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Fault diagnosis

Diagnosis

Remedy

Incomplete clutch release (clutch spin)

1. Excessive gaps in clutch release drive

2. Buckling of clutch disc (camming action more than 0.5 mm)

3. Roughness on clutch disc friction linings

4. Jammed rivets or broken clutch disc friction linings

5. Jammed clutch disc hub on primary shaft splines

6. Broken thrust flange-to-clutch cover connecting plates

7. Air in clutch hydraulic drive system

8. Liquid leak from hydraulic drive system through connections or dam-

aged pipelines

9. Leaking master cylinder or clutch release cylinder

10. Plugged opening in reservoir cover, causing underpressure and vac-

uum leak in cylinder through sealings

11. Vacuum leak due to fouling or wear of front sealing ring in master

cylinder

12. Skew or buckling of pressure plate

Incomplete clutch engagement (clutch slips)

1. No gaps in clutch release drive

2. Badly worn or burnt clutch disc friction linings

3. Excessive oil on clutch disc friction linings, surfaces of flywheel and

pressure plate

4. Plugged compensation port in master cylinder

5. Damaged or jammed clutch release drive

Clutch judder

1. Jammed clutch disc hub on primary shaft splines

2. Excessive oil on clutch disc friction linings, surfaces of flywheel and

pressure plate

3. Jammed clutch release drive mechanism

4. Badly worn clutch disc friction linings

5. Loose rivets on clutch disc friction linings

6. Damaged surface or buckling of pressure plate

Excessive noise at clutch release

1. Worn, damaged or dry clutch release bearing

2. Worn front bearing on gearbox primary shaft

Excessive noise at clutch engagement

1. Broken or weak damper spring

2. Broken, weak or detached clutch release fork return spring

3. Broken pressure plate-to-clutch cover connecting plates

Clutch release drive adjustment

58

1. Adjust clutch release drive
2. Straighten or replace disc
3. Renew linings or clutch disc assembly
4. Renew linings, check disc runout
5. Clean splines, apply grease ãëñ-15 or îËÓÎ-1, îËÓÎ-2. In case of badly
worn splines causing seizure, renew input shaft or clutch disc
6. Renew clutch cover/pressure plate assembly
7. Bleed system
8. Tighten connections, renew damaged components, bleed system

9. Renew sealing rings, bleed system
10. Clean opening in tank cover, bleed system

11. Clean sealing ring, replace in case of wear

12. Renew clutch cover/pressure plate assembly

1. Adjust clutch release drive

2. Renew linings or clutch disc assembly

3. Clean oily surfaces with white-spirit, remedy the situation

4. Wash cylinder and clean port

5. Rectify malfunctions causing jamming

1. Clean splines, apply grease ãëñ-15 or îËÓÎ-1, îËÓÎ-2. In case of badly

worn splines causing seizure, renew input shaft or clutch disc

2. Clean oily surfaces with white-spirit, remedy the situation

3. Replace damaged parts, rectify malfunctions causing jamming

4. Renew linings, check for damages on disc surfaces

5. Renew damaged rivets and linings, if necessary

6. Renew clutch cover/pressure plate assembly

1. Renew clutch disc assembly

2. Renew spring or secure

3. Renew clutch cover/pressure plate assembly

1. Renew bearing

2. Renew bearing

The following adjustments are carried out in the clutch

release drive:

- the 0.1-0.5 mm gap between the pushrod and the piston of the

master cylinder (see fig. 3-2) is set. This gap, necessary for comp-

lete clutch release, is adjusted by the clutch pedal limiter bolt 5. The

clearance is determined by the pedal free travel equal to 0.4-2 mm;

- the free travel of the clutch release fork pushrod, equal to 4-

5 mm, is adjusted by bolt 5 (fig. 3-3) and fixed by locknut 6. The dis-

tance of the pushrod free travel is controlled by a special pattern.

After carrying out the above described adjustments the clutch

pedal free travel should make 25-35 mm.

