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REPAIR MAINTENANCE OPERATION OF MOTOR VEHICLES
Hyundai Getz (2002 release)

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Hyundai Getz
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Getz
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Front suspension



Technical characteristics of the front suspension
Type
McPherson
Type telescopic racks
Hydraulic
The length of the stroke counter, mm
143
The force exerted by the strut when the rod displacement velocity of 0.3 m / h (kg):
during the course of return
during compression


680 ? 110 (68 ? 11)
220 ? 60 (22 ? 6)
Color label
Red (vehicles without ABS)
yellow (vehicles with ABS)

The length of the spring front suspension in a free state and their labeling
Model Car
Length mm
Color label
For European countries
1.1 L INC
338.6
White and white
1.1 liter automatic transmission, 1.3 / 1.5 L INC
347.7
White-yellow
1.5 / 1.6 l DOHC INC (standard)
1.5 / 1.6 l DOHC INC (Other equipment)
1.5 / 1.6 l DOHC automatic transmission
356.8
White-Blue
For the other countries and the Middle East
1.1 liter automatic transmission, 1.1 liter automatic transmission (standard)
338.6
White and white
1.1 liter automatic transmission (other equipment)
1.3 / 1.5 liters of PCR,
347.7
White-yellow
1.3 / 1.5 liters of automatic transmission (standard), 1.5 / 1.6 l DOHC INC 1.3 / 1.5 liters of automatic transmission (the other level), 1.5 / 1.6 l DOHC (all models except the 1.5 / 1.6 l DOHC MCP)
356.8
White-Blue
Legend: MCP - vehicles with manual transmission; ACP - vehicles with automatic transmission.

The length of the spring front suspension in a free state and their labeling
Model Car
Length mm
Color labels
For European countries 1.1 L
317.2
White and white
1.3 / 1.5 / 1.6 liters (all models)
327.8
White-yellow

Front Strut

Front Strut
Fig. 4.1. Front Strut: 1 - the nut of the top support of a rack; 2 - cap; 3 - stem nut rack; 4 - the top support of a rack; 5 - the top bearing cup spring; 6 - a protective cover; 7 - buffer compression stroke; 8 - a spring front suspension; 9 - the lower bearing cup spring; 10 - the case of the strut


Front Strut is shown in Fig. 4.1.

Removing and installing strut front suspension
Withdrawal
Remove the front wheel.
With reasonable effort, disconnect from the strut mount brake hose connector and the wheel speed sensor.
Remove the wiper cover scuttle.

Nuts of fastening of the top support strut
Fig. 4.2. Nuts of fastening of the top support strut


Unscrew the top support strut (Fig. 4.2).

Nuts of fastening strut to knuckle
Fig. 4.3. Nuts of fastening strut to knuckle


Remove the rack front suspension assembly (Fig. 4.3).
Setting
When installing the rack, make sure that between the bearing surfaces to no foreign objects.

The front anti-roll bar
Fig. 4.4. The front anti-roll bar: 1 - anti-roll bar; 2 - a brake hose; 3 - pin wheel speed sensor


Connect the brake hose connector, the wheel speed sensor and anti-roll bar (Fig. 4.4).
Tighten the screw connections the date specified below.
Tightening torques in Nm:
Nut of the top support strut ..... 20-30
Nuts and bolts fastening the strut to knuckle ..... 110-130
Nuts of fastening Ball joint anti-roll bar ..... 35-45

Dismantling and assembling strut front suspension
Dismantling
Remove the protective cover with a flat blade screwdriver.

The adaptation for compression of springs suspension
Fig. 4.5. The adaptation for compression of springs suspension


Using the tool J38402, A20 compress a spring suspension to almost completely remove the spring force from the rack (Fig. 4.5).
Remove the nut on the rod rack.

NOTE
Do not use compression springs shock device.

Remove the rack from the top support of a suspension bearing cup springs, spring suspension and a protective cover.
Disposal suspension struts
Pull the strut rod.

Zone (A) drilling holes for discharging gas
Fig. 4.6. Zone (A) drilling holes for discharging gas


Release gas from the cylinder rack, making a hole (inscription) in the area A (Fig. 4.6).

