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Front Disc Brake (06.03)Brake Systems (06.00)

Issue 6, March 2010 Workshop Manual 6-3-1

Brake Systems (06.00)

Front Disc Brake (06.03)Description

Figure 06.03.01

The front disc brake has a caliper that is attached to the vertical link with two bolts. The caliper body is one-piece and has four pistons. The two-pairs of pistons in the caliper operate directly on the brake pads that are installed, one each side of the disc.The Brake discs are ventilated and are made of steel and they have grooves to remove surface water. The discs are attached to the wheel hub with two bolts.

SpecificationsKey to Figure 06.03.01

1. Brake Hose Assembly.2. Caliper Bolt3. Brake Pad Sensor4. Brake Pad Kit5. Front Caliper6. Grooved Brake Disc7. Front Brake Disc Shield

Oils/GreasesBrake Fluid Castrol Super Response DOT 4 (Not

silicon based brake fluid).Qty. 2.5 ltrs

Brake discsFront

Initial Thickness 32 mmMinimum Thickness

30 mm

Brake Disc ‘Runout’ <70 μm measured @ 2 mm in from the brake disc edge.


6-3-2 Workshop Manual Issue 6, March 2010

MaintenanceBrake Caliper (Front and Rear)

Removal

1. Put a cloth around the brake reservoir filler neck to absorb all brake fluid spillage.

2. Raise the vehicle and make it safe.3. Remove the applicable wheels.

4. Disconnect the brake pad wear sensor (1) from the brake pad..

5. Disconnect the brake hose union.6. Install sealing plugs into the hose and the port in the

caliper to prevent contamination.7. Remove and discard the two bolts to release the caliper

from the vertical link.

Installation1. Put the caliper in position on the vertical link.

2. Install two new bolts and torque them to 20 Nm.3. Tighten the caliper bolts 66 degrees to 70 degrees

more.

Brake padsNew pad thickness 9.4 mmMinimum lining thickness

2.5 mm

Torque FiguresDescription Nm. lb. / ft.Brake Hose Unions 22 16.5Brake Hose Bracket to Body

9 6.6

Brake Caliper to Vertical Link

20 + 66°-70° 15 + 66°-70°

Handbrake Caliper to Vertical Link

15 +90°-94° 11.5 + 90°-94°

Brake Disc Screws 10.5 8

Repair Operation Time (ROT)Item CodeBrake Caliper - Front - Renew (Left)

(Right)06.03.AC06.03.AB

Brake Caliper - Rear - Renew (Left) (Right)

06.04.AC06.04.AB

Front calipers shown.

Retract the caliper pistons to to help release the caliper. When you retract the caliper pistons, the brake fluid

reservoir can overflow.

Replace the brake pad if there are the conditions that follow:

There less than one-third of the friction material remains on the brake pad, the vehicle is used regularly and there is a

long period before the next service.

WARNING DO NOT USE COMPRESSED AIR TO REMOVE BRAKE

PAD DUST. THE DUST CAN BE DANGEROUS. ALWAYS USE A VACUUM BRUSH OR AQUEOUS BRAKE CLEANER TO REMOVE BRAKE PAD DUST.

WARNING BRAKE FLUID IS POISONOUS.

DO NOT DRINK THE BRAKE FLUID OR LET IT TOUCH YOUR SKIN OR EYES. IF YOU GET BRAKE FLUID IN YOUR MOUTH, GET MEDICAL AID IMMEDIATELY.

FLUSH ALL BRAKE FLUID FROM YOUR EYES OR SKIN WITH WATER AND GET MEDICAL AID.

CAUTIONDO NOT LET BRAKE FLUID TOUCH THE VEHICLE

PAINT WORK. IF YOU DO THE PAINTWORK CAN BE DAMAGED. FLUSH ALL SPILLED BRAKE FLUID FROM

THE PAINTWORK WITH WATER.

WARNING ALWAYS INSTALL NEW BOLTS WHEN YOU INSTALL THE BRAKE CALIPER. IF YOU DO NOT THE BOLTS CAN BREAK AND CAUSE FAILURE OF THE BRAKE.



4. Remove the sealing plug from the brake-pipe port.

4.1 Loosely install the brake hose union into the caliper.4.2 Make sure that the brake hose alignment line is

straight. Adjust the hose if necessary.4.3 Install the alignment tool (206-100).

4.4 Use the tool to align the hose and tighten the union to 22 Nm.

4.5 Do a check of the hose alignment again. If the hose is not correctly aligned, loosen the union and adjust the hose. Tighten the union to 22 Nm.

