How to change rear brake discs on Opel Zafira B A05 – replacement guide
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Recommended replacement interval for the part category Brake disc : 50000km
Important!
This replacement procedure can be used for:
OPEL ZAFIRA B (A05) 1.6 (M75),
OPEL ZAFIRA B (A05) 2.0 (M75),
OPEL ZAFIRA B (A05) 2.2 (M75),
OPEL ZAFIRA B (A05) 1.9 CDTI (M75),
OPEL ZAFIRA B (A05) 1.9 CDTI (M75),
OPEL ZAFIRA B (A05) 1.9 CDTI (M75),
OPEL ZAFIRA B (A05) 1.6 (M75),
OPEL ZAFIRA B (A05) 1.7 CDTI (M75),
OPEL ZAFIRA B (A05) 1.7 CDTI (M75),
OPEL ZAFIRA B (A05) 1.8 (M75),
OPEL ZAFIRA B (A05) 1.8 LPG (M75),
OPEL ZAFIRA B (A05) 1.6 FlexFuel (M75)
…
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The steps may slightly vary depending on the car design.
How to change rear brake discs / rear brake rotors on OPEL ZAFIRA-B 2 (A05) [TUTORIAL AUTODOC]
All the parts you need to replace – Brake Discs for ZAFIRA B (A05) and other OPEL models
Replacement: brake discs – Opel Zafira B A05. AUTODOC recommends:
Replace the brake disks on the car Opel Zafira B A05 in complete set for each axis. Regardless of the state of components. This will ensure even braking.
The replacement procedure is identical for both brake disks on the same axle.
When changing the brake discs, always replace the brake pads.
Please note: all work on the car – Opel Zafira B A05 – should be done with the engine switched off.
Carry out replacement in the following order:
Step 1
Open the bonnet. Unscrew the brake fluid reservoir cap.
Step 2
Secure the wheels with chocks.
Step 3
Loosen the wheel mounting bolts. Use wheel impact socket #17.
Step 4
Raise the rear of the car and secure on supports.
Step 5
Unscrew the wheel bolts.
Replacement: brake discs – Opel Zafira B A05. Tip from AUTODOC:
To avoid injury, hold up the wheel when unscrewing the bolts.
Step 6
Remove the wheel.
Step 7
Clean the brake caliper fasteners. Use a wire brush. Use WD-40 spray.
Step 8
Clean the area where the brake hose is connected to the caliper, and the guide pins area. Use a wire brush. Use a brake cleaner.
AUTODOC recommends:
Replacement: brake discs – Opel Zafira B A05. After applying the spray, wait a few minutes.
Step 9
Clamp the brake hose off using a brake hose clamp.
Step 10
Unscrew the brake hose from the brake caliper. Use a combination spanner #11.
Step 11
Disconnect the brake hose.
Step 12
Unscrew the brake caliper fastening. Use a combination spanner #13.
Step 13
Spread the brake pads. Use a crowbar.
Step 14
Remove the brake caliper. Use a crowbar.
Replacement: brake discs – Opel Zafira B A05. Professionals recommend:
Tie the caliper to the suspension or to the body with a wire without disconnecting from the brake hose to prevent depressurization of the brake system.Make sure that the brake caliper is not hanging on the brake hose.Don't press the brake pedal after the brake caliper has been removed. As a result, the piston can fall out from the brake cylinder, and brake fluid leakage and depressurization of the system may occur. Check the brake caliper bracket, brake caliper guide pins and boots. Clean them. Replace, if necessary.
Step 15
Remove the brake pads. Use a crowbar.
Step 16
Clean the brake caliper bracket fasteners. Use a wire brush. Use a brake cleaner.
Replacement: brake discs – Opel Zafira B A05. Tip from AUTODOC:
After applying the spray, wait a few minutes.
Step 17
Unscrew the caliper bracket fastening. Use a drive socket #E20. Use a tap wrench.
Step 18
Remove the caliper bracket.
Step 19
Clean the brake disc fasteners. Use a wire brush. Use WD-40 spray.
Step 20
Unscrew the brake disc fastening. Use Torx T30. Use a ratchet wrench.
Step 21
Remove the brake disc.
Replacement: brake discs – Opel Zafira B A05. Tip:
If necessary, use a rubber mallet.
Step 22
Clean the hub. Use a wire brush. Treat the contacting surface. Use copper grease.
Step 23
Install the brake disc.
Step 24
Tighten the brake disc fastening. Use Torx T30. Use a torque wrench. Tighten it to 4 Nm torque.
Step 25
Clean the brake caliper bracket from dirt and dust. Use a wire brush. Use a brake cleaner.
AUTODOC recommends:
Replacement: brake discs – Opel Zafira B A05. After applying the spray, wait a few minutes.
Step 26
Install the brake caliper bracket.
Step 27
Tighten the brake caliper bracket. Use a drive socket #E20. Use a torque wrench. Tighten it to 100 Nm torque.
Step 28
Install the brake pads.
Step 29
Treat the brake caliper piston. Use a brake cleaner.
Replacement: brake discs – Opel Zafira B A05. Tip from AUTODOC experts:
After applying the spray, wait a few minutes.
Step 30
Press in the brake caliper piston. Use brake caliper wind back tool.
Step 31
Install the brake caliper and fix it.
Step 32
Tighten the brake caliper fasteners. Use a combination spanner #17. Use a drive socket #13. Use a torque wrench. Tighten it to 25 Nm torque.
Step 33
Treat the brake hose. Use a brake cleaner.
AUTODOC recommends:
Replacement: brake discs – Opel Zafira B A05. After applying the spray, wait a few minutes.
Step 34
Attach the brake hose.
Step 35
Tighten the brake hose fastener. Use a drive socket #11. Use a torque wrench. Tighten it to 40 Nm torque.
Step 36
Remove the brake hose clamp.
Step 37
Clean dirt from the brake hose bolt. Use a wire brush. Use a brake cleaner.
Replacement: brake discs – Opel Zafira B A05. AUTODOC recommends:
After applying the spray, wait a few minutes.
Step 38
Undo the brake bleeder screw. Use a drive socket #11. Use a ratchet wrench.
Step 39
Connect the brake bleeder kit to the brake bleeder screw.
Step 40
Bleed the brake caliper system. Without starting the engine, press the brake pedal several times until you feel significant resistance.
Step 41
Disconnect the brake bleeder kit.
Step 42
Tighten the brake bleeder screw. Use a drive socket #11. Use a ratchet wrench.
Step 43
Tighten the brake caliper bleed screw. Use a drive socket #11. Use a torque wrench. Tighten it to 10 Nm torque.
Step 44
Treat the surface where the brake disc contacts the wheel rim. Use copper grease.
Step 45
Clean the brake disk surface. Use a brake cleaner.
Replacement: brake discs – Opel Zafira B A05. AUTODOC experts recommend:
After applying the spray, wait a few minutes.
Step 46
Install the wheel.
AUTODOC recommends:
Important! Hold the wheel while screwing in the fastening bolts. Opel Zafira B A05
Step 47
Screw in the wheel bolts. Use wheel impact socket #17.
Step 48
Lower the car and working in a cross order, tighten the wheel bolts. Use a torque wrench. Tighten it to 110 Nm torque.
Step 49
Remove the jacks and chocks.
Replacement: brake discs – Opel Zafira B A05. Tip from AUTODOC experts:
Check the brake fluid level in the expansion tank and refill if necessary.
Step 50
Tighten the brake fluid reservoir cap.
AUTODOC recommends:
Opel Zafira B A05 – Press the brake pedal several times with the engine shut down until you feel the resistance built up.
Step 51
Close the hood.
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