NEXON

BRAKES

CONTENTS

1.1 PRECAUTIONS ........................................................................................................................................ 1

1.2 TECHNICAL SPECIFICATIONS .............................................................................................................. 2

1.3 TIGHTENING TORQUES ......................................................................................................................... 4

1.4 DIAGNOSIS .............................................................................................................................................. 5

1.5 NESSECITY OF ABS WITH EBD ............................................................................................................ 8

1.6 BRAKE HYDRAULIC LINES.................................................................................................................... 9

1.7 VACUUM BRAKE BOOSTER................................................................................................................ 10

1.8 WORKING OF ANTI-LOCK BRAKING SYSTEM (ABS) ....................................................................... 11

1.9 ABS COMPONENTS .............................................................................................................................. 15

1.9.1 ABS 9 ELECTRONIC CONTROL UNIT

/ HYDRAULIC CONTROL UNIT

(ECU

/ HCU) ................. 16

1.9.2 HYDRAULIC CONTROL UNIT ....................................................................................................... 17

1.9.3 WHEEL

SPEED

SENSOR:

(MONITORS WHEEL SPEED) ......................................................... 18

1.9.4 ABS SYSTEM FAILURE WARNING LIGHT ................................................................................... 19

1.10 MAINTENANCE, ADJUSTMENTS & TEST........................................................................................... 20

1.10.1 FRONT BRAKE MAINTENANCE ................................................................................................... 20

1.10.2 REAR BRAKE MAINTENANCE...................................................................................................... 22

1.10.3 BRAKE TROUBLE SHOOTING...................................................................................................... 27

1.10.4 CHECK LIST FOR ENSURING SATISFACTORY FUNCTIONING OF SERVO............................. 28

1.11 BRAKE PEDAL ASSEMBLY ................................................................................................................. 30

1.12 SNAP TYPE BRAKE LIGHT SWITCH INSTALLATION PROCEDURE ............................................... 31

1.13 REPAIRS................................................................................................................................................. 32

1.13.1 FRONT BRAKE

ADJUSTMENT, REMOVAL AND REFITMENT ................................................... 33

1.13.2 REMOVAL OF FRONT BRAKE DISC............................................................................................. 38

1.13.3 REMOVAL

AND REFITMENT OF TMC & BOOSTER ASSEMBLY............................................... 39

1.13.4 REAR BRAKE ASSEMBLY............................................................................................................. 41

1.13.5 REMOVAL AND REFITMENT OF REAR BRAKE ASSEMBLY ...................................................... 42

1.13.6 REMOVAL OF PARKING BRAKE LEVER...................................................................................... 48