Opel Frontera UBS. Service manual — part 224
POWER ASSISTED BRAKE SYSTEM 5C – 41
VACUUM BOOSTER ASSEMBLY
1
P&B valve
equipped
vehicle
LSPV
equipped
vehicle
2
4
3
3
5
Removal Steps
1.
Master cylinder
2.
Vacuum hose
3.
Yoke clevis
4.
Vacuum booster fixing nut
5.
Vauum booster
Installation Steps
To install, follow the removal steps in the
reverse order.
This illustration is based on the LHD model.
331RW010
5C – 42 POWER ASSISTED BRAKE SYSTEM
REMOVAL
•
Before removing the vacuum booster assembly,
disconnect and remove brake pipes.
1. Master Cylinder
•
Refer to Master Cylinder Assembly in this Section.
CAUTION:
When removing master cylinder from vacuum booster,
be sure to get rid of the internal negative pressure of
the vacuum booster (by, for instance, disconnecting
vacuum hose) in advance.
If any negative pressure remains in the vacuum
booster, the piston may possibly come out when the
master cylinder is being removed, letting the brake
fluid run out.
While removing master cylinder, further, do not hold
the piston as it can be easily pulled out.
Outside surface of the piston is the surface on which
seals are to slide. Care should be taken to keep the
surface free of cuts and dents.
2. Vacuum Hose
3. Yoke Clevis
•
Disconnect the yoke clevis from the brake pedal.
4. Vacuum Booster Fixing Nut
5. Vacuum Booster
INSPECTION AND REPAIR
Vacuum Hose
Inspect the check valve (1), which is installed inside
the vacuum hose.
1) Air should pass freely from the vacuum booster
side (3) to the engine side (2).
2) Air should not pass from the engine side (2) to the
vacuum booster side (3). If it does, the check valve
is inoperative and vacuum hose must be replaced.
INSTALLATION
5. Vacuum Booster
Vacuum booster push rod adjustment.
NOTE:
When replacing either master cylinder or vacuum
booster, be sure to measure push rod, and adjust
required.
Push rod gauge: 5-8840-2300-0 (J-39216)
Vacuum pump: 5-8840-0279-0 (J-23738-A)
Push rod support: 5-8840-2305-0 (J-39241)
1) Remove retainer from vacuum booster front shell
using a small screwdriver. Then gently draw plate
and seal assembly out of the shell inside.
ENG
1
2
3
360RX001
POWER ASSISTED BRAKE SYSTEM 5C – 43
2) Set push rod gauge on vacuum booster, and
apply negative pressure by means of vacuum
pump so that the pressure in the vacuum booster
becomes 500 mm Hg.
NOTE:
Be sure to apply. NEGATIVE pressure after installing
a push rod gauge on vacuum booster.
3) Measure dimension L
Dimension L (Standard)
mm
0 ± 0.1
5-8840-0279-0
5-8840-2300-0
L
5-8840-2300-0
4) If dimension L is out of the standard range,
adjust push rod using the special tool.
5) Mount plate and seal assembly in vacuum
booster front shell. Then install retainer.
4. Vacuum Booster Fixing Nut
Vacuum Booster Fixing Nut Torque
N·m (kg·m / lb·ft)
21 (2.1 / 16)
3. Yoke Clevis
2. Vacuum Hose
•
In case of the gasoline engine model, make sure
that the arrow on the hose points in the direction of
the engine.
1. Master Cylinder
•
Refer to Master Cylinder Assembly in this Section.
5-8840-2305-0
T-wrench
5C – 44 POWER ASSISTED BRAKE SYSTEM
EXTERIOR COMPONENTS
P&B valve
equipped
vehicle
LSPV
equipped
vehicle
1
10
11
2
9
3
4 5
6
7
8
Removal Steps
1.
Master cylinder
2.
Vacuum booster
3.
Yoke clevis
4.
Lock nut
5.
Retaining clip
6.
Valve body guard
7.
Silencer
8.
Filter
9.
2 gaskets and spacer
10. Retainer
11. Plate and seal assembly
Installation Steps
To install, follow the removal steps in the
reverse order.
This illustration is based on the LHD model.
331RW011
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