General information about the brake system Vehicles are equipped with disc or drum hydraulic brakes. Clearances between pads and disc (or drum) adjusted automatically. The rear brake pads are adjusted when the handbrake is applied. Hydraulic drive Hydraulic...
Specifications of the brake system Clearance between brake booster tappet and master cylinder piston Disc brakes: - lining thickness: • standard 10,0 • ultimate 4,0 – thickness of the handbrake lining: • standard 4,0 • ultimate 1,0 - disc beat no more...
ABS system units Since 1993, the FJ80 has been equipped with an automatic brake release system (ABS system), designed to improve vehicle stability under heavy braking conditions. The pressure in the brake circuit is regulated depending...
Diagnostics and repair of the ABS system When the ignition is switched on, the ABS warning lamp lights up, and goes out after the engine is started. If the lamp continues to burn, then a malfunction has been registered in the ABS system. Attention! The ABS...
Disc brake deck replacement (front or rear) Attention! Pads are changed only as a set for one axle. When cleaning the pads, remove dust and dirt by wiping with a rag soaked in alcohol or a special liquid; blowing is prohibited. Replacement 1. Unscrew the stopper...
Brake caliper — removal, disassembly and installation Attention! For serious damage (e.g. liquid leakage) the caliper is recommended to be replaced. Calipers change in pairs for one axle. The procedure below applies to both 4-cylinder and 1-cylinder calipers (these...
Brake disc — check, removal and installation 1. Loosen wheel nuts, raise vehicle and place on stands. 2. Remove the wheels and screw the wheel nuts back in place to secure the disc to the hub (to ensure the application of force to the disk, washers can be put on)....
Replacing drum brake pads Shoe side A installation 1. Left wheel; 2. Right wheel; 3. To the front of the car The position of the pads after assembly 1. Left wheel; 2. Right wheel; 3. To the front of the car Attention! Pads are changed only as a...
Wheel brake cylinder — removal and disassembly Details of the wheel cylinder of brakes with a horizontal arrangement of pads Details of the wheel cylinder of brakes with a vertical arrangement of pads 1. cap; 2. Connection for pumping; 3. Case; 4. Piston; 5. Cuff;...
Brake master cylinder — removal, disassembly and installation Parts of brake master cylinder with small reservoir 1. Cork and strainer; 2. Tank; 3. Retaining ring; 4. Primary piston with spring; 5. Secondary piston with spring; 6. Locking bolt; 7. Plug; 8. Fitting Large reservoir...
Hydraulic hoses and tubes — replacement It is recommended to check the condition of hoses and tubes every 6 months. If cracks, leaks, swelling or other damage are found, replace the hose. Replacing the front brake hoses 1. Raise the car and remove the wheel....
Removal of air from a hydraulic drive of brakes The need for pumping occurs after disconnecting the tubes of the main cylinder or when the level in the tank is greatly reduced. When disassembling the hydraulic drive of one wheel, you can limit yourself to removing...
Vacuum brake booster — removal, inspection and installation Checking work 1. Press the brake pedal several times with the engine off. The pedal stroke should not change with each press. 2. Press the pedal and start the engine - the pedal should move forward a little. Leak test...
Hand brake pads, rear disc brakes Check and replacement 1. Remove the brake disc. 2. Clean the handbrake mechanism. 3. Check the remaining thickness of the friction linings. Replace pads if material thickness is less than 1.0 mm. 4. Remove the handbrake...
Handbrake adjustment The handbrake should provide 5 clicks of incline braking. Adjustment is necessary if the brake travel is less than 4 clicks or more than 5 clicks. 1. Remove the center section to gain access to the regulator. 2. Loosen...
Handbrake cable — replacement 1. Remove the center section to gain access to the regulator. 2. Release the brake lever and unscrew the locknut and adjusting (lower) nut. 3. Remove cable from lever. 4. Working under the vehicle, pull the cable...
The switch of a signal of braking — removal and installation Switch location Switch (indicated by an arrow) mounted on the top of the pedal. When you press the pedal, the switch contacts close and the brake light comes on. Removal and installation 1. Disconnect the battery from...
Rear brake pressure regulator (dosing and bypass valve) Regulator location The pressure regulator is designed to compensate for the pressure in the rear brakes when the load on the rear axle increases. The unit is located above the rear axle beam and contains a valve, a...