Note: This Chapter describes the removal and installation of the caliper assembly as a unit: if the caliper needs to be rebuilt, follow the instructions Chapter 14 from this Section Before starting work, read the Note at the beginning Chapter 12.
1. Apply the handbrake and block the rear wheels. Loosen the wheel nuts and lift the front of the car. Remove the wheel.
2. To limit fluid loss, remove the master cylinder reservoir cap and cover it with plastic, or clamp the flexible hose with a G-clamp or similar tool.
3. Clean the area around the connection. unscrew the banjo bolt from the flexible hose connection ('C' in fig. 9.15). Remove the two sealing gaskets.
Pic. 9.15. Front brake caliper mountings: A Bolts securing the caliper to the hub fastening element; B Guide pin bolts; With Banjo Bolt Connection Flexible Hose
4. Remove the two bolts securing the caliper bracket to the hub fastener ('A' in Fig. 9.15). Remove the caliper assembly and insert a clean piece of wood (the same thickness as the brake disc) between the brake pads to secure them.
5. Installation is carried out in reverse order. Tighten all bolts and nuts to the specified torque and check that the flexible hose is routed correctly before compressing the banjo bolt.
6. Bleed the system as described in Chapter 8 of this Section, then check the fluid level in the master cylinder reservoir and add if necessary (see Chapter 2).