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Disc: Removal & Installation Volvo V70 II

Mechanical - Hydraulic 34 illustrations ~3792 words

Removal & Installation

  1. Turn ignition off. Secure pedal in depressed position using a pedal jack.
  2. Clean around the brake fluid reservoir cap at the pipe couplings, and if necessary at the hose connectors and at the terminals between the reservoir and the master cylinder. It is important that no contaminants enter the brake system.
  3. Remove the cross member attached to the top of the left and right shock towers. (Scheme 6)
  4. On models equipped with manual transmission, disconnect and block hose to clutch cylinder.
  5. On all models, remove the plastic cap and the positive battery cable holder at left rear of engine compartment.
  6. Remove bolts attaching master cylinder to brake booster and pull out slightly. Disconnect connectors from reservoir.
  7. Remove screw attaching reservoir to master cylinder and pull reservoir upward to remove. (Scheme 7)
  8. To install, reverse removal procedure. Lubricate reservoir "O" rings with brake fluid. Tighten fasteners to specification. See «TORQUE SPECIFICATIONS»(ref-160726-S16242453732004022600000).
  9. Top off brake fluid reservoir and remove pedal jack from brake pedal. Bleed brake system if necessary. See «BLEEDING»(ref-160726-S10541844012004022600000). On models equipped with manual transmissions, bleed clutch.
  10. Wash away any spilled brake fluid with warm water and car shampoo. Check for air in the brake system and for brake fluid leakage.

Scheme 6

Scheme 6
Scheme 6

Scheme 7

Scheme 7
Scheme 7

Removal

  1. Remove soundproof panel below left side of instrument panel. Remove retaining clip and push the push rod to one side at the brake pedal.
  2. Press brake light switch housing (1) forward against the pedal box bracket. This is to release white locking sleeve (2). (Scheme 8)
  3. Pull the white locking sleeve towards the tip of brake light switch as far as it will go. Press in the brake light switch catches (3) from underneath and turn switch down, pull out. Remove the connector.

Scheme 8

Scheme 8
Scheme 8

Installation

Before installation, check that the white locking sleeve is pulled out towards the tip of brake light switch as far as it will go and the catches (4) do not come into contact with the white locking sleeve. (Scheme 9)

Note. The brake pedal must be depressed when installing the brake light switch.

  1. When brake light switch is installed into bracket, there is a distinct click when catches engage with bracket. CAUTION: Do not lift the pedal too high or the basic adjustment may be incorrect.
  2. Gently pull brake pedal up and install the push rod and secure it using the retaining clip. The brake light switch will then adjust itself automatically. Verify that brake lights operate properly. On vehicles with automatic transmission, verify that shift lock operates properly.

Scheme 9

Scheme 9
Scheme 9

Note. For additional information (Scheme 10)

Note. See DISC BRAKE SPECIFICATIONS for minimum thickness for replacing brake pads.

Note. Do not depress the brake pedal while the brake pads are removed.

  1. Raise and support vehicle. Remove wheel to be serviced.
  2. Remove the securing spring (3) carefully so that it does not deform. (Scheme 11)
  3. Remove the protective caps (1) from the two locating pins (2). (Scheme 11)
  4. Remove the locating pins by using a 7 mm hex socket.
  5. Remove the brake caliper from the holder. Hang brake caliper from a safety wire from the front spring so as not to damage brake hose. Remove the brake pads.

Scheme 10

Scheme 10
Scheme 10

Scheme 11

Scheme 11
Scheme 11
  1. Raise and support vehicle. Remove wheel to be serviced.
  2. Secure pedal in depressed position using a pedal jack.
  3. Clean brake caliper thoroughly.
  4. Remove protective cap from bleed nipple.
  5. Install a plastic hose on the nipple.
  6. Open bleed nipple. Collect brake fluid in a container and shut the bleed nipple.
  7. Loosen the brake hose (4) from the brake caliper half a turn. (Scheme 12)
  8. Remove the securing spring (3) carefully so that it does not deform. (Scheme 12)
  9. Remove the protective caps (1) from the two locating pins (2). (Scheme 12)
  10. Remove the locating pins by using a 7 mm hex socket.
  11. Remove the brake caliper from the holder.
  12. Remove the brake hose from the brake caliper. Drain the remaining brake fluid.
  13. Remove the brake pads.

