Repair Hyundai Getz
Hyundai Getz. The maintenance+ 1. Operation and maintenance service
+ 2. The engine
+ 3. Transmission
+ 4. A running gear
+ 5. A steering
- 6. Brake system
The general data
Check and adjustment of elements of brake system
Working brake system
Lay brake system
Antiblocking system of brakes (ABS)
Possible malfunctions of brake system, their reason and ways of elimination
+ 7. An electric equipment
+ 8. A body
9. Electric equipment schemes
Hyundai Getz>> Brake system>> Working brake system
The vacuum amplifier of brakes
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Fig. 6.7. The vacuum amplifier of brakes: 1 – a vacuum hose; 2 – the return valve; 3 – a collar; 4 – a pusher axis; 5 – a washer; 6 – шплинт; 7 – knot of a pedal of a brake; 8 – the vacuum amplifier of brakes; 9 – the main brake cylinder
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The vacuum amplifier of brakes is shown on fig. 6.7.
At failure of the vacuum amplifier the effort to a brake pedal considerably increases that negatively affects driving. For repair of the vacuum amplifier the special tool is required, therefore it is recommended to replace it in gathering.
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PREVENTIONS
At removal of the main brake cylinder do not suppose excesses and damage of brake pipelines.
Do not suppose hit of a brake liquid on a car detail. It can damage a paint and varnish covering of a body. At liquid hit on a paint and varnish covering of a body immediately смойте its water.
For prevention of passage of a brake liquid wrap up connections of hoses by rags or napkins.
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Removal
Remove the air filter.
Separate a contact socket of the gauge of level of a brake liquid (fig. 6.8).
Remove a stopper of a tank of a hydrodrive of brakes and a syringe or other adaptation remove a liquid from a tank.
Disconnect brake pipelines from the main brake cylinder.
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THE PREVENTION
Take measures against hit of a brake liquid on surrounding details.
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Fig. 6.9. Elements of a hydrodrive of working brake system: 1 – the vacuum amplifier of brakes; 2 – a vacuum hose; 3 – a pressure regulator (on cars without antiblocking system of brakes); 4 – brake pipelines
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Remove the main brake cylinder from the vacuum amplifier, having turned away a nut of its fastening (fig. 6.9).
Disconnect a pusher from a brake pedal.
Turn away a nut of hairpins of fastening of the vacuum amplifier of brakes.
Check of work of the return valve of the amplifier of brakes
Check spend on the return valve established in a vacuum hose.
Remove a vacuum hose of the amplifier of brakes.
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THE NOTE
The return valve is established with a tightness in a vacuum hose on adjusting labels.
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Check up work of the return valve by means of the vacuum pump.
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THE PREVENTION
In case of malfunction of the return valve replace it in gathering with a vacuum hose.
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Installation
Establish the vacuum amplifier of brakes and tighten fastening nuts the specified mo-cop.
The moment of an inhaling of nuts of hairpins of fastening of the vacuum amplifier of brakes 8–12 Н·м.
Put greasing in a contact place between a pedal of a brake and a pusher.
Attach a pusher to a pedal of a brake an axis, законтрите a pedal axis шплинтом.
Establish the main brake cylinder, attach to it brake pipelines.
Attach to the amplifier a vacuum hose.
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THE PREVENTION
Do not suppose an excess, twisting and infringement of tightness of a vacuum hose. At connection of a vacuum hose to an amplifier branch pipe put on a hose 25–27 mm, as is shown in fig. 6.10.
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Fill in a brake liquid in a tank of a hydrodrive of brakes and remove air from a hydrodrive.
Be convinced of absence подтекания a brake liquid.
Check up and if necessary adjust a brake pedal (height of a pedal of a brake over a floor).
After installation put greasing enough in contact places between an axis and a pedal (fig. 6.11).
The main brake cylinder
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Fig. 6.12. The main brake cylinder: 1 – a stopper of a tank of a hydrodrive of brakes; 2 – the filter; 3 – a tank of a hydrodrive of brakes; 4 – a sealing lining; 5 – the piston of a forward cavity of the main brake cylinder; 6 – the piston of a back cavity main tor-moznogo the cylinder; 7 – the main brake cylinder; 8 – the screw of fastening of a tank gidroprivo-yes brakes; 9 – a cylindrical pin (on the cars equipped antiblokiro-vochnoj with system of brakes)
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The main brake cylinder is shown on fig. 6.12.
