Scheme 5
Scheme 6
- Release the Maxi-fuse holder.
- Unplug the electrical connector on the anti-theft alarm.
- Cut off the cable ties securing the positive battery cable to the main fuse box.
- Undo the nuts and move the main fuse box out of the way.
- Suspend the main fuse box from a cable tie.
- Use a brake pedal clamp to depress the brake pedal about 50 mm to prevent brake fluid from running out of the master cylinder.
- Unplug the connector and tuck it out of the way.
- Use compressed air to clean the surfaces around the brake-pipe couplings.
- Undo the brake-pipe couplings using a brake pipe spanner and plug the openings.
- Place a cover over the splash guard to protect it from any brake-fluid spillage.
- Undo the two nuts on the hydraulic unit.
- Lift out the hydraulic unit, taking care not to damage the pipes.
Scheme 7
Scheme 8
- Lift the hydraulic unit into position, taking care not to damage the pipes.
- Fit the two nuts. Tightening torque 20 Nm (15 lbf ft) .
- Remove the plugs and reconnect the pipes. Fit the brake-pipe nipples (rear pipes first) finger tight and then tighten with a spanner.
- Plug in the connector and fit the main fuse box.
- Secure the battery lead to the fuse box with a cable tie.
- Plug in the connector to the anti-theft alarm.
- Hook on the Maxi-fuse holder.
- Bleed the brake system, see «BLEEDING BRAKE SYSTEM»(ref-162812-S07977462432004061100000).
Scheme 9
Scheme 10
- Unplug the connector.
- Raise the car and remove the wheel.
- Clean the area round the wheel sensor using a soft wire brush.
- Undo the wheel sensor retaining bolt and remove the wheel sensor.
- Remove the grommet and withdraw the lead.
- Detach the lead from the clips and lift out the sensor.
Scheme 11
Scheme 12
- Fit the wheel sensor in its holder and tighten the retaining bolt.
- Insert the lead.
- Push the lead into the clips and fit the grommet.
- Fit the wheel, see «WHEELS»(ref-212251-S31509283572005122300000), and lower the car. Tightening torque. aluminum wheel 110 Nm (81 lbf ft). steel wheel 50 Nm +2x90°, max. 110 Nm (37 lbf ft +2x90°, max. 81 lbf ft).
- Plug in the connector.
Scheme 13
Scheme 14
- Depress the locking tab on the connector and remove it from the holder.
- Unplug the connector.
- Raise the car and remove the wheel.
- Clean the area round the wheel sensor using a soft wire brush.
- Remove the grommet and withdraw the lead.
- Detach the lead from the clips and lift out the sensor.
Scheme 15
Scheme 16
- Fit the wheel sensor in its holder and tighten the retaining bolt.
- Insert the lead.
- Push the lead into the clips and fit the grommet.
- Fit the wheel, see «WHEELS»(ref-212251-S31509283572005122300000), and lower the car. Tightening torque. aluminum wheel 110 Nm (81 lbf ft). steel wheel 50 Nm +2x90°, max. 110 Nm (37 lbf ft +2x90°, max. 81 lbf ft).
- Plug in the connector
- Plug The Connector Into The Holder.
Scheme 17
Scheme 18
Scheme 19
- Raise the car and remove the wheel.
- Press back the brake piston with slip-joint pliers.
- Remove the brake caliper and suspend it.
- Back off the handbrake adjuster. It is accessible through a hole in the brake disc.
- Remove the brake disc retaining bolt. Remove the brake disc.
- Remove the air separator.
- Remove the bolt securing the handbrake cable mounting.
- Unplug the connector from the wheel sensor.
- Detach the wheel sensor cable from the holder.
- Remove the mounting for the wheel sensor cable and brake pipe (2 nuts).
- Remove the wheel hub nuts. Use a long 15mm socket with 3/8 drive, part no. 30 34 444 and extension with ball fitting.
- Remove the wheel hub from the disc back-plate. Let the disc back-plate and handbrake unit hang from the cable.
Scheme 20
Scheme 21
Scheme 22
- Clean the contact surfaces using a wire brush.
- Fit the wheel hub on the back-plate and secure them to the longitudinal link using new nuts. Tighten the nuts alternately. Tightening torque: 50 Nm +30° (40 lbf ft +30°) .
- Fit the brake disc. Fit the lock screw with LOCTITE 242. Tightening torque: 10 Nm (7 lbf ft) .
- Adjust the handbrake, see «PARKING BRAKE SHOES»(ref-162812-S12491336722004061100000).
- Fit the brake caliper. Use 74 96 268 LOCTITE 242 on the bolts. Tightening torque: 80 Nm (59 lbf ft) .
- Fit the mounting for the wheel sensor cable and brake pipe. Tightening torque: 24 Nm (18 lbf ft) .
- Fit the wheel sensor cable to the mounting.
- Plug in the connector to the wheel sensor.
- Fit the mounting for the handbrake cable. Tightening torque: 8 Nm (6 lbf ft) .
- Fit the air separator.
- Fit the wheel. See «WHEELS»(ref-212251-S31509283572005122300000). Tightening torque. aluminum rim 110 Nm (81 lbf ft). pressed steel rim 50 Nm +2x90°, max. 110 Nm (37 lbf ft +2x90°, max. 81 lbf ft).
- Lower the car to the floor.
- Depress the brake pedal to press out the pistons in the brake calipers.
Scheme 23
Scheme 24
Scheme 25
Scheme 26
Scheme 27
Scheme 28
Scheme 29
Scheme 30
Scheme 31
Scheme 32
Scheme 33
Scheme 34
Scheme 35
Scheme 36
Scheme 37
Scheme 38
Scheme 39
Scheme 40
Scheme 41
Scheme 42
Scheme 43
Scheme 44
Scheme 45
Scheme 46
Scheme 47
Scheme 48
Scheme 49
Scheme 50
Scheme 51
Scheme 52
Scheme 53
Scheme 54
Scheme 55
Scheme 56
Scheme 57
Scheme 58
Location: On the left-hand structural member behind the headlamp (battery ground).
See also:
• SELF-DIAGNOSTICS