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 and installation of the main brake cylinder

Failed GTTs is subject to replacement. Manufacturers do not recommend to undertake attempt of carrying out regenerative repair of the main brake cylinder.

Removal

The main brake cylinder is in an impellent compartment of the car and is fixed on assembly of the vacuum amplifier of brakes.

 PERFORMANCE ORDER

  1. Several times squeeze out a pedal of a foot brake for the purpose of dumping of residual pressure in system. On the Zafira models remove a plastic slip in a back part of an impellent compartment.
  2. Pump out from the GTTs tank as the bigger amount of liquid available in it (use a syringe or a rubber pear) is possible.
  3. Enclose rags under shtutserny connections and prepare caps or plastic bags for a blockage of the open ends of brake lines for the purpose of hit prevention in dirt system.

Brake liquid is among aggressive chemical compounds and at contact to body panels destroys a paint and varnish covering. Before starting performance of procedure cover wings and the panel of a front of the car with special covers, or simply old blankets.

  1. At the corresponding complete set disconnect from the GTTs tank electroconducting of the sensor switch of level of brake liquid.
  1. Weaken nuts of shtutserny knots of connection to GTTs of brake lines. In order to avoid a rounding off шлицов nuts give them by means of a special cap natural a cutting head. Having slightly delayed outside, separate brake lines from unions of the main cylinder. At once закупорьте open ends of tubes.
  1. Disconnect from the GTTs tank a tube of a hydraulic path of coupling, - at once закупорьте the open end of a tube.
  1. Release two fixing nuts and separate the main cylinder from assembly of the brake amplifier. Remove the cylinder from fixing hairpins and take it from an impellent compartment, - try not to spill hydraulic liquid filling the cylinder on the painted body panels. Remove sealing laying.
  1. In case of need, having accurately hooked a screw-driver, release clamps and remove from assembly of the main cylinder the tank of brake liquid. Take from openings in the cylinder landing plugs of the tank, - plugs are subject to replacement without fail.

Installation

 PERFORMANCE ORDER

  1. Before installation new GTTs is necessary for pumping over on a workbench. For convenience clamp a landing flange of the cylinder in a vice with soft sponges. Further it is necessary to manipulate at the same time the piston in the cylinder and to watch a stream of the brake liquid which is pushed out through the final union. Establish on the cylinder the tank of brake liquid, - do not forget to replace plugs through passage.
  2. Connect to the GTTs final unions pair of tubes from a special set for pumping (ask in shops of automobile accessories).
  1. Fill in in the tank fresh brake liquid of a demanded grade (see. Head Routine maintenance).
  2. Slowly push pistons in the cylinder (it will be most convenient to use a big screw-driver with a crosswise sting), - air should start to leave delivery chambers in the tank. It is thus important, that the ends of both tubes were completely shipped in the brake liquid which was in the tank to exclude probability of a podsasyvaniye it back in the cylinder at an otpuskaniye of pistons.
  3. Continue pumping until liquid pushed out through tubes completely will not be released from air bubbles.
  4. Serially disconnect tubes, at once corking the open ends of unions. Close the GTTs tank a cover.
  5. Plant GTTs on hairpins on assembly of the vacuum amplifier (do not forget to replace sealing laying) and while only by hand, tighten fixing nuts.
  6. Screw in the cylinder unions of brake lines. As the cylinder is not fixed yet finally, its situation can be corrected slightly for the purpose of simplification of procedure of a vvorachivaniye of unions - try not to strip a thread.
  7. Tighten with demanded effort of a nut of fastening of GTTs, then densely tighten shtutserny connections.
  8. Fill in in the GTTs tank fresh brake liquid and pump over hydraulic system (see. Pumping of brake system). GTTs pumping on the car (if did not do it on a workbench) will need the help of the assistant which will manipulate a pedal of a foot brake. Ask the assistant to squeeze out several times a pedal, then to fix it in the bottom situation. Weaken a shtutserny nut, letting out from the cylinder an air mix with brake liquid. Repeat procedure until pushed-out liquid completely will not be released from air bubbles. Operating in a similar manner, pump over the second union.

Hold near at hand pure rags for the purpose of immediate removal of traces of brake liquid getting on painted body surfaces.

  1. Before starting car operation, make sure of serviceability of functioning of brakes.