Power Brake Booster Replacement - Left Hand Drive (Hydraulic Brakes)

Make

Vauxhall

Model

Astra J

Section

Hydraulic Brakes › Repair Instructions › Power Brake Booster Replacement - Left Hand Drive

BrakesPower Brake Booster Replacement - Left Hand Drive

Power Brake Booster Replacement (Left Hand Drive) Special Tools CH-558-10   Closure Cap For equivalent regional tools, refer to Special Tools . Warning:  Refer to Brake Fluid Irritant Warning . Caution: Refer to Brake Fluid Effects on Paint and Electrical Components Caution . Removal Procedure 1. Turn the ignition to the OFF position. 2. Remove dash upper extension panel opening cover. refer to Dash Upper Extension Panel Opening Cover Replacement .            Note:  Do NOT disconnect engine coolant hoses. 3. Remove the radiator surge tank clip (2). 4. Remove the radiator surge tank (1).   Position the radiator surge tank (1) aside.            5. Remove the brake fluid reservoir cap and install CH-558-10   cap (1) in order to prevent fluid loss and contamination. Caution: Always connect or disconnect the wiring harness connector from the EBCM/EBTCM with the ignition switch in the OFF position. Failure to observe this precaution could result in damage to the EBCM/EBTCM. 6. Disconnect the electrical connector from the EBCM/EBTCM.            Note:  Cap the brake pipe fittings to prevent brake fluid loss and contamination. 7. Remove the 6 brake pipes (1, 2) from the BPMV.            Note:  Cap the brake pipe fittings to prevent brake fluid loss and contamination. 8. Disconnect the master cylinder secondary brake pipe fitting (1).            Note:  Cap the brake pipe fittings to prevent brake fluid loss and contamination. 9. Disconnect the master cylinder primary brake pipe fitting (1).            10. Remove the BPMV bracket bolts (2). 11. Remove the BPMV bracket assembly (1). 12. Remove the brake master cylinder assembly from the booster. Refer to Master Cylinder Replacement .            13. Remove the booster vacuum pipe (1) from the booster.            14. Disconnect the brake pedal pushrod (1) from the brake pedal.            15. Replace click fit connector (1) between booster pushrod and brake pedal with NEW part.            16. Remove the brake booster bolts (1). 17. Remove the booster from the vehicle. Installation Procedure            1. Install the booster to the vehicle. Caution: Refer to Fastener Caution . 2. Install the brake booster bolts (1) and tighten to 19 N·m (14 lb ft) .            3. Connect the brake pedal pushrod (1) to the brake pedal.            4. Install the booster vacuum pipe (1) to the booster. 5. Install the master cylinder assembly to the booster. Refer to Master Cylinder Replacement .            6. Install the BPMV bracket assembly (1). 7. Install the BPMV bracket bolts (2) and tighten to 20 N·m (15 lb ft) .            8. Connect the master cylinder primary brake pipe fitting (1) and tighten to 18 N·m (13 lb ft) .            9. Connect the master cylinder primary brake pipe fitting (1) and tighten to 18 N·m (13 lb ft) .            10. Install the 6 brake pipes (1, 2) to the BPMV and tighten to 18 N·m (13 lb ft) . 11. Connect the electrical connector with to the EBCM/EBTCM.            12. Remove the CH-558-10   cap (1) and install the brake fluid reservoir cap.            13. Install the radiator surge tank (1) 14. Install the radiator surge tank clip (2). 15. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding .

07 Brakes