Scribd Logo
Upload

Welcome to Scribd!

  • Lada Niva Braking System

    Uploaded by

    ektoras49
    417 views16 pages
    Lada Niva 1700 4X4

    Copyright

    © © All Rights Reserved

    Available Formats

    PDF or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    Report this Document
    Lada Niva 1700 4X4

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    417 views16 pages

    Lada Niva Braking System

    Uploaded by

    ektoras49
    Lada Niva 1700 4X4

    Copyright:

    © All Rights Reserved
    Download as PDF or read online from Scribd
    Flag for inappropriate content
    of 16
    TURBONutter Lada Niva 4x4 Service Manual Fuel Injection This manual and a host of other wonderful Lada Niva documentation is available free of charge at: http://www.turbo-nutter.com You can do anything you like with this manual except sell it or otherwise make money from it. While | can't stop you sticking it on your own website | would much prefer you linked to its original location on turbo-nutter.com You use the information contained with this manual at you 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: Lada UK Ltd Lada Parts Australia P/L Askew Rigg 42 Aerodrome Road Troutbeck Caboolture Penrith, Cumbria Queensland CA11 0SZ 4510 United Kingdom Australia T: +44 (0) 17 6877 9794 T: +61 7 5495 5100 F: +44 (0) 17 6877 9197 F: +61 7 5495 5152 E: alan@lada.co.uk E: andy@ladaparts.com W: http://www.lada.co.uk W: http://www. ladaparts.com Section VI BRAKES The layout of the brake Pig. 6-1. Pig. 6-1, Brake System, Diagramatic: 1 = front brake cylinder block; 2 - brake fluid reservoir; 3 - brake master cylinder; 4 - primary jcontary eireuit pipes 7 = brake pedal; 6 ~ parking Bo Renedy Foor Braking Effect 1. Pluid leaks from wheel 1, Replace faulty parte cylinders of front or of wheel cylinders, wash rear brakes ‘and dry shoea and dre, vleed hydraulic systen 2. Air im brake system 2. Bleed 3+ Damaged rubber scale 3. Replace of brake master cylinder Dleed syaten 4, Hydraulic rubber hoses 4, Replace hoses danaged ra brake lever; 9 = parking brake front cable; 10 = rear cable guide; 11 ~ parking brake rear cable; 12 - rear brake wheel cylinder; 13 - prea sure regulator operating lever; 14 ~ pressure regulator ie Contra Cause Tenedy Spontaneous Breking with Engine Run Wrong position of Btop- Light switch caust Anfiltretion of air between valve body and boot. As @ result: (a) cover seal te damaged, cocked or improperly fixed Do the following: (a) replace vacuut doonter conta contta ue to defective locking parta; (b) lubrication of cover seal ia insufficient Incomplete Release of All Wheel 5: No free travel of ke pedal due to wrong sition of stoplight Aton Frotrusion of vacuum oster adjusting bolt om brake master cylin~ F ounting surface ex- ed6 1.25_9,2 am Jonging of vacuum este alve body ca | by ewelling of aphraga oF seizure of ester cover seal or Clogging of master Linder compensating ne Swelling of master Linder rubber seala waged by penetration " gasoline, mineral 1a, etc. into fluid Janming of brake ster cylinder piston Reneay (>) remove boot and pack seal with lub- rheant 1. Adjust position of ewiteh 2. Adjust protrusion of adjusting bolts (See Pig. 6-2) 3+ Replace vacua, booster 4, Clear out hole, Bleed nydraulic ayaten 5. Yash entire systen ‘thoroughly with brake fluid, replace feulty rubber parts, bleed hyd~ ruulic aysten 6. Sxamine master cylin~ der, replace it, if necessary; bleed hyd~ reulic system ‘Ope Wheel Drage with Pedal Released Rea. rake shoe retum ring week or broken Jaming of wheel Linder piston due to rresion Swelling of wheel finder nealing rings 1. Replace spring 2, Disassemble cylinder, clean and wash parts, replace faulty one: 3+ Replace rings, wash brake oysten with fluid e to penetration of fuel - oi] into fluid Mo shoe~to-druz wrong position of “ake caliper relative ) brake disc due to joaening of shoe guid ~ateoring-Imuckle bolts | Exconsive rmout of rake disc (over 15 am) 4. Adjust parking and rear brakes 5. TMghten bolts; 1¢ necessary, replace | foulty parte 6. Grind disc. Replace, Af St da thinner than om Bs cause Remedy Skids or Pulls Sideways on Broking 1, Fluid leak from one of wheel cylinders 2. Jamming of wheel eylinéer piston 3+ Clogging of one of steel pipe due to den - ‘ting or soiling 4. Won-unitom tyre pressure 5. Wrong front wheel alignment angl: 6. Soiling or ofling of @iscs, drune and shoe Linings 7. Wrong installation of pressure regulator 8. Pressure regulator faulty Boas 1. Clogging of vacuum booster air filter 2. Booster valve body Jaming due to swelling of diaphregn or seizure of booster cover seal or boot 3. Hose between booster ana engine intake mani- fold damaged or loosely fitted on pipe unions 4, Brake pedal mete bushings oxidized or run dry (drying of lubricant) Pressure 200 1. Replace bleed systen 2, Eliminate jaming, replace faulty parts, Af necessary 3+ Replace or clean out pipe. Bleed system jel and + Adjust tyre pressure 5. Adjust + Clean brake parte 7. Adjust postion of pressure regulator 8, Repair or replace pressure regulator Replace air filter 2. Replace vacuum dooater 3s Replace hose or tighten its clamps 4. Replace wom parts oF change lubricant Brakes Squeak or Squesl 1. Weakening of roar brake shoe retum spring 2+ Rear brake drans out of round i 3+ Shoe Linings smeared with ofl” 4, Shoe linings worn or fouled with enbeaded foreign particle 5. Excessive runout or uneven wear of brake aise 1. Bxamine retum pring Af neces- 3. Clean Linings with ire brush, wam water and detergents. Prevent penetration of fluid oF off to brake shoes 4+ Replace shoes 5 Grind disc. Replace, Af it 1s thinner than 9am QHECKS aN apsusmenT GUECKING PIPES AND JOINTS "79 prevent sudden feilure of the brake sys~ ‘tem, exanine closely all pipes: = the metal pipes should be free from dents, enacks and should be located sufficiently fer from sharp edges which might cause their damages should have no penetrating cracks on the extemal casing and should be out of contact with minerel oils and lubricants that are apt to attack rubber; deprese the brake pedal sharply and see thet the hoses do not bulges bulging is indicative of sone defect; = ell the pipe clips should be well tightened since their loosening will result in vibration and breakages = there should be no fluid lesks from the pipe uniona; if necessary, tighten the mute home, taking care not to distort the pipes. Replace the parts by new ones if there is even the slightest doubt as to their serviceabi- lity. Tt 4 recomended that the flexible hoses, irrespective of their condition, be replaced by = the brake hoses $A 2 3 Ri) 3 a, % Ey Pig. 6-2. Brake Vacuum Booster: 1 = nipple fastening flange; 2 - booster casing: 3 - rod; 4 ~ cover; 5 - piston; 6 - booster bolt; 7 = epacer ring; 8 - valve spring seat; 9 ~ valve; 10 - valve aupporting cup; 11 - return spring peat; 12 - boot; 13 - boot holder; 14 ~ pushrod; 15 ~ eir filter; 16 - valve return spring; 17 - valve spring; 18 - casing cover woal; 19 = seal lockring; 20 - thrust plete; 21 - but- pam 3) 2b ot new ones after 100,000 kiloneters of min or five yeara of service in onter to preclude sudden bursting due to ageing. After five years of operation it is good practice to fi11 the brake system with fresh flut! (CHECKING VACUUM BOOSTER With the engine shut down press the drake pedal 5 ~ 6 times, thus building up an equal prei sure, close to atmospheric, in spaces A and E (Pig. 6-2). at the mene time see that valve body is not jammed, judging by the force on the pedal. Stopping the brake pedal midway of ite trave start the engine. If the booster is in order, the brake pedal will sink forverd efter engine stert- ing. If, however, the pedal fatle to move formant check the fastening of hose nipple 29, condition and fastening of flange 1, fastening of the hose to the nipple and to the union of the engine inteke manifold because a loosely fastened or damaged hove end flange 1 decrease shazply the me fer; 22 - valve body; 23 - diaphragn; 24 - valve ody retum spring; 25 - rod seal; 26 - master cylinder bolt; 27 ~ rod seal holder; 28 ~ adjust- ing bolt; 29 - hose nipple; 30 ~ valve A= vacuum space; B- channel from vacuum space ti Amide space of valve; C - chennel from inside apace of valve to atmospheric pressure space; B ~ atmospheric pressure space 9 18 vacuun in space 4 and the efficiency of booster operation. If the car gets braked spontaneously check the vacuum booster for tightness with the engine mumning, first by releasing the brake pedal, then pressing and holding it so. Sticking of boot 12 to the extension of the valve body and the hissing sound of infiltrating air will indicate insufti- chent tightness of the booster. Byon in the absence of boot sticking, seal 18 should be examined as follow = remove boot 12 carefully then ahirt it from the flange of the hole in cover 4; = with the engine running, rock the protrud~ ing extension of the valve body laterally with a force of 29.4 ~ 39.2 H (3-4 kgf); there should be no characteristic hissing of the air entering the booster past cover seal 18, If the vacuum booster is found to be leaky, ai ~umnect pushrod 14 from the brake pedal, renove bo.. 12 and pack 5 g of WATIM-221 grease between the seal and the flanges of the cover and valve body; then examine air filter 15, replace it, if necessary, and put the boot back in position. If these measures Zail to do away with the infiltration of air, replace the vacuum booster. ADJUSTIENT OF BRAKE OPERATING MECHANISM Free travel of the brake pedal should be 3-5 mm with the engine inoperative. This travel is engured by moving stoplight switch 6 (Pig. 6-3). If the stoplight switch is too close to the pedal, the latter fails to come beck to the initial position; as a result, valve 9 (Pig. 6-2) bears against body 22 and disccmects spaces A “and 2 which causes incomplete releasing of the whoo) brakes when