Impulse L4-1994cc 2.0L (1985)
Brake Caliper: Service and Repair
Front Caliper
Removal and Installation
1.
Raise and support vehicle and remove front wheels.
2.
Disconnect flexible brake hose at caliper and cap hose openings.
3.
Remove upper and lower caliper mounting bolts, then remove caliper from disc.
4.
Reverse procedure to install, torquing caliper attaching bolts to 25-28 ft. lbs. and the brake hose to 10-13 ft. lbs.
Disassembly and Reassembly
1.
Remove caliper as previously described.
2.
Remove boot guide pin and boot lock pin.
3.
Remove breather with cap.
4.
Remove dust boot using small screwdriver.
5.
Remove piston boot.
6.
Install block of wood into caliper and remove piston by applying compressed air through opening for brake hose.
7.
Reverse procedure to assemble, using new guide pin boot, lock pin boot, piston ring boot and caliper to piston seal supplied with overhaul kit, and
note the following:
a. Using special grease supplied with overhaul kit, lubricate ring seal and cylinder wall, then insert ring seal into cylinder bore.
b. When installing piston into cylinder bore, use finger pressure only.
c. Using special grease supplied with overhaul kit, lubricate boot fitting face of piston before installing piston boot.
d. Fill guide pin boot with grease before installing on caliper.
e. Apply grease to inner face of lock pin boot after applying grease into lock pin hose in caliper.
f.
Install guide pin boot after applying grease into lock pin hole in caliper.
g. Install new gaskets for flexible brake hoses.
h. Torque breather to 4.5-6.5 ft. lbs. and install cap.
i.
Torque flexible brake hose to 24-27 ft. lbs.
