Opel Insignia: Description and Operation

DISC BRAKE SYSTEM DESCRIPTION AND OPERATION

System Component Description

The measurement used to identify the brake system indicates the minimum wheel size that must be installed. For example: If a 16 inch brake system is identified, the smallest wheel that can be installed is a 16 inch wheel.

The disc brake system consists of the following components:

Disc Brake Pads: Applies mechanical output force from the hydraulic brake calipers to friction surfaces of brake rotors.

Disc Brake Rotors: Uses mechanical output force applied to friction surfaces from the disc brake pads to slow speed of tire and wheel assembly rotation.

Disc Brake Pad Hardware: Secures disc brake pads firmly in proper relationship to the hydraulic brake calipers. Enables a sliding motion of brake pads when mechanical output force is applied.

Disc Brake Caliper Hardware: Provides mounting for hydraulic brake caliper and secures the caliper firmly in proper relationship to caliper bracket. Enables a sliding motion of the brake caliper to the brake pads when mechanical output force is applied.

System Operation

Mechanical output force is applied from the hydraulic brake caliper pistons to the inner brake pads. As the pistons press the inner brake pads outward, the caliper housings draw the outer brake pads inward. This allows the output force to be equally distributed. The brake pads apply the output force to the friction surfaces on both sides of the brake rotors, which slows the rotation of the tire and wheel assemblies. The correct function of both the brake pad and brake caliper hardware is essential for even distribution of braking force.

System Characteristics

Brake Noise

Brake noise can occur and to a degree, some brake noise is normal. Variations in driving conditions such as the weather, environment, driving patterns, differences in vehicle loading, and type or style of driving, can affect brake wear. Any one of these variations can cause brake noise to become apparent. Inspect and verify that all metal-to-metal contact areas of the brake pads, brake pad guides or springs, brake caliper housing, caliper bracket and/or suspension knuckle, as applicable, are clean and free of corrosion and scale.

Brake noise is a "slip-stick" vibration of disc brake components and, if it occurs intermittently, can be considered normal. Most brake noise may be eliminated or temporarily reduced by performing 3 or 4 aggressive brake applications. If the brake noise persists or consistently recurs, application of a damping compound to the brake pad mounting plate where it contacts the caliper can lessen the vibration as the components move relative to each other. Refer to Adhesives, Fluids, Lubricants, and Sealers in this section for recommended compounds.

The following brake noises are characteristic of all brake systems. These noises cannot be avoided, and may not indicate improper operation of the brake system.

Squeak/Squeal Noise

A squeak or squeal noise can occur on vehicles with front semi-metalic brake pads during light to medium brake pedal application at low to moderate vehicle speeds. Occasionally this noise may appear from the front or rear brakes after a period of non-use such as overnight, or cold brakes and/or in high humidity conditions.

Grinding Noise

Common occurrence for rear brakes and some front disc brakes during initial brake applications after the vehicle has been parked overnight. Caused by light corrosion forming on the metal brake component friction surfaces during vehicle non-use. Typically disappears after the first few brake applications.

Groan Noise

A groan type noise may be heard during a quick stop, or when slowly moving forward from a complete stop. On vehicles equipped with antilock brake systems (ABS), a groan or moan noise may occur during heavy brake application or on road surfaces with compromised traction such as loose gravel, or on wet or icy roads. This is a normal function of ABS activation.

SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS

CH-230-A

MKM-230- A

J-21177-A

Disc Gauge

CH-41013

J-41013

Rotor Resurfacing Kit

CH-42450- A

J-42450-A

Wheel Hub Resurfacing Kit

CH-45101

J-45101

Hub and Wheel Runout Gauge

CH-45101- 100

J-45101- 100

Conical Brake Rotor Washers

CH-6007- 50

Adapter

EN-45059

J-45059

Angle Meter

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