the pedal is released. Jo adjust the position of the stoplight sw'~n back off nut 5 (Pig 6-3) and move the Pig. 6-3. Broke Pedal: 1/= vacua booster; 2 - pushrod; 3 ~ brake pedal; 4 = stoplight switch butfer; 5 - aritch muty 6 ~ otoplight witch; 7 ~ pedal retum spring; @ ~ naster cylinder 17 switch oo that ite buffer is in light contact with ‘the brake pede stop. In this position free travel of the brake pedal should be within 3 and 5 mm. After adjustaent do not fail to tighten nut 5. Saution Pree travel of the brake pedal should be adjusted with the engine shut down. If it proves dupossible to eliminate incom plete releasing of brakes by moving the stoplight awiteh, disconnect the brake master cylinder from ‘the vacuum booster and check the protrusion of adjusting bolt 28 (Pig. 6-2) relative to the mounting surface of the master cylinder flange (1,25_o,2 mm). This distance can be set by hold~ ing the’end of rod 3 with a special wrench and turing adjusting bolt 26 in or out with another wrench. ADJUSTMENT CF PARKING BRARE If the parking brake faile to hold the oar reliably on a 20% gradient or is applied only atter its lever hus been shifted by more than 4-5 teeth of the ratchet mechanian, adjust the brake aa follows: = deck up the rear end of the car uti) the wheels are free to rotate and move the lever all ‘the way dom; = loosen locimut 5 (Pig. 6-4) of the tension~ ing device and keep tuming in adjusting mut 6 to tension the cable util the rear wheels are braked and cannot be tumed by hand; ‘Hate. If the cables have been replaced by new ones, apply the parking brake 2-3 tines, pulling the lever with a force of about 392 M (40 ket). Mais will stretch out the cable ~ unscrewing the adjusting aut set 6 4-Setooth travel of the lever on the quadrant and tighten the mut. Pig. 6-4. Parking Brake Control Linkege: 1 = front cable; 2 - rear cable guide; 3 - front cable retum spring; 4 - rear cable; 5 - locmut; 6 = adjusting nut; 7 ~ spacer bushing Apply the brakes several times to make sure thet the lever travel has not changed, and the wnesla are free to rotate without dragging when the lever is pushed to the downnost position. CHECKING SBRVICEARILITY OP PRESSURE REGULATOR Put the car on a lift or en inspection pit and clean the pressure regulator end its protec- tive boot. Bake off the boot carefully, renove rements of lubricant end clean the toreion lever-piston joint. Ask an assiotant to press the brake pedal with @ force of 686 - 784 ¥ (70-80 kgf), at the sane ‘time watching the protruding part of the pressure regulator piston. If the piston moves 0.5 ~ 0.9 m relative to ‘the regulator body and teists the torsion lever, 4t means that the pressure regulator ie in order. Proce the brake pedal agein 2 or 3 tines to make certain that the pressure regulator ie fully viceable. If the piston steys still after depression of the brake pedal (thie ie coused by sticking of the corroded piston to the body), replace the regule- tore om ascertaining that the pressure regulator is fully serviceable end there are no fluid leaks between the regulator piston and body, apply e ‘thin leyer of [T-1 grease to the axle and to ‘the protruding portion of the piston, pack 5-6 g of the sane lubricant into the rubber boot and put ‘the latter back in position. ADJUSMIONT OF SHOE~TO-DRUM CLEARANCE Proceed ao follows: = press the brake pedal with a foree of 98 = 117.5 H (10-12 kgf) to bring the ahoes in contact with the drun; = holding the shoes in the position, tum the hex heads of eccentrics A and B (Pig. 6-5) in the @irection shown by arrons in the figure until they come in contact with the shoe: Pig. 6-5. Shoe-to-Drum Clearunce Adjuetnen' A= front shoe adjusting eccentrics; B- rear shoe edjusting eccontrice. Arrows above show the direc- tion of car travel; € = Lal. wheel; 4 ~ RH. wheel 128 = let go off the brake pedal and tum the adjusting eccentrics in the opposite direction ‘through 10° approxinately; = press the brake pedal sharply 3 - 4 times, release it end rotate the Jacked-up wheele; the shoes should be clear of the drums, After adjustments it ie good pructice to drive the car 5-7 lm without using the brakes, ‘then to stop and hand-feel the brake druns to make sure they are not heated because of friction against the shoes. If the dmume feel hot which should be attributed to friction between the shoes and Grums, repeat the adjustments. If adjustments fail to set the required shoe- to-drum cleerance, renove the breke run, exenine ‘the shoes and the drum; if neceasary, replace or recondition the worn parts, then aasemble the bral fand adjust once again. ADJUSTING POSITION OP PRESSURE REGULATOR If the regulator fastening bolts become Loose, adjust the reguletor position firet jacking up the rear axle of the car. ‘Then @iscomnect lever 4 (Fig. 6-6) from Link and attech fixture 67.7820.9519 to the end of the lever. Direct the spindle of the fixture upward to dear against the cer body floor (Pig. 