1. Remove the new caliper and guide sleeve kit from the packaging – use suitable lifting equipment for the caliper. Check that the new parts correspond with those that have been removed.
2. Grease both guide sleeves bores using the grease sachets provided. Slide the long guide sleeve in to the brass bush in the direction indicated.
3. Locate the boot into the sealing groove in the guide sleeve ensuring it seals correctly all around the sleeve. A little grease will help the boot slip into the groove.
4. Locate the plastic washer over the boot to retain it in the sealing groove in the guide sleeve ensuring the washer is in the correct orientation.
5. Fit the short bolt into the guide sleeve with pre-assembled rubber boot in the direction indicated.
6. Slide the guide sleeve and bolt into the rubber bush in the direction indicated.
7. Locate the boot into the sealing groove in the housing retainer ensuring it seals correctly all around the groove.
8. Roll the guide sleeve boot bellows back against the housing and push the bolt back into the rubber bush to provide clearance with the carrier during assembly.
9. Ensure the carrier threads are clean and dry (free of lubrication and residuals of pre-applied adhesive). Lift the caliper over the carrier and locate the bolts into the carrier – use suitable lifting equipment for the caliper. Ensure the correct new bolts are used for each guide sleeve – the long guide sleeve bolt has a pre-applied adhesive. If the caliper is being fitted away from the vehicle ensure the carrier is securely located to resist the bolt torque, at a location close to the bolt being tightened. Tighten both bolts to 180 Nm, then tighten by a further 90° – check that the caliper slides easily on the guide sleeves.
10. Locate the protective cap for the long guide sleeve into the caliper bore – protective cap and bore must be clean and free from lubrication. Press the metal protective cap into the long guide sleeve bore ensuring it is seated squarely until the cap protrudes 0 to 2 mm from the cast boss. Fitting the protective caps can only be done after the caliper has been fully bolted to the carrier. The guide sleeve boots must be in a compressed condition or the caliper’s freedom of movement will be limited.
11. Stretch the rubber bush bellows over the short guide sleeve, and position the plastic cap in the end of the guide sleeve bore – do not push into the bore yet. Slide the bellows back over the plastic cap, ensuring it locates correctly all around the groove, and then push the cap firmly into the guide sleeve so that it clicks into place.