Vauxhall Workshop Service and Repair Manuals

Replace brake pedal and clutch pedal (RHD)

Note:   The pedal mounting is only to be replaced as a complete unit (brake pedal and clutch pedal).

  Remove

3.   Detach brake master cylinder from brake servo •   Unscrew 2x nut (1), (3) 4.   Detach vacuum hose (2) from brake servo

6.   Remove air guide driver's side lower (1) •   Remove expanding rivet (2) – Remove air guide (1)

7.   Lower inner panelling instrument panel padding - driver's side •   Open cover flap left and right •   Unscrew 2x bolts (1) •   Release and separate wiring harness plug for light switch centre (2)

9.   Remove panelling instrument panel padding (1) lower centre - both sides •   Unscrew bolt (2) •   Remove 2x from guide

10.   Detach fixing brace (1) instrument panel padding - both sides •   Unscrew 2x bolts (2) •   Unscrew nut (3)

Important:   Before pulling the steering intermediate spindle (1) from the steering pinion or spindle, move the steering to the straight ahead position and lock with steering lock. 11.   Detach steering intermediate spindle from steering gear •   Unscrew 2x bolt (1), (2) •   Push up joint (arrow) and pull steering spindle from steering gear

12.   Detach steering intermediate spindle from EPS steering column •   Twist steering wheel (1) to right in direction of travel by 90°! •   Unscrew bolt (2) through assembly opening (3) on EPS control unit (4) Note:   Diagram shows LHD. Procedure for RHD is similar.

13.   For MT: Detach clutch pedal from clutch master cylinder •   Detach clamps (2) – Remove bolt (1) •   Unscrew 2x bolts (3)

14.   Release and separate 2x wiring harness plug •   Brake light switch (1) and accelerator pedal sensor (2) •   Unclip wiring harness

15.   For MT: release and separate wiring harness plug (1) clutch pedal sensor

16.   Remove accelerator pedal (2) •   Unscrew 2x bolts (1)

17.   Release and separate wiring harness plug (1) EPS unit •   Unclip wiring harness (2) from pedal mounting

18.   Detach pedal mounting •   Unscrew 5x fastening nut (1), (2)

19.   Remove A-pillar panelling (2) - both sides •   Unclip 2x clip (1) •   Remove A-pillar panelling from guide

20.   Detach instrument panel padding cover top side - both sides •   Unclip and remove from guide

21.   Detach assembly of steering crossmember and instrument panel padding (2) •   Unscrew 4x bolt (1), (3) Note:   Watch for spacers at bottom! 22.   Pull assembly of steering crossmember and instrument panel padding (2) to rear and swivel up (arrow) 23.   Remove pedal mounting in conjunction with brake servo Note:   2nd person required to hold assembly of steering crossmember and instrument panel padding (2). Closing plate drops out! 24.   Swivel assembly of steering crossmember and instrument panel padding (2) back to installation position.

25.   Detach piston rod from brake pedal •   Detach retaining clip (3) •   Remove bolt 26.   Detach brake servo from pedal mounting •   Unscrew 2x nut (1), (2)

27.   Detach brake light switch (2), and on MT clutch pedal switch (1) •   Release 2x switch retainer (3) in direction of arrow. •   Remove brake light switch (2), and on MT clutch pedal switch (1) – Release 4x retaining lug (4)

28.   Transfer spacer plate (1) (when replacing brake servo) •   Replace seal front on brake servo

32.   Replace seal (arrow) on brake master cylinder (1)

  Install

34.   Insert pedal mounting in conjunction with brake servo Note:   2nd person required to hold assembly of steering crossmember and instrument panel padding. Fit closing plate (2)! Ensure that the pushrods of the brake servo (1) sit in the piston rod (3) of the brake master cylinder.

37.   Release pedal set •   Remove locking pin (1) Note:   Top view shows pedal mounting for MT. Bottom view shows pedal mounting for AT.

46.   Push upper universal joint of steering intermediate spindle onto steering column Note:   The square of the upper universal joint only aligns in one position. •   Tighten new bolt at top 24 Nm + 60° 47.   Fit upper clamping bolt of steering intermediate spindle on steering spindle with locking compound and tighten 48.   Attach lower universal joint (1) •   Push onto steering spindle (arrow) Note:   The recess (3) in the fine toothing in the lower universal joint must align precisely with the recess (5) in the fine toothing on the steering pinion. The bore in lower universal joint (1) must align with the groove on the steering pinion (4). •   Clean 2x threads •   Fit bolt (6) with locking compound and tighten 55 Nm •   Fit bolt (2) with locking compound and tighten 40 Nm

55.	Bleed brake system and check for leaks