Front brake caliper parts for vehicles produced since mid-1995: 1 - protective cover; 2 - air bleed nipple; 3 - retaining ring; 4 - dust ring; 5 - piston; 6 - cuff; 7 - support
When repairing the caliper, follow the instructions given in subsection 12.1.2 for the caliper of a vehicle manufactured since mid-1995.
Installing the caliper
If there are any external defects in the brake hose connection seals, they should be replaced.
1. If the shoe guide was removed, install and bolt it to the axle housing.
2. Tighten the bolts to a torque of 104 Nm.
3. Attach the brake hose to the caliper, making sure the hose is positioned correctly. The guide pin should fit into the caliper hole.
4. Tighten the hollow brake hose connection bolt to a torque of 35 Nm.
5. Tighten the air bleed nipples to 8 Nm and close with caps.
6. Reinstall the brake pads as described above.
7. Remove the polyethylene from the filler neck of the master cylinder reservoir.
8. Add brake fluid if necessary and tighten the reservoir cap.
9. Other work is carried out in the reverse order of removal.
10. Bleed the brake system as described below.
11. After assembly, check the system for leaks.
12. Check the operation of the braking system while the vehicle is moving.
Before removing the brake disc, it must be checked for runout, as the disc may be deformed. The brake disc is secured with a Torx head bolt. However, the bolt does not fully press the disc to the wheel hub. To ensure a complete fit, one of the wheel mounting bolts is screwed with a spacer sleeve into the hub opposite the brake disc mounting bolt and clamps the hub. This ensures uniform fastening on the right and left.
The disc runout test is carried out in accordance with the description given in Section 1. Brake discs can be ground if necessary. The minimum permissible disc thickness is given in Specifications.
The brake disc is removed as follows:
1. If the wheel has already been removed, as was done above, remove the wheel mounting bolt used to check the runout.
2. Remove the brake disc and, as described in Section 2, tie the caliper to the chassis with wire.
3. Remove both bolts and disconnect the guide from the brake disc.
4. Use a special key to unscrew the mounting bolt on the end surface of the brake disc. The bolt has a Torx head.
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5. Remove the brake disc from the wheel hub. If necessary, you can use a rubber mallet for this purpose.
Before installing the brake disc, clean the mating surfaces of the disc and wheel hub with fine sandpaper. If a new brake disc is installed, it must be cleaned of grease.
1. Install the brake disc and tap it with a rubber hammer.
2. Screw in and tighten the mounting bolt.
3. Check the brake disc for runout as described above.
4. Unexpected beating may be a result of foreign particles getting between the mating planes of the disc and the hub. Then disassemble the connection again, clean and reassemble.
5. Install the guide and tighten its mounting bolts to a torque of 104 Nm.
6. Install the brake shoes as described in Section 2, observing the tightening torque of the guide pins. On the rear calipers, the guide pins are tightened with a torque of 44 Nm.
7. Lower the vehicle onto its wheels and tighten the wheel mounting bolts to 110 Nm.
Please note! Light alloy wheels are secured with a torque of 120 Nm.
Note: The thickness of the brake discs can be measured without removing them. This is done with a caliper as shown. Please note the differences in execution.
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