Brake Specifications System type — With a vacuum booster. Front disc brakes, rear drum brakes. The brake hydraulic line is divided into two diagonal circuits. The pressure in the rear brake units is regulated using special valves. A...
General description of the braking system Pic. 9.1. Arrangement of brake system components (Hatchback, Wagon and Van models) 1. Assembling the vacuum booster of the main cylinder; 2. Brake tube; 3. Hose; 4. Brake tube; 5. Brake tube; 6. Brake tube; 7. Bracket;...
Brake pedal — removal, inspection and installation Removing 1. Remove the clutch pedal ( see Section 6 ). 2. Detach the return spring from the brake pedal, then remove the black plastic clutch pedal bushing (see photo). 3. Remove the locking bracket that secures the...
Brake Pedal Height — Adjustment Note: Although the pedal height is checked inside the vehicle, it is adjusted in the engine compartment. This procedure is much easier to perform if you involve an assistant in it. 1. Working in the cabin, measure the...
Vacuum booster unit — removal and installation Removing 1. Open the hood and disconnect the hose from the vacuum booster unit (see photo). 2. Turn off two nuts fixing the main cylinder to the block of the vacuum amplifier. 3. Very carefully move the master cylinder...
Non-return valve of the vacuum booster block — check of serviceability 1. When checking the serviceability of the valve, remember that its function is to pass air in only one direction, namely from the vacuum booster unit. If the valve allows air to flow in both directions or neither, it...
Vacuum booster non-return valve — removal and installation Removing 1. Cut or loosen the clamps securing the hose to the valve, then disconnect the hose and remove the valve, noting its correct position (see photo). Installation 2. Install in the reverse order of removal, using...
Vacuum Booster Unit Hose — Replace 1. Cut or loosen the hose clamps, then separate the hose from the couplings and from the non-return valve. 2. Install in the reverse order of removal, using new clamps if required. Cut the new hose to the correct length...
Brake hydraulic system — pumping Note: Brake fluid is poisonous. Rinse the affected parts with copious amounts of cold running water and seek immediate medical attention if the fluid enters the mouth or eyes. Some types of brake fluid are flammable and...
Brake pipes and hoses — replacement Note: Please refer to the note given at the beginning of the Chapter 9 . 1. If any tube or hose needs to be replaced, remove the master cylinder feed tank cap and re-tighten it with a piece of polyethylene under the cap...
Master cylinder — removal, reassembly and installation Pic. 9.5. Master cylinder components (early modification) 1. Brake pressure control valves (Hatchback models only. Wagon and Van); 2. Master cylinder; 3. Piston seal; 4. Washer; 5. Piston collar; 6. Spring support; 7....
Brake pressure control valves (except Pickup models) Pic. 9.8. Brake Pressure Control Valve Components (except Pickup models) 1. End cap; 2. Piston; 3. Small O-ring; 4. Large O-ring; 5. Piston spring; 6. Valve spring; 7. Plastic valve; 8. Valve body; 9. O-ring. Pic. 9.9....
Front brake caliper — removal and installation Note: Please refer to the note given at the beginning of the Chapter 9 and the warning given at the beginning Chapter 13 (regarding asbestos dust). Removing 1. Jack up the front of the vehicle, place it securely on axle...
Front brake caliper — bulkhead Pic. 9.11. Sectional front brake caliper 1. Caliper; 2. Piston; 3. Piston seal; 4. Dust-proof cuff of the piston; 5. Brake pads. Note: Please refer to the note given at the beginning of the Chapter 9 and the warning...
Front brake disc — inspection, removal and installation Note: Please refer to the note given at the beginning of the Chapter 9 and the warning given at the beginning Chapter 13 (regarding asbestos dust). Inspection Note: To ensure equal and effective braking, the discs of...
Front brake disc guard — removal and installation Note: Please refer to the warning at the beginning before operation Chapter 13 . Removing 1. See relevant Section 10 Chapters and this section and remove the steering knuckle, then separate the brake disc and push out...
Brake pressure control valve (pickup models) — health check 1. If one or both rear wheels lock up several times under heavy braking, first check that this is not caused by adverse road conditions or incorrect tire pressure/heavy tread wear. Then check the condition of all four...
Rear brake drum — removal, inspection and installation Note: Please refer to the warning given at the beginning of the Chapter 21 . Removing 1. Jack up the rear of the vehicle, place it securely on axle stands, then remove the wheel. 2. Using chalk or paint, mark the drum...
Rear brake pads — inspection and replacement Warning: Brake pad sets on coaxial wheels should be changed at the same time - never change pads on just one wheel. because this will result in uneven braking. Please note that the dust generated during pad wear may...
Drum brake support shield — removal and installation Note: Please refer to the note given at the beginning of the Chapter 9 , and the warning given at the beginning Chapter 21 (regarding asbestos dust). Removing 1. Remove the rear wheel hub ( see Section 10 ). 2. After...
Handbrake cables — removal, inspection and installation Pic. 9.18. The location of the handbrake cable in the hinged part of the lever 1. Locknut; 2. Adjusting nut; 3. Cable compensator; 4. Cable; 5. Hinge part of the lever; 6. Retaining ring (where available). Removing 1....
Stop Lamp Switch — Adjustment 1. The brake light switch must be installed so that the lights come on when the brake pedal is depressed 10-15 mm from its original position. 2. To access the switch, remove the lower steering column cover if necessary...
Warning lamps, sensors and brake switches Stoplights 1. The brake light circuit is closed by a plunger-type switch mounted on the brake pedal bracket (see photo). 2. Check and adjust switch setting as described in Chapter 26 of this Section. 3. If there is a...