Opel Frontera UBS. Service manual — part 215
POWER ASSISTED BRAKE SYSTEM 5C – 5
TROUBLESHOOTING
Condition
Possible Cause
Correction
Brake Pull
1. Tire inflation pressures unequal.
1. Adjust
2. Front wheel alignment incorrect.
2. Adjust
3. Unmatched tires on same axle.
3. Tire with approx. the same amount of
tread should be used on the same axle.
4. Restricted brake pipes or hoses.
4. Check for soft hoses and damaged
lines. Replace with new hoses and new
double-walled steel brake piping.
5. Water or oil on brake pads.
5. Clean or replace.
6. Brake pads hardened.
6. Replace.
7. Brake pads worn excessively.
7. Replace.
8. Brake rotor worn or scored.
8. Grind or replace.
9. Disc brake caliper malfunctioning.
9. Clean or replace.
10. Front hub bearing preload incorrect.
10. Adjust or replace.
11. Loose suspension parts.
11. Check all suspension mountings.
12. Loose calipers.
12. Check and tighten bolts to specifications.
Brake
1. Excessive lateral runout.
1. Check per instructions.
Roughness-or
If not within specifications, replace or
Chatter
machine the rotor.
(Pulsates)
2. Parallelism not within specifications.
2. Check per instructions.
If not within specifications, replace or
machine the rotor.
3. Wheel bearings not adjusted.
3. Adjust wheel bearings to correct
specifications.
4. Pad reversed (steel against iron).
4. Replace brake pad and machine rotor
to within specifications.
Excessive
1. Malfunctioning vacuum booster.
1. Check vacuum booster operation and
Pedal
repair, if necessary.
Effort
2. Partial system failure.
2. Check front and rear brake system for
failure and repair. Also, check brake
warning light. If a failed system is
found, the light should indicate a
failure.
3. Excessively worn pad.
3. Check and replace pads in sets.
4. Piston in caliper stuck or sluggish.
4. Remove caliper and rebuild.
5. Fading brakes due to incorrect pad.
5. Remove and replace with original
equipment pad or equivalent.
6. Vacuum leak to vacuum booster.
6. Check for ruptured or loose hose.
7. Check direction of check valve within
7. Correct vacuum hose direction.
vacuum hose.
8. Grease on the brake pads.
8. Replace or clean.
Excessive
1. Air in hydraulic circuit.
1. Bleed hydraulic circuit.
Brake Pedal
2. Level of brake fluid in resevoir too low.
2. Replenish brake fluid resevoir to
Travel
specified level and bleed hydraulic
circuit as necessary.
3. Master cylinder push rod clearance
3. Adjust.
excessive.
4. Leakage in hydraulic system.
4. Correct or replace defective parts.
5C – 6 POWER ASSISTED BRAKE SYSTEM
Condition
Possible Cause
Correction
Brake Drag
1. Master cylinder pistons not returning
1. Adjust stop light switch and vacuum
correctly.
booster operating rod. If necessary,
rebuild.
2. Restricted brake pipes or hoses.
2. Check for soft hoses or damaged pipes,
and replace with new hoses and new
double-walled steel brake piping.
3. Parking brake maladjusted.
3. Adjust.
4. Parking brake lining clearance
4. Adjust.
insufficient.
5. Brake pedal free play insufficient.
5. Adjust brake pedal height or power
cylinder operating rod.
6. Piston in master cylinder sticking.
6. Replace.
7. Piston in disc brake caliper sticking.
7. Replace piston seals.
8. Brake pads sticking in caliper.
8. Clean.
9. Return spring weakened.
9. Replace.
10. Parking brake binding.
10. Overhaul parking brakes and correct.
11. Front hub bearing preload incorrect.
11. Adjust or replace.
12. Parking brake shoes not returning.
12. Correct or replace brake back plate and
brake shoe as necessary.
13. Obstructions in hydraulic circuit.
13. Clean.
14. Rotor warped excessively.
14. Grind or replace.
15. Rear brake drum distorted.
15. Grind or replace.
16. Parking cable sticking.
16. Clean or replace.
Grabbing or
1. Malfunctioning vacuum booster.
1. Check operation and correct as
Uneven
necessary.
