On the surface of the brake discs there should be no grooves formed as a result of friction due to contamination. These grooves lead to premature wear of new brake linings and reduce braking efficiency. Grooved brake discs can be refinished by grinding if they are not worn and their thickness allows this. The blue color of the brake disc metal can be ignored.
2. Replace brake discs on both wheels at the same time. Replacing the brake disc on only one wheel can result in uneven braking of the wheels.
3. Install in front of the car on the goats.
4. Remove the wheel.
5. Turn out bolts of fastening of a support and remove a support. Do not disconnect the brake hose from the caliper.
6. Remove the Phillips screw, if present.
7. Remove the brake disc from the hub. If it does not give in, then knock it down with a hammer, provided that this disk will no longer be installed.
8. Before installing a new brake disc, clean the surface of the hub that the disc rests on.
When replacing the brake pads, the brake pads of both wheel brakes must be replaced. When replacing brake pads on a Girling brake (Girling) two new self-locking caliper mounting bolts are needed. They are included in the brake lining kit. When replacing the brake pads of the ATE brake mechanism, it is not necessary to change the old bolts for new ones.
As the brake pads wear, the pistons in the wheel cylinders move forward more and more. Therefore, before installing new brake pads, they must be pressed back. This forces the brake fluid back into the expansion tank. If the brake fluid was previously added to the reservoir, it is possible that as a result the amount of fluid in the reservoir will be excessive. In this case, remove the excess liquid in the reservoir so that it does not spill out and damage adjacent parts.
9. Install in front of the car on the goats.
10. Remove the wheel.
11. Turn the steering wheel all the way to provide access to the brake pads.
12. ATE brake mechanism. Remove the protective cover on the inside of the brake mechanism.
13. Insert a socket wrench into the hole on the head of the lower brake caliper mounting bolt and remove the bolt (see illustration). Do not unscrew the upper bracket bolt.
14. Raise the caliper (brace) up. If both fastening bolts are unscrewed, then the bracket can be removed and fixed to the body.
15. Girling brake mechanism. Remove only the lower brake caliper bolt. While doing this, hold the guide pin on the hexagon to prevent it from turning (see illustration).
16. Tilt the caliper up (see illustration).
17. Both types of brake mechanisms. Remove the brake pads from the guides (see illustration).
18. Press the piston of the wheel cylinder with a clamp. Place a piece of wood between the piston and the clamp support ring to prevent damage to the piston (see illustration).
The floating caliper pistons with two wheel cylinders are pressed in the same way both together or one at a time.
19. Check that the wheel cylinder piston heat shield is installed correctly (see illustration 2.17).
20. Install new brake pads.
21. Reinstall the caliper (brace) and secure it with screws. Tighten the ATE brake caliper bolt with a torque of 25 Nm and put on the protective cap.
22. Replace the Girling brake caliper lower bolt with a new one and tighten to 35 Nm. Do not tighten the upper mounting bolt. This bolt is also self-locking and over tightening it will break this effect. When tightening the bottom bolt, hold the guide pin with a thin wrench from turning. If you use a wrench that is thick enough to keep the guide pin from turning, then the wrench will tighten when tightened and the tightening torque will be set incorrectly.
23. Depress the brake pedal several times to allow the brake pads to self-adjust.
Attention! After installing new brake pads, avoid sudden braking if possible until the first 500 km.
The brake calipers of the front wheels are attached with two rip bolts to the suspension strut. Under no circumstances should these bolts be replaced with regular ones. Torque for rip bolts 125 Nm.
If the cuff of the wheel cylinder in the caliper is damaged, it must be replaced immediately. Otherwise, dirt entering the cylinder will jam its piston. The cuff is sold complete with a piston sealing ring. In order to install these parts, the piston must be squeezed out of the cylinder. We recommend having this work done by a workshop by removing the caliper yourself and bringing it to the workshop.
Attention! The brake system must be bled if the brake hose or pipe had to be disconnected to carry out repairs.
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