Volvo Cars 1999-05

Brake Caliper

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Removal & Installation



  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the wheels.
  4.  
  5. Disconnect the ABS wires.
  6.  
  7. Remove the spring.
  8.  
  9. Remove the caliper bolts, lift the caliper off and unscrew the caliper from the hose.
  10.  

To install:

  1. Grease the caliper bolts with lithium grease and insert them into the sleeves.
  2.  
  3. Screw the caliper onto the brake hose.
  4.  
  5. Install the caliper and tighten the caliper bolts to 22 ft. lbs. (30 Nm).
  6.  
  7. If loosened, tighten the brake hose to 13 ft. lbs. (18 Nm).
  8.  
  9. Fill the master cylinder and bleed the brake system.
  10.  
  11. Connect the ABS wires.
  12.  
  13. Install the wheels.
  14.  

  1. Before servicing the vehicle, refer to the Precautions section.
  2.  
  3. Remove the wheels.
  4.  
  5. Disconnect the ABS wires.
  6.  
  7. Remove the spring.
  8.  
  9. Remove the caliper bolts, lift the caliper off and unscrew the caliper from the hose.
  10.  


    Click image to see an enlarged view

    Fig. Front caliper removal-S60, V70, V70XC, S80

    Front caliper removal-S60, V70, V70XC, S80

To install:

  1. Grease the caliper bolts with lithium grease and insert them into the sleeves.
  2.  
  3. Screw the caliper onto the brake hose.
  4.  
  5. Install the caliper and tighten the caliper bolts to 22 ft. lbs. (30 Nm).
  6.  
  7. If loosened, tighten the brake hose to 13 ft. lbs. (18 Nm).
  8.  
  9. Fill the master cylinder and bleed the brake system.
  10.  
  11. Connect the ABS wires.
  12.  
  13. Install the wheels.
  14.  

  1. Remove the hub cap and the wheel.
  2.  
  3. Clean brake caliper carefully.
  4.  
  5. Remove the protective cap from the bleed nipple, connect a hose and open the nipple.
  6.  
  7. Lock pedal in depressed position using a pedal jack.
  8.  
  9. Use a container to collect brake fluid.
  10.  
  11. Loosen the bolt of the brake hose mounting.
  12.  
  13. Remove the banjo bolt with the washers.
  14.  
  15. Remove the two bolts from the brake caliper guide pin.
  16.  
  17. Remove the brake caliper from the holder.
  18.  
  19. Remove the brake pads.
  20.  
  21. Remove the remaining brake fluid.
  22.  


    Click image to see an enlarged view

    Fig. Front caliper removal-S40, V40

    Front caliper removal-S40, V40

To install:

  1. Install the brake pads, paying attention to the wear-indicator.
  2.  
  3. Install the brake caliper to the guide pins. Tighten to 27 ft. lbs. (35 Nm).
  4.  
  5. Install the brake hose. Use new washers. Tightening torque 11 ft. lbs. (15 Nm). Make sure that the brake hose is not twisted.
  6.  
  7. Bleed the brake system.
  8.  
  9. Install the wheel
  10.  

  1. Remove the wheel.
  2.  
  3. Secure the pedal in the depressed position using a pedal jack.
  4.  
  5. Remove the protective cap from the bleed nipple, connect a hose and open the nipple.
  6.  
  7. Use a container to collect brake fluid.
  8.  
  9. Slacken off the brake hose half a turn
  10.  
  11. Remove the brake pads.
  12.  
  13. Remove the brake caliper
  14.  
  15. Unscrew the caliper from the brake hose.
  16.  

To install:

  1. Install the brake hose in the brake caliper, but do not tighten.
  2.  
  3. Install the brake pads.
  4.  
  5. Tighten the brake hose to 17 ft. lbs. (23 Nm).
  6.  
  7. Bleed the brake system.
  8.  
  9. Install the wheel. Depress the brake pedal a few times. Check the brake fluid level.
  10.  

  1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
  2.  
  3. Remove the wheels.
  4.  
  5. Disconnect the ABS wires.
  6.  
  7. Loosen the brake hose a half turn.
  8.  
  9. Remove the caliper bolts, lift the caliper off and unscrew the caliper from the hose.
  10.  