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Содержание Niva 4x4

Страница 1: ...u use the information contained with this manual at your own risk If you re not sure how to do something either don t do it or ask someone who knows about such things The font of all Lada knowledge can be found at http www lada co uk forum For Lada parts advice and general all round Lada wonderfulness these blokes aren t bad Contact Tom Grealey tom lada co uk ...

Страница 2: ...7 clutch bellhousing 8 bellhousing to flywheel bolt 9 gearbox input shaft 10 clutch release bearing assembly 11 clutch release fork 12 release fork ball socket 13 clutch release bearing 14 pressure plate thrust flange 15 clutch release fork boot 16 clutch release fork spring 17 pressure plate fulcrum ring 18 clutch cover 19 clutch release fork pushrod 20 adjusting nut 21 locknut 22 protective cap ...

Страница 3: ...drive adjustment 58 1 Adjust clutch release drive 2 Straighten or replace disc 3 Renew linings or clutch disc assembly 4 Renew linings check disc runout 5 Clean splines apply grease ãëñ 15 or îËÓÎ 1 îËÓÎ 2 In case of badly worn splines causing seizure renew input shaft or clutch disc 6 Renew clutch cover pressure plate assembly 7 Bleed system 8 Tighten connections renew damaged components bleed sy...

Страница 4: ... check the tightness of connections find out if there are cracks on tubes or leaks in places of connections Air inleak is possible through damaged sealing rings of the master or slave cylinders During bleeding the liquid level in the reservoir should be higher than the opening of the tube connecting the reservoir with the master cylinder the end of the bleeding hose should be always dipped in liqu...

Страница 5: ...disc hub and the gearbox input shaft clean the splines and grease with a thin layer of greasing ãëñ 15 or îàéã 1 îàéã 2 refit the clutch disc with the hub protruding part facing the gear box and centralise the plate against the bearing using tool A 70081 simulating the gearbox input shaft splined end fig 3 4 60 Fig 3 3 Slave cylinder and clutch release fork 1 release bearing 2 ball pivot 3 clutch ...

Страница 6: ...ed 0 5 mm If this value is exceeded straighten the disc fig 3 7 or replace with a new one Also replace the clutch disc assembly in case of cracks on the clutch disc or the damper springs Master and slave cylinders removal and refitting First drain working liquid To do this attach one end of the hose to bleeder 9 see fig 3 3 on the slave cylinder and the other end place in a clean reservoir unscrew...

Страница 7: ...etaining washer 7 cap 8 circlip 9 pushrod piston 10 sealing ring 11 master cylinder piston 12 spring Fig 3 7 Straightening the clutch disc Fig 3 9 Slave cylinder components 1 body 2 bleeder 3 cap 4 pushrod 5 sealing ring 6 piston 7 sealing ring 8 sleeve 9 spring 10 disc 11 lock ring ...

Страница 8: ...king the leak proofness of the rear sealing ring Place the master cylinder on the test bench see fig 3 10 and ensure good sealing between the cylinder flange and the surface of the test bench Connect reservoir 2 with hydraulic liquid to the cylinder Open the compressed air vent with the adjusting screw 6 being open and then slowly close the adjusting screw until all air will be expelled from reser...

Страница 9: ...er hose remains on the vehicle what excludes loosing brake liquid and necessity of the subsequent bleeding of the clutch release hydraulic drive Put clip 2 A 70025 on the flexible coupling 3 fig 3 14 and tighten This will help in subsequent removal and refitting of the flexible coupling Undo nuts 1 and by turning the layshaft remove the bolts that are fastening the flexible coupling 3 to the flang...

Страница 10: ...d 29 grommet 30 distance washer 31 retaining sleeve 32 collar 33 cap washer 34 ball socket 35 gearshift lever housing 36 guide plate 37 driveline coupling flange 38 nut 39 centering ring oil seal 40 centering ring 41 circlip 42 output shaft rear bearing oil seal 43 output shaft rear bear ing 44 distance washer 45 oil deflector washer 46 5th reverse gear unit 47 5th synchro unit hub 48 reverse idle...