Braking Action
2. Binding brake pedal mechanism.
2. Check and lubricate, if necessary.
(All conditions
3. Corroded caliper assembly.
3. Clean and lubricate.
listed under
“Pulls”)
Brake Noisy
1. Brake pads worn.
1. Replace.
2. Brake pads hardened.
2. Replace.
3. Brake pads in poor contact with rotor.
3. Correct.
4. Brake disc(s) warped, worn or
4. Grind or replace.
damaged.
5. Disc brake anti-squeak shims fatigued.
5. Replace.
6. Front hub bearings loose or preload is
6. Adjust or replace.
incorrect.
7. Brake disc rusted.
7. Grind or replace.
Poor Brake
1. Master cylinder faulty.
1. Correct or replace.
Action
2. Vacuum booster faulty.
2. Correct or replace.
3. Level of brake fluid in reservoir too
3. Replenish and bleed.
low.
4. Air in hydraulic circuit.
4. Bleed.
5. Disc brake caliper faulty.
5. Clean or replace.
6. Water or oil on brake pads.
6. Clean or replace.
7. Brake pads in poor contact with rotor.
7. Correct.
8. Brake pads worn.
8. Replace.
9. Brake disc rusted.
9. Grind or replace.
10. Check valve in vacuum hose faulty.
10. Correct or replace.
POWER ASSISTED BRAKE SYSTEM 5C – 7
MAIN DATA AND SPECIFICATIONS
MASTER CYLINDER
Type
Dual-circuit
Piston Bore Diameter
mm (in)
25.4 (1.000)
VACUUM BOOSTER
Diaphragm Diameter
Front; mm (in)
205 (8.07) (Gasoline) / 180 (7.09) (Diesel)
Rear; mm (in)
230 (9.06) (Gasoline) / 205 (8.07) (Diesel)
Push Rod Stroke
mm (in)
More than 32.0 (1.26)
Plunger Diameter
mm (in)
10.13 (0.399)
Push Rod Diameter
mm (in)
27.4 (1.08)
FRONT DISC BRAKE
Type
Floating, Pin Slide
Pad Dimension
cm
2
(in
2
)
55 (8.52)
Adjusting Method
Self-adjusting
Piston Diameter
mm (in)
60.33 (2.38)
Disc (Rotor) Type
Ventilated
Disc (Rotor) Thickness
mm (in)
26 (1.02)
Disc (Rotor) Effective Diameter
mm (in)
222 (8.74)
REAR DISC BRAKE
Type
Floating, Pin Slide
Pad Dimension
cm
2
(in
2
)
33 (5.11)
Adjusting Method
Self-adjusting
Piston Diameter
mm (in)
41.3 (1.63)
Disc (Rotor) Type
Ventilated
Disc (Rotor) Thickness
mm (in)
18 (0.71)
Disc (Rotor) Effective Diameter
mm (in)
269.2 (10.60)
5C – 8 POWER ASSISTED BRAKE SYSTEM
SERVICE STANDARD
HYDRAULIC BRAKE FLUID
DOT 3 grade
BRAKE PEDAL
Pedal Free Play
mm (in)
6 to 10 (0.23 to 0.39)
Pedal Height (LHD / RHD)
mm (in)
208 to 218 (8.19 to 8.58) / 211 to 221 (8.31 to 8.70)
Stop Light Switch Clearance
mm (in)
0 to 0.2 (0 to 0.008)
FRONT DISC BRAKE
Pad Thickness Minimum Limit
mm (in)
1.0 (0.039)
Disc (Rotor) Maximum Runout
mm (in)
0.13 (0.005)
Disc (Rotor) Maximum Parallelism mm (in)
0.010 (0.0004)
Disc (Rotor) Minimum Wear
Dimensions (Thickness)
mm (in)
24.60 (0.969)
Disc (Rotor) Minimum Refinish
Dimensions (Thickness)
mm (in)
24.97 (0.983)
REAR DISC BRAKE
Pad Thickness Minimum Limit
mm (in)
1.0 (0.039)
Disc (Rotor) Maximum Runout
mm (in)
0.13 (0.005)
Disc (Rotor) Maximum Parallelism mm (in)
0.010 (0.0004)
Disc (Rotor) Minimum Wear
Dimensions (Thickness)
mm (in)
16.60 (0.654)
Disc (Rotor) Minimum Refinish
Dimensions (Thickness)
mm (in)
16.97 (0.668)
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