Scheme 12

Scheme 12
Scheme 12
  1. Install the brake hose (4) in the brake caliper. Do not tighten the hose yet. (Scheme 12)
  2. Install the brake pads.
  3. Install the brake caliper.
  4. Check the rubber sleeves of the locating pins. Replace if necessary.
  5. Lubricate the locating pins using grease (part no. 1161325-4, or equivalent) and insert the locating pins into the rubber sleeves. The pins should slide into the sleeves easily. Tighten them to specification. See «TORQUE SPECIFICATIONS»(ref-160726-S16242453732004022600000).
  6. Install the protective caps and the securing spring (3). (Scheme 12)
  7. Tighten the brake hose in the caliper to specification. See «TORQUE SPECIFICATIONS»(ref-160726-S16242453732004022600000). NOTE: Ensure that the brake hose is not twisted. If necessary adjust the hose at the other end (brake pipe end). If the brake hose is twisted it may rub against the tire, rim or wheel arc. This could cause the brakes to fail.
  8. Remove pedal jack from brake pedal. Fill brake fluid reservoir and bleed the brake system. See «BLEEDING»(ref-160726-S10541844012004022600000).
  9. Install wheels and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-160726-S16242453732004022600000).

Note. For additional information (Scheme 10)

  1. Raise and support vehicle. Remove the securing spring and locating pins.
  2. Remove the brake caliper and brake pads. See «FRONT DISC BRAKE PADS»(ref-160726-S20306523182004022600000).
  3. Remove and discard both mounting screw (4) for the caliper holder. (Scheme 13)
  4. Remove the front brake caliper holder (mounting bracket).
  5. Remove the locating pin (5) and the brake disc. (Scheme 13)

Scheme 13

Scheme 13
Scheme 13
  1. Install the new brake disc. Tighten the locating pin (5) to specification. See «TORQUE SPECIFICATIONS»(ref-160726-S16242453732004022600000) .
  2. Install the caliper holder. Use NEW mounting screw (4) and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-160726-S16242453732004022600000) .
  3. Install the brake pads and brake caliper.
  4. Install the locating pins in the brake caliper and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-160726-S16242453732004022600000) .
  5. Install wheels and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-160726-S16242453732004022600000) .

Remove the integrated relay/fusebox bracket screw. Lift it up and put to one side. Tie it up using safety wire. (Scheme 14) To install, reverse removal procedure. Screw in the bracket and tighten to specification. See TORQUE SPECIFICATIONS.

Scheme 14

Scheme 14: Removal & Installation
Scheme 14: Removal & Installation

Scheme 15

Scheme 15
Scheme 15
  1. Disconnect negative battery cable.
  2. Clean around the brake fluid reservoir cap at the pipe couplings, and if necessary at the hose connectors and at the terminals between the reservoir and the master cylinder. It is important that no contaminants enter the brake system.
  3. Turn ignition off.
  4. Remove the cross member attached to the top of the left and right shock towers. (Scheme 6)
  5. Remove the air cleaner housing and intake duct.
  6. Remove the plastic cap and the positive battery cable holder at left rear of engine compartment.
  7. Remove the integrated relay/fusebox. See «INTEGRATED RELAY/FUSEBOX»(ref-160726-S22859688762004022600000).
  8. Remove the connectors at the brake fluid reservoir and at the power brake booster.
  9. On manual transmission vehicles only, block the hose to the clutch cylinder. On all vehicles, remove the brake pipes at the master cylinder. (Scheme 18)
  10. Remove the two upper brake pipes on the ABS hydraulic modulator. Plug the holes on the ABS hydraulic modulator so that contaminants cannot get into it.
  11. Remove the two nuts from the master cylinder.
  12. Remove the master cylinder from the power brake booster. (Scheme 7)
  13. On manual transmission vehicles with hydraulic clutch, remove the hose from the brake fluid reservoir.

Scheme 16

Scheme 16
Scheme 16

Scheme 17

Scheme 17
Scheme 17

Scheme 18

Scheme 18
Scheme 18

Note. Do not use soap solution or mineral oil to lubricate the hoses.

