Hydrovacuum booster — removal and installation (Opel Astra F)

Removal

Disconnect the negative battery terminal.

Working inside the vehicle, remove the clamps and remove the lower trim panel at the driver's feet.

Disconnect the wire connector from the brake light switch, then turn the switch counterclockwise and remove it from the bracket.

Remove the retaining ring from the right side of the booster fork-pedal connection shaft.

Using suitable pliers, remove the return spring from the pedal so that the booster fork axle and pedal can be removed.

Disconnect the vacuum line from the power steering.

Remove the two nuts and carefully detach the master cylinder from the studs on the power steering. Move the master cylinder forward slightly, being careful not to put any stress on the brake fluid lines.

Unscrew the four nuts securing the amplifier bracket to the bulkhead (to get the bottom bolt out you will need a socket wrench with a flexible joint), then tilt the bracket/reinforcement assembly and remove it from the engine compartment.

If desired, the support bracket can be detached from the amplifier by unscrewing the four nuts. The rubber bushing can now be removed from the amplifier.

To remove the fork from the coupling on the booster rod, remove the retaining ring.

Installation

Before installing the amplifier, check the plug size as follows.

Measure the distance from the end face of the amplifier housing to the center of the axle hole at the end of the fork. It should be 255.5 mm (fig. 9.25.).



If adjustment is required, loosen the lock nut on the traction coupling (drive rod). Turn the fork to get the required size, then tighten the lock nut.



Where required, install the rubber bushing and reinforcement on the support bracket. Tighten the nuts to the specified torque.

Install the amplifier with the bracket in place, and then the assembly itself on the partition. Using new self-locking nuts, tighten the nuts to the required torque.

Connect the master cylinder to the booster and tighten the nuts to the specified torque.

Connect the vacuum line to the booster.

Then the installation is carried out in the reverse order of removal. After its completion, check the operation of the hydraulic vacuum booster.