Vauxhall Workshop Service and Repair Manuals

Brake Caliper, Remove and Install or Replace

Close off brake fluid reservoir with blind screw cap, commercially available.

On vehicles with brake fluid level warning indicator, detach cable.

Raise vehicle and remove relevant wheel.

Mark position of wheel relative to wheel hub.

Brake Caliper, Rear Wheel Brake

Fixed Caliper, Remove

Remove brake pads.

See corresponding operation in this group.

Unscrew brake line from brake caliper and close with plug.

Unbolt brake caliper.

Install

Before installing brake caliper, check that pistons can be moved:

To do this, turn pistons slightly in both directions using piston turning pliers, commercially available.

Check piston position using piston adjustment gauge, commercially available, correct with piston turning pliers if necessary.

If a defect in the protective caps of the pistons is discovered while carrying out these operations, replace the caps.

This is described as part of the operation "Brake Caliper, Overhaul" in this group.

Bolt on brake caliper and tighten - 65 Nm/47.9 lbf. ft.

Bolt brake line to brake caliper and tighten - 11 Nm/8.1 lbf. ft.

Install brake pads.

See corresponding operation in this group.

Note:

When installing new brake pads, the piston in the brake caliper must first be pushed back and the brake pads on the other side must then also be replaced.

Each time brake pads are replaced, measure remaining thickness of brake disc using KM-230 and check surface condition of disc.

The remaining thickness of the brake disc must be at least 8 mm/0.315 in.

Brake Caliper, Front Wheel Brake

On vehicles with Check Control, remove sensor with cable from brake pad.

Note: Sensor and cable must always be replaced when replacing brake pads.

Unscrew brake hose from brake caliper - ensure seal rings on hollow screw are not lost.

Illus. C 0640 shows GMF brake caliper.

Operations are identical with other types.

GMF Brake Caliper, Remove

Loosen outer protective caps from seat on brake caliper using chisel and lever off using screwdriver.

Unscrew brake caliper fastening bolts from steering knuckle and remove brake caliper.

Note: Fastening bolts are micro-encapsulated.

Check brake pads visually for perfect condition and wear.

See corresponding operation in this group.

Ate Brake Caliper, Remove (both types)

Unscrew brake caliper fastening bolts from steering knuckle.

Remove brake caliper.

Note: Fastening bolts are micro-encapsulated.

Check brake pads visually for perfect condition and wear.

See corresponding operation in this group.

Illus. C 0531 shows Ate brake caliper with retaining pins.

Operation for Ate brake caliper with guide pins is identical.

Recut thread in steering knuckle using M 12 x 1.5 thread tap.

Thinly coat new fastening bolts - not micro-encapsulated - with Locking Compound 15 10 177 (90 167 347).

GMF Brake Caliper, Install

Bolt new brake caliper to steering knuckle and tighten - observe prescribed torque of 95 Nm/70.07 lbf. ft.

Fasten brake hose to brake caliper with hollow screw and new seal rings - observe prescribed torque of 40 Nm/29.5 lbf. ft.

Check if brake caliper can be moved.

Mount outer protective caps on brake caliper as far as stop using KM-404-1 and -3.

Always use new protective caps.

Protective caps must rest evenly on brake caliper.

Ate Brake Caliper, Install (Both Types)

Bolt new brake caliper to steering knuckle and tighten - observe prescribed torque of 95 Nm/70.07 lbf. ft.

Thinly coat new fastening bolts - not micro-encapsulated - with Locking Compound 15 10 177 (90 167 347).

Screw brake hose to brake caliper with new hollow screw and seal rings - observe prescribed torque of 40 Nm/29.5 lbf. ft.

Install brake pads - ensure proper seating of retaining pins and expanding springs.

Note: Mount retainers, if available.

Insert sensor for Check Control in inner brake pad.

Mount front wheel and tighten wheel bolts to 90 Nm/66.38 lbf. ft.

Lower vehicle.

Remove blind screw cap and bleed brake system.

Check brake system for leaks.