6-7). This will set © eistance "I" of (15045) mm detwoer the end of the lever end the body sidenenber (Pig. 6-6). Lift rubber boot 6 (Fig. 6-6) a little ana, turing the prossure regulator on its bolts ectablish a light contact between the lever ond piston 2. Holding the regulator in thie position, tighten bolts 1 end 7 as fer as they will go and Pig. 6-6. Installation and Adjustment of Rear Brake Pressure Regulator: 1, 7 = regulator fastening bolts; 2 - pistons 3 = supporting bushing bracket; 4 - regulator operating lever; 5 - axle; 6 - boot; 8 ~ link; 9 = pressure regulator; X= (150 +5) mm Pig. 6-1. Pixture 67.7620.9519 for Rear Brake Pressure Regulator Adjustuent 1 ~ fixture 67.7620.9519; 2 - pressure regulator operating lever apply a thin coat of 27-1 grease to axle 5 and to the protruding part of piston 2. Pack 5 - 6 6 of * sane lubricant into rubber boot 6 and put Lt back in position, Remove fixture 67.7820.9519 and connect the end of the lever with link 8. ‘SUBEDING HYDRAULIC BRAKE SYSTEM The air gotting into the hydraulic breke ays- ten during replacenant of the pipes, hoses, sealing rings or though looms joints incressea tree travel ot tne brake podel, causes it to feet spongy ant iapaive ‘he Disking effect considerably. Prior to bleeding the ayeten, nate oure that 1 tue unite of the brake operating wechant an a thesr joints are presmuretignt, check ene aout of fluid in the Teaervoir and top it up) Sf ocesoary, with Drake f1uld NEVA (OHEBA")” Men lem the bleeder unions (valves) carefully of éirt nd dust and senove the tutber boots (cape) from a 54 mumeer blowing hose (Pig. 6-8) on the ead of the union ant ip the other end of the coe snto e transparent ressel pertly filled with be brake Flute. Depress the Yowke pedal sharply 3-5 tines th 20) a intervals betveen suocesstve depres tous, unscrew the union = g of a revolution with ne pada depressed, then’ Iaep depressing, the Dedad renove the fsia with air from the speten trough iis ose into the vessels At soon ae tha eal roaches ita foremost posttion and the fluid 32 tu flow fron tbe Hose, sorew tx: the Bleeder nion ell the ay. Repeat thooe operations well ne sprey of ‘lui floving fron the hose becomes ree of air tbbles. Holding the petal depresseds crew in the bleeter union eli the may ent renews ne hose. Wipe ary the blesder inion an put in lace the mibter boot, Ferfor alt the above operations first through ne upper unions of the reer Rois mueel waich ta m9 Fig. 6-8. Bleeding Hydraulic Brake System ferthest from the asater cylinder, then work tx the clockwise direction, Sve. Lully rear wheel, La front wheela. thie will expel air fro oe of the brake circuits, Bleed the other eireult through the lower union on the block of eylingers of the Lalls and Rutls front Drakes. Bleeding may be started either fron the Rul. or Like Wheels thie bleoding the hydraulic brake systen take cere to saintain a nomal fluid level in the brate Fluid reservoiz. If there io no air in the hyte raulie brake ayotes, the brake pedal should aove hot farther than d= 3 of {to travel. fo exclude the influence of the vacuun boos~ ‘ter and pressure regulator on the bleeding opera- ‘tion, do it with the engine shut down and the rear wieels loaded (do not jack up the rear end of the cer). If the hydraulic system has been completely drained, the bleeding operation should be preceded by the following: ~ unscrew the bleeder unions 1.5 - 2 revolu= ‘tions on the brake cylinders of all wheels; + pressing the brake pedal abarply ond eles ing it slowly, screw in the unione aa the fluid has flowed out. then bleed the aysten aa described above. If the air bubbles continue to energe from the hose even after prolonged bleeding, it means that air penetrates into the system through danag- ed pipes, leaky jointe or faulty master or wheel cylinders. 7 If the hydraulic “system is being bled on the car whose brake system has been operating for e long Mime, it da recommended thet the systen be filled with fresh Miuta. The fluid considered fit for reuse should de carefully filtered end settled in e tightly elo! vessel. é CLUTCH AND SRAKE PEDAL BRACKET Removal ond ino bracke: = take off the steering shaft bracket as advived under "Steering gear"; = detach the vacuum booster pushrod from the brake pedal by removing locking clip 26 (Pig- 6-9) and pin 24; ; = unscrew the nuts which fasten the vacuum booster and clutch master cylinder to the bracket, = unacrew the bracket-to-bedy nuts and renove the bracket, discomecting the wires from the atop-Light switen. To inatell the bracket reverse the removal operations seeing that the pushrod is properly in- stalled im the socket of the clutch master cylin der piston ation. To remove the pedal 23 19 Fig. 6-9. Parts of Clutch end Broke Fedals Bracke 1 = bracket; 2 - mut; 3 - epring masher; 4 ~ brake pedal inner bushing; 5 ~ brake pedal outer bush- inga; 6 - brake pedel; 7 - spacer bushing; 8 - brake pedal retum spring; 9 - clutch pedal