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How To: Fit 280mm 'G60' Brakes to a Lupo


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G60 brakes (Named after the vehicles they were fitted too) are a direct fit to a Lupo providing you have a suitable car and components to fit. It allows the use of 280 x 22mm brake discs. It's a simple bolt on conversion that takes no more time than just swapping over brake discs.

Suitable Models...

· Lupo GTI (Factory fitted with 256 x 25mm discs)

· Lupo Sport (Factory fitted with 256 x 20mm discs)

· Lupo TDI (Factory fitted with 256 x 20mm discs)

This modification in not suitable for 1.0 or 1.4 Lupo's without changing the hub/upright and calliper to components from the above models. To check this, insure the carrier part of the calliper is bolted to the hub, and not cast on. Lesser engine Lupo's use 239 x 15mm discs.

Parts Needed....

'G60' Calliper carrier

'G60' 280 x 22mm 4x100mm stud pattern brake discs. (eBay search will find you the correct discs.)

Other VW recommended parts required when changing carriers and discs...

4x N 010 241 24 M8x21mm self locking bolt calliper to carrier.

Brake pads.

Brake Carriers...

These can be found on the following cars.... (All with part No: 357 615 125 c)

Volkswagen Passat (Models with 280mm discs)

Volkswagen Corrado G60

Volkswagen Golf Mk2 G60, Rallye, Syncro

Volkswagen Jetta, Syncro (Models with 280mm discs)

Volkswagen Golf Mk3 GTI (Early models with 280mm discs)

Volkswagen Golf VR6 (Early models with 280mm discs)

Volkswagen Vento (Models with 280mm discs)

Seat Cordoba SX

Seat Toledo GTI

Seat Mk2 Ibiza 2L 16V

Seat Mk3 Ibiza Cupra

Brake discs...

These can be found on the following cars (...and others)... (All with the part No: 535 615 301)

Volkswagen Corrado G60

Volkswagen Golf Mk2 G60, Rallye, Syncro

Seat Mk2 Ibiza 2L 16V

Seat Mk3 Ibiza Cupra

It's best to use new discs when doing this conversion.

Brake Pads...

There were varying calliper widths used across the VAG range, Lupo GTI uses 15.6mm pads(16mm) which are the same as a Mk2 Golf GTI and are the thinnest available due to the wider than Sport disc. They are suitable for all conversions.

It's possible on some applications to use the G60/Ibiza Cupra pad that's thicker 19.6mm (19mm), some GTI owners have found it necessary to remove 1mm of friction material to get these pads to fit the callipers, these pads provide longer pad life due to the increased thickness. I found them a direct fit into my GTI callipers. The Sport calliper needs Sport or Lupo GTI pads.

Callipers...

All the cars that use 256 or 280mm brakes use the Lucas '54' calliper with a single 54mm piston, there are two internal widths to these callipers depending on application so it's best to stick to the Lupo callipers if they are in good working order and then no separating of the hydraulic system is needed. There are no advantages changing to the G60 or Ibiza Cupra calliper, although they will fit, possibly needing new hoses.

Fitting Pictures and basic instructions.... Images from Loopy Lupo

Jack up and support car, remove wheels...

fitting280mmbrakes002.jpg

Undo 13mm headed bolts, remove calliper, support calliper or tie out of way, to prevent damaging brake hose...

fitting280mmbrakes003.jpg

Remove brake pads, mark location and direction if reusing...

fitting280mmbrakes004.jpg

Undo the two 18mm headed bolts and remove carrier from housing... (Note calliper resting on driveshaft)

fitting280mmbrakes005.jpg

fitting280mmbrakes006.jpg

Remove cross headed screw and pull off brake disc... (Blue item on hub is a wheel spigot ring)

fitting280mmbrakes007.jpg

Clean hub with solvent and grit paper if needed to remove dirt and rust, fit new disc, degrease friction area with solvent...

fitting280mmbrakes008.jpg

Fit new carrier and pads, its good practice to use new pads when using new discs, if using new pads, the calliper piston should be pushed back using suitable tool wit the brake bleed nipple open to prevent damage to the ABS pump valves...

fitting280mmbrakes009.jpg

Here is the completed set up...

fitting280mmbrakes010.jpg

Torque Settings... (Use new bolts if corroded of unsure of condition)

· Cross-head screw M6 x 1.0 (Disc to hub) 4-6nm

· Hexagon bolt M8 x 1.25 [13mm head] (Calliper to carrier) 35nm (Using new bolts)

· Hexagon bolt M12 x 1.50 [18mm head] (Carrier to wheel bearing housing) 125nm

· Bleed nipple M10 x 1.00 [11mm head] (Undo when pushing piston back) 11nm

Other Information...

· Wear limit on the 280mm discs is 20mm

· Minimum wheel size is usually 15", most wheels are OK offset wise, BBS RA's are known to need spacing. OEM Lupo GTI Bathurst wheels fit fine.

· Weight increase on disc is 0.2-0.3kg per side(5.6 vs 5.8kg). Weight increase on carrier is 0.1kg per side (1.0 vs 1.1kg).

· Pad thicknesses are measured including metal backing plate.

Other Useful Threads...

http://forums.clublu...showtopic=12487

http://forums.clublu...showtopic=54146

http://forums.clublu...showtopic=67779

Much of the thread below is wrong and shows what happens when use the wider 19mm pads in a Sport calliper.

http://forums.clublu...showtopic=42298

Edited by 99hjhm
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