Section3 Removal and InstallationI. Precautions for removal and installation1. Firstly use diagnostic instrument to find out source of trouble, then repair.
2. Repair front prior use excluding mineral oil of detergent will surface clean Neatness ; repair when should note
before repair, use detergent without mineral oil to wipe off surface; pay attention to cleaning during repair, only
use rag without wool to wipe removed components.
3. Only use original factory spare parts, and new spare parts could only be unpacked just before installation.
4. Return liquid pump motor and hydraulic controller (HCU) is integrated structure, can not be separated.MK-60 ABS system -ABS System Check/ Removal and Installation5-116 d. Rotate the wheel at speed of about 1 / 2 turns per second, use multimeter or oscillograph to measure output
voltage
Terminal 45-46
Terminal 33-34
Terminal 37-36
Terminal 42-43
Output voltage
When use multimeter for measurement
See front wheel sensor drawing for front wheel.
See rear wheel sensor drawing for rear wheel
When use oscillograph for measurement
See relevant standard for front wheel.
See relevant standard for rear wheel.
e. If output voltage is not in above-mentioned range, the cause might be the following:
Air gap between sensor and pulse ring is too large.
Sensor fails.
Check sensor resistance value (1. 0 - 1. 3 k ohm).
Take four points on pulse ring to check air gap between pulse ring and wheel speed sensor (pulse ring
distortion).
2. Check hydraulic pressure unit HCU
a. Jack up vehicle to confirm that wheel may rotate freely.
b. Release manual brake.
c. After connecting fault diagnosis instrument, turn ignition switch to ON, here it is not necessary to start up
engine.
e. Check with reference to hydraulic control unit diagnosis.
Note: when connect or remove fault diagnosis instrument, ignition switch must be in OFF position
(f). Flatten the edge with hammer or sizing block, and remove the burr with file to make sure that it is aligned
with the both side alternative plates with a clearance not more than 1mm;
(g). Replace the plate, and clamp it with pincers. Carry out the spot welding along the seam at a space of
approximately 50mm;
(h). Make the welding from the center to both sides alternately block by block. Which can reduce the
deformation;
(i). Strike the welding line with the hammer or sizing block to remove the retaining stress. Polish the welding
lien wit the file or manual grinding wheel to make it even and smooth for the painting.
c. Repair for Accidented Damage
(a). Plate work flattening
When the accidented damage occurs on the plate work of the body, it can be repaired by means of beating.
In the repair process, start from Point C as shown in Fig. 5-26. Put the sizing block on the convex point, and beat
it with the hammer and change the block's position correspondingly. When the convex point is flattened, the
concaved part in Point B will rise. Similar wit the original profile of the plate, for the remaining dent, a sizing block
with the same radian can be employed. Press the bottom of the plate with hand, and beat the high point of the dent
with the hammer. (Fig. 5-27)Fig. 5-27 Plate Work Flattening (II)
A. Hammer B. Plate work
C. Sizing block Fig. 5-26 Plate Work Flattening (I)
A. Impact point B. Concaved point after impact
C. Convex point after impactFig. 5-28 Heating & Planishing
Convex Point
1. Heating pointBody Repair -Repair After Body Damage7-19 In the beating process, beat the work piece heavily at the beginning and lightly at the end. Attention shall
be paid to reduce the number of beating as possible as it can. Don't beat the same points repeatedly to prevent the
metal plate extending locally, which can complicate the repair work.
For the larger arc concave, a sizing block can be used under the center of the concave. The area of the sizing
block shall be a little larger. Jack the concaved plate up with a supporting tool. Sometime, heat the concaved part
to wine color to reduce the force. When jacking the plate up, a little excess is acceptable. (Fig. 5-28)
(b) Thermal contraction
When the concave is jacked up, if the plate extends seriously and the area is large, the thermal contraction
method can be used in case that the traditional methods don't work. (Fig. 5-29)
Heat the work piece to cerise color with oxyacetylene flame. The heating scope depends on the degree of extension.
If the extension is serious or the area is large, the heating point shall be larger relatively (diameter: approx.20-
30mm). If the extension is not serious or the area is small, the heating point shall be a little smaller (diameter:
approx.10-15mm). After the heating, beat the heating point immediately. In the beating process, a proper sizing
block is used under the plate. After it is cooled down, beat it lightly with the hammer.
The contraction starts from the highest point to the center, and then to the edge. Heat and flatten the extended
part repeatedly till the plate is flattened fully. If the convex part is too high, compress it to one half of the original
height. After it is cooled down, heat it at the original heating point till the other half of convex part is removed.
