Checking and adjusting the brake pedal 1. Check that the pedal height is adjusted according to the figure. Pedal height from floor: Models up to '96: 159-169 mm Models since 96: 149-159 mm 1 - brake light switch, 2 - control rod, 3 - pedal height 2. Adjust...
Checking the performance of the vacuum booster 1. Functional check A) Depress the brake pedal several times with the engine off and check that the pedal reserve does not change. b) Press the brake pedal and start the engine. If the brake pedal smoothly goes down,...
Bleeding the brake system Note: after any work related to the ingress of air into the brake system, bleed it. Caution: Do not allow brake fluid to come into contact with painted surfaces. If brake fluid comes into contact with a painted surface,...
Checking and adjusting the parking brake 1. Check the travel of the parking brake lever. Pull the parking brake lever all the way and count the number of clicks. Parking brake lever travel at 196 N tension: 4-7 clicks. 2. If necessary, adjust the travel of the...
Removing the brake master cylinder (Models up to 96) Removing the brake master cylinder: 1 - tee, 2 - connector, 3 - brake master cylinder, 4 - gasket, 5 - vacuum brake booster (Models since 96) Removing the brake master cylinder: 1 - fitting,! - brake...
Assembling the brake master cylinder 1. Lubricate the surfaces indicated by the arrows in the illustrations. For vehicles with ABS For vehicles without ABS 2. Install pistons. Caution Be careful not to damage the cuffs. A) Install the pistons strictly...
Installation of the main brake cylinder 1. Adjust the length of the vacuum booster rod before installing the master brake cylinder on it. 2. Establish a new lining and the main brake cylinder on the vacuum amplifier and tighten nuts of fastening. Tightening...
Removing the vacuum brake booster 1. Remove the main brake cylinder. 2. Disconnect the hose from the vacuum brake booster. 3. Remove the brake pedal return spring. 4. Remove cotter pin and fork axle. (Models since 96) Remove the clutch master cylinder....
Installing a vacuum brake booster 1. Install the vacuum brake booster. A) Install the vacuum booster and a new gasket. b) Install and tighten the vacuum booster mounting nuts. Tightening torque 13 Nm. V) Install the fork axle into the fork and brake...
Camshaft Driven Vacuum Pump Vacuum pump: 1 - vacuum hose, 2 - vacuum pump, 3 - gasket, 4 - plug, 5 - lower engine protection Removing the vacuum pump 1. Remove the lower engine protection. 2. Remove the plug from the protective cover of the timing...
Front brakes — design description Front brakes (Caliper with one working cylinder): 1, 10 - anti-squeak gasket, 2 - dust cover, 3 - bushing, 4 - guide pin, 5 - caliper bracket, 6 - gasket, 7, 11 - retaining plate insert, 8 - block, 9 - internal...
Replacing the front brake pads 1. Remove the front wheel and temporarily secure the brake disc with wheel nuts. 2. Through the control hole in the caliper, check the thickness of the brake pads. Minimum thickness 1.0 mm. Replace pads if necessary. 3....
Removing the front caliper 1. Disconnect the brake hose. A) Turn away a nipple bolt, remove two linings and disconnect a brake hose. b) Using a container, drain the brake fluid. 2. Remove the caliper. A) While holding the guide pins, loosen the...
Dismantling the front caliper 1. Using a screwdriver, remove the brake cylinder boot spring ring and boot. 2. Remove the piston. A) Place a rag between piston and cylinder. b) Using compressed air, remove the piston from the cylinder. Caution: Do...
Checking and repairing the front brakes 1. Using a ruler, measure the thickness of the brake pads Caliper with one working cylinder: Standard thickness 12.0mm Minimum thickness 1.0 mm Caliper with two working cylinders: Standard thickness 10.0mm Minimum...
Front caliper assembly 1. Lubricate the surfaces indicated by the arrows in the figures 2. Install dust covers and guide pins. A) Using a suitable drift and a hammer, install two new dust covers. b) Make sure the dust covers fit snugly into...
Installing the front caliper 1. Install two brake pads. 2. Install the caliper. A) Install the caliper onto the bracket. b) While holding the guide pins, tighten the two mounting bolts. Tightening torque 34 Nm. 3. Connect the brake hose. Install...
Rear drum brakes — removal 1. Remove the inspection hole plug and check the thickness of the brake pads through it. If the pad thickness is less than the minimum, replace the brake pads. Minimum thickness 1.0 mm. 2. Remove the rear wheel. 3....
Rear drum brakes — checking details 1. Check the removed parts for wear, rust and damage. 2. Measure the thickness of the brake pads. Standard: 4.0 mm Minimum allowable: 1.0 mm If the thickness of the pads is less than the minimum or they have uneven...
