How to install a car

General automobile assembly process is as follows:

1 ; Installing front axle

Push the front axle assembly with tire and steel plate under the frame smoothly and horizontally, align the front hole of the steel plate with the bracket hole on the frame, install the steel plate pin, and then install the rear end of the steel plate and lifting lug so that the rear end of the steel plate can be installed in the bracket, or install the steel plate on the frame first, and then install the front axle and wheels. Install the shock absorber on the frame in advance and connect it with the front axle.

① Fit clearance During installation, attention should be paid to the fit of steel plate pin, lug pin and bushing, the fit clearance of front steel plate pin and bushing, and the clearance between steel plate spring pin and lug end. If it is not suitable, add steel gasket to adjust. After installing the pin, the locking bolt and lubricating oil nozzle should be installed.

(2) Tightening torque When installing, pay attention to the tightening torque of the nut on the U-bolt.

③ When installing the shock absorber, the rubber bushing in the pull rod hole should be complete.

2 ; Installing rear axle

Push the rear axle assembly with tires and steel plates under the frame, and connect the rear axle with the frame with steel plate pins and ear pins. You can also install the steel plate on the frame first, and then install the rear axle and wheels. The precautions are the same as those of the front axle. Tightening torque of U-bolt and nut: Dongfeng EQ 1092 is 294 ~ 343N·m；; The liberated CA 109 1 car is 400 ~ 450N·m；; The tightening torque of the front nut and rear axle riding bolt of Beijing BJ2020 automobile is150 ~ 200 N m. ..

3 ; Installing brake controller

For the pneumatic braking device, the gas storage tank and control valve should be installed first, and then the gas pipes of various departments should be connected. All pipes and pipe joints should be installed firmly to avoid breakage or wear when the car bumps. When installing the hydraulic brake device, first install the brake master cylinder, and then install the oil pipe to connect the front and rear wheel cylinders.

4 ; Install clutch and brake pedal.

Install the pedal bracket on the frame, and install the clutch and brake pedal on the shaft. Clearance between the shaft in the bracket hole and the brake pedal and the shaft: Dongfeng EQ 1092 car is 0. 1~0.2mm, and the service limit is 0.3mm；; Liberation CA 109 1 car is 0.08 ~ 0.25mm；; The car should be less than the above value. Install the clutch release fork pull rod, master cylinder push rod or control valve pull rod, and install the return springs of all parts.

5 ; Installing engine and transmission

When installing, first assemble the transmission with the engine, and then install it on the frame. Rubber washers should be installed at the engine bracket, and the connecting rod between the engine and the frame should also be assembled. Can also be installed separately, depending on the actual situation. ;

6 ; Installing transmission shaft

After installing the intermediate bracket, connect the flange joint of the universal joint with the flanges of the transmission and final drive with bolts. The universal joint forks at both ends of the installed transmission shaft should be in the same plane; When two sections of transmission shaft are installed separately, the short section at the front should be installed first, and then the long section at the back should be installed. The universal joint forks at both ends of the short transmission shaft are perpendicular to each other, and the universal joint forks at both ends of the long transmission shaft should be in the same plane. All nozzles should be lubricated on the same plane; Don't tighten the bearing cover combination bolts on both sides of the middle bracket too tightly, and then tighten them according to the specified torque after the car travels for a certain distance to prevent the bearing from being damaged early due to incorrect position. ;

7 ; Installing silencer

Put the asbestos pad between the muffler and the exhaust manifold, install the combination bolt and tighten it according to the specified torque. Spring washers must be installed on the fixing bolts of muffler and exhaust pipe clamp.

8 ; Installing cab

When lifting the cab, be careful not to damage all external parts. Rubber pads should be installed in a fixed position with the frame. A flat washer should be installed under the nut of the fixing bolt. After tightening, the cotter pin should be inserted and locked. After installing the cab, you can install the accelerator pedal, the connecting part between the pull rod and the steel wire connecting the carburetor throttle and choke valve, and the brake pedal, clutch pedal and connecting part.

9 ; Installing steering gear

The spring washer should be installed on the fixing bolt of the steering gear housing on the frame. Do not tighten the fixing bolts after installation. First connect the steering transmission shaft with the upper part of the steering column in front of the cab, and then install and tighten the fixing bolts, so that the steering rocker shaft is in the middle meshing position with the steering rod or steering nut. Then install the rocker arm and connect it with the straight rod according to the mark, and then fix the steering screw on the steering gear with the universal transmission device at the lower end of the steering shaft. After the steering wheel is installed in the cab, the steering screw should be in the meshing position between the kingpin or the toothed sector, and the two front wheels of the car should be in the straight-line driving position. Finally, tighten the bolts and nuts on all connecting parts according to the specified torque and lock them.

