Opel Astra A

1991-1998 of release

Repair and operation of the car



Opel Astra A
+ 1. Maintenance instruction
+ 2. Maintenance
+ 3. Engines
+ 4. Ventilation and heating
+ 5. Power supply system
+ 6. System of decrease in toxicity
+ 7. Coupling
+ 8. Transmissions
+ 9. Half shafts
- 10. Brake system
   10.1. Technical characteristics
   10.2. System of anti-blocking of brakes (ABS)
   10.3. Protivobuksovochny system
   10.4. Hydraulic system
   10.5. Hydraulic tubes and hoses
   10.6. Brake overlays of forward brakes
   10.7. Support of a forward brake
   10.8. Brake disk
   10.9. Protective guard of a forward disk brake
   10:10. Brake shoes of back brakes
   10:11. Brake drum of back brakes
   10:12. Wheel cylinder of a back brake
   10:13. Brake overlays of back brakes
   10:14. A support of a back brake (model with back disk brakes)
   10:15. Brake overlays of the emergency brake
   10:16. Guard of a back brake
   10:17. Brake pedal
   10:18. Vacuum amplifier
   10:19. Unilateral valve (servoamplifier)
   10:20. Main brake cylinder
   10:21. Emergency brake
   10:22. Lever of the emergency brake
   10:23. Ropes of the emergency brake
   10:24. The valve of restriction of pressure in a contour of back brakes
   10:25. Switch of fires of a stoplight
   10:26. Switch of alarm bulbs of the brake system
   10:27. ABS modulator
   10:28. ABS wheel sensor of a forward wheel
   10:29. Electronic control unit and ABS relay
   10:30. Case of a butterfly valve
   10:31. Vacuum diaphragm of a butterfly valve (antitowing system)
   10:32. Electronic control unit (antitowing system)
   10:33. Switch of antitowing system
+ 11. Suspension bracket and steering
+ 12. Body
+ 13. Electric equipment
+ 14. Electrical circuitries







10:20. Main brake cylinder

Removal

PERFORMANCE ORDER
1. Disconnect a wire of the minus plug of the accumulator.
2. Squeeze out a brake pedal several times to release pressure from the vacuum amplifier.
3. Disconnect the socket of connection of the sensor of level of brake fluid.
4. Pump out brake fluid from a tank.
5. Establish capacity under the main cylinder for collecting the following liquid.
6. Turn off nuts of connections and disconnect brake tubes from the cylinder, having marked the provision of their installation.
7. Turn off two fixing nuts and remove the main brake cylinder from a servoamplifier.
8. Clear the cylinder and remove a tank and consolidations from the cylinder.

Partition

The main brake cylinder on models with ABS is not subject to a partition.

On models without ABS the partition of the cylinder is carried out as follows.

MAIN BRAKE GMF CYLINDER

Elements of the main brake GMF cylinder

1 – cap (usual);
2 – a cap (with the sensor of level of brake fluid);
3 – tank;
4 – fixing clips of a tank;
5 – consolidations;
6 – cylinder;
7 – secondary piston and springs;
8 – primary piston;
9 – lock ring;
10 – sealing ring

PERFORMANCE ORDER
1. Install the cylinder in a vice.
2. Remove a sealing ring from the cylinder.
3. Press primary piston deep into of the cylinder and record it in this situation, having inserted a drill or a pin with a diameter of 3,0 mm into an opening for installation of a tank on the cylinder.
4. Remove a lock ring on the end of the cylinder.
5. Remove the pin fixing the piston and take elements of primary piston from the cylinder.
6. Squeeze out the secondary piston, having directed compressed air to a forward opening for installation of a tank on the cylinder.
7. Clear all elements in pure brake fluid or methyl alcohol and examine them on existence of damages or wear. If the cylinder is worn-out, replace it entirely.
8. If the cylinder as it should be, get the repair kit including all elements which need to be replaced.
9. Grease the cylinder with brake fluid and install it in a vice.
10. Remove a cap from a tube of a repair kit and insert a short part of a tube into the cylinder.
11. Remove a cap from a tube of a repair kit and insert a short part of a tube into the cylinder.
12. Squeeze out cylinder elements from a tube in the cylinder, then fix primary piston in the depth of the cylinder, having inserted a pin into an opening for installation of a tank on the cylinder.
13. Install a new lock ring on the cylinder.
14. Remove the fixing pin of primary piston and install a new sealing ring on the cylinder.

MAIN BRAKE ATE CYLINDER

Elements of the main brake ATE cylinder

1 – cap (usual);
2 – filter;
3 – a cap (with the sensor of level of brake fluid);
4 – the directing float plug;
5 – tank;
6 – cylinder;
7 – sealing ring;
8 – consolidations of a tank;
9 – lock screw;
10 – repair kit

PERFORMANCE ORDER
1. Clamp the cylinder in a vice. Remove a sealing ring from the cylinder. Lower primary piston deep into of the cylinder and remove a lock ring from the cylinder.
2. Remove primary piston.
3. Press the secondary piston deep into of the cylinder and remove the lock screw.
4. Get the secondary piston from the cylinder.
5. Clear all elements in brake fluid or methyl alcohol and examine them on existence of damages or wear tracks. If the cylinder is worn-out, it needs to be replaced entirely.
6. If the cylinder as it should be, get the repair kit including all elements which need to be replaced.
7. Grease the cylinder with brake fluid and install it in a vice.
8. Install a new sealing ring on the lock screw and twirl it in the cylinder, but it is not so deep that its tip left in the cylinder.
9. Remove caps from a tube of a set and get all elements from a short part of a tube. Insert a short part into a long part of a tube.
10. Install a tube in the cylinder and press the secondary piston deep into of the cylinder.
11. Slightly twirl the lock screw, get a tube and twirl the lock screw up to the end.
12. Install the cylinder vertically in a vice.
13. Grease primary piston and consolidation with lubricant. Install a lock washer on the piston.
14. Adjust a tube of a repair kit so that a long part was flush with an inner edge of a short part.
15. Install consolidation on primary piston.
16. Install a tube on the cylinder, having squeezed consolidation, insert the piston and a tube into the cylinder and get a tube.
17. Install an intermediate ring on primary piston, then establish the remained consolidation.
18. Install a lock washer on primary piston and install a lock ring on the cylinder.
19. Establish a new sealing ring for the end of the cylinder.

Installation

Installation is made in the sequence, the return to removal.