Models With 16 Inch Wheels
Component Notes and Information
NOTE:
^ During service procedures, refer to the illustration above and the information below
^ After servicing calipers, depress brake pedal firmly several times with vehicle stationary so that the brake pads are properly seated in their normal operating position.
^ To remove brake fluid from the reservoir use a bleeder bottle which is used only for brake fluid
WARNING: Brake fluid is poisonous.
1 Hex bolt
- Always replace each time after removing
- Tightening torque on vehicles with all wheel drive:
Tighten to: 150 Nm (111 ft lb) and turn 90° further
- All wheel drive vehicles: loosen and tighten only when vehicle is on its wheels (danger of accident)
2 Washer
3 Hex socket head bolt
- Tighten to: 10 Nm (7 ft lb)
4 Brake rotor
- Thickness: 13.5 mm
- Wear limit: 11.5 mm
- When worn always replace on both sides
5 Hex bolt
- Tighten to: 10 Nm (7 ft lb)
6 Splash plate
7 Control arm
- Removing and installing refer to Steering and Suspension
8 Self-locking hex nut
- Tighten to: 200 Nm (148 ft lb)
- Always replace
9 Tensioning disc
- With impulse rotor for ABS speed sensor
10 Hex bolt
- Tighten to: 170 Nm (125 ft lb)
11 Hex socket head bolt
- Tighten to: 10 Nm (7 ft lb)
12 Speed sensor
13 Wire
- For brake pad wear indicator
14 Self-locking hex bolt
- Tighten to: 35 Nm (26 ft lb)
- Always replace
- When loosening and tightening counter-hold on guide pin
15 Cable,bracket
- Secured to brake caliper with upper bolt
16 Guide pin
17 Protective cap
18 Retaining spring
- Clipped into brake caliper
- Secures wiring for brake pad wear indicator
19 Brake caliper
- Servicing refer to Overhaul. Service and Repair
20 Spring clip
21 Parking brake cable
- Adjusting parking brake. Adjustments
22 Anti-rattle spring
- Always replace when changing pads
23 Brake carrier with guide pins and protective cap
- Supplied as replacement part assembled with guide pin grease
- If protective caps or guide pins are damaged use repair kit.
- Use grease packet supplied in repair kit to lubricate guide pins
24 Brake pads
- Always replace on both sides
- With wear indicator: Warning lamp lights up on instrument cluster when wear limit is reached (limit: 2 to 3 mm)
- Thickness when new: 10.75 mm without backing plate
- Wear limit: 2 mm, not including backing plate (remaining pad thickness)
- Removing and installing, refer to procedure below
NOTE: If reusing brake pads mark and return to same location.
Removal
- Remove wheels.
- Release spring clip -1-
- Remove parking brake cable -2- from brake caliper.
- Turn brake pad wear indicator connector 900 and pull sideways out of bracket.
- Separate connectors for brake pad wear indicator.
- Unclip brake pad wear indicator retaining spring -A- from brake caliper.
- Remove brake caliper housing securing bolts (arrows).
- Remove brake caliper housing and lay to one side so that weight of brake caliper does not stress or damage brake hose.
- Remove brake pads and pad anti-rattle springs (arrows).
Installation
WARNING: Brake fluid is poisonous.
NOTE:
^ Before pressing the piston back, remove some brake fluid from the reservoir.
^ Use a bleeder bottle or a plastic bottle which is only used for brake fluid.
- Hang brake caliper housing on hook (arrow B).
- Screw in piston by turning knurled wheel of special tool 3272 clockwise.
NOTE:
^ Do not damage the protective cap when turning in the brake caliper piston.
^ Position special tool 3272 so that the collar (arrow) of the tool is seated on the brake caliper
^ If the piston is difficult to move, use a 13 mm open end wrench on the flats (arrow A) provided for this purpose.
^ If the piston is pushed back with a piston resetting tool or by operating the foot brake the automatic adjustment in the brake caliper will be destroyed.
- Thoroughly clean contact surfaces for anti-rattle springs on brake carrier and remove corrosion.
- Install brake pads and anti-rattle springs into brake carrier.
- Measure clearance between brake pads -1- and anti-rattle springs on brake carrier -2- with feeler gauges -A-.
Clearance: Minimum 0.4 mm (0.016 inch)
- If the clearance is less than 0.4 mm (0.016 inch):
Clean contact surfaces for anti-rattle springs on brake carrier again.
Re-measure clearance between brake pads and anti-rattle springs on brake carrier again.
- Install brake pads and brake pad retaining springs (arrows) into brake carrier.
- Secure brake caliper housing with new self-locking bolts.
NOTE: The repair kit includes four self-locking hex bolts which must be installed.
- Press brake lever -3- in direction of arrow and connect parking brake cable -2,
- Install spring clip -1-
- Connect brake pad wear indicator connectors -5- and push them into bracket -4-.
- Turn connector in bracket 900°
- Adjust parking brake.
NOTE: Only depress the brake pedal after first adjusting the parking brake.
- Install wheels.
NOTE:
^ After each brake pad change firmly depress the brake pedal several times with the vehicle stationary so that the brake pads are properly seated in their normal operating position.
^ After changing brake pads check the brake fluid level.