Removal and installation the brake booster servo vacuum pump (diesel models) (Opel Astra G)

Removal

1. On models with 1.7 l engines the vacuum pump is mounted on the rear of the generator 2.0L engines the vacuum pump is mounted on the left side of the cylinder head. Access to the pump is on 1.7 l models can be achieved by removing the heat shield of the manifold inlet pipe, or by dismantling the generator (see Chapter Engine electrical equipment).

Vacuum pump location on 1.7L model



2. On 1.7 l models set the parking brake, jack up the front of the vehicle and place it on supports. If equipped, remove the crankcase guard.

[Material copied from this website: www.opelbook.ru]

3. On 2.0L models to gain access, loosen the clamps and remove the intake air ducts and the hose that leads from the turbo to the intercooler. Disconnect the small vacuum hose from the bottom of the vacuum pump, remove the bolts from the two powertrain lifting eyes on the left side of the cylinder head. Release the fuel lines from their support brackets and move the wiring harness and bracket down away from the vacuum pump.

4. Disconnect the booster vacuum tube from the pump, holding the large nut of the nipple connector, release the small one - some models use a quick-connect connector (2).





5. On 1.7 l models loosen the union nut and disconnect the oil feed pipe from the pump. Also disconnect the oil return pipe, drain the oil into a prepared container. Immediately plug the holes to prevent dirt from getting into the system.

6. Unscrew the mounting bolts - pay attention to the support brackets they secure - and remove the pump from the generator splines (1.7L engine) or from the cylinder head (2.0L engine).

7. Remove the O-ring from the generator (1.7L engine), or pump grooves (2.0L engine), - the ring must be replaced without fail 1.7 l engines, if necessary, mark the plate internal to the pump body, remove the plate and sealing gasket.

Installation

Installation is carried out in reverse order. Please note the following points.

1. On 1.7L models, pour approximately 5 ml of clean engine oil into the oil feed tube installation hole before installing the pump.

2. Clean the mating surfaces and install a new O-ring.

3. On 1.7L models, after installing the pump on the generator, manually check its freedom of rotation.