Opel Frontera UBS. Manual - part 2062

5C – 60 POWER ASSISTED BRAKE SYSTEM

3. Lock Bolt

4. Guide Bolt

4

3

5. Caliper Assembly

6

Support Bracket

•

Take care not to damage the flexible brake hose
when removing the support bracket.

7. Pad Assembly with Shim

•

Mark the lining locations if they are to be
reinstalled.

8. Clip

INSTALLATION

8. Clip

Clip

7. Pad Assembly with Shim

•

Apply special grease (approx. 0.2 g) to both
contacting surfaces of inner shims. Wipe off
extruded grease after installing.

Inner shim

Wear indicator

6. Support Bracket

Support Bracket Torque

N·m (kg·m / lb·ft)

104 (10.6 / 77)

5. Caliper Assembly

POWER ASSISTED BRAKE SYSTEM  5C – 61

4. Guide Bolt

3. Lock Bolt

Lock Bolt Torque

N·m (kg·m / lb·ft)

44 (4.5 / 32)

3

4

2. Brake Flexible Hose

1) Always use new gaskets.
2) Be sure to put the hooked edge of the flexible

hose end into the anti-rotation cavity.

Brake Flexible Hose Torque

N·m (kg·m / lb·ft)

35 (3.5 / 26)

Hooked edge

Gasket

1. Wheel and Tire Assembly

1) Refer to Wheels and Tires in Suspension section.
2) Bleed brakes.

5C – 62 POWER ASSISTED BRAKE SYSTEM

REBUILDING THE CALIPER

3

4

6

5

7

9

1

2

3

8

Disassembly Steps

1.

Guide bolt

2.

Lock bolt

3.

Dust boot

4.

Dust boot ring

5.

Piston

6.

Dust boot; piston

7.

Piston seal

8.

Bleeder with cap

9.

Caliper body

Reassembly Steps

9.

Caliper body

8.

Bleeder with cap

7.

Piston seal

5.

Piston

6.

Dust boot; pisotn

4.

Dust boot ring

3.

Dust boot

2.

Lock bolt

1.

Guide bolt

DISASSEMBLY

1. Guide Bolt

2. Lock Bolt

3. Dust Boot

4. Dust Boot Ring

•

Using a small screwdriver, remove the dust boot
ring.

POWER ASSISTED BRAKE SYSTEM  5C – 63

5. Piston

•

Insert a block of wood into the caliper and force
out the piston by blowing compressed air into the
caliper at the flexible hose attachment. This
procedure must be done prior to removal of dust
boot.

WARNING:
DO NOT PLACE YOUR FINGERS IN FRONT OF THE
PISTON IN AN ATTEMPT TO CATCH OR PROTECT IT
WHEN APPLYING COMPRESSED AIR. THIS COULD
RESULT IN PERSONAL INJURY.

CAUTION:
Use just enough air to ease the piston out of the
bore. If the piston is blown out, it may be damaged.

6. Dust Boot; Piston

7. Piston Seal

8. Bleeder with Cap

9. Caliper Body

REASSEMBLY

9. Caliper Body

8. Bleeder with Cap

Bleeder Torque

N·m (kg·cm / lb·in)

8 (80 / 69)

7. Piston Seal

•

Apply special rubber grease to the piston seal and
cylinder wall, then insert the piston seal into the
cylinder. The special rubber grease is included in
the repair kit.

INSPECTION AND REPAIR

Make necessary parts replacement, if wear, damage,
corrosion or any other abnormal conditions are found
through inspection.
Check the following parts;

•

Rotor

•

Cylinder body

•

Cylinder bore

•

Piston

•

Slide pin

•

Support bracket

NOTE:
The piston dust seal and dust boot are to be replaced
each time the caliper is overhauled.
Discard these used rubber parts and replace with
new ones.

5. Piston