Removing
Loosen wheel bolts. Raise the car, remove the wheel.
Unscrew the 2 ribbed bolts of the front caliper or 2 hexagon bolts of the rear caliper respectively and remove the caliper complete with brake shield from the wheel bearing housing. For the location of the mounting bolts, see also the overview drawings of the front and rear wheel caliper.
If necessary, detach brake hose from wheel bearing housing.
Hang the brake caliper on a wire hook made by yourself so that the brake hose is not twisted or stretched.
Caution: Do not let go of the brake hose, otherwise air will need to be bled from the brake system.
If the caliper is to be removed completely, then the brake hose of the connecting head of the brake actuator must first be unscrewed. Otherwise, you cannot unscrew the brake hose from the caliper.
Caution: Brake fluid will leak out. Collect the brake fluid in a bottle that is only for brake fluid. Brake fluid can also be sucked out of the expansion tank using a siphon. At the rear caliper, the handbrake cable must also be removed.
Front brake disc: Remove countersunk screw.
Remove brake disc.
Caution: The brake disc must not be separated from the wheel hub by force (hammer blows). Instead, use a standard rust remover to avoid disc damage. If removal is only possible with strong hammer blows, both the brake disc and the wheel bearing must be replaced for safety reasons. The replacement of the front wheel bearing should only be carried out in a workshop, as usually only a suitable press is available there. The brake disc must also be replaced using a suitable puller.
Installation
In order to guarantee uniform braking on both sides, both brake discs must have the same surfaces in terms of wear pattern and roughness depth. Therefore, it is imperative to replace or grind both brake discs.
In the workshop, the brake discs can be checked for runout. The maximum measured runout value of the braking surface must not exceed 0.03 mm. The maximum allowable thickness difference for one disc is 0.01 mm.
Measure the thickness of the disc see above. If there is rust on the brake disc flange and front wheel hub, remove it with a wire brush.
Remove protective varnish from new brake discs with a nitro thinner. 9 Fit the brake disc onto the wheel hub. Secure the front brake discs with a countersunk screw. Insert caliper with installed brake pads. In this case, the brake hose must not twist or stretch. Check the freedom of movement of the brake hose when turning the steered wheels to the stop. Connect the handbrake cable to the rear caliper.
Attach the brake hose to the wheel bearing housing.
Tighten front brake caliper to 125 Nm. If used finned head bolts are used again, the fins must first be cleaned with a wire brush.
Tighten rear brake caliper to 65 Nm.
Caution: If the brake hose has been removed, screw on the brake hose and bleed the brake system, see below.
Screw on the wheel. Lower vehicle and tighten wheel bolts crosswise to 110 Nm.
Caution: Depress the brake pedal strongly repeatedly until strong resistance is felt.
If the rear brake disc was removed, perform a basic adjustment of the rear wheel brake.
Check the fluid level in the compensation tank, see below.
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