Opel Astra, Zafira

since 1998 of release

Repair and car operation



Opel Astra
+ Opel Astra and Zafira Cars
+ Operation manual
+ Routine maintenance
+ Engine
+ Systems of cooling, heating
+ Power supply system and release
+ engine Electric equipment
+ Manual transmission
+ Automatic transmission
+ Coupling and power shafts
- Brake system
   Specifications
   System of anti-blocking of brakes (ABS) and antiprobuksovochny system (TCS) - the general information and codes of malfunctions
   Pumping of brake system
   Check of a condition and replacement of brake lines and hoses
   Replacement of blocks of disk brake mechanisms of forward wheels
   Replacement of blocks of disk brake mechanisms of back wheels
   Replacement of boots of drum-type brake mechanisms of back wheels
   Condition check, removal and installation of a brake disk
   Removal, check of a condition and installation of a brake drum
   Removal, regenerative repair and installation of supports of disk brake mechanisms of forward wheels
   Removal, regenerative repair and installation of supports of disk brake mechanisms of back wheels
   Removal, service and installation of wheel cylinders of drum-type brake mechanisms of back wheels
   Removal and installation of the main brake cylinder
   Removal and installation of a pedal of a foot brake
   Check of serviceability of functioning/tightness, removal and installation of assembly of the vacuum amplifier of brakes
   Removal, check of serviceability of functioning and installation of the return valve of the vacuum amplifier of brakes
   Removal and installation of the vacuum pump of the servo-driver of the brake amplifier (diesel models)
   Check of serviceability of functioning of the vacuum pump of the servo-driver of the brake amplifier (diesel models)
   Adjustment of a drive of the parking brake
   Removal and installation of the lever of the parking brake
   Removal and installation of cables of a drive of the parking brake
   Removal, installation and adjustment of the sensor switch of stoplights
   Removal and installation of the sensor switch of a control lamp of raising of the parking brake
   Removal and installation of the ABS and TCS components
   Removal, installation and adjustment of the valve regulator of pressure in hydraulic contours of brake mechanisms of back wheels
+ Suspension bracket and steering
+ Body
+ Onboard electric equipment


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Brake system

General information

All models of cars considered in the real Management are equipped with hydraulic brake system with vacuum strengthening. On forward wheels disk brake mechanisms whereas mechanisms of back wheels can have both disk, and a drum-type design are always established.

The dual design of the main brake cylinder (GTTs) equipped with two separate tanks allows to break a hydraulic path into two, operating independently from each other, a contour. The last means that in default one of the contours, the second continues to work as before, providing adequate braking of the car. Hydraulic contours have a diagonal arrangement. Refusal of any of contours, naturally, conducts to decrease in efficiency of braking and is accompanied by operation of a control lamp on an instrument guard when squeezing a pedal of a foot brake.

All brake mechanisms are equipped with self-regulators. Thus compensation of wear of brake shoes of disk mechanisms (forward and back) is carried out automatically whereas, on drum-type brake mechanisms the special adjusting devices which activation occurs during braking, and also when raising the parking brake are established.

The system of anti-blocking of brakes (ABS) can be established on all models. On the Zafira models without ABS the valves regulators providing correction of pressure of brake liquid depending on extent of loading of the car are built in both back brake contours sensitive to load of a back axis.

Main brake cylinder (GTTs)

GTTs is established on assembly of the servo-driver of the vacuum amplifier of the brakes, fixed on a back partition of an impellent compartment. From above on the cylinder the big tank of hydraulic liquid equipped with a plastic cover is located. The tank fastens in the cylinder by means of plugs through passage and a cylindrical pin.

As it was already mentioned above, GTTs has the dual design providing functioning of two independent hydraulic contours. Pressure of liquid in each of contours is forced by the individual piston in the main cylinder.

Vacuum amplifier of brakes

The amplifier uses depression created in the inlet pipeline for increase of efficiency of functioning of a hydraulic actuator of brake system. The servo-driver of the vacuum amplifier is fixed on a back partition of an impellent compartment.

Parking brake

The control lever of the parking brake is located in salon of the car and by means of a hummock drive influences brake mechanisms of back wheels. When raising lever on the models equipped with drum-type back brake mechanisms, cables delay the executive levers attached to assemblies of brake boots in mechanisms of both back wheels. Thus boots get divorced in the parties, nestling on a working surface of drums.

Precautionary measures

At service of components of brake system of cars it is necessary to observe some special precautionary measures:

  1. For filling of brake system use only hydraulic liquid of a demanded grade (see. Head Routine maintenance).
  2. Frictional overlays of brake blocks/boots can contain unhealthy asbestos. Try not to inhale a brake dust, do not blow off it the compressed air. To rubbing of components of brake mechanisms apply only special cleaning structures.
  3. Watch observance of all demanded admissions and efforts of a tightening of fixture. At service of components use only the serviceable tool. At the slightest doubts address for the help to experts. Remember that serviceability of functioning of brakes is guarantee of traffic safety.
  4. At the slightest signs of violation of serviceability of functioning of brake system operation of the car should be suspended!
  5. At service of any part of system act accurately and methodically, scrupulously observing purity. In the absence of confidence of operability of components make their replacement in a set for both brake mechanisms of each axis. Use only spare parts of known producers.