FREE REPAIR MANUALS & LABOR GUIDES 1982-2013 Vehicles
Courtesy of Operation CHARM: Car repair manuals for everyone.

Front



NOTE: For model name/model number cross reference refer to Model Designation Table. Application and ID






NOTE: Brake hose connection on brake pipe modified. Description and Operation

DANGER
^ Risk of poisoning due to consuming brake fluid.
^ Risk of injury due to brake fluid coming into contact with the skin or eyes.
^ Only pour brake fluid into suitable, appropriately marked containers.
^ Wear protective clothing and safety glasses when handling brake fluid.

Removal

NOTE:
^ Refer to Notes On Brake Fluid. Vehicle Damage Warnings
^ Refer to Notes on Test and Repair Work to brake system. Vehicle Damage Warnings

1. First disconnect brake hose (51) on brake pipe (5) and then on floating caliper (31a).
- Immediately seal connections with plugs.
- The brake fluid reservoir must not empty completely.
2. Disconnect front brake pad wear sensor (S10/1) from connector (S10/1x1).
3. Unscrew and discard microencapsulated bolt (31e) for front brake pad wear sensor connector (S10/1xl) on floating caliper
4. Remove and discard self-locking bolt (35)
5. Unscrew floating caliper (31a) together with brake caliper carrier.

Installation
6. Install in reverse order, noting the following
- Replace self-locking bolts (35) for caliper carrier, tighten to 115 Nm.
- Tighten microencapsulated bolt (31e) for front brake pad wear sensor connector to 30 Nm

NOTE:
^ Install one or two wear sensors for each wheel side corresponding to the number of sensor plug contacts.
^ Location of wear sensors for:
Lucas floating caliper: on outer brake pad.
Teves floating caliper: on inner brake pad
^ One wear sensor is installed on model 202 and taxi version as of 09.95.

- Tighten brake pipe (5) on brake hose (51) to:
Except model 210 14 Nm
Model 210: 18 Nm
- Tighten brake hose (51) on floating caliper (31a) to: 18 Nm
- Refer to Replacement, for notes on installing brake hoses. [1][2]Procedures

NOTE:
^ Brake hose connection on brake pipe modified.
^ The versions are not interchangeable.

- Refer to notes on installing brake pad wear indicator contact sensors. Service and Repair
7. Bleed brake system. Service and Repair
8. Check brake system for leaks, refer to Using Pedal Pressure. Testing and Inspection