Brake booster — replacement (Opel Zafira A)

The necessity of performing this operation should be determined during the process of checking the technical condition of the brake system (see "Brake system - checking technical condition").

Sequence of execution

1. Prepare the car for work (see "Preparing the car for maintenance and repair").

2. Remove the master brake cylinder (see "Master Brake Cylinder - Replacement").

3. Using a 13 mm wrench, unscrew the three nuts securing the fuse and relay box bracket from the ABS hydraulic unit housing.



4. Remove the bracket.



5. Remove the ABS unit wiring harness connector retainer.



6. Disconnect the block.





7. Raise the ABS hydraulic unit and move it slightly away from the vacuum booster.

8. Press the side clamps and disconnect the vacuum supply hose from the intake manifold fitting.



9. In the car's interior, under the instrument panel, remove the spring retainer of the vacuum booster rod fork pin.



10. Disconnect the brake pedal return spring.





11. Remove the pin securing the vacuum booster rod fork to the brake pedal.



12. Using a 13 mm socket wrench with an extension, unscrew the left upper nut securing the vacuum booster to the brake pedal bracket.



13. Using the same wrench, unscrew the lower right nut securing the vacuum booster to the brake pedal bracket.





(Material copied from this website: opelbook.ru)

14. Remove the vacuum booster from the car.



15. If necessary, disconnect the vacuum tube.

16. The vacuum booster cannot be repaired; if it malfunctions, it must be replaced.

17. Install the vacuum booster in the reverse order.

18. After installing the master brake cylinder, bleed the hydraulic drive of the brake system (see "Hydraulic brake drive - bleeding").