Recommended replacement interval for the part category Repair Kit, brake caliper : 50000 km

Important!

This replacement procedure can be used for:
OPEL Vivaro A Combi (X83) 1.9 DI (F7, J7, A07), OPEL Vivaro A Combi (X83) 1.9 DTI (F7, J7, A07), OPEL Vivaro A Combi (X83) 2.0 16V (F7, J7, A07), OPEL Vivaro A Combi (X83) 2.5 DTI (F7, J7, A07), OPEL Vivaro A Combi (X83) 2.0 CDTI (F7, J7, A07), OPEL Vivaro A Combi (X83) 2.0 CDTI (F7, J7, A07), OPEL Vivaro A Combi (X83) 2.5 CDTI (F7, J7, A07), OPEL Vivaro A Combi (X83) 2.0 ECOTEC (F7, A07, J7), OPEL Vivaro A Combi (X83) 2.5 CDTI (F7, J7, A07) … View more

The steps may slightly vary depending on the car design.

How to change a front brake hose and install caliper repair kit on OPEL VIVARO A Van [AUTODOC]

Alternative products

Repair Kit, brake caliper

Replacement: brake caliper repair kit – Opel Vivaro A van. Tools you need:

                      Wire brush
                    
                      Wire bore brush
                    
                      WD-40 spray
                    
                      All-purpose cleaning spray
                    
                      Brake caliper guide pin grease
                    
                      Specialised brake caliper piston grease
                    
                      Ceramic grease
                    
                      Torque wrench
                    
                      11 mm combination spanner
                    
                      11 mm flare nut wrench
                    
                      11 mm flare nut socket
                    
                      14 mm combination spanner
                    
                      14 mm flare nut socket
                    
                      11 mm socket
                    
                      13 mm socket
                    
                      18 mm socket
                    
                      19 mm wheel impact socket
                    
                      Ratchet wrench or power tool for removal/installation of threaded fasteners
                    
                      Tommy bar
                    
                      Adjustable pliers
                    
                      Mounting lever
                    
                      Slotted screwdriver
                    
                      Fluid drain pan
                    
                      Brake hose clamp
                    
                      Fluid line stopper
                    
                      Brake bleeder kit
                    
                      Brake caliper wind back tool
                    
                      Car lift or jack with jack stands, and wheel chocks

Buy tools

Replacement: brake caliper repair kit – Opel Vivaro A van. AUTODOC recommends:

Follow the maintenance intervals, recommendations, and requirements for using the part as specified by the manufacturer.
For both the brake hoses and the caliper components, the replacement procedure is identical for the left and right sides of the axle.
All the work should be carried out with the ignition switched off.

Replacement: brake caliper repair kit – Opel Vivaro A van. Take the following steps:

Step 1

Open the bonnet.
Step 2

Loosen the brake fluid reservoir cap.
Step 3

Secure the wheels with chocks.
Step 4

Loosen the wheel fasteners. Use a 19 mm wheel impact socket. Use a tommy bar.
Step 5

Raise the vehicle.

Warning!
If you are using a jack, make sure the car is parked on a hard, flat surface.Make sure to additionally secure the car with jack stands.
Step 6

Unscrew the wheel fasteners.

Replacement: brake caliper repair kit – Opel Vivaro A van. Tip:
To avoid injury, hold up the wheel when unscrewing the fasteners.
Step 7

Remove the wheel.
Step 8

Prepare a fluid drain pan.
Step 9

Spread the brake pads apart. Use a mounting lever.
Step 10

Clean the fastener that connects the brake hose to the brake caliper. Use a wire brush. Use WD-40 spray.
Step 11

Detach the brake hose from the bracket on the suspension strut.
Step 12

Attach the brake hose clamp to the brake hose.
Step 13

Loosen the fastener that connects the brake hose to the brake caliper. Use an 14 mm combination spanner.
Step 14

Unscrew the brake hose from the brake caliper.
Step 15

Clean the brake caliper fasteners. Use a wire brush. Use WD-40 spray.

Step 16

Unscrew the brake caliper fasteners. Use a 13 mm socket. Use a ratchet wrench.
Step 17

Remove the fastening bolts.
Step 18

Remove the brake caliper.
Step 19

Remove the brake pads.
Step 20

Clean the brake caliper bracket fasteners. Use a wire brush. Use WD-40 spray.

