*HOW TO* Fit 2L 16v/Turbo/V6 front brakes
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/v8...0748Custom.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/v8...t/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/v8...0752Custom.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%2...s/IMG_2643.JPG
And its off
http://img.photobucket.com/albums/v8...0753Medium.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/v8...0762Custom.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/v8...0765Custom.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/v8...0763Custom.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