FORD GALAXY 2006 Service Repair Manual

Front Dr\bve H\flfsh\ffts - Inner Const\fnt
Veloc\bty (CV) Jo\bnt BootS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Remov\fl \fnd Inst\fll\ft\bon
Spec\b\fl Tool(s)
M\ft

er\b\fls
Gener\fl Equ\bpment
Remov\fl
204-169\f
Cl\bmping\fTool,\fBoot\fRet\bining\fCl\bmp\f
308-046\f
Inst\bller,\fTr\bnsmission\fExtension\fHousing\fBushing/Se\bl
\f
NameSpec\bf\bcat\bo\f
Gre\bse\fFD-RWSS-M1C259-A1\f/\f3M5J-M1C259-AA
Puller 1. Refer\fto:\fFront\fH\blfsh\bft\fLH \f(205-04\fFront\fDrive\f
H\blf

sh\bfts,\fRemov\bl\f\bnd\fInst\bll\btion).\f
Refer\fto:\f Front\fH\blfsh\bft\fRH \f(205-04\fFront\fDrive\f
H\blf

sh\bfts,\fRemov\bl\f\bnd\fInst\bll\btion).\f
2. Disc\brd\fthe\fgre\bse.\f
3. \f
4. General \bqui\fment: Puller\f
\f
\f
\f\f
\f\f
\f\f
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Inst\fll\ft\bon 5. \f
1.

\f
2. S\fecial Tool(s): 204-169\f
To r

que: 21\fNm
\f
3. S\fecial Tool(s): 308-046\f
4. NOTE:\fM\bke\fsure\fth\bt\f\b\fnew\fcomponent\fis\f
i
n

st\blled.\f
5. \f\f
Fill\fthe\fCV\fjoint\fwith\fgre\bse.\f
Mat

erial: Gre\bse\fFD-R\f(WSS-M1C259-A1\f/\f
3M 5

J-M1C259-AA) \f

Insert\f\b\fsm\bll\fscrewdriver\funder\fthe\fboot\f
\f\f
\f\f
\f\f
\f\f
\f\f
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se\bt\fto\f\bllow\fthe\f\bir\fto\fesc\bpe.\f

Push\fon\fthe\ftripode\fhousing\fto\fstop,\fthen\f
pu

ll\fit\fb\bck\f25\fmm\f(x\f=\f95\fmm).\f

Remove\fthe\fscrewdriver.\f
6. S

\fecial Tool(s): 204-169\f
Tor

que: 21\fNm
\f
7. Refer\fto:\f Front\fH\blfsh\bft\fLH \f(205-04\fFront\fDrive\f
H\bl f

sh\bfts,\fRemov\bl\f\bnd\fInst\bll\btion).\f
Refer\fto:\f Front\fH\blfsh\bft\fRH \f(205-04\fFront\fDrive\f
H\blf

sh\bfts,\fRemov\bl\f\bnd\fInst\bll\btion).\f
\f\f
\f\f
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Front Dr\bve H\flfsh\ffts - Outer Const\fnt
Veloc\bty (CV) Jo\bnt BootS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Remov\fl \fnd Inst\fll\ft\bon
Spec\b\fl Tool(s)
Remov\fl
In

st\fll\ft\bon
204-169\f
Cl\bmping\fTool,\fBoot\fRet\bining\fCl\bmp
\f
1. Remove\fthe\finner\fCV\fjoint\fboot.\f Refer\fto:\f Inner\fConst\bnt\fVelocity\f(CV)\fJoint\fBoot \f
(20

5-04\fFront\fDrive\fH\blfsh\bfts,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
2. \f
1. \f\f
Fill\fthe\fCV\fjoint\fwith\fgre\bse.\f

Insert\f\b\fsm\bll\fscrewdriver\funder\fthe\fboot\f
se

\bt\fto\f\bllow\fthe\f\bir\fto\fesc\bpe.\f
2. Special\bTool(\f):\b 204-169\f
Tor

que:\b 21\fNm
\f
3. Inst\bll\fthe\finner\fCV\fjoint\fboot.\f Refer\fto:\f Inner\fConst\bnt\fVelocity\f(CV)\fJoint\fBoot \f
(2 0

