5.2.8. Malfunction elimination under operating conditions

The reason of emergence of malfunction can be too big люфт in the plug of the bearing of the steering mechanism.

In case of malfunction establish a repair kit of the steering mechanism.

For replacement of the plug it is necessary to prepare an assembly arm for the steering mechanism.

NOTE Manufacturing of an assembly arm is described in points 1-4.

1. Cut off a steel pipe of square section of 40х40 mm in length of 500 mm.

2. Drill 2 openings in diameter of 12,5 mm.

Distance between centers openings of 400 mm.

3. Fix the steering mechanism on a square pipe 2 M12kh130 screws (1, 2).

Use podkladny washers and nuts.

4. Take spot welding of a head of screws (1, 2).

5. Remove forward wheels.

6. Suspend a radiator on the air deflector.

Use 2 cable collars.

7. Disconnect an intermediate steering shaft 2 from a steering gear wheel (fig. II).

Turn off and take out a bolt 1.

8. Disconnect 2 pendular levers 1 from a basic pipe of an amortization rack (fig. III).

Hold an open wrench for two лыски on a bolt of a rotary fist.

9. Disconnect 2 tips of cross-section steering drafts 1 by means of the adaptation KM-507-C 2 from rotary fists (fig. IV).

10. Remove a forward exhaust pipe 1 from the catalyst (fig. V).

Turn off 3 nuts 2.

11. Remove the amortization block of a back jet bar.

Turn off the screw.

12. Disconnect an exhaust system.

Remove 2 rubber suspension brackets.

NOTE Attach an exhaust system to the bottom suitable means.

13. Disconnect the socket of a plait of wires of the sensor of oxygen.

14. Disconnect a front bumper from the bridge case.

Take out 3 plastic rivets.

15. Disconnect the switching mechanism (fig. VI).

Remove a fixing clip 1 from the mechanism of switching 2.

To unhook the switching mechanism from above from an arm of the mechanism of switching.

16. Establish under the case of the forward bridge a hydraulic jack together with KM-904 and KM-6168 adaptations.

NOTE To be convinced of that directing pins of KM-6168 are inserted into directing openings from both parties on the case of the forward bridge.

17. Turn off 4 screws on the case of the forward bridge (fig. VII, shooters).

18. By means of a hydraulic jack lower the case of the forward bridge until access to screws of the steering mechanism will open.

NOTE Watch that the case of the forward bridge did not rise from the KM-6168 adaptation.

19. Remove the steering mechanism from the case of the forward bridge.

Turn off 2 screws.

Remove the steering mechanism.

20. Establish the steering mechanism on the prepared assembly arm (see fig. I).

21. Remove 2 boots.

Remove 4 collars.

22. Remove 2 cross-section steering drafts (fig. VIII).

23. Establish the steering mechanism in average situation (fig. IX).

NOTE Measure a vystupaniye of both ends of a steering shaft 1 concerning the case 2 by a calliper 3.

The size should be identical from both parties.

Vystupaniye of a gear lath can be adjusted, turning a steering shaft.

24. Put marks (fig. X, shooters) on the case of rather lock nut 1 and the adjusting screw 2.

25. Put marks (fig. XI, shooters) on the case of rather steering shaft.

26. Release a lock-nut (fig. XII).

Use the KM-280 2 adaptation.

27 Turn off the adjusting screw 3.

NOTE Change of provision of a lock-nut of rather adjusting screw is not allowed. It is necessary to provide the correct assembly situation.

28. Remove a sealing ring (fig. XIII, 2).

Use the suitable tool 3 to press a sealing ring in the case.

Take out a sealing ring from the case, operating with a screw-driver 1 as the lever.

29. Remove a lock ring (fig. XIV).

Remove greasing.

Remove a lock ring.

30. Take out a steering shaft from the case.

31. Take out a gear lath from the case and check a surface.

NOTE If the surface is damaged, for example, furrows were formed, it is necessary to replace the steering mechanism.

32. Take out the old plug of the bearing (fig. XV).

Release the bearing 1 plug by means of the suitable tool 2.

To Vytolknita the bearing plug from the case from the opposite side by means of the long tool.

33. Clear a nest for the bearing.

34. Establish the new plug of the bearing (fig. XVI).

Insert the bearing plug against the stop.

Establish a lock ring 1.

35. Slightly to grease the plug of the bearing with being applied greasing.

36. Establish a gear lath.

Evenly grease a gear lath with being applied greasing.

Insert a gear lath into the case center.

37. Establish a steering shaft.

NOTE The gear lath should be established in average situation.

Marks in the helmsman to a shaft and the case should coincide (see fig. XI).

Measure a vystupaniye of both ends of a steering rack concerning the case by means of a calliper.

NOTE The size should be identical from both parties.

If the vystupaniye is not identical, repeat operation for receiving demanded result.

38. Establish a lock ring.

39. Establish a new sealing ring (1, fig. XVII).

Enclose being applied greasing in the case.

Press a sealing ring fingers.

40. Twist the adjusting screw with a lock-nut.

NOTE Change of provision of a lock nut of rather adjusting screw is not allowed.

41. Tighten a lock-nut with the moment of 80 N · m. Marks in the case and in the adjusting screw should coincide.

NOTE If necessary hold the adjusting screw. Surely observe adjusting marks.

42. Establish 2 cross-section steering drafts.

Put lock mastic on a carving of a shaft of a gear wheel.

Tighten 2 tips of steering drafts (the moment of an inhaling of 70 N · м).

NOTE Hold an open wrench for лыски on a gear lath.

43. Establish 2 boots.

Establish 4 collars.

44. Remove the steering mechanism from an assembly arm.

Turn off 2 nuts.

45. Attach the steering mechanism to the case of the forward bridge.

Insert 2 new bolts.

Use 2 new washers.

Tighten 2 new nuts with the moment of 45 N · m + 45 ° + 15 °.

46. Establish the case of the forward bridge.

By means of a hydraulic jack carefully lift the case of the forward bridge with KM-6394 adaptations on KM-6168-A and KM-904 to the car bottom, an arm of a back jet bar or a forward jet bar.

47. Fix the case of the forward bridge.

Tighten 4 new screws with the moment of 90 N · m + 45 ° + 15 °.

48. Attach the switching mechanism.

Insert the switching mechanism in кроншейн the switching mechanism from above.

Establish a fixing clip.

49. Attach a front bumper to the case of the forward bridge.

Insert 3 plastic rivets.

50. Attach the socket of a plait of wires of the sensor of oxygen.

51. Attach an exhaust system.

Establish 2 rubber suspension brackets.

52. Establish the amortization block of a forward jet bar.

Tighten the screw with the moment of 60 N · m.

53. Attach a forward exhaust pipe to the catalyst.

Tighten 3 nuts with the moment of 25 N · m.

54. Attach 2 tips of steering bent for to a rotary fist.

Tighten new nuts with the moment of 35 N · m.

55. Attach 2 pendular levers to a basic pipe of an amortization rack.

Tighten nuts with the moment of 65 N · m.

Hold an open wrench for two лыски on a bolt of a rotary fist.

56. Attach an intermediate steering shaft to a steering gear wheel.

Tighten a nut on a clip bolt with the moment of 24 N · m.

57. To clean a radiator suspension bracket to the air deflector.

Cut off 2 plastic cable collars.

58. Establish forward wheels.