Страница 11: ...1 fork return spring 2 locknut 3 adjusting nut 4 cotter pin 5 clutch release fork 6 pushrod 7 slave cylinder fastening bolt 8 slave cylinder Fig 3 14 Flexible coupling between the propeller shaft and the gearbox 1 propeller shaft flange to flexible coupling fastening nuts 2 clamp A 70025 3 flexible coupling 4 rear engine mounting crossmember Fig 3 15 Clutch bellhousing view from inside The black a...

Страница 12: ...removing the rear cover place the gearshift lever in neutral position undo the gear selector mechanism fastening nuts and remove the gearshift lever fig 3 19 in assembly with the selector mechanism One of the cover fastening nuts is undone from the inside of the transmission casing with the bottom cover being removed When removing the rear cover it is neces sary to move it not only backwards but a...

Страница 13: ...haft 6 1st 2nd selector rod 7 3rd 4th selector rod Fig 3 22 Removing the 5th speed reverse selector rod 1 5th reverse selector rod 2 5th reverse fork 3 distance sleeve 4 gear unit Fig 3 21 Removing the 5th gear bush 1 bush Fig 3 23 Removing the reverse idler gear 5th gear synchro unit and fork assembly 1 reverse idler gear 2 5th speed coupling 3 5th speed reverse gear ...

Страница 14: ... out from the transmission casing the 1st 2nd 3rd and 4th selector rods one by one previously having undone the securing bolts Taking out the rods simultaneously remove three detents 6 fig 3 26 Remove the output shaft idler bearing lock plate fig 3 27 Undo the fastening nut of the reverse idler gear shaft and remove it 69 Fig 3 25 Withdrawing the intermediate shaft from transmission casing Fig 3 2...

Страница 15: ...t fig 3 31 from the rear end of the shaft remove the 1st synchro gear 11 with bush 12 hub 3 with 1st 2nd synchro sleeve 4 2nd speed gear 10 together with baulk ring 5 place the output shaft with tool 41 7816 4069 on a press fig 3 32 place two thrust half rings 3 under 3rd speed gear and by pressing the spring washer with the mandrel remove the circlip 2 then spring washer 4 3rd 4th sleeve hub and ...

Страница 16: ... with the transmission cas ing front cover the opening in the front cover should be located as shown on fig 3 15 grease the oil seals with ãàíéã 24 before refitting use tools 41 7853 4028 41 7853 4032 41 7853 4039 to install the sealings and bearings Inspection Cleaning Before inspection carefully clean all gearbox com ponents Brush or scrape all deposits or residues clean the bores and splines th...

Страница 17: ...ase of any insignificant defect renew the seals Shafts On the working surfaces and on the splines of the output shaft no damages or excessive wear is allowed There 72 Fig 3 33 Gear change mechanism and lever 1 gear change lever 2 gasket 3 ball socket 4 cap 5 spring 6 ring 7 circlip 8 flange 9 collar 10 rubber boot 11 lever knob 12 lever exten sion 13 pad 14 rubber bush 15 spacer 16 securing collar...

Страница 18: ... special attention to the condition of the sleeve spline face The synchro rings should show no sign of excessive wear They should be renewed in case the end face is resting on the synchro unit sleeve Roughness interfering free sliding should be removed with a fine cut file Badly worn parts should be renewed Transfer box Fault diagnosis Diagnosis Remedy Vibration of the transfer box and body floor ...

Страница 19: ...ge Unscrew nuts 3 fig 3 37 on the transfer box mounting bracket 1 fastening bolts and remove it together with brackets and shims 5 which are placed under the brackets in assembly with the layshaft Mark each shim so that to refit them in the same amount Refitting and centering the transfer box is done in the fol lowing order ensure proper refitting of engine support pads in brackets the centering w...

