Manageability Improvement Systems Depending on the configuration and year of manufacture on different models, the controllability improvement system may include different systems: ABS / EBD...
Automated bleeding of the brake system Note: When adding brake fluid to the master cylinder reservoir, use only Delco Supreme 11 fluid or equivalent (DOT-3) from a clean sealed container. Attention:...
Manual bleeding of the brake system Note: When adding brake fluid to the master cylinder reservoir, use only Delco Supreme 11 fluid or equivalent (DOT-3) from a clean sealed container. 1. Place a...
System pressure modulator valve Withdrawal Attention: to prevent the loss of brake fluid and the ingress of dirt into the system, plug open openings. 1. Raise the vehicle and slide the safety...
Electronic brake control Withdrawal 1. Raise the vehicle and slide the safety struts under the frame. 2. Remove dirt from the surfaces of the electronic brake control unit and the...
Front wheel speed sensor Withdrawal 1. Raise the vehicle and slide the safety struts under the frame. 2. Remove the front wheel. 3. Remove the brake disc. 4. Remove the wheel speed...
Rear wheel speed sensor Withdrawal 1. Raise the vehicle and slide the safety struts under the frame. 2. Disconnect the sensor wiring connector. 3. Turn away a bolt of fastening of the...
Rear wheel speed sensor timing ring Withdrawal 1. Raise the vehicle and slide the safety struts under the frame. 2. Remove the rear wheel. 3. Remove the rear wheel speed sensor. 4. Remove the...
Traction control switch Withdrawal 1. Change the front panel access panel. 2. Disconnect the switch wiring connector. 3. Use a small screwdriver to unfasten the switch latches, remove...
The sensor of deviation from the course of the car Withdrawal 1. Remove the passenger seat. 2. Remove two nuts (1) sensor mounts. Tightening torque 7 Nm. 3. If sensor access is needed, pull back the mat. 4....
Location of components and parts of the brake system GMT900. The front of the chassis. 1 - right wheel speed sensor, 2 - right shock absorber solenoid valve, 3 - right body height sensor, 4 - left body height...
Disc brakes — specification Note: The brake disc thickness limit is indicated on the disc casting. Permissible scratch depth 1.5 mm. Brake disc thickness Front brake JC3/JC4/JH2 (GMT800):...
Measuring the thickness of the brake disc 1. If the friction surface of the brake disc is not accessible, remove the caliper together with the brake pads. 2. Clean the friction surfaces of the brake...
Brake disc surface 1. If the friction surface of the brake disc is not accessible, remove the caliper together with the brake pads 2. Clean the friction surfaces of the brake...
Measuring brake disc runout Attention: Increased axial runout of the brake disc can lead to the development of uneven disc wear during 5000-10000 km of run. A brake disc thickness...
Correction of brake disc runout Correction of brake disc runout can be done in two ways. Determine an acceptable correction method. The disk repositioning method is effective if the disk...
Checking the brake pad Check the brake pads regularly and whenever a wheel is removed. If pad replacement is necessary, replace pads on all wheels of the same axle. Check pad...
Checking the brake caliper 1. Inspect the brake caliper housing. Look for cracks, signs of excessive wear and/or damage. If any of these conditions are present, replace the caliper. 2....
Checking the brake caliper support 1. Check up liquid level in a tank of the main brake cylinder. 2. If the brake fluid level is in the middle between the maximum and minimum level marks, the...
Brake pads — replacement Attention: Do not leave the caliper hanging on the brake hose as this will deform the hose and cause brake fluid to leak. Tie the caliper with wire. If the...
Lapping brake pad and disc The lapping of the brake pads and brake discs is essential for maximum disc brake performance. This procedure should be performed after replacing or repairing...
Brake caliper — removal and installation All brakes 1. Check up liquid level in a tank of the main brake cylinder. 2. If the brake fluid level is in the middle between the maximum and minimum level...
Brake Caliper Repair Disassembly Note: Brake caliper repair is shown using a 2500 series front caliper as an example. 1. Remove the brake caliper. 2. Drain the brake fluid from the...
Replacing Disc Brake Hardware Note: Replacing disc brake hardware is shown using a 1500 series front brake as an example. 1. Remove the brake caliper (without disconnecting the brake hose)....
Brake disc — removal and installation Attention: do not leave the caliper hanging on the brake hose, this will deform the hose and leak brake fluid. Tie the caliper with wire. Note: Before...
Front brake screen Withdrawal 1. Remove the wheel hub. Attention: Please note the orientation of the screen to ensure proper installation. 2. Remove the brake screen from the...
Rear brake shield Withdrawal 1. Remove the parking brake base plate. 2. Remove the brake shield from the axle beam tube flange. Installation 3. Installation is carried out in...
Checking the brake system on the road Preliminary Operations 1. Inspect easily accessible components for obvious damage and/or leaks, which may indicate that the vehicle should not be driven until...
Measuring the brake pedal stroke 1. With the ignition off and the brakes cold, apply the brakes five times or more to release the vacuum in the brake booster. 2. Install a pedal force meter on...
Evaluation of the work of the hydraulic brake booster 1. Install a pedal force meter on the brake pedal. 2. Run the engine to idle. Set the front wheels to the straight ahead position. 3. Apply 111 N of force to...
