Warning: On models equipped with ABS, before opening the hydraulic system, disconnect the battery and do not connect it until the robot has finished bleeding and filled the reservoir with fluid. If this is not done, air may enter the ABS hydraulic system. which will require specialized diagnostic equipment to remove - you will have to seek help from a dealer.
Note: Please refer to the warnings at the beginning of the paragraphs before starting work 2 and 4, containing information about the harmfulness of brake fluid and asbestos dust.
Withdrawal
1. Apply the handbrake and raise the front of the car with a jack, install the safety supports. Remove the corresponding wheel. When removing the wheels, wrap one bolt into the hubs so that the brake discs do not move relative to the hub.
2. Remove the cap from the brake fluid reservoir and place a circle of polyethylene film under it to seal the cap tightly and minimize brake fluid loss when the hose is unscrewed. Acting otherwise, you can pinch the hose with a clamp or wrench "parrot".
3. If necessary, disconnect the wiring from the brake pad wear sensor, disconnect the sensor from the connector on the caliper bracket.
4. Clean the area around the tube connection. Loosen the hose connection nut. Remove the mounting bracket from the caliper and remove the tube. Plug the tube and hole in the caliper to prevent dirt from entering the system and spilling brake fluid. Rinse spilled liquid immediately with cold water.
5. On models with ATE/Teves calipers, carefully pry off the retaining spring with a screwdriver. Remove the plugs from the guide bushings and unscrew the guide mounting bolts.
6. On models with Lucas calipers, holding the guide pins with an open-end wrench, unscrew and remove the bolts of their fastening
7. Remove the caliper, freeing it from the wear sensor wiring (if available). Remove the inner brake pad from the piston and the outer pad from the caliper bracket. Loosen the bolts and remove the caliper bracket.
Repair
8. On a workbench, clean and wash off dirt and rust from the caliper using brake cleaning fluid, without inhaling dust, so as not to harm your health.
9. Remove the piston from the caliper housing and remove the boot.
10. Using a non-sharp tool such as an old plastic knife, remove the hydraulic seal from the cylinder, being very careful not to damage the cylinder surface.
11. Thoroughly wash all components using only special liquid - methyl or isopropyl alcohol. Do not use mineral solvents such as kerosene or gasoline for washing, they are aggressive for rubber parts of hydraulics. Dry the components immediately with compressed air or a lint-free cloth. Blow out the channels with compressed air.
12. Replace damaged and worn parts. Pay special attention to the surface of the cylinder and piston. If they have scratches, scuffs or corrosion, then the parts must be replaced. Check the condition of the guide pins and corresponding bores in the caliper. The fingers should not be damaged and mix easily enough in the bores, but not hang out in them. If in doubt, replace defective parts.
13. If you plan to install the old caliper back, then purchase the necessary parts for it, they are available from the dealer in various combinations. All rubber seals and caliper anthers must be replaced - an axiom. Never use old seals and dusters.
14. Before assembly, make sure that all components are absolutely clean and dry (pic. 8.14, a, 6).
Pic. 8.14 a. Components of the Tevee/ATE front caliper: 1. Plug; 2. Guide pins (bolts); 3. Fitting for pumping; 4. Cap; 5. Caliper (brace); 6. Fixing spring pads; 7. Guide bushings; 8. Caliper mounting bracket; 9. Piston seal; 10. Piston; 11. Dustcoat
Pic. 8.14b. Components of the Lucas front caliper: 1. cap; 2. Connection for pumping; 3. Caliper (brace); 4. Bolts of fastening of guides; 5. Piston seal; 6. Piston; 7. Anther; 8. Caliper mounting bracket
15. Immerse the piston and new seal in clean brake fluid, lubricate the inner surface of the cylinder with it.
16. Install the piston seal into the cylinder groove using only finger strength - the use of tools may damage the seal.
17. Install a new boot on the piston. Insert the piston into the cylinder. Gently press the piston into the cylinder, turning it slightly so that it enters without tilting. Push the piston completely into the cylinder until the outer edge of the boot fits into the groove on the caliper.
18. If you are replacing guide bushings, push the old bushings out of the housing and press in new ones.
19. Before installation, fill the caliper with fresh brake fluid by unscrewing the bleeder and pumping it until bubbles stop coming out of the bleeder.
Installation
20. Bolt the caliper bracket to the steering knuckle using new bolts and tighten to specified torque (pic. 8.20, a-c). Install the brake pads as described in paragraph 4. Slide the caliper over the pads.
21. Wrap bolts of fastening of directing fingers and tighten them the prescribed moment. Install the plugs on the bushings.
Note: On Lucas models, install new pin bolts.
22. Attach to a support a brake tube and an arm of fastening. Tighten the bracket mounting bolt and the tube connecting nut to the prescribed torques.
23. Establish a spring fixing pads.
24. Route the wiring correctly into the loop of the bottom plug and connect the pad wear sensor wiring connector on the caliper bracket.
25. Remove the clip or plastic circle (what was installed) and bleed the hydraulic system as described in paragraph 2. Note that it may be sufficient to pump only one disturbed circuit.
26. Mount the wheel, lower the vehicle to the ground and tighten the wheel bolts to the prescribed torque as described in chapter 1A or 1B.
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