A WARNING
The exhaust gas is harmless, but should take precautions for release resulting metal shavings.

Technical condition
Check the top support strut for wear or damage.
Check the rubber parts for damage or deterioration of the material.
Check the spring suspension to shrink and weaken.

Check the operation of the strut
Fig. 4.7. Check the operation of the strut


Check the strut for the presence of excessive stiffness or unusual sound during operation (Fig. 4.7).
Assembly

Installing cushion lower support spring cups
Fig. 4.8. Installing cushion lower support spring cups


Install the lower bearing cup cushion spring suspension, the tabs are darling cup with holes (Fig. 4.8).
Install a protective cover on the rack.
Fully compress a spring suspension device J38401, A2 and set it on the bar suspension.

NOTE
Coil springs set colored mark towards the knuckle.

Fully extend the rack rod and set the upper support plate and the top support of a rack.

NOTE
Installation of the upper support spring cups
Fig. 4.9. Installation of the upper support spring cups


Align the D-shaped opening of the upper bearing cup spring with flattened rod racks (Fig. 4.9).

Correctly placing the upper and lower spring coils in the grooves of the upper and lower bearing cups, pre-tighten the self-locking nut on the rod rack.
Remove tool J38402, A20.
Tighten the self-locking nut to 69-70 Nm.
Mortgage bearing grease rack and place the cap of the top support strut.

WARNINGS
Replace self-locking nuts with new after each removal.
The grease used - NGLI No.0 to chassis or similar.
When laying lubrication Make sure that it does not hit on the rubber pillow top support.

Wishbone

Arm front suspension
Fig. 4.10. Arm front suspension: 1 - anti-roll bar; 2 - Disc; 3 - Tie Rod; 4 - control arm; 5 - sub-frame; 6 - anti-roll bar


Arm front suspension is shown in Fig. 4.10.
Withdrawal
Remove the front wheel.

Pulling out ball joint tie rod from the steering knuckle
Fig. 4.11. Pulling out ball joint tie rod from the steering knuckle


Extract the finger of the spherical rod end from the steering knuckle with special tool 09568-34000 (Fig. 4.11).

Pulling out of the ball joint of the thumb knuckle
Fig. 4.12. Pulling out of the ball joint of the thumb knuckle


Press out using puller 09568-34000 spherical support of the lower arm (Fig. 4.12).
Remove the bolts from the strut to knuckle.

Hobs suspension arm
Fig. 4.13. Hobs suspension arm: 1 - Hob A; 2 - Hob G; 3 - sub-frame; 4 - wishbone


Remove the bolts silent blocks A and G (Fig. 4.13) suspension arm.
Remove the control arm.
Setting
Installing the control arm is held in reverse order of removal.
Tighten the screw connections the date specified below.
Tightening torque Nm:
Wheel nuts ..... 90-100
Nut finger ball joint suspension ..... 60-72
Bolt Hob A (see. Fig. 4.13) ..... 95-120
Bolt Hob G (see. Fig. 4.13) ..... 130-150
Nuts of fastening Ball joint anti-roll bar ..... 35-45

Replacement of ball bearings and a protective cover strut front suspension
Removal of ball bearings and a protective cover

Protective cover ball joint suspension
Fig. 4.14. Protective cover ball joint suspension: 1 - a lock ring; 2 - Case; 3 - Screwdriver


Remove the protective cover of the lower arm ball joint with a flat-blade screwdriver (Fig. 4.14).

Install the retaining ring of the ball joint
Fig. 4.15. Install locking ring of ball bearing: 1 - a device or 09545-1S000A 09545-1C000B; 2 - a lock ring; 3 - ball bearing


Install a tool 09545-1S000A / The retaining ring (Fig. 4.15).
Using the tool 09545-1S000A / V set a new protective cover.
Remove the retaining ring.

Remove the ball joint of control arm
Fig. 4.16. Remove the ball joint of control arm


Plastic mallet finger knock the ball joint of the control arm (Figure 4.16).