outer bush- ings; 10 - hook; 11 - cap; 12 - cluteh pedal stop 130 Disassembly and assembly. To ddeaseenble remove clutch pedal servo spring 14, springs @ and WT, unscrew mut 2 of bolt 20, take out the bolt fend renove the pedals complete with their bushings. ‘The springs should be renoved and installed by the use of tool 4.70017. To assenble proceed in the reveree sequence of operations. Before assembly apply 2ur02-24 grease to pedal bushings, to the ends of the springs, the joints of the pushrods with the pedals end to the end of the pushrod contacting the piston of the clutch master cylinde: a a screw; 13 - nuts 14 - servo spring; 15 - clutch pedal inner bushing; 16 - plete; 17 - clutch pedal retracting apring; 18 - washer; 19 - pedal pad 20 = bolt; 21 - clutch pedal; 22 - cotter pin; 23 = eluteh pedal pushrod; 24 - piny 25 ~ vacuum booster pushrod; 26 - locking clip ecko ang repeirs. If the pedals nove with dittsculty examine the working surfaces of the pedaie, bushings and shaft. Tf the metal parts are found to be Lightly scratched or oxidized, it 1s enough to dreas then with abrasive cloth; the outer plastic bushings of the pedals, 1f wom, should de replaced by new check the springs for reatltence. The length of the brake pedal spring should be 80 mm under @ force of (12.841-96) [(1.34042) gt] and 160 mm under a force of (1174545.88) (1220.6) ket]. ‘the length of the clutch pedal retracting opring should be 130 aa under a force of ¢32.3423"32) w [(3.39'9) kee] and 155 om under a force of (45.00%S"42) x [(4.699-$5) et] « the length of the eluich aervo apring ahould be 120 mm under a force of (199-9219.6) W [(20.422) ket] and 152 mn under a force of (587-02458.8) 1 [(59.946) ket]. Yacuins pooszeR REMOVAL AND INSTALLATION When renoving the vacuum booster, brake master cylinder in place to prevent air from r-tting into the hydraulic system. ‘20 remove the boos: = iscomect the Yooster pushrod from the pedal; eave the = unscrew the nuts which fasten the master BRAKE WASTER The doi Fig. 6-10. ge of the master cylinder Ss show in Fg LLL Pig. 6-10, Brake Master Cylinde 1 = plug; 2 - cylinder barrel; 3 - front brake con- trol piston; 4 - washer; 5 - rear brake control B and front brake auxiliary control piston; 6 - ing ring; 7 - stop screna; 8 - piston retum springs; 9 = spring seat; 10 - seal holddown spring; 11 = spacer ring; 12 - inlet hole; A - compensating hole (clearances between sealing ring 6, ring 11 and piston 5) al BI cylinder to the booster, take the cylinder off the studs and shift it sidewise = @isconnect the hose fron the boost = uiscrew the nuts which hold the booster to the clutch and brake pedal bracket and take off the boosters To install the booster reverse the renoval operations, cxnmmsR REMOVAL AND INSTALLATION Disconnect the flexible hoses from the cester cylinder and stop the holes of the cylinder hoses and unions to keep the fluid in and dust and dirt Disconnect from the master cylinder the steel pipe leading to the wheel cylinders of the front and rear brakes, first unscrewing the pipe muta. Remove the maater cylinder, unscrewing the nute which fasten it to the vacuum booster. Qo install the master cylinder reverse the removal operations. After installation bleed the brake system. DISASSEMBLY AND ASSEMBLY Regove uniona 3 (Pig. 6-11) with sealing washere 4, take off cap 5, turn out screws 7 and ‘take out all parts in the order show in Fig. 6-116 Assemble the cylinder in the reverse order steps, using mandrel 67.7853.9543 and lubricating the parts with brake fluid. of Ghecking Master Cylinder Part: Before assembly wash all parts with Leopropy] alcohol, dry thea with compressed air or wipe with clean rags, keeping the parta out of contact with mineral ofle, Kerosene end diesel fuel which ere apt to attack the seals, “ Pig. 6-11. Farts of Brake Master Cylinder: 1 = cylinder barrel; 2 - lock washer; 3 - unions 4 = sealing washer; 5 - dust cep; 6 ~ sealing washer; 7 - piston locating scren; 8 - piston retum spring; 9 - seat; 10 - seal holddom springs 11 = seal; 12 - spacer ring; 13 - floating’ pist 14 = washer Yate, The washing tine of the sealing Fines im isopropyl eleohol should not be over 20 8, with subsequent blowing the rings with compressed cir. si nena the cylinder imer face and the working sur- faces of the pistons ahould be perfectly clean and free of rust, notehes and other defects. Excessive clearance between the’ cylinder and pistons is impemniesibie. Each time when diassvenbling the cylinder, ‘take care to replace the seals by new ones, even if ‘the old seals appear to be quite serviceable. Check the piston spring for resilience; ite Jength should be 36 mm under @ load of 34.3% Fig. 6-12, Checking Master cylinder for Tight~ 1 = atend priming valve; 2 - pressure gauge; 3 = receiving cylinder; 4 - master cylinder; 5 = handmheel; 6 ~ pushrod travel indicator; 7 = cock; & ~ vessel (9.57 gt), 21 ma under @ Load of 62,2399 x (6.35¢1+0 uge) and 