Before starting to service the single
Piston disc brake caliper in front, disconnect the battery's negative cable from its post. Press the brake pedal past its first inch with a brake pedal holding tool to separate the master cylinder from the hydraulic brakes. Lift the vehicle up, remove the wheel from the mounting bolts and then take off the tire and wheel assembly. To disconnect the brake hose from the caliper, take out the banjo bolt, throw away the old washers and install new ones when you reassemble it. With the guide pins in place, take out the caliper guide pin bolts and pull the caliper off the brake adapter and its pads. Don't use high-pressure air to take out the piston from the caliper, since it can be dangerous. It's important to check and clean the caliper before taking it apart. Let the brake fluid drain, clamp the caliper in a vise on the jaws and cover the piston with a padded wooden block. Gently use low-pressure compressed air to move the piston out of the bore and remove it by hand. Be sure to avoid using metal tools while removing your seals to prevent harm. Clean the chamber and the drilled piston channels with alcohol or a good solvent, checking them for signs of damage. Wet the parts you're cleaning with water, then wipe them away, making sure any asbestos-contaminated cloths end up in an air-tight bin. You should clean and dry the area, well-oil the caliper piston, piston seal and bore with new brake fluid and fit a new piston seal and dust boot. Work the piston into the bore completely and then sit the dust boot in place using Special Tool 9315 and Special Tool C-4171. In the proper threaded hole, use the bleeder screw and tighten it to 15 Nm. Before fitting the caliper, pulling back the piston will let you examine the
Brake Pads. Put the caliper on the adapter without crossing the guide pin bolts and then tighten them up to 60 Nm. Screw the banjo bolt back into place using new washers and tighten to 43 Nm. Put the tire and wheel assembly back on, tighten the nuts on the wheel mounts to 150 Nm, drive the vehicle down, release the brake tool, secure the cable from the battery negative terminal, flush the brake hydraulic system as required and check that everything works well on the road test.