Front Brakes Servicing Guide

Front brakes, servicing Page 1 / 38
46-1
Front brakes
servicing
Front brakes,
servicing (VW II
caliper)
WARNING!
Do not re-use
fasteners that a
worn or
deformed in
normal use.
Some fasteners
are designed to
be used only
once, and are
unreliable and
may fail if used a
second time. Th
includes, but is
not limited to,
nuts, bolts,
washers, circlips
and cotter pins.
Always follow
recommendation
in this manual-
replace these
fasteners with
new parts where
indicated, and
any other time it
is deemed
necessary by
inspection.
CAUTION!
After installing
brake pads, depre
the brake pedal
firmly several time
to seat the pads in
their normal
operating position
46-2
Note:
Wheel bolt
tightening
torque: 110
Nm (81 ft
lb).
Do not
reuse used
brake fluid.
1 - 10 Nm
(7 ft lb)
2 - ABS
wheel
speed
sensor
Before
inserting
sensor,
clean
fitting hole
inner
surface
and coat
with
lubricating
paste G
000 650
3 - ABS
wheel
speed
sensor
rotor
4 - Wheel
hub
Pressing
in and
out:
Plus
suspension
Page
40-29
Base
suspension
Page
40-1
5 - Screw
6 - Splash
shield
7 - Brake
disc
Thickness:
12 mm
(0.472 in.)
Wear
limit:
10
mm
(0.394
in.)
When
worn
always
replace
both
front
discs
Use
penetrating
oil to
loosen
discs from
wheel hub
if
necessary;
do not use
force to
remove
discs
46-3
8 - Wheel
bolt
9 - 10 Nm (7
ft lb)
10 - Brake
pads
For
vehicles
m.y.
from
1996
(T)
Thickness:
14 mm
(0.551 in.)
Wear
limit: 7
mm
(0.276
in.)
Checking
thickness
Repair
Manual,
Maintenance
Pad
with
larger
friction
area
installed
on
outside
Always
replace
both
pairs at
the
same
time
Removing
and
installing
Page
46-9
11 - Brake
caliper
For
vehicles
m.y.
from
1996
(T)
Removing
and
installing
Page
46-9
CAUTION!
Do not
disconnect
the brake
hose from
the caliper
when
replacing
brake pads.
Do not allow
the caliper
to hang by
the brake
hose. The
unsupported
weight can
stretch and
damage the
hose.
46-4
12 Air
- deflector
plate
13 - Socket-
head
bolt,
lower
25
Nm
(18 ft
lb)
14 - Socket-
head
bolt,
upper
25
Nm
(18 ft
lb)
15 - Lower
spacer
sleeve
16 - Upper
spacer
sleeve
17 - Lower
sleeve
18 - Upper
sleeve
19 - Lower
bushing
20 - Upper
bushing
21 - Brake
caliper
For
vehicles
up to
m.y.
1995
(S)
Removing
and
installing
Page
46-6
46-5
22 - Brake
pads
For
vehicles
up to
m.y.
1995
(S)
Thickness:
14 mm
(0.551 in.)
Wear
limit:
7 mm
(0.276
in.)
Checking
thickness:
Repair
Manual,
Maintenance
Pad
with
larger
friction
area
installed
on
outside
Always
replace
both
sides
Removing
and
installing
Page
46-6
23 Brake
- pad
retaining
spring
For
vehicles
up to
m.y.
1995
(S)
Mount in
position
before
installing
brake
pads
Page
46-6
Replace
when
replacing
pads
24 - Wheel
bearing
housing
46-6
Front brake pads, removing

and installing (VW II caliper,
up to m.y. 1995)
Removing
- Remove bolts securing caliper to

wheel bearing housing.
- Swing caliper out from bottom to
top.
CAUTION!
Do not allow the caliper to hang

by the brake hose. The
unsupported weight can stretch
and damage the hose.
Do not disconnect the brake
hose from the caliper when
removing brake pads.
- Remove brake pad retaining
springs and brake pads.
46-7
Installing
WARNING!
Brake fluid is poisonous and must never

extracted by mouth through a hose.
CAUTION!
Extract part of the brake fluid from the

