Brake system — general information Brake system components: 1. Front disc brakes. 2. Rear drum brakes. 3. Vacuum brake booster with brake master cylinder. 4. Hydroelectronic fjr-jr ABS control. 5. Brake force compensator. Brake drive: 5. Master brake...
Front disc brake mechanism Note: : replace the part with a new one after each removal. : a special tool/fixture must be used. : apply a special composition. Front brake mechanism: 1. Front steering knuckle assembly. 2. Wheel speed sensor. 3....
Rear drum brake mechanism Rear brake: 1. Brake drum. 2. Retainer. 3. Clamping spring pads. 4. Secondary brake pad. 5. Spacer spring 6. Lower return spring. 7. Automatic gap adjuster. 8. Brake shoe return spring. 9. Top return spring 10. Primary...
Parking brake Note: : Replace the part with a new one after each removal. 1. Parking brake lever. 2. Parking brake lever mounting plate. 3. The balancer of the secondary drive brakes of the parking brake. 4. Balance clamp. 5. Parking...
Electronic braking systems (ABS/ESP) 1. Hydroelectronic control unit. 2. Steering angle sensor. 3. Protect the gel in the dashboard relay and fuse box 4. ABS indicator on the instrument cluster 5. Diagnostic connector. 6. Brake disc. 7. Wheel speed sensor....
Brake system specification Front brakes Note: *: brake discs cannot be reground. If there is excessive wear, the brake discs must be replaced with new ones. Rear brakes Models B52 and L52 Piston diameter 17.5mm Brake drum inner diameter 203.3 mm...
Repair Precautions When performing any work related to lifting the vehicle on a lift, observe the relevant safety regulations. The drive of the brake system must be fully operational both in terms of hydraulic and electronic parts. If...
Bleeding the brake system Attention: To avoid residual air in the brake system, the parking brake must be released before starting the bleeding procedure. The procedure for bleeding the brake system must be performed after removing or replacing...
Removing and installing the brake pedal Removing the brake pedal 1. Remove the lower buffer element of the dashboard (if equipped). 2. Disconnect the connector from the brake pedal switch. 3. Remove the brake pedal switch by turning it a quarter of a turn...
Removal and installation of the main brake cylinder Attention: Be sure to replace the brake master cylinder with a new one if it has been hit or dropped (risk of failure). Prepare suitable containers to collect fluid and take measures to protect surrounding components...
Removal and installation of the vacuum amplifier of brakes Attention: To avoid loss of brake efficiency, do not kink the vacuum line of the brake booster. Prepare suitable containers to collect fluid and take measures to protect surrounding components from contact with brake...
Checking the brake force compensator Note: Checking principle: The brake pressure is read from the diagonal circuit, after which the values for the front and rear wheels are compared. It is necessary to check both diagonal contours (front right-rear left...
Adjusting the brake force compensator 1. Place the vehicle on a level surface (wheels must be on the ground). 2. Loosen the adjusting screw (1). 3. Move bushing (2) before contact with the brake force compensator lever (3). 4. Tighten the adjusting screw....
Removal and installation of forward brake hoses Removing the front brake hoses 1. Place the vehicle on a two post lift. 2. Set the front wheels of the vehicle to the straight ahead position. 3. Install a spacer on the brake pedal to limit the flow of brake fluid. 4....
Removal and installation of brake pipelines from the rear axle beam Warning: Prepare suitable containers to collect fluid and take measures to protect surrounding components from contact with brake fluid. Removal of brake pipelines 1. Place the vehicle on a two post lift. 2. Install a...
Repair of brake pipelines Note: The procedure below applies to 4.7mm copper piping. The procedure does not apply to hybrid highways (pipeline + hose) and pipelines with a diameter of 6 mm and 8 mm. The tightening torques given in this procedure...
Replacing the front brake pads Attention: To avoid damage to the brake hose: do not stretch the hose; do not twist the hose; make sure that the hose does not come into contact with surrounding components. Removing the front brake pads 1. Place the...
Removal and installation of the front brake caliper Attention: To avoid damage to the brake hose: do not stretch the hose; do not twist the hose; make sure that the hose does not come into contact with surrounding components. Prepare suitable containers to collect fluid...
Disassembly and assembly of the brake caliper Warning: Prepare suitable containers to collect fluid and take measures to protect surrounding components from contact with brake fluid. Dismantling the brake caliper 1. Place the vehicle on a two post lift. 2. Place a...
Removing and installing brake caliper bracket Attention: To avoid damage to the brake hose: do not stretch the hose; do not twist the hose; make sure that the hose does not come into contact with surrounding components. Prepare suitable containers to collect fluid...
Removal and installation of a brake disk Note: Brake discs cannot be reground. If there is excessive wear, the brake discs must be replaced with new ones. Removing the brake disc 1. Place the vehicle on a two post lift. 2. Set the front wheels of the vehicle...
Checking the brake disc 1. Place the vehicle on a two post lift. 2. Remove the corresponding front wheel from the vehicle. Note: It is best to use a micrometer to check the brake disc thickness. 3. Micrometer (1) measure the thickness of the...
Replacing the rear brake pads Note: Replace the brake pads at the same time with one set for the wheels of the same axle. Do not mix brake pads from different manufacturers or different qualities. Removing the rear brake pads 1. Place the vehicle on...
Removal and installation of the back working brake cylinder Warning: Prepare suitable containers to collect fluid and take measures to protect surrounding components from contact with brake fluid. Removing the rear working brake cylinder 1. Place the vehicle on a two post lift....
Checking the brake drum 1. Place the vehicle on a two post lift. 2. Remove the corresponding rear wheel from the vehicle. 3. Remove the brake drum. Note: A suitable vernier caliper must be used to check the inside diameter of the brake drum....
Brake System — Parking Brake Removal and installation of parking brake cables Removing the parking brake cables 1. Place the vehicle on a two post lift. 2. Remove the center console. 3. Remove the rear wheels from the vehicle. 4. Remove the rear...
Removal and installation of the hydroelectronic control unit Warning: Prepare suitable containers to collect fluid and take measures to protect surrounding components from contact with brake fluid. Removing the hydroelectronic control unit 1. Place the vehicle on a two post lift....
Removal and installation of the front wheel sensor Removing the front wheel sensor 1. Place the vehicle on a two post lift. 2. Remove the front wheel from the vehicle. 3. Remove the front fender liner. 4. Disconnect connector (1) front wheel rotation sensor. 5. Remove...
Removal and installation of the rear wheel sensor Removing the rear wheel sensor 1. Place the vehicle on a two post lift. 2. Remove the rear wheel from the vehicle. 3. Remove the rear fender liner. 4. Disconnect connector (1) rear wheel speed sensor. 5. Remove...
Special tools and fixtures Name of tool and fixtures Catalog number Front brake caliper piston pusher Fre. 1842 or Fre. 1190-01 Hydraulic brake test kit Fre. 1085