Pressing the ball joint in the wishbone
Fig. 4.17. Pressing the ball joint in the wishbone


Using the tool 09545-11000A / The press-fit into the new control arm ball joint (Fig. 4.17).
Put grease Variant R-2 in the case and on the hinge pin.
Technical condition
Check the following:
- Silent blocks for wear and damage;
- Suspension arm for deformation or breakage;
- Case of ball bearings for cracks and damage;
- All bolts for damage and deformation;

Checking the technical condition of the ball joint with a torque wrench
Fig. 4.18. Checking the technical condition of the ball joint with a torque wrench


- Moment of resistance-rotation pin of the ball joint (Fig. 4.18).
In the presence of cracks in the cover, replace the ball bearing support assembly.
Several times shake a finger of the spherical hinge.
Check the resistance moment-rotation pin of the ball joint.
The reference value 3.5-10 Nm.
If the turning point the finger of a spherical support exceeds the upper limit, replace the ball joint. If the rotation pivot point below the lower limit, allowed it to be used in the absence of jamming and excessive backlash.

Removal Kit
Remove the front wheel.
Knock out the cotter pin and loosen the nut of the front wheel hub.
Remove the caliper assembly with the guide pads and brake shoes from the knuckle and hang it on a hook or wire technology to the car body.
Remove the knuckle the wheel speed sensor.

Pulling out ball joint tie rod from the steering knuckle with special tool 09568-34000
Fig. 4.19. Pulling out ball joint tie rod from the steering knuckle with special tool 09568-34000


Puller 09568-34000 Extract the finger of the spherical rod end from the knuckle (Fig. 4.19).

NOTE
To puller 09568-34000 fell, tie it to a close situated parts.

Replacement Bearing Kit front suspension

Stub strut front suspension
Fig. 4.20. Stub strut front suspension: 1 - the brake caliper assembly with blocks; 2 - a protective casing; 3 - Disc; 4 - a nut of fastening of a nave; 5 - a nave; 6 - knuckle; 7 - control arm; 8 - bearing; 9 - lock ring


Stub strut front suspension is shown in Fig. 4.20.
Puller 09568-34000 press out of the pivot arm finger ball joint suspension.
Install a washer under the nut inside the concave side of the hub, as shown in Fig. 4.20.

Rounded fist
Disconnect the drive shaft from the hub.
Remove the rack from the suspension knuckle.
Remove the knuckle assembly to the hub.
Setting
Installation is the reverse order of removal.
Tighten the screw connections of the specified below, Nm:
Nut Kit ..... 200-260
Nut toe control arm ball joint to knuckle ..... 60-72
Nuts and bolts fastening the strut to knuckle ..... 110-130
Dismantling
Remove the brake disc from the hub by removing the two screws that secure.

Removing retaining ring
Fig. 4.21. Removing retaining ring


Remove the retaining ring (Fig. 4.21).

Installation of devices 09517-21500 and 09517-29000 for Extrusion Bearing Kit
Fig. 4.22. Installation of devices 09517-21500 and 09517-29000 for Extrusion Bearing Kit


Install devices 09517-21500 and 09517-29000, as shown in Fig. 4.22.
Extract the hub from the knuckle by turning the nut devices 09517-29000.
Remove tool 09517-21500 and 09517-29000, as well as gryazeotrazhatelnoe ring.
Technical condition
Check hub for cracks and slots for wear.
Check the brake disc for scoring or other damage.
Check the knuckle for cracks.
Check the bearing for cracks and damage.
Apply a thin layer of universal grease on the contact surfaces knuckle and the outer ring of the bearing.
Using the tool 09532-31200A press-fit bearing in the rotation-tion fist.
Assembly
Extract the hub of the bearing inner ring with special tool 09495-33000.
Using the tool 09517-02000 and 09977-21811 press out of the rotary Ku polish the outer ring of the bearing hub.

NOTES
To prevent damage to the bearing, the force pressing apply to its outer ring.
Bearing replace new at each removal.

Set gryazeotrazhatelnoe ring.

09495-33100 device for pressing the hub knuckle
Fig. 4.23. 09495-33100 device for pressing the hub knuckle


Using the tool 09495-33100 zapressuyte hub to the steering knuckle (Fig. 4.23).

