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

Make

Vauxhall

Model

Astra J

Section

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

BrakesPower Brake Booster Replacement - Right Hand Drive

Power Brake Booster Replacement (Right 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 . Caution: When adding fluid to the brake fluid reservoir or to the clutch fluid reservoir, use only DOT-4+ brake fluid from a clean, sealed container. This polyglycol brake fluid is hygroscopic and absorbs moisture. Do not use fluid from an open container that may be contaminated with water. Improper or contaminated fluid could result in damage to the system components. Removal Procedure 1. Turn the ignition to the OFF position. 2. Remove the air cleaner assembly. Refer to:   •  1.3 L diesel engine. Refer to Air Cleaner Replacement .   •  1.4 L engine. Refer to Air Cleaner Assembly Replacement .   •  1.6 L engine. Refer to Air Cleaner Assembly Replacement .   •  1.7 L diesel engine. Refer to Air Cleaner Assembly Replacement .   •  2.0 L diesel engine. Refer to Air Cleaner Assembly Replacement . 3. Remove dash upper extension panel opening cover. Refer to Dash Upper Extension Panel Opening Cover Replacement . Note:  DO NOT open hydraulic power steering system: 4. If equipped, loosen power steering fluid reservoir and lay aside. Refer to Power Steering Fluid Reservoir Replacement .            5. Remove the brake fluid reservoir cap and install CH-558-10   cap (1) in order to prevent fluid loss and contamination.            Note:  Cap the brake pipe fittings to prevent brake fluid loss and contamination. 6. Disconnect the master cylinder secondary brake pipe fitting (1).            Note:  Cap the brake pipe fittings to prevent brake fluid loss and contamination. 7. Disconnect the master cylinder primary brake pipe fitting 8. Remove the brake master cylinder assembly from the booster. Refer to Master Cylinder Replacement .            9. Remove the booster vacuum pipe (1) from the booster.            10. Disconnect the brake pedal pushrod (1) from the brake pedal.            11. Replace click fit connector (1) between booster pushrod and brake pedal with new part.            12. Remove 2 the brake booster bolts (1). 13. Remove the booster from the vehicle. Installation Procedure            1. Install the booster to the vehicle. Caution: Refer to Fastener Caution . 2. Install the 2 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. Connect the master cylinder primary brake pipe fitting (1) and tighten to 18 N·m (13 lb ft) .            7. Connect the master cylinder secondary brake pipe fitting (1) and tighten to 18 N·m (13 lb ft) .            8. Remove the CH-558-10   cap (1) and install the brake fluid reservoir cap. 9. If equipped, install power steering fluid. Refer to Power Steering Fluid Reservoir Replacement . 10. Install dash upper extension panel opening cover. refer to Dash Upper Extension Panel Opening Cover Replacement . 11. Install the air cleaner assembly. Refer to:   •  1.3 L diesel engine. Refer to Air Cleaner Replacement .   •  1.4 L engine. Refer to Air Cleaner Assembly Replacement .   •  1.6 L engine. Refer to Air Cleaner Assembly Replacement .   •  1.7 L diesel engine. Refer to Air Cleaner Assembly Replacement .   •  2.0 L diesel engine. Refer to Air Cleaner Assembly Replacement . 12. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding .

07 Brakes