Attention: It is necessary to replace all the brake pads of one vehicle axle at the same time, even if only one of them has reached the wear limit! Use only pads approved by the manufacturer!
1. Apply the parking brake, jack up the front of the vehicle and place it on jack stands. Remove the front wheels.
2. Using a small slotted screwdriver, remove the pad wear sensor from the hole in the caliper (with appropriate equipment) and take him aside (see resist. illustration).
3. Remove the large spring clip from the caliper (see resist. illustration) - be careful, in order to avoid jumping off the spring, first cover it with a rag.
4. Remove the dust caps of the caliper guide pin holes (see resist. illustration).
5. Turn out the guide bolts and remove the caliper with pads from the anchor bracket or hub carriage (depending on the execution method) (see resist. illustration). Tie the caliper to the rack with a piece of wire - do not leave it hanging on the hose.
Note: After prolonged use, it may be difficult to remove the caliper with pads manually - use a pry bar or other suitable tool. Remove the brake fluid reservoir cap first.
6. Remove the outer pad from the caliper, then remove the inner pad (see illustration 5.5).
Attention: If you plan to re-install the same brake pads, when removing them, you must mark the places of their installation. It is not allowed to change the brake pads from the outside to the inside and from the right wheel to the left!
Attention: After removing the brake pads, do not press the brake pedal, otherwise the piston may be squeezed out of the housing. In this case, to install the piston in place, you will have to contact the service station.
7. Sweep away dust accumulated on their surfaces from the brake components (see Precautions in Section 1). Wipe the caliper and piston face with a clean rag. Remove rust from the edge of the brake disc.
8. Check the condition and thickness of the brake pads (see Chapter 1, Section 14). Oily pads must be replaced without fail - first eliminate the cause of the leak. Feel the surface of the brake disc with your fingers. A brake disc that has bumps can be machined if it is thick enough - contact an Opel workshop.
Attention: Both brake discs of the same axle must always be machined to the same thickness. If the thickness of the disk has reached the wear limit (see specs), replace it.
9. If the condition of the brake pads and disc is found to be satisfactory, carefully clean them and the contact surfaces of the brake discs from dirt with a soft wire brush, paying particular attention to the back and sides. Clean the grooves in the friction linings, completely removing foreign inclusions from them. Clean the pad seats in the caliper and anchor bracket. After that, wipe all mating surfaces with a rag soaked in alcohol.
Caution: Use only alcohol to clean the brakes, and do not use sharp-edged tools to avoid damage to the seals!
10. The guide pins should move easily in the caliper bushings, clean the pins if necessary. Check the condition of the anther installed on the piston, inspect the piston for signs of brake fluid leakage, corrosion and mechanical damage. Replace defective components. Disassembly of the caliper for refurbishment should only be done at a service station.
11. When installing new pads, the piston must be sunk into the caliper cylinder in order to release it for installing thicker new pads. The piston is pressed using a special tool, although a suitable clamp or wooden lever will work no less effectively (see resist. illustrations), if necessary, lay the old brake pad as a bearing surface in front of the piston. Be careful not to damage the piston surface and protective cap. When the piston reverses, the brake fluid is squeezed out of the brake cylinder into the reservoir, so the reservoir cap must be removed. To prevent leakage of brake fluid, first check its level - if necessary, pump out the excess.
Caution: Pushing back the piston risks damage to the sealing collar and the piston surface - be careful!
12. Before installing new brake pads, clean the guide. Lubricate the guide surfaces of the pads (see resist. illustration) thin layer of heat-resistant grease (e.g. Liqui Moly paste).
13. Fill the caliper with the inner brake shoe, seating its spring in the recess in the end surface of the piston, and then install the outer shoe.
Note: Inner and outer pads are different in design - note the arrow mark on the base of the pad (see resist. illustration) - the arrow should point in the direction of disk rotation when the vehicle is moving forward.
14. Reinstall the caliper with brake pads, make sure that the brake hose is not twisted.
15. Lubricate the threads of the guide bushing bolts with locking compound (e.g. Loctite Tour 243) - if the bolts have traces of rust or damage, they should be replaced with new ones. Screw in the bolts and tighten them to the required torque.
16. Install the anthers.
17. Install the caliper spring by inserting its ends into the holes in the bracket.
Note: Two types of springs are used - one is connected to the caliper, the other to the mounts on the outer shoe. If the last type of spring is installed, first connect it to the shoe, then slide it over the tabs on the caliper.
18. With the appropriate equipment, install the pad wear sensor in the inner brake shoe, fix the electrical wiring on the shock absorber strut.
19. Squeeze the foot brake pedal several times until you feel a firm movement - the brake pads are in contact with the discs and are in a position corresponding to the state of use.
20. In the same manner, replace the brake pads on the opposite wheel.
21. Install the wheels, lower the vehicle to the ground and tighten the wheel bolts to specification.
22. Check the brake fluid level, correct if necessary (see chapter 1).
23. Before starting intensive use, let the brake pads get used a little, for which brake the car several times from a speed of 80 km / h to a speed of 40 km / h by gently pressing the pedal. Then let the brake cool down.
Note: After changing the pads, try to avoid sudden braking as much as possible for about 200 km.
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