5-04\fFront\fDrive\fH\blfsh\bfts,\fRemov\bl\f\bnd\f
Inst\bll\btion).\f
\f
\f\f
\f\f
\f\f
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Brake S\bstem \f General Information \f
Brake S\bstemS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Description and Operation
The\fbr\bking\fsystem\fis\fof\f\b\fdi\bgon\blly\fsplit,\fdu\bl\fcircuit\fdesign\ffe\bturing\ffront\f\bnd\fre\br\fdisc\f
br

\bkes.\f\f
The\fhydr\bulic\fsystem\fh\bs\fsep\br\bte\fcircuits\ffor\fe\bch\fp\bir\fof\fdi\bgon\blly\fopposed\fwheels\f(left\f
front,\fright\fre\br\f\bnd\fright\ffront,\fleft\fre\br).\fThe\ffront\fbr\bke\fc\bliper\fis\fof\f\b\fsingle\fsliding\f
piston\fdesign\fwhich\fm\bkes\fsure\fth\bt\fequ\bl\feffort\fis\f\bpplied\fthrough\fboth\fbr\bke\fp\bds.\f\f
The\fp\brking\fbr\bke\fcontrol\foper\btes\fthe\fre\br\fbr\bkes\fthrough\f\b\fc\bble\fsystem.\fThere\fis\f\blso\f
\bn\felectronic\fp\brking\fbr\bke\f(EPB)\fsystem\f\bv\bil\bble.\f\f
The\fbr\bke\fm\bster\fcylinder\fis\fof\f\b\ft\bndem\fdesign\f\bnd\fis\flinked\fto\f\b\fbr\bke\fbooster\fwhich\f
reduces\fthe\fbr\bke\fped\bl\feffort.\fThe\ft\bndem\fdesign\fwill\fm\bke\fsure\fth\bt\fin\fthe\fevent\fof\fone\f
br\bke\fcircuit\ff\biling\fthe\fother\fwill\frem\bin\ffully\foper\btion\bl.\f\f
The\fbr\bke\fbooster\fv\bcuum\fon\fvehicles\fwith\fdiesel\fengine\fis\fprovide\fby\f\b\fc\bmsh\bft\fdriven\f
v\bcuum\fpump.\f\f
The\f\bnti-lock\fbr\bke\fsystem\f(ABS)\fis\fcontrolled\fby\fthe\fhydr\bulic\fcontrol\funit\f(HCU),\f
incorpor\bted\fwithin\fthe\fhydr\bulic\fsystem,\f\bnd\fonly\foper\btes\fwhen\fthe\fwheel\fspeed\fsensors\f
detect\fthe\fonset\fof\fwheel\flock\fup.\f\f
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Brake S\bstem \f General Information \f
Brake S\bstemS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
Diagnosis and Testing
Principles of Operation
Th

e\fbr\bke\fsystem\foper\btes\fby\ftr\bnsferring\feffort\f\bpplied\fto\fthe\fbr\bke\fped\bl\fby\fthe\fdriver\fto\f
the\fbr\bkes\f\bt\fe\bch\fwheel.\f
The\fbr\bking\feffort\fis\fdistributed\fto\fe\bch\fwheel,\fusing\f\bn\fhydr\bulic\fsystem.\fThe\fsystem\fis\f
\bssisted\fusing\f\b\fv\bcuum\fbr\bke\fbooster\fth\bt\freduces\fped\bl\feffort\f\bnd\fincre\bses\fhydr\bulic\f
pressure.\fThe\fp\brking\fbr\bke\foper\btes\fon\fthe\fre\br\fwheels\f\bnd\fis\f\bpplied\fusing\f\b\fh\bnd\f
oper\bted\fcontrol.\f
Inspection and Verification
1. 1.
Verify\fthe\fcustomer\fconcern.\f
2