Step 21

Unscrew the brake caliper bracket fasteners. Use an 18 mm socket. Use a ratchet wrench.
Step 22

Remove the fastening bolts.
Step 23

Remove the brake caliper bracket.
Step 24

Remove the pistons from the brake caliper.

Replacement: brake caliper repair kit – Opel Vivaro A van. AUTODOC experts recommend:
Exercise extreme caution when removing the piston. Use a suitable mechanical stop to prevent injury from them suddenly ejecting.Use adjustable pliers if necessary.
Step 25

Remove the boots of the brake caliper pistons.
Step 26

Remove the sealing rings of the brake caliper pistons. Use a slotted screwdriver.
Step 27

Clean the brake caliper piston bores and the caliper body. Use a wire brush. Use an all-purpose cleaning spray.
Step 28

Clean the brake caliper pistons. Use an all-purpose cleaning spray.
Step 29

Remove the guide pins from the brake caliper bracket.
Step 30

Remove the guide pin boots.
Step 31.1

Clean the guide pin mounting seats on the caliper bracket. Use a wire bore brush.

Step 31.2

Use an all-purpose cleaning spray.
Step 32

Install new caliper piston sealing rings.
Step 33

Install new brake caliper piston boots.
Step 34

Install the pistons into the brake caliper. Use a brake caliper wind back tool.

Important!
Before installation, treat the pistons and their bores with a specialised brake caliper piston grease or brake fluid to prevent scuffs on the bore walls.Proceed with caution so as not to damage the sealing rings or boots.
Step 35

Install new boots on the brake caliper guide pins.
Step 36

Treat the caliper guide pins. Use brake caliper guide pin grease.
Step 37

Install the new guide pins into the caliper bracket.
Step 38

Install the brake caliper bracket.
Step 39

Install the fastening bolts.
Step 40

Tighten the fasteners of the brake caliper bracket. Use an 18 mm socket. Use a torque wrench. Tightening torque: 100 N·m.
Step 41

Install the brake pads.
Step 42

Install the brake caliper.
Step 43

Install the fastening bolts.
Step 44

Tighten the brake caliper fasteners. Use a 13 mm socket. Use a torque wrench. Tightening torque: 35 N·m.
Step 45

Screw in the nut fitting connecting the brake hose to the brake caliper.
Step 46

Securely tighten the brake hose connection to the brake caliper. Use a 14 mm flare nut socket. Use a torque wrench. Tightening torque: 14 N·m.
Step 47

Remove the brake hose clamp from the brake hose.

Step 48

Secure the brake hose in the bracket on the suspension strut.
Step 49

Remove the brake bleeder screw cap.
Step 50

Connect the brake bleeder kit to the brake bleeder screw.
Step 51

Loosen the brake bleeder screw. Use an 11 mm combination spanner.
Step 52

Press the brake pedal several times to remove any air from the system.

Replacement: brake caliper repair kit – Opel Vivaro A van. AUTODOC recommends:
Monitor the brake fluid level while bleeding: it should not fall below the Min mark on the brake fluid reservoir. Top up with fresh brake fluid if necessary.You can find detailed instructions on how to bleed the brake system in our other video: https://youtu.be/JTFNlg0uUp0
Step 53

Screw in the brake bleeder screw. Use an 11 mm combination spanner.
Step 54

Disconnect the brake bleeder kit.
Step 55

Tighten the brake bleeder screw. Use an 11 mm socket. Use a torque wrench. Tightening torque: 9 N·m.
Step 56

Reattach the brake bleeder screw cap.
Step 57

Clean the wheel rim mounting seat. Use a wire brush. Use an all-purpose cleaning spray.
Step 58

Treat the brake disc surface that contacts the wheel rim. Use ceramic grease.
Step 59

Install the wheel.

Replacement: brake caliper repair kit – Opel Vivaro A van. Tip:
To avoid injury, hold up the wheel when screwing in the fasteners.
Step 60

Screw in the wheel fasteners. Use a 19 mm wheel impact socket. Use a ratchet wrench.
Step 61

Lower the car and tighten the wheel fasteners in a criss-cross pattern. Use a 19 mm wheel impact socket. Use a torque wrench. Tightening torque: 142 N·m.
Step 62

Remove the jack, jack stands, and wheel chocks.
Step 63

Without starting the engine, press the brake pedal several times until you feel significant resistance.
Step 64

Check the brake fluid level in the reservoir and top up if necessary.
Step 65

Tighten the brake fluid reservoir cap.
Step 66

Close the bonnet.

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