fluid reservoir before pushing back the
pistons.
Use the bleeder bottle or a plastic bott

which is used only for brake fluid, for
extracting the fluid.
If this is not done, particularly if the br

fluid has been topped up in the meanti
brake fluid may flow out and cause da
- Push piston into caliper.
- Install inner brake pad and pad retaining

on wheel bearing housing.
- Install outer brake pad.
46-8
- Install brake caliper only as far as

necessary to start bolts.
Note:
The brake pad retaining springs

could be bent if the caliper is pushed
on too far. Bent brake pad retaining
springs can cause noise during
braking.
- Tighten caliper mounting bolts.

Tightening torque: 25 Nm (18 ft
lb)
- Depress brake pedal firmly
several times to seat brake pads
in their normal operating position.
- Refill reservoir only to MAX mark
(if necessary).
46-9

and installing (VW II caliper,
from m.y. 1996)
Removing
- Remove both guide pins from

brake caliper.
- Remove brake pads.
CAUTION!

Installing
CAUTION!
Extract part of the brake fluid

from the brake fluid reservoir
before pushing back the
pistons.
Use the bleeder bottle or a
plastic bottle, which is used
only for brake fluid, for
If this is not done, particularly if
the brake fluid has been topped
up in the meantime, brake fluid
may flow out and cause
damage.
46-10
WARNING!
Brake fluid is poisonous and must

never be extracted by mouth
through a hose.
- Press piston back into caliper.

- Install brake pads.
- Locate lower brake caliper

(arrow).
- Install brake caliper with brake
pads.
Brake caliper lug (arrow) must
be behind the wheel bearing
housing guide
- Install guide pins into brake
caliper.
lb)
- Refill reservoir only to MAX mark
(if necessary).
46-11
Front brakes,
servicing (Girlin
caliper)
WARNING!
Do not re-use
fasteners that a
worn or
deformed in
normal use.
Some fasteners
are designed to
be used only
once, and are
unreliable and
may fail if reuse
This includes, b
is not limited to,
nuts, bolts,
washers, circlips
and cotter pins.
Always follow
recommendation
in this manual-
replace these
fasteners with
new parts where
indicated, and
any other time it
is deemed
necessary by
inspection.
CAUTION!
After installing
brake pads, depre
the brake pedal
firmly several time
to seat the pads in
their normal
operating position
Note:
Wheel bolt tightenin

torque: 110 Nm (81

lb).
46-12
1 - Screw
2 - Brake
pads
With
wear
pad
indicator
Always
replace
both
pairs at
the
same
time
Removing
and
installing
Page
46-15
Thickness:
14 mm
(0.551 in.)
Wear
limit: 7
mm
(0.276
in.)
including
backing
plate
3 - Brake
disc
Removing:
first
remove
brake
caliper
Ventilated
brake
disc (with
4-cyl.
engine):
Diameter:
256 mm
(10.08
in.)
Thickness:
20 mm
(0.787 in.)
Wear
limit:
18
mm
(0.709
in.)
Ventilated
brake
disc (with
VR6
engine):
Diameter:
280 mm
(11.02
in.)
Thickness:
22 mm
(0.866 in.)
Wear
limit:
20
mm
(0.787
in.)
4 - Screw
5 - Wheel
hub
Pressing
out
Page
40-45
Pressing
in
Page
40-48
46-13
6 - ABS
wheel
speed
sensor
rotor
For
ABS
wheel
speed
sensor
7 - 10 Nm (7
ft lb)
8 - Splash
shield
9 - Wheel
bearing
housing
10 - Brake
carrier
Girling
caliper
shown
Replacement
part comes
assembled
with grease
Use
repair kit
if
protective
caps are
damaged
Lubricate
guide
bolts
with
grease
supplied
in repair
kit
11 - Heat
deflector
Insert in
piston
12 - Brake
caliper
CAUTION!
Do not
disconnect
the brake
hose from
the caliper
when
replacing
brake pads.
Do not allow
the caliper to
hang by the
brake hose.
The
unsupported
weight can
stretch and
damage the
hose.
46-14
13 - Bracket
14 - Self-
locking
bolt
Always
replace
35 Nm
(26 ft
lb)
15 - 125 Nm
(92 ft lb)
16 Protective
- cap
17 - Guide
pin
18
Connector
-
For
brake
pad
wear
indicator
19 - Bracket
20 - Bracket
21
Connector
-
For
ABS
wheel
speed
sensor
22 - 10 Nm
(7 ft lb)
23 - ABS
wheel
speed
sensor -
G45-/-
G47-
Install
with
lubricating
paste,
Part No.
G 000
650
46-15
Front brake pads, removing and