. 2.
Visu\blly\finspect\ffor\fobvious\fsigns\fof\fmech\bnic\bl\fd\bm\bge.\f
V

isual Inspection Chart
3. 3.
If\f\bn\fobvious\fc\buse\ffor\f\bn\fobserved\for\freported\fconcern\fis\ffound,\fcorrect\fthe\fc\buse\f
(if\fpossible)\fbefore\fproceeding\fto\fthe\fnext\fstep.\f
4. 4.
If\fthe\fconcern\fis\fnot\fvisu\blly\fevident,\fverify\fthe\fsymptom\f\bnd\frefer\fto\fthe\f
S
ymptom\fCh\brt.\f
Road Test
C\brry\fout\f\b\fro\bd\ftest\fto\fcomp\bre\f\bctu\bl\fvehicle\fbr\bking\fperform\bnce\fwith\fthe\fperform\bnce\f
st\bnd\brds\fexpected\fby\fthe\fdriver.\fThe\f\bbility\fof\fthe\ftest\fdriver\fto\fm\bke\fv\blid\fcomp\brison\f
\bnd\fdetect\fperform\bnce\fdeficiencies\fwill\fdepend\fon\fexperience.\f
The\fdriver\fshould\fh\bve\f\b\fthorough\fknowledge\fof\fbr\bke\fsystem\foper\btion\f\bnd\f\bccepted\f
gener\bl\fperform\bnce\fguidelines\fto\fm\bke\fgood\fcomp\brisons\f\bnd\fdetect\fperform\bnce\f
concerns.\f
An\fexperienced\fbr\bke\ftechnici\bn\fwill\f\blw\bys\fest\bblish\f\b\froute\fth\bt\fwill\fbe\fused\ffor\f\bll\fbr\bke\f
di\bgnosis\fro\bd\ftests.\fThe\fro\bds\fselected\fwill\fbe\fre\bson\bbly\fsmooth\f\bnd\flevel.\fGr\bvel\for\f
bumpy\fro\bds\f\bre\fnot\fsuit\bble\fbec\buse\fthe\fsurf\bce\fdoes\fnot\f\bllow\fthe\ftires\fto\fgrip\fthe\fro\bd\f
equ\blly.\fCrowned\fro\bds\fshould\fbe\f\bvoided\fbec\buse\fof\fthe\fl\brge\f\bmount\fof\fweight\fshifted\fto\f
the\flow\fset\fof\fwheels\fon\fthis\ftype\fof\fro\bd.\fOnce\fthe\froute\fis\fest\bblished\f\bnd\fconsistently\f
used,\fthe\fro\bd\fsurf\bce\fv\bri\bble\fc\bn\fbe\felimin\bted\ffrom\fthe\ftest\fresults.\f
Before\f\b\fro\bd\ftest,\fobt\bin\f\b\fcomplete\fdescription\fof\fthe\fcustomer\fconcerns\for\fsuspected\f
condition.\fFrom\fthe\fdescription,\fthe\ftechnici\bn's\fexperience\fwill\f\bllow\fthe\ftechnici\bn\fto\f
m\btch\fpossible\fc\buses\fwith\fsymptoms.\fCert\bin\fcomponents\fwill\fbe\ft\bgged\f\bs\fpossible\f
suspects\fwhile\fother\fwill\fbe\felimin\bted\fby\fthe\fevidence.\fMore\fimport\bntly,\fthe\fcustomer\f
description\fc\bn\freve\bl\funs\bfe\fconditions\fwhich\fshould\fbe\fchecked\for\fcorrected\fbefore\fthe\f
ro\bd\ftest.\fThe\fdescription\fwill\f\blso\fhelp\fform\fthe\fb\bsic\f\bppro\bch\fto\fthe\fro\bd\ftest\fby\f
n\brrowing\fthe\fconcern\fto\fspecific\fcomponents,\fvehicle\fspeed\for\fconditions.\f
Mechanica\b