Страница 20: ...fig 3 35 in assembly with the rear axle drive shaft taking care not to damage the sealing Then remove flanges 12 from the input shaft and the drive shafts of the front and rear axles 75 Fig 3 35 Transfer box 1 driven gear 2 differential bearing 3 spring washer 4 circlip 5 differential locking coupling 6 differential housing crown 7 front axle drive shaft crown 8 front axle drive shaft bearing 9 oi...

Страница 21: ...l locking fork rod 7 front axle case cover 8 lock washer 9 lever shaft bush 10 lever shaft 11 differential locking lever 12 gear shift fork rod 13 gearshift lever bracket 14 gear shift lever 15 knob 16 gear shift clutch 17 gear shift clutch fork 18 distance sleeve 19 detent ball 20 detent spring bush 21 detent spring 22 differential lock warning light switch ...

Страница 22: ...t the shaft and remove lever 14 Undo the locking bolt of the gear shift fork 17 close the detent socket with a finger and carefully take out rod 12 and the detent components 77 Fig 3 38 Transfer box installation 1 layshaft and drive shaft flange fastening pin 2 transfer box 3 shims 4 transfer box to car body fastening nuts 5 nuts fastening mounting brack ets on shafts Fig 3 37 Transfer box mountin...

Страница 23: ...r and front bearings from the differential cas ing fig 3 43 using a universal puller and a rest block 67 7853 9559 undo the differential driven gear fastening bolts make risks on the differential casings to mark their location against to each other and dismantle the casing remove the differential driven gear 78 Fig 3 41 Drive shaft and layshaft components 1 flange 2 oil seal 3 bearing thrust ring ...

Страница 24: ...gear moment of resistance to rotation should not exceed 14 7 N m 1 5 kgf m If the gap is greater renew the support washers with those having bigger thickness if this will not help to obtain the specified gap renew the gears because of their exces sive wear drive and layshafts are installed in the transfer box casing simultaneously see fig 3 44 bearings are press fitted on the differential casing w...

Страница 25: ...or balls and no cracks and choppings on rings The bearing radial gap should not exceed 0 05 mm When turned a clean dry bearing should not knock It should run smooth without jamming Renew damaged bearings Rods forks No deformation of forks and jamming of rods in the casing apertures is allowed In case of jamming renew the detent components Weak springs should be replaced The spring length under loa...

Страница 26: ...layshaft pro tective shroud Dismantling Rear and front shafts Make marks with paint or punch to note mutual location of mating parts so that to refit them in the same position and avoid misalignment of shafts Place the front rear shaft in vice with aluminum jaws Remove the circlips using round nose pliers Press out the bearing housing from the U joint yoke Proceed as follows place the propeller sh...

Страница 27: ...he dismantled parts after reassembling the spline joint apply axial load to press the seal by 0 3 0 5 mm and crimp the retainer on the yoke groove The reassembly of the U joint is carried out in the following sequence remove old greasing lubricate the inner surface of the bear ing housing with grease 158 or îàéã 2ì 0 8 1 2 gr on each bearing Do not grease the spider thorns to avoid an air plug dur...

Страница 28: ... mm After reassembly check for easy rotation of the U joint yokes and the shaft balance To reassemble the layshaft U joint follow the procedure described in chapter Front wheel drive When reassembling install retainer 7 see fig 3 49 with the chamfer facing the trans fer box input shaft and grease the U joint with 20 cm3 of Longtern 00 from Dow corning Shaft balance The front and rear propeller sha...

Страница 29: ...oving the brake drum and undoing the braking plate fastening nuts with pusher 67 7823 9516 fig 3 55 take out the axle shaft in assembly with the oil screen the bearing fastening plate the bearing and a stop ring Remove the braking plate and the sealing ring If necessary to renew take out the sealing ring from the axle beam flange Do the same on the other end of the beam then remove the reduction g...

