Vacuum booster — removal and installation (Opel Vectra A)

Note: During 1989, some vehicles were produced with the brake pedal not correctly installed (approximately 15.0 mm above the clutch pedal instead of the usual 4.0 mm below it). The correct pedal installation height can be achieved by adjusting the working length of the vacuum booster fork as described in points 15 and 16.

Removal

1. Disconnect the negative cable from the battery.

2. Working inside the passenger compartment, remove the lower trim panel from the driver's footwell.

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

4. Pull the spring clip off the right end of the pivot pin that secures the booster fork to the pedal.

5. Using pliers, disconnect the end of the return spring from the pedal and remove the pivot pin that secures the booster fork to the pedal.

6. Remove the windshield fairing as described in Section 11, then remove the motor and wiper link as described in Section 12.

7. Remove the coolant expansion tank as described in Section 3.

8. Disconnect the vacuum line from the brake booster.

9. Remove the two mounting nuts and carefully remove the master cylinder from the mounts on the booster. Move the master cylinder forward slightly, being careful not to deform the brake lines.

10. Remove the two plugs covering the amplifier mounting bolts (see illustrations).





11. Loosen the amplifier mounting bolts with a socket wrench and remove them, then remove the amplifier from the bulkhead (see illustrations).







12. If necessary, remove the mounting bracket from the amplifier by unscrewing the four mounting nuts. Note that the bracket is seated on the amplifier using sealant.

13. It is impossible to disassemble the amplifier; if it is faulty, replace the unit.

Installation

14. Before installing the amplifier, make sure the working length of the fork is correct as described below.

[Material copied from this resource OpelBook.ru]

15. Measure the distance from the end of the booster housing to the center of the pivot pin hole in the fork. The distance should be 144.0 mm. To make the measurement easier, insert a bolt or rod of suitable diameter through the pivot pin holes and mark its center (see illustration).





16. If adjustment is necessary, loosen the lock nut and rotate the fork to achieve the desired length, then tighten the lock nut.

17. Where applicable, coat the mating surfaces of the amplifier and mounting bracket with sealant, then install the bracket onto the amplifier and tighten the mounting nuts to the specified tightening torque Specifications.

18. Coat the threads of the booster mounting bolts with blocking compound, then install the booster onto the bulkhead and tighten the bolts.

19. Install the amplifier mounting bolt covers.

20. Install the master cylinder on the booster and tighten the fastening nuts to the specified tightening torque Specifications.

21. Connect the vacuum tube to the amplifier.

22. Install the coolant expansion tank as described in Section 3.

23. Install the windshield wiper motor and linkage as described in Section 12 then install the windshield fairing.

24. Then install in reverse order. Finally, check the amplifier operation as described in Chapter 18.