Tire\fpressure\f\f

Wheels\f\bnd\ftires\f\f

Fluid\fle\bk\ffrom\fbr\bke\fline(s)\f\f

Fluid\flevel\f\f

Fluid\fcont\bmin\btion\f
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Begin\fthe\fro\bd\ftest\fwith\f\b\fgener\bl\fbr\bke\fperform\bnce\fcheck.\fKeeping\fthe\fdescription\fof\fthe\f
concern\fin\fmind,\ftest\fthe\fbr\bkes\f\bt\fdifferent\fvehicle\fspeeds\fusing\fboth\flight\f\bnd\fhe\bvy\f
ped\bl\fpressure.\fTo\fdetermine\fif\fthe\fconcern\fis\fin\fthe\ffront\for\fre\br\fbr\bking\fsystem,\fuse\fthe\f
br\bke\fped\bl\f\bnd\fthen\fuse\fthe\fp\brking\fbr\bke\fcontrol.\fIf\fthe\fcondition\f(pull,\fvibr\btion,\f
isol\btion)\foccurs\fonly\fwith\fthe\fp\brking\fbr\bke,\fthe\fconcern\fis\fin\fthe\fre\br\fbr\bke\fsystem.\f
Avoid\flocking\fthe\fbr\bkes\f\bnd\fsliding\fthe\ftires.\fLocked\fbr\bkes\f\bnd\fsliding\ftires\fdo\fnot\f
indic\bte\fbr\bke\fefficiency.\fA\fhe\bvily\fbr\bked\f\bnd\fturning\fwheel\fwill\fstop\fthe\fvehicle\fin\f\b\f
shorter\fdist\bnce\fth\bn\flocked\fbr\bkes.\f
If\fthe\fconcern\fbecomes\fevident\fduring\fthis\fcheck,\fverify\fit\ffits\fthe\fdescription\fgiven\fbefore\f
the\fro\bd\ftest.\fIf\fthe\fconcern\fis\fnot\fevident,\f\bttempt\fto\fduplic\bte\fthe\fcondition\fusing\fthe\f
inform\btion\ffrom\fthe\fdescription.\f
If\f\b\fconcern\fexists,\fuse\fthe\fSymptom\fCh\brt\fin\forder\fto\fisol\bte\fit\fto\f\b\fspecific\fsub-system\f
\bnd\fcondition\fdescription.\fFrom\fthis\fdescription,\f\b\flist\fof\fpossible\fsources\fc\bn\fbe\fused\fto\f
further\fn\brrow\fthe\fc\buse\fto\f\b\fspecific\fcomponent\for\fcondition.\f
S\bmptom Chart
Sym\ftomPossib\be SourcesAction
The\fbr\bkes\fpull\for\fdriftWheel\f\blignment\f
\bngles.\f
*CHECK\fthe\fwheel\f\blignment\f\bngles.\fREFER\fto\f
Section\f \f204-00\fSuspension\fSystem\f-\fGener\bl\f
Inf

orm\btion .\f
*
Br\bke\fp\bds.\f
*CHECK\f\bnd\fINSTALL\fnew\fcomponents\f\bs\f
necess\bry.\fREFER\fto\fSection\f \f206-03\fFront\fDisc\f
Br\b

ke \f/\f206-04\fRe\br\fDisc\fBr\bke.\f
*
Br\bke\fdisc.\f
*CHECK\f\bnd\fINSTALL\fnew\fcomponents\f\bs\f
necess\bry.\fREFER\fto\fSection\f \f206-03\fFront\fDisc\f
Br\b

ke \f/\f206-04\fRe\br\fDisc\fBr\bke.\f
*
Br\bke\fc\bliper.\f
*CHECK\f\bnd\fINSTALL\fnew\fcomponents\f\bs\f
necess\bry.\fREFER\fto\fSection\f \f206-03\fFront\fDisc\f
Br\b

ke \f/\f206-04\fRe\br\fDisc\fBr\bke.\f
*
The\fred\fbr\bke\fw\brning\f
indic\btor\fis\f\blw\bys\fonBr\bke\ffluid\flevel\f
sensor.\f
*REFER\fto\fWDS.\f
*
P\brking\fbr\bke\f
control.\f
*RELEASE\f\bnd\fADJUST\fthe\fp\brking\fbr\bke.\fREFER\f
to\fSection\f
\f206-05\fP\brking\fBr\bke\f\bnd\fActu\btion .\f
*
Excessively\fworn\f
br\bke\fp\bds.\f
*CHECK\f\bnd\fINSTALL\fnew\fcomponents\f\bs\f
necess\bry.\fREFER\fto\fSection\f \f206-03\fFront\fDisc\f
Br\b

ke \f/\f206-04\fRe\br\fDisc\fBr\bke.\f
*
Br\bke\fm\bster\f
cylinder\fprim\bry\f
piston\fcup.\f
*INSTALL\f\b\fnew\fbr\bke\fm\bster\fcylinder.\fREFER\fto\f
Section\f
\f206-06\fHydr\bulic\fBr\bke\fActu\btion.\f
*
Vibr\btion\fwhen\fbr\bkes\f
\bre\f\bppliedBr\bke\fp\bds.\f
*CHECK\f\bnd\fINSTALL\fnew\fcomponents\f\bs\f
necess\bry.\fREFER\fto\fSection\f \f206-03\fFront\fDisc\f
Br\b

ke \f/\f206-04\fRe\br\fDisc\fBr\bke.\f
*
Br\bke\fc\bliper.\f
*CHECK\f\bnd\fINSTALL\fnew\fcomponents\f\bs\f
necess\bry.\fREFER\fto\fSection\f \f206-03\fFront\fDisc\f
Br\b

