Replacing the brake booster (Opel Insignia A)

1. With the engine off, press the brake pedal several times until it becomes firm to use up the vacuum reserve in the vacuum booster.

2. Pull the brake pedal up to release it from the brake lever.

3. Using a syringe, remove the brake fluid from the expansion tank.

4. Disconnect the electrical connector of the brake fluid level sensor.

5. Remove the master brake cylinder.

6. Remove the modulator valve.

7. Disconnect the check valve (1) of the brake booster.

Note: If necessary, a small amount of denatured alcohol applied to the vacuum booster bushing may be used to aid in installation of the check valve. Do not use soap solution.

8. Loosen the two bolts (2) securing the brake booster.

Note: Tightening torque: 19 Nm.

9. Remove the brake booster (3).

10. Installation is carried out in the reverse order of removal.

Note.

• If equipped, calibrate the brake pedal position sensor.
• Install a new latch onto the brake pedal lever.