*HOW TO* Fit 2L 16v/Turbo/V6 front brakes

[Adam]

Right, this procedure covers fitting the 256(2L 16v), 284(Turbo), 288 (V6), front brake setups to your nova.
For 256 you will need a minimum wheel size of 5.5J 14"
For 284/288 you will need a minimum wheel size of 6J 15" (some 15s fit, others dont)

Tools required:
-10mm Hex/Alley kit bit/socket and breaker bar, to remove the main bracket bolts
-17mm socket to undo wheel nuts
-Philips screwdriver
-Mole grips/brake hose clamp
-11mm spanner to undo hose bolt
-Can of carb/brake cleaner
-Copper grease
-Brake fluid to top up the system

*First start by loosening the wheel bolts 1/2 a turn, then jack the car up and place an axle stand under the chassis leg.
Once fully supported completely undo the wheel bolts and remove the wheel:


*Now, using the 10mm hex socket, undo the two bracket bolts holding the front caliper/bracket to the hub (highlighted in red)
These are usually very tight, and may require a breaker bar to undo


*Once undone, persuade the caliper off the disc, you may need to "wiggle" it side to side gently if the disc has a lip on, but it should slip off.


*Now, clamp the flexi brake hose using mole grips (cover the jaws with cloth to stop them cutting in), or use a proper hose clamp.
NOTE-This is only possible on standard flexi's, dont clamp braided hose. If you have braided hoses fitted you will have to leave the hose bolted to the old caliper until you have the new one fitted and can quickly swap the hose over. Hang the caliper off the suspension strut with some wire to take its weight.
Now you can undo the 11m bolt holding the hose, be prepared for fluid spillage as the caliper will be full of fluid. Put the rubber glove over the end of the hose to stop any dirt/grit getting into it.

*Finally, undo the philips screw that holds the disc to the hub.


And its off


*Wire brush the hub to remove any rust/dirt, as it needs to be TOTALLY flat for the disc to rotate correctly.
Now, copper grease the hub to prevent the disc rusting to it.
If this is your cars first brake upgrade then it will probably still have the disc shield fitted to the hub, gently bend this out of the way to clear the new disc, or remove it (i chose to remove it)

*Onto fitting the new stuff, prepare the new disc by cleaning it with brake cleaner. This is VERY important because they come coated with a wax/grease to stop them rusting. Grease and brakes dont work well together....
Once all the grease has been removed, fit the disc, and fit the philips screw:
NOTE-If fitting V6/Turbo discs, you will need to fit a spigot ring to the centre of the disc to make sure it sits correctly, and re-drill the disc to 4stud fitment if they are currently 5 stud.



Now, take the new caliper(assuming the pads are already fitted), and slide it over the disc until the bolt holes line up with the hub(the bolts you undid earlier on)
Now refit the two bolts that hold the caliper to the hub, do these bolts to 95NM


Next, fit the brake hose to the caliper(make sure the copper sealing rings are still fitted to the end of the hose/bolt)
Just nip these up, spanner tight. Then remove the pipe clamp
NOTE-If you have braided hoses, you will have to remove the hose from the old caliper, and quickly fit to the new, so you will loose a bit of fluid in the process

*Fitted:


Now do the exact same method to change the other side.

*You will now just need to bleed the front brake system. I recommend buying a Eezibleed kit for around £15, which makes bleeding much easier, and will come with instructions on how to use it.
If you prefer using the 2 man method, then this is covered in a haynes manual.
Remember to keep the fluid topped up, and check the level after bleeding to make sure its correct.

*Refit the road wheels and tighten the bolts to hold them
Remove the axle stand and lower the jack down, then FULLY tighten the wheel bolts

That is the conversion complete.
Have you first drive slowly around a few local streets to make sure all seems well, also check for any brake fluid leaks. If youve fitted new discs/pads, remember to bed them in

And finally i will say that as most people know, brakes are kind of handy to have. So if you're not 100% confident you can complete the job, get someone who is confident to help you. Brakes are not something you want to make a mistake with.

Any more info needed to be added to this guide, please say so.

Adam

[Jack]

If you don't want to re-drill the 5 stud Vauxhall discs, you can use Fiat Coupe discs - these are 4 stud, but the PCD is 1mm out so you will need to enlarge the bolt holes by 1mm each way. Lee used a 15mm drill bit to do mine, and they sit perfectly. Again, for ease of mounting the discs and wheels you may want to use a spigot ring.

The discs you need for this are the Fiat Coupe 16v/20v N/A discs, NOT the turbo ones. They are 284mm x 22mm x 39.4mm.

[Adam]

Aye, i have used the above discs in my conversion pics.
The reason they dont fit as standard is as said, the pcd is out by this much(hole slightly off):


Easily sorted with a drill bit, or a carbide bit to open the hole out slightly

[matt_vaughan]

Great guide Cheers Adam.

Will get round to doing this shortly!

[Stuart]

Adam, Dont forget the 7mm hex bit for the caliper to carrier sliders incase you wish to whip it all appart to give it a clean/new pads etc.

[craig green]

Being picky I'd be tempted to add new copper washers for the hose to caliper joint faces, esp if old.

[Adam]

Good points.

Aye, if you need to fit new pads/clean& grease the slide bolts, you will need a 7mm hex bit to unbolt the caliper from the carrier bracket.

I didn't use new copper washers, but had new braided hoses so mine were new anyway. So worthwhile doing if yours are old. You can restore old ones sealing ability by heating them till there red, and dunking them into cold water too.

[leenovagsi]

ive got 256 mm discs on my nova gsi could i just swap discs to 284 or 288 discs or would i need to change calipers i know it might seem a silly question but they look the same from wat i saw at the scrappies

[Adam]

Have to swap calipers and carriers.
OR a few companies make specially adapted brackets to keep the 256 calipers, and use 288 discs.

But in short, no you can't directly swap them.

[mayhem]

small trick for loosing brake fluid:

get both calipers off, push the pads fully back, put the brake pedal down with a piece of wood or something, slide the driversseat forward against the stick, so that the pedal stays down.

now you can remove the calipers from the brakelines without losing any fluid, just the little bit what is left in youre old calipers.