Removal
Remove the air filter.
Separate a contact socket of the gauge of level of a brake liquid.
Disconnect brake pipelines from the main brake cylinder and close apertures technological заглушками.
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THE PREVENTION
At removal of the main brake cylinder do not suppose an excess or damage of brake pipelines.
Do not suppose hit of a brake liquid on surrounding details as it can damage a paint and varnish covering of a body. At liquid hit on a paint and varnish covering of a body immediately смойте its water.
For prevention of flood of a liquid wrap up connections of pipelines by rags or napkins.
Remove the main brake cylinder, having turned away a nut of hairpins of its fastening.
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Dismantling
Remove a stopper of a tank of a hydrodrive of brakes and merge a brake liquid in the prepared capacity.
Turn away the screw of fastening of a tank and separate a tank from the main brake cylinder (fig. 6.13).
Nippers remove a lock ring (fig. 6.14).
Take out the piston of a forward cavity of the cylinder. A screw-driver shift the piston of a back cavity and take out a cylindrical pin. Take out the piston of a back cavity.
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THE NOTE
Pistons of forward and back cavities of the cylinder do not assort.
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Check of a technical condition
Check up cylinder cavities on presence of traces of corrosion, задиров or рисок on surfaces.
Check up the main brake cylinder on presence of deterioration or damages. If necessary clear or replace the cylinder.
Wash out the polluted details spirit.
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THE NOTE
In the presence of damages of a mirror of the cylinder replace the main brake cylinder in gathering.
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Assemblage
Put a brake liquid of the demanded mark on rubber details of pistons and sealing linings.
Cautiously insert into the cylinder of a spring and pistons, having provided their correct position (fig. 6.15).
Screw-driver drown pistons in the cylinder and establish in проточку the cylinder a lock ring.
Drown pistons in the cylinder against the stop a screw-driver and insert a cylindrical pin (fig. 6.16) (only on the cars equipped with antiblocking system of brakes).
Installation
Establish the main brake cylinder on the vacuum amplifier of brakes.
Attach to the cylinder brake pipelines.
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THE PREVENTION
Fill in a brake liquid in a tank and remove air from a hydrodrive of brakes.
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Establish both sealing linings of a tank.
Establish on the cylinder a tank of a hydrodrive of brakes.
Pressure regulator
The pressure regulator serves for distribution of pressure of a brake liquid in brake mechanisms of forward and back wheels for the purpose of increase of efficiency of braking and prevention of premature blocking of wheels. Dismantling of a regulator of pressure is not supposed, as its working capacity directly depends on a correct tension of its spring at installation.
Pressure regulators (on one for each brake mechanism of back wheels) are established on the main brake cylinder.
Check of a technical condition
Check of a technical condition of a regulator of pressure should be made in the conditions of servicing deport of cars Hyundai.
For check of a technical condition of a regulator of pressure control manometres are used.
Brake pipelines
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Fig. 6.17. Pipelines of a contour of a hydrodrive of brakes of forward wheels of cars without antiblocking system of brakes: 1 – a brake hose of the left forward wheel; 2 – a brake hose of the right forward wheel
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Fig. 6.18. Pipelines of a contour of a hydrodrive of brakes of forward wheels of the cars equipped with antiblocking system of brakes: 1 – the hydraulic block of antiblocking system of brakes; 2 – an arm of fastening of the hydraulic block of antiblocking system of brakes; 3 – a brake hose of the left forward wheel; 4 – a brake hose of the right forward wheel
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Pipelines of a contour of a hydrodrive of brakes of forward wheels of cars without antiblocking system of brakes are shown on fig. 6.17. Pipelines of a contour of a hydrodrive of brakes of forward wheels of the cars equipped with antiblocking system of brakes, are presented on fig. 6.18.
