Braking System - Opel Zafira B MPV 2006 Owners Workshop Manual

Chapter 9
Braking system
Contents
Section number
Anti-lock Braking and Traction Control systems - general
information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Anti-lock Braking and Traction Control system components -
removal and refitting .................................... 18
Brake pedal - removal and refitting . . . . . . . . . . . . . . . . . . . . . . . . . . 1 O
Front brake caliper - removal, overhaul and refitting. . . . . . . . . . . . 7
Front brake pads - renewal . . . . . . . . . . . . . . . . . . . . ...... '. . . 4
Front/rear brake disc - inspection, removal and refitting. . . . . . . . . 6
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Handbrake cables - removal and refitting . . . . . . . . . . . . . . . . . . . . . 14
Handbrake lever - removal and refitting. . . . .................. 13
Handbrake operation and adjustment check .... See Chapter 1A or 1 B
Degrees of difficulty
Section number
Handbrake warning light switch - removal and refitting .......... 16
Hydraulic pipes and hoses - renewal. . . . . . . . . . . . . . . . . . . . . . . . . 3
Hydraulic system - bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Master cylinder - removal, overhaul and refitting . . . . . . . . . . . . . . . 9
Rear brake caliper - removal, overhaul and refitting . . . . . . . . . . . . . 8
Rear brake pads - renewal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Stop-light switch - removal, refitting and adjustment ............ 15
Vacuum pump (diesel engine models) - removal and refitting ...... 19
Vacuum servo unit - testing, removal and refitting .............. 11
Vacuum servo unit check valve and hose - removal, testing and
refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Easy, suitable for
novice with little
experience
~
I
Fairly easy, suitable
~. 1
~
for beginne~ with
~
~
some expenence "
Fairly difficult,
~
I
Difficult, suitable
~
I
Very difficult,
suitable for competent~ for experienced DIY
§
suitable for expert
DIY mechanic " mechanic " DIY or professional
Specifications
Front brakes
Type ............................... · .... ················
Disc diameter:
1.6 and 1.8 litre petrol engine models ...................... .
2.2 litre petrol engine models .............................. .
Diesel engine models .................................... .
Disc thickness:
New .............................. · ... ················
Minimum ............................................. .
Maximum disc run-out ..................................... .
Brake pad friction material minimum thickness. . . . . . . . ......... .
Brake caliper piston diameter . . . . . . . . . . .................... .
Rear brakes
Type .............................. ·····,················
Disc diameter . . . . . . . . . . . . . . . . . . ........................ .
Disc thickness:
New ................................................. .
Minimum ............................................. .
Maximum disc run-out. . . . . . . . . . . . . ....................... .
Brake pad friction material minimum thickness .................. .
Brake caliper piston diameter ............................... .
ABS system type
Ventilated disc, with single-piston sliding caliper
280.0 mm
308.0 mm
308.0mm
25.0 mm
22.0 mm
0.11 mm
2.0mm
57.0 mm
Solid disc, with single-piston sliding caliper
264.0 mm
10.0 mm
8.0mm
0.13 mm
2.0mm
41.0 mm
Standard ABS system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ATE Mk 70
ABS with traction control and electronic stability program . . . . . . . . . . ATE Mk 60 ESP