DISC BRAKE CALIPER

REPAIR OPERATION MANUAL

DISC BRAKE CALIPER

WHAT WE DO

We create repair kits for different hydrau-lic elements of the brake and the hydrau-lic clutch operator: master cylinders, wheel cylinders, caliper, clutch slave cylinder...

We provide our customer, THE FREE GARAGE with a wide range of kits covering from vehicles more than 20 years old to the newest models.

HOW WE COLLABORATE WITH YOU

Providing you with the following elements through our distributor:

- This manual, that will aid in a correct repair.- The catalogue comes in both written and CD-ROM versions.- A team of specialists who work to offer you the highest quality in all our products and services.

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MARCA VERSIÓN(mm.) (mm.) PAÍS

ALFA ROMEO 1 2 3 4 5 6 7 8 9ALFA 1.300 GT-1.750-2.000

BOMBA FRENO - MASTER CYLINDER - MAÎTRE CYLINDRETODOS LOS TIPOS (ALL TYPES) 70>> 20,6 0 D1123 ATE-FAG AMERICA2 >>71 20,6 0 D1136 BONALDI

PINZA DELANTERA - FRONT CALIPER - ETRIER AVANTETODOS LOS TIPOS (ALL TYPES) 48 0 D4063 ATE-LUCAS

PINZA TRASERA - REAR CALIPER - ETRIER ARRIERETODOS LOS TIPOS (ALL TYPES) 38 0 D4066 ATE

BOMBA EMBRAGUE - CLUTCH MASTER CYLINDER - ÈMETTEUR D’EMBRAYAGETODOS LOS TIPOS (ALL TYPES) 70>> 17,5 0 D1141 ATE

RECEPTOR EMBRAGUE - CLUTCH SLAVE CYLINDER - RECEPTEUR D’EMBRAYAGE1.750, 2.000 >>69 25,4 0 D3157 BREMBO TODOS LOS TIPOS (ALL TYPES) 70>> 25,4 0 D3158 ATE

ALFA 145,146

BOMBA FRENO - MASTER CYLINDER - MAÎTRE CYLINDRETODOS LOS TIPOS (ALL TYPES) LHD 22,2 0 D1334 BENDIX-BOSCH

PINZA DELANTERA - FRONT CALIPER - ETRIER AVANTE1.9 TD, 1.4, 1.6 94>>96 54 0 D025110 1.7 94>>96 54 0 D025138 TODOS LOS TIPOS (ALL TYPES) 94>> 54 0 D02520 1.6,1.9TD,1.8,2.0 97>>01 54 0 D02556 2.0 94>>96 54 0 D02556 TODOS LOS TIPOS (ALL TYPES) 94>> 54 0 D4025 ATE 1.6,1.9TD,1.8,2.0 97>>01 KIT COMPLETO 54 0 D41037C ATE 2.0 94>>96 KIT COMPLETO 54 0 D41037C ATE 1.7 16V 48 0 D4110 LUCAS 1.9 TD, 1.4, 1.6 94>>96 KIT COMPLETO 54 0 D41172C LUCAS 1.7 94>>96 KIT COMPLETO 54 0 D41179C LUCAS TODOS LOS TIPOS (ALL TYPES) 97>> 54 0 D4359 ATE 146 1.9 JTD 99>>01 54 0 D4365 ATE

BOMBÍN TRASERO - REAR WHEEL CYLINDER - CYLINDRE DE ROUE ARRIÈRE1.3, 1.6, TD 20,6 0 D3274 BENDIX-BOSCH

PINZA TRASERA - REAR CALIPER - ETRIER ARRIERE2.0 97>> 38 0 D02519 1.8, 1.9 TD, 1.4, 1.6 97>>01 34 0 D02578 1.9 TD, 1.6, 1.7 94>>96 34 0 D02578 2.0 94>>96 34 0 D02578 1.9 TD, 1.6, 1.7 94>>96 KIT COMPLETO 34 0 D41160C LUCAS 1.8, 1.9 TD, 1.4, 1.6 97>>01 KIT COMPLETO 34 0 D41161C LUCAS 2.0 94>>96 KIT COMPLETO 34 0 D41161C LUCAS 1.7 16V 34 0 D4129 LUCAS 2.0 97>> 38 0 D4468 LUCAS TODOS LOS TIPOS (ALL TYPES) 94>> 34 0 D4494 LUCAS 2.0 97>> KIT COMPLETO 38 0 D4846C LUCAS