installing (Girling caliper)
Removing
- Separate connector for brake pad wear

indicator.
- Remove lower caliper to guide pin mount

(hold guide pin while loosening).
- Swing brake caliper upward.

- Remove brake pads.
CAUTION!
Do not allow the caliper to hang by the

hose. The unsupported weight can str
Do not disconnect the brake hose from
caliper when removing brake pads.
46-16
Installing
WARNING!
Brake fluid is poisonous and must never

extracted by mouth through a hose.
CAUTION!
Extract part of the brake fluid from the

fluid reservoir before pushing back the
pistons.
Use the bleeder bottle or a plastic bott

which is used only for brake fluid, for
If this is not done, particularly if the br

fluid has been topped up in the meanti
brake fluid may flow out and cause da
- Press piston into caliper.

- Install brake pads and heat shield.
- Swing brake caliper down and install new
bolt (supplied in repair kit).
- Tighten caliper to guide pin mounting bolt
Tightening torque: 35 Nm (26 ft lb)
- Depress brake pedal firmly several times
brake pads in normal operating position.
46-17
Front brakes,
servicing
(Teves/Ate
caliper)
Vehicles with VR6

engine from 01.95
VIN number 1H-SW
560 001
WARNING!
Do not re-use
fasteners that a
worn or
deformed in
normal use.
Some fasteners
are designed to
be used only
once, and are
unreliable and
may fail if used a
second time. Th
includes, but is
not limited to,
nuts, bolts,
washers, circlips
and cotter pins.
Always follow
recommendation
in this manual-
replace these
fasteners with
new parts where
indicated, and
any other time it
is deemed
necessary by
inspection.
CAUTION!
After installing
brake pads, depre
the brake pedal
firmly several time
to seat the pads in

their normal
operating position
46-18
Note:
Wheel bolt
tightening
torque: 110
Nm (81 ft lb).
1 - Screw
2 - Brake
disc
Before
removing,
remove
brake
caliper
Ventilated
brake
disc
diameter:
288 mm
(11.34
in.)
Brake
disk
thickness:
25 mm
(0.98 in.)
Wear
limit:
23
mm
(0.90
in.)
3 - Brake
pads
Always
replace
both
pairs at
the
same
time
Pads
are
different,
pad with
retaining
spring to
piston
side
Removing
and
installing
Page
46-22
Pad
thickness:
14 mm
(0.551
in.)
Checking
thickness:
Repair
Manual,
Maintenance
Wear
limit: 7
mm
(0.276
in.)
including
backing
plate
4 - Brake
pad
retaining
spring
Insert in
both
brake
caliper
mounting
holes
46-19
5 - Brake
carrier
Replacement
part comes
assembled
with guide
pins greased
Use
repair kit
if
protective
caps are
damaged
Lubricate
guide
pins with
grease
supplied
in repair
kit
6 - Brake
caliper
Removing
and
installing
Page
46-22
CAUTION!
Do not
disconnect
the brake
hose from
the caliper
when
replacing
brake pads.
Do not allow
the caliper to
hang by the
brake hose.
The
unsupported
weight can
stretch and
damage the
hose.
7 - Guide pin
25 Nm
(18 ft lb)
Removing
and
installing
Page
46-22
8 - Protective
cap
46-20
9 - Seal
Always
replace
To
remove,
lever
out
using
suitable
tool
10 - Brake
hose
11 - Banjo
bolt
30
Nm
(22 ft
lb)
12 - Bolt
125
Nm
(92 ft
lb)
13 - Wheel
bearing
housing
14 - Socket
head
bolt
10
Nm
(89 in.
lb)
15 - ABS
wheel
speed
sensor
-G45-/-
G47-
Only on
vehicles
with
ABS
Before
installing
sensor,
clean
mounting
hole inner
surface
and coat
with
lubricating
paste,
Part No.
G 000
650
16 - Splash
shield
17 - Bolt
10
Nm
(89 in.
lb)
46-21
18 - ABS
wheel
speed
sensor
rotor
Only on
vehicles
with ABS
19 - Wheel hub
Removing
and
installing
Page
40-39
20 Countersunk
- bolt
46-22

