Brake caliper assembly. 1. Brake hose; 2. Connecting bolt; 3. Copper washer; 4. Cap; 5. Bleeding fitting; 6. Guide pin bolt; 7. Cylinder body; 8. Piston seal; 9. Piston; 10. Piston boot; 11. Retaining ring; 12. Guide pin boot; 13. Bushing; 14. Caliper bracket; 15. Inner gasket cover; 16. Internal gasket; 17. Inner block; 18. Pad wear sensor (only on the right side from the inside); 19. Pad holder; 20. Outer block; 21. External gasket.
Removal and installation
Removal
Attention:
- To reduce the health hazard posed by dust particles or other materials, clean the caliper and brake pads with a vacuum cleaner. Do not use compressed air.
- Do not press the brake pedal, otherwise brake fluid may splash out when removing the brake hose.
1. Remove the wheels.
2. Secure the brake disc with wheel nuts.
3. Drain the brake fluid. See above.
Attention. Do not spill brake fluid onto the brake disc.
4. Unscrew the connecting bolt (1) and disconnect the brake hose (2) from the caliper assembly.
5. Unscrew the caliper bracket mounting bolts and remove the brake caliper assembly.
Attention. Do not drop the brake pads or brake caliper assembly.
6. Remove the brake disc.
Attention:
- Before removing the brake rotor, make alignment marks on the wheel hub and wheel bearing assembly and brake rotor.
- Do not drop the brake disc.
Installation
Attention:
- To reduce the health hazard posed by dust particles or other materials, clean the caliper and brake pads with a vacuum cleaner. Do not use compressed air.
- Do not press the brake pedal, otherwise brake fluid may splash out when removing the brake hose.
1. Install the brake disc.
Attention. If you are reusing the brake disc, align the marks made during removal.
2. Install the brake caliper assembly onto the vehicle and tighten the caliper bracket mounting bolts to the required torque.
Attention. Before installing the caliper assembly, wipe off any grease and moisture from all mounting surfaces of the caliper assembly, as well as threads, bolts, and washers.
3. Connect the brake hose to the brake caliper assembly and tighten the connecting bolts to the required torque.
4. Fill with fresh brake fluid and bleed. See above.
Attention:
- Do not reuse drained brake fluid.
- Do not spill brake fluid onto the brake disc.
5. Check if the rear wheel brakes are sticking.
6. Install the wheels.
Disassembly and assembly
Disassembly
Note. When disassembling and reassembling the cylinder body, do not remove the caliper bracket, brake pads, shim cover gaskets, and pad holders.
1. Remove the bolts from the guide pins and remove the cylinder body from the caliper bracket.
Attention. Do not drop the brake pads, shims, shim caps and pad holders from the caliper bracket.
2. Remove the guide pins and boots from the caliper bracket.
3. Remove the bushings from the guide pins.
4. Place the wooden block as shown in the picture. Remove the pistons and piston boots by blowing air through the mounting hole under the connecting bolt.
Attention. Be careful not to get your fingers pinched by the piston.
5. Using a flathead screwdriver, remove the piston seals from the cylinder body.
Attention. Be careful not to scratch the inner walls of the cylinder.
Assembly
1. Apply rubber lubricant to the piston seals (1) and install them into the cylinder body.
Attention. Do not reuse the piston seal.
2. Apply rubber lubricant to the piston boots (1). Place the boot on the end of the piston (2), then firmly insert the protrusion on the cylinder side piston boot into the groove on the cylinder body.
Attention. Do not reuse the piston boot.
3. Apply brake fluid to the piston (1). Press the piston into the cylinder body by hand and insert the protrusion on the piston boot (2) from the piston side into the groove on the piston.
Attention. Press the piston evenly. To avoid scratches on the inner walls of the cylinder, change the point of application of force.
4. Apply polyglycol ether lubricant to the bushings and insert into the guide pins.
5. Apply rubber grease to the guide pins and boots and insert into the caliper bracket.
6. Install the cylinder body into the caliper bracket and tighten the guide pin bolts to the required torque.
Check and adjustment
Check after disassembly
Cylinder body.
Check for corrosion, wear, cracks or damage on the inner cylinder walls. If necessary, replace the cylinder body.
Attention. Use fresh brake fluid for cleaning. Do not use mineral oils, e.g. gasoline or kerosene.
Caliper bracket.
Check for corrosion, wear, cracks or damage. If necessary, replace the caliper bracket.
Piston.
Check for corrosion, wear, cracks or damage. If necessary, replace the piston.
Attention. The sliding surface of the piston is galvanized. Do not sand it with sandpaper.
Guide pin and guide pin boot.
Check the guide pins and guide pin boots for corrosion, wear, cracks or damage. If necessary, replace the relevant component.
Adjustment after installation
Brake running-in procedure
Run-in the friction surfaces of new brakes in accordance with the procedure below in case of boring or replacing discs, after replacing brake pads, also if after a short mileage it begins to «fall through» pedal.
Attention. Watch the speed of the car, because... The brakes only function properly if the brake pads and discs are properly run-in. Carry out this procedure only on safe roads, without interfering with traffic. Be extremely careful.
1. Drive your car on a straight, level road.
2. Adjust the pressure on the brake pedal so that the time it takes to stop the car is 3-5 seconds.
3. Allow the brake system to cool by driving the car without pressing the brake pedal.
4. Repeat pp. 1-3 until the break-in of the brake pads and discs is complete.