Attention! Be sure to replace all pads on the vehicle axle, even if only one pad is worn. If you reinstall the old brake pads, be sure to mark them before removing them.
To remove the front brake pads:
- loosen the front wheel mounting bolts, then raise the front of the car and secure it on stands. Unscrew the mounting bolts and remove the wheel;
- remove the cap from the compensation tank with brake fluid;
- partially pump out the brake fluid from the reservoir with a syringe;
- install the cap on the compensation tank with brake fluid;
Pic. 8.7. Bolt location (1) caliper lower guide pin mounting
- remove bolt 1 (pic. 8.7) fixing the lower guide pin;
Pic. 8.8. BOSCH front brake caliper: 1 - protective corrugated cap; 2 - cuff; 3 - piston; 4 - support
- turn the caliper 4 on the upper guide pin (pic. 8.8) up;
- remove the brake pads from the caliper holder;
- clean dust and dirt from the caliper, and rust from the edge of the brake disc;
- clean the brake disc with HENKEL solvent;
- check that there are no leaks of brake fluid from under piston 3;
- check the condition and correct fit of the cuff 2 and protective corrugated caps 1;
- check the brake disc for cracks, especially around the wheel bolt holes, as well as for wear or mechanical damage, and replace both discs if necessary;
- measure the thickness of the brake disc;
- make sure that the guide pins of the caliper slide freely;
- replace defective parts if necessary.
Attention! Do not depress the brake pedal with the brake pads removed. When replacing brake pads, do not unscrew the brake hose.
To install the front brake pads:
Pic. 8.9. Using the special tool FACOM D60 A (1) for pushing the piston into the caliper
- press the piston into the caliper using the special tool FACOM D60 A 1 (pic. 8.9). In addition to the FACOM D60 A 1 tool, you can also press the piston into the caliper with a wooden rod or a hammer handle. At the same time, make sure that the piston is not warped and the surfaces of the piston and cuff are not damaged. When the piston is pressed in, the brake fluid is forced out of the brake cylinder into the compensation tank, so constantly monitor the fluid level in the tank, and if necessary, pump out a small amount from the tank;
- install the brake pads in the front brake caliper holder;
- lower the caliper down;
Attention! Lower the caliper carefully so as not to pinch the top guide pin.
- apply a locking compound to the thread of the guide pin mounting bolt to prevent its self-unscrewing, screw in the bolt and tighten it with a torque of 30 Nm;
- similarly replace the brake pads on the second front wheel;
- check the brake fluid level in the reservoir, top up if necessary;
- start the engine and repeatedly, calmly and with increasing effort, press the brake pedal several times so that the brake pads are pressed against the brake disc;
- after installing new brake pads, avoid sudden braking for the first 200 km of the vehicle.