Disc: Removal & Installation Volvo V90 I

Removal (850, C70, S70 & V70)

1. Raise and support vehicle. Remove tire and wheel.
2. Carefully remove retaining spring to avoid bending. Remove protective caps from 2 guide pin bolts. Using a 7-mm Allen wrench, remove both guide pin bolts.
3. Carefully remove brake caliper from mounting to avoid damage to brake hose. Remove brake pads. Suspend brake caliper from a steel wire.

Installation

1. Check guide pin rubber sleeves and replace if necessary. Grease guide pin bolts with silicone.
2. Press piston into brake caliper cylinder. Check dust boot is correctly seated. Insert NEW brake pads and reinstall brake caliper. Tighten caliper guide pin bolts to specification.
3. Check level in brake fluid reservoir. Operate pedal repeatedly. See «TORQUE SPECIFICATIONS»(ref-121766-S08341159722001090500000) .

Removal (960, S90 & V90)

1. Raise and support vehicle. Remove tire and wheel.
2. Remove lower guide pin retaining bolt. Raise piston housing and tie back with steel wire. Remove brake pads.

1. Press piston into brake caliper cylinder. Check dust boot is correctly seated. Insert NEW brake pads and reinstall brake caliper. Tighten caliper guide pin bolts to specification.
2. Check level in brake fluid reservoir. Operate pedal repeatedly. See «TORQUE SPECIFICATIONS»(ref-121766-S08341159722001090500000) .

Note. DO NOT operate brake pedal while pads are removed.

1. Raise and support vehicle. Remove tire and wheel. Using a 3-mm drift, knock out retaining pins. Pull out retaining spring.
2. Remove brake pads and shims. Use Puller (2917) if brake pads are difficult to remove.

1. Grease shims on both sides with a thin coating of silicone. Install shims on brake pad plates.
2. Install NEW brake pads. Replace one retaining pin and retaining spring, then replace other retaining pin and retaining spring.
3. Check level in brake fluid reservoir. Operate pedal repeatedly. See «TORQUE SPECIFICATIONS»(ref-121766-S08341159722001090500000) .

Removal (960, S90 & V90 Series Live Rear Axle)

1. Raise and support vehicle. Remove tire and wheel. Using a 3-mm drift, to remove split pins. Pull out retaining spring.
2. Remove brake pads. Use Puller (2917) if brake pads are difficult to remove.

1. Grease shims on both sides with a thin coating of silicone. Install shims on brake pad plates.
2. Install NEW brake pads. Replace one retaining pin and retaining spring, then replace other retaining pin and retaining spring.
3. Check level in brake fluid reservoir. Operate pedal repeatedly. See «TORQUE SPECIFICATIONS»(ref-121766-S08341159722001090500000) .

Removal (960, S90 & V90 Multi-Link)

1. Raise and support vehicle. Remove tire and wheel.
2. Remove lower guide pin retaining bolt. Counter hold guide pin with 15 mm spanner. Raise piston housing and tie back with steel wire. Remove brake pads.

1. Press piston into brake caliper cylinder. Check dust boot is correctly seated. Insert NEW brake pads and reinstall brake caliper. Tighten caliper guide pin bolts to specification.
2. Check level in brake fluid reservoir. Operate pedal repeatedly. See «TORQUE SPECIFICATIONS»(ref-121766-S08341159722001090500000) .

Remove brake pads. See DISC PADS under REMOVAL & INSTALLATION . Remove 2 caliper mounting bolts and remove mounting. Remove locating pins and bolt. Remove disc rotor.

To install, reverse removal procedure. Tighten locating pins and bolt.

Remove brake pads. See FRONT DISC PADS. Remove brake caliper, using 10 mm Allen key. Place caliper on support arm. Remove guide pin. Remove brake disc rotor.

To install, reverse removal procedure. Tighten locating pins and mounting bolt.

1. Remove brake pads. See REAR DISC PADS. Remove 2 caliper mounting bolts and remove brake pipe from clips. Remove brake caliper.
2. Undo parking brake adjusting screw until brake disc rotor can be removed. Unscrew locating pin and remove brake disc rotor.

To install, reverse removal procedure. Tighten locating pins and mounting bolt.

Removal (960, S90 & V90 Series Live Rear Axle & Multi-Link)

1. Remove brake pads. See «REAR DISC PADS»(ref-121766-S10281499912001090500000) . Remove 2 caliper mounting bolts. Remove caliper and tie caliper to spring.
2. Remove locating pin and remove brake disc rotor.

To install, reverse removal procedure. Tighten locating pins and mounting bolt.

Disconnect brake pipes and undo master cylinder mounting nuts. Disconnect clutch hose from fluid reservoir (if equipped). Plug openings to prevent entry of foreign matter. Remove cylinder assembly from vehicle.

To install, reverse removal procedure. Bleed hydraulic system.

1. Turn ignition off. Disconnect negative battery cable. Depress brake pedal several times to purge vacuum from power brake booster. Remove hydraulic modulator bracket. See appropriate ANTI-LOCK article. Remove clutch master cylinder. See appropriate article in CLUTCHES.
2. Remove non-return valve and vacuum hose. Disconnect connector from pedal sensor. Remove ventilation hose and disconnect wire above power brake booster to allow clearance.
3. Remove sound proofing under steering wheel. Remove 4 nuts holding power brake booster to inside of firewall. (Scheme 6) Remove spring clip holding push rod at brake pedal. Remove power brake booster. Carefully handle sealing ring located between power brake booster and firewall.

Install sealing ring on power brake booster. Install power brake booster. Connect push rod to brake pedal and replace spring clip. Install 4 mounting nuts and tighten to 19 ft. lbs. (25 N.m). To complete installation, reverse removal procedure.

Scheme 6

1. Disconnect master cylinder and move it aside. Leave brake pipes attached to master cylinder. Disconnect vacuum hose and non-return valve. Remove fuel filter and move it aside.
2. Disconnect vacuum pump and move it aside. Remove soundproofing on left side of center console. Disconnect pushrod from brake pedal.

Install seal in power brake unit. Ensure seal is correctly seated. To complete installation, reverse removal procedure.