Rear drum brakes — installation Note: install the parts as shown in the picture. 1. Apply grease to the following parts: two cuffs, two pistons two anthers. 2. Assemble the Wheel Brake Cylinder. A) Install two new cuffs. b) Install the spring and two...
Rear disc brakes — replacing pads 1. Remove the rear wheel and temporarily secure the brake disc with wheel nuts. 2. Through the control hole in the caliper, check the thickness of the brake pads. Minimum thickness 1.0 mm. Replace pads if necessary. 3....
Rear disc brakes — caliper removal 1. Disconnect the brake hose. A) Turn away a nipple bolt, remove two linings and disconnect a brake hose. b) Using a container, drain the brake fluid. 2. Remove the caliper. A) Turn away a bolt of fastening. b) Remove...
Rear disc brakes — caliper disassembly 1. Remove the bushing and two dust covers (for 3S-GE engine) or dust cover (for 3S-FE engine). 2. Remove the dust cover from the main guide pin. 3. Using a screw-driver, remove a spring ring of a cover of the brake...
Checking and repairing the rear disc brakes 1. Using a ruler, measure the thickness of the brake pads. Standard Thickness: 10.0mm Minimum Thickness: 10mm Replace the brake pads if the brake pad thickness is less than the minimum, or if uneven pad wear is...
Rear disc brakes — caliper assembly 1. Lubricate the surfaces indicated by the arrows in the illustrations. 2. Install the piston collar and piston into the cylinder. 3. Install the boot and cylinder boot snap ring. 4. Install the main guide pin dust...
Rear disc brakes — caliper installation 1. Install the main guide pin and tighten the mounting bolt. Tightening torque 27 Nm. 2. Install two pads with pad wear indicator on top (3S-GE engine) or from below (3S-FE engine). Caution: Do not allow oil or grease...
Parking brake disassembly 1. Remove the rear wheel. 2. Remove the rear caliper assembly. A) Remove the two mounting bolts and remove the rear caliper assembly. b) Hang the caliper so as not to stretch the hose. 3. Remove the brake disc. Note: If...
Checking the parking brake 1. Check the removed parts for wear, rust or damage. 2. Using a ruler, measure the thickness of the brake pads. Standard Thickness: 2.0mm Minimum Thickness: 1.0mm Replace the brake pads if the brake lining thickness is...
Setting the parking brake Application: install the parts as shown in the figure. Parking brake parts installation diagram 1. Apply high temperature grease to the brake shield as shown. 2. Apply high temperature grease to the regulator as shown....
Brake force distribution valve depending on the load on the rear axle 1 - Valve for redistributing brake forces depending on the load on the rear axle (LSPV) Fluid pressure test 1. Setting the load on the rear axle. A) Make sure the vehicle is unloaded. b) Measure the rear axle load and...
Anti-Lock Braking System (ABS) — Components Models up to 96 Models from '96 Anti-Lock Braking System (ABS): 1 - front wheel speed sensor, 2 - ABS indicator, 3 - rear wheel speed sensor, 4 - sensor rotor, 5 - ABS electronic control unit, 6 - diagnostic connector,...
Description of the ABS diagnostic system The electronic control unit has a fault protection system that can detect any signal or malfunction in the system. When a malfunction is detected, the electronic control unit disables the ABS system and the ABS...
Checking the anti-lock system (ABS) 1. Check that the battery voltage is about 12V. 2. Checking the ABS indicator. A) Turn on the ignition. b) Check that the ABS indicator lights up for 3 seconds. V) If the indicator does not illuminate, check, repair or...
Pressure modulator — removal, installation and inspection Models up to '96 Pressure modulator: 1 - bracket #2, 2 - pressure modulator, 3 - connector, 4 - pressure modulator with bracket, 5 - bracket #5, 6 - adapter, 7 - bracket #1, 8 - holder, 9 - cushion Models since '96...
Control relay (models up to 1996) Checking the control relay 1. Checking the conductivity of the electric pump relay. A) Check for continuity between terminals "9" and ''10". b) Check for continuity between terminals "7" And "8". If the conditions are...
Control relay (models since 1996) Checking the control relay 1. Checking the continuity of the electric pump relay A) Check for continuity between terminals "1" And "2" b) Check for continuity between terminals "3" And "4". If the conditions are not...
Front wheel speed sensors Scheme of installation of the speed sensor Front wheel speed sensor: 1 - sensor rotor, 2 - front wheel speed sensor (for all engines except 3S-GE), 3 - front wheel speed sensor (for 3S-GE engine) 1. Checking the front...
Checking the anti-lock braking system circuit 1. Checking the purpose of the system with connected connectors. A) Remove the ABS control unit. b) Using a voltmeter with a large input resistance (minimum 10 kOhm/V), measure the voltage between each pin and ground"....