Warning! Always replace all pads on one axle of the vehicle, even if one pad has reached the wear limit. If the pads are to be reinstalled, they must be marked before removal.
When brake pads are in operation, brake dust is generated, which contains asbestos, which is harmful to health, so when cleaning brake pads, do not use compressed air or inhale the dust.
1. Raise the front of the car and secure it on stands. Remove the front wheels.
2. Disconnect the electrical connector from the brake pad wear sensor.
3. Remove the retaining spring from the outside of the caliper.
4. Remove the dust caps from the inner ends of the guide bolts.
5. Remove the caliper guide bolts.
6. Lift the caliper with the inner shoe.
7. Using soft wire, tie it to the front post.
(Source is on the website: opelbook)
8. Remove the inner pad from the caliper piston.
9. Remove the outer pad from the caliper bracket.
10. Clean dust and dirt from the caliper and rust from the edge of the brake disc.
11. Measure the thickness of the brake pads.
12. If the pads are suitable for further use, clean them using a wire brush or rag.
13. Before installing the pads, check that the guide bolts move freely in the caliper.
14. If new brake pads are to be installed, press the piston into the caliper with a wooden rod or a hammer handle. Make sure that the piston is not warped and that the surfaces of the piston and dust boot are not damaged. When the piston is pushed in, the brake fluid is forced out of the brake cylinder into the expansion tank. Therefore, constantly monitor the fluid level in the tank, and if necessary, pump out a small amount of it from the tank.
15. Check that the notches on the caliper piston are positioned as shown in the figure. If necessary, rotate the piston to the correct position.
16. Install the inner shoe on the caliper. The spring clip should fit into the piston recess.
17. Install the outer brake shoe.
18. Install the caliper with the inner shoe onto the caliper holder.
19. Screw in the caliper guide bolts and tighten them to the specified torque.
20. Install the dust caps onto the caliper guide bolts.
21. Install the retaining spring onto the caliper, with the ends of the spring positioned in the caliper hole.
22. Connect the brake pad wear sensor.
23. Press the brake pedal several times to press the brake pads against the brake disc. Check the brake fluid level in the reservoir.
24. Repeat the above steps on the second wheel.
25. Install the wheels and lower the vehicle.
26. Check the brake fluid level.
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