PDA

View Full Version : *HOW TO* Fit 2L 16v/Turbo/V6 front brakes



Adam
25-05-08, 10:21 PM
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:
http://img.photobucket.com/albums/v86/Nova-crew/Turbo%20brake%20fitment/DSCN0748Custom.jpg

*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
http://img.photobucket.com/albums/v86/Nova-crew/Turbo%20brake%20fitment/Img_2639.jpg

*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.
http://img.photobucket.com/albums/v86/Nova-crew/Turbo%20brake%20fitment/DSCN0752Custom.jpg

*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.
http://iainel.no-ip.org/%7Eiain/29%20Brakes/IMG_2643.JPG

And its off
http://img.photobucket.com/albums/v86/Nova-crew/Turbo%20brake%20fitment/DSCN0753Medium.jpg

*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.

http://img.photobucket.com/albums/v86/Nova-crew/Turbo%20brake%20fitment/DSCN0762Custom.jpg

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
http://img.photobucket.com/albums/v86/Nova-crew/Turbo%20brake%20fitment/DSCN0765Custom.jpg

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:
http://img.photobucket.com/albums/v86/Nova-crew/Turbo%20brake%20fitment/DSCN0763Custom.jpg

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
26-05-08, 11:51 AM
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
26-05-08, 12:11 PM
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):
http://img.photobucket.com/albums/v86/Nova-crew/Turbo%20brake%20fitment/DSCN0756Custom.jpg

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

matt_vaughan
28-05-08, 09:38 AM
Great guide Cheers Adam.

Will get round to doing this shortly!

Stuart
28-05-08, 09:59 AM
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
28-05-08, 10:14 AM
Being picky I'd be tempted to add new copper washers for the hose to caliper joint faces, esp if old.

Adam
28-05-08, 04:15 PM
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
28-05-08, 06:02 PM
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
28-05-08, 06:04 PM
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
01-07-08, 05:02 PM
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.

DaveyLC
15-09-08, 05:12 PM
Are they Vectra calipers or Fiat Calipers?

Adam
15-09-08, 05:48 PM
Vauxhall

Only the discs are fiat items

DaveyLC
15-09-08, 07:04 PM
They are the big vectra V6 calipers though? I only ask because I'm about to have some V6 discs re-drilled and I'd rather go buy the fiat items if they are compatible :)

Cheers!

Adam
15-09-08, 07:07 PM
They aren't compatible. Its only the discs that you can use.

Yes ,v6 calipers.
Although mine are Cally turbo ones

DaveyLC
15-09-08, 11:00 PM
Thats all im interested in, the discs that is :) I'd rather use the fiat discs if they are almost bolt on with my v6 calipers.

Cheers.

kc_08
16-10-08, 02:33 PM
so if i upgrade my nova to 2.0 16v brakes, i will need to change the calipers aswell then yeah mate? thats a good guide, im sure i cold do it useing this guide now :D

matt_vaughan
31-10-08, 08:46 PM
KC_08 you need to change discs and calipers yer.

DaveyLC
31-10-08, 11:12 PM
I went for 03 Meriva 1.7TD discs in the end.. They bolt straight on:

http://www.dohc.co.uk/temp/corsa/28-10-08/28102008076.jpg

matt_vaughan
08-11-08, 01:10 AM
Just to clarify, is there need for a larger master cylinder, say off a GTE/GSI?

Adam
08-11-08, 07:03 PM
All nova master cylinders are the same size.
GTE/GSi have a bigger Servo, but its NOT needed.
If you have one though, fit it.

matt_vaughan
08-11-08, 09:03 PM
Thanks very much adam, have some Rep

mayhem
11-11-08, 09:29 PM
for turbo brakes you can also use meriva opc disks. these are already 4 stud.

DaveyLC
11-11-08, 11:13 PM
<cough>

I went for 03 Meriva 1.7TD discs in the end.. They bolt straight on:

http://www.dohc.co.uk/temp/corsa/28-10-08/28102008076.jpg

mayhem
12-11-08, 10:51 PM
didnt know there the same. the opc disks are used here.

jonn
29-03-09, 11:29 AM
what car has these brakes beacuse i need to find a set of brake calipers

Adam
13-04-09, 07:02 PM
I had a look in a parts catalogue tother day, and Meriva front discs are only 260mm? (1.6/1.7/1.8)

djbrowney
13-04-09, 07:11 PM
I had a look in a parts catalogue tother day, and Meriva front discs are only 260mm? (1.6/1.7/1.8)

i spoke to auto vaux the other day an they said 280 mm are you sure you meant 260 adam :thumb:

sparkie1401
16-04-09, 01:37 AM
meriva come in 260 and 280mm, i checked last week with my friend who works in a motor factors, they come in 4 and 5 stud to

Adam
18-04-09, 03:27 PM
Which model are the 280 4stud off?

sparkie1401
18-04-09, 08:00 PM
:thumb:
Which model are the 280 4stud off?

you can get 280mm in both 4 an 5 stud

2003 Meriva TDCi 1700

i will be getting some rather soon, beats the V6/fiat coupe set up for easyness!

im not sure if you need any spiggot rings as im not done my homework fully. next time i go to where my mates work ill meaure the central hole compared to a cav 256mm disc

Adam
19-04-09, 01:22 PM
Fiat discs are too big for a nova hub, but i ran then without spigots with no problems.....

Edit-Had a look on ebay and cant find any 280 Meriva discs, there all 260/264 on there...

sparkie1401
19-04-09, 02:42 PM
i realise the fiat discs need a spigot as do the V6 set up

trust me Meriva are available in 280mm 4 stud, i know a lad who works in a motorfactors, and ebay is not worth the time of day most of the time

illget some concrete evidence 4 you this week

Adam
19-04-09, 02:56 PM
Find me some, i want some! lol

Yes Fiat discs "need" spigots, but as said ive NEVER run any.... and had no problems.