Check of pipelines and their connections without removal from the car
For the prevention of sudden refusal of brake system carefully check up a condition of all pipelines and connections, paying special attention on the following:
– Metal pipelines should not have забоин, scratches, задиров, active ocha-gov corrosion and should be located far from sharp edges which can damage them;
– The brake hose should be elastic, not have anguishes and cracks. The hose should be closed strongly up in tips. The carving of tips of a hose should not have damages. If by pressing a pedal of a brake the hose is inflated, means, threads of cords are torn. At detection of any of these defects it is necessary to replace a hose. On hoses mineral oils and the greasings dissolving rubber should not get;
– All скобы fastenings of pipelines should be whole and are well fixed. Easing of fastening or destruction скоб leads to vibration of pipelines which causes their breakages;
– Leak of a brake liquid from connections of the main cylinder with pipelines and a tank is not supposed.
At detection of malfunctions replace the damaged details new. Flexible hoses (irrespective of their condition) replace with km of run new after 120 thousand or after 5 years of operation of the car to warn sudden ruptures because of rubber ageing.
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THE PREVENTION
Do not suppose проливания a brake liquid on surrounding details as it can damage a paint and varnish covering of a body. At liquid hit on a paint and varnish covering of a body immediately смойте its water.
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THE NOTE
Before connection of pipelines and hoses of a hydrodrive of brake system be convinced of absence on all details of a dust and other extraneous particles.
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Removal
Replace brake hoses with twisting traces, cracks and traces подтекания a brake liquid.
For a detachment of brake hoses from brake pipelines use a special key for unions.
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Fig. 6.19. Removal of a clip of fastening of a brake hose: 1 – the brake pipeline; 2 – a clip; 3 – a brake hose
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By means of flat-nose pliers or a hammer remove a clip of fastening of a hose (fig. 6.19).
Remove a brake hose.
Check of a technical condition
Check up brake pipelines on presence of cracks, folds and corrosion traces.
Check up brake hoses on presence of cracks, damages and traces of leak of a brake liquid.
Check up nuts of unions of pipelines on presence of damages and traces of leak of a brake liquid.
Installation
Establish a brake hose, without supposing its twisting.
Brake pipelines establish so that they did not concern sharp edges of nearby details, welded seams and mobile parts.
Combine a tip of a brake hose with an arm groove.
Establish a clip of fastening of a hose.
Tighten a nut of the union of fastening of a brake hose.
Tighten nuts of unions the moment 13–17 Н·м, the union of fastening of brake hoses to supports of brake mechanisms of forward wheels the moment 25–30 Н·м.
After joining of brake hoses remove air from a hydrodrive of brakes.
Brake pedal
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Fig. 6.20. A brake pedal: 1 – nuts with a fillet; 2 – nuts of the switch of a signal of braking; 3 – the switch of a signal of braking; 4 – a nut; 5 – a spring washer; 6 – the right plug of a pedal of a brake; 7 – a brake pedal (cars without antiblocking system); 8 – an emphasis of a pedal of a brake; 9 – a brake pedal (the cars equipped with antiblocking system); 10 – the left plug of a pedal of a brake; 11 – a bolt of fastening of a pedal of a brake; 12 – a returnable spring of a pedal
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The brake pedal is shown on fig. 6.20.
Removal
Remove the switch of a signal of braking.
Remove шплинт and an axis of a pusher of a pedal.
Turn away a nut of fastening of knot of a pedal of a brake.
Remove knot of a pedal of a brake in gathering.
Check of a technical condition
Check up the following:
– Pedal plugs on deterioration presence;
– A brake pedal on presence of deformations;
– A returnable spring of a pedal on presence of damages;
– The switch of a signal of braking.
Attach an ohmmeter to conclusions of the switch of a signal of braking and be convinced of absence of breakage of an electric chain fig. 6.21).
If the chain is broken off at the pressed pusher of the switch and restored at not pressed pusher, the switch of a signal of braking is serviceable (fig. 6.21) see.
Installation
Installation of a pedal of a brake spend in an order, the return to removal.
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THE NOTE
Fix a pusher axis шплинтом. Put on an axis greasing NGLI No.2.
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Establish knot of a pedal of a brake, tighten nuts with a fillet (a nut of fastening of the vacuum amplifier of brakes) and a bolt of fastening of a pedal.
