Vauxhall Workshop Service and Repair Manuals

Caution

The brake caliper housing must not be disassembled. All operations, e.g. pressing out the pistons, replacing the seal rings etc. are performed on the assembled brake caliper housing. Clean all individual brake caliper parts with brake fluid or alcohol only – under no circumstance use other fluids.

  Remove

Remove brake caliper – see operation "Brake Caliper – Rear Wheel Brake, Remove and Install or Replace".

  Disassemble

Block one piston with KM-286 (1) and carefully press out the other piston using compressed air.

Close off bore of removed piston with KM-286 (1) and carefully press out the remaining piston.

  Disassemble

Lever seal rings (1) out of groove with plastic wedge.

Clean piston and bore with brake fluid or alcohol – under no circumstance use other fluids – and check for wear.

Caution

Material-removing work on the piston and bores is not permitted. The entire brake caliper must be replaced if parts are rusted or if the piston or bores are damaged.

  Assemble

Coat bores, piston and new seal rings with brake cylinder paste. Insert new seal rings in bores. Carefully insert piston in bore – ensure that piston does not become tilted during installation.

Note:   Do not insert the piston up to stop, otherwise the protective cap is difficult to install.

  Assemble

Insert new protective cap for piston in groove and press onto brake caliper. Install clamp ring (1) on protective cap.

  Inspect

Check piston position with piston adjusting gauge. The piston should press completely onto the brake pad retaining plate with the raised side of the piston pressure face – if necessary. Correct piston position with piston turning pliers.

  Install

Install brake caliper – see operation "Brake Caliper – Rear Wheel Brake, Remove and Install or Replace".