Order of execution
Warning: Do not depress the brake pedal with the brake pads removed.
1. Clean dust and dirt from the caliper and rust from the edge of the brake disc. If the pads are serviceable, clean them using a wire brush and a rag.
2. Check the brake disc for cracks, especially around the wheel bolt holes, as well as for wear and mechanical damage, and replace it if necessary.
3. Measure the brake disc thickness.
4. Check the condition of the caliper piston dust cap and replace if necessary.
Warning: If the brake pads are heavily worn, check the ease of movement of the caliper piston. To do this, insert a wooden block between the brake pads in the caliper and have an assistant depress the brake pedal. When you press the brake pedal, the piston should move smoothly, compressing the brake pads. Otherwise, repair the caliper in stationary conditions.
5. If new brake pads are to be installed, use the special tool to press the piston into the caliper.
6. To press the piston into the caliper, you can use 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 anther are not damaged.
7. When the piston is pushed in, the brake fluid is forced out of the brake cylinder into the expansion tank, so constantly monitor the fluid level in the tank, and if necessary, pump out a small amount of fluid from the tank.
8. Install the brake pads into the caliper.
9. Since May 1998, the design of the brake pads has been changed. The reverse side of the inner brake pad is painted white. The outer brake shoe is painted black and has a three-arm locking clip.
10. Install the caliper on the steering knuckle. First of all, the lower part of the caliper is installed (arrow) grooves on the steering knuckle guide.
11. Fasten the caliper with guide bolts to the steering knuckle and tighten them to a torque of 28 Nm.
12. Install the guide bolt guards.
13. Install the front wheels, then lower the vehicle and tighten the wheel bolts to 120 Nm.
14. Check the brake fluid level in the reservoir and top up if necessary.
15. Depress the brake pedal several times until the brake pads press against the brake disc.
Warning: Carefully allow new brake pads to run in. To do this, at a speed of about 80 km / h, brake several times to a speed of 40 km / h by lightly pressing the pedal. Allow the brake pads to cool down a little in between.
Warning: After installing new brake pads, avoid hard braking during the first 200 km of the vehicle.
Security Control Check
1. Check if the brake hoses are securely tightened.
2. Check if the brake hose is fixed in the holder.
3. Check if the bleeder fittings are securely tightened.
4. Check if the brake fluid level is sufficient.
5. Check with the engine running. Within about 10 seconds, press the brake pedal with a force of 20–30 kg / m, while the pedal should not fall through.
6. Check the tightness of all listed connections.
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