Страница 30: ... axle shaft 1 axle shaft 2 knockout tool 67 7823 9516 Fig 3 54 Rear axle 1 wheel cap 2 brake drum to wheel securing bolt 3 oil deflector 4 brake drum 5 brake drum iron ring 6 wheel cylinder 7 bleeder 8 axle shaft bearing 9 bearing locking ring 10 rear axle beam flange 11 oil seal 12 suspension spring cup 13 rear axle beam 14 rear suspension bar mounting bracket 15 axle shaft guide 16 differential ...

Страница 31: ...icator or a feeler gauge with a try square 4 The maximum pressing force during straightening should not exceed 98 kN 10000 kgf so that not to affect the housing pro file Note If the height of the rest was experimentally correctly adjusted the beam can be straightened without monitoring by a try square or an indicator Remove the beam from the press and check as mentioned above having replaced flang...

Страница 32: ...d out bolt retainers 39 see fig 3 54 that are fas tening plate 38 with the oil screen and the brake plate and take out the bolts Straddle the bearing with tool 67 7823 9529 and place the axle shaft vertically so that the half rings are rested on the thrust ring Place the axle shaft under the press fig 3 61 and apply gradually increasing force to the spline end of the axle shaft until the bearing s...

Страница 33: ... to the axle shaft pass through one of the axle shaft openings the indicator 1 leg extension until it will rest against the braking plate or the oil screen and fix the indicator Make the measurement with the indicator applying to the axle shaft flange force of approx 49 N 5 kgf in both directions along the rear axle shaft The free play should not exceed 0 7 mm Reduction gear The rear axle reductio...

Страница 34: ...le beam from oil Place a sealing on the mating surface fit the reduc tion gear into the beam and fix with bolts Grease the bolt threads with a sealant Before greasing the bolts and connections in the beam carefully degrease all surfaces Connect the propeller shaft to the reduction gear Install the axle shafts and brake drums Install a wheel with a tyre and fasten without tightening the wheel nuts ...

Страница 35: ... and no wear Replace bearings in slightest doubt in their serviceability as bad condition of bearings can cause noise and teeth jamming Check for deformations or cracks on the casing and on the differential box renew if necessary Reduction gear reassembly The reliable operation of the reduction gear is provided by strict observance of following guidelines on reassembly and adjustment The reduction...

Страница 36: ...inimum reading of a1 fig 3 72 and record Repeat this operation on the landing surface of the second bearing and record the reading of a2 Define thickness S of the driving gear adjusting ring which is an algebraic difference between a and b S a b Where a average arithmetic distance from the tool 1 face fig 3 64 to the differential bearing journals a a1 a2 2 b deviation of the driving gear from the ...

Страница 37: ...the bearing s moment of resistance to the rotation of the driving gear To check the resistance torque fix the dynamometer on sleeve 3 fig 3 76 place the torque limit indicator 2 fig 3 75 on the scale division corresponding to 196 N cm 20 kgf cm and make a few turns clockwise with handle 4 During rotation of the driving gear the movable indicator 1 should not pass indicator 2 and should show no les...

Страница 38: ...distance D fig 3 79 will increase by 0 14 0 18 mm Having established the exact preload of the differential hous ing bearings finally check the side gap in the final drive gears mesh which should not change If the gears mesh gap is more than 0 08 0 13 mm move the driven gear closer to the driving gear or move it away if the gap is below this value To maintain the bearings preload move the driven ge...

Страница 39: ...d oxide start the bench and decelerate the rotation of the axle shafts so that under load on the driven gear teeth surfaces there were visible traces of contact with the driving gear teeth change the rotation direction and while decelerating ensure forming the contact patterns on the other side of the driven gear teeth what will simulate the reverse movement of the vehicle The gear mesh is conside...

Страница 40: ...is the following drain oil from the rear axle casing loosen the rear wheels fastening nuts put blocks under front wheels and raise the rear axle release the handbrake and place the gear shift lever in neutral take off the wheels and brake drums undo the nuts that are fastening the braking plate to the axle beam and using a pusher remove the axle shafts from the differ ential box disconnect the pro...

