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




Check of serviceability of functioning/tightness, removal and installation of assembly of the vacuum amplifier of brakes

Check of serviceability of functioning

 PERFORMANCE ORDER

  1. Without starting the engine, several times squeeze out a pedal of a foot brake. Make sure of absence of changes in size of a reserve course of a pedal (distance between a pedal and a floor).
  2. Holding a pedal squeezed out, start the engine. If right after start the pedal slightly "fails", therefore, the vacuum amplifier of brakes works regularly.

Tightness check

 PERFORMANCE ORDER

  1. Start the engine for few minutes, then muffle. Several times slowly squeeze out a pedal of a foot brake. If at first the pedal course with each squeezing is gradually reduced, however, through three-four musclemen is stabilized, tightness of assembly of the vacuum amplifier is not broken.
  2. Squeeze out a pedal of a foot brake at the working engine. Holding a pedal pressed, muffle the engine. If 30 seconds of keeping of a pedal later pressed its reserve course does not change, therefore, tightness of assembly of the vacuum amplifier is not broken, - in case of need check serviceability of the return valve of the servo-driver of the amplifier (see. Removal, check of serviceability of functioning and installation of the return valve of the vacuum amplifier of brakes). On diesel models check serviceability of functioning of the vacuum pump (see. Check of serviceability of functioning of the vacuum pump of the servo-driver of the brake amplifier (diesel models)). Any violations it is not observed, replace the block of the servo-driver of the amplifier of brakes, - the block is not subject to regenerative repair and in default should be replaced assembled.

Removal

The models equipped with central air of air

 PERFORMANCE ORDER

  1. Make a discharge of an okhladitelny path in the conditions of a specialized workshop.
  2. Remove an air purifier and inlet air lines (see. Head of the Power supply system and release).
  3. Remove the electromotor of a drive of screen wipers (see. Head Onboard electric equipment).
  4. Remove the generator (see. Head engine Electric equipment).
  5. Turn out fixing bolts and remove a basic arm of the generator from the inlet pipeline and a head of cylinders.
  6. Remove GTTs (see. Removal and installation of the main brake cylinder).
  7. On models with engines of 2.0 l remove the MAF sensor, disconnect electroconducting and hoses and remove the electromagnetic valve of control of pressure of loading.
  8. Disconnect from the amplifier a vacuum tube or remove the return valve.
  9. Turn out fixing bolt of a refrigerator tube on a back partition of an impellent compartment behind the inlet pipeline and remove the broad valve and internal consolidation.

This procedure should be made by forces on refrigeration units in the conditions of a car-care center workshop. If the system is opened for a long time, it is necessary for isolating from the atmosphere till filling.

  1. Remove lateral panels of furnish of a driver's foot well. From the driver's party, disconnect a returnable spring of a pedal of a foot brake.
  2. Remove a clamp and separate from a pedal of a foot brake a rod of a pusher of the servo-driver of the vacuum amplifier of brakes. Remove a washer.
  1. Give top left and bottom right nuts of fastening of an arm of a pedal to the servo-driver block.

    A — the Left nuts of fastening of the vacuum amplifier of brakes
    B — the Right nuts of fastening of the vacuum amplifier of brakes

A.

B.
  1. Remove the servo-driver from a partition of an impellent compartment, - try not to damage brake tubes and the other components located on proximity. Remove sealing laying.

Models without the air conditioner

Models with ABS

 PERFORMANCE ORDER

  1. Remove assembly of the hydraulic modulator (see. Removal and installation of the ABS and TCS components).
  2. Remove the main brake cylinder (see. Removal and installation of the main brake cylinder).
  3. Turn out bolts of fastening of an arm of the hydromodulator.
  4. Disconnect a vacuum tube from the amplifier or remove the return valve.
  5. Remove lateral panels of furnish of a driver's foot well and disconnect a returnable spring of a pedal of a foot brake.
  6. Remove a clamp and separate from a pedal of a foot brake a rod of a pusher of the servo-driver of the vacuum amplifier of brakes. Remove a washer.
  7. Give top left and bottom right nuts of fastening of an arm of a pedal to the servo-driver block.
  8. Remove the servo-driver from a partition of an impellent compartment, - try not to damage brake tubes and the other components located on proximity. Remove sealing laying.

Models without ABS

 PERFORMANCE ORDER

  1. Remove the main brake cylinder (see. Removal and installation of the main brake cylinder).
  2. Disconnect a vacuum tube from the amplifier or remove the return valve.
  3. Separate a relay support from a basic arm and take her aside, remove from an arm the multicontact socket.
  4. Give nuts of shtutserny connections of the brake tubes laid between the main cylinder and a transitional nozzle.
  5. Put under a transitional nozzle rags and turn out it.
  6. Remove lateral panels of furnish of a driver's foot well and disconnect a returnable spring of a pedal of a foot brake.
  7. Remove a clamp and separate from a pedal of a foot brake a rod of a pusher of the servo-driver of the vacuum amplifier of brakes. Remove a washer.
  8. Give top left and bottom right nuts of fastening of an arm of a pedal to the servo-driver block.
  9. Remove the servo-driver from a partition of an impellent compartment, - try not to damage brake tubes and the other components located on proximity. Remove sealing laying.

Installation

Installation is made as it should be, the return to an order of dismantle of components.

 PERFORMANCE ORDER

  1. Do not forget to replace the sealing laying established between assembly of the servo-driver and a partition of an impellent compartment. Track, that all fixture was tightened with demanded effort.
  2. In summary pump over brake system (see. Pumping of brake system), then start the engine and check tightness of connection of vacuum lines.