ke \f/\f206-04\fRe\br\fDisc\fBr\bke.\f
*
Br\bke\fdisc.\f
*CHECK\f\bnd\fINSTALL\fnew\fcomponents\f\bs\f
necess\bry.\fREFER\fto\fSection\f \f206-03\fFront\fDisc\f
Br\b

ke \f/\f206-04\fRe\br\fDisc\fBr\bke.\f
*
The\fped\bl\fgoes\fdown\f
f\bstAir\fin\fsystem.\f
*BLEED\fthe\fsystem.\fREFER\fto\fSection\f \f206-00\f
Br\b
ke\fSystem\f-\fGener\bl\fInform\btion .\f
*
Br\bke\fm\bster\f
cylinder\f
*C\brry\fout\fthe\fbr\bke\fm\bster\fcylinder\fcomponent\f
test\fin\fthis\fsection.\f
*
Br\bke\fdisc.\f
*CHECK\f\bnd\fINSTALL\fnew\fcomponents\f\bs\f
necess\bry.\fREFER\fto\fSection\f \f206-03\fFront\fDisc\f
Br\b

ke \f/\f206-04\fRe\br\fDisc\fBr\bke.\f
*
Br\bke\fp\bds.\f
*CHECK\f\bnd\fINSTALL\fnew\fcomponents\f\bs\f
*
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Pinpoint Tests
necess\bry.\fREFER\fto\fSection\f\f206-03\fFront\fDisc\f
Br\b
ke \f/\f206-04\fRe\br\fDisc\fBr\bke.\f
The\fped\bl\fe\bses\fdown\f
slowlyBr\bke\fc\bliper\f
*CHECK\f\bnd\fINSTALL\fnew\fcomponents\f\bs\f
necess\bry.\fCHECK\f\bnd\fINSTALL\fnew\f
components\f\bs\fnecess\bry.\fREFER\fto\fSection\f \f
206

-03\fFront\fDisc\fBr\bke\f/\f 206-04\fRe\br\fDisc\f
Br\b

ke .\f
*
Br\bke\fm\bster\f
cylinder.\f
*C\brry\fout\fthe\fbr\bke\fm\bster\fcylinder\fcomponent\f
test\fin\fthis\fsection.\f
*
The\fped\bl\fis\flow\for\f
feels\fspongyAir\fin\fsystem.\f
*Bleed\fthe\fsystem.\fREFER\fto\fSection\f \f206-00\f
Br\b
ke\fSystem\f-\fGener\bl\fInform\btion .\f
*
Br\bke\fp\bds.\f
*CHECK\f\bnd\fINSTALL\fnew\fcomponents\f\bs\f
necess\bry.\fREFER\fto\fSection\f \f206-03\fFront\fDisc\f
Br \b

ke \f/\f206-04\fRe\br\fDisc\fBr\bke.\f
*
Br\bke\fbooster\f
*CARRY\fout\fthe\fbr\bke\fbooster\fcomponent\ftest\fin\f
this\fsection.\f
*
Br\bke\flockup\fduring\f
light\fbr\bke\fped\bl\fforceBr\bke\fp\bds.\f
*CHECK\f\bnd\fINSTALL\fnew\fcomponents\f\bs\f
necess\bry.\fREFER\fto\fSection\f \f206-03\fFront\fDisc\f
Br\b

ke \f/\f206-04\fRe\br\fDisc\fBr\bke.\f
*
Br\bke\fdisc.\f
*CHECK\f\bnd\fINSTALL\fnew\fcomponents\f\bs\f
necess\bry.\fREFER\fto\fSection\f \f206-03\fFront\fDisc\f
Br\b

ke \f/\f206-04\fRe\br\fDisc\fBr\bke.\f
*
Br\bke\fbooster.\f
*CARRY\fout\fthe\fbr\bke\fbooster\fcomponent\ftest\fin\f
this\fsection.\f
*
Excessive/err\btic\fbr\bke\f
ped\bl\ftr\bvel
Insufficient\f
gre\bse\fon\fsliding\f
p\brts.\f
*APPLY\fgre\bse\fwhere\fnecess\bry.\f
*
Br\bke\fp\bds.\f
*CHECK\f\bnd\fINSTALL\fnew\fcomponents\f\bs\f
necess\bry.\fREFER\fto\fSection\f \f206-03\fFront\fDisc\f
Br\b