4.6 Make sure that the brake pipe is in the correct position:• Flexible hose alignment line is straight.

4.7 If the alignment is not correct, carefully loosen the pipe union at the brake caliper until you can turn the pipe backwards to allow forward movement when being re-torqued. Re torque the brake pipe union to 22 Nm then re check alignment as listed above.

5. Install the brake pads.

6. Install the brake pad wear sensor. Install the left and right shims as recorded at removal.

7. Bleed the brakes (Refer to ’Brake Bleed - Manual’, page 6-6-5).

8. Install the road wheels (Refer to ’Torque Tightening of Road Wheel Nuts’, page 4-4-8).

9. “Bed-In” the brakes (Refer to ’Brake Pad ‘Bedding-in’’, page 6-3-6).

CAUTIONMAKE SURE THAT THE ALIGNMENT LINE ON THE BRAKE HOSE STAYS IN A STRAIGHT LINE. IF THE ALIGNMENT LINE IS NOT STRAIGHT, THE BRAKE HOSE IS TWISTED. THIS CAN CAUSE IT TO FAIL.

CAUTIONON LEFT AND RIGHT CALIPERS, THE BRAKE HOSE MUST GO TOWARDS THE FRONT OF THE CAR.

When you install new brake pads, install a new brake pad wear sensor.



Brake Discs (Front and Rear)

Removal

1. Raise the vehicle and make it safe.2. Remove the applicable roadwheels.

3. On Rear Road Wheels Only.Remove the park brake caliper (Refer to ’Brake Caliper’, page 6-5-2).

4. Remove and discard the two bolts to release the caliper.5. Use a cable tie to attach the caliper to the suspension

spring..

6. Remove the two attachment screws to release the brake disc from the hub.

Installation1. Make sure that the surfaces of the disc and the hub are

clean.2. Install the brake disc on the hub.3. Install and torque the two disc attachment screws to

10.5 Nm.4. Do a check of the brake disc “run-out” (Refer to

’Specifications’, page 6-3-1).5. Put the caliper in position.

6. Install two new caliper attachment bolts and torque the bolts to 20 Nm.

7. Tighten the bolts 66 degrees to 70 degrees Nm more.8. On the rear wheels only, install the handbrake caliper.9. Torque the two handbrake caliper bolts to 15 Nm.10. Tighten the bolts 90 degrees to 94 degrees Nm more.11. Install the road wheels (Refer to ’Torque Tightening of

Road Wheel Nuts’, page 4-4-8).

12. “Bed-in” the brake pads (Refer to ’Brake Pad ‘Bedding-in’’, page 6-3-6).

Repair Operation Time (ROT)Item CodeBrake Disc Renew (Front) 06.03.CB

(Rear) 06.04.CB

Put a cloth around the brake reservoir filler neck to absorb spilled brake fluid.



CAUTIONDO NOT LET THE CALIPER HANG ON THE HOSE. IF

YOU DO THE HOSE CAN BE DAMAGED. WARNING

ALWAYS INSTALL NEW BOLTS WHEN YOU INSTALL THE BRAKE CALIPER. IF YOU DO NOT THE BOLTS CAN BREAK AND CAUSE FAILURE OF THE BRAKE.

WARNING BEFORE YOU DRIVE THE VEHICLE, OPERATE THE

FOOT BRAKE PEDAL 2 OR 3 TIMES TO MAKE SURE THAT THE FOOT BRAKE OPERATES CORRECTLY. YOU MUST OPERATE BRAKE CALIPER PISTONS TO CLOSE

THE SPACE BETWEEN THE BRAKE PADS AND THE DISC.



Brake Pads (Front and Rear)

Removal

1. Raise the vehicle and make it safe.2. Remove the applicable road wheels.

3. Disconnect the brake pad wear sensor.

4. Remove the brake pads. Record the left and right shims for the assembly procedure.

5. Use approved materials to clean the brake caliper area. Installation1. Install the left and right shims (1) to the pads (2) in the

positions recorded at removal. 2. Install the brake pads (2) with the shims (1).3. Install the pad retaining pins.

4. Connect the brake pad wear sensor to the brake pads.5. Install the road wheels (Refer to ’Torque Tightening of

Road Wheel Nuts’, page 4-4-8).

6. “Bed-in” the brake pads (Refer to ’Brake Pad ‘Bedding-in’’, page 6-3-6).

