Removing
Safety note
There is a risk of accident when lifting the vehicle! You must first read the section «Vehicle lifting».
Mark the direction of tire rotation with an arrow. Loosen wheel bolts. Raise the car in front on the goats and remove the wheels.
Attention: Strictly follow the instructions given in chapter «Removal and installation of a wheel».
Front wheel brake: remove the brake pads and brake caliper, see relevant chapter.
Rear wheel brake: Remove the 2 hexagon socket head screws -13- securing the brake pad guide to the axle carrier, see drawing S46-0097 on page 136.
Suspend the brake caliper on a wire hook to the body so that the brake hose is not twisted or stretched.
Attention: If the brake caliper does not need to be completely removed, do not let go of the brake hose. Otherwise, after installation, you will have to remove air from the brake system.
If the brake caliper is to be removed completely:
- For the front caliper, unscrew the brake pipe at the brake hose connector.
- For the rear caliper, first unscrew the brake pipe at the connection from the brake hose, and then, if necessary, the brake hose from the caliper. Additionally, the handbrake cable must be unhooked.
Safety instructions:
When opening the circulation circuit, the brake fluid flows out. Collect the fluid in a bottle designed exclusively for brake fluid. You can also suck the brake fluid out of the expansion tank with a siphon.
Loosen the two screws securing the brake disc, see the corresponding figure showing the brake mechanism.
Remove brake disc.
Caution: Remove the brake disc from the wheel hub without using force (hammer blows). Instead, use a conventional rust converter to avoid damage to the brake disc. If removal without hammering is not possible, replace the brake disc and wheel bearing with new ones for safety reasons. If a puller was used, also replace the brake disc.
Installation
In order to guarantee uniform braking on both sides, both brake discs must have the same wear pattern and roughness depth. Therefore, it is imperative to replace or grind both brake discs.
At the service station, brake discs can be checked for runout. The measured disc runout at the braking surface must not exceed 0.05 mm. The disc thickness tolerance must not exceed 0.01 mm.
Measure the thickness of the brake disc, see relevant chapter.
If present, remove rust from brake disc flange and wheel hub.
Remove protective varnish from new brake discs with a cloth soaked in nitro thinner.
Install the brake disc onto the wheel hub and secure with a Phillips head screw. Tighten screw to 4 Nm.
Insert brake pads and screw on brake caliper, see relevant chapter.
Rear wheel brake: adjust the handbrake, see relevant chapter.
Attention: If it was disconnected, then screw on the brake hose and bleed the air from the brake system, see the relevant chapter.
Ensure the same direction of rotation of the tires, bolt the wheels, lower the vehicle and only then tighten the wheel bolts in a crosswise manner to 120 Nm.
Attention: Strictly follow the instructions given in chapter «Removal and installation of a wheel».
Depress the brake pedal strongly repeatedly while the vehicle is stationary until strong resistance is felt.
Check and, if necessary, top up the brake fluid level in the reservoir.
Attention, perform a security compliance check:
- Are the brake lines tight?
- Is the brake hose in the holder?
- Are the bleed valves tight?
- Is there enough fluid in the brake system?
- With the engine running, perform a leak test. To do this, act on the brake pedal with a force of 200 to 300 N for about 10 seconds (from 20 to 30 kg). Do not loosen the brake pedal. Check all connections for tightness.
Carefully run in new brake pads by repeatedly braking the vehicle from a speed of 80 km/h to 40 km/h by lightly depressing the brake pedal. Allow the brakes to cool down between braking.
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