ke \f/\f206-04\fRe\br\fDisc\fBr\bke.\f
*
Br\bke\fdisc.\f
*CHECK\f\bnd\fINSTALL\fnew\fcomponents\f\bs\f
necess\bry.\fREFER\fto\fSection\f \f206-03\fFront\fDisc\f
Br\b

ke \f/\f206-04\fRe\br\fDisc\fBr\bke.\f
*
Wheel\fbe\bring.\f
*CHECK\for\fINSTALL\f\b\fnew\fwheel\fbe\bring.\fREFER\f
to\fSection\f \f204-01\fFront\fSuspension .\f
*
Br\bke\fped\bl.\f
*GO\fto\fPinpoint\fTest\f A.\f\f
*
Br\bke\fdr\bgBr\bke\fbooster.\f
*C\brry\fout\fthe\fbr\bke\fbooster\fcomponent\ftest\fin\f
this\fsection.\f
*
Br\bke\fc\bliper.\f
*CHECK\f\bnd\fINSTALL\fnew\fcomponents\f\bs\f
necess\bry.\fREFER\fto\fSection\f \f206-03\fFront\fDisc\f
Br\b

ke \f/\f206-04\fRe\br\fDisc\fBr\bke.\f
*
St\bbility\f\bssist\f
system\f(if\f
equipped)\f
*REFER\fto\fWDS.\f
*
Br\bke\fped\bl.\f
*GO\fto\fPinpoint\fTest\f B.\f\f
*
Slow\for\fincomplete\f
br\bke\fped\bl\freturnSt\bbility\f\bssist\f
system\f(if\f
equipped)\f
*REFER\fto\fWDS.\f
*
Br\bke\fm\bster\f
cylinder.\f
*C\brry\fout\fthe\fbr\bke\fm\bster\fcylinder\fcomponent\f
test\fin\fthis\fsection.\f
*
Br\bke\fped\bl.\f
*GO\fto\fPinpoint\fTest\f C.\f\f
*
PINPOINT TEST A : EXCESSIVE/ERRATIC BRAKE PEDAL TRAVEL
TEST
CONDITIONSDETAILS/RESULTS/ACTIONS
A1: CHECK FOR BRAKE PEDAL RETURN
Стр. 3 из 7
04.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G37387&guid...procarmanuals.com
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Run\fthe\fengine\f\bt\ff\bst\fidle\fwhilst\fm\bking\fsever\bl\fbr\bke\f\bpplic\btions.\f1
Pull\fthe\fbr\bke\fped\bl\fupw\brds.\f2
Rele\bse\fthe\fbr\bke\fped\bl\f\bnd\fme\bsure\fthe\fdist\bnce\ffrom\fthe\frubber\fto\fthe\f
floor.\f3
M\bke\f\b\fh\brd\fbr\bke\f\bpplic\btion.\f4
Rele\bse\fthe\fbr\bke\fped\bl\f\bnd\fme\bsure\fthe\fdist\bnce\ffrom\fbr\bke\fped\bl\f
rubber\fto\fthe\ffloor.\fThe\fbr\bke\fped\bl\fshould\freturn\fto\fits\forigin\bl\fposition.\f5
Does\fthe\fbr\bke\fped\bl\freturn\fto\fits\forigin\bl\fposition?\f
Yes Vehicle\fis\fOK.\f
No
GO\fto\fA2.\f\f
A2: CHECK FOR BRAKE PEDAL BINDING
Check\fthe\fbr\bke\fped\bl\fto\fm\bke\fsure\fit\fis\foper\bting\ffreely.\f1
Is\fthe\fbr\bke\fped\bl\foper\bting\ffreely?\f
Yes INSTALL\f\b\fnew\fbr\bke\fbooster.\fREFER\fto\fSection\f \f206-07\fPower\fBr\bke\f
Act

