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Zafira A (1999-2005, petrol)
  • Main
  • Zafira
  • Zafira A
  • Chassis
  • Brake system
  • Front Brake Caliper — Removal, Repair and Installation

Front Brake Caliper — Removal, Repair and Installation (Opel Zafira A)

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Contents: Removal ⬇ Repair ⬇ Installation ⬇
The necessity of performing this operation should be determined during the process of checking the technical condition of the brake system (see "Brake system - checking technical condition").

Removal



1. Prepare the car for work (see, "Preparing the car for maintenance and repair").

2. Remove the wheel (see "Wheel - replacement").

3. Unscrew the bolt-fitting of the brake hose tip (see "Brake hoses - replacement").

Warning: Do not press the brake pedal when the brake hose is disconnected.


4. Remove the caliper from the steering knuckle and take out the brake pads (see "Front brake pads - replacement").

Repair



Note: Subject to repair (anthers and cuffs are supplied as spare parts) brake mechanism support only with removable shoe guide. Brake mechanism support with shoe guide made as a single element with steering knuckle cannot be repaired, in case of malfunction it should be replaced as a whole.


(Material copied from this resource: Opelbook.ru)

1. Push the piston out through the hole for the bolt-fitting.

1. Push the piston out through the hole for the bolt-fitting.


2. You can also use a pneumatic tool by applying a small amount of compressed air pressure.



Warning! Be careful, the piston may shoot. To avoid injury and damage to the piston, place a rag or a wooden block between the piston body and the bracket.

Warning! Be careful, the piston may shoot. To avoid injury and damage to the piston, place a rag or…


3. Remove the piston from the caliper body.

3. Remove the piston from the caliper body.


4. Remove the boot...

4. Remove the boot...


...and carefully remove the ring, trying not to damage the cylinder mirror.

...and carefully remove the ring, trying not to damage the cylinder mirror.


5. Replace the removed dust cover and seal, inspect the surfaces of the piston and cylinder; in case of wear, scratches or corrosion, we replace the parts.



6. Before assembly, lubricate the parts with clean brake fluid.

7. Install the parts in the reverse order, aligning the recesses in the cylinder during assembly...

7. Install the parts in the reverse order, aligning the recesses in the cylinder during assembly...


...and on the piston.

...and on the piston.


Installation



1. Install the caliper in the reverse order, replacing the brake hose sealing ring with a new one.

2. Remove air from the brake hydraulic system (see "Hydraulic brake drive - bleeding") and make sure that the connection between the hose tip and the caliper is tight.


This article is available at russian, bulgarian, belarusian, ukrainian, serbian, croatian, romanian, polish, slovak, hungarian
Checking the article: Chernov Alexander

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Previous articles
Opel Zafira A: Brake system
Next articles

Front brake pads — replacement
Brake pipes — replacement
Brake hoses — replacement
Brake booster — replacement
Master Brake Cylinder — Replacement
Hydraulic brake drive — brake fluid replacement
Front brake discs — replacement
Rear brake drums of the rear drum brake mechanism — replacement
Rear brake shoes of the rear drum brake mechanism — replacement
Rear brake cylinders of the rear drum brake mechanism — removal and installation
Rear brake pads of the rear disc brake mechanism — replacement
Rear Disc Brake Caliper — Removal and Installation


See similar ones from other Opel car manuals:
▶ Front Brake Caliper — Removal, Repair and Installation Opel Astra F (1991-1998, petrol)
▶ Front Brake Caliper — Removal, Repair and Installation Opel Omega A (1986-1993)
▶ Front Brake Caliper Repair Opel Frontera B (1998-2004)
▶ Removal, repair and installation of front wheel disc brake… Opel Corsa B (1993-2000)
▶ Replacing the front brake caliper Opel Insignia A (2008-2017)
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Zafira A (1999-2005, petrol) 
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