Jack
19-04-09, 09:00 PM
Meriva 1.7TD are 280x25mm, 4 stud, with a 60mm centre bore.

[edit] But as to whether you'd find any "decent" discs for them... a derv Meriva isn't exactly a performance machine now is it!

Andy_L
19-04-09, 09:23 PM
Just to add, a Cav Slab does not go over a 288 disc and caliper (well not on my Cav anyway). Both were new discs and pads. I reckon on about 3mm spacers or grind caliper and alloy a bit.

sparkie1401
19-04-09, 11:09 PM
Meriva 1.7TD are 280x25mm, 4 stud, with a 60mm centre bore.

cheers statolol

next Question, is the 256mm a 60mm centre bore?

adam im gonna try get a set of callipers ill let you know how much i can get em for as i have contacts in the salvage world:thumb:

Jack
21-04-09, 07:40 AM
next Question, is the 256mm a 60mm centre bore?
Yep.

OllieKing
11-05-10, 08:02 PM
Hi, What do the 256mm come off?
will they make a noticable difference from standard?
any help is appreciated!
cheers

Annie
11-05-10, 10:04 PM
most vauxhalls, astra, cav, calibra, vectra... straight swop :)

AlexW
12-05-10, 08:58 PM
There is also a thinner disced 256 setup on Corsas and Tigras (and some others) which is only 20mm wide. Helps with some wheel clearance issues.

Brakes are a masssive improvment!

swedge
12-05-10, 10:16 PM
put a plastic bag underneath the lid of the brake fluid resevoir and tighten it up, also stops fluid leaking out

LEWI007
15-09-10, 11:58 AM
So if i order a set of 2003 Meriva TDCi 1.7TD 280x25mm 4 stud discs.

They will fit straight onto 4 stud nova hubs with vectra V6 calipers and pads?

Sloth
15-09-10, 03:22 PM
thats what page 1 says.

LEWI007
15-09-10, 04:27 PM
thats what page 1 says.


it doesnt someone just said they fit and id rather get a definitive answer before i spend 40 quid ordering a set

Iain
15-09-10, 07:02 PM
it doesnt someone just said they fit and id rather get a definitive answer before i spend 40 quid ordering a set

Just nick some from the scrappy then.

LEWI007
15-09-10, 09:11 PM
lol

dont take the p1ss, i seriously need to know so i can order some.

Pistol Pete
15-09-10, 09:27 PM
Well, they are 4 stud, WIN. 60mm centre bore, WIN. And of a large diameter, WIN. Order them up. If they dont fit return them. Simples.

LEWI007
15-09-10, 10:27 PM
Ill have to ask if i can return them if they dont fit. Meanwhile ill wait and see if anyones got experience of using them

Jack
15-09-10, 11:22 PM
I'd be confident they'd fit. If you get no joy, sling them on ebay :)

Sloth
16-09-10, 09:17 PM
i doubt peeps say they fit when they dont...

LEWI007
16-09-10, 11:13 PM
well ive ordered some they cost 18 pounds each ill let you all know if they fit.

LEWI007
17-09-10, 12:45 PM
Just picked my discs up and i can confirm theyre a straight fit!

LEWI007
17-09-10, 05:11 PM
but for some reason the pads are really tight up against the discs im working on a fix for it.

brainsnova
17-09-10, 05:16 PM
you have to shave the pads down a bit. http://www.pngclub.com/forum/showthread.php?t=155348

LEWI007
17-09-10, 05:43 PM
cheers ill trry it. I got moffat to make that thread for me so i could get info and already read it, ill try it and report back

Jack
18-09-10, 10:53 AM
but for some reason the pads are really tight up against the discs im working on a fix for it.
That will probably be down to the height of the discs being different, so they sit a little off centre.

LEWI007
18-09-10, 05:29 PM
what do you mean as in height, the 280mm length of them?

Its something with the thickness, i had to squeeze them into the calipers, but theyre 25mm and the vectra discs are 25mm but theyre tight as ** for some reason

Jack
18-09-10, 09:27 PM
No, I mean the overall height (as in the back of the disc to the front of the mounting face).

Meriva is 43.2mm and Vectra is 42mm, then consider than a Nova is 41mm - so the back of the disc is 2.2mm further inboard when using Meriva discs on a Nova hub.



....at least I think I've got that right lol Does it hit the inboard pad? I'll go look at some dimensions in a min and see how things all size up.

[edit] Then there's differences in the calipers too I believe - what car & year did they come off? They should have a number stamped on them, are you able to see it?

scott.parker
18-09-10, 10:07 PM
Is it worth adding that mavira 280mm 4 stud disks fit too?

Paul
18-09-10, 10:11 PM
thats what theyre talking about Scott

Jack
18-09-10, 10:18 PM
Which one of these do your pads look like?

http://www.dweltd.com/photos/FDB1068.JPG

http://www.dweltd.com/photos/FDB584.JPG

http://www.dweltd.com/photos/FDB901.JPG

http://www.ycp-braking.com/PHOTOS/DP9901.jpg
^ lmfao at those spakkers spelling copyright wrong lol

scott.parker
18-09-10, 10:24 PM
thats what theyre talking about Scott

lol i never read the last pages, just the first and added my comment!

LEWI007
20-09-10, 04:48 PM
they look like the 1st ones, i think clumsy me didnt have the piston pushed in enough though so im building my hub back up now to see if its freely spinning now

LEWI007
20-09-10, 05:24 PM
they fit straight on i hadnt pushed the caliper back lol im stil learning.

Ordered a brand new set of pads aswell.