Opel Frontera UE. Manual - part 1390

ANTI-LOCK BRAKE SYSTEM

5B–3

4. Remove harness connector.

5. Remove EHCU ASM.

6. Remove EHCU.

Disassembled View

350RW025

Legend

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Disassembly

1. Remove fixing bolts from EHCU.

2. Remove coil integrated module from hydraulic unit.

Reassembly

To reassembly, follow the disassembly steps in the 
reverse order, noting the following points:

Torque:

Fixing bolts: 4.4 N·m (4.5 kg·cm/39 lb in)

Installation

To install, follow the removal steps in the reverse order, 
noting the following points:

Torque:

Hydraulic unit fixing nuts : 22 N·m (2.2 kg·m/16 

lbft)

Ground cable : 14 N·m (1.4 kg·m/10 lbft)

Brake pipe (joint bolts) : 16 N·m (1.6 kg·m/12 lbft)

• After installing the hydraulic unit, bleed brakes 

completely.  See 

Hydraulic Brakes

 in Power–assisted 

brake system section.

(1) Fixing Bolts
(2) Coil Integrated Module
(3) Hydraulic Unit (H/U)

SECTION

5B–4

ANTI-LOCK BRAKE SYSTEM

Front Wheel Speed Sensor

Front Wheel Speed Sensor and Associated Parts

350RS033

Legend

EndOFCallout

Removal

1. Remove speed sensor connector.

2. Remove sensor cable fixing bolt (Upper side).

3. Remove sensor cable fixing bolt (Lower side).

4. Remove the speed sensor cable fixing bolt.

5. Remove speed sensor.

Inspection and Repair

1. Check the speed sensor pole piece for presence of 

foreign materials; remove any dirt, etc.

2. Check the pole piece for damage; replace speed 

sensor if necessary.

3. Check the speed sensor cable for short or open 

circuit, and replace with a new one if necessary.
To check for cable short or open, bend or stretch the 
cable while checking for continuity.

4. Check the sensor ring for damage including tooth 

chipping, and if damaged, replace the sensor ring 

assembly.   Refer to 

removal of the sensor ring

 in 

Section 4C “Front hub and disc".

Installation

1. Install speed sensor and take care not to hit the 

speed sensor pole piece during installation.

2. Install speed sensor fixing bolt and tighten the fixing 

bolt to the specified torque.

Torque: 8 N·m (0.8 kg·m/69 lbin)

3. Install speed sensor cable fixing bolt (Lower side) 

and tighten the fixing bolt to the specified torque.

Torque : 24 N·m (2.4 kg·m/17 lbft)

4. Install speed sensor cable fixing bolt (Upper side) 

and tighten the fixing bolt to the specified torque.

Torque : 6 N·m (0.6 kg·m/52 lbft)

NOTE:  Confirm that a white line marked on the cable is 
not twisted when connecting the speed sensor cable.

5. Install speed sensor connector.

(1) Speed Sensor Connector
(2) Sensor Cable Fixing Bolt (Upper side)
(3) Sensor Cable Fixing Bolt (Lower side)

(4) Speed Sensor Fixing Bolt
(5) Speed Sensor

SECTION

ANTI-LOCK BRAKE SYSTEM

5B–5

Rear Wheel Speed Sensor

Removal

1. Disconnect harness connector (1).

2. Remove sensor fixing bolt (2) .

3. Remove speed sensor (3).

350RX003

Inspection and Repair

1. Check speed sensor pole piece for presence of 

foreign materials; remove any dirt, etc.

2. Check the pole piece for damage, and replace 

speed sensor if necessary.

3. Check speed sensor cable for short or open, and 

replace with a new one if necessary.   To check for 
cable short or open, bend or stretch the cable while 
checking for continuity.

4. Check the sensor ring for damage including tooth 

chipping, and if damaged, replace the axle shaft 
assembly.   Refer to 

removal of the sensor ring

 in 

Section 4A2 “Differential (Rear)".

Installation

1. Install speed sensor (3).

2. Tighten the sensor fixing bolt (2) to the specified 

torque.