  1. Check that there is no dirt in the terminals. Lubricate the "O" rings and any hoses with brake fluid or glycerin.
  2. Install the brake fluid reservoir from directly above.
  3. Install the screw on the underneath of the brake fluid reservoir. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-160726-S16242453732004022600000).
  4. Check that there is no dirt in the master cylinder terminals. Check that the "O" ring is in its groove in the connector flange.
  5. Install the master cylinder and tighten nuts to specification. See «TORQUE SPECIFICATIONS»(ref-160726-S16242453732004022600000).
  6. Install the brake pipes on the ABS hydraulic modulator and the master cylinder. Tighten the pipes to specification. See «TORQUE SPECIFICATIONS»(ref-160726-S16242453732004022600000).
  7. Install the connectors on the brake fluid reservoir and the power brake booster.
  8. Install the integrated relay/fusebox.
  9. Install the air cleaner housing.
  10. Install the cross member and tighten to specification. (Scheme 6) See «TORQUE SPECIFICATIONS»(ref-160726-S16242453732004022600000).
  11. Bleed the brake system. See «BLEEDING»(ref-160726-S10541844012004022600000). If car is equipped with a manual transmission, bleed the clutch.
  12. Wash away any spilled brake fluid with warm water and car shampoo. Check for air in the brake system and for brake fluid leakage.

Scheme 19

Scheme 19: Removal
Scheme 19: Removal

Scheme 20

Scheme 20
Scheme 20

Scheme 21

Scheme 21
Scheme 21

Scheme 22

Scheme 22
Scheme 22

Scheme 23

Scheme 23
Scheme 23

Scheme 24

Scheme 24
Scheme 24

Scheme 25

Scheme 25
Scheme 25
  1. Remove the center console. Slide the seat backwards and downwards. Fully apply the parking brake. Shift the gearshift lever to neutral.
  2. Remove the pen holder. Unclip both sides using weatherstrip tools. (Scheme 19) Use care not to mark the edge of the dashboard. Carefully insert the weatherstrip tools between the dashboard panel and the short side of the pen holder.
  3. Remove the side panel. Move the front seat to the rearmost position. Turn the clips a quarter turn using a washer or a coin. (Scheme 20) Slide the panel backwards. Remove the panel. Unsnap the nozzle.
  4. Remove the rubber mat from the storage compartment. Loose the 2 screws at the front and rear edges of the center console.
  5. Remove the gearshift selector panel. Move the gear selector to a rear position. Release the catches at the front edge. Lift the front edge of the panel. Lift up the panel.
  6. Remove the parking brake panel. Open the armrest hatch and the cover on the cup holder. Thread the boot over the parking brake lever. (Scheme 21)
  7. Remove the rear ashtray. Open the ashtray so that it passes the hooks. Release the catches on one side using a screwdriver. (Scheme 22) Pull the same side straight out. Carry out the above procedure on the other side. Remove the connector.
  8. Separate the cable harness at the rear edge of the center console. Loosen the 2 screws at the front edge of the center console and the 2 screws at the rear edge. (Scheme 23) Carefully lift the front edge of the center console. Then lift the rear edge and slide the center console over the parking brake.
  9. Move the gear selector lever forward. Apply the parking brake. Release the adjustment as necessary.
  10. Pull out the rear edge of the center console. Carefully push it forward past the lever for the parking brake. Lift out bracket.
  11. Release the parking brake adjuster.
  12. Take hold of the mechanical cable and bend it to the side so that it can be removed. (Scheme 24)
  13. Bend a thick metal wire (welding rod) as illustrated. (Scheme 25)
  14. Secure the wire in the cable eyelet. Bend the wire over the eyelet.
  15. Remove the seat cushion for the rear seat. Fold up the floor carpet by the rear set. Place a wooden block or similar between the carpet and the floor.
  16. Remove the rubber cable grommet by pressing it backwards in the bodywork.
  17. Raise and support vehicle. Remove rear brake caliper, without disconnecting brake hose. Hang the caliper from the spring. Use a wire so as not to damage the brake pipe.
  18. Remove the locating pin and the rear brake disc.
  19. Remove the return spring at the parking brake expander. (Scheme 26)
  20. Remove the expander. Lift the brake shoe slightly. Grip the expander and pull it outwards to access the cable.
  21. Unhook or pry apart the expander (1) by the mechanical cable to remove it. (Scheme 26)
  22. Insert a screw driver between the guide sleeve lug and the wheel unit. Pry apart slightly to remove the sleeve.
  23. Remove the clamp (1) by the track rod. (Scheme 27)
  24. Remove the mechanical cable from its mountings (2). (Scheme 27)
  25. Pull the mechanical cable from the floor until the welding rod is visible (3). (Scheme 27)
  26. Remove the mechanical cable from the welding rod.