57-5 ma when noncompressed. ‘BRAKE WASTER CYLINDER TIGHTBSS CHECK Wount the master cylinder on a stand and con nect it to the letter es show in Pig. 6-12. open stand priming valves 1 and, moving the master cylinder pistons a few times through their complete stroke, prine the syster. Then close valves 1+ Rotating handwneel 5, move the master cylinder pietone slowly until the pressure read by preesure gauges 2 reaches 12.5 MPs (125 kef/en*). In thia position lock the master cylinder pushrod. This pressure should stay constent for at lea 5s. In cose of fluid Leake or when pressure fails to remain constant for 5 6, replace the cylinéer Piston seals, PRON? BRAKES ‘the design of the front brake is illustrated im Pig. 6-13. cIEAKING prior to repairing the brakes wash then thoroughly with warm water and a special detergent and éry immediately with compressed air. _— Caution ‘nder no circumstances should &: Asesel fuel, trichloroetbylene or any other line, mineral solvents be used for cleaning the brakes since these liquide destroy cylinder seal: eee 132 REMOVAL AND INSTALLATION Removal. Jack up the front end of the car, put At on supports and remove the wheel. Take off the guide brackets of the hoses, unscrew the bypass bolts, detach hoves 10 (Pig. 6-13) from the block of cylinders, keeping dirt from getting into the cylinders. Stop the Aniet holes of the block ané hoses. Unbend the edges of the front broke guard, unscrew the brake-to-steering-Imucide bolts (Pig. 6-14) and remove the brake as a complete unit. Yo install the front brake proceed in the reverse order of step: Pig. 6-13. Front Wheel Brake Mechaniaa: 1 = cylinder block; 2 ~ brake shoes; 3 - caliper holddow lever; 4 - guard hous = holddom, lever axle; 6 - shoe guide; 7 - brake caliper; @ ~ brake disc; 9 - blesder unions; 10 - brake hoi After installation restore the fluid level in the reservoir and bleed the brake systex. iG Fig. 6-15. Front Brake Parts: 1+ shoe guide; 2 ~ brake caliper; 3 - dust caps 4 = sealing ring; 5 ~ cylinder block; 6 - brake shoes; 7 - brake disc; 8 - front brake guard hous ing: 9 - caliper guard; 10 ~ bleeder union; Fig. 6-14. Renoving Front Brake: Arrows show bolts to be unscrewed for renoving brake DISASSEUBLY AND ASSEMBLY Pull out the cotter ping, then axles 5 (Pigs 6-13), holding levera } to prevent the springs fron getting out. Remove the holddow levers and their springs, ‘then caliper 7 complete with cylinder block 1, Renove brake shoes 2. Zeke cylinder block 1 from the slota in the caliper, spreading apart the oaliper alota to 178.5 mm, Remove dust caps 3 (Pig. 6-15) from the cylinders, 6 6B 2 = cylinder block detent; 13 ~ detent spring; 14 - platon; 15 - holddown lever spring; 16 ~ holddown lever; 17 - cotter pin; 18 = holddown lever axle Feeding compressed air through the fluid inlet hole, push pistons 14 out of the cylinder block fand renove sealing rings ¢. Aseenblv the front brake in the reverse quence, coating the sealing rings, pistons and cylinder faces with brake fluid at assembly; pack ‘the cope with MI-1 ere: CHECKING BRAKE PARTS Wash all parte with lukewarm water and deter- gent, @ry them with compressed air and exanine carefully. If traces of weur or Jamming are discovered on ‘the piston or cylinder face, replace the cylinder block by a new one, complete with pistone, Mote. In all cases when the piston ds removed from the cylinder, it is good practice to replace ‘the sealing ring in the cylinder grooves and the dust cap to ensure satisfactory performance of the syston. RUNOU? CHECK OP BRAKE DISC Check the brake disc for face munout without removing it from the car (Pig. 6-16). The maximum pemissible runout is 0.15 mm show by an indica 3 Fig. 6-16. Checking Brake Disc for Pace Runout: 1 = magnetic support; 2 - indicator; 3 - brake asec The design of the rear brake is im Pig. 6-18. REMOVAL AND DISASSEXMELY Lift the rear end of the car and renove the wheel. tor; 4f it is lerger, grind the disc, bearing én mind that the thickness of the disc after grinding should be not under 9.5 ma. If the @isc is danag~ ed, deeply notched or worn in excess of 1 mm on each side, replace it by e new one. REPLACEMENT OF BRAKE SHOES the brake shoes must be replaced by new ones Sf the thickness of the Linings has diminished to 1.5 mm. 0 replace the shoes: = uncotter the axle of the upper holédowm lever, take out the axle and remove the lever; remove the caliper assenbly end pull the worn shoes from the slots of the guide (Pig- 6-17); = push the pistone gently into the cylinders all the way, taking care that the fluid 4s not splashed out of the breke reservoir and insert new shoes into the guide slots; = bringing the lower guide slant of the caliper under the lower holddown lever, press the caliper against the shoes, insert the lever axle with its head et the wheel aide and cotter up the exlee ‘The brake shoes must be replaced simultaneous- ay on the Ret. and Ll. wheels. Fig. 6-17. Replacing Brake Shoe: 1 = brake shoes; 2 ~ shoe guide; 3 - brake disc; 4 = brake hoses; 5 - cylinder block (assembled with caliper) ‘Take measures to prevent fluid leske from the reservoir. Using renover tool 67.7823.9519 (Pig. 6-19), renove the brake drum. Disconnect the end of esble 5 (Pig. 6-18) from bend~operated shoe control lever 2, pull out the Tt 10 2. 