Preparation work
 WARNING!
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Risk of poisoning and injury when handling brake fluid!
Swallowing brake fluid can cause symptoms of poisoning such as headaches, dizziness, stomach pains, vomiting, diarrhoea, cramps and unconsciousness.
A dose of more than 100 cm3 can have fatal consequences.
Contact with brake fluid can cause serious skin damage to unprotected skin.
Wear safety glasses and protective clothing such as rubber gloves.
| • | Ensure that brake fluid is only accessible to authorized personnel.
| | • | Store brake fluid in original containers only.
| | • | Only store brake fluid in suitable, appropriately marked containers.
| | • | Never put brake fluid in beverage containers.
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WARNING!
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Risk of accident due to lack of braking effect!
When the brakes are used for the first time after any work was performed on the braking system’s hydraulics area, the risk of an accident is increased due to an impaired braking effect.
Press the brake pedal several times to build up pressure in the brake system after finishing work on the braking system’s hydraulics area and before starting the vehicle.
| • | Hold the brake pedal in a pressed down position for approximately 30 s once pressure has been built up in the brake system, the pressure in the brake system must not drop during this time.
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WARNING!
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Possible fluid spills from vehicle systems during repairs or maintenance.
Risk of thermal incidents, slip hazards, corrosion of electrical components, failure of electrical or mechanical components or unwanted odours.
Always limit fluid spills and fully clean the spilled fluid after repairs or maintenance.
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Detach brake caliper - Front
| 1. | | | | | | Care Point: | Support caliper whilst removing bolts (2).
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| | | 2. | | | | | | Care Point: | Do not allow caliper to hang from brake hose and pad wear sensor flylead.
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| | | 3. | Hang caliper (3) in a suitable position with cable ties.
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Remove brake caliper - Front
| 1. | Disconnect electrical connector (1).
| | | 2. | | | | 3. | Detach pad wear sensor flylead from harness clips.
| | | | | Care Point: | Use a suitable container to catch excess fluid.
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| Care Point: | Plug caliper and hose once disconnected.
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| | | 4. | | | | | | Care Point: | Support caliper whilst removing bolts (4).
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| | | 5. | | | | 6. | Remove caliper (5).
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Install brake caliper - Front
| | | Care Point: | Replace copper washer of banjo bolt.
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| Care Point: | Replace caliper bolts.
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| Care Point: | Make sure brake components are clean and free from dirt and debris.
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| Care Point: | Risk of component damage: Do not use brake cleaner on calipers.
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| | | 1. | Install brake caliper in reverse order.
| | | | | Care Point: | The procedure below must be claimed separately if you make a warranty claim.
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| | | 2. | | | | 3. | Install remaining components in reverse order.
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