u\btion .\fTEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
No R

EPAIR\for\fINSTALL\fnew\fbr\bke\fped\bl\f\bnd\fbr\bcket.\fTEST\fthe\fsystem\ffor\f
norm\bl\foper\btion.\f
PINPOINT TEST B : BRAKES DRAG
TEST
CONDITIONSDETAILS/RESULTS/ACTIONS
B1: CHECK FOR BRAKE PEDAL RETURN
Run\fthe\fengine\f\bt\ff\bst\fidle\fwhilst\fm\bking\fsever\bl\fbr\bke\f\bpplic\btions\f1
Pull\fthe\fbr\bke\fped\bl\fupw\brds.\f2
Rele\bse\fthe\fbr\bke\fped\bl\f\bnd\fme\bsure\fthe\fdist\bnce\ffrom\fthe\frubber\fto\fthe\f
floor.\f3
M\bke\f\b\fh\brd\fbr\bke\f\bpplic\btion.\f4
Rele\bse\fthe\fbr\bke\fped\bl\f\bnd\fme\bsure\fthe\fdist\bnce\ffrom\fbr\bke\fped\bl\f
rubber\fto\fthe\ffloor.\fThe\fbr\bke\fped\bl\fshould\freturn\fto\fits\forigin\bl\fposition.\f5
Does\fthe\fbr\bke\fped\bl\freturn\fto\fits\forigin\bl\fposition?\f
Yes Vehicle\fis\fOK.\f
No
GO\fto\fB2.\f\f
B2: CHECK FOR BRAKE PEDAL BINDING
Check\fthe\fbr\bke\fped\bl\fto\fm\bke\fsure\fit\fis\foper\bting\ffreely.\f1
Is\fthe\fbr\bke\fped\bl\foper\bting\ffreely?\f
Yes INSTALL\f\b\fnew\fbr\bke\fbooster.\fREFER\fto\fSection\f \f206-07\fPower\fBr\bke\f
Act

u\btion .\fTEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
No
R

EPAIR\for\fINSTALL\fnew\fbr\bke\fped\bl\f\bnd\fbr\bcket.\fTEST\fthe\fsystem\ffor\f
norm\bl\foper\btion.\f
PINPOINT TEST C : SLOW OR INCOMPLETE BRAKE PEDAL RETURN
TEST
CONDITIONSDETAILS/RESULTS/ACTIONS
C1: CHECK FOR BRAKE PEDAL RETURN
Run\fthe\fengine\f\bt\ff\bst\fidle\fwhilst\fm\bking\fsever\bl\fbr\bke\f\bpplic\btions.\f1
Pull\fthe\fbr\bke\fped\bl\fupw\brds.\f2
Rele\bse\fthe\fbr\bke\fped\bl\f\bnd\fme\bsure\fthe\fdist\bnce\ffrom\fthe\frubber\fto\fthe\f
floor.\f3
Стр. 4 из 7
04.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G37387&guid...procarmanuals.com
http://vnx.su

Component Tests
Brake Booster 1. 1.
Inspect\f\bll\fhoses\f\bnd\fconnections.\fAll\funused\fv\bcuum\fconnectors\fshould\fbe\f
c
\bpped.\fHoses\f\bnd\ftheir\fconnections\fshould\fbe\fcorrectly\fsecured\f\bnd\fin\fgood\f
condition\fwith\fno\fholes\f\bnd\fno\fcoll\bpsed\f\bre\bs.\fInspect\fthe\fbr\bke\fbooster\fcheck\f
v\blve\ffor\fd\bm\bge.\f
2. 2.
Check\fthe\fhydr\bulic\fbr\bke\fsystem\ffor\fle\bks\for\flow\ffluid.\f
3

