NEXON BSVI MCE - SERVICE MANUAL

BRAKES 31 INSTALLATION 1. Hold the brake control bracket on firewall. 2. Tighten the brake upper mounting M8 nut. 3. Tighten the brake mounting M8 nuts on panel firewall RHD. 4. Match clevis hole to the pedal lever hole and insert clevis pin into the hole. 5. Insert split pin in to the hole of clevis pin and split the end of split pin. NOTE: 1. Not to add carpet over the basic carpet in the pedal region. 2. Basic carpet should be held firmly in the pedal region. 12. SNAP TYPE BRAKE LIGHT SWITCH INSTALLATION PROCEDURE 1. Adjuster (B) to be snapped on Brake light switch mounting bracket. 2. There should not be play in the adjuster after fitment with mounting bracket. 3. Insert the switch (A) in adjuster (B) till the switch plunger get completely Pressed against brake pedal (at this point switch body will rest on brake pedal) 4. Rotate the switch in direction ‘C until its lock. 5. After locking, the switch will set back by 1±0.15mm. INSPECTION OF BOOSTER OPERATION NOTE: Before inspection, make sure that there is no air in the hydraulic system. 3. Check air tightness a. Start and stop engine, after running for 1 to 2 minutes. b. Depress brake pedal several times with the same effort as used while normal braking operation and observe pedal travel. If pedal goes deep down for first time and its travel decreases for the following depression, then air tightness is observed. c. If pedal travel does not change then air tightness is not obtained. Inspect vacuum lines and sealing parts and replace defective parts. d. Repeat the entire test after replacing defective parts. 4. Check operation a. With engine stopped, depress pedal for several times with the same effort as used while normal braking operation and make sure that pedal travel doesn’t change. b. Start engine and depress brake pedal. A small increase in pedal travel indicated satisfactory functioning of booster. However, if there is no change in pedal travel, it indicates a malfunction. 5. Check air tightness under load a. Start engine. Depress brake pedal. Stop engine while holding the brake pedal in depressed condition. b. Hold the brake pedal in depressed condition for 30 seconds. If pedal height does not change, it indicates proper operating condition and if pedal travel rises, it indicates malfunctioning.