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!
Removing
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.
1. Apply the parking brake, remove the front wheels and place the front of the vehicle on jack stands.
2. Turn out a bolt of the lower directing finger of a support (see resist. illustration) and rotate the caliper on the axis of the upper guide pin upwards, while making sure that the brake hose is not too tight.
5.2. Bolt (2) caliper mounting lower guide pin (1)
3. Remove the brake pads from the guide (see resist. illustration).
5.3. brake pads (4) installed in the front disc brake guide: 3. Brake piston
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!
Examination
4. 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.
5. 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 irregularities can be machined if it is thick enough - contact a specialist.
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 both discs of the same axle.
6. 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.
Attention: To clean the brakes, use only alcohol or liquids specially designed for this purpose, and in order to avoid damage to the sealing collars, do not use a tool with sharp edges!
7. The guide pins should move easily in the caliper bushings, clean the pins if necessary. Check the condition of the piston seal, inspect the piston for signs of brake fluid leakage, corrosion and mechanical damage. Replace defective components. Disassembly of the caliper for refurbishment and replacement of the piston collar should only be done at a service station.
Installation
8. 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 (e.g. Hazet 4970/6), although a suitable clamp or wooden lever will work no less effectively (see resist. illustration), 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.
5.8. Pressing the brake piston with a wooden lever
Caution: Pushing the piston in comes with a risk of damage to the sealing collar and the piston surface - be careful!
9. Before installing new brake pads, clean the mating surfaces of the brake mechanism and guides. Lubricate the guide surfaces of the pads with a thin layer of heat-resistant grease.
10. Insert the brake pads into the guide, make sure they are installed correctly - the inner pad has a stop for the brake piston.
11. Install the caliper on the guide, screw in the bolt of the lower guide pin, tighten with the required force (28 Nm).
12. 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.
13. In the same manner, replace the brake pads on the opposite wheel.
14. Install the wheels, lower the vehicle to the ground and tighten the wheel bolts to specification.
15. Check the brake fluid level, correct if necessary (see chapter 1).
16. 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.
Features of Corsa C models equipped with the Z17DTH engine
Note: For these models, all the above requirements for checking and installing brake pads, as well as checking the functioning of the brake system, are valid.
17. Set the parking brake, remove the front wheels and place the front of the car on jack stands.
18. Using a screwdriver, disconnect the spring clips (see resist. illustration) brake pads from the caliper and remove them.
5.18. Removing the spring clip (1) front wheel brake
19. Remove the dust caps of the caliper guide pin holes (see resist. illustration).
5.19. Dust caps (2) guide pins (3) caliper
20. Turn out bolts of fastening of directing fingers and remove a support with an internal brake pad. Remove the inner pad from the caliper and tie the caliper to the strut with a piece of wire - do not leave it hanging on the hose.
21. Remove the outer pad with wear indicator from the guide (see resist. illustration).
5.21. Outer shoe (1) front brake mechanism with indicator (3) wear a is installed in the guide (2) (Z17DTH engine)
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!
22. Check the elements of the brake mechanism (see above), if necessary, replace the failed parts.
23. Insert the outer brake pad with wear indicator into the guide (see illustration 5.21).
24. Depress the brake piston using Hazet 4970/6 or a suitable block of wood and insert the inner brake shoe into the caliper (see resist. illustration).
5.24. Installing the inner brake pad (5) into the caliper (Z17DTH engine): 4. Brake cylinder
25. Clean the threads of the caliper guide pins, remove the remnants of the old compound.
26. Lubricate the new caliper mounting bolts with fresh fixing compound (e.g. Loctite 243), install the caliper on the guide and tighten the mounting bolts with a force of 28 Nm.
27. Further installation is carried out in the reverse order of removal.
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