Front Brake Pads, Removing And Installing : Installing

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Do not loosen the bolts -arrows-.

Fig 1: Do Not Loosen The Bolts

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WARNING: There is a risk of malfunction. Do not loosen the bolts -arrows-.

If old brake pads are being replaced with new ones, then it is necessary to check the brake rotor thickness for wear. Pay attention to the wear limit for the brake rotor thickness.

-- Check the brake rotor thickness. For the correct wear limit. Refer to FRONT BRAKES .

Installation is performed in reverse order of removal, while noting the following:

Tightening specifications. Refer to OVERVIEW - FRONT BRAKES .

NOTE:

Use the complete repair kit when installing new brake pads.

If the brake pads are being replaced, then it is necessary to check the respective brake rotor for wear. For brake rotor wear limit. Refer to BRAKES, TECHNICAL DATA .

Always replace brake pads on both sides of the axle.

CAUTION:

Danger of contamination and paint damage from escaping brake fluid.

If the brake pads are worn out and unnecessary brake fluid is filled, the brake fluid may overflow, causing the pistons in the brake cylinders to be pressed back.
Check the brake fluid level before pressing back the pistons. If there is brake fluid up to the "MAX" mark, some brake fluid will need to be extracted.
Use the Brake Charger/Bleeder Unit VAS 5234 to extract brake fluid from brake fluid reservoir.

NOTE:

Use only mineral spirits or commercially available brake cleaner to clean the brake caliper.

Check the brake piston protective caps for damage and install the complete repair kit, if necessary. Refer to BRAKE CALIPER, SERVICING, THREE-PISTON BRAKE .

WARNING: Do not blow out brake system with compressed air.

-- Use the Piston Resetting Tool T10145 to press the brake piston completely into the brake caliper.

-- Clean the brake caliper on the brake pad contact surfaces -1 and 2- and thinly coat them with Lithium grease.

Fig 2: Identifying Brake Pad Contact Surfaces

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-- Install the brake pad wear sensor -2-.

Fig 3: Identifying Brake Pads

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-- Check the brake pad wear sensor for correct seating and damage if installing used brake pads.

NOTE: Replace the damaged brake pad wear sensor.

-- Insert brake pads -1 and 3- into the brake caliper.

The brake pad with the brake pad wear sensor mount faces toward the inside of the vehicle.

-- Note the installed position of the brake pad spring:

Fig 4: Installed Position For Brake Pad Spring

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The "arrow" points in the direction of forward wheel rotation.

-- Insert the tension strut -2- and tighten with a new bolt -4-.

Fig 5: Identifying Brake Pad Spring

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-- Insert the upper brake pad pin -3- with the brake pad spring -5- into the brake caliper.

-- Drive the brake pad pin into the brake caliper until it stops.

-- Press the bottom of the brake pad spring down and drive the lower brake pad pin -1- into the brake caliper until it stops.

-- Secure the brake pad wear sensor electrical wire -3- by guiding it on the brake caliper -arrow- and securing it with the dust cap -2- as shown.

Fig 6: Identifying Brake Pad Wear Sensor Electrical Wire And Dust Cap

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NOTE: Ignore -item 1-.

-- Bring the connector into its installed position and turn in direction of the -arrow- until the tab -1- engages in the hole -2- on the bracket.

Fig 7: Identifying Tab

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-- Connect the electrical connector -3-.

-- Install the front wheel. Refer to Wheels, Tires, Wheel Alignment .

WARNING:

Make sure the brakes are working correctly before driving the vehicle for the first time.

After installing, press the brake pedal several times firmly to properly seat brake pads in their normal operating position.

Check brake fluid level, and fill if necessary.

-- Check brake fluid level, and fill if necessary.