Withdrawal
Attention. If the brake pads are to be reinstalled, they must be marked before removal. Be sure to replace all the pads on one axle of the car, even if only one pad has reached the wear limit.
Paint mark the position of the rear wheels in relation to the hubs. This is necessary to reinstall the wheels in their original position, as a result of which their balance is maintained. With the vehicle on wheels, loosen the rear wheel bolts. Raise the rear of the car and secure it on stands, unscrew the bolts and remove the rear wheels.
Unscrew the upper and lower bolts of the rear wheel caliper, while holding the guide pin from turning with the second key (see fig. 11.10).
Remove the caliper and with a soft wire, tie it to the rear rack, while the caliper should not hang on the brake hose, as well as stretch or twist.
Remove the brake pads.
Installation
Attention. Do not press the brake pedal with the brake pads removed, otherwise the piston will be squeezed out of the caliper.
Use a rag and alcohol to clean dust and dirt from the bearing surface and the place where the pads are installed. Do not use solvents containing mineral oils or sharp tools.
If the pads are serviceable, clean them using a wire brush and a rag.
Check the brake disc for cracks, especially around the wheel bolt holes, and for wear or mechanical damage, and regrind if necessary, provided that the thickness of the disc after machining is within limits.
Measure the brake disc thickness and replace if necessary.
Check the caliper piston dust cover for cracks. Otherwise, immediately replace the cover, as the dirt that has penetrated into the cylinder violates the tightness of the caliper. To perform this work, you must disassemble the caliper.
When installing new brake pads, the piston must be screwed into the caliper.
Attention. When the piston is screwed in, brake fluid is forced out of the brake cylinder into the reservoir, so constantly monitor the fluid level in the reservoir, and if necessary, pump out a small amount of fluid from the reservoir.
Safety instructions
When pumping out the brake fluid, use a deaeration bottle or a plastic bottle; which are designed for use with brake fluid only. Brake fluid is poisonous and must not be sucked out by mouth through a hose. To do this, use a bellows. After replacing the brake pads, the brake fluid level in the reservoir must not exceed the mark «MAX», as the volume of the brake fluid increases with heating. Excess brake fluid that escapes onto the brake master cylinder destroys the paintwork and promotes corrosion.
To screw the piston into the cylinder, place tool 3272 on the caliper so that the shoulder of the tool rests in the grooves of the piston and rests accordingly on tool 3272/1. Turn the knurled roller of the tool to the left until it stops. Turning the handle of the special tool to the right, screw the piston into the caliper. If it is difficult to screw in the piston, install a 13 wrench on the slots in the base of the handle and screw the piston by the wrench (see fig. 11.11).
If no special tool is available, screw the piston into the caliper using steel plates inserted into the piston grooves. Pressing firmly on the plates, screw in the piston.
Remove the protective film from the bases of the new brake pads and install the brake pads in the caliper holder (see fig. 11.12). If old pads are installed, check that they are installed in their original position.
Install the caliper and secure with new self-locking bolts, screwing them into the guide pins and tighten them to a torque of 35 Nm.
Attention. Each original set of brake pads comes with four new self-locking bolts.
Apply a thin layer of lubricant to the shoulder that centered the wheel disc. Install the wheel, aligning the previously applied marks, and secure it with bolts. Lower the vehicle to the ground and tighten the wheel bolts to 120 Nm.
Attention. Depress the brake pedal several times until the brake pads press against the brake disc.
Check the brake fluid level in the reservoir and top up if necessary.
Attach the parking brake cable to the caliper.
Being careful, let the new brake pads run in to the brake disc. To do this, brake the car several times from a speed of 80 km/h to a speed of 40 km/h. Allow the brakes to cool down between braking.
After installing new brake pads, avoid hard braking during the first 200 km of the vehicle.
Pic. 11.9. Rear brake caliper
1 - self-locking bolt, 35 Nm,
When installing, a new bolt must be used.
When unscrewing the bolt, hold the guide pin from turning.
2 - brake pads,
Replace brake pads as a set on one axle of the vehicle.
3 - bolt with ribbed head base, 95 Nm,
4 - caliper holder with guide pins and protective covers,
Supplied as a spare part assembled with sufficient grease on the guide pins. If the protective cover is damaged, a complete spare set must be installed.
5 - bolt with ribbed head base, 95 Nm,
6 - brake disc,
It is necessary to replace both brake discs on the same vehicle axle.
7 - support
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