BOMBA EMBRAGUE - CLUTCH MASTER CYLINDER - ÈMETTEUR D’EMBRAYAGE1.3i, 1.6i Base, 1.7i 16V 19 0 D1271 BENDIX-BOSCH 1.4i, 1.6i 16V, 1.8i 16V, 1.9 TD, 2.0i LHD 19 0 D1339 BENDIX-BOSCH

RECEPTOR EMBRAGUE - CLUTCH SLAVE CYLINDER - RECEPTEUR D’EMBRAYAGE1.4, 1.6, 1.7 16V 94>>96 25,4 0 D3155 ATE TODOS LOS TIPOS (ALL TYPES) 25,4 0 D3156 BENDIX-BOSCH TODOS LOS TIPOS (ALL TYPES) 94>>01 25,4 0 D3541 BENDIX-BOSCH

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WHO WE ARE

Specialists with over 40 years of expe-rience in manufacturing precison rub-ber parts, in particular brake parts.

Our quality is ensured by the ISO 9002 stan-dard, we are market leaders and our pro-ducts are exported to over 65 countries.

REPAIR KITS FOR BRAKE CALIPERS

This repair operation manual focuses on brake calipers. The different repair kits for the brake calipers that Seinsa develops are:

- Piston Repair Kit: Kit composed of one piston. Named 150*-C (* is the kit number).

- Repair kit without piston: Kit to repair the brake caliper composed of : seals, boots, guide boots and clamps.

- Complete repair kit: Complete brake caliper repair kit composed of: seals, boots, guide boots, clamps and pis- tons. This kit is complete for one wheel.

KINDS OF CALIPERS

There are different kinds of calipers: front calipers and rear calipers.The great majority of cars has the rear calipers with only one piston.However, depending on the model of car, the front caliper can be designed with two, four, six even eight pistons.

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2. Remove the boot and the piston using compressed air if necessary, being careful to place a wooden shim between the running board and the piston.

3. Remove the o-ring with a flexible blade with a rounded edge, or the Seinsa tool.Clean the inside of the caliper and the piston only with alcohol or brake fluid, ensuring the perfect cleanli-ness of the groove where the ring fits.

4. Before introducing the new o-ring in the sealing groove, lubricate it with special grease, Vaseline or brake fluid. Fit it in its place with your finger and check that it fits well throughout the entire the surface of the sealing groove.

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WARNING!! Every time those brake pads are replaced, it is very important

to replace the piston seal, a worn seal, impedes the piston’s return when finished

braking, producing quicker erosion of pads and annoying noises.

1. Remove the caliper and dismantle it if necessary to remove the piston.

5. Press to introduce the piston, prevent the piston from crossing the seal position, because in such a case it will damage the seal. NOTE: There are two main types of caliper that

require different procedures to assemble the piston and the boot:

6. To assemble TYPE A: fit the boot in the piston groove and then introduce it into the caliper, then, put the boot in the sealing groove and fit the shim.

7. To assemble TYPE B: fit the boot in the piston (not in its groove), and introduce it in the sealing groove before fitting the piston.

8. If the caliper has a movable part which slides on the guides, Seinsa recommends to clean and grease the guides, and then replace the guide boots even if the parts slide correctly.

YOU CAN SEE THE VIDEO DEMONSTRATIONS ON OUR WEBSITE http://www.ertcompany.com

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ERTC/Elizguíbel s/n, 31638, Eugi (Navarra), SPAIN

Export Tel.: +34 948 304 060 Fax. +34 948 304 286

Export e-mail: export@ertcompany.comhttp://www.ertcompany.com