Checking the correct functioning
1. Without starting the engine, press the foot brake pedal several times. Make sure there is no change in the amount of reserve pedal travel (distance between pedal and floor).
2. Keeping the pedal depressed, start the engine. If the pedal "sinks" slightly immediately after starting, then the brake booster is working properly.
Checking for leaks
1. Run the engine for a couple of minutes, then turn it off. Slowly press the foot brake pedal several times. If at first the pedal travel gradually decreases with each press, but stabilizes after three or four pumps, the vacuum booster assembly is not damaged.
2. Press the foot brake pedal with the engine running. Keep the pedal pressed and turn off the engine. If after 30 seconds of holding the pedal pressed its reserve travel does not change, therefore, the tightness of the vacuum booster assembly is not broken, - if necessary, check the serviceability of the booster servo check valve (see Removal, checking the correct operation and installation of the brake booster check valve). On diesel models, check the vacuum pump for proper operation (see Checking the proper functioning of the brake booster servo vacuum pump (diesel models)). If no violations are observed, replace the brake booster servo unit - the unit cannot be repaired and in case of failure must be replaced as a whole.
Removal
Models equipped with air conditioning
1. Discharge the cooling system in a specialized workshop.
2. Remove the air cleaner and air intake ducts (see Chapter Power and exhaust systems).
3. Remove the windshield wiper motor (see Chapter On-board electrical equipment).
4. Remove the generator (see Chapter Engine electrical equipment).
5. Remove the mounting bolts and the generator support bracket from the intake manifold and cylinder head.
6. Remove the GTZ (see Removal and installation the master brake cylinder).
7. On 2.0L engine models, remove the MAF sensor, disconnect the wiring and hoses, and remove the LPG control solenoid valve.
8. Disconnect the vacuum tube from the booster or remove the check valve.
9. Remove the refrigeration pipe retaining bolt on the rear bulkhead of the engine compartment behind the intake manifold and remove the expansion valve and inner seal.
This procedure should be performed by refrigeration units in a car service workshop. If the system is opened for a long time, it must be isolated from the atmosphere until the moment of filling.
10. Remove the driver's footwell side trim panels. On the driver's side, disconnect the foot brake pedal return spring.
11. Remove the retainer and separate the brake booster servo push rod from the foot brake pedal. Remove the washer.
12. Remove the upper left and lower right nuts securing the pedal bracket to the servo unit.
A — Left brake booster mounting nuts
B — Right brake booster mounting nuts
A.
B.
13. Remove the servo from the engine compartment bulkhead, being careful not to damage the brake pipes or other nearby components. Remove the sealing gasket.
Models without air conditioning
Models with ABS
1. Remove the hydraulic modulator assembly (see Removal and installation of ABS and TCS components).
2. Remove the brake master cylinder (see Removal and installation the master brake cylinder).
3. Unscrew the hydraulic modulator bracket mounting bolts.
4. Disconnect the vacuum tube from the booster or remove the check valve.
5. Remove the driver's footwell side trim panels and disconnect the foot brake pedal return spring.
6. Remove the retainer and separate the brake booster servo push rod from the foot brake pedal. Remove the washer.
Material copied from the portal: www.OPELBOOK.ru
7. Remove the upper left and lower right nuts securing the pedal bracket to the servo unit.
8. Remove the servo from the engine compartment bulkhead, being careful not to damage the brake lines or other nearby components. Remove the sealing gasket.
Models without ABS
1. Remove the brake master cylinder (see Removal and installation the master brake cylinder).
2. Disconnect the vacuum tube from the booster or remove the check valve.
3. Separate the relay stand from the support bracket and move it to the side, remove the multi-pin connector from the bracket.
4. Loosen the nuts of the union nut connections of the brake pipes laid between the master cylinder and the adapter nozzle.
5. Place a rag under the adapter and turn it inside out.
6. Remove the driver's footwell side trim panels and disconnect the foot brake pedal return spring.
7. Remove the retainer and separate the brake booster servo push rod from the foot brake pedal. Remove the washer.
8. Remove the upper left and lower right nuts securing the pedal bracket to the servo unit.
9. Remove the servo from the engine compartment bulkhead, being careful not to damage the brake lines or other nearby components. Remove the sealing gasket.
Installation
Installation is carried out in the reverse order of dismantling the components.
1. Be sure to replace the sealing gasket installed between the servo assembly and the engine compartment bulkhead. Make sure all fasteners are tightened to the required torque.
2. Finally, bleed the brake system (see Bleeding the brake system), then start the engine and check the vacuum line connections for leaks.
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