Scheme 26

Scheme 26
Scheme 26

Scheme 27

Scheme 27
Scheme 27
  1. Lubricate the "O" ring on the wheel unit lightly using petroleum jelly. Install and press the guide lug for the cable sleeve into place in the wheel unit.
  2. Install the expander on the cable. (Scheme 26) Press the mounting together to lock the cable in the expander.
  3. Install the expander between the brake shoes.
  4. Install the return spring.
  5. Check the function of the mechanical cable.
  6. Secure the cable in its clamps and on the welding rod.
  7. Bend the welding rod over the end of the cable.
  8. Install the cable in the hole in the floor.
  9. Press the rubber grommet into the hole in the floor.
  10. Press the mechanical cable into place in its mounting on the bodywork between the heat shield and the fuel tank.
  11. Press the cable between the fuel tank and the edge of the heat deflector (the anti-vibration shield should be inside the edge).
  12. Lower the car.
  13. Take hold of the welding rod. Pull the mechanical cable with the sleeve through the bodywork and up to the parking brake lever.
  14. Remove the welding rod.
  15. Take hold of the rubber seal for the mechanical cable. Pull it until the rubber seals against the body work. Fold back the carpet. Reinstall the seat cushion.
  16. Install the cable end on the segment.
  17. Install the adjuster nut at the parking brake lever.
  18. Install the center console.
  19. Install the disc locating pin. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-160726-S16242453732004022600000).
  20. Tighten screws for the caliper holder.
  21. Install wheels and tighten to specification.
  22. Adjust parking brake. See «PARKING/EMERGENCY BRAKE»(ref-160726-S22309192632004022600000) under ADJUSTMENTS.
  1. Lift handle slightly. Using a sharp knife, pry the handle apart so that the lugs are released. The lugs are at the front of the handle. (Scheme 28) Remove handle by pulling forward. Knob comes off by pulling firmly.
  2. Press the handle into place until the lugs in the handle lock onto the lever. (Scheme 29) Press the knob onto the lever.

Scheme 28

Scheme 28
Scheme 28

Scheme 29

Scheme 29
Scheme 29
  1. Remove the center console. Slide the seat backwards and downwards. Fully apply the parking brake. Shift the gearshift lever to neutral.
  2. Remove the pen holder. Unclip both sides using weatherstrip tools. (Scheme 19) Use care not to mark the edge of the dashboard. Carefully insert the weatherstrip tools between the dashboard panel and the short side of the pen holder.
  3. Remove the side panel. Move the front seat to the rearmost position. Turn the clips a quarter turn using a washer or a coin. (Scheme 20) Slide the panel backwards. Remove the panel. Unsnap the nozzle.
  4. Remove the rubber mat from the storage compartment. Loose the 2 screws at the front and rear edges of the center console.
  5. Remove the gearshift selector panel. Move the gear selector to a rear position. Release the catches at the front edge. Lift the front edge of the panel. Lift up the panel.
  6. Remove the parking brake panel. Open the armrest hatch and the cover on the cup holder. Thread the boot over the parking brake lever. (Scheme 21)
  7. Remove the rear ashtray. Open the ashtray so that it passes the hooks. Release the catches on one side using a screwdriver. (Scheme 22) Pull the same side straight out. Carry out the above procedure on the other side. Remove the connector.
  8. Separate the cable harness at the rear edge of the center console. Loosen the 2 screws at the front edge of the center console and the 2 screws at the rear edge. (Scheme 23) Carefully lift the front edge of the center console. Then lift the rear edge and slide the center console over the parking brake.
  9. Remove the nut for adjuster for the parking brake. Pull out the cable.
  10. Disconnect the warning lamp connector.
  11. Remove the three screws holding the bracket for the parking brake lever. Remove the lever. (Scheme 30)