3 9 4 4 8 t \ OU, 5 6 Fig. 6-18. Rear Brake Mechaniaa: 1 heel cylinder; 2 - hand-operated shoe con~ tr. lever; 3 = brake shoe: 5 ~ parking brake operating cable in casing; 6 = lower pull-back spring; 7 - friction lining; 8 ~ shoo-to-drum clearance adjusting eccentri 9 = expander strap; 10 - upper pull-back spring Pig. 6019. Removing Brake Drun: 1+ renover tool 67-7823.9519 4 = cup and shoe guides 15 cotter pin, press on the pin and teke off lever 2. Digconnect upper 10 and lower 6 pull~back eprings. Turn the shoe guide cups and take then out complete with the shoe guides, springs and lower cups; then remove the shoes complete with expander strep 9. Detach the fluid feed pipe fro the wheel cylinder and stop the inlet holes of the cylind and pipe. Rewove wheel cylinder 1. hen replacing the backing plete, take off the oxle-shert as prescribed under "Kear Axle” and Aisconnect the parking brake contrel cable, unscrew= ing two bolte which hold {t to the brake backing plate. ASSGUBLY AND INSTALLATION Mount and secure the wheel cylinder on the backing plate, connect the fluid inlet pipe to 1t ‘and tighten home the union mut. Connect hand-operated lever 2 to the shoe and snatall the brake shoes with expander strap 9; then install shoe guides with springs and lower cups, imatall the upper cups and secure then on the shoe guides by tuming right or le! ‘hat ‘the ends of the.brake shoes fit properly into the sockets of the wheel cylinder ané on the backing plate. Install the shoe pullback springs and connect ‘the end of shoe hand-operating cable 5 to lever 2. Install the brake drum, first coating the mounting band on the axle-sheft and ite flange contacting the drua with graphite or ACll-15 grease and tighten the drum bolts securely. The grease will facilitate subsequent removal of the brake aman. If the wheel cylintar has boon renoved during Ateassembly, bleed the rear brake hydraulic cir Make sure NSPECEION OP PARTS Sheol cylinders. Dismantle the wheel cylinders fas follows: take off caps 1 (Pig. 6-20) and pis tons 2, take out seale 3, spring seats § and spring 7. Then unscrew bleeder union 6. Check the abtive surfaces of the cylinder and pistons for cleanliness. These curfaces should be perfectly mooth, without roughness ao ae to mule out fluid 6-20. Wheel Cylinder Parte: 1+ cap; 2 ~ piston; 3 ~ 5 = spring 6 ~ bleeder union; 7 - eats and proseture wear of the seals and platens. Eliminate ony defects on the cylinder face by ep. ping or grinding. However, Dear in mind that the cylinder bore aust not be enlarged. Replace seals 3 by new onea, Exanine cops 1 and replace then, 4 necessary. Erasine pring 7. Ite free length should be 34 mm, wale under @ load of (54.541-96) 1 [(34520.2) et], 17-8 mm. Replace it, 4f necessary. Goat ail parte Itberaliy with brake fuld before assenbly. Instell the parts in the reverse oesuerce of operations, Arter aseeably check the pistons for mooth and free ‘motion. Shoeg. Inspect the shoes carefully for danage ant distortion. check both he upper and tower pull-beck springs for resilience and replace then by new ones, 1f necessary. There should be no pemmanent defomations after the loner and upper springs have been stretched ny « force of 349.8 (35 kes) ant 412 (42 gt), respectively. Check the Linings for cleusliness; {f dirt o oft Ss discovered, clean then thoroughly with & wize brush and wash with white spirit; besides, took for penetration of Iutricant or ofl into the rus; correct any discovered defects. Replace the shoes by new ones if the thickness of thelr Linings bas dininiahed below 1.5-2 me Brake dnmg. Exanine the brake amuse, Zf the working surface 12 deeply accred or excessively out of round, rebore the dma on a lathe. After reboring finish the working murface of the Gran on @ fuming lathe with fine-grain brasive stones. this will extend the service ite of the Lininge ond proncte the uniformity end effi- cienoy of breving. ‘he noninad Gieneter of the Arum (250 mm) etter retoring end grinding shoul4 not be incress- fd by nore then 11mu. Thie Limit shoud be strictly cbserved, otherwise the atrength of the drun and the beaking efficiency will be inpeires. ‘STAND CHECKS OP REAR BRAKE WEEEL CYLINDERS Mount the cylinder on the stand, connect & pipe fron the pressure gauges to it (Pig. 6-21) end Bleed the aysten. Adjust stops 1 so thet they Dear against the wae) oylinder pistons. Gheck for absence of fluid leaks. Connect @ ow presmure gauge; rotating slowly the handwhee? of the etand cylinder, act a {uid pressure of 0.05 wpe (0.5 ket/en®). Make sure that thie pressure reasins constant for 5 mine eure of 0.1; 