NOTE
Pressing spend with a focus on the inner ring of the bearing to avoid damaging the bearing.

Install the brake disc.
Tighten the hub nut torque 200-260 Nm using tool 09517-21500.

Checking the axial clearance in the bearing hub
Fig. 4.24. Checking the axial clearance in the bearing hub


If, after tightening the nut the hub axial clearance in the bearing (Fig. 4.24) is higher than the legal limit, then improperly installed wheel bearing and pivot arm. In this case, disassemble the unit and assemble it again.
Maximum permissible axial play of the hub bearing should not exceed 0.008 mm.
Remove tool 09517-21500.
Several times turn the hub for self-aligning bearing.

Checking moment resistance turning of the bearing hub
Fig. 4.25. Checking moment resistance turning of the bearing hub


Check the torque-rotation resistance of the bearing hub (Fig. 4.25).
Maximum allowable moment of resistance to turning of the bearing hub should not exceed 0.99 Nm.
If the moment-rotation resistance is zero, check the axial clearance in the bearing.

Anti-roll bar

Anti-roll bar
Fig. 4.26. Anti-roll bar: 1 - an arm of the stabilizer bar; 2 - Hob stabilizer bar; 3 - the stabilizer bar; 4 - strut front suspension; 5 - anti-roll bar; 6 - the stopper; 7 - subframe


Anti-roll bar is shown in Fig. 4.26.
Withdrawal
Remove the front wheel.

The front anti-roll bar
Fig. 4.27. The front anti-roll bar


Remove the stabilizer (Fig. 4.27).

Anti-roll bar
Fig. 4.28. Anti-roll bar


Remove the bolts from the stabilizer bar bracket (Fig. 4.28).
Remove the stabilizer bar.
Technical condition
Check the stabilizer bar to material deterioration and damage.
Check all bolts for damage and deformation.
Check the dust cover ball joint stabilizer for cracks or damage.

Checking the rotation Ball joint stabilizer
Fig. 4.29. Checking the rotation Ball joint stabilizer


Check the time of rotation Ball joint stabilizer (Fig. 4.29).
In the presence of cracks in the cover, replace the ball joint cover new, giving it a lubricant.
Several times shake a finger of the spherical hinge.
Screw the self-locking nut on the ball joint and measure the time of rotation of the hinge pin. It should be equal to 0.7-2 Nm.
If the moment of turning the pivot pin exceeds the upper limit of the stabilizer-menite. If the moment of turning the ball joint is less than the lower limit, allowed it to be used in the absence of jamming and excessive backlash.
Setting
Replace the stabilizer bar Hob located on the outside on the bar stopper.
Install the bracket on the Hob.
Pre-tighten the bracket bolts and install the bracket on the other side of the car.
Install the stabilizer link.

Stretcher

Stretcher
Fig. 4.30. Stretcher: 1 - anti-roll bar; 2 - an arm of the rear engine mount support equalizer; 3 - sub-frame; 4 - wishbone


The subframe is shown in Fig. 4.30.
Withdrawal
Unscrew control arm silent blocks.

Front exhaust pipe
Fig. 4.31. Front exhaust pipe


Remove the front exhaust pipe (Fig. 4.31).

Bracket engine mounting support equalizer
Fig. 4.32. Bracket engine mounting support equalizer


Remove the bracket back equalizer support the engine mount (Fig. 4.32).
To facilitate the removal of the sub-frame mounting bolts loosen the steering mechanism and nuts Ball joint stabilizer racks, hang me-steering mechanisms and tie rods to the engine.

Set the jack under the sub-frame
Fig. 4.33. Set the jack under the sub-frame


Place the jack under the sub-frame (Fig. 4.33) and remove the sub-frame by unscrewing the screws securing it to the body.
Technical condition
Check the sub-frame for cracks or deformation.
Check bearings and suspension silent blocks for cracks or deterioration of the material.
Setting
Install the frame, maintaining its jack.
Install the steering rack and anti-roll bar.
Tighten bolts and nuts silent blocks suspension arms.
Install the rear bracket equalizer support the engine mount.
Install the front exhaust pipe.




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