Inspection
1. Where applicable, remove the hubcap, then loosen the bolts of the relevant wheel. If the front brake disc is being inspected, apply the handbrake; if the procedure is being carried out on the rear brake disc, block the front wheels. Jack up and support the relevant part of the vehicle on axle stands. Remove the wheel.
2. Where applicable, ensure that the brake disc mounting screw is securely tightened. Place a shim of approximately 10.0 mm thickness on one of the wheel bolts, insert the bolt into the hole diagonally opposite the disc mounting screw and tighten it (see illustration).
3. Rotate the brake disc and inspect it for deep scratches, if any are found the disc should be re-sharpened or replaced. Shallow scratches are quite acceptable.
4. Using a micrometer or flat metal block and feeler gauges, ensure that the disc runout is within the limits given in Specifications. Measure the disc runout at 10.0 mm from its outer edge.
5. On models with a single overhead camshaft (SOHC), if the rear brake disc is running out excessively, check the rear wheel bearing adjustment as described in Section 10.
6. If the front brake disc is beating (all models) if the rear brake disc (models with two overhead camshafts (DOHC)) is running out of control, remove the disc as described later in this Chapter. Make sure that the surface of the disc facing the hub is completely clean. Install the disk and check the heartbeat again.
7. If the runout is still excessive, the disc should be replaced.
8. To remove the disc, proceed as follows.
Front brake disc
Removal
9. Where applicable, remove the wheel bolt and shim installed to inspect the disc.
10. Remove the brake pads (Chapter 4).
11. On 2.0L models, remove the two mounting bolts and caliper bracket.
12. Loosen the mounting screw and remove the disc from the hub.
Installation
13. Installation is carried out in the reverse order. Make sure that the mating surfaces of the disc and hub are completely clean and apply a small amount of locking compound to the threads of the mounting screw. Install the brake pads (Chapter 4). Rear brake disc - single overhead camshaft models
14. On these models the rear wheel hub is built into the disc. Removal and installation are described in Section 10.
Rear Brake Disc - DOHC Models
Removal
15. Remove the wheel bolt and the gasket installed during the inspection of the disc.
16. Remove the brake pads as described in Chapter 5.
17. Remove the brake caliper (see Chapter 9), without disconnecting the brake pipe. Move the caliper to the side and tie it to the body so as not to deform the pipe.
18. Loosen the mounting screw and remove the disc from the hub. If this is not possible, remove the handbrake pads by inserting a screwdriver into the hole in the disc and turning the adjuster wheel.
Installation
19. Installation is carried out in the reverse order. Make sure that the mating surfaces of the disc and hub are completely clean and apply a small amount of locking compound to the threads of the mounting screw. Install the brake pads as described in Chapter 5.
Material copied from the portal [OPELBOOK]
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