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Summary of Content
FRONT BRAKES ALFA ROMEO MiTo FRONT BRAKES 1.4, 1.3 JTDm, and 1.6 JTDm front brake view Ventilated disc brake, with floating caliper and control cylinder. BRAKE PADS REMOVAL - Position vehicle onto lift. - Remove front wheels. ➧ Note: Brake pad wear sensor is fitted on left front brake caliper, only. - Disconnect electrical connector (1) from brake pad wear sensor, and release wiring from middle retaining clip. - Loosen lower retaining screw (2) between front brake caliper and bracket. Brake caliper lower retainer removal - Eliminate any glue residues present under side tabs, and caliper piston. - Remove front brake pads (3) from bracket. Brake shoe removal 3 3 - Remove sliding clips (4) from brake caliper bracket. Sliding clip removal 1 4 2 4 - Turn front brake caliper, and secure it in place. WARNING: When retracting the piston into the caliper housing, brake fluid is pushed into the reservoir. When retracting the caliper, ensure that caliper piston is supported. Make sure that brake pad contact points are clean and free from any contamination. INSTALLATION GUIDE 1.4 • 1.3/1.6 JTDm FRONT BRAKES ALFA ROMEO MiTo 1.4 • 1.3/1.6 JTDm ASSEMBLY - Clean caliper bracket before fitting pad sliding clips. - Position the sliding clips inside bracket seats. - Place front brake pads inside their seats, taking care to correctly position pad on vehicle piston side. This pad is identified with the rivets (1) parallel to locking tabs (2). - Place front brake pads inside their seats, taking care to correctly position pad on vehicle reaction side identified with the rivets (3) at right angles with locking tabs (4). - Remove any double-sided film protection from brake pad back side. - Loosen screws (5), and remove front brake caliper (6). Brake caliper removal 6 5 Brake pad positioning PISTON SIDE 1 2 2 - Loosen mount retaining screws, and remove front brake caliper. - Loosen retaining screws, and remove brake caliper holder bracket. - Loosen screws (7), and remove front brake disc (8). REACTION SIDE Brake disc removal 3 4 4 7 - Position front brake caliper inside its seat, and tighten a new screw to a torque of 27 ÷ 30 Nm. - Connect brake pad wear sensor electrical connector, and secure wiring in place with middle retaining clip. 8 BRAKE DISC REMOVAL - Position vehicle onto lift. - Remove front wheels. ➧ Note: Brake pad wear sensor is fitted on left front brake caliper, only. - Disconnect electrical connector from brake pad wear sensor, and release wiring from middle retaining clip. ASSEMBLY - Reposition front brake disc into its seat, and tighten screws to a torque of 10 ÷ 15 Nm. - Put front brake caliper into its seat, and tighten screws following the correct sequence (start with a torque of 15 Nm, and then tighten to a torque of 27 ÷ 30 Nm starting from the upper screw). - Connect brake pad wear sensor electrical connector, and secure the corresponding wiring in place. OPERATIONAL PRECAUTIONS Brake fluid is hygroscopic, and it should be changed at regular intervals. Do not use fluid which does not comply with the specifications indicated in the table. Take care not to let fluid accidentally drop onto painted, rubber, plastic and mechanical parts. PARKING BRAKE Hand brake mechanical control consists of a lever (1), positioned between the two front seats, operating a rocker arm with two flexible link bars (2) connected with parking brake levers on rear brakes. ➧ Note: The caliper lever must always be at the stops before the piston is wound back when new pads are fitted. If not the park brake will not function correctly. Parking brake view Park brake applied 2 1 ADJUSTMENT ➧ Note: Parking brake should be adjusted after having replaced rear brake pads or the complete cable, as wear clearance is automatically closed up. - First check before cable is adjusted that the lever that comes from the caliper is at the stop. - Mark adjuster nut (3) position, then loosen it at least by 2 or 3 turns so as to ensure complete loosening of the cable. Park brake adjuster nut Lever at the stop 3 - Apply one notch to the park brake and check that the lever has moved away from the stops and the gap is the same on both calipers. One notch - Start engine, and operate brake pedal vigourously at least 10 times. - Pull hand brake lever up to the fifth click of the toothed section. - Tighten adjuster nut onto hand brake lever until rear wheels are braked. - Make sure that, with the hand brake lever in rest position, rear wheels are free to turn. - Switch engine off. FRONT BRAKES ΜΠΡΟΣΤΙΝΑ ΦΡΕΝΑ ALFA ROMEO MiTo 1.4 • 1.3/1.6 JTDm HYDRAULIC CIRCUIT FILLING AND BLEEDING - Position vehicle onto lift. - Make sure that brake-clutch fluid level is between MIN and MAX marks. - Remove brake-clutch fluid reservoir cap, and connect a suitable tool to the reservoir. ➧ Note: To prevent any impurities from entering the brake-clutch fluid reservoir, before loosening cap thoroughly clean both cap and the whole reservoir surface around it. ➧ Note: To ensure complete bleeding of the braking system the bleeder operating overpressure should be set to 1.0 bar. - Slowly open bleeder cock, and wait for all air inside the hydraulic system to be evacuated. - All brake bleeding needs to be conducted in a set order, starting with the brake caliper furthest from the master cylinder. - Once the bleeding operations have been completed, carry out a road test where at least one instance of ABS braking occurs. - Remove protective cap. - Connect the recovery device, and open bleeder valve onto brake caliper. BRAKE FLUID Product: Capacity: Maintenance intervals: DOT4 SAE J1703 1.0 litre Replacement and bleeding every 2 years BRAKE FLUID DOT4 FBX050 500ml FBX100 1 lt FBX500 5 lt FBX2000 20 lt FERODO PART NOS Brake Pads FDB1468 Bosch Brake Caliper Brake Pads FDB1468 Length (mm) 151.0 Height (mm) 57.3 Thickness (mm)* 18.4 Min. thickness (mm)* 8.0 Brake Discs DDF762 Type Ventilated Diameter (mm) 257.0 Thickness (mm) 22.0 Min. thickness (mm) 20.2 * Support included The Ferodo brand is a registered trademark of PRMFE1122-EN In co-operation with: Semantica automotive Srl