Removing
1. Support the front wheels with wheel chocks, jack up the rear of the vehicle and support it on jack stands. Remove rear wheels.
2. On Wagon models, equipped with a rear ride height adjustment system, remove the cover of the right rear combination lamp in the luggage compartment and bleed the pressure from the system through the valve. Disconnect the air tube from the shock absorber.
3. In the car, fully release the parking brake lever and remove the protective cover from it. Loosen the adjusting nut and remove it from the primary section of the parking brake cable.
4. On models with rear disc brakes use a screwdriver to press the parking brake actuating levers on the calipers and disconnect the drive cables from them. Release the clips and release the cable sheaths from the support brackets on the calipers. Release the cables from the intermediate clips on the lever connector.
5. On models with rear drum brakes Disconnect the short rear cables from the ends in front of the brake drums.
6. On models equipped with ABS, release the wheel sensor wiring from the retainers on the back of the hubs and torsion beam.
7. On models equipped with a pressure regulator valve in the rear brake circuit, disconnect the tension spring.
8. In order to minimize hydraulic fluid loss, remove the cap from the GTZ reservoir, put polyethylene under it, screw it into place and tighten it tightly.
9. Release union nuts and disconnect brake pipes from hoses on both parties of the car. Remove fixing plates. Seal the open ends of the in-line connectors immediately to prevent dirt from entering the system.
10. Support the beam with two trolley jacks, in order to distribute the load, laying the heads of the latter with wooden blocks.
You can get by with one jack, but then you have to resort to the help of an assistant.
11. Turn out the bottom fixing bolts and disconnect both shock-absorbers from trailing arms of a suspension bracket.
12. Carefully lower the torsion beam as far down as possible and remove the rubber seated suspension coil springs. Please note that the top saddles are equipped with built-in bumpers.
13. Check the reliability of fixing the beam with jacks, then unscrew the bolts of the brackets for fastening the front rubber-metal hinges of the trailing arms of the beam to the bottom of the car.
14. Lower a beam and take it from under the car.
15. If necessary, parts of the brake mechanisms can be removed from the beam (see chapter Brake system). Refer to the procedure for removing hub assemblies. Removal and installation of the rear hub assembly.
16. If necessary, remove rubber-metal hinges from the beam (see Replacing the rubber-metal hinges of the trailing arms of the torsion beam).
Installation
1. Install the removed components on the beam (see the relevant Sections of this Chapter and Chapter Brake system).
2. Check the condition of the threads of the permanently fixed nuts in the hinge brackets, if necessary, drive the thread with a tap of the appropriate size.
3. Install the beam on the cart jack (s) and get it under the car.
4. Raise the beam to its original position and screw in the mounting bolts of the rubber-metal hinges - do not tighten the bolts yet completely.
5. Set the beam on the jack so that the distance between the supporting surfaces of the springs on the levers and body elements is 168±10.0 mm (sedan and hatchback models) / 198±10.0 mm (other models), then the bolts of the hinge mounting brackets and tighten them again, this time with the required force, then tighten them to the specified Specifications corners.
6. Place the rubber seats on the springs and install the springs on the beam.
7. Raise the beam so that it is possible to install the shock absorber mounting bolts.
8. Connect the brake pipes to the hoses, tighten the union nuts to the required torque, then install the fixing plates.
9. On models equipped with a pressure regulating valve in the rear brake circuits, install the retainer and spring and tighten the fixing bolt to the required torque (see Specifications to the head Brake system).
10. On models with ABS fix the electrical wiring in the intermediate clamps on the beam and connect it to the wheel sensors.
11. On models with rear wheel drum brakes restore the original connection of the short sections of the drive cables.
12. On models with disc rear brakes connect the parking brake cables to the actuating ones on the calipers - do not forget to fix the cables in the support brackets.
13. Bleed the brake system (see chapter Brake system).
14. Adjust the parking brake actuator (see chapter Brake system), then attach the protective cover to the lever.
15. On Wagon models, equipped with a rear ride height adjustment system, pressurize the system to 0.8 bar, then adjust it according to the vehicle's load, and install the rear combination lamp cover.
16. Install the wheels and lower the vehicle to the ground.
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