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



Replacement of boots of drum-type brake mechanisms of back wheels

Replacement of boots should be made simultaneously on both brake mechanisms. Remember that developed in the course of work 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 spirit!


Simultaneously 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 / in due course should be made also give, stopping to develop demanded effort that conducts to прихватыванию brakes and to acceleration of deterioration of drums.


Dismantling of brake mechanisms correctly to make serially, — the collected mechanism in case of need can be used as the sample at assemblage of the dismantled.


 PERFORMANCE ORDER

  1. Remove a back brake drum (Removal, check of a condition and installation of a brake drum see).
  2. Сметите from components of the brake mechanism accumulated on from surfaces a dust (the prevention in the beginning see).
  3. In several places measure a thickness of frictional overlays of boots. If the result at least one of measurements exceeds limiting admissible value (Specifications see), all four boots are subject to replacement.
  4. Greasy boots are subject to replacement without fail, — preliminary eliminate the reason of development of leak.
  5. Try to remember an order of installation of components of the brake mechanism, — will make more correctly a sketch.
  1. Disconnect and remove the top coupling spring.
  2. Remove the holder and disconnect the adjusting lever in gathering 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 established between them adjusting разжимную a lath.
  1. By means of special adaptation KM-346 or suitable flat-nose pliers develop plates of holders of directing springs of boots so that the last have appeared released.
  1. Disconnect the bottom coupling spring (9) from a back boot and remove it in gathering with forward (8).
  1. Remove back колодку (10) with анкерного a finger and disconnect it from приводного a cable of a lay 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 simultaneously, try not to mix their components, — adjusting laths of the right and left mechanisms are marked by letters L and R accordingly. Colour labels are put on other details of the left brake mechanism, right — silvery.
  1. Disassemble and clear an adjusting lath, grease a carving of a rod with silicone greasing.
  2. Believe a condition of coupling springs. Damaged by corrosion and the stretched springs are subject to replacement.

Installation ослабших springs can lead to blocking of brakes!

  1. In case of need transfer on a new boot the executive lever of a lay 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 пыльники from the wheel cylinder and check up it on presence of signs of development of leaks. Check up freedom of a course of both pistons, in case of need make corresponding regenerative repair (Removal, regenerative repair and installation of supports of disk brake mechanisms of forward wheels see).
  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 admit greasing hit on frictional overlays.
  1. Hook on a tip of a cable of a bench hammer for a hook on the boot lever, — track, that the cable has got in directing on a brake board. Establish on a brake board a back boot.
  1. Establish анкерный a 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 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 its holder.
  1. Against the stop screw a carving rod in вильчатую a part adjusting разжимной laths, to a limit having truncated last. On a half-turn turn out a cogwheel and check up freedom of its rotation.
  1. Establish a lath 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 разжимной laths.
  1. Then plant the lever on an axis and fix it in the given position by the holder.
  1. Remove обвязку 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 приводного the lever of a lay brake has rested against an edge of a boot and establish to the place of a brake drum (Removal, check of a condition and installation of a brake drum see).
  2. Operating in a similar manner, make service of the second brake mechanism,
  3. Having established both drums, at completely released lay 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 a lay brake (Adjustment of a drive of a lay brake see).
  5. In summary check up level of a brake liquid in tank GTTS, in case of need make corresponding updating (Routine maintenance see the Head).

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