Astra L4-1.8L (2009)
Note: Collect the brake fluid and the seal apertures.
3. Remove the banjo bolt (1) from the brake caliper.
Note: Overhaul the brake caliper or the brake carrier if the brake caliper is leaking, protective cap on the brake caliper is damaged, sealing sleeve
for the brake carrier is damaged or the guide bolts are corroded. Refer to Front Brake Caliper Overhaul (See: Overhaul).
4. Remove the front brake pads. Refer to Front Disc Brake Pads Replacement (See: Disc Brake System/Brake Pad/Service and Repair/Front Disc
Brake Pads Replacement).
5. Remove the brake carrier (2) from the steering knuckle.
Installation Procedure
Caution: Refer to Fastener Caution (See: Service Precautions/Vehicle Damage Warnings/Fastener Caution).
Note: Clean the thread and insert the bolts with the locking compound.
1. Install the brake carrier to the steering knuckle.
Tighten the brake carrier to steering knuckle bolt to 100 Nm (74 lb ft).
2. Install the front brake pads. Refer to Front Disc Brake Pads Replacement (See: Disc Brake System/Brake Pad/Service and Repair/Front Disc
Brake Pads Replacement).
Note: Ensure that the brake hose is not twisted.
3. Install the brake hose to the brake caliper with new seal rings.
Tighten the brake hose to brake caliper banjo bolt to 40 Nm (30 lb ft).
4. Install the front wheels. Refer to Tire and Wheel Removal and Installation (See: Maintenance/Wheels and Tires/Service and Repair).
5. Lower the vehicle.
6. Bleed the brake system and check for leaks. Refer to Hydraulic Brake System Bleeding (See: Brake Bleeding/Service and Repair).
7. Actuate the brake pedal repeatedly.
8. Top up the brake fluid to the MAX mark. Refer to Master Cylinder Reservoir Filling (See: Brake Master Cylinder/Service and Repair/Procedures
).
Rear Brake Caliper Replacement
Rear Brake Caliper Replacement
Special Tools
*
KM-6007 Resetting Tool
*
KM-6007-30 Adaptor
Removal Procedure
Warning: Refer to Brake Dust Warning (See: Service Precautions/Technician Safety Information/Brake Dust Warning).
Warning: Refer to Brake Fluid Irritant Warning (See: Service Precautions/Technician Safety Information/Brake Fluid Irritant Warning).
Note: The brake pads must be removed to remove the brake caliper of the rear wheel brake.
1. Release the parking brake cable.
*
Release the parking brake lever.
*
Remove the parking brake bellows.
*
Release the parking brake cable by unscrewing the adjusting nut.
2. Top up the brake fluid the reservoir to the MAX marking and seal. Refer to Master Cylinder Reservoir Filling (See: Brake Master
Cylinder/Service and Repair/Procedures).
Note: Mark the position in relation to center of wheel.
