Calipers and guide pads of rear brake mechanisms (Opel Corsa C)

Caution: For operations on removal/installation of the rear brake calipers/shoe guides, all notes and instructions given in Section 7.

Corsa models produced up to August 2003

Removal

1. Support the front wheels with wheel chocks, remove both rear wheels and place the rear of the vehicle on stands.

2. Remove the brake hose (see Section 4) and immediately attach it to the new caliper.

Note: If the caliper is removed only to remove the brake pads or brake disc, do not disconnect the hose. In this case, tie the caliper to the body with wire so that the hose is not twisted or stretched.

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3. Release the parking brake lever, remove the parking brake drive cable retaining clip (see accompanying illustration).



4. Press the actuator lever on the rear brake caliper, disconnect the parking brake cable end from it (see illustration 8.3) and release the cable from the holder.

5. Remove the caliper guide pin mounting bolts (see accompanying illustration), holding the bolts from turning by the hexagonal part with a second wrench. Remove the caliper from the guide.





6. Remove the brake pads with sliding plates from the pad guide, mark their installation position (see accompanying illustration). Remove the 2 brake shoe guide mounting bolts - follow the instructions in Section 7. Remove the guide.

Installation

7. Before installation, clean the threads of all bolts from any remaining compound and lubricate them with fresh compound (for example, Loctite Tour 243).

8. Install the brake shoe guide and tighten the mounting bolts. A lot of force is required to tighten the guide mounting bolts (65 Nm!) - check the reliability of the vehicle mounting in the suspended position. It is recommended to replace the wheels and lower the vehicle.



9. Press the brake piston using a special tool (see Section 6) and install the brake pads in place.

10. Insert the upper guide pin of the caliper into the holder, lower the caliper down and screw in the lower guide pin mounting bolt.

11. If the brake hose was disconnected, do not forget to replace the sealing washers and bleed air from the brake system (see Section 3), the hose should not be twisted or kinked.

Note: It is sufficient to bleed only the circuit whose support was removed. Check the fluid level in the master cylinder reservoir, and make the appropriate adjustments if necessary.

12. Further installation is carried out in the reverse order of removal. Before starting to operate the vehicle, check the correct functioning of the brake system.

Corsa models from September 2003 and Meriva models

13. On these models, the removal/installation of the calipers and guides of the rear brake mechanisms is performed completely similarly to those described above. The difference lies in the appearance and a slightly different design of some parts (see accompanying illustration), as well as in the tightening force of some fastening elements (see Specifications).