ordinate control points on the diagrams of front and rear shock absorbers are given for cold shock absorbers at shock absorber liquid temperature 20 5 C After checking remove the shock absorber from the test bench overhaul or renew the components if necessary Repeat the tests to ensure the shock absorber efficiency Shock absorber dismantle and reassembly After washing fix the shock absorber in vice Note Special grips 67 7824 9513 001 are used to fasten the shock absorber and its components in vice Fully extend the shock absorber rod undo tank nut 29 see fig 4 18 with key A 57034 R take out from the tank the slave cylinder 21 in assembly with the rod and compression valve 2 Remove the tank from vice and drain liquid Using key 67 7824 9513 005 take out the rod g
26. tions of lower and upper arm shafts is deter mined by visual check The deformation of the front suspension crossmember is determined by measuring the distance between the outer surface of the crossmember bracket in the zone of the upper arm shaft fastening bolt This distance should be 736 1 5 mm If the crossmember is so badly deformed that it is impossible to adjust the wheel alignment angles with the help of washers but at satisfactory condition of all suspension components renew the crossmember The condition of the silent blocks is checked in the following order ensure there are no deformations of the suspension arms the lower arm shaft the suspension crossmember raise the vehicle front wheels measure the outer bush 2 radial displacement A fig 4 2 in relation to the inner bush 6 and distance B between the thrust washer 5 and the outer end face of the outer bush 2 The silent blocks of the top and lower arms are subject to replacement in case of 102 1 Ensure normal pressure 2 Adjust wheel alignment angles 3 Replace deformed parts rectify body front elements breaks and one sided buckling of rubber undercutting and wear of rubber on the end faces of joints if the outer bush radial displacement A relative to the inner bush exceeds 2 5 mm if size B is not within the limits of 3 7 5 mm If size B exceeds the specified limits check the press fitting of the silent block in the arm sock
27. uide bush 23 from the slave cylinder Take out from the cylinder rod 20 com plete with piston 10 and drain the liquid Carefully using a spe cial tool punch out from the cylinder the compression valve 2 housing in assembly with other components Place the rod in assembly with the piston in grips fix in vice and undo the recoil valve nut 8 Remove piston 10 with valves bypass and recoil rod guide bush 23 rod sealing 26 sealing race 25 and other components Note To facilitate the inspection of the rod in the front sus pension shock absorber it might be helpful to press off the cover from the rod To dismantle the compression valve first remove race 6 and then sequentially take out from case 2 spring 5 plate 7 and valve discs 4 and 3 The reassembly of the shock absorber is carried out in reverse sequence paying attention to the following after the reassembly of the compression valve ensure the free play of plate 7 and valve discs race 6 is press fitted on case 2 with special tool the compression valve is press fitted in the cylinder using tool 67 7824 9513 004 to facilitate the reassembly of components located on the rod use guide 67 7824 9513 003 the throttle disc 15 of the front shock absorber has two grooves on the outer diameter and the rear shock absorber throttle disc three the recoil valve nut is tightened with torque of 11 76 15 68 Nem 1 2 1 6 kgfem the tank nut is tightened with key
28. umper and then on the front one The wheel alignment angle should be checked and adjusted in the following sequence 1 Caster angle 2 Camber angle 3 Toe in Caster angle If the check will show that the angle size does not correspond to the above data it is necessary to change the quantity of adjusting washers 50 see fig 4 1 between the upper arm shaft and the crossmember arm see tab 4 2 Table 4 2 Camber and caster angle vs number of washers in a set Number of washers added to the set or withdrawn camber caster front bolt rear bolt 1 1 8 42 0 1 1 8 42 0 1 0 7 30 20 24 1 0 7 30 20 24 0 1 15 18 25 18 0 1 15 18 25 18 1 1 27 30 43 18 1 1 21 36 40 Note Data are given for washers with thickness of 0 75 mm Plus adding a washer minus removing a washer To adjust the caster angle undo the fastening nuts of the front suspension upper arm shaft and replace the washers from one bolt to the other one until a normal reading of the angle will be obtained The caster angle increases at rearrangement of washers from the rear bolt to the front one and decreases at reverse swapping tighten the nuts with a torque wrench and check the caster angle 104 Fig 4 2 Inspection of the front suspension arm silent block 1 rubber bush 2 outer bush 3 shaft securing nut 4 suspension arm sh
29. ustment of the front wheel alignment angle Front wheels for vehicle with vehicle kurb weight is carried out on special test benches according to the instruc alignment angle load 3140 N 320 kgf tions Camber 0 30 20 0 30 2 0 20 20 0 20 ATTENTION It is necessary to check the wheel align ment angle after replacement or repair of suspension com ponents that could have caused the misalignment of wheel Caster 3 30 30 3 30 40 1 30 30 1 30 20 angle The check and adjustment of wheel angles is carried out on a vehicle under static load of 3140 N 320 kgf four men and 40 Toe in 2 4 mm 1 7 mm 4 5 6 5 mm 3 5 9 5 mm kg in boot Follow the parameters specified in tab 4 1 to check and permissible front wheel alignment angle for the elastic elements stabilization time before adjust the wheel alignment angles the first maintenance 2000 3000 km 103 Before adjusting the wheel alignment angles check the fol lowing pressure in tyres axial gap in front wheel hub bearings serviceability of shock absorbers absence of rod jamming radial and axial runout of tyres gap in suspension balljoints free play of steering wheel Rectify any detected malfunctions and make necessary adjustments After placing the vehicle on a test bench immediately prior to inspection apply 2 or 3 times a downward force of 392 490 N 40 50 kgf first on the rear b
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