vauxhall Workshop Repair Guides

Vauxhall Workshop Service and Repair Manuals

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Vacuum Line - Brake Servo, Remove and Install and / or Non-return Valve, Replace > < Brake Servo, Replace (LHD)

Astra H

Brake Servo, Replace (RHD)

  Remove

1.   For vehicles with air conditioning: drain air conditioning
•   Connect service station
•   Blue hose to low pressure service connection (1) with small diameter
•   Red hose to high pressure service connection (2) with large diameter
Note:   Comply with operating instructions for service station
•   Determine quantity of compressor lubricant drawn out at the oil separator of the service station
Object Number: 2414549 Size: DEFAULT


2.   Remove seal of plenum cowl (1)
3.   Remove windscreen wiper arms (2)
•   Remove 2x cover cap
•   Unscrew 2x nut
•   Remove 2x washer
•   Remove 2x wiper arm from shaft
Object Number: 3446487 Size: DEFAULT


4.   Remove windscreen wiper linkage with motor
•   Unscrew 3x bolt (1)
•   Disconnect wiring harness plug (2)
Object Number: 3446679 Size: DEFAULT


5.   For Z 19 DTH, Z 19 DTJ: detach attaching parts, engine timing side
See - Alternator Support, Remove and Install LUREF_1.gif
6.   Detach cover of brake fluid reservoir
7.   Siphon out as much brake fluid as possible with siphon bottle
8.   Unclip wiring harness from brake fluid reservoir (1)
9.   Disconnect wiring harness plug (2) from brake fluid level sensor
10.   For vehicles with manual transmission: detach supply line for clutch master cylinder from brake fluid reservoir
Note:   Collect brake fluid and seal apertures.
11.   Detach brake line (3) from brake master cylinder
•   Unscrew 2x union bolt
12.   Detach brake master cylinder from brake servo
•   Unscrew 2x nut
Object Number: 3447189 Size: DEFAULT


13.   Detach vacuum line from brake servo
14.   For vehicles with air conditioning: detach refrigerant line from expansion valve
•   Unscrew bolt
15.   For vehicles with air conditioning: detach refrigerant line from inner part of wheel housing
•   Unclip 2x from bracket
•   Unscrew 2x nut
16.   Remove driver's side footwell panelling
•   Detach 2x clip
17.   Detach piston rod for brake servo (1) from brake pedal
•   Remove pedal bolt from brake pedal (2)
– Detach retaining spring
– Remove pedal bolt
Object Number: 3447194 Size: DEFAULT


18.   Detach brake servo from bulkhead
•   Unscrew 2x nut (arrows)
Object Number: 8230532 Size: DEFAULT


19.   Remove brake servo

  Install

20.   Insert brake servo
21.   Attach brake servo to bulkhead
•   Tighten 2x nut 20 Nm
22.   Remove pedal bolt from brake pedal
•   Detach retaining spring
•   Remove bolt
23.   Install driver's side footwell panelling
•   Attach 2x clip
24.   For vehicles with air conditioning: attach refrigerant line to inner part of wheel housing
•   Clip 2x into bracket
•   Tighten 2x nut
25.   For vehicles with air conditioning: attach refrigerant line to expansion valve
•   Use new gaskets
•   Tighten bolt
26.   Attach vacuum line to brake servo
•   Clip into bracket
27.   Attach brake master cylinder to brake servo
•   Tighten 2x nut
  • except for Z 19 DT, Z 19 DTJ, Z 19 DTL, Z 19 DTH (120 HP), Z 19 DTH 15 Nm
  • Z 19 DT, Z 19 DTJ, Z 19 DTL, Z 19 DTH (120 HP), Z 19 DTH and as of model year 2007: 21 Nm
28.   Attach brake line to brake master cylinder
•   Tighten 2x retaining bolt 14 Nm
29.   For vehicles with manual transmission: Attach supply line for clutch master cylinder to brake fluid reservoir.
30.   Connect wiring harness plug to brake fluid level sensor
31.   Clip wiring harness on at brake fluid reservoir
32.   For Z 19 DTH, Z 19 DTJ: install attaching parts, engine timing side
See - Alternator Support, Remove and Install LUREF_1.gif
33.   Install windscreen wiper linkage with motor
•   Tighten 3x bolt 9 Nm
•   Connect wiring harness plug
34.   Attach plenum cowl
•   Attach hose, windscreen washing system
•   Clip in 5x clip
35.   Install windscreen wiper arms
•   Plug 2x windscreen wiper arm on to shaft
Note:   Note correct installation position of the windscreen wiper arms!
•   Install 2x washer
•   Tighten 2x nut 17 Nm
•   Install 2x cover cap
36.   Install seal of plenum cowl
37.   Install air cleaner housing with air mass flow meter
•   Insert air cleaner housing
•   Attach air intake hose to air intake pipe
– Fasten clamp
•   Screw in bolt
•   Connect air mass flow meter wiring harness plug
38.   For vehicles with diesel engine: clip water drain hose into bracket
39.   Bleed brake system and check for leaks LUREF_1.gif
40.   Top up brake fluid reservoir to "MAX" marking
41.   Screw cover on to brake fluid reservoir
42.   For vehicles with air conditioning: fill air conditioning
•   Connect service station
•   Connect blue hose to low pressure service connection (1) with small diameter
•   Connect red hose to high pressure service connection (2) with large diameter
Note:   Comply with operating instructions for service station
•   Using the service station, add the quantity of new compressor lubricant to the air conditioning which was drained out during emptying
– Fill air conditioning with refrigerant R 134a

Vacuum Line - Brake Servo, Remove and Install and / or Non-return Valve, Replace > < Brake Servo, Replace (LHD)