Opel Astra, Zafira

Since 1998 of release

Repair and car operation



Opel Astra
+ Cars Opel Astra and Zafira
+ The operation manual
+ Routine maintenance
+ The engine
+ Systems of cooling, heating
+ The power supply system and release
+ Engine electric equipment
+ Manual transmission
+ Automatic transmission
+ Coupling and power shafts
- Brake system
   Specifications
   System of antiblocking of brakes (ABS) and антипробуксовочная system (TCS) - the general information and codes of malfunctions
   Prorolling of brake system
   Check of a condition and replacement of brake lines and hoses
   Replacement колодок disk brake mechanisms of forward wheels
   Replacement колодок 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 assemblage 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 a lay brake
   Removal and installation of the lever of a lay brake
   Removal and installation of cables of a drive of a lay brake
   Removal, installation and adjustment of the gauge-switch of stoplights
   Removal and installation of the gauge-switch of a control lamp of raising of a lay brake
   Removal and installation of components ABS and TCS
   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 ГТЦ is subject to replacement. Manufacturers do not recommend to undertake attempt of carrying out of regenerative repair of the main brake cylinder.

Removal

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

 PERFORMANCE ORDER

  1. Some times squeeze out a pedal of a foot brake for the purpose of dump of residual pressure in system. On models Zafira remove a plastic overlay in a back part of an impellent compartment.
  2. Pump out from tank GTTS as it is possible большее quantity of a liquid available in it (take advantage of a syringe or a rubber pear).
  3. Enclose rags under штуцерные connections and prepare caps or polyethylene packages for закупоривания the open ends of brake lines for the purpose of hit prevention in dirt system.

The brake liquid is among aggressive chemical compounds and at contact with кузовными panels destroys a paint and varnish covering. Before to start procedure performance cover wings and the panel передка the car with special covers, or simply old blankets.

  1. At a corresponding complete set disconnect from tank GTTS electroconducting of the gauge-switch of level of a brake liquid.
  1. Ослабьте nuts штуцерных connection knots to ГТЦ brake lines. In order to avoid a rounding off шлицов nuts give them by means of special накидного a key with a cutting head. Slightly having delayed outside, separate brake lines from unions of the main cylinder. At once закупорьте the open ends of tubes.
  1. Disconnect from tank GTTS 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 assemblage of the brake amplifier. Remove the cylinder from fixing hairpins and take it from an impellent compartment, - try not to spill a hydraulic liquid filling the cylinder on painted кузовные panels. Remove a sealing lining.
  1. In case of need, accurately having hooked a screw-driver, release clamps and remove from assemblage of the main cylinder the tank of a brake liquid. Take from apertures in the cylinder landing plugs of the tank, - plugs are subject to replacement without fail.

Installation

 PERFORMANCE ORDER

  1. Before installation new ГТЦ it is necessary to pump 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 simultaneously the piston in the cylinder and to observe of a stream of the brake liquid which are pushed out through the final union. Establish on the cylinder the tank of a brake liquid, - do not forget to replace plugs through passage.
  2. Connect to final unions GTTS pair of tubes from a special set for prorolling (ask in shops of automobile accessories).
  1. Fill in in the tank a fresh brake liquid of a demanded grade (Routine maintenance see the Head).
  2. Slowly push pistons in the cylinder (it will be most convenient to take advantage of the 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 have been completely shipped in a brake liquid being in the tank to exclude probability подсасывания it back in the cylinder at отпускании pistons.
  3. Continue prorolling until the 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 tank GTTS a cover.
  5. Plant ГТЦ on hairpins on assemblage of the vacuum amplifier (do not forget to replace a sealing lining) and while only by hand, tighten fixing nuts.
  6. Screw in the cylinder unions of brake lines. As the cylinder is not fixed yet definitively, its position it is possible to correct slightly for the purpose of simplification of procedure вворачивания unions - try not to strip a thread.
  7. Tighten with demanded effort of a nut of fastening ГТЦ, then densely tighten штуцерные connections.
  8. Fill in in tank GTTS a fresh brake liquid and pump over hydraulic system (Prorolling of brake system see). For prorolling ГТЦ on the car (if have not done it on a workbench) the help of the assistant which will manipulate a pedal of a foot brake is required. Ask the assistant to squeeze out some times a pedal, then to fix it in the bottom position. Ослабьте штуцерную a nut, letting out from the cylinder a mix of air with a brake liquid. Repeat procedure until the 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 getting on painted кузовные surfaces of a brake liquid.

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