10 ; Installing gasoline tank

When installing the oil tank to its original position, a spring washer should be installed. If the fuel tank is in the transverse direction of the frame, it should be fixed on the bracket of the frame with lining clips and installed firmly.

1 1 ; Install bumper and fender.

If the pedals have not been installed, they can be installed alternately at the same time. If there are rubber strip and cloth strips between mudguards, the joint with pedals should be padded with rubber pads. Finally, the bumper and towing hook should be installed on the frame.

12 ; Install radiator and hood.

Rubber pad or spring should be installed at the joint between radiator and frame, and the nut should not be tightened too tightly to avoid the spring washer being pressed or the rubber pad losing its elasticity. Nuts must be locked with cotter pins. Then tighten the frame stud, connect the rubber water jacket, and install the shutter and shutter pull rod and handle. Louvers should be airtight, and finally install components such as a hood.

13 ; Install the electrical wiring, electrical equipment and instruments of the whole vehicle.

Where the conductor passes, it should be close to the surface of the board wall, and clips should be installed, and the conductor between the two clips should be tightened. The connectors shall be in good contact and reliable fastening, and the electrical switches shall be reliable everywhere. The light bulb should be fastened, and the light should not flash when it vibrates.

14 ; Fill all parts with lubricating oil (liquid)

Fill grease and oil at all places where grease fittings, oil plugs and oil caps are installed. Fill up the brake fluid in the hydraulic brake master cylinder and release the air in the hydraulic brake system. After filling gasoline and water, check the liquid level in the transmission, transfer case and drive axle housing. You can initially start the automobile engine, stop before driving, check and adjust the technical performance of each assembly, and then consider the road test.

15 ; Installing frame (body)

When hoisting the carriage (car body), the carriage and the frame shall be fixed by riding and climbing bolts. Install the lining wood in the groove between the riding bolt and the frame longitudinal beam, and tighten the nut on the bolt according to the specified torque.

The above installation sequence is not fixed, so each unit can master it flexibly according to its own situation. For example, the installation of the carriage is often carried out before the installation of the electrical circuit; Brake fluid is usually filled before installing the brake pedal.

16 ; Review and adjustment

After final assembly, the free stroke of clutch pedal, toe-in of front wheel, steering wheel clearance, ignition timing, valve foot clearance, carburetor, free stroke of brake pedal, shoe clearance and tire pressure should also be reviewed and adjusted. If it does not meet the requirements of the original car, it should be readjusted to avoid accidents during driving and cause undue losses.

1 ; Installing front axle

Push the front axle assembly with tire and steel plate under the frame smoothly and horizontally, align the front hole of the steel plate with the bracket hole on the frame, install the steel plate pin, and then install the rear end of the steel plate and lifting lug so that the rear end of the steel plate can be installed in the bracket, or install the steel plate on the frame first, and then install the front axle and wheels. Install the shock absorber on the frame in advance and connect it with the front axle.

① Fit clearance During installation, attention should be paid to the fit of steel plate pin, lug pin and bushing, the fit clearance of front steel plate pin and bushing, and the clearance between steel plate spring pin and lug end. If it is not suitable, add steel gasket to adjust. After installing the pin, the locking bolt and lubricating oil nozzle should be installed.

(2) Tightening torque When installing, pay attention to the tightening torque of the nut on the U-bolt.

③ When installing the shock absorber, the rubber bushing in the pull rod hole should be complete.

2 ; Installing rear axle

Push the rear axle assembly with tires and steel plates under the frame, and connect the rear axle with the frame with steel plate pins and ear pins. You can also install the steel plate on the frame first, and then install the rear axle and wheels. The precautions are the same as those of the front axle. Tightening torque of U-bolt and nut: Dongfeng EQ 1092 is 294 ~ 343N·m；; The liberated CA 109 1 car is 400 ~ 450N·m；; The tightening torque of the front nut and rear axle riding bolt of Beijing BJ2020 automobile is150 ~ 200 N m. ..

3 ; Installing brake controller

For pneumatic braking devices, gas storage tanks and control valves should be installed first, and then the gas pipes of various departments should be connected. All pipes and pipe joints should be installed firmly to avoid breakage or wear when the car bumps. When installing the hydraulic brake device, first install the brake master cylinder, and then install the oil pipe to connect the front and rear wheel cylinders.

4 ; Install clutch and brake pedal.

Install the pedal bracket on the frame, and install the clutch and brake pedal on the shaft. Clearance between the shaft in the bracket hole and the brake pedal and the shaft: Dongfeng EQ 1092 car is 0. 1~0.2mm, and the service limit is 0.3mm；; Liberation CA 109 1 car is 0.08 ~ 0.25mm；; The car should be less than the above value. Install the clutch release fork pull rod, master cylinder push rod or control valve pull rod, and install the return springs of all parts.

