Vauxhall Workshop Service and Repair Manuals

BRAKE SERVO, SINGLE PARTS, BRAKE PROPORTIONING VALVE, VACUUM HOSE

Brake Servo, Remove and Install - Left Hand Drive

Unbolt tandem master cylinder from brake servo, remove and push forwards slightly.

Note: Brake lines must not be unscrewed.

Loosen union nut for vacuum tube connection to intake manifold.

Pull vacuum tube from brake servo.

Detach windscreen washer fluid reservoir.

Remove brake lamp switch.

Turn switch to right or left and remove from pedal bracket.

Detach brake pedal spring.

Remove retainer from piston rod pin and remove pin.

Unscrew hex nuts (arrows) for pedal bracket from bulkhead.

Except on vehicles with power steering.

On vehicles with power steering, unscrew lower mounting screw (arrow) behind fluid lines using commercially available flex head socket wrench, e.g. Uniflex double hex.

Remove brake servo and support bracket from bulkhead.

To do this, tilt brake servo slightly and remove upwards.

Unscrew and remove two-part support bracket for brake servo.

Remove rubber sleeve from brake servo.

Lever retainer for piston rod from adjustment piece.

Remove fork and pin.

Unscrew and remove adjustment sleeve from piston rod.

Unscrew hex nut.

Clamp new brake servo in vice - use protective jaws.

Mount hex nut and adjustment sleeve on piston rod.

Insert fork and pin in sleeve and mount retainer.

Adjust adjustment sleeve so that distance A (from brake servo to centre of fork) = 278.5 mm/10.96 in.

Mount rubber sleeve on brake servo.

Bolt left support bracket (A) to brake servo and tighten lower hex nut - observe prescribed torque of 22 Nm/16.23 lbf. ft.

Mount right support bracket (B) on stay bolt and tighten hex nuts - observe prescribed torque of 22 Nm/16.23 lbf. ft.

Mount brake servo with support bracket on stay bolt and tighten hex nuts - observe prescribed torque of 22 Nm/16.23 lbf. ft.

Always use new self-locking nuts.

Tighten upper hex nut of left support bracket - observe prescribed torque of 22 Nm/16.23 lbf. ft.

Install windscreen washer fluid reservoir.

Attach tandem master cylinder to brake servo and tighten observe prescribed torque of 18 Nm/13.28 lbf. ft.

Insert vacuum tube in brake servo and tighten union nut at suction pipe connection - observe prescribed torque of 15 Nm/11.06 lbf. ft.

Insert pins for piston rod in fork and brake pedal.

Mount retainer and connect spring.

Spring is effective in actuation direction.

Insert brake lamp switch in bracket and twist into place.

Note: Since adjustment of the fork is no longer required, the brake lamp switch has been equipped with catch positions. Before installation, pull push rod of switch out as far as stop.