Vacuum Source Check Attention: The vacuum created is affected by engine temperature, the operation of attachments and altitude; The vacuum created is reduced by approximately 3...
Search for leaks in the hydraulic drive of the brakes Finding external leaks 1. Check up liquid level in a tank of the main brake cylinder. A slight decrease in the fluid level can be considered the norm, which is...
Visual inspection of hydraulic system components 1. Remove the wheel, secure the brake disc with wheel nuts and inspect the area around the anthers (2) caliper pistons. 2. If there are clear signs of leakage,...
Checking brake pipes and hoses 1. Inspect all brake pipes and hoses, look for: loops, incorrect tube/hose routing, missing or damaged tube or hose support clips; signs of corrosion or fluid...
Checking the brake pedal pusher 1. Disconnect the pusher (1) brake pedal from the pedal. 2. Inspect the sleeve of the earring (2) tappet, look for cracks and signs of wear. 3. Slide the boot...
Filling the Master Cylinder Reservoir Note: When adding brake fluid to the master cylinder reservoir, use only Delco Supreme 11 fluid or equivalent (DOT-3) from a clean sealed container. 1. Assess...
Master cylinder reservoir Withdrawal 1. Apply the parking brake and block the wheels of the vehicle. 2. Remove the main brake cylinder. 3. Drain the master cylinder reservoir. 4. Fix...
Master brake cylinder Withdrawal Models with a vacuum brake booster Models with hydraulic brake booster 1. Using a siphon, pump out the brake fluid from the reservoir of the master...
Brake fluid level sensor Withdrawal 1. Disconnect the brake fluid level sensor harness connector. 2. Using pliers, squeeze the transducer locking keys (on the opposite side of the...
Brake pedal — removal and installation 1. Remove clip (4) fixing the pusher of the brake pedal. 2. Remove from hairpin (1) brake pedal stop light switch (2) and pusher (3). 3. Turn away a nut of a...
Vacuum brake booster Withdrawal 1. Apply the parking brake. 2. Relieve the vacuum in the vacuum booster. To do this, press the brake pedal 3-5 times. 3. (GMT900) Disconnect vacuum...
Brake booster check valve and hose Withdrawal 1. Remove the check valve from the vacuum brake booster. 2. Remove a clamp of fastening of a vacuum hose on the valve. 3. Remove the valve from the...
Hydraulic brake booster Examination Caution: The hydraulic booster may look wet due to excess hydraulic fluid when installed at the factory or if brake fluid is spilled while filling...
Hydraulic brake booster accumulator Withdrawal Warning: The accumulator contains compressed gas. Always use the special tools and follow the instructions given here, otherwise there is a risk of...
Brake pipes — replacement Withdrawal Caution: When replacing brake pipes, always install a double-walled steel pipe. The use of pipes of any other design is not recommended as it may...
Front brake hose Brake hose front brake Removal and installation Withdrawal Note: The removal and installation procedures are shown using GMT900 models as an example. 1. Raise...
Brake hose frame and rear axle Brake hose frame and rear axle Removal and installation Withdrawal Note: The removal and installation procedures are shown using GMT900 models as an example....
Rear brake hose Rear brake hose - removal and installation, 1500 series (top and 2500 (at the bottom) Withdrawal Series 1500 1. Raise the vehicle and place the safety stands...
Checking the parking brake pad 1. Raise the vehicle and place the safety stands under the frame. 2. Remove the rear wheel. 3. Remove a brake support together with an arm. Attention: do not...
Parking brake shoe replacement Series 1500 1. Raise the vehicle and slide the safety struts under the frame. 2. Remove the brake disc. 3. Disconnect the parking brake cable from the brake...
Parking brake release handle 1. Remove the bolt (1) securing the parking brake release handle. Tightening torque 9 Nm. 2. Move the rope (2) parking brake actuator forward, disconnect the...
Parking brake pedal Withdrawal Caution: The service procedure includes the removal of the front parking brake cable. The front parking brake cable is not replaced separately, only...
Parking brake indicator switch Withdrawal 1. Disconnect the negative battery cable. 2. Without disconnecting the wiring connectors, remove the electrical distribution block from the left...
Rear parking brake cable Withdrawal 1. Release the parking brake. 2. Lock the automatic parking brake cable adjuster. 3. Raise the car and place the safety stands under the frame. 4....
Parking brake cable guide Withdrawal 1. Release the parking brake. 2. Raise the vehicle and place the safety stands under the frame. 3. Turn away a bolt of fastening directing a cable...
Parking brake cable adjuster Before starting work on servicing the parking brake system, it is necessary to block (at the end of the unlock) parking brake cable adjuster. To carry out this...
Parking brake actuator Withdrawal 1. Release the parking brake. 2. Lock the automatic parking brake cable adjuster. 3. Disconnect the parking brake cable from the brake lever. 4....
Parking brake base plate Removal and installation 1. Lock the parking brake cable adjuster. 2. Disconnect the parking brake cable from the brake lever. 3. Remove parking brake pads. 4....
Parking brake adjustment 1. Install a special caliper on the inner diameter of the rear brake disc. 2. Install the caliper on the brake pads. 3. Turn the adjuster nut until the shoe...
Parking brake cable tension adjustment Attention: before adjusting the tension of the cable, adjust the gap between the brake pads and the disc. 1. Remove the cable adjuster retainer. 2. Apply and...