Brake Pedal; Vacuum Servo Unit; Right-Hand Drive Petrol Models; Unscrew Quick-Release Catch On The Left-Hand Side - Opel Zafira B MPV 2006 Owners Workshop Manual

9•12 Braking system
10.2a Unscrew the quick-release catch
(arrowed) on the left-hand side ••.
Removal
1 Disconnect the battery negative terminal
(refer to Disconnecting the battery in the
Reference Chapter).
2 Unscrew the two quick-release catches and
remove the facia lower panel above the pedals
(see illustrations).
3 Remove the steering column shrouds and
the lower trim panel beneath the facia on the
driver's side, as described in Chapter 11.
4 Release the expanding rivet and remove the
driver's side footwell air duct.
5 Disconnect the wiring connector at the
stop-light switch and release the wiring
harness from the support clips.
6 Unhook the return spring from the brake
pedal, then slide off the spring clip, and
withdraw the clevis pin securing the pedal to
the servo unit pushrod (see illustration}.
7 On left-hand drive models, remove the
steering column intermediate shaft as
described in Chapter 10.
8 Undo the six mounting bracket retaining
nuts (right-hand drive models) or the four
nuts and two bolts (left-hand drive models)
and remove the pedal and support bracket
assembly from the vehicle.
9 Check the pedal and bracket for excessive
wear and damage. It is not possible to renew
10.6 Unhook the pedal return spring
(A) then slide off the spring clip (B) and
withdraw the clevis pin
10.2b ..• and right-hand side (arrowed) •.•
the pedal pivot bushes separately, so if they
are worn, the complete assembly must be
renewed.
Refitting
10 Manoeuvre the pedal and support bracket
assembly into place making sure the brake
servo pushrod fits correctly over the brake
pedal.
11 Refit the pedal mounting bracket bolts/
nuts and tighten to the specified torque.
12 Align the pedal hole with the pushrod end,
and insert the clevis pin. Secure the pin in
position with the spring clip.
13 Refit the return spring to the brake pedal.
14 Reconnect the stop-light switch wiring
connector.
15 On left-hand drive models, refit the
steering column intermediate shaft as
described in Chapter 10.
16 Refit the driver's side footwell air duct,
then refit the facia trim panels as described in
Chapter 11.
11
Vacuum servo unit·"'
testing, removal andreflttlng ·
Testing
1 To test the operation of the servo unit, with
the engine off, depress the footbrake several
times to exhaust the vacuum. Now start the
engine, keeping the pedal firmly depressed.
As the engine starts, there should be a
11.8 Undo the bolt (arrowed) and withdraw
the refrigerant pipes from the expansion
valve
10.2c .•• and remove the facia lower panel
above the pedals
noticeable 'give' in the brake pedal as the
vacuum builds-up. Allow the engine to run
for at least two minutes, then switch it off.
The brake pedal should now feel normal, but
further applications should result in the pedal
feeling firmer, the pedal stroke decreasing with
each application.
2 If the servo does not operate as described,
first inspect the servo unit check valve as
described in Section 12.
3 If the servo unit still fails to operate
satisfactorily, the fault lies within the unit itself.
Repairs to the unit are not possible; if faulty,
the servo unit must be renewed.
Removal
Note: On 1.6 and 1.8 litre models equipped
with air conditioning, refer to the air
conditioning system precautionary information
contained in Chapter 3.
Right-hand drive petrol models
4 On 1.6 and 1.8 litre models equipped
with air conditioning, have the refrigerant
discharged at a dealer service department or
an automotive air conditioning repair facility.
5 Disconnect the battery negative terminal
(refer to Disconnecting the battery in the
Reference Chapter).
6 On 1.6 and 1.8 litre models, remove the air
cleaner assembly as described in Chapter 4A.
7 Remove the windscreen cowl panel as
described in Chapter 11.
8 On 1.6 and 1.8 litre models equipped
with air conditioning, undo the bolt securing
the refrigerant pipe block connection to the
expansion valve and withdraw the refrigerant
pipes from the valve (see illustration). Note
that new seals for the refrigerant pipes will be
required for refitting. Suitably plug or cover
the disconnected pipes.
9 On 1.6 and 1.8 litre models equipped with
air conditioning, unscrew the retaining nut,
release the two clips and free the refrigerant
pipes from the vicinity of the servo unit.
10 On 2.2 litre engines, remove the camshaft
cover as described in Chapter 28.
11 Remove the master cylinder as described
in Section 9.
12 Carefully ease the vacuum hose out of
the servo unit, taking care not to displace the
sealing grommet (see illustration).