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



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

Check of serviceability of functioning

 PERFORMANCE ORDER

  1. Without starting the engine, some 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. Keeping a pedal squeezed out, start the engine. If right after start the pedal slightly "fails", hence, the vacuum amplifier of brakes works regularly.

Tightness check

 PERFORMANCE ORDER

  1. Start the engine on pair minutes, then muffle. Some times slowly squeeze out a pedal of a foot brake. If at first the course of a pedal with each squeezing is gradually reduced, however, through three-four rolling is stabilised, tightness of assemblage of the vacuum amplifier is not broken.
  2. Squeeze out a pedal of a foot brake at the working engine. Keeping a pedal pressed, muffle the engine. If later 30 seconds of keeping of a pedal pressed its reserve course does not change, hence, tightness of assemblage of the vacuum amplifier is not broken, - in case of need check up serviceability of the return valve of the servo-driver of the amplifier (Removal, check of serviceability of functioning and installation of the return valve of the vacuum amplifier of brakes see). On diesel models check up serviceability of functioning of the vacuum pump (Check of serviceability of functioning of the vacuum pump of the servo-driver of the brake amplifier (diesel models) see). Any infringements 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 in gathering.

Removal

The models equipped with a central air of air

 PERFORMANCE ORDER

  1. Make a discharge охладительного a path in the conditions of a specialised workshop.
  2. Remove an air cleaner and inlet air lines (see the Head of the Power supply system and release).
  3. Remove the electromotor of a drive of screen wipers (the Onboard electric equipment see the Head).
  4. Remove the generator (the engine Electric equipment see the Head).
  5. Turn out fixing bolts and remove a basic arm of the generator from the inlet pipeline and a head of cylinders.
  6. Remove ГТЦ (Removal and installation of the main brake cylinder see).
  7. On models with engines of 2.0 l remove gauge MAF, disconnect electroconducting and hoses and remove the electromagnetic valve of the 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.

The given procedure should be made by forces on a refrigerating machinery in the conditions of a car-care centre workshop. If the system is opened for a long time, it is necessary for isolating from atmosphere till the refuelling moment.

  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 affinity. Remove a sealing lining.

Models without air conditioner

Models with ABS

 PERFORMANCE ORDER

  1. Remove assemblage of the hydraulic modulator (Removal and installation of components ABS and TCS see).
  2. Remove the main brake cylinder (Removal and installation of the main brake cylinder see).
  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 affinity. Remove a sealing lining.

Models without ABS

 PERFORMANCE ORDER

  1. Remove the main brake cylinder (Removal and installation of the main brake cylinder see).
  2. Disconnect a vacuum tube from the amplifier or remove the return valve.
  3. Separate a support of the relay from a basic arm and take her aside, remove from an arm a multicontact socket.
  4. Give nuts штуцерных connections of the brake tubes laid between the main cylinder and a transitive nozzle.
  5. Put under a transitive 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 affinity. Remove a sealing lining.

Installation

Installation is made in an order, the return to an order of dismantle of components.

 PERFORMANCE ORDER

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