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Front Brake Calliper Bracket Replacement - 15 inch Brake System > < Rear Brake Shield Replacement

Astra J

Front Brake Caliper Replacement

Special Tools

CH-558-10   Vacuum Cap

For equivalent regional tools, refer to Special Tools .

Removal Procedure

Warning:  Refer to Brake Dust Warning .
Warning:  Refer to Brake Fluid Irritant Warning .
Warning: Use of eye goggles is necessary to prevent personal injury.


1. Inspect the fluid level in the brake master cylinder reservoir.
2. If the brake fluid level is midway between the maximum-full point and the minimum allowable level, no brake fluid needs to be removed from the reservoir before proceeding.
3. If the brake fluid level is higher than midway between the maximum-full point and the minimum allowable level, remove brake fluid to the midway point before proceeding.

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4. Remove the brake fluid reservoir cap and install CH-558-10   vacuum cap (1) to prevent fluid loss and contamination.
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
6. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .

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7. Remove the brake hose-to-caliper bolt (3) from the brake caliper.
8. Remove the brake hose (2) from the brake caliper.
  Remove and discard the copper brake hose washers. These washers may be stuck to the brake caliper and/or the brake hose end.
9. Cap or plug the opening in the brake caliper and the brake hose to prevent fluid loss and contamination.
10. Remove the brake caliper guide pin bolts (1).
11. Remove the brake caliper from the caliper bracket.
12. Inspect the brake caliper guide pins for freedom of movement, and inspect the condition of the guide pin boots. Move the guide pins inboard and outboard within the bracket bores, without disengaging the slides from the boots, and observe for the following:
  •  Restricted caliper guide pin movement
  •  Looseness in the brake caliper mounting bracket
  •  Seized or binding caliper guide pins
  •  Split or torn boots
13. If any of the conditions listed are found, the brake caliper guide pins and/or boots require replacement.

Installation Procedure

1. Install the brake caliper to the brake caliper bracket.

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Note:  Do not reuse the brake hose washers.
2. Install NEW copper brake hose washers (1) to the brake hose-to-caliper bolt and to the brake hose.

Caution: Refer to Fastener Caution


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3. Install the brake caliper guide pin bolts (1) and tighten to 28 N·m (21 lb ft) .
4. Remove the caps or plugs from the brake caliper opening and the brake hose.
5. Install the brake hose (2) to the caliper.
6. Install brake hose-to-calliper bolt (3) to the calliper and tighten to 40 N·m (30 lb ft) .
7. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding .
8. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
9. Lower the vehicle.

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10. Remove the CH-558-10   vacuum cap (1) and install brake fluid reservoir cap.
11. With the engine OFF, gradually apply the brake pedal to approximately 2/3 of its travel distance.
12. Slowly release the brake pedal.
13. Wait 15 seconds, then repeat steps 10 and 11 until a firm brake pedal is obtained. This will properly seat the brake caliper piston and brake pads.

Front Brake Calliper Bracket Replacement - 15 inch Brake System > < Rear Brake Shield Replacement