5 kef/ea?). Reduce the pressure and connect @ bigh- pressure gauge. Observing the above miles, repeat the teste under a pressure of 5, 10, 15 ube (50, 100, 150 ket/en®). There should be no pressure drop ceused by TAusé Leaks past the sealing elenenta, pipe jotnte and Dieeder unions or through the casting pores. A alight pressure drop [not over 0.5 ue (5 ket/ea®) within 5 min] 4s permtesible, par tioularly et high pressures, when it 4e caused by the shrinkage of the scale, t 2 similar test under a prea 5 0.45 O15 URE (1, 2, 3, 4, Pig. 6-21. Rear Wheel Cylinder Checking Setus = piston stops; 2 - cylinder under test; 3 ~ cylinder bracket; 4 - low-pressure gauges 5 ~ high-pressure gauge; 6 - pressure build-up cylinder; 7 - vessel; 8 - handwhos REAR RUG PRESSURE REGULATOR REMOVAL AND INSTALLATION Disconnect lever 12 (Fig. 6-22) from Link 7, then detach holder 18 from bracket 14 and the clips of the pipes leading to the pressure regulator. Disconnect the muffler mounting parts fron the body and shift aside the pipeline with mufflers. Unscrew the regulator-to-bracket and bracket torbody bolts. Remove the regulator bracket, ease dow the regulator and disconnect ita pipes. Renove the regulator and detach its operating lever. Stop the inlet end outlet holes of the pres. sure regulator and pipeas 138 Yo install the preamure regulator reverse the renoval operations. Before tightening the regulator volts install fixture 67.7820.9519 (Pig. 6-7) on ‘the end of the regulator opereting lever. Direct ‘the fixture spindle uprard to bear against the ca: body. This will ect a distance of (15045) mm (see under "Adjusting Position of Pressure Regulator") vetween the and of lever 2 and the body sidemember. Lift boot 3 (Fig. 6-22) a iittle end, tuming the regulator on its bolts, bring the end of the lever in light contact with the reguletor piston. Holding the reguletor in this position Fig. 6-22. Pressure Regulator Control Linkage: 1 = pressure regulator; 2 - pressure regulator operating lever axle; 3 - boot; 4 - locking plate; 5 ~ bolt with epring washer; 6 - rear axle be 7 ~ link from pressure regulator operating lever to rear axle bracket; 8 = mut of bolt 11; ‘ighten its fastening bolts all the way, then ‘apply a coat of 7-1 grease to arle 2 and to the protruding part of the piston. Put rubber boot 3 in position, having packed 5-6 g of the grease into the boot. Remove fixture 67.7820.9519 and connect the end of the lever with link 7, first applying 2T+1 greage to the bushings of the link-to-lever art lated joint. Pasten the exaust aysten pipes to the car boay. Bleed the brakes to remove any air from the rear brake system. DIGASSENBLY AND ASSEMBLY Using wrench 4.56124, unserew the plug, venove gasket 5 (Pig. 6-23), take out piston 10, Fig. 6-23. Rear Brake Presgure Regulator (Inactive Position): A ~ nomal pressure chanber; B - controlled pres- sure chamber; P ~ force exerted by reguletor lever 4 1 ~ regulator body; 2 - spacer bushing; 3 - sealing ring: 4 - regulator operating lever; 5 - gasket; 137 9 ~ plastic bushing; 10 ~ spacer buahing; 11 - link Dolt; 12 - pressure regulator operating lever; 13 = operating lever supporting bushing; 14 ~ supporting bushing bracket; 15 ~ washer 16 = spring washer; 17 - nut; 18 - supporting ‘Dushing holder; 19 - holder-to-bracket bolt 6 = plug; 7 - rubber seal; 8 - spring seat; 9 - piston spring; 10 - piston spacer bushing 2, seal 7, spring seat 8, spring 9, and thrust washer with sealing ring 3+ To,aseenble reverge the disassembly opere~ ‘tons, lubricating all parte with brake fluia. jaution ‘The pressure regulator of the VAz-2121 car has @ recess on the lower part of the piston, to @istinguish it from the like regulators of other cer modelo. REMOVAL AND INSTALLATION Shift the parking brake lever to the downnost position and disconnect the ends of the cables from the brake shoe operating levers (see "Rear Brakes"). Loosen locinut 5 (Pig. 6-4) and adjusting nut 6, remove retum spring 9 (Pig. 6-24) and unscrew completely the locknut and the mut. Take the front-end fittings of the rear cable fron the body floor brackets and the cable casing out of the brackets on the rear axle beam and remove rear cable 12+ Take off the lever guard case, the lever ‘assembly and the front cable. Pull out the cotter pin, take off the thrust washer and @iscomnect the front cable from the parking brake lever. Yo install the parking brake reverse the removel operations, then sdjust it (see "Adjust~ 4 6 6 este 1 Pig. 6-24. Forking Brake Control Linkage: 1 = case; 2 ~ front cable; 3 ~ eve: 5 ~ vod spring; 6 - pawl rods 7 - rear eable 4 = button; van the parte with isopropyi sicobel oF brake stutd and inspect then, The surfaces of the parte should be free of scratches ant Tough pote. Check the condition and resilience of te springs ite free Leng! should be. 17,0 mm, wile ter & load of (68-60-98) m [(790-8) het], 9 me Tepiace eli danaged parte, the seal and’

    You might also like