Repair Operation Time (ROT)Item CodeBrake Pads Renew (Front) 06.03.DB

(Rear) 06.04.DB

The front calipers are shown.

Put a cloth around the brake reservoir filler neck to absorb spilled brake fluid.



WARNING DO NOT USE COMPRESSED AIR TO REMOVE BRAKE

PAD DUST. THE DUST CAN BE DANGEROUS. ALWAYS USE A VACUUM BRUSH OR AQUEOUS BRAKE CLEANER TO REMOVE BRAKE PAD DUST.

When you install new brake pads, you must install a new brake pad wear sensor.

WARNING BEFORE YOU DRIVE THE VEHICLE, OPERATE THE

FOOT BRAKE PEDAL 2 OR 3 TIMES TO MAKE SURE THAT THE FOOT BRAKE OPERATES CORRECTLY. YOU MUST OPERATE BRAKE CALIPER PISTONS TO CLOSE

THE SPACE BETWEEN THE BRAKE PADS AND THE DISC.



Brake Pad ‘Bedding-in’

After you install new brake pads, the brake performance can be decreased because the brake discs and pads must be “Bedded-in”.

ProcedureThis procedure will take approximately 17 minutes if you do it in a controlled environment. It is recommended that you use an analogue decelerometer for this procedure.

1. Slow the vehicle three times from 100 km/h to 32 km/h at 0.3g. Increase the speed normally after you have slowed down.

2. Drive 3 km to let the brakes cool.3. Slow the vehicle three times from 100 km/h to 32 km/h

@ 0.5g. Increase the speed normally after you have slowed down.

4. Drive 4 km to let the brakes cool.5. Use the ABS and slow the vehicle three times from 100

km/h to 0 km/h. Increase the speed normally after you have slowed down.

6. Drive 8 km to let the brakes cool.

Repair Operation Time (ROT)Item CodeBedding-in TBA

CAUTIONIF YOU DO NOT “BED-IN” NEW BRAKE PADS, THE

PERFORMANCE OF THE BRAKES CAN BE DECREASED AND YOU CAN GET BRAKE JUDDER OR SQUEAL.

Make sure that the brakes are cold (Less than 80° C) before you do this procedure.

Only apply the brakes lightly, if possible, when the vehicle is driven to a suitable location to carry out this procedure.

If possible, use light brake applications only during all cool- down periods.

The cool-down periods are the minimum needed and can be longer.

Rear Disc Brakes (06.04)Brake system (06.00)

Issue 3, October 2007 Workshop Manual 6-4-1

Brake system (06.00)

Rear Disc Brakes (06.04)Description

Figure 06.04. 01

The rear disc brake has a caliper that is attached to the vertical link with two bolts. The caliper body is one-piece and has four pistons. The two-pairs of pistons in the caliper operate directly on the brake pads that are installed, one each side of the disc.The Brake discs are ventilated and are made of steel and they have grooves to remove surface water. The discs are attached to the wheel hub with two bolts.

Key to Figure 06.04.018. Brake Hose Assembly 11.Rear Caliper 14.Brake Pad Sensor Assembly9. Rear Brake Disc Shield 12.Caliper Bolt10.Grooved Brake Disc 13.Brake Pad Kit

Rear Disc Brakes (06.04)Brake system (06.00)

6-4-2 Workshop Manual Issue 3, October 2007

Specifications

MaintenanceFor symptoms and maintenance of the rear brake system (Brake Discs, Pads and Calipers) follow the same procedures as detailed for the front brake system.

Oils/GreasesBrake Fluid Castrol Super Response DOT 4 (Not

silicon based brake fluid)

Brake discsBrake Disc Initial Thickness 28.0 mmBrake Disc Minimum Thickness

26.0 mm

Brake Disc ‘Runout’ <70 μm measured @ 2 mm in from the brake disc edge.

Brake padsMinimum Lining Thickness

2.5

Torque FiguresDescription Nm. lb. / ft.Brake Hose Unions 22 16.5Service Brake Caliper to Vertical Link

20 then 66° to 70° more


Handbrake Caliper to Vertical Link


11.5 then 90° to 94° more

Brake Calipers (Refer to ’Brake Caliper (Front and Rear)’, page 6-3-2)

Brake Discs (Refer to ’Brake Discs (Front and Rear)’, page 6-3-4)

Brake Pads (Refer to ’Brake Pads (Front and rear)’, page 6-3-5)

front disc brake (06.03) - wordpress.com · front disc brake (06.03) brake systems (06.00) issue 6,...

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