Removing
1. Apply the handbrake, then jack up the front of the vehicle and place it on axle stands. Remove the wheel.
2. Remove the master cylinder reservoir cap and retighten it with a piece of polyethylene underneath to create an airtight seal and prevent fluid loss. Alternatively, pinch the hose with a hose clamp or clamp.
3. Clean the area around the caliper hose coupler, then loosen the coupler. Disconnect the pad wear sensor wiring connector and release the wires from the mounting brackets.
4. Loosen and remove the upper and lower caliper guide pin bolts by locking the pins with a thin wrench. Discard the bolts, they must be replaced. Lift the caliper off the brake disc, then unscrew it from the end of the hose. Plug the end of the hose. to minimize fluid loss and prevent dirt from entering the system. Note that the brake pads can be left in position in the caliper bracket.
Bulkhead
1. Place the caliper on a workbench and clean it of dust and dirt, being careful not to inhale particles that have risen into the air, as this is harmful to health.
2. Carefully remove the circlip from the outside of the caliper dust seal. Remove the partially released piston from the caliper and remove the dust seal. If the piston cannot be removed, push it out by blowing air into the brake hose coupling hole using a foot pump. Be very careful not to put your fingers under the piston.
3. Use a small screwdriver to pry out the hydraulic piston seal being careful not to damage the caliper bore.
4. Thoroughly clean all components using only methyl/isopropyl alcohol or clean brake fluid. Never use mineral solvents such as benzene as they will destroy the rubber components of the hydraulic brake system. Dry the components with compressed air or a clean, dense (lint-free) cloth. Use compressed air to blow out the channels.
5. Inspect all components and replace worn or damaged parts. Pay special attention to the cylinder walls and piston; they should be replaced (note that this means replacing the complete caliper assembly) if they are scratched, worn or corroded. Check the condition of the guide pins and of the protective covers; both pins should slide fairly tight in the caliper bracket. If there is any doubt about the condition of any of the components, replace it.
6. If the assembly is fit for further use, purchase the appropriate parts repair kit. All rubber seals should be replaced; they cannot be reused.
7. Make sure all components are clean and dry before assembly.
8. Soak the piston and its new hydraulic seal with clean brake fluid. Lubricate the inner walls of the cylinder with clean fluid.
9. Install the new hydraulic piston seal into the cylinder groove without using any tools.
10. Install a new dust seal in the piston groove, then carefully insert the piston into the cylinder using a twisting motion. Slide the piston into position, then install the outer lug of the dust seal onto the caliper and secure it with the circlip.
11. If the drive pins are to be replaced, lubricate the new pins with the special grease included in the rubber kit and install protective covers in the grooves of the pins. Insert the pins into the caliper bracket and place the protective boots into the bracket grooves.
Installation
1. Screw the caliper onto the hose coupling.
2. Check that the brake pads have not moved in the caliper bracket and install the caliper, observing the position of the pad wear sensor wire.
3. Make sure that the shoe springs are installed correctly, then press the caliper and install new guide pin bolts. Tighten both bolts, starting with the bottom one, as shown in Specifications effort.
4. Tighten the brake hose connecting nut to the specified torque, then remove the clamp from the brake hose or polyethylene from under the reservoir cap.
5. Bleed the brake hydraulic system as described in Section Bleeding the hydraulic system of the brakes. Note that if precautions have been taken to minimize brake fluid loss, only this front brake will need to be bled.
6. Install the wheel, then lower the vehicle to the ground and tighten the wheel bolts to Specifications effort.