Establish the switch of a signal of braking.
Adjust height of a pedal of a brake over a floor and a pedal free wheeling.
The brake mechanism of a forward wheel
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Fig. 6.22. The brake mechanism of a forward wheel: 1 – a bolt of fastening of a brake hose; 2 – a brake hose; 3 – a support of the brake mechanism with directing brake колодок in gathering; 4 – a brake disk; 5 – a nut of a nave of a wheel; 6 – the screw of fastening a disk brake th to a nave; 7 – the screw of fastening of a protective casing
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The brake mechanism of a forward wheel is shown on fig. 6.22.
The brake mechanism of a forward wheel disk, with automatic adjustment of a backlash between колодками and a disk, with floating скобой and a signalling device of deterioration brake колодок. Скоба it is formed by support and the wheel cylinder which are pulled together by bolts. Mobile скоба fastens bolts to fingers which are established in apertures directing brake колодок. To grooves directing brake колодки are drawn in by springs. Internal колодка it is supplied by a signalling device of deterioration of overlays.
In a cavity of the brake cylinder the piston with a sealing ring is established. At the expense of elasticity of this ring the optimum backlash between колодками and a disk is supported.
Removal and installation brake колодок
Removal
Turn away a bolt of fastening of the bottom directing finger of a support, turn a support upwards and suspend to a car body on a wire or in another way (fig. 6.23).
Remove brake колодки.
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THE PREVENTION
At removal brake колодок do not press a brake pedal (fig. 6.24).
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Check of a technical condition
Check up deterioration brake колодок and if necessary replace them.
Replace колодки in following cases:
– A thickness of frictional overlays of less admissible;
– The surface of overlays is made oily;
– The frictional overlay is unsteadily connected to the basis колодки;
– Overlays have deep furrows and сколы.
Check up колодки on presence of damages or deformation.
The nominal thickness of frictional overlays brake колодок makes
9 mm, maximum permissible at deterioration – 1 mm.
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PREVENTIONS
Колодки replace in brake mechanisms of both forward wheels simultaneously. Replacement internal and external колодок among themselves, and also between left and right wheels is inadmissible. It can lead to non-uniform braking.
At replacement brake колодок check up колодки on deformation presence. Keeping springs of directing fingers replace new or establish reusable springs, having cleared them of pollution.
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Installation
Establish keeping springs колодок.
Establish колодки in keeping springs (fig. 6.25).
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THE NOTE
Колодки establish so that the deterioration indicator on колодке from outside the piston has been turned upwards.
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After installation колодок before moving a support into position, drown the piston in the cylinder by means of the adaptation 09581-11000 (fig. 6.26).
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Fig. 6.27. Brake колодки with linings: 1 – the adjusting complete set internal brake колодки; 2 – the adjusting complete set external brake колодки; 3 – a lining external brake колодки; 4 – external brake колодка; 5 – internal brake колодка with the deterioration gauge; 6 – a lining internal brake колодки; 7 – a cover of a lining internal brake колодки
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Establish new brake колодки with linings (fig. 6.27).
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THE PREVENTION
Do not suppose greasing hit on brake disks and колодки.
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Wrap a bolt of fastening of a directing finger of a support and tighten it динамометрическим a key (fig. 6.28).
Removal and installation of the brake mechanism
Removal
Remove a wheel.
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Fig. 6.29. Connecting details of a head of a brake hose: 1 – a brake hose; 2 – the brake mechanism; 3 – sealing linings; 4 – a bolt of fastening of a head of a hose to the brake mechanism
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Disconnect a brake hose (fig. 6.29).
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PREVENTIONS
Do not suppose hit of a brake liquid on a car detail. It can damage a paint and varnish covering of a body. At liquid hit on a paint and varnish covering of a body immediately смойте its water.
For prevention of passage of a brake liquid wrap up connections of hoses by rags or napkins.
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Turn away a bolt of fastening of the cylinder.
Turn away bolts of fastening directing колодок to a rotary fist.
Remove directing колодок.