Torque : 24 N·m (2.4 kg·m/17 lbft)

3. Connect harness connector (1).

350RX003

SECTION

POWER-ASSISTED BRAKE SYSTEM

5C–1

FRONTERA

BRAKES

POWER-ASSISTED BRAKE SYSTEM

CONTENTS

Service Precaution......................................... 5C - 2
General Description ....................................... 5C - 2
Diagnosis ....................................................... 5C - 5
General Diagnosis ......................................... 5C - 6

Hydraulic Brakes ........................................... 5C - 9

Filling Master Cylinder Reservoir................ 5C - 9
Deterioration of Brake Fluid ........................ 5C - 9
Leakage of Brake Fluid............................... 5C - 9
Bleeding Brake Hydraulic System .............. 5C - 9
Flushing Brake Hydraulic System............... 5C - 10
Brake Pipes and Hoses .............................. 5C - 10
Brake Hose Inspection ............................... 5C - 10

Front Caliper Brake Hose.............................. 5C - 11

Front Caliper Brake Hose and

Associated Parts ....................................... 5C - 11

Removal ..................................................... 5C - 11
Installation .................................................. 5C - 11

Rear Axle Brake Hose................................... 5C - 12

Rear Axle Brake Hose and

Associated Parts ....................................... 5C - 12

Removal ..................................................... 5C - 12
Installation .................................................. 5C - 12

Brake Pipe..................................................... 5C - 13

Removal ..................................................... 5C - 13
Installation .................................................. 5C - 13

P & B (Proportioning and Bypass) Valve ...... 5C - 14

P & B (Proportioning and Bypass) Valve 

Sectional View .......................................... 5C - 14

Removal ..................................................... 5C - 14
Installation .................................................. 5C - 14

Main Data and Specifications ........................ 5C - 15

Brake Pedal................................................... 5C - 16

Checking Pedal Height ............................... 5C - 16
Checking Pedal Travel ............................... 5C - 16
Brake Pedal and Associated Parts ............. 5C - 17
Removal ..................................................... 5C - 17
Installation .................................................. 5C - 17

Stoplight Switch............................................. 5C - 18

Parts Location............................................. 5C - 18
Removal ..................................................... 5C - 18
Installation .................................................. 5C - 18
Main Data and Specifications ..................... 5C - 19

Fluid Reservoir Tank ..................................... 5C - 20

Fluid Reservoir Tank and

Associated Parts ....................................... 5C - 20

Removal ..................................................... 5C - 20
Installation .................................................. 5C - 20

Master Cylinder Assembly ............................ 5C - 21

Master Cylinder Assembly and

Associated Parts ....................................... 5C - 21

Removal...................................................... 5C - 21
Inspection and Repair................................. 5C - 21
Installation................................................... 5C - 23

Main Data and Specifications ........................ 5C - 23
Special Tools ................................................. 5C - 23

Vacuum Booster Assembly ........................... 5C - 24

Vacuum Booster Assembly and 

Associated Parts ....................................... 5C - 24

Removal...................................................... 5C - 24
Inspection and Repair................................. 5C - 24
Installation................................................... 5C - 25

Exterior Components .................................... 5C - 27

Exterior Components and

Associated Parts ....................................... 5C - 27

Removal...................................................... 5C - 27
Inspection and Repair................................. 5C - 28
Installation................................................... 5C - 28

Vacuum Booster Overhaul ............................ 5C - 28

Vacuum Booster ......................................... 5C - 28

Main Data and Specifications ........................ 5C - 29
Special Tools ................................................. 5C - 30

Front Disc Brake Pads .................................. 5C - 31

Front Disc Brake Pads Inspection .............. 5C - 31
Front Disc Brake Pads and 

Associated Parts ....................................... 5C - 31

Removal...................................................... 5C - 32
Installation................................................... 5C - 32

Front Disc Brake Rotor.................................. 5C - 34

Inspection ................................................... 5C - 34
Replacing Brake Rotors.............................. 5C - 34
Refinishing Brake Rotors ............................ 5C - 34

Front Disc Brake Caliper Assembly............... 5C - 36

Front Disc Brake Caliper Assembly and 

Associated Parts ....................................... 5C - 36

Removal...................................................... 5C - 36
Installation................................................... 5C - 37

Front Disc Brake Caliper ............................... 5C - 39

Front Disc Brake Caliper 

Disassembled View................................... 5C - 39

Disassembly ............................................... 5C - 39
Inspection and Repair................................. 5C - 40
Reassembly ................................................ 5C - 40

Main Data and Specifications ........................ 5C - 42

Rear Disc Brake Pads ................................... 5C - 43

Brake Pads Inspection................................ 5C - 43
Brake Pads and Associated Parts .............. 5C - 43
Removal...................................................... 5C - 44
Installation................................................... 5C - 44

SECTION