Removing
1. Loosen the front wheel nuts.
2.
WARNING: Support with secure supports. Raise the front of the car.
3. Remove the wheel.
4. Remove the cotter pins from the shoe mounting pins.
5. Remove the brake pad retainers and springs.
6. Remove the brake pads and shim (if installed).
7. Move back the brake hose screen.
8. Using a suitable clamp, pinch the brake hose.
9. Place a container under the brake caliper to collect spilled fluid.
10. Loosen the brake line fitting and disconnect from the caliper.
11. Plug the open connections of the brake line and caliper with plugs.
12. Unscrew 2 bolts of fastening of a support.
13. Remove the brake caliper.
WARNING: Do not separate caliper halves.
14. Clean the outer surfaces of the caliper with an aerosol brake cleaner.
15. Using the special tool LRT-70-500, clamp the pistons into the inner half of the caliper. Gently, being careful not to get your fingers dirty, and CAREFULLY apply pressurized air to the brake fluid inlet to dislodge the pistons. It is unlikely that the pistons will be displaced at the same time, adjust the degree of displacement with a suitable piece of wood inserted between the corresponding piston and caliper.
16. Finally, remove the pistons by marking according to their bores.
17. Remove the wiper holder by inserting a blunt screwdriver between the holder and the wiper. Gently lift the holder from the entry end of the hole.
18. Taking care not to damage the sealing grooves, remove the wiper and fluid seal.
19. Using only clean brake fluid, clean bores, pistons and sealing recesses. If the caliper or pistons are rusty or not in perfect condition, new elements must be installed.
20. Apply brake fluid to the new fluid seal. Only use your fingers to release the seal into the notch in the hole. Make sure the seal is properly installed. The liquid seal and the recess have a different section, so that after the seal is installed, it slightly protrudes to the touch over the edge of the inlet end of the hole.
21. Apply brake fluid to the appropriate piston. Manually insert it into the hole without tilting. While inserting, do not tilt the piston, leave it to protrude from the hole by approximately 8 mm.
22. Apply brake fluid to a new wiper and install it in the holder. Slide cuff assembly with holder (cuff first) above the protruding piston into the hole recess. Use the plunger clamp to press the cuff holder and plunger into place.
23. Clamp the outer pistons and follow the same procedure to remove and install the outer pistons and seals.
Installation
1. Clean the mating surfaces of the caliper and hub.
2. Install the caliper on the hub, screw in the bolts and tighten them (tightening torque 82 Nm).
3. Remove the plugs from the brake line and caliper connection holes and wipe the connections clean.
4. Connect the line to the caliper, tighten the fitting (tightening torque 15 Nm).
5. Apply a thin film of grease to the back of the brake pads.
6. Install the brake pads on the calipers. Starting with 2002 model year vehicles, make sure the brake pads are properly installed. The illustration shows how the leading edge chamfer should be set.
7. Install brake pad retainers and springs.
8. Install cotter pins into retainers.
9. Remove the brake hose clamp.
10. Remove air from the brake system.
For more information, refer to the chapter: Bleeding the brake system (206-00 Brake system - General information, General procedures).
11. Depress the brake pedal to seat the pads on the discs.
12. Install the wheels, remove the axle supports and tighten the wheel nuts (tightening torque 130 Nm).
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