Страница 41: ... the engine and two fastening nuts of the front axle from the left side Raise the engine by 25 30 mm remove the front axle in assembly with the front wheel drives Refitting of the front axle on the vehicle is carried out in a reverse sequence When refitting the axle the fastening nuts and bolts should be tightened with torque specified in the appendix Fill the front axle casing with transmission o...

Страница 42: ...nt is connected with the front wheel hub it is of a rigid type with angular degree of freedom The inner joint is of universal type with an angular and axial degree of freedom It is connected with the front axle shaft gear The outer joint consists of case 13 race 11 cage 8 with balls 10 lock ring 12 and thrust ring 7 Race 11 is connected with case 13 through balls which come into race grooves made ...

Страница 43: ...el hub cap and undo the wheel hub bearing nut then unscrew the fastening nut of the inner joint housing bearing cover undo the fastening bolt of the front axle suspension right arm remove the outer and inner joints from the wheel hub and from the front axle The refitting of the front wheel drive is carried out in reverse sequence When tightening the wheel hub bearing nuts adjust the bearing cleara...

Страница 44: ...and blow with compressed air The reassembly of the outer joint is carried out in reverse sequence paying attention to the following grease all components with òêìë 4 before reassembly when refitting the cage race assembly in the joint casing ensure the matching of labels made before dismantle the race should be fitted with the ring groove for the thrust ring facing the shaft when refitting the bal...

Страница 45: ...t work 4 Loose fastening nuts on balljoint pins 5 Misalignment of front wheels 6 Worn arm shaft silent blocks 7 Wheels are significantly out of balance 8 Worn arm balljoints Often stiffness in suspension 1 Suspension springs set down 2 Shock absorbers do not work 3 Deformed front suspension arms Excessive gap in balljoints 1 Worn balljoint rubbing surfaces as a result of fouling due to leaks in sh...

Страница 46: ... valve leak 2 Insufficient amount of liquid due to leak 3 Worn guide bush and rod 4 Impurities in liquid 5 Worn or damaged compression valve discs Shock absorber knock and squeak 1 Worn rubber bushes in eyes 2 Impact deformation of boot 3 Insufficient amount of liquid due to leak 4 Loose tank and piston fastening nuts 5 Jammed rod due to deformation of cylinder tank or rod 6 Loose shock absorber f...

Страница 47: ... 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 e...

Страница 48: ...ower arm silent block 4 lower control arm 5 lower control arm shims 6 lower control arm shaft bush 7 crossmember bracket 8 coil 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 2...

Страница 49: ...ness 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 nut...

Страница 50: ...ion 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 front part of the vehicle and take off the wheel unbend the edge of the brake front splash guard und...

Страница 51: ...he rim with special springs 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...

Страница 52: ...ngles and toe in Suspension units dismantle and reassembly Dismantle If 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 ou...

Страница 53: ...e 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 Ä 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 sid...

Страница 54: ...r 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...

Страница 55: ...draulic jack Disconnect the longitudinal 3 and 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 c...

Страница 56: ...oils and class B marked with black paint on the external side of the coils Check for spring 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 i...

Страница 57: ...valve cap 12 recoil valve discs 13 piston ring 14 recoil valve nut washer 15 recoil valve throttling disc 16 by pass valve cap 17 by pass valve spring 18 restricting plate 19 tank 20 rod 21 cylinder 22 housing 23 rod guide sleeve 24 tank sealing ring 25 oil seal retainer 26 rod oil seal 27 gasket 28 rod guard ring 29 tank nut 30 shock absorber eye upper 31 front suspension shock absorber securing ...

Страница 58: ... 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...

Страница 59: ...e tie rod ballpin nuts 6 Loose fastening bolts on stee ring box or slave arm shaft brack et 7 Wrong roller to worm gap Vehicle wandering 1 Unequal pressure in tyres 2 Wrong front wheel alignment angle 3 Different tension in front sus pension springs 4 Deformed steering knuckles or suspension arms 5 Incomplete brake release on one or several wheels Vehicle unstable 1 Wrong front wheel alignment ang...