Check of a technical condition
Check up the following:
– A support on presence of deterioration, damages, cracks;
– The piston on presence of a dust, damages, cracks and deterioration of an external surface;
– The plug and directing finger on presence of damages and a dust;
– Springs and protective caps колодок on presence of damages;
– Directing колодок on presence of damages, a dust, deterioration and cracks.
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THE PREVENTION
Do not apply an emery paper to clearing of a surface of the piston of the brake cylinder.
All rubber details replace new.
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Check up a brake disk by means of a calliper and the indicator (fig. 6.31).
The nominal thickness of a brake disk (it is checked by means of a calliper) should be 19 mm, is minimum admissible at deterioration – 17 mm.
The difference in thickness at measurement in different places of a disk should not exceed 0,01 mm.
Axial palpation of a working surface of a disk (it is checked with the help стрелочного the indicator of hour type) should not exceed 0,04 mm (see fig. 6.31).
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THE NOTE
By means of a micrometer check up a thickness of a brake disk in eight points located on distance about 10 mm from an edge of a disk with step 45 °.
Define a difference in a thickness of a disk as a difference between the greatest and least thickness.
For measurement of axial palpation of a working surface of a disk fix стрелочный the indicator of hour type on distance about 5 mm from an edge of a disk and turn a disk on 360 °.
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Define axial palpation of a working surface of a disk as a difference between the greatest and the least values of palpation.
Installation of the brake mechanism
Installation of the brake mechanism spend in an order, the return to removal, taking into account the following.
Do not suppose hit of greasing or oil on working surfaces brake колодок and a disk.
Tighten bolts of fastening of the brake mechanism the specified moment.
Attach a brake hose to the hydraulic cylinder of the brake mechanism, having established new sealing linings.
Remove air from a hydrodrive of brakes.
Dismantling and assemblage of the brake mechanism
Dismantling
Remove a dustproof cover of the piston.
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Fig. 6.32. Removal of the piston from the cylinder by means of a source of compressed air (for prevention of damage of the piston at an exit from the cylinder on support ledges the wooden lining is established)
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Take the piston from the cylinder, having submitted to the cylinder the compressed air (fig. 6.32).
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PREVENTIONS
At piston pushing out by the compressed air protect fingers from blow.
Do not suppose разбрызгивания a brake liquid.
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Screw-driver take from the cylinder a sealing ring of the piston, trying not to damage a cylinder surface.
Assemblage
All details, except brake колодок and their linings, wash out изопропиловым spirit.
Establish a sealing ring of the piston in the cylinder, preliminary put on a ring greasing for rubber details.
Put greasing for rubber details in проточку a support, on an external surface of the piston and in a piston cover.
Establish a protective cover on the piston, as is shown in fig. 6.33.
Get отбортовку a piston cover in an internal flute of a support and displace the piston in a support (fig. 6.33 see).
Put greasing for rubber details on an external surface of the plug and I direct-shchego a finger, to an aperture for the plug and a finger in a support, in a protective cap of a finger and a plug cap.
Get отбортовку a cap in a support flute (fig. 6.34).
Establish brake колодки.
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THE NOTE
Do not suppose greasing hit on working surfaces of a brake disk and колодок.
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The brake mechanism of a back wheel
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Fig. 6.35. The brake mechanism of a back wheel: 1 – the mechanism of automatic adjustment of a backlash between a drum and колодками; 2 – the top coupling spring колодок; 3 – the lever of the mechanism of automatic adjustment of a backlash between a drum and колодками; 4 – a spring of the mechanism of automatic adjustment of a backlash between a drum and колодками; 5 – a washer; 6 – the bottom coupling spring колодок; 7 – a directing spring; 8 – brake колодка; 9 – a rack of a directing spring
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The brake mechanism of a back wheel is shown on fig. 6.35.
The brake mechanism of a back wheel drum-type, with automatic adjustment of a backlash between колодками and a drum. The device of automatic adjustment of a backlash is located separately from the wheel brake cylinder and directly is not connected with a hydrodrive of brakes.
Removal and installation of the brake mechanism
Removal
Release a lay brake.
Remove a wheel and a brake drum.
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THE NOTE
For removal of a brake drum turn away the fastening screw (fig. 6.36).
