Push Handbrake Operating Lever Downwards And Detach Cable End Fitting; Prise Out The Handbrake Outer Cable Retaining Clip; Withdraw The Handbrake Cable From The Caliper Bracket; Unscrew Upper Guide Pin Bolt - Opel Zafira B MPV 2006 Owners Workshop Manual

carefully clean them using a clean, fine wire
brush or similar, paying particular attention to
the sides and back of the metal backing plate.
Clean out the grooves in the friction material,
and pick out any large embedded particles of
dirt or debris. Carefully clean the pad locations
in the caliper body/mounting bracket.
5 Prior to fitting the pads, check that the
guide pins are a snug fit in the caliper
mounting bracket. Brush the dust and dirt
from the caliper and piston, but do not inhale
it, as it is injurious to health. Inspect the dust
seal around the piston for damage, and the
piston for evidence of fluid leaks, corrosion
or damage. If attention to any of these
components is necessary, refer to Section 8.
6 If new brake pads are to be fitted, it will
be necessary to retract the piston fully into
the caliper bore by rotating it in a clockwise
direction. This can be achieved by using sturdy
circlip pliers, noting that as well as being turned,
5.3a Using a screwdriver, push the
handbrake operating lever downwards, and
detach the cable end fitting from the lever
5.3d Unscrew the upper guide pin bolt
while counterholding the guide pin with a
second spanner
5.3g Remove the inner pad •••
the piston has to be pressed in very firmly.
Special tools are readily available to achieve
this with less effort. While the caliper is being
retracted, clamp off the flexible brake hose
leading to the caliper then connect a brake
bleeding kit to the caliper bleed screw. Open
the bleed screw as the piston is retracted, the
surplus brake fluid will then be collected in the
bleed kit vessel (see illustration 5.31). Close
the bleed screw just before the caliper piston is
pushed fully into the caliper. This should ensure
no air enters the hydraulic system. Note: The
ABS unit contains hydraulic components that
are very sensitive to impurities in the brake
fluid. Even the smallest particles can cause
the system to fail through blockage. The pad
retraction method described here prevents
any debris in the brake fluid expelled from the
caliper from being passed back to the ABS
hydraulic unit, as well as preventing any chance
of damage to the master cylinder seals.
5.3b Prise out the handbrake outer cable
retaining clip •••
5.3e Unscrew the lower guide pin bolt in
the same way
5.3h .•• and outer pad from the caliper
mounting bracket
Braking system 9•7
7 With the brake pads installed, depress the
brake pedal repeatedly, until normal (non-
assisted} pedal pressure is restored, and the
pads are pressed into firm contact with the
brake disc.
8 Repeat the above procedure on the
remaining rear brake caliper.
9 Adjust the handbrake cable as described
in Chapter 1 A or 1 B after fitting both sets of
brake pads.
10 Refit the roadwheels, then lower the vehicle
to the ground and tighten the roadwheel bolts
to the specified torque setting.
11 Check the hydraulic fluid level as
described in Weekly checks.
Caution: New pads will not give full braking
efficiency until they have bedded-in. Be
prepared for this, and avoid hard braking
as far as possible for the first hundred
miles or so after pad renewal.
5.3c •.• and withdraw the handbrake
cable from the caliper bracket
5.3f Lift the caliper off the mounting
bracket and suspend it under the wheel
arch using a cable tie or similar
5.3i Remove the lower guide plate •••