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

Important!

This replacement procedure can be used for:
ALFA ROMEO 159 (939) 1.9 JTS (939AXA1B), ALFA ROMEO 159 (939) 2.2 JTS (939AXB1B, 939AXB11), ALFA ROMEO 159 (939) 1.9 JTDM 8V (939AXE1B), ALFA ROMEO 159 (939) 1.9 JTDM 16V (939AXC1B, 939AXC12), ALFA ROMEO 159 (939) 1.9 JTDM 8V (939AXE1B, 939BXE1B, 939BXH1B), ALFA ROMEO 159 (939) 1.9 JTDM 16V (939AXF1B, 939AXC1B), ALFA ROMEO 159 (939) 1.8 MPI (939AXL1A) … 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

All the parts you need to replace – Brake Discs for 159 (939) and other ALFA ROMEO models

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Replacement: brake discs – ALFA ROMEO 159 (939). Tools you need:

                      Wire brush
                    
                      WD-40 spray
                    
                      Brake cleaner 
                    
                      All-purpose cleaning spray
                    
                      Copper grease 
                    
                      Combination spanner #13
                    
                      Combination spanner #15
                    
                      HEX bit No.H5.
                    
                      Drive socket # E12 
                    
                      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 159 (939). AUTODOC recommends:

Replace the brake disks on the car ALFA ROMEO 159 (939) 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.
Warning! Shut down the engine before starting any work – ALFA ROMEO 159 (939).

Carry out replacement in the following order:

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 rear of the car and secure on supports.

Step 5

Unscrew the wheel bolts.

Replacement: brake discs – ALFA ROMEO 159 (939). Tip:
To avoid injury, hold up the wheel when unscrewing the bolts.
Step 6

Remove the wheel.
Step 7

Clean the brake caliper fasteners. Use a wire brush. Use WD-40 spray.
Step 8

Unscrew the brake caliper fastening. Use a combination spanner #13. Use a combination spanner #15.
Step 9

Remove the brake caliper. Use a crowbar.

Replacement: brake discs – ALFA ROMEO 159 (939). AUTODOC experts recommend:
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 10

Remove the brake pads. Use a crowbar.
Step 11

Clean the brake caliper bracket fasteners. Use a wire brush. Use WD-40 spray.
Step 12

Unscrew the caliper bracket fastening. Use a drive socket #E12. Use a tap wrench.
Step 13

Remove the caliper bracket.
Step 14

Clean the brake disc fasteners. Use a wire brush. Use WD-40 spray.
Step 15

Unscrew the brake disc fastening. Use HEX No.H5. Use a ratchet wrench.
Step 16

Remove the brake disc.
Step 17

Treat the hub where it contacts the brake disk. Use copper grease.
Step 18

Install the brake disc.
Step 19

Tighten the brake disc fastening. Use HEX No.H5. Use a torque wrench. Tighten it to 7 Nm torque.
Step 20

Remove the retaining springs of the brake pads.
Step 21

Clean the brake caliper bracket from dirt and dust. Use a wire brush. Use all-purpose cleaning spray.
Step 22

Install the brake caliper bracket.
Step 23

Tighten the brake caliper bracket. Use a drive socket #E12. Use a torque wrench. Tighten it to 60 Nm torque.
Step 24

Treat the brake caliper piston. Use a brake cleaner.

AUTODOC recommends:
Replacement: brake discs – ALFA ROMEO 159 (939). After applying the spray, wait a few minutes.
Step 25

Press in the brake caliper piston. Use brake caliper wind back tool.
Step 26

Install the retaining springs of the brake pads.
Step 27

Install the brake pads.
Step 28

Install the brake caliper and fix it. Use a combination spanner #13. Use a combination spanner #15. Use a torque wrench. Tighten it to 35 Nm torque.
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.

Replacement: brake discs – ALFA ROMEO 159 (939). Tip from AUTODOC:
After applying the spray, wait a few minutes.
Step 31

Install the wheel.

AUTODOC recommends:
Important! Hold the wheel while screwing in the fastening bolts. ALFA ROMEO 159 (939)
Step 32

Screw in the wheel bolts. Use wheel impact socket #17.
Step 33

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

Replacement: brake discs – ALFA ROMEO 159 (939). Professionals recommend:
Check the brake fluid level in the expansion tank and refill if necessary.
Step 34

Tighten the brake fluid reservoir cap. Close the hood.

AUTODOC recommends:
ALFA ROMEO 159 (939) – Press the brake pedal several times with the engine shut down until you feel the resistance built up.
Step 35

Remove the jacks and chocks.

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