Contents: Removal ⬇ Installation ⬇
Removal
Loosen the front wheel mounting nuts. Raise the front of the vehicle and support it on jack stands.
Loosen the nuts and remove the front wheel.
Loosen the locking bolt (1) securing the caliper, lift the caliper up, remove it from the brake pad guide and secure it to the front suspension strut with soft wire, without disconnecting the brake hose from the caliper.
Disconnect the connector from the brake pad wear sensor.
Remove 2 clamps (3), 2 shims (2) and 2 brake shoes (1) from the brake shoe guide.
Remove 2 bolts and brake shoe guide (4).
Remove 6 bolts (1) and remove the cover from the wheel hub.
Remove the retaining (1) and adjusting (2) rings from the drive shaft.
Remove the hub drive flange (3) from the drive shaft.
Remove 3 screws (1) and lock washer from wheel hub nut.
Using a special KM-741 wrench, unscrew the hub mounting nut.
Remove the outer bearing inner race from the wheel hub.
Remove the hub with the brake disc from the steering knuckle.
Clean and inspect bearings for wear or damage.
Secure the hub in a vice with soft jaws, remove the 3 bolts (1) and remove the ABS rotor from the brake disc.
Remove 6 bolts (1) and remove the brake disc from the hub.
Installation
Secure the hub in a vice with soft jaws, install a new brake disc on the hub and secure with 6 bolts, tightening them to a torque of 100 Nm.
Install the ABS rotor onto the brake discs and secure with 3 bolts, tightening them to a torque of 18 Nm.
Fill the bearings with universal grease and lubricate the working edge of the seal, install the brake disc assembly with the hub on the steering knuckle. Install the outer bearing inner race onto the wheel hub.
Using a special KM-741-A wrench, tighten the hub mounting nut to a torque of 29 N·m, then completely loosen the nut.
Using a special KM-741-A wrench, tighten the nut so that the preload of the hub bearings, measured by a spring dynamometer connected to the wheel mounting stud, corresponds to the required value.
Front wheel hub bearing preload:
- new:20-25 Nm
- reinstalled:12-18 Nm.
If the preload is not as required, adjust it by turning the hub mounting nut.
Install the locking washer and screw in the bolts (1) securing the washer.
Note: If the bolt hole in the washer does not line up with the bolt hole in the nut, turn the washer over. If the holes do not line up again, turn the nut slightly, just until the holes in the washer and nut line up.
Tighten the retaining bolts until their heads do not protrude above the surface of the washer.
Install the drive flange (1) of the hub onto the drive shaft and secure with 3 bolts (4), tightening them to a torque of 55 Nm.
Install the adjusting (2) and retaining (3) rings on the drive shaft.
Using a dial indicator, check the clearance between the hub drive flange and the drive shaft retaining ring. If necessary, select an adjusting ring of such thickness that the gap is within 0-0.3 mm.
Note: Adjusting rings are available in thicknesses of 0.2, 0.3, 0.5 and 1.0 mm.
Remove 3 bolts (4) and remove the drive flange (1) from the wheel hub.
Remove the retaining (3) and adjusting (2) rings from the drive shaft.
Install the hub drive flange onto the drive shaft.
Install the adjusting and retaining rings onto the drive shaft.
Apply a thin layer of sealant to the mating surfaces of the cover and drive flange.
Install the cover and secure the hub drive flange and cover with 6 bolts (1), tightening them to a torque of 55 Nm.
Install the brake shoe guide (4) onto the steering knuckle.
Clean the threads of the brake shoe guide mounting bolts, apply locking compound to the threads, screw in the bolts and tighten them to a torque of 150 Nm.
Note: When installing a new brake disc, use solvent to clean off any grease.
Install the brake pads (1), shims (2) and clamps (3) onto the brake pad guide and connect the connector to the brake pad wear sensor.
Note: Check the brake fluid level in the brake system hydraulic drive reservoir.
Lower the caliper onto the brake pads and press it into position, then screw in and tighten the locking bolt (1) to 74 N·m.
Replace the brake disc on the second front wheel in the same manner.
Install the wheel and secure with nuts, tightening them by hand.
Lower the car.
Tighten the wheel nuts to 118 Nm.
Press the brake pedal several times to press the pads against the brake disc.
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