The performance of the brakes is also affected by the condition of the tyres, the vehicle load and the alignment of the front wheels.
Checking the operation of the vacuum booster
Release the existing vacuum with the engine off by depressing the brake pedal several times at 5 second intervals. Fully depressing the brake pedal, start the engine. Make sure the clearance between the brake pedal and the floor panel decreases as the vacuum in the engine stabilizes.
Leak test
Start the engine and let it idle for about 1 minute. Shut it off by applying vacuum to the booster. Press the brake pedal several times with normal force and release the existing vacuum. Make sure that the gap between the brake pedal and the floor panel gradually increases as the brake pedal is depressed. Start the engine. Press and hold the brake pedal, then stop the engine. Keep the pedal depressed for about 30 seconds or more and check that the pedal travel does not change.
Removing
Remove decorative covers.
Disconnect the wires from the battery terminals, starting with the negative terminal.
Remove the battery.
Pic. 6.16. Removing the air resonator
Remove air resonator (only for K4J engine) (pic. 6.16).
Remove the battery tray.
Remove the injection computer.
Pic. 6.17. Removing the air filter components: 1 - air intake pipe; 2 - air pipe; 3 - air filter housing
Remove the air intake pipe, air pipe and air filter housing (pic. 6.17).
Pic. 6.18. Removing intake silencers: 1 - mufflers
Remove the left front wheel, fender liner and both intake silencers (pic. 6.18).
Disconnect select and shift cables from transmission.
Pic. 6.19. Select and shift cables
Disconnect both cables from the levers on the gearbox (pic. 6.19).
Pic. 6.20. How to remove the gear selector cable end
Squeeze the tip of the cable at points A, pull the lock in direction B and lift the cable at point C (pic. 6.20).
Pic. 6.21. Installing plugs in the tips of the gear selection cables
Insert plugs into gear selector cable ends (pic. 6.21).
Remove the brake pedal switch.
Use a syringe to remove the brake fluid from the reservoir so that its level is below the fluid supply hole in the clutch master cylinder.
Disconnect the brake fluid level sensor connector.
Remove the vacuum brake booster valve.
Partially remove the noise insulation of the bulkhead shield.
Disconnect the clutch master cylinder pipe.
Remove the upper ball joint of the transmission control mechanism.
Pic. 6.22. Removing the axle of the brake pedal fork
Remove from the passenger compartment the axle of the brake pedal fork A from the pusher of the vacuum brake booster (pic. 6.22).
Remove the two nuts securing the master cylinder to the vacuum brake booster.
Tilt the brake master cylinder forward to separate it from the booster without applying force to the brake lines.
Pic. 6.23. Removing the vacuum booster: B - fixing bolts of the vacuum brake booster
Remove the two brake booster mounting bolts B (pic. 6.23).
Installation
Installation is made in an order, the return to removal.
Pic. 6.24. Measuring the length of the vacuum booster fork rod
Before installation, measure the length of the stem of the fork (pic. 6.24):
- for left-hand drive vehicles: X1 = 163.7 mm;
- for vehicles with right-hand drive: X1 = 133.2 mm.
If the length is not as specified, replace the amplifier.
Attention! Check the presence and blocking of the connecting shaft between the push rod of the vacuum brake booster and the brake pedal.
Establish the vacuum amplifier of brakes, without fixing on it a pusher.
Tighten the two brake booster mounting bolts to 21 Nm.
Install the master brake cylinder to the vacuum brake booster.
Tighten the two nuts securing the brake master cylinder to 50 Nm.
Check the position and reliability of fixation of holder C on the front panel and brake pipes in this holder.
Pic. 6.25. Checking the reliability of the holders
Make sure that the spacer holder D is in place.
From the cabin side, install the pusher into the vacuum brake booster and onto the brake pedal.
Step on the brake pedal to connect the pushrod and booster.
Reinstall the brake pedal fork axle.
Be convinced of reliability of fixing of an axis of a plug of a pedal of a brake on a pusher.
Reinstall the brake pedal switch.
Check the operation of the brake pedal switch (brake lights should go out when the brake pedal is released).
Add brake fluid.
Replace the brake master cylinder reservoir cap.
Install the remaining removed parts in the reverse order of removal.
Attach the wires to the battery terminals, starting with the positive terminal.
Carry out a road test.