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Fig. 6.37. Elements of the brake mechanism of a back wheel: 1 – the wheel cylinder; 2 – the lever of the mechanism of automatic adjustment of a backlash between a drum and колодками; 3 – a spring of the mechanism of automatic adjustment of a backlash between a drum and колодками; 4 – brake колодка; 5 – the bottom coupling spring колодок; 6 – a washer, a directing spring and a spring rack; 7 – the mechanism of automatic adjustment of a backlash between a drum and колодками; 8 – the top coupling spring колодок
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Remove a spring and the lever of the mechanism of automatic adjustment of a backlash between a drum and колодками (fig. 6.37).
Remove washers of racks of the directing springs, directing springs колодок and racks of directing springs (fig. 6.37 see).
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Fig. 6.38. Removal brake колодки: 1 – brake колодка; 2 – the lever of a drive of a lay brake; 3 – a cable of a drive of a lay brake
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Remove the bottom and top coupling springs колодок, disconnect a cable from the lever of a drive of a lay brake (fig. 6.38).
Check of a technical condition
Check up internal diameter of a brake drum (fig. 6.39).
By means of the indicator check up radial palpation of a brake drum.
Nominal internal diameter of a brake drum, mm:
Cars without antiblocking system of brakes..... 180
The cars equipped with antiblocking system of brakes..... 203,2
Maximum permissible diameter of a brake drum, mm:
Cars безантиблокировочной systems of brakes..... 182
The cars equipped with antiblocking system of brakes..... 205,2
Maximum permissible radial palpation of a brake drum of 0,05 mm.
Check up a thickness of frictional overlays brake колодок.
The nominal thickness of frictional overlays brake колодок should be 5,14 mm, a maximum permissible thickness – 1 mm.
Check up an external surface of the wheel brake cylinder on presence of deterioration or damages.
Check up a board of the brake mechanism on presence of deterioration or damages.
Installation
Put universal greasing SAE J310, NGLI No.2 in places of contact brake kolo-dock and a board of the brake mechanism, and also in places of contact brake колодок and the bottom support (fig. 6.41).
Attach a cable to the lever of a drive of a lay brake.
Establish brake колодки and directing springs.
Establish the mechanism of automatic adjustment of a backlash between a drum and колодками and coupling springs колодок.
Establish the lever and a spring of the mechanism of automatic adjustment of a backlash between a drum and колодками.
Establish a brake drum and some times completely tighten the lever of lay brake system.
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THE PREVENTION
Do not suppose hit of greasing and other pollution on a working surface of a brake drum.
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THE NOTE
Before installation of a brake drum check up external diameter brake колодок (fig. 6.42) (at established колодках).
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External diameter brake колодок cars without antiblocking system (diameter of a drum of 7 inches) should be 179,5–179,0 mm; the cars equipped with antiblocking system of brakes (diameter of a drum of 8 inches), – 202,2–201,7 mm.
Adjust a backlash between колодками and a drum, having pressed a pedal of a brake with effort 10 кгс more than 20 times.
Dismantling and assemblage of the brake cylinder
Remove brake колодки.
Disconnect from the cylinder the brake pipeline.
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Fig. 6.43. Bolts of fastening of the wheel brake cylinder (a kind from an underside of a board of the brake mechanism)
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Remove the wheel cylinder (fig. 6.43).
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Fig. 6.44. The brake cylinder: 1 – the case of the brake cylinder; 2 – a spring; 3 – the union of prorolling of a hydrodrive of brake system; 4 – a sealing ring; 5 – the piston; 6 – a protective cap of the piston
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Remove protective caps of pistons (fig. 6.44).
Before assemblage of the wheel cylinder check up:
– The cylinder and pistons on presence of deterioration, damages and a dust;
– The cylinder case on presence of damages and cracks;
– Basic surfaces of pistons and колодок on deterioration presence;
– A piston spring on rigidity decrease.
Assemblage spend in an order, the return to dismantling.
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THE NOTE
Before assemblage wash out a cavity of the cylinder and internal details изопропиловым spirit.
Put enough of a brake liquid on sealing cuffs of pistons and a cylinder wall.
Always replace sealing cuffs and protective caps new.
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THE PREVENTION
Track that the ball has not dropped out of the prorolling union.
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