Scheme 30

Scheme 30
Scheme 30
  1. Install the new bracket with brake lever in its mountings and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-160726-S16242453732004022600000).
  2. Install the warning lamp connector.
  3. Install the cable to the brake lever.
  4. Install the adjuster nut.
  5. Move the gear selector lever forward. Apply the parking brake. Locate the parking brake lever in its socket. Fold the bracket down.
  6. Remove the masking tape from the parking brake handle.
  7. Adjust parking brake. See «PARKING/EMERGENCY BRAKE»(ref-160726-S22309192632004022600000) under ADJUSTMENTS.
  8. Install the center console in reverse order of disassembly. (Scheme 23)
  1. Remove the panel covering the parking brake lever.
  2. Slacken off the adjustment screw 5-10 turns so that the brake disc can be removed. See «PARKING/EMERGENCY BRAKE»(ref-160726-S22309192632004022600000) under ADJUSTMENTS.
  3. Raise and support vehicle. Remove the rear wheels. NOTE: Use caution as not to damage the ABS line.
  4. Remove the brake caliper and holder (mounting bracket). Discard the caliper holder bolts. Hang the caliper from the spring using a wire.
  5. Remove the brake disc. See «REAR BRAKE DISC»(ref-160726-S04731451362004022600000).
  6. Remove the two securing springs on the brake shoes.
  7. Press in the springs (1) and turn them slightly (less than 1/4 of a turn). (Scheme 32)
  8. Pull out the springs (2). (Scheme 32)
  9. Detach the return spring at the expander. Bend the brake shoes apart and remove the with the return spring and spacer.

Scheme 31

Scheme 31
Scheme 31

Scheme 32

Scheme 32
Scheme 32
  1. Ensure that ignition switch is off. Disconnect negative battery cable.
  2. Remove the cross member attached to the top of the left and right shock towers. (Scheme 6)
  3. Remove the air cleaner housing.
  4. Remove the plastic cap and the cable holder at left rear of engine compartment.
  5. Remove the integrated relay/fusebox. See «INTEGRATED RELAY/FUSEBOX»(ref-160726-S22859688762004022600000).
  6. Clean the brake pipes terminals at the master cylinder and ABS unit. Place paper under the master cylinder to avoid brake fluid spillage. Remove all the brake pipes from the master cylinder and the ABS unit. Plug the master cylinder socket for the brake pipes.
  7. Remove the ABS unit and bracket from the side member. The unit is secured with three screws. (Scheme 33)
  8. On cars with 6-cylinder engines, disconnect the connectors from the master cylinder.
  9. On all cars, disconnect the connectors on the power brake booster.
  10. Remove the master cylinder. See «MASTER CYLINDER»(ref-160726-S30815450582004022600000).
  11. Remove the soundproofing panel.
  12. Unclip brake booster from pedal. Remove bolts and power brake booster.

Scheme 33

Scheme 33
Scheme 33

Scheme 34

Scheme 34: Installation
Scheme 34: Installation
  1. Install the power brake booster. (Scheme 34)
  2. Install the push rod for the power brake booster and the retaining clip on the brake pedal. Tighten the power brake booster bolts to specification. See «TORQUE SPECIFICATIONS»(ref-160726-S16242453732004022600000).
  3. Install the soundproofing panel.
  4. Install the master cylinder. Check that the gasket is in place on the master cylinder. Tighten the nuts to specification. See «TORQUE SPECIFICATIONS»(ref-160726-S16242453732004022600000). (Scheme 34)
  5. Install the vacuum hose on the check valve for the power brake booster.
  6. Install the connectors on the master cylinder and the power brake booster.
  7. Install the vacuum hose on the check valve.
  8. Install the ABS unit.
  9. Install the bracket in the side member and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-160726-S16242453732004022600000).
  10. Install the brake pipes in the master cylinder and in the hydraulic modulator. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-160726-S16242453732004022600000).
  11. Install the integrated relay/fusebox and the connector for the ABS unit.
  12. Install the air cleaner housing.
  13. Install the cross member to both shock towers in engine compartment. (Scheme 6)
  14. Fill and bleed the brake system. See «BLEEDING»(ref-160726-S10541844012004022600000).
  15. Perform power brake booster check. See «POWER BRAKE BOOSTER»(ref-160726-S14638967842004022600000) under COMPONENT TESTS.

Note. See DISC BRAKE SPECIFICATIONS for minimum thickness for replacing brake pads.

Note. Do not depress the brake pedal while the brake pads are removed.

