Vauxhall Workshop Service and Repair Manuals

Brake Servo, Remove and Install (LHD Vehicles)  

  Remove, Disconnect   

Remove footwell panelling.   Lever locking plate (2) out with screwdriver and remove. Press bolt (1) out of brake pedal. Loosen sealing sleeve (3) from bulkhead.   Remove master brake cylinder - see operation "Master Brake Cylinder, Remove and Install".   For ABS-415, ABS-430, ABS 5.3 TC: Remove hydraulic modulator with ABS control unit - see corresponding operation. Remove hydraulic modulator bracket (5).   Disconnect elbow (6) with vacuum line from brake servo.

  Remove, Disconnect   

For X 25 XE, Y 26 SE: Remove intake pipe (above cylinders 1-3-5) - see operation "Intake Pipe (above Cylinders 1-3-5), Remove and Install " in group "J".   With ABS 5/TC: disconnect brake lines (1) from hydraulic modulator.   Disconnect fastening bolts (2) (4 units) from brake servo - remove washer. Pull brake servo forwards and remove upwards.   For 10" brake servo at bulkhead, release 4 bolts and remove with support.

  Adjust   

Adjust piston rod with adjustment nut (2) at dimension (1) 149.5 + 0.5 m - 18 Nm / 13 lbf. ft.     Install, Connect    Insert brake servo. Align piston rod to brake pedal. Install bolt and new locking plate. Insert sealing sleeve in bulkhead - make sure seating is correct.   Attach brake servo 9" with washer and new nuts to support bracket.   Attach brake servo 10" with support and new nuts to bulkhead.   For ABS 5/TC, ABS 5.3/TC: attach brake lines to hydraulic modulator - tightening torque 20 Nm / 15 lbf. ft.   For X 25 XE, Y 26 SE: Install intake pipe (above cylinders 1-3-5) - see operation "Intake Pipe (above Cylinders 1-3-5), Remove and Install" in group "J".

  Install, Connect   

For ABS-415, ABS-430: install hydraulic modulator bracket. Install hydraulic modulator with ABS control unit - see operation "Hydraulic Modulator with ABS Control Unit, Remove and Install (Vehicles with ABS-415)".  

Install brake master cylinder - see operation "Brake Master Cylinder, Remove and Install".  

Connect elbow with vacuum line to brake servo.  

Install footwell panelling.  

  Tighten (Torque)   

Piston rod locking nut to adjusting piece - 18 Nm / 13 lbf. ft.  

Brake servo to support bracket - 20 Nm / 15 lbf. ft.  

Brake lines to hydraulic modulator - 16 Nm / 12 lbf. ft.  

Hydraulic modulator bracket to front frame and support - 20 Nm / 15 lbf. ft.  

  Inspect   

Bleed brake system bleed and check for leaks - see operation "Brake System, Bleed and Check for Leaks".