Contents: Checking and adjusting the brake…↓ Checking the operation of the brake…↓ Bleeding the brake system ↓ Checking and adjusting the parking…↓
Checking and adjusting the brake pedal travel
1. Check the height of the brake pedal from the floor surface.
Pedal height - 161-171 mm
2. Adjusting the height of the pedal (if necessary).
a) Loosen the brake light switch nut.
b) Loosen the lock nut.
c) Adjust the pedal height by rotating the pusher.
d) Tighten the brake light switch until its housing comes into light contact with the pedal travel limiter.
d) After adjusting the pedal height, check and adjust the pedal free play.
e) Tighten the lock nut.
Tightening torque: 37 Nm
3. Checking the pedal free travel.
a) Turn off the engine and press the pedal several times until there is no more vacuum left in the booster.
b) Press the pedal with your hand until you feel a secondary increase in the resistance force to its movement and measure this pedal stroke.
Pedal free travel - 3-6 mm
4. Adjusting the pedal free travel (if necessary).
a) If the free play is not within the standard, adjust it by rotating the pusher.
b) Start the engine and make sure that the pedal has free play.
c) After adjusting the free play, check the pedal height.
5. Checking the full pedal travel.
a) Tighten the parking brake lever.
b) With the engine running, press the pedal with a force of 490 N and measure the full travel of the pedal from the floor of the body.
Full pedal travel:
front disc brakes - not less than 68 mm
front drum brakes - not less than 105 mm
c) If the full travel is not within the norm, check the brake system.
Checking the operation of the brake booster
Note: If the amplifier is not sealed, repair it before testing.
1. Checking the functionality.
a) Press the brake pedal several times with the engine off and check that the pedal travel does not change.
b) Press the brake pedal and start the engine. If the brake pedal goes down smoothly, the vacuum booster is working.
2. Checking for leaks.
a) Start the engine and stop it after one or two minutes of operation. Slowly press the brake pedal several times. If the pedal drops lower on the first press than on the second and third press, the vacuum booster is sealed.
b) Press the brake pedal with the engine running and stop it with the pedal pressed. If the distance between the floor and the pressed pedal does not change within thirty seconds, the vacuum booster is sealed.
Bleeding the brake system
Note:
- Bleeding the brake system is necessary after any work on the brake system, or if air has entered the system.
- Do not allow brake fluid to come into contact with painted surfaces of the car body. Wash it off the car body immediately.
1. After bleeding the brakes of each wheel, check the brake fluid level in the reservoir. Add brake fluid to it if necessary.
Brake fluid type - SAEJ1703 or FMVSS #116 DOT3
2. Bleeding the master brake cylinder.
Note: bleeding the master brake cylinder is carried out after it has been disassembled or if the reservoir was empty.
a) Disconnect the brake pipe from the master cylinder. Drain the brake fluid into the reservoir.
b) Slowly press the brake pedal and hold it in this position.
c) Close the outlet holes of the master cylinder with your fingers and release the pedal.
d) Repeat operations (b) and (c) three or four times.
3. Place one end of the vinyl tube over the bleed nipple of the wheel brake cylinder and lower the other end into a transparent container half filled with brake fluid.
Note: Start bleeding the brakes from the wheel with the longest brake line.
4. Bleeding the brake line.
a) Slowly press the brake pedal several times.
b) While the assistant holds the pedal down, slightly open the bleed nipple and the fluid with air bubbles will start to come out into the container. When the pedal goes down, tighten the bleed nipple and then release the pedal.
c) Repeat this procedure until all air has been removed from the brake fluid.
Tightening torque of the nipple - 11 Nm
5. Repeat these operations for each of the wheels of the car.
Checking and adjusting the parking brake
1. Pull the parking brake lever to its full stroke and check that the number of clicks is normal.
Full stroke - 7 - 9 clicks (at a force of 196 N)
2. If the lever movement is not normal, make adjustments.
Note: Before adjusting the parking brake, it is necessary to adjust the clearance between the brake linings and the brake drum.
a) Remove the parking brake lever cover.
b) Loosen the lock nut and turn the adjusting nut until the correct amount of lever travel is established.
c) Tighten the lock nut.
d) Replace the parking brake lever cover.
