Note: Calipers are not subject to refurbishment under the conditions of an ordinary workshop - contact the Opel campaign service station or replace them as an assembly.
Removing
Attention: After removing the brake pads, do not press the brake pedal, otherwise the piston may be squeezed out of the housing. In this case, to install the piston in place, you will have to contact the service station.
1. Hang the car and place it on stands, remove the corresponding wheels.
2. Remove the cap from the GTZ reservoir, put a plastic film under it and screw it in place - laying the film seals the fit of the cap and prevents fluid from escaping when the flexible brake hose fitting is released. Alternatively, the hose can be clamped with a suitable clamp.
3. Thoroughly clean the hose fitting on the caliper. Turn out a hollow bolt of a socket and remove copper sealing washers, washers are subject to replacement without fail. Seal the open end of the hose and fitting immediately to prevent dirt from entering the system, or attach it to a new caliper
Note: If the caliper is removed only to remove the brake pads or brake disc, the hose should not be disconnected. In this case, tie the caliper with wire to the body so that the hose is not twisted or stretched.
4. Remove the brake pads and caliper (see Section 5 and 6).
5. Turn out 2 fixing bolts (Togh) and remove the shoe guide from the steering knuckle (see resist. illustrations).
7.5 Torx bolts (4) rail fasteners (5) front brake mechanism
Attention: A lot of force is required to unscrew/tighten the rail fastening bolts! It is recommended to replace the wheels and lower the vehicle to the ground before performing this operation.
Installation
6. Before installation, clean the threads of all bolts from the remnants of the compound and lubricate it with fresh compound (e.g. Loctite Tour 243).
7. Installation is made in an order, the return to an order of removal. A lot of force is required to tighten the rail mounting bolts (230 Nm!), - check the reliability of fastening the car in the suspended position. It is recommended to replace the wheels and lower the vehicle.
8. If the brake hose was disconnected, do not forget to replace the sealing washers and remove air from the brake path (see Section 3), the hose must not be kinked or kinked.
Note: It is enough to pump only the circuit whose caliper was removed.
Check that the hoses on the front wheels do not touch them at the maximum steering angle.
9. Remove the clamp clamping the hose, or remove the polyethylene from under the cover of the GTZ tank.
10. Depress the foot brake pedal several times to shrink the shoes.
12. Install the wheel, lower the vehicle to the ground and tighten the wheel bolts to specification.
13. Check the liquid level in the GTZ tank, if necessary, make the appropriate adjustment (see chapter 1)
14. Before starting the operation of the car, check the proper functioning of the brake system.
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