Fiat Bravo Quiz
Brake system

Removing and installing front brake pads

In this manual: Brake system
Dear Reader — 1Engine — 35Engine lubrication — 3Engine cooling — 10Ignition/spark plugs — 14Fuel system — 10Petrol fuel injection — 13Diesel injection system — 13Exhaust system — 7Clutch — 7Transmission / Gearshift / Automatic Transmission — 5Front Axle — 11Rear axle — 4Steering — 9Wheel alignment — 1Brake system — 22Wheels and tyres — 10Body — 34Heating — 6Electrical system — 39Lighting system — 14Instruments — 7Windscreen wiper system — 8Vehicle care / tools — 6Jump Starting / Towing the Vehicle — 3Jacking up the vehicle — 1Fiat Bravo / Brava Maintenance Schedule — 1Maintenance — 38Wiring diagrams — 5
8steps
~48min
2/5difficulty
0204060801005037N·mlb·ft
Tightening torque found on this page
Done 0 of 8
Front brake caliper
Bremssattel vorn

  1. Retaining bolts

  2. Rubber boots

  3. Brake carrier

  4. Brake pads

  5. Bleed screw

  6. Brake caliper

  7. Protective cap

  8. Gasket

Removal

Caution: If the brake pads are to be reused, they must be marked during removal.

Pads must not be swapped between the right and left wheels. Swapping can lead to uneven braking. Always use only genuine Fiat brake pads or pads approved by Fiat. Always replace all front disc brake pads at the same time, even if only one pad has reached the wear limit.

  • Mark the position of the front wheels relative to the wheel hub with paint.

    This allows the balanced wheel to be refitted in the same position. Loosen the wheel bolts. The vehicle must be standing on the ground.

    Raise the vehicle at the front and remove the front wheels.

  • Pull the brake caliper outwards by hand, pushing the brake piston back slightly.

Ausbau

  • Pull the brake hose out of the holder on the strut.

  • Disconnect the plug connector for the brake pad wear indicator.

  • Lever out the retaining spring with a screwdriver.

Ausbau

  • Remove the cover caps and unscrew the retaining bolts with an 7 mm internal hex key. Remove the brake caliper and hang it from the body with wire. Caution: leave the brake hose connected, otherwise the system must be bled after installation. Make sure the brake hose is not under tension.

  • Visually check the brake hose for good condition, see chapter "Maintenance".

Ausbau

  • Remove the brake pads.

Installation Caution: With the brake pads removed, do not press the brake pedal, otherwise the piston will be pushed out of the housing. If the piston has been pushed out accidentally, remove the brake caliper and have it reassembled at a specialist workshop.
Bremsbeläge vorn aus- und einbauen

  • Clean the guide surface or seat of the pads in the caliper housing slot with a suitable soft-metal wire brush, or wipe out with a cloth and methylated spirits. Do not use mineral-oil-based solvents or sharp-edged tools. If the brake pads are to be reused, clean them as well.

  • Before installing new pads, check the brake disc for grooves by running your fingers over the surface. Replace brake discs with deep grooves. Clean discs with grey or blue discoloration before installing new pads.

  • Measure brake disc thickness, see page 176.

Bremsbeläge vorn aus- und einbauen

  • Check dust cap - 4 5 - for cracks. Have a damaged dust cap replaced immediately, as dirt that gets in quickly causes the caliper to leak. The floating caliper must be removed and disassembled for this (workshop job). 47 - Brake piston.

Bremsbeläge vorn aus- und einbauen

  • Push the brake piston back using the piston reset tool. A hardwood stick (hammer handle) can also be used, but take special care that the piston does not tilt and that the piston surface and dust cap are not damaged.

Bremsbeläge vorn aus- und einbauen

Caution: when the pistons are pushed back, brake fluid is forced from the brake cylinders into the brake fluid reservoir.

Monitor the fluid in the reservoir; if necessary, extract brake fluid with a suction pump.

Use a bleeder or plastic bottle for suction that will only come into contact with brake fluid. Do not use drinking bottles! Brake fluid is poisonous and must under no circumstances be sucked through a hose with the mouth. Use a suction pump.

Even after changing the pads, do not exceed the MAX mark on the brake fluid reservoir, as the fluid expands when heated. Spilled brake fluid runs down the brake master cylinder, damages the paint and causes rust.

Caution: Unevenly worn brake pads are not a reason for complaint. However, if the difference between the inner and outer pad exceeds 2 mm, check the caliper guide pins or the pistons for free movement. To do this, insert a wooden block into the brake caliper and have an assistant slowly press the brake pedal. The brake piston must move out and in easily. For this check the other brake caliper must be installed. Make sure the brake piston is not pushed out completely. If the piston moves stiffly, have the brake caliper repaired (workshop work).
Bremsbeläge vorn aus- und einbauen

  • The following step is not absolutely necessary: to prevent disc brake squeal, the back of the brake pads and the side parts of the backing plate (arrows) can be thinly coated with lubricant (e.g. Plastilube, Tunap VC 582/S, Chevron SRJ/2, Liqui Moly LM-36 or LM-508-ASC). The paste must never get onto the brake pad friction material or the brake disc. If necessary, wipe off the paste immediately and clean the brake pad with denatured alcohol.

Caution: The paste must under no circumstances get onto the dust boot, the brake pad itself or the brake disc. If necessary, wipe off the paste immediately and clean with methylated spirits, or have the dust cap replaced.

  • Carefully clean the thread in the brake carrier with a tap.

Bremsbeläge vorn aus- und einbauen

  • Insert the brake pads into the brake carrier. The brake pad with retaining spring and wear indicator cable is installed on the inside.

  • Position the brake caliper on the brake carrier. Make sure the brake hose is not twisted.

  • Bolt the brake caliper on with new self-locking bolts and tighten to 50 N·m, then press on the cover caps. Caution: the self-locking mounting bolts must be replaced every time they are loosened or removed.

  • Press the clip onto the brake caliper.

  • Connect the plug connector for the brake pad wear indicator.

  • Insert the brake hose with its mounting rubber into the bracket on the strut. Visually check that the mounting rubber sits on the brake hose in the same position as before it was pulled out of the bracket.

  • Position the front wheels so that the marks made during removal line up. Before fitting, lightly grease the centering seat of the rim on the wheel hub and the conical surface of the wheel bolts with wheel bearing grease. Do not grease or oil the threads of the wheel bolts. Fit the wheels.

    Lower the vehicle and tighten the wheel bolts crosswise to 90 N·m.

Caution: With the vehicle stationary, press the brake pedal down firmly several times until firm resistance is felt. This brings the brake pads into contact with the brake disc and seats them to match operating conditions.

  • Check the brake fluid in the reservoir and top up to the MAX mark if necessary.

Caution, carry out safety check:

  • Are the brake hose connections tightened?

  • Is the brake hose seated in the bracket?

  • Are the bleeder screws tightened?

  • Is there enough brake fluid in the reservoir?

  • With the engine running, carry out a leak check.

    To do this, press the brake pedal with 200 to 300 N (equivalent to 20 to 30 kg) for about 10 seconds. The brake pedal must not sink. Check all connections for leaks.

  • Bed in new brake pads carefully: on a quiet road, brake several times from approx. 80 km/h to 40 km/h with light pedal pressure.

    Let the brakes cool down somewhat between applications.

Caution: Do not perform full braking until a driving distance of approx. 200 km has been covered.

Note: brake pads must be disposed of as hazardous waste.

Local authorities can advise whether disposal with commercial waste similar to household waste is permitted.

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