Caliper (type ATE) — removal, inspection and installation (Opel Ascona C)

1. Raise the front of the car and remove the brake pads (Section 3).

2. Loosen and remove the caliper fluid coupling bolt. Plug the coupling with two suitable rings or allow the liquid to drain into a container.

3. On older models, remove the two caliper mounting bolts and remove the caliper.

4. On later models, remove the caliper from the mounting plate by pushing the caliper inward from the front (towards the wheel hub) and at the same time moving the caliper towards the center of the car.

5. Clean off any external dirt from the caliper assembly without inhaling the powder. Clamp the caliper in a vice. Use a soft jaw on the vice and be careful not to damage or bend the caliper.

6. On older models, separate the caliper body from its bracket by lifting it off its keyways (Figure 9.4).



7. Using a screwdriver, remove the retaining ring from the boot (Figure 9.5).





8. Remove the dust cover (Figure 9.6).



9. Place a thin piece of wood or cardboard on the end of the piston and apply compressed air to the tube connection on the caliper body. To remove the piston, you will need a little air pressure, such as from a foot tire pump.

10. After removing the piston, pull the oil seal out of its groove in the cylinder using a plastic or wooden tool.

11. Inspect the piston and cylinder bore surfaces for scratches or signs of metal-to-metal friction. If the damage is not in doubt, replace the caliper completely.

12. If these components are in good condition, then discard the rubber seal and boot and purchase a repair kit that contains all the necessary spare parts.

13. The rubber guides of the latest type of caliper can be replaced if necessary. Remove the nylon compression sleeve from each rubber guide, then gently squeeze the collar of the sleeve and press it down to remove it from the inside (photo).







14. Clean the piston and cylinder bore with hydraulic fluid or methylated spirits - nothing else.

(The article was published on the website: «www.OpelBook.ru»)

15. Begin assembly by installing the seal into the groove of the cylinder (Figure 9.7).



16. Position the dust boot in its groove in the piston. Dip the piston in clean brake fluid or lubricate its outer surface with rubber grease and insert it into the cylinder at a right angle. Make sure the piston is positioned as shown in Figure 9.8.





17. When the piston is partially depressed, connect the dust boot to the cylinder rim and install the retaining ring.

18. Press the piston so that it goes completely into the cylinder barrel.

19. If you are dealing with the latest type of caliper, install the rubber guide bushing and insert the compression seal. Do not damage the guide bushing and collar during installation and make sure that the flange of the rubber guide bushing is fully engaged (photo).



20. On older models, secure the caliper bracket in a vice and install the spring guides (Figure 9.9). Install the caliper body into the caliper keyways so that the body and caliper are positioned close to each other (Figure 9.10).







21. Install the caliper onto the hub carrier. On older models, clean the threads of the mounting bolts and lubricate them with a thread-locking compound. Install the bolts, tighten them to the specified torque value, and then install the disc pads as shown in Section 3. On later models, install the caliper onto the guide pins and push it into place (photo), then install the disc pads.



22. Connect the fluid hose using new seals in the coupling.

23. Blow the system as indicated in Section 20.

24. Install the wheel, paying attention to the alignment marks, and lower the car to the ground. Press the brake pedal several times to bring the pads to the disc, then add fluid to the master cylinder if necessary.