Removal
Attention! If the caliper is to be removed only to dismantle the brake disc, do not disconnect the brake hose of the wheel brake cylinder from the caliper, because the brake system will have to be bled after installation. Secure the caliper to the body using a wire hook or wire. The brake hose should not be twisted or stretched.
1. Mark the position of the rear wheels on the hub with paint. This will allow you to install the balanced wheel in its original position during assembly.
2. Loosen the wheel mounting bolts. The car must stand on its wheels when performing this operation.
3. Place the vehicle on jack stands and remove the rear wheels.
4. Clamp the brake hose near the caliper with a special clamp if the hose is going to be disconnected (see illustration). It is also recommended to unscrew the brake fluid reservoir cap, cover the opening with plastic film and screw the cap back on. This technique helps to minimize the loss of brake fluid when disconnecting the hose from the caliper.
5. Remove the brake pads (see the relevant chapter).
6. Unscrew the lock nut securing the brake line to the caliper and disconnect the line (see illustrations 5.6 and 5.6a).
7. Unscrew the caliper mounting bolts and remove the caliper from the brake pad guide (see illustrations 5.7 and 5.7a).
Bulkhead
8. Clean the outer surface of the caliper.
9. Press the dust seals on the caliper and remove them from the piston grooves (see illustration).
[Text copied from an online resource opelbook.ru]
10. Place a wooden block between the pistons and blow through the inlet hole to remove the pistons from the cylinders. If one piston comes out before the other, remove it and plug the empty cylinder to allow the other piston to come out.
11. Remove the piston seals, being careful not to damage the cylinder walls.
12. Clean the pistons and cylinders with brake fluid and let them dry. Inspect the pistons and cylinders for damage, signs of wear and corrosion. If such damage is found, replace the caliper assembly. If the caliper is suitable for further use, purchase a repair kit of parts, which includes piston seals and dust seals, as well as a tube of paste for brake cylinders.
13. Apply a small amount of paste to the pistons, their seals and cylinder walls.
14. Install the piston seals into the cylinder grooves, then carefully insert the pistons so that they engage the seals. You may need to rotate the pistons to avoid them getting stuck in the seals.
Do not push the pistons all the way into the cylinders as this will make it difficult to install the dust seals.
15. Install the dust seals first into the piston grooves and then onto the caliper.
16. Install the retaining rings on the cuffs.
17. Press the pistons into the cylinders, then rotate them so that the slots point downwards at an angle of approximately 23°. This will ensure that the pistons are seated correctly on the pads.
Installation
18. Fasten the brake shoe guide to the steering knuckle if it was removed. In this case, replace the guide mounting bolts with new ones and lubricate them with a protective paste, such as Loctite 243. The tightening torque of the bolts is 130 Nm.
19. Install the brake pads.
20. Install the caliper on the brake pad guide, insert the mounting bolts and tighten them to 30 Nm.
21. Connect the brake line to the caliper by tightening the lock nut.
22. Remove the special clamp from the hose, remove the polyethylene from under the expansion tank cap and bleed the brake system drive (see the relevant chapter).
23. Install the wheels in accordance with the marks made during removal and secure with bolts.
24. Lower the vehicle and tighten the wheel bolts in a criss-cross pattern to 110 Nm.
Caution! Press the brake pedal forcefully several times until you feel strong resistance. This action centers the brake pads and they automatically adjust to the working position.
25. Check the brake fluid level in the expansion tank. If necessary, top up to the maximum mark.
26. Check the operation of the braking system.
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