Assembly diagram of disc brakes. Parts marked with "*" are installed on carburetor models; parts marked with "**" on injection engines
1 - guide pin **; 2 - rubber cuff **; 3 - rubber cuff *; 4 - caliper holder; 5 - caliper holder bolts, 73-100 Nm; 6 - guide pin **; 7 - rubber cuff **; 8 - inner lining **; 9 - spring plate of the pads **; 10 - brake pads **; 11 - external lining **; 12 - inner lining *; 13 - brake pads *; 14 - brake shoe spring *; 15 - guide pin * 3.2-4.2 N·m; 16 - caliper bolt **, 22-33 Nm; 17 - hollow bolt, 17-21 Nm; 18 - copper washers; 19 - bleed valve, 7-13 Nm; 20 - cylinder body; 21 - external linings*
1. Raise the front of the vehicle.
2. Remove the wheels.
3. On the inside of the caliper, remove the bolt shown in the illustration and swing the entire caliper up.
4. Remove the guide plates from the caliper at the top and bottom, the inner and outer brake pads. To remove the guide plates, insert a screwdriver.
After removing the shown bolt, you can fold the caliper upwards. Secure the caliper with a piece of wire (see illustration).
5. After removing the brake pads, do not press the brake pedal, otherwise the piston will jump out. Replace the brake pads if the thickness of the brake lining material is 2.0 mm. Never replace only one pad or move the brake pads from one side to the other. The illustration below shows where the pad thickness is measured. Brake pads for carburetor models are 10 mm thick, pads for injection models are 11 mm thick. From these dimensions, you can determine the current service life of the pad.
Measuring the thickness of the overlay material.
6. Brake pad repair kits include parts that must all be used during installation. Clean the calipers with brake fluid or alcohol. Never use gasoline for this. Check that the piston gaskets are sealing properly. Check the brake disc for deep grooves caused by worn pads. Measure the thickness of the brake discs with a micrometer, as shown in the illustration below. Discs of carburetor models have a minimum permissible thickness of 18 mm, brake discs of injection models (ventilated) have a thickness of 20 mm. If the thickness is less than the specified values, they should be replaced.
Measuring the thickness of the brake disc.
7. You can replace just one disc, but most likely both discs will need to be replaced. Installing the brake pads is done in reverse order, but keep the following in mind. The illustration below shows the caliper components and how the caliper cylinder is suspended on the wire:
Elements for removing and installing the brake caliper.
8. Insert the inner pad with the intermediate plate, pull the caliper outward and insert the outer pad with the intermediate plate.
9. Insert the brake shoe guide plates.
10. Untie the wire and lower the caliper cylinder down without damaging the inserted brake pads.
11. Insert the bolts (see illustration) and tighten to the tightening torques shown in Illustration 2.0. The tightening torques for the two caliper designs differ slightly.
12. After installation, press the brake pedal several times and check if air has entered the system. If air has entered the system, bleed it (Section Bleeding the brakes).