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




Removal, regenerative repair and installation of supports of disk brake mechanisms of forward wheels

Remember that developed in the course of operation of brake mechanisms the dust can contain extremely unhealthy the person asbestos. At all do not blow off a dust the compressed air and do not inhale it, - at service of mechanisms put on a protective mask or a respirator. At all do not use for rubbing of components of brake system by gasoline or solvents on an oil basis, - apply only firm cleaners or methyl alcohol!


Supports of both brake mechanisms of one axis should change at the same time.

Removal

 PERFORMANCE ORDER

  1. Cock the parking brake, поддомкратьте a front of the car and establish it on props, remove the corresponding forward wheel.
  2. Uncover the GTTs tank put under it a polyethylene film and screw on a place, - the podkladyvaniye of a film pressurizes landing of a cover and will prevent a liquid effluence at an otpuskaniye of shtutserny connection of a flexible brake hose. Alternatively the hose can be pressed by a suitable clamp.
  3. Carefully wipe shtutserny connection of a hose on a support. Turn out a hollow bolt of the socket and remove copper sealing washers, - washers are subject to replacement without fail. At once закупорьте the open end of a hose and the union in order to avoid hit in dirt system.
  4. Remove brake shoes (see. Replacement of blocks of disk brake mechanisms of forward wheels). Remove a support.
  1. On equipped ABS and two-liter models in case of need disconnect an anchor bracket of a support from the nave carriage.

On other models the bracket is created by carriage molding.

Repair

The supports applied on diesel models of 1.7 l and 2.0 l, are not subject to regenerative repair and in case of violation of serviceability of functioning are replaced assembled.


 PERFORMANCE ORDER

  1. Transfer a support on a workbench and carefully clear it of dirt and a rust with application of a special cleaner or methyl alcohol.

At all do not apply to rubbing of brake mechanisms solvents on an oil basis!

  1. Take the piston from the cylinder of a support and remove a boot. The piston should be taken out freely by a hand, - in case of need connect to its union a source of the compressed air with low pressure of giving (most reasonable to use the foot pump) and lay between the piston and a support bracket wooden whetstone.

On models with a monolithic anchor bracket the piston is made of plastic.

  1. Having hooked a plastic applikator, take from the cylinder a piston cuff, - try not to damage a cylinder mirror.
  1. Vypressuyte from the support case directing plugs.
  2. Carefully wash out all components a special cleaner and dry them the compressed air, - do not forget to put on goggles.
  3. Replace the damaged and worn-out details. Attentively study a condition of working surfaces of the piston and the cylinder, in case of detection of defects replace the corresponding components. Check a condition of directing fingers and drillings under their landing, - fingers should be free from damages and it is rather easy to move in the landing nests. In case of absence of confidence of definition of a condition of components make their replacement.
  4. If installation to the place of an old support is supposed, prepare all necessary repair details. Sealing cuffs and boots of pistons are subject to replacement without fail.
  5. Before assembly make sure of absoluteness of purity and dryness of all components.
  6. Lower the piston and a new sealing cuff in pure brake liquid, with it grease a cylinder mirror.
  7. With fingers fill a cuff in a cylinder flute, - use of any tools is fraught with damage of a working surface! Fix on the piston a new boot, turn out it an external edge up, then fill the piston in the cylinder.
  8. Carefully drown the piston in the cylinder, in order to avoid distortions making it rotary progress, - the external edge of a boot should get to a reception flute on a support.
  9. Fill in the support case directing plugs.

Installation

 PERFORMANCE ORDER

  1. On models of 1.7 l with ABS and all two-liter models establish an anchor bracket of a support on the nave carriage, screw fixing bolts and tighten them with demanded effort, - before installation it is necessary to grease a carving part of bolts with fixing hermetic.
  2. Establish on a hollow bolt of the shtutserny socket new copper sealing washers and attach a hose to a support. Make sure of correctness of landing of a hose in support dredging, then tighten a shtutserny bolt with demanded effort.
  3. Remove a clamp pressing a hose, or or remove polyethylene from under a cover of the GTTs tank and pump over brake system (see. Pumping of brake system).

It is enough to pump over only that contour which support acted in film.

  1. Establish a wheel, lower the car on the earth and tighten wheel bolts with demanded effort.