Withdrawal
1. Mark with paint the position of the wheels relative to the hub. This will allow the assembly to install the balanced wheel in its original position. Loosen the wheel bolts with the vehicle on the ground. Raise the car and place it on stands. Remove wheels.
2. Front brake with FN-3 caliper: Remove 2 fixing screws (indicated by arrows) and remove the guide caliper from the brake disc. Caliper FN–3, shown in illustration Rear wheel disc brake in subsection Removal and installation of disk brake mechanisms of back wheels.
3. Front brake with FN-III caliper: Remove the brake pads, while referring to subsection Replacing the front brake pads.
4. Rear wheel brakes: Unscrew the 2 bolts securing the caliper at the axle beam and remove the caliper from the brake disc, while referring to the illustration Rear wheel disc brake in subsection Removal and installation of disk brake mechanisms of back wheels.
5. Attach the caliper to the wire hook on the suspension so that the brake hose is not under tension.
Warning: Do not disconnect the brake hose, otherwise, after installation, you will have to remove air from the brake system.
6. If the caliper is to be completely removed:
- At the front caliper, unscrew the brake pipe at the clutch.
- At the rear caliper, first unscrew the brake pipe at the junction with the hose. Then, if necessary, unscrew the hose from the caliper. Additionally, disconnect the parking brake cable.
Warning: When the brake circuit is opened, brake fluid flows out. The liquid must be collected in a container designed specifically for this. You can also pump out the liquid beforehand from the tank.
7. Remove the Phillips head screw securing the brake discs.
8. Remove the brake disc.
Warning: Do not remove the brake disc from the hub by force (hammer blows). You need to use a rust remover for this. If the disc can only be removed with hammer blows, for safety reasons the brake discs and wheel bearings must be replaced. The replacement of bearings should be carried out in a workshop, as only there, as a rule, can an appropriate press be available. After using the puller, it is also necessary to replace the brake discs.
Installation
To obtain uniform braking on both sides, both brake discs must have the same surface in terms of roughness. Therefore, it is imperative to replace both brake discs. In service station conditions, you can check the disc for runout. Maximum runout of the disc surface: 0.05 mm; maximum allowable disc thickness difference: 0.01 mm.
1. Measure a thickness of a brake disk, thus address to the corresponding Section.
2. If present, remove rust from brake disc flange and hub.
3. Clean the new disc with thinner to remove the protective varnish.
4. Install new brake discs on the hub and secure with Phillips head screws.
5. Front wheel brakes with FS–III caliper: Establish brake shoes, at the same time address to subsection Replacing the front brake pads.
6. Front wheel brakes with FS-3 caliper: Install the caliper with brake pads. When doing this, make sure that the brake hose is not kinked or stretched. Fasten the caliper with a torque of 125 Nm.
Warning: If old ribbed bolts are reused, clean the ribs first with a brush.
7. Rear wheel brakes: fasten with a torque of 65 Nm. Connect the parking brake cable.
Warning: If the brake hose was removed, install it and bleed the air from the brake system, while referring to subsection Removal of air from the brake system.
8. Install the wheels so that the markings made during removal match. Pre-lubricate with a thin layer of bearing grease the centering collar of the rim on the hub. Tighten the wheel bolts. Lower the vehicle onto the wheels and tighten the bolts crosswise to 120 Nm.
Warning: Press the brake pedal hard several times until you feel a distinct resistance on the pedal. Thus, the pads will lie against the brake disc and take their place.
9. Check the brake fluid level in the reservoir. Top up if necessary.
10. Rear wheel brakes: Adjust the parking brake, while referring to subsection Parking brake adjustment.
Warning: Do a Reliability Check:
- Are the brake hoses securely tightened?
- Is the brake hose secured in the holder?
- Are the bleed fittings tight?
- Is there enough brake fluid in the reservoir?
- With the engine running, check the system for leaks. To do this, press the brake pedal with a force of 200–300 N (20–30 kg) within 10 s. The pedal must not move. Check all connections for leaks
11. Carefully let the new brake pads run in. To do this, brake the car several times from a speed of 80 to 40 km / h by lightly pressing the pedal. Let the brake cool down between braking.
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