Front Brake Pads - Replacement

Dust produced by pad wear may contain asbestos, which is hazardous to health. Never blow it off with compressed air and never inhale any of this dust.

Do NOT use gasoline-based solvents to clean brake parts. Use only brake cleaner or denatured alcohol.

Do NOT allow brake fluid, oil or grease to contact the pad friction surfaces or the discs. Also observe the hazards associated with brake fluid.

The pads can be replaced in the following sequence:

• · Place chocks under the rear wheels, then raise the front of the vehicle with a jack and support it on stands.
• · Remove the front wheels.

All models except GTi:

• · Push back the caliper piston by pulling the caliper outward by hand.
• · Loosen the lower caliper guide bolt with a socket wrench, holding the guide from turning with an open-end wrench.
• · Remove the lower guide bolt and swing the caliper upward to access the brake pads. Tie the caliper up in the raised position.
• · Remove the spring clips and take out the outer and inner pads with the anti-squeal shims. If the old pads will be reinstalled, mark their positions.
• · Remove the four guide pins from the caliper support bracket.
• · Measure the thickness of the friction material on the brake pads. If at least one is worn to the minimum or is contaminated with oil, replace the complete set of four pads. Do not swap pads side to side to even out wear.
• · Brush the caliper, piston and disc clean of dust and dirt.

· Inspect the piston boot for damage and fluid leakage. If any is found, the caliper must be repaired. · Inspect the disc for cracks, chips and excessive wear. · To install new pads, press the piston into the caliper with a C-clamp, because new pads are thicker. Note that pressing the piston will push some brake fluid back into the reservoir, which may cause it to overflow. To prevent this, remove some fluid from the reservoir. If fluid spills onto body panels, hoses or other engine compartment components, wipe it off immediately.

• · Before installation, make sure the pads and disc are clean. Remove the protective paper from new pads before fitting. Install the old pads in their original positions.
• · Insert the four guide pins into the caliper support bracket.
• · Install the brake pads with the anti-squeal shims into the support bracket. · Install the spring clips, then lower the caliper onto the pads.
• · Install the lower guide bolt and, holding the guide with a second wrench, tighten the bolt to the specified torque (34 N·m).
• Repeat this procedure on the other brake assembly.
• · Check the brake fluid level in the master cylinder reservoir and, if necessary, top up to the MAX level. Press the brake pedal several times so the pistons press the pads against the disc, then check and top up the fluid level again.
• · Install the wheels and lower the vehicle to the ground. Tighten the wheel nuts to the specified torque.
• · To bed in new pads, drive the vehicle for approximately 100 miles, avoiding hard braking whenever possible.