Страница 60: ...m bear ing cover lower 21 roller shaft 22 ball bearing 23 worm shaft oil seal B C marks Fig 5 1 Steering 1 track rod 2 drop arm 3 relay rod 4 idler arm 5 adjuster pin 6 lower balljoint 7 right steering knuckle 8 upper balljoint 9 right steering knuckle arm 10 idler bracket 11 upper shaft bearing 12 steering wheel mounting bracket 13 sleeve ignition switch anti theft device 14 steering wheel mounti...

Страница 61: ...Check the tie rod adjuster pins ensure reliable tightening of the clamps Inspect the balljoint and protective caps as set forth below Inspection of the tie rod balljoint First check the movement of the tie rod ends along the pins For this purpose move the end parallel to the pin using a lever and a support The axial movement of the end in relation to the pin should be 1 1 5 mm This will prove that...

Страница 62: ...fit cap 3 Steering mechanism Removal and refitting Removal Disconnect the wires from the battery and take off the horn push pad trim Undo the steering wheel fastening nut remove the steering wheel and both halves of the steering col umn shroud Note If it is necessary to remove only the steering box undo the bolt that is fastening the intermediate shaft lower U joint fork on the worm shaft and the ...

Страница 63: ...rizon tally and connect the worm shaft to the lower end of the interme diate shaft paying attention that the lock bolts pass through a ring groove on the worm shaft and the wheel shaft Prior to completely fastening the bracket bolts rotate the steering wheel in both directions several times and only then tighten the bracket fastening bolts Steering mechanism dismantle and reassembly Dismantle Drai...

Страница 64: ...ten jam nut 4 After adjusting the roller to worm mesh gap use a dynamometer to check the worm friction which should be equal to 68 7 88 3 N cm 7 9 kgf cm when turning the worm shaft by 30 both to the left and to the right from the middle position and should smoothly reduce to 49 N cm 5 kgf cm when turned from the 30 position further to the stop After the reassembly check the angles of pitman rotat...

Страница 65: ...t the pins from the corresponding jacks on the arms and remove the tie rods The tie rods are refitted in reverse order All ballpin nuts are tightened with a dynamometer with subsequent splinting If the nut cut does not match the opening for the pin the nut should be screwed in to an angle smaller than 60 to provide for subse quent splinting After refitting adjust the front wheel toe in Check and r...

Страница 66: ...of drums 3 Excessive oil on friction linings 4 Worn linings or trapped detri mental inclusions 5 Excessive disc runout or non uniform wear Inspection and adjustment Pipelines and connections inspection To prevent any occasional failure of the braking system care fully inspect all pipelines metal pipelines should have no dents or cracks and should lie far from sharp edges that can damage them brake...

Страница 67: ...linder tank 13 pressure regulator 14 pressure regulator control arm Fig 6 2 Brake servo unit 1 rod 2 master cylinder flange sealing ring 3 servo housing cup 4 adjuster bolt 5 rod sealing 6 diaphragm return spring 7 pin 8 sealing boot 9 servo unit housing 10 diaphragm 11 servo unit housing cover 12 piston 13 valve body boot 14 air cleaner 15 push rod 16 push rod return spring 17 valve spring 18 val...

Страница 68: ...lightly touch the pedal rest thus the pedal free travel should make 3 5 mm After adjustment tighten nut 8 ATTENTION The brake pedal free travel adjustment is made with the engine not working If the adjustment of the stoplight switch fails to remedy the brake mechanism disconnect the master cylinder from the servo unit and check the protrusion of the adjusting bolt 4 see fig 6 2 in relation to the ...

Страница 69: ...n layer of Ñí 1 on the shaft and the acting part of the piston fill 5 6 gr of this greasing in the rubber boot and refit the cover Pressure regulator position adjustment The pressure regulator position adjustment is required if the fastening bolts became loose Raise the vehicle rear axle Disconnect arm 4 fig 6 5 from tie rod 8 and fix on its end tool 67 7820 9519 Direct the core of the tool upward...