and installing (Teves/Ate
caliper)
VR6 vehicles from m.y. 1996
Removing
Note:
If used pads are to be re-installed,

first mark their original locations. Re-
install pads to the same positions to
avoid uneven braking.
- Remove guide pin protective

caps.
- Using screwdriver, pry off brake

pad retaining spring from brake
caliper (arrow), and remove
spring.
46-23
- Remove both guide pins from

brake caliper.
- Remove brake caliper and lay to
one side or suspend from body
with wire, and remove brake pads
from brake caliper or from carrier.
CAUTION!

46-24
Installing
Brake pads with specified direction

of brake rotor rotation:
1 - Right-side caliper, piston-side

pad
2 - Left-side caliper, piston-side pad
WARNING!
Brake fluid is poisonous and must

never be extracted by mouth
through a hose.
CAUTION!
Extract part of the brake fluid

from the brake fluid reservoir
before pushing back the
pistons.
Use the bleeder bottle or a
plastic bottle, which is used
only for brake fluid, for
If this is not done, particularly if
the brake fluid has been topped
up in the meantime, brake fluid
may flow out and cause
damage.
- Clean brake caliper thoroughly
before installing new brake pads.
In particular, bonding surface for
brake pad must be free of
adhesive and grease residues
- Remove any adhesive foil
remains from outer brake pads.
46-25
- Press piston back into brake

caliper.
- Install brake pad with brake pad
retaining spring into brake caliper
(piston side).
- When installed, make sure that

arrow -A- on brake pad backing
plate faces downward.
- Install outer brake pad in brake
pad carrier.
46-26
- Pull protective foil off outer brake

pad backing plate.
- Mount brake caliper to brake pad
carrier with guide pins.
lb)
- Install guide pin protective caps.
- Install brake pad retaining spring
in brake caliper.

Front Brakes Servicing Guide

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Front Brakes Servicing Guide

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Front brakes, servicing Page 1 / 38

Front brake pads, removing

- Remove bolts securing caliper to

Do not allow the caliper to hang

Brake fluid is poisonous and must never

Extract part of the brake fluid from the

Use the bleeder bottle or a plastic bott

If this is not done, particularly if the br

- Push piston into caliper.

- Install inner brake pad and pad retaining

- Install brake caliper only as far as

The brake pad retaining springs

- Tighten caliper mounting bolts.

Front brake pads, removing

- Remove both guide pins from

Do not allow the caliper to hang

Extract part of the brake fluid

Brake fluid is poisonous and must

- Press piston back into caliper.

- Locate lower brake caliper

Wheel bolt tightenin

torque: 110 Nm (81

Front brake pads, removing and

- Separate connector for brake pad wear

- Remove lower caliper to guide pin mount

- Swing brake caliper upward.

Do not allow the caliper to hang by the

Brake fluid is poisonous and must never

Extract part of the brake fluid from the

Use the bleeder bottle or a plastic bott

If this is not done, particularly if the br

- Press piston into caliper.

Vehicles with VR6

to seat the pads in

Front brake pads, removing

VR6 vehicles from m.y. 1996

If used pads are to be re-installed,

- Remove guide pin protective

- Using screwdriver, pry off brake

- Remove both guide pins from

Do not allow the caliper to hang

Brake pads with specified direction

1 - Right-side caliper, piston-side

Brake fluid is poisonous and must

Extract part of the brake fluid

- Press piston back into brake

- When installed, make sure that

- Pull protective foil off outer brake

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