. 3.
With\fthe\ftr\bnsmission\fin\fPARK\f(\butom\btic\ftr\bnsmission),\fstop\fthe\fengine\f\bnd\f
o
per\bte\fthe\fp\brking\fbr\bke.\fOper\bte\fthe\fbr\bke\fped\bl\fsever\bl\ftimes\fto\fexh\bust\f\bll\f
v\bcuum\fin\fthe\fsystem.\f
4. 4.
With\fthe\fengine\fturned\fOFF\f\bnd\f\bll\fv\bcuum\fin\fthe\fsystem\fexh\busted\foper\bte\fthe\f
b
r\bke\fped\bl\f\bnd\fhold\fit\fdown.\fSt\brt\fthe\fengine.\fIf\fthe\fv\bcuum\fsystem\fis\foper\bting,\f
the\fbr\bke\fped\bl\fwill\ftend\fto\fmove\fdownw\brd\funder\fconst\bnt\ffoot\fpressure.\fIf\fno\f
motion\fis\ffelt,\fthe\fv\bcuum\fbooster\fsystem\fis\fnot\ffunctioning.\f
5. 5.
Remove\fthe\fv\bcuum\fhose\ffrom\fthe\fbr\bke\fbooster.\fM\bnifold\fv\bcuum\fshould\fbe\f
\b
v\bil\bble\f\bt\fthe\fbr\bke\fbooster\fend\fof\fthe\fhose\fwith\fthe\fengine\f\bt\fidle\fspeed\f\bnd\fthe\f
tr\bnsmission\fin\fPARK\for\fNEUTRAL.\fM\bke\fsure\fth\bt\f\bll\funused\fv\bcuum\foutlets\f\bre\f
correctly\fc\bpped,\fhose\fconnectors\f\bre\fcorrectly\fsecured\f\bnd\fv\bcuum\fhoses\f\bre\fin\f
good\fcondition.\fWhen\fit\fis\fest\bblished\fth\bt\fm\bnifold\fv\bcuum\fis\f\bv\bil\bble\fto\fthe\f
br\bke\fbooster,\fconnect\fthe\fv\bcuum\fhose\fto\fthe\fbr\bke\fbooster\f\bnd\frepe\bt\fStep\f3.\fIf\f
no\fdownw\brd\fmovement\fof\fthe\fbr\bke\fped\bl\fis\ffelt,\fthe\fv\bcuum\fbooster\fsystem\fis\f
not\ffunctioning.\f
6. 6.
Run\fthe\fengine\ffor\f\b\fminimum\fof\f10\fseconds\f\bt\ff\bst\fidle.\fStop\fthe\fengine\f\bnd\flet\f
t
he\fvehicle\fst\bnd\ffor\f10\fminutes.\fThen,\foper\bte\fthe\fbr\bke\fped\bl\fwith\f\bpproxim\btely\f
98N\f(20\flb)\fof\fforce.\fThe\fped\bl\ffeel\f(br\bke\f\bpplic\btions)\fshould\fbe\fthe\fs\bme\f\bs\f
noted\fwith\fthe\fengine\frunning.\fIf\fthe\fbr\bke\fped\bl\ffeels\fh\brd\f(no\fpower\f\bssist),\f
inst\bll\f\b\fnew\fcheck\fv\blve\f\bnd\fthen\frepe\bt\fthe\ftesting.\fIf\fthe\fbr\bke\fped\bl\fstill\ffeels\f
h\brd,\finst\bll\f\b\fnew\fbr\bke\fbooster.\fIf\fthe\fbr\bke\fped\bl\fmovement\ffeels\fspongy,\fbleed\f
the\fbr\bke\fsystem.\fRefer\fto\fGener\bl\fProcedures.\f
Brake Master C\blinder
Usu\blly,\fthe\ffirst\f\bnd\fstrongest\findic\btor\fof\f\bnything\fwrong\fin\fthe\fbr\bke\fsystem\fis\f\b\ffeeling\f
t h

rough\fthe\fbr\bke\fped\bl.\fIn\fdi\bgnosing\fthe\fcondition\fof\fthe\fbr\bke\fm\bster\fcylinder,\fcheck\f
M\bke\f\b\fh\brd\fbr\bke\f\bpplic\btion.\f4
Rele\bse\fthe\fbr\bke\fped\bl\f\bnd\fme\bsure\fthe\fdist\bnce\ffrom\fbr\bke\fped\bl\f
rubber\fto\fthe\ffloor.\fThe\fbr\bke\fped\bl\fshould\freturn\fto\fits\forigin\bl\fposition.\f5
Does\fthe\fbr\bke\fped\bl\freturn\fto\fits\forigin\bl\fposition?\f
Yes Vehicle\fis\fOK.\f
No GO\fto\fC2 .\f\f
C2: CHECK FOR BRAKE PEDAL BINDING
Check\fthe\fbr\bke\fped\bl\fto\fm\bke\fsure\fit\fis\foper\bting\ffreely.\f1
Is\fthe\fbr\bke\fped\bl\foper\bting\ffreely?\f
Yes
INSTALL\f\b\fnew\fbr\bke\fbooster.\fREFER\fto\fSection\f \f206-07\fPower\fBr\bke\f
Ac t

u\btion .\fTEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
No R

EPAIR\for\fINSTALL\fnew\fbr\bke\fped\bl\f\bnd\fbr\bcket.\fTEST\fthe\fsystem\ffor\f
norm\bl\foper\btion.\f
Стр. 5 из 7
04.01.2013http://127.0.0.1:8888/wsm/js/procedure.do?variantId=1431&proc-uid=G37387&guid...procarmanuals.com
http://vnx.su