Страница 70: ...ector and refit the protective cap All above operations should be carried out through the upper connectors first on the right rear wheel the most remote from the master cylinder then further clockwise the left rear wheel left and right front wheels Thus air from one circuit will be removed To bleed the other circuit use the lower connectors on the cylin der block of the left and right front brakes...

Страница 71: ...and refit the springs use tool A 70017 Reassembly of the master cylinder is carried out in reverse order When reassembling grease with ãàíéã 24 the pedal bushes spring ends connection places between the push rods and pedals and the push rod end adjoining the piston of the clutch master cylinder 126 Fig 6 8 Clutch brake pedal bracket exploded view 1 bracket 2 nut 3 spring washer 4 brake pedal inner...

Страница 72: ...he unit in assembly with the bracket Refitting of the servo unit is carried out in reverse order Master cylinder The design of the master cylinder is shown on fig 6 9 Removal and refitting Disconnect the flexible hoses from the master cylinder and close the openings of hoses and con nectors on the cylinder to prevent liquid leak from reservoir and penetration of dust dirt or foreign matters Undo t...

Страница 73: ...2 Before repairing the brakes carefully wash them in warm water with washing liquids and immediately dry with a jet of com pressed air ATTENTION Do not use petrol diesel fuel trichloroeth ylene or any other mineral solvents to clean the brakes as these materials damage the cylinder sealings Removal and refitting Removal Lift the front part of the vehicle place it on supports and remove the wheel R...

Страница 74: ... Check the axial runout of the brake disc without removing it from the vehicle fig 6 15 The maximum allowable runout by the indicator is 0 15 mm if the runout is greater it is necessary to grind the disc but the final thickness of the disc after grinding should be no less than 9 5 mm In case of damage or very deep risks and also if wear exceeds 1 mm on each side renew the disc Replacement of brake...

Страница 75: ...ake plate 4 Assembly and refitting Assembly and refitting is carried out as follows Fit and fix the wheel cylinder on the brake backplate attach it to the pipeline and fully tighten the connector nut Attach the shoe manual lever 18 see fig 6 17 and refit the brake shoes with expander strut 20 then insert posts 17 with springs and bottom cups put the upper springs and fix them on racks by turning o...

Страница 76: ...st rings The surfaces should be absolutely smooth without roughness to avoid liquid leak and premature wear of sealings and pistons The defects on the cylin der mirror can be eliminated by lapping or polishing However no increase of the cylinder inner diameter is allowed Inspect screw 3 see fig 6 20 spring 6 thrust cup 7 and retainers 5 If necessary renew damaged components Renew sealings 8 Inspec...

Страница 77: ... a high pressure manometer 5 Ensure that pressure holds steady for 5 minutes repeat similar test at liquid pressure of 5 10 15 MPA 50 100 150 kgf cm2 There should be no pressure decrease due to liquid leak through sealing elements pipeline connections bleeding con nectors or through casting pores An insignificant reduction of pressure no more than 0 5 MPA 5 kgf cm2 during 5 minutes is permissible ...

Страница 78: ...g 3 When reassembling which is carried out in reverse sequence grease all components with brake liquid ATTENTION To differentiate the VAZ 2121 and 21213 pressure regulators from others of similar design there is a groove on the bottom part of the piston Wash the components with isopropyl alcohol or brake liquid and inspect The components surfaces should have no marks and roughness Check the spring...

Страница 79: ...e Handbrake adjustment When refitting grease with ãàíéã 24 or ãëñ 15 the rear cable guide the handbrake lever shaft and the front cable end Check and repair Carefully inspect the components of the handbrake mechanism If breakage or wire scuffing is detected renew the cable Make sure that the quadrant teeth and handle lock are not damaged worn components should be replaced Check the condition of th...

Страница 80: ...135 ...

Страница 81: ...136 ...

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