Note. For additional information (Scheme 35)

  1. Raise and support vehicle. Remove rear wheels. Remove the securing spring (3) carefully so that it does not deform. (Scheme 36)
  2. Remove the protective caps (1) from the two locating pins (2). (Scheme 36)
  3. Remove the locating pins using a 7 mm hex socket.
  4. Remove the brake caliper from the holder.
  5. Remove the brake pads. (Scheme 37)

Scheme 35

Scheme 35
Scheme 35

Scheme 36

Scheme 36
Scheme 36

Scheme 37

Scheme 37
Scheme 37
  1. Press piston back into cylinder on brake caliper. Check that the dust cover is correctly positioned.
  2. Install new brake pads. (Scheme 37)
  3. Install the brake caliper. (Scheme 37)
  4. Instal the rubber sleeves of the locating pins. Replace if necessary.
  5. Lubricate the locating pins with grease. Insert the locating pins (2) into the rubber sleeves. (Scheme 36) The pins should slide into the sleeves easily.
  6. Tighten locating pins to specification. See «TORQUE SPECIFICATIONS»(ref-160726-S16242453732004022600000).
  7. Install protective caps (1). (Scheme 36)
  8. Install retaining spring (3). (Scheme 36)
  9. Depress brake pedal a few times. Top off brake fluid if necessary. Adjust parking brake as required. See «PARKING/EMERGENCY BRAKE»(ref-160726-S22309192632004022600000) under ADJUSTMENTS.
  10. Install wheels and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-160726-S16242453732004022600000).
  1. Remove wheel to be serviced.
  2. Secure pedal in depressed position using a pedal jack.
  3. Clean brake caliper thoroughly.
  4. Remove protective cap from bleed nipple.
  5. Install a plastic hose on the nipple.
  6. Open bleed nipple. Collect brake fluid in a container and shut the bleed nipple.
  7. Slacken off the brake hose (4) half a turn. (Scheme 38)
  8. Remove the securing spring (3) carefully so that it does not deform. (Scheme 38)
  9. Remove the protective caps (1) from the two locating pins (2). (Scheme 38)
  10. Remove the locating pins using a 7 mm hex socket.
  11. Remove the brake caliper from the holder.
  12. Remove the brake hose from the caliper.
  13. Remove the brake pads.
  14. Drain any remaining brake fluid.

Scheme 38

Scheme 38
Scheme 38
  1. Install the brake hose (4) in the brake caliper (do not tighten the hose yet). (Scheme 38)
  2. Install the brake pads.
  3. Install the brake caliper.
  4. Check the rubber sleeves of the locating pins. Replace if necessary.
  5. Lubricate the locating pins using grease.
  6. Insert the locating pins into the rubber sleeves. The pins should slide into the sleeves easily.
  7. Tighten the locating pins to specification. See «TORQUE SPECIFICATIONS»(ref-160726-S16242453732004022600000).
  8. Install the protective caps (1) and the securing spring (3). (Scheme 38)
  9. Tighten the brake hose in the caliper to specification. See «TORQUE SPECIFICATIONS»(ref-160726-S16242453732004022600000). NOTE: Check the brake hose. Ensure that the brake hose is not twisted. If necessary adjust the hose at the other end (brake pipe end). If the brake hose is twisted it may rub against the tire, rim or wheel arch. This could cause the brakes to fail.
  10. Remove pedal jack from brake pedal. Fill brake fluid reservoir and bleed the brake system. See «BLEEDING»(ref-160726-S10541844012004022600000).
  11. Install wheels and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-160726-S16242453732004022600000).
  1. Remove the panel covering the parking brake lever.
  2. Release the parking brake adjuster.
  3. Remove the brake caliper and the brake pads. See «REAR DISC BRAKE PADS»(ref-160726-S10432793772004022600000).
  4. Remove and discard both the mounting bolts (4) for the caliper holder. (Scheme 39) Remove the holder.
  5. Remove the locating pin (5) and the brake disc. (Scheme 39)

Scheme 39

Scheme 39
Scheme 39
  1. Install the brake disc and tighten the locating pin to specification. See «TORQUE SPECIFICATIONS»(ref-160726-S16242453732004022600000) .
  2. Install the caliper holder. Use NEW mounting bolt. Tighten to specification. See «TORQUE SPECIFICATIONS»(ref-160726-S16242453732004022600000) .
  3. Install the brake pads and brake caliper.
  4. Install the locating pins in the brake caliper.
  5. Depress the brake pedal a few times. Check the fluid level in the brake fluid reservoir. Top off if necessary.
  6. Adjust parking brake. See «PARKING/EMERGENCY BRAKE»(ref-160726-S22309192632004022600000) under ADJUSTMENTS.
  7. Install wheels and tighten to specification. See «TORQUE SPECIFICATIONS»(ref-160726-S16242453732004022600000) .

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