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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 boots of drum-type brake mechanisms of back wheels

Replacement of boots should be made at the same time on both 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 by gasoline or solvents on an oil basis — apply only firm cleaners or methyl alcohol!


At the same time with replacement of brake boots replacement of their coupling and directing springs which as a result of constant cyclic mechanical and thermal loadings are stretched / give over time should be made also, stopping to develop demanded effort that conducts to a prikhvatyvaniye of brakes and acceleration of wear of drums.


Dismantling of brake mechanisms is correct for making serially — the assembled mechanism in case of need can be used as an example at assembly of the dismantled.


 PERFORMANCE ORDER

  1. Remove a back brake drum (see. Removal, check of a condition and installation of a brake drum).
  2. To Smetita from components of the brake mechanism accumulated on from surfaces a dust (see the prevention at the beginning).
  3. In several places measure thickness of frictional overlays of boots. If the result at least one of measurements exceeds limiting admissible value (see. Specifications), all four boots are subject to replacement.
  4. Greasy boots are subject to replacement without fail — previously eliminate the reason of development of leak.
  5. Try to remember an order of installation of components of the brake mechanism — it will be more correct to make a sketch.
  1. Disconnect and remove the top coupling spring.
  2. Remove the holder and disconnect the adjusting lever assembled with the spring.

    1 — the Spring of the adjusting lever
    2 — the Holder
    3 — the Adjusting lever
    4 — the Top coupling spring

  1. Slightly dissolve the top ends of boots in the parties and remove the adjusting razzhimny level established between them.
  1. By means of the special KM-346 adaptation or suitable flat-nose pliers develop plates of holders of directing springs of boots so that the last appeared released.
  1. Disconnect the bottom coupling spring (9) from a back boot and remove it assembled with forward (8).
  1. Remove a back block (10) from an anchor finger and disconnect it from a driving cable of the parking brake (11).
  1. Do not press a pedal of a foot brake at the removed boots of brake mechanisms, - for reliability pull together pistons of the wheel cylinder with a wire or plastic bandage.
  1. If both brake mechanisms are disassembled at the same time, try not to mix their components — adjusting levels of the right and left mechanisms are marked by letters of L and R respectively. Color labels are put on other details of the left brake mechanism, right — silvery.
  1. Disassemble and clear an adjusting level, grease a rod carving with silicone greasing.
  2. Believe a condition of coupling springs. Damaged by corrosion and the stretched springs are subject to replacement.

Installation of the weakened springs can lead to blocking of brakes!

  1. In case of need transfer on a new boot the executive lever of the parking brake. The lever приклепывается to a boot, or fastens by means of a pin — the rivet should be drilled. Probably, it is necessary to rearrange from an old boot on new as well an axis of the adjusting lever with a clamp.
  1. Remove rubber boots from the wheel cylinder and check it on existence of signs of development of leaks. Check freedom of a course of both pistons, in case of need make the corresponding regenerative repair (see. Removal, regenerative repair and installation of supports of disk brake mechanisms of forward wheels).
  1. Before installation clear a brake board. With high-temperature greasing grease contacting to moving components of the brake mechanism of a surface of a board, and also pistons of the wheel cylinder — try not to allow greasing hits on frictional slips.
  1. Hook on a tip of a cable of a bench hammer for a hook on the boot lever — track, that the cable got in directing on a brake board. Establish on a brake board a back boot.
  1. Establish an anchor finger and directing spring of a back boot and fix components the holder.
  1. Connect the bottom coupling spring to a back boot, then hook for it on a forward boot and establish the last on the regular place, having entered it into gearing from the directing.

    3 — Directing
    4 — the Bottom coupling spring

  1. Establish directing spring and fix it the holder.
  1. Against the stop screw a carving rod in a bifurcate part of an adjusting razzhimny level, to a limit having truncated the last. On a half of turn turn out a cogwheel and check freedom of its rotation.
  1. Establish a level between boots, the long end to a back boot.
  1. Hook on the lever of the adjusting mechanism for a cogwheel of the ratchet mechanism of a razzhimny level.
  1. Then plant the lever on an axis and fix it in this situation by the holder.
  1. Remove a binding from pistons of the wheel cylinder. Make sure of correctness of combination of boots with pistons and establish the top coupling spring.

    A — Connection of the top coupling spring to a back boot
    B — Connection of the top coupling spring to a forward boot

A.

B.
  1. Establish a spring of the adjusting mechanism.
  1. Make sure that the lock pin of the driving lever of the parking brake rested against an edge of a boot and establish to the place of a brake drum (see. Removal, check of a condition and installation of a brake drum).
  2. Operating in a similar manner, make service of the second brake mechanism,
  3. Having established both drums, at completely released parking brake of 20 — 25 times squeeze out a pedal of a foot brake, having asked the assistant to listen to serviceability of operation of adjusting mechanisms.
  4. Make adjustment of a drive of the parking brake (see. Adjustment of a drive of the parking brake).
  5. In summary check level of brake liquid in the GTTs tank, in case of need make the corresponding adjustment (see. Head Routine maintenance).

Full efficiency of braking after replacement of boots is reached only after 100 — 150 km of run — avoid sharp braking!