Operation CHARM: Car repair manuals for everyone.
Manuals through 2025 now available!

Our trusted friends have launched a new website named LEMON, which has newer manuals. It also contains all the CHARM manuals.

LEMON is the spiritual successor to CHARM, I recommend you try it!

Link: lemon-manuals.la or lemon-manuals.org.ua

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Front


Brake Pads, Replace

Replace left and right brake pads at the same time. Do not replace one wheel side only.
1. Raise and support front of vehicle.
2. Remove tire and wheel assembly.
3. Remove lock pin bolt and lift caliper assembly with brake line connected, from disc assembly.
4. Remove brake pads from caliper assembly.
5. Reverse procedure to install. When installing new brake pads, push caliper piston inward using tool 490221600C or equivalent. Torque lock bolt to 23-30 ft.lbs.

Caliper, Replace

1. Raise and support front of vehicle.
2. Remove tire and wheel assembly.
3. Remove lock pin bolt.
4. Disconnect and cap brake line.
5. Lift caliper assembly from brake disc.
6. Reverse procedure to install.

Caliper Overhaul

1. With caliper removed from vehicle, remove caliper clip and dust seal.
2. Remove piston, piston seal, cap and bleeder screw.
3. When removing piston from caliper, place a piece of wood into the caliper assembly. Using compressed air, blow air through the flexible hose connection hole to force out the piston from the caliper assembly. Apply air pressure gradually to prevent the piston from jumping out.