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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Replacement of blocks of disk brake mechanisms of forward wheels

In order to avoid car withdrawals aside during braking replacement of brake shoes should be made at the same time on both forward / back brake mechanisms. 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 gasoline or solvents on an oil basis — apply only firm cleaners or methyl alcohol!


 PERFORMANCE ORDER

  1. Cock the parking brake, поддомкратьте a front of the car and establish it on props. Remove forward wheels.
  1. By means of a small shlitsevy screw-driver take from an opening about a support the sensor of wear of blocks (1) and take him aside.
  1. Remove a big spring clip from a support — be attentive, in order to avoid a spring soskakivaniye before hooking it a screw-driver cover it with rags.

    A — Removal of a fixing spring from a support of the forward brake mechanism on the Astra models
    B — Removal of a fixing spring from a support of the forward brake mechanism on the Zafira models

A.

B.
  1. Remove dustproof caps of openings of directing fingers of a support.
  1. Turn out directing bolts and remove a support with blocks from an anchor bracket or the nave carriage (depending on a way of execution). Tie up a support to a rack a piece of a wire — do not leave it hanging on a hose.
  2. Take from a support an external block, then remove the internal block withheld by a metal spring attached to its basis.

    1 — the Internal block
    2 — the External block

  1. To Smetita from components of the brake mechanism accumulated on from surfaces a dust (see the prevention at the beginning). Wipe a support and a face surface of the piston pure rags. Remove a rust from edge of a brake disk.
  2. Measure thickness of each block, not including a metal substrate. If any block is damaged, or is worn-out over an admissible limit (see. Specifications), replace all set of the blocks, both forward wheels. Greasy blocks are subject to replacement without fail — previously eliminate the reason of development of leak. At an entrance of the indicator of wear of blocks in contact to a disk (on the dashboard the control lamp works), also it is necessary to replace it.
  3. If the condition of brake shoes is found satisfactory, carefully clear them of dirt a soft wire brush, special attention giving back and to lateral faces. Clean flutes in frictional slips, having completely removed from them extraneous inclusions. Smooth out seats of blocks in a support and an anchor bracket.
  4. Directing fingers should move easily in support plugs. Grease the back parties of blocks with copper greasing. Check a condition of a boot established on the piston, examine the piston on existence of signs of development of leakages of brake liquid, traces of corrosion and mechanical damages. In case of need make necessary regenerative repair (see. Removal, regenerative repair and installation of supports of disk brake mechanisms of forward wheels). Defective components replace.
  1. At installation of new blocks, the piston is necessary for drowning in the support cylinder for the purpose of release under installation of thicker new blocks. Otzhimaniye of the piston is made by means of the special Vauxhall adaptation though will not less effectively work and a clamp suitable on the size or the wooden lever. If the GTTs tank is not filled up to the top, the otzhimaniye of the piston should not lead to an effluence from it some brake liquid, however, reasonably previously to check its level — in case of need pump out surplus.

    A — the Special tool for an otzhimaniye of the piston of a support of the brake mechanism
    B — Otzhimaniye of the piston by means of an adjustable clamp

A.

B.

By Otzhimaniye of the piston it is interfaced to risk of damage of a sealing cuff! Originators of the real Management recommend to press a brake hose a clamp and to pit liquid via the pumping union, previously having released it on a half of turn.

  1. Fill in a support an internal brake shoe, having planted its spring in deepening in a face surface of the piston.

Internal and external blocks differ from each other on a design — pay attention to marking in the form of an arrow, put on the block basis — the arrow should indicate in the direction of rotation of a disk at car movement by a forward course.

  1. Establish on a support an external block, a frictional slip to a disk, the block is equipped with the acoustic alarm spring (1) warning the driver about wear of a block.
  1. Establish a floating bracket with an internal block over an external block and lay it on an arm.
  2. Screw bolts of directing plugs and tighten them with demanded effort.
  3. Establish boots.
  4. Establish a support spring, having got its ends in openings in a bracket.

Springs of two types are used, - one is connected to a support, another — to fastenings on an external block. If the spring of the last type is established, at first connect it to a block, then get for ledges on a support.

  1. Establish into place the sensor of wear of blocks.
  2. Several times squeeze out a pedal of a foot brake before emergence of feeling of hardness of a course.
  3. Operating in a similar manner, make replacement of blocks of the brake mechanism of an opposite wheel.
  4. Establish wheels, lower the car on the earth and tighten wheel bolts with demanded effort.
  5. Check level of brake liquid, in case of need make the corresponding adjustment (see. Head Routine maintenance).