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Brake Caliper – Front Wheel Brake, Remove
and Install (Steering Knuckle without Integrated Brake Carrier)
 Remove
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Detach banjo bolt (1) from brake caliper – collect
escaping fluid and seal aperture.
Remove brake linings – see operation "Brake Linings
– Front Wheel Brake, Remove and Install (Steering Knuckle
without Integrated Brake Carrier)".
Caution
For Astra OPC a larger brake carrier is used.
If brake caliper leaks protective cap at brake caliper is
damaged, brake carrier sealing sleeve is damaged or guide pins have
started to rust: overhaul brake caliper or brake carrier –
see operation "Brake Caliper – Front Wheel Brake, Overhaul
(Steering Knuckle without Integrated Brake Carrier)".
Remove brake carrier (2) from steering knuckle.
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Install
Clean thread and insert fastening bolts with locking compound.
Attach brake carrier to steering knuckle – tightening torque
110 Nm / 81 lbf. ft.
Install brake linings – see operation "Brake Linings,
Remove and Install (Steering Knuckle without Integrated Brake
Carrier)".
Attach brake hose with new seal rings to brake caliper thereby
ensuring that brake hose is not twisted – tightening torque
40 Nm / 30 lbf. ft.
Connect front wheel – 110 Nm / 81 lbf. ft.
Inspect
Bleed brake system and check for leaks – see operation
"Brake System, Bleed and Check for Leaks".
Actuate brake pedal repeatedly. Top up brake fluid to "MAX" mark
on brake fluid reservoir.
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