How to change front brake discs on VOLVO S40 II (544) – replacement guide
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Recommended replacement interval for the part category Brake disc : 50000km
Important!
This replacement procedure can be used for:
VOLVO S40 II (544) D3,
VOLVO S40 II (544) D4,
VOLVO S40 II (544) D2,
VOLVO S40 II (544) 2.0 F,
VOLVO S40 II (544) 2.4,
VOLVO S40 II (544) 2.4,
VOLVO S40 II (544) T5,
VOLVO S40 II (544) 2.0 D,
VOLVO S40 II (544) T5 AWD,
VOLVO S40 II (544) 1.8,
VOLVO S40 II (544) 1.6,
VOLVO S40 II (544) 1.6 D,
VOLVO S40 II (544) 2.0,
VOLVO S40 II (544) D5,
VOLVO S40 II (544) T5,
VOLVO S40 II (544) T5 AWD,
VOLVO S40 II (544) 1.8 FlexFuel,
VOLVO S40 II (544) D4,
VOLVO S40 II (544) 2.0 CDI,
VOLVO S40 II (544) 2.4 CDI,
VOLVO S40 II (544) 1.9
…
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The steps may slightly vary depending on the car design.
This video shows the replacement procedure of a similar car part on another vehicle
All the parts you need to replace – Brake Discs for S40 II (544) and other VOLVO models
Replacement: brake discs – VOLVO S40 II (MS). Tip from AUTODOC experts:
Replace the brake disks on the car VOLVO S40 II (MS) 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 – VOLVO S40 II (MS). 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 #19.
Step 4
Raise the front of the car and secure on supports.
Step 5
Unscrew the wheel bolts.
Replacement: brake discs – VOLVO S40 II (MS). Tip:
To avoid injury, hold up the wheel when unscrewing the bolts.
Step 6
Remove the wheel.
Step 7
Remove the dust boot caps of the brake caliper guide pins. Use a crowbar.
Step 8
Unscrew the brake caliper fastening. Use HEX No.H7. Use a ratchet wrench.
Step 9
Detach the brake caliper retaining spring. Use a crowbar.
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. Check the brake caliper bracket, brake caliper guide pins and boots. Clean them. Replace, if necessary.
Step 12
Remove the brake pads. Use a crowbar.
Step 13
Clean the brake caliper bracket fasteners. Use a wire brush. Use WD-40 spray.
Step 14
Unscrew the caliper bracket fastening. Use a drive socket #15. Use a ratchet wrench. Use a tap wrench.
Step 15
Remove the caliper bracket.
Step 16
Remove the brake disc.
Step 17
Clean the hub. Use a wire brush. Treat the contacting surface. Use copper grease.
Step 18
Install the brake disc.
Step 19
Clean the brake caliper bracket from dirt and dust. Use a wire brush. Use a brake cleaner.
AUTODOC recommends:
Replacement: brake discs – VOLVO S40 II (MS). After applying the spray, wait a few minutes.
Step 20
Install the brake caliper bracket.
Step 21
Tighten the brake caliper bracket. Use a drive socket #15. Use a torque wrench. Tighten it to 120 Nm torque.
Step 22
Treat the brake caliper piston. Use a brake cleaner.
Replacement: brake discs – VOLVO S40 II (MS). AUTODOC recommends:
After applying the spray, wait a few minutes.
Step 23
Press in the brake caliper piston. Use brake caliper wind back tool.
Step 24
Install the brake pads.
Step 25
Install the brake caliper and fix it.
Step 26
Install the brake caliper retaining spring. Use HEX No.H7. Use a ratchet wrench.
Step 27
Tighten the brake caliper fasteners. Use HEX No.H7. Use a torque wrench. Tighten it to 28 Nm torque.
Step 28
Install the dust boot caps of the brake caliper guide pins.
Step 29
Treat the surface where the brake disc contacts the wheel rim. Use copper grease.
Step 30
Clean the brake disk surface. Use a brake cleaner.
AUTODOC recommends:
Replacement: brake discs – VOLVO S40 II (MS). After applying the spray, wait a few minutes.
Step 31
Install the wheel.
Replacement: brake discs – VOLVO S40 II (MS). Tip from AUTODOC:
To avoid injury, hold up the wheel when screwing in the fastening bolts.
Step 32
Screw in the wheel bolts. Use wheel impact socket #19.
Step 33
Lower the car and working in a cross order, tighten the wheel bolts. Use a torque wrench. Tighten it to 110 Nm torque.
Step 34
Remove the jacks and chocks.
AUTODOC recommends:
Important! Replacement: brake discs – VOLVO S40 II (MS). Check the brake fluid level in the reservoir and top up if necessary.
Step 35
Tighten the brake fluid reservoir cap.
Replacement: brake discs – VOLVO S40 II (MS). Tip from AUTODOC experts:
Without starting the engine, press the brake pedal several times until you feel significant resistance.
Step 36
Close the hood.
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