Recommended replacement interval for the part category Brake disc : 50000 km

Important!

This replacement procedure can be used for:
ALFA ROMEO GIULIETTA (940) 2.0 JTDM (940.FXL1A), ALFA ROMEO GIULIETTA (940) 2.0 JTDM (940FXH1A, 940FXH11, 940FXZ11, 940FXZ1A), ALFA ROMEO GIULIETTA (940) 2.0 JTDM (940FXM1A, 940FXS1A, 940FYD1A), ALFA ROMEO GIULIETTA (940) 2.0 JTDM (940FXQ1A, 940FYC1A), ALFA ROMEO GIULIETTA (940) 1.4 TB (940FXB1A, 940FXB11), ALFA ROMEO GIULIETTA (940) 2.0 JTDM (940FXE1A, 940FXG11), ALFA ROMEO GIULIETTA (940) 2.0 JTDM (940FXV11), ALFA ROMEO GIULIETTA (940) 1.4 TB (940.FYA1A) … View more

The steps may slightly vary depending on the car design.

This video shows the replacement procedure of a similar car part on another vehicle

Alternative products

Brake disc

Replacement: brake discs – ALFA ROMEO GIULIETTA (940). List of the tools you'll need:

                      Wire brush
                    
                      WD-40 spray
                    
                      Brake cleaner 
                    
                      Copper grease 
                    
                      Drive socket # 19 
                    
                      HEX bit No.H4.
                    
                      HEX bit No.H7.
                    
                      Wheel impact socket #17
                    
                      Brake caliper wind back tool
                    
                      Ratchet wrench
                    
                      Torque wrench
                    
                      Tap wrench
                    
                      Crow bar
                    
                      Wheel chock

Buy tools

Replacement: brake discs – ALFA ROMEO GIULIETTA (940). Tip from AUTODOC:

Replace the brake disks on the car ALFA ROMEO GIULIETTA (940) in complete set for each axis. Regardless of the state of components. This will ensure even braking.
The replacement procedure is identical for both brake disks on the same axle.
When changing the brake discs, always replace the brake pads.
All work should be done with the engine stopped.

Replacement: brake discs – ALFA ROMEO GIULIETTA (940). Take the following steps:

Step 1

Open the bonnet. Unscrew the brake fluid reservoir cap.
Step 2

Secure the wheels with chocks.
Step 3

Loosen the wheel mounting bolts. Use wheel impact socket #17.
Step 4

Raise the front of the car and secure on supports.

Step 5

Unscrew the wheel bolts.

AUTODOC recommends:
Warning! To avoid injury, hold the wheel while unscrewing the fastening bolts. ALFA ROMEO GIULIETTA (940)
Step 6

Remove the wheel.
Step 7

Remove the dust boot caps of the brake caliper guide pins. Use a crowbar.
Step 8

Disconnect the brake pad wear sensor plug.

Please note!
Some cars are not equipped with the brake pad wear sensor.
Step 9

Spread the brake pads. Use a crowbar.
Step 10

Clean the brake caliper fasteners. Use a wire brush. Use WD-40 spray.

Step 11

Unscrew the brake caliper fastening. Use HEX No.H7. Use a ratchet wrench.
Step 12

Detach the brake caliper retaining spring. Use a crowbar.
Step 13

Remove the brake caliper.

Replacement: brake discs – ALFA ROMEO GIULIETTA (940). AUTODOC recommends:
Tie the caliper to the suspension or to the body with a wire without disconnecting from the brake hose to prevent depressurization of the brake system.Make sure that the brake caliper is not hanging on the brake hose.Don't press the brake pedal after the brake caliper has been removed. As a result, the piston can fall out from the brake cylinder, and brake fluid leakage and depressurization of the system may occur.
Step 14

Remove the brake pads.
Step 15

Clean the brake caliper bracket fasteners. Use a wire brush. Use WD-40 spray.
Step 16

Unscrew the caliper bracket fastening. Use a drive socket #19. Use a tap wrench. Use a ratchet wrench.
Step 17

Remove the caliper bracket.
Step 18

Unscrew the brake disc fastening. Use HEX No.H4. Use a ratchet wrench.
Step 19

Remove the brake disc.
Step 20

Clean the hub. Use a wire brush. Treat the contacting surface. Use copper grease.
Step 21

Install the brake disc.
Step 22

Tighten the brake disc fastening. Use HEX No.H4. Use a torque wrench. Tighten it to 7 Nm torque.

Replacement: brake discs – ALFA ROMEO GIULIETTA (940). AUTODOC experts recommend:
You might need other tools.
Step 23

Clean the brake disk surface. Use a brake cleaner.

AUTODOC recommends:
Replacement: brake discs – ALFA ROMEO GIULIETTA (940). After applying the spray, wait a few minutes.
Step 24

Clean the brake caliper bracket from dirt and dust. Use a wire brush. Use a brake cleaner.

Replacement: brake discs – ALFA ROMEO GIULIETTA (940). Professionals recommend:
After applying the spray, wait a few minutes.
Step 25

Install the brake caliper bracket.
Step 26

Tighten the brake caliper bracket. Use a drive socket #19. Use a torque wrench. Tighten it to 152 Nm torque.
Step 27

Treat the brake caliper piston. Use a brake cleaner.

AUTODOC recommends:
Replacement: brake discs – ALFA ROMEO GIULIETTA (940). After applying the spray, wait a few minutes.
Step 28

Press in the brake caliper piston. Use brake caliper wind back tool.
Step 29

Install the brake pads.
Step 30

Install the brake caliper and fix it. Use HEX No.H7. Use a torque wrench. Tighten it to 30 Nm torque.
Step 31

Connect the brake pad wear sensor plug.
Step 32

Install the dust boot caps of the brake caliper guide pins.
Step 33

Install the brake caliper retaining spring.
Step 34

Treat the surface where the brake disc contacts the wheel rim. Use copper grease.
Step 35

Clean the brake disk surface. Use a brake cleaner.

Replacement: brake discs – ALFA ROMEO GIULIETTA (940). Tip from AUTODOC:
After applying the spray, wait a few minutes.
Step 36

Install the wheel.

AUTODOC recommends:
Important! Hold the wheel while screwing in the fastening bolts. ALFA ROMEO GIULIETTA (940)
Step 37

Screw in the wheel bolts. Use wheel impact socket #17.
Step 38

Lower the car and working in a cross order, tighten the wheel bolts. Use a torque wrench. Tighten it to 120 Nm torque.
Step 39

Remove the jacks and chocks.

Replacement: brake discs – ALFA ROMEO GIULIETTA (940). Tip:
Check the brake fluid level in the expansion tank and refill if necessary.
Step 40

Tighten the brake fluid reservoir cap.

AUTODOC recommends:
ALFA ROMEO GIULIETTA (940) – Press the brake pedal several times with the engine shut down until you feel the resistance built up.
Step 41

Close the hood.

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