To install:

  1. Grease the caliper bolts with lithium grease and insert them into the sleeves.
  2.  
  3. Screw the caliper onto the brake hose.
  4.  
  5. Install the caliper and tighten the caliper bolts to 22 ft. lbs. (30 Nm).
  6.  
  7. Tighten the brake hose to 13 ft. lbs. (18 Nm).
  8.  
  9. Fill the master cylinder and bleed the brake system.
  10.  
  11. Connect the ABS wires.
  12.  
  13. Install the wheels.
  14.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the wheels.
  4.  
  5. Disconnect the ABS wires.
  6.  
  7. Remove the spring.
  8.  
  9. Remove the caliper bolts, lift the caliper off and unscrew the caliper from the hose.
  10.  

To install:

  1. Grease the caliper bolts with lithium grease and insert them into the sleeves.
  2.  
  3. Screw the caliper onto the brake hose.
  4.  
  5. Install the caliper and tighten the caliper bolts to 22 ft. lbs. (30 Nm).
  6.  
  7. If loosened, tighten the brake hose to 13 ft. lbs. (18 Nm).
  8.  
  9. Fill the master cylinder and bleed the brake system.
  10.  
  11. Connect the ABS wires.
  12.  
  13. Install the wheels.
  14.  

  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the wheels.
  4.  
  5. Disconnect the ABS wires.
  6.  
  7. Remove the spring.
  8.  
  9. Remove the caliper bolts, lift the caliper off and unscrew the caliper from the hose.

    Click image to see an enlarged view

    Fig. Front caliper removal-S60, V70, V70XC, S80

    Front caliper removal-S60, V70, V70XC, S80
  10.  

To install:

  1. Grease the caliper bolts with lithium grease and insert them into the sleeves.
  2.  
  3. Screw the caliper onto the brake hose.
  4.  
  5. Install the caliper and tighten the caliper bolts to 22 ft. lbs. (30 Nm).
  6.  
  7. If loosened, tighten the brake hose to 13 ft. lbs. (18 Nm).
  8.  
  9. Fill the master cylinder and bleed the brake system.
  10.  
  11. Connect the ABS wires.
  12.  
  13. Install the wheels.
  14.  

  1. Remove the hub cap and the wheel.
  2.  
  3. Clean brake caliper carefully.
  4.  
  5. Remove the protective cap from the bleed nipple, connect a hose and open the nipple.
  6.  
  7. Lock pedal in depressed position using a pedal jack.
  8.  
  9. Use a container to collect brake fluid.
  10.  
  11. Loosen the bolt of the brake hose mounting.
  12.  
  13. Remove the banjo bolt with the washers.
  14.  
  15. Remove the two bolts from the brake caliper guide pin.
  16.  
  17. Remove the brake caliper from the holder.
  18.  
  19. Remove the brake pads.
  20.  
  21. Remove the remaining brake fluid.

    Click image to see an enlarged view

    Fig. Front caliper removal-2002-04 S40, V40

    Front caliper removal-2002-04 S40, V40
  22.  

To install:

  1. Install the brake pads, paying attention to the wear-indicator.
  2.  
  3. Install the brake caliper to the guide pins. Tighten to 27 ft. lbs. (35 Nm).
  4.  
  5. Install the brake hose. Use new washers. Tightening torque 11 ft. lbs. (15 Nm). Make sure that the brake hose is not twisted.
  6.  
  7. Bleed the brake system.
  8.  
  9. Install the wheel
  10.  

  1. Remove the wheel.
  2.  
  3. Secure the pedal in the depressed position using a pedal jack.
  4.  
  5. Remove the protective cap from the bleed nipple, connect a hose and open the nipple.
  6.  
  7. Use a container to collect brake fluid.
  8.  
  9. Slacken off the brake hose half a turn
  10.  
  11. Remove the brake pads.
  12.  
  13. Remove the brake caliper
  14.  
  15. Unscrew the caliper from the brake hose.
  16.  

To install:

  1. Install the brake hose in the brake caliper, but do not tighten.
  2.  
  3. Install the brake pads.
  4.  
  5. Tighten the brake hose to 17 ft. lbs. (23 Nm).
  6.  
  7. Bleed the brake system.
  8.  
  9. Install the wheel. Depress the brake pedal a few times. Check the brake fluid level.
  10.  

 
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