Rear Brake Caliper — Removal, Repair and Installation (Opel Omega A)

1. Block the front wheels, jack up the rear of the car and secure it on axle stands. Remove the wheel.

2. Install the clamp on the high pressure brake line tubes on the way to the flexible hose to the brake caliper.

3. Remove the brake pads as described in Chapter 4.

4. Unscrew the connecting nut securing the brake system pipe to the caliper and remove it.

5. Remove the hexagonal mounting bolts and separate the caliper from the trailing arm (photo).



6. Clean the outer surfaces of the caliper.

7. Do not attempt to separate the two halves of the caliper.

8. Using a pry bar, remove the rings and dust caps from each side of the caliper and separate the facings from the piston grooves.

9. Place a thin block between the pistons, then using an air compressor through the fluid inlet, gently push the pistons out of the cylinders. Remove the pistons.

10. Remove the piston seals from the cylinders using a lever, being careful not to scratch the bore surfaces.

11. Clean the pistons and cylinders with methyl alcohol and allow to dry. Inspect the piston surfaces and cylinder bores for wear, damage and corrosion.



12. Apply a small amount of brake cylinder paste to the pistons, cylinder bores and piston seals.

13. Position the piston seals in the cylinder grooves, then carefully insert the pistons until they engage the seals. Rotate the pistons if necessary to prevent them from getting pinched in the seals.

14. Loosen the dust caps into the piston grooves, then place them on the caliper housing. Press the retaining rings over the dust caps.





15. Press the pistons into their cylinders, then rotate them so that the recesses are positioned downwards at an angle of approximately 23°. Make a template beforehand to check the installation.

16. When installing the caliper, place it on the diagonal arm, insert the mounting bolts and tighten them to the tightening torque specified in the Specification.



17. Place the brake pipe on the caliper and tighten the connecting nut with the specified tightening torque Specification.

18. Install the brake pads.

19. Remove the clamp of the high-pressure brake line pipe and bleed the hydraulic system as described in Chapter 13. If there was no loss of brake fluid, it is enough to bleed the caliper that was removed.

20. Install the wheel and lower the car to the ground.