TABLE OF CONTENTS 1. PRECAUTIONS ..........................................................................................................................................1 2. TECHNICAL SPECIFICATIONS ................................................................................................................2 3. TIGHTENING TORQUES...........................................................................................................................4 4. DIAGNOSIS ................................................................................................................................................5 5. NESSECITY OF ABS WITH EBD...............................................................................................................8 6. BRAKE HYDRAULIC LINES......................................................................................................................9 7. VACUUM BRAKE BOOSTER..................................................................................................................10 8. WORKING OF ANTI-LOCK BRAKING SYSTEM (ABS):........................................................................12 9. ABS COMPONENTS................................................................................................................................16 A. ABS 9 ELECTRONIC CONTROL UNIT / HYDRAULIC CONTROL UNIT (ECU / HCU):...................17 B. HYDRAULIC CONTROL UNIT...........................................................................................................18 C. WHEEL SPEED SENSOR: (MONITORS WHEEL SPEED)...............................................................19 D. ABS SYSTEM FAILURE WARNING LIGHT.......................................................................................20 MAINTENANCE, ADJUSTMENTS & TEST............................................................................................21 10. A. FRONT BRAKE MAINTENANCE.......................................................................................................21 B. REAR BRAKE MAINTENANCE:........................................................................................................23 C. BRAKE TROUBLE SHOOTING.........................................................................................................28 D. CHECK LIST FOR ENSURING SATISFACTORY FUNCTIONING OF SERVO ................................29 BRAKE PEDAL ASSEMBLY REMOVAL................................................................................................32 11. SNAP TYPE BRAKE LIGHT SWITCH INSTALLATION PROCEDURE.................................................34 12. REPAIRS .................................................................................................................................................35 13. A. FRONT BRAKE ADJUSTMENT, REMOVAL AND REFITMENT ........................................................36 B. REMOVAL OF FRONT BRAKE DISC................................................................................................41 C. REMOVAL AND REFITMENT OF TMC & BOOSTER ASSEMBLY....................................................42 D. REAR BRAKE ASSEMBLY :...............................................................................................................44 E. REMOVAL AND REFITMENT OF REAR BRAKE ASSEMBLY ..........................................................47 F. REMOVAL OF PARKING BRAKE LEVER..........................................................................................53 G. REMOVAL AND INSTALLATION OF PARKING BRAKE CABLE.......................................................54 H. PARKING BRAKE CABLE ADJUSTMENT.........................................................................................56 REMOVAL AND REFITMENT OF ABS ECU / HCU...........................................................................56 I. J. REMOVAL AND REFITMENT OF FRONT WHEEL SPEED SENSOR..............................................58 K. REMOVAL AND REFITMENT OF REAR WHEEL SPEED SENSOR ................................................59 TROUBLE SHOOTING & DIAGNOSIS...................................................................................................60 14. BRAKE_PETROL
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