Removing
1. Pump out a brake liquid from a tank.
2. Raise the car and remove the wheels.
Sumitomo calipers
3. Remove the brake pads from the caliper.
4. Disconnect a brake hose from a support and close its end.
4.5 When removing the Sumitomo caliper, remove the bolts holding the caliper halves together (A) - unscrew the fixing bolts of the caliper (IN) and remove the caliper from the car
5. Remove the two bolts holding the halves of the caliper together (4.5). Unscrew the two mounting bolts and remove the caliper from the car.
All other caliper models
4.6 Loosen the banjo connection bolt (indicated by an arrow) on models with this connection
6. Disconnect the brake hose from the caliper and cover the end of the hose (4.6).
7. Turn off fixing bolts of a support and remove it.
Bulkhead
8. Clean the outer surface of the caliper with alcohol or brake cleaner.
4.9a Clamp the Sumitomo caliper in a vise, unscrew the bolts holding the inner and outer halves of the caliper together and separate them
4.9b The inner part of the caliper can now be removed from the bracket
9. When rebuilding a Sumitomo caliper, remove the two bolts holding the caliper halves together, then separate them (4.9a). Then remove the bracket (4.9b).
10. To remove the piston from the caliper:
4.10a On Sumitomo calipers, place the caliper piston down and press out the piston with compressed air
- A) On Sumitomo calipers, place the caliper piston side down on a work bench and press out the piston with compressed air (4.10a).
4.10b On all other calipers, install a piece of wood into the caliper
- b) On all other calipers, place a wooden block or rags in the caliper (4.10b), then push the piston out with compressed air.
4.11 Remove the dust cover
11. Remove the dust cover (4.11).
4.12 Remove the piston seal from the groove in the cylinder
12. Remove the piston seal from the groove in the cylinder (4.12).
4.13 Remove the bleeder screw
13. Remove the bleed screw. On Sumitomo calipers, remove the pin bushing from the caliper bracket (4.13). On all other models, remove the covers and bushings.
14. Clean the rest of the parts with alcohol or brake cleaner, then dry them.
15. Inspect piston for scratches or nicks and replace if present.
16. Inspect the cylinder for scratches, nicks, or corrosion.
17. Lubricate the cylinder with clean brake fluid, lubricate the new piston seal with silicone grease or brake fluid, and install the seal in the cylinder.
4.18a On calipers where a mounting ring is used to attach the dust cover, lubricate the piston with brake fluid. Insert the piston into the cylinder and press it deep into the cylinder
4.18b Install the cover on top of the piston.
4.18v...then install a new retaining ring
18. On calipers where a mounting ring is used to secure the dust cover, lubricate the piston with brake fluid. Insert the piston into the cylinder and press it deep into the cylinder (4.18a). Lubricate the groove on the piston with silicone grease, then install the dust cover and retaining ring (4.18b and 4.18c).
4.19a On models without a mounting ring of the boot, install the boot on the bottom of the piston...
4.19b... then install the edge of the boot into the upper groove in the cylinder and lower the piston i cylinder
19. On the remaining calipers, lubricate the piston and edges of the piston boot with silicone grease, then install the boot on the bottom edge of the piston (4.19a). Install the piston and boot into the cylinder and install the boot into the groove in the cylinder (4.19b). Then lower the piston deep into the cylinder.
4.20 On Sumitomo calipers, lubricate the bracket pins with silicone grease, install the inner half of the caliper onto the bracket
20. On a Sumitomo caliper, lubricate the pins of the caliper bracket with silicone grease and install the bracket onto the inner half of the caliper (4.20).
Fold the halves of the caliper, install the bolts and tighten them to the required torque.
4.21 On calipers of other models, lubricate the bushings and pins, cylinders and edges of the rubber boots with silicone grease
A)
Bush side
1. Caliper; 2. Sleeve
b)
Finger side
1. Narrow Wide; 2. Caliper; 3. Finger
21. On all other caliper models, lubricate the bushings, caliper bores, and boots with silicone grease, then install these items on the caliper (4.21).
Installation
22. On Sumitomo calipers, install the caliper onto the brake disc. Install the fixing bolts and tighten them to the required torque. Then connect the brake hose and install the brake pads.
23. On other caliper models, install the brake pads, then install the caliper and pins or mounting bolts and tighten them to the required torque. Connect the brake hose.
24. Bleed the brakes.
25. Install the wheels and lower the vehicle to the ground.
26. Depress the brake pedal several times.