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Brake Servo|Specifications > < Replace brake servo (Z 13 DTH RHD)

Astra H

Replace brake servo (Z22YH)

  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 air cleaner housing
3.   Remove seal of plenum cowl (1)
4.   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


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


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
•   Unclip brake lines from bulkhead
Object Number: 3447189 Size: DEFAULT


13.   Detach vacuum line from brake servo
14.   Remove coolant line from expansion valve
•   Unscrew bolt (arrow)
Object Number: 9008084 Size: DEFAULT


15.   Remove coolant line from wheel housing inner section
•   Unscrew 2x nut (2)
•   Unclip 2x from bracket (1)
Object Number: 10677984 Size: DEFAULT


16.   Remove driver's side footwell panelling
•   Remove 2x bracket (1)
Object Number: 10677982 Size: DEFAULT


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 2x tank bleed line (2)
•   Open 2x fast closure (1)
•   Unclip 2x tank bleed line (2) and place to one side
Object Number: 10680494 Size: DEFAULT


20.   Remove rocker cover
21.   Detach rear engine transport shackle (2)
•   Unscrew nut (3)
22.   Unscrew exhaust manifold heat shield fastening bolt (1)
Object Number: 10680492 Size: DEFAULT


23.   Detach front trim panel
24.   Remove 2x headlight
25.   Detach 2x brake line from bulkhead
•   Unclip fuel line
•   Unclip 4x brake line
Object Number: 2414110 Size: DEFAULT

26.   Attach KM-6001-A (1)
Note:   Attaching KM-6001-A ensures perfect alignment of the drive unit to front axle body
•   Undo 3x screw (arrows) for the adjusting rails
•   Insert KM-6001-A
– Insert pins (2) and (5) in the guide holes for the front axle body
•   Insert support bearings front (4) and rear (3)
– Tighten support bearings to the stop on the guide pins
Note:   Guide pins must be seated without play in the support bearings
•   Tighten 3x screw for the adjusting rails

Object Number: 3447109 Size: DEFAULT

27.   Attach MKM-883-1

Allocation list MKM-883-1:

Pos. no.:

Description

1

Jack

2

MKM-883-1

3

Safety hook

4

Safety spindle
28.   Apply MKM-883-1
Note:   2nd person required
Note:   Secure wing against tipping using safety hook (3) on engine bonnet hinge

29.   Attach engine to engine bridge
30.   Detach right engine damping block (2)
•   3x bolt (1)
Object Number: 10680493 Size: DEFAULT


31.   Lower engine
•   With hexagonal section on engine bridge
Note:   Is removable up to brake servo.
32.   Remove brake servo

  Install

33.   Insert brake servo
34.   Raise engine
35.   Attach engine damping block
•   Tighten 3x bolt 55 Nm
36.   Attach brake master cylinder to brake servo
•   Tighten 2x nut 21 Nm
37.   Detach engine bridge MKM-883-1
Note:   2nd person required
•   Detach retaining hook
38.   Tighten exhaust manifold heat shield fastening bolt 23 Nm
39.   Attach engine transport shackle
•   Tighten nut
40.   Attach engine mount KM-6001-A
•   Undo 3x bolt
41.   Install rocker cover
42.   Attach brake servo to spray surface
•   Tighten 2x nut 20 Nm
43.   Attach brake pedal bearing bolt
•   Insert bolt
•   Attach retaining spring
44.   Install lower footwell panelling
•   Close 2x fast closure
45.   Attach 2x coolant line
•   Put in installation position
•   Clip on 2x upper coolant line
•   Attach 2x lower coolant line retainer
– Tighten 2x nut
– Tighten bolt
46.   Attach coolant line to expansion valve
•   Use new gaskets
•   Tighten bolt
47.   Attach wiring harness to brake fluid reservoir
•   Clip in 2x wiring harness
•   Connect wiring harness plug
48.   Attach brake servo vacuum line
•   Close fast closure on inlet side
49.   Attach brake master cylinder with brake fluid reservoir
•   Tighten 2x nut 21 Nm
50.   Attach 2x brake line to bulkhead
•   Clip on 4x brake line
•   Clip on fuel line
51.   2x brake line to brake master cylinder
•   Tighten 2x retaining bolt 14 Nm
52.   Attach rocker cover
53.   Install 2x tank bleed line
•   Close 2x fast closure
•   Clip on 2x
54.   Install windscreen wiper linkage with motor
•   Tighten 3x bolt 9 Nm
•   Connect wiring harness plug
55.   Attach plenum cowl
•   Attach hose, windscreen washing system
•   Clip in 5x clip
56.   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
57.   Install seal of plenum cowl
58.   Air filter housing
59.   Fill AC
•   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 [155x77.5 L0790]]
60.   Attach radiator grille
•   Clip in
•   Attach 4x expanding rivet
61.   Install headlight
62.   Install front trim panel

Brake Servo|Specifications > < Replace brake servo (Z 13 DTH RHD)