5 ; Installing engine and transmission

When installing, first assemble the transmission with the engine, and then install it on the frame. Rubber washers should be installed at the engine bracket, and the connecting rod between the engine and the frame should also be assembled. Can also be installed separately, depending on the actual situation. ;

6 ; Installing transmission shaft

After installing the intermediate bracket, connect the flange joint of the universal joint with the flanges of the transmission and final drive with bolts. The universal joint forks at both ends of the installed transmission shaft should be in the same plane; When two sections of transmission shaft are installed separately, the short section at the front should be installed first, and then the long section at the back should be installed. The universal joint forks at both ends of the short transmission shaft are perpendicular to each other, and the universal joint forks at both ends of the long transmission shaft should be in the same plane. All nozzles should be lubricated on the same plane; Don't tighten the bearing cover combination bolts on both sides of the middle bracket too tightly, and then tighten them according to the specified torque after the car travels for a certain distance to prevent the bearing from being damaged early due to incorrect position. ;

7 ; Installing silencer

Put the asbestos pad between the muffler and the exhaust manifold, install the combination bolt and tighten it according to the specified torque. Spring washers must be installed on the fixing bolts of muffler and exhaust pipe clamp.

8 ; Installing cab

When lifting the cab, be careful not to damage all external parts. Rubber pads should be installed in a fixed position with the frame. A flat washer should be installed under the nut of the fixing bolt. After tightening, the cotter pin should be inserted and locked. After installing the cab, you can install the accelerator pedal, the connecting part between the pull rod and the steel wire connecting the carburetor throttle and choke valve, and the brake pedal, clutch pedal and connecting part.

9 ; Installing steering gear

The spring washer should be installed on the fixing bolt of the steering gear housing on the frame. Do not tighten the fixing bolts after installation. First, connect the steering transmission shaft with the upper part of the steering column in front of the cab, then install and tighten the fixing bolts, so that the steering rocker shaft is in the middle meshing position with the steering rod or steering nut. Then install the rocker arm and connect it with the straight rod according to the mark, and then fix the steering screw on the steering gear with the universal transmission device at the lower end of the steering shaft. After the steering wheel is installed in the cab, the steering screw should be in the meshing position between the kingpin or the toothed sector, and the two front wheels of the car should be in the straight-line driving position. Finally, tighten the bolts and nuts on all connecting parts according to the specified torque and lock them.

10 ; Installing gasoline tank

When installing the oil tank to its original position, a spring washer should be installed. If the fuel tank is in the transverse direction of the frame, it should be fixed on the bracket of the frame with lining clips and installed firmly.

1 1 ; Install bumper and fender.

If the pedals have not been installed, they can be installed alternately at the same time. If there are rubber strip and cloth strips between mudguards, the joint with pedals should be padded with rubber pads. Finally, the bumper and towing hook should be installed on the frame.

12 ; Install radiator and hood.

Rubber pad or spring should be installed at the joint between radiator and frame, and the nut should not be tightened too tightly to avoid the spring washer being pressed or the rubber pad losing its elasticity. Nuts must be locked with cotter pins. Then tighten the frame stud, connect the rubber water jacket, and install the shutter and shutter pull rod and handle. Louvers should be airtight, and finally install components such as a hood.

13 ; Install the electrical wiring, electrical equipment and instruments of the whole vehicle.

Where the conductor passes, it should be close to the surface of the board wall, and clips should be installed, and the conductor between the two clips should be tightened. The connectors shall be in good contact and reliable fastening, and the electrical switches shall be reliable everywhere. The light bulb should be fastened, and the light should not flash when it vibrates.

14 ; Fill all parts with lubricating oil (liquid)

Fill grease and oil at all places where grease fittings, oil plugs and oil caps are installed. Fill up the brake fluid in the hydraulic brake master cylinder and release the air in the hydraulic brake system. After filling gasoline and water, check the liquid level in the transmission, transfer case and drive axle housing. You can initially start the automobile engine, stop before driving, check and adjust the technical performance of each assembly, and then consider the road test.

15 ; Installing frame (body)

When hoisting the carriage (car body), the carriage and the frame shall be fixed by riding and climbing bolts. Install the lining wood in the groove between the riding bolt and the frame longitudinal beam, and tighten the nut on the bolt according to the specified torque.

The above installation sequence is not fixed, so each unit can master it flexibly according to its own situation. For example, the installation of the carriage is often carried out before the installation of the electrical circuit; Brake fluid is usually filled before installing the brake pedal.

16 ; Review and adjustment

After final assembly, the free stroke of clutch pedal, toe-in of front wheel, steering wheel clearance, ignition timing, valve foot clearance, carburetor, free stroke of brake pedal, shoe clearance and tire pressure should also be reviewed and adjusted. If it does not meet the requirements of the original car, it should be readjusted to avoid accidents during driving and cause undue losses.