Removal and installation the foot brake pedal (Opel Astra G)

Removal

1. Disconnect the negative cable from the battery and set it aside.

2. Remove the instrument panel (see Chapter On-board electrical equipment).

3. Unscrew the side nuts securing the pedal support bracket to the steering crossmember.

4. Inside the vehicle, remove the mounting screws and the driver's footwell side trim panels.

5. Release the twist locks and remove the left lower section of the instrument panel trim. Remove the air supply hose to the driver's footwell. Disconnect the electrical wiring from the brake light switch sensor, turn the switch and release it from the pedal bracket.

6. Loosen the mounting nuts and remove the accelerator pedal from the floor panel.

7. Disconnect the wiring harness from the fuse box holder.

8. Unhook the return spring.

9. Using a screwdriver, pry off the retainer and remove the pin securing the split pin of the vacuum booster servo rod to the pedal. Remove the washer.

10. Loosen the nuts securing the vacuum booster to the pedal bracket and remove the bracket together with the pedal - the working space is very limited. First, separate the bracket from the steering crossmember struts, then bend it upwards and remove it with a twist - try not to damage the electrical wiring and components located in the immediate vicinity. If necessary, remove the intermediate shaft of the steering column (see Chapter Suspension and steering).

11. Remembering the pedal installation Loosen the mounting nut and remove the pedal axle - try to remember the installation position of the components. Remove the pedal, bushings and return spring from the bracket.



12. Check the pedal assembly components for signs of wear and mechanical damage. Pay particular attention to the condition of the axle bushings. Replace defective components.

Installation

1. Lubricate the friction and bearing surfaces of the assembly components with universal grease. Install the pedal on the bracket, screw on the fastening nuts and tighten them to the required force.

2. Carefully slide the pedal assembly into its regular place and position it on the engine compartment bulkhead, making sure that the holes in the bracket are correctly aligned with the studs of the brake booster servo. Screw on the mounting nuts and tighten them to the required torque. If removed, install the intermediate steering column shaft in place (see Chapter Suspension and steering).

3. Connect the vacuum booster pushrod to the pedal and secure it with a pin and retainer.

4. Connect the pedal return spring.

5. Secure the wiring harness to the base of the fuse box.

6. Connect the electrical wiring to the accelerator pedal, install the pedal and tighten the mounting nuts.

7. Before installing the brake light switch sensor on the bracket, fully recess its plunger. Insert the switch sensor into its regular place and, by turning, fix it in the bracket. Connect the electrical wiring. Press the pedal and pull out the plunger of the switch sensor. After releasing the pedal, the plunger will take the working position.

8. Install the air supply hose to the driver's footwell and lower instrument panel trim section.



9. Install the driver's footwell side trim panels.

10. Screw on and tighten the side nuts securing the pedal bracket to the steering crossmember.

11. Install the instrument panel (see Chapter On-board electrical equipment).

12. Connect the negative cable to the battery.

13. Check the proper functioning of the pedal and the brake light switch sensor.