Vauxhall Workshop Service and Repair Manuals

Important

Clean all individual parts of brake caliper only with brake fluid or alcohol - do not use other fluids.

Ate Version (with Retaining Pins)

Clamp complete brake caliper with bracket in vice.

Remove brake pads.

Drive brake pad retaining pins out of brake caliper from inside outwards. Ensure that expanding springs do not become detached.

Note: Remove retainers, if present.

Remove brake caliper housing from bracket.

Press housing downwards near front of bracket.

Press brake caliper housing backwards on bracket and remove from guide pin.

Remove guide springs from bracket.

Remove bracket from vice.

Clamp housing in vice.

Remove retaining ring from protective cap using screwdriver.

Remove protective cap from housing.

Remove piston.

Insert piece of hard wood approx. 15 to 20 mm/0.6 to 0.8 in. thick in brake pad shaft of housing.

Press piston out of housing with compressed air until it contacts wood.

Remove piston from cylinder bore.

Remove protective cap from piston.

Lever seal ring out of housing bore using plastic wedge.

Clean piston and bore with alcohol or brake fluid.

Check piston and bore for damage.

Work involving removal of material from piston or cylinder is not permitted.

Replace damaged parts except piston. Always replace parts subject to wear. If cylinder bore or piston is rusted, replace complete brake caliper.

Before assembling, coat all parts with brake cylinder paste.

Insert protective cap in groove in piston.

Insert seal ring in groove of cylinder bore.

Before installation, thinly coat piston with brake cylinder paste.

Carefully insert piston in cylinder bore.

Ensure that piston does not jam and that seal ring is properly seated in groove. Do not insert piston into cylinder bore as far as stop, since protective cap is then difficult to install.

Insert protective cap in groove on housing.

Ensure cap is properly seated.

Remove brake caliper housing from vice.

Clamp bracket in vice and insert guide springs in bracket as shown in illustration.

Push brake caliper housing onto bracket as shown in illustration, pressing down slightly in front area.

Push brake caliper housing onto bracket so far that sleeves for guide pins rest against bracket.

Check piston position using piston adjustment gauge, commercially available.

If required, correct piston position using piston turning pliers, commercially available.

Press piston further into cylinder bore and mount retaining ring on protective cap.

Snap Ring Pliers KM-396 can also be used for mounting retaining ring.

Mount brake pads.

Clean sliding guides with a soft wire brush and thinly coat with Anti-squeak Solution 90 166 282/19 42 586 before installing brake pads.

Ensure retaining pins and expanding springs are correctly installed.