DIY repair of a vacuum brake booster VAZ 2115

In detail: do-it-yourself repair of a VAZ 2115 vacuum brake booster from a real master for the site my.housecope.com.

Image - DIY repair of a vacuum brake booster VAZ 2115

The VAZ 2115 vacuum brake booster is one of the main working mechanisms of the car brake system. The efficiency of braking largely depends on its serviceability, and therefore your safety. Consequently, the vacuum brake booster must be regularly checked in order to detect its malfunctions or malfunctions in a timely manner.

Together with the replacement of the brake discs, I also changed the vacuum brake booster, although the old one worked, but when I pressed the brake pedal, it made hissing sounds.

I bought a vacuum called the original, at a cost of 1320, the choice was not yet the original, it is cheaper by 150 rubles, you cannot save on this, and 150 rubles. the weather will not be improved.

We climb under the hood and begin to release the vacuum cleaner. For convenience, I removed the air filter housing and moved the absorber aside. We unscrew the brake pipes, suitable for the brake master cylinder, and two bolts of the brake cylinder to the vacuum booster (arrows in the photo)

We remove the main brake cylinder and put it aside, you can throw it out if there is a new one.

Then, unscrew the 4 bolts securing the bracket of the vacuum cleaner to the body

We go to the salon, climb under the pedals, remove the corkscrew fastening the vacuum rod to the pedal, disconnect the rod

We take out the vacuum amplifier from under the hood. Now you can work on the ground.

We unscrew the last two bolts securing the vacuum cleaner to the bracket.

We put the new and old vacuum next to each other, look at them, admire, rejoice at the new spare part

Then we collect everything in reverse order, do not forget to pump the brakes.

After replacing the vacuum and brakes, as I wrote earlier, I was not completely happy with the result. The reason for this was a faulty master cylinder.

Methods and signs of detecting malfunctions of the vacuum brake booster

For instance. Start the engine and turn it off after a few minutes. Then press the brake pedal some times with the usual effort. With a working amplifier, at the moment of the first pressing, the pedal will be pressed, as expected, all the way. The system will work, and the created vacuum will attract the diaphragm, which helps to push the piston of the brake master cylinder through the piston rod.

Video (click to play).

Then the valve will equalize the pressure in the chamber with the atmospheric one. During the second and subsequent presses of the pedal, there will be no place for the discharge to take, which makes the pedal travel less and less. If there is no difference between the initial and further pressing on the pedal, then it is clear: this device does not provide additional force in the master brake cylinder.

Following the experience done, it is worthwhile to perform another one. The engine is off. The brake pedal has been pressed several times in a row. Her move testified to something. Either the results of the experiment seemed inconclusive, or there was a desire to make a control approbation. The following actions are performed. The brake pedal is depressed and the engine starts when the pedal is depressed.

With a working vacuum amplifier, a vacuum is formed in its vacuum chamber, due to which the membrane presses on the stem, the stem pulls the pusher connected to the pedal, and the latter is slightly lowered.

In the case when the pedal remained in place, the conclusion is drawn: the expected chain of events did not take place due to a malfunction of the vacuum brake booster. Such checks reveal significant damage to the part.

Another test makes it possible to determine the presence of small air leaks.When the car engine is running, press the brake pedal, then, without releasing it, turn off the engine. Hold the pedal in the same position for half a minute.

Due to the leakage of the amplifier, the pressure in the vacuum chamber will increase. The diaphragm, under the influence of the return spring, having lost the support of the force that balances its position, will press on the pusher and raise the brake pedal.

Image - DIY repair of a vacuum brake booster VAZ 2115

brake unit The importance of proper operation of the vehicle's braking system is difficult to dispute. Even a novice driver understands that not only his own safety, but also those of those around him, depends on this. On AvtoVAZ models, a special role in the design is assigned to the braking device, which facilitates the process of reducing the speed. Its breakdown does not lead to a complete failure of the system, but seriously affects the comfort of operating the machine.

Before proceeding with the replacement of a faulty vacuum brake booster (VUT), as well as determining its breakdown, it does not hurt to know the device of the unit. Structurally, the unit forms one whole with the brake master cylinder and includes the following parts:

  • frame;
  • diaphragm;
  • follower valve;
  • pusher;
  • stock;
  • return spring.

Image - DIY repair of a vacuum brake booster VAZ 2115

under the hood The body is divided into two parts, the one that connects to the GTZ is called a vacuum; the opposite chamber (from the side of the brake pedal) is atmospheric. The diaphragm is connected to the piston rod of the master brake cylinder, which ensures the supply of brake fluid to the wheel cylinders. After the end of braking, the spring returns the diaphragm to its normal position.

The principle of operation of the VUT is based on the creation of the effect of the pressure difference in two chambers. The force from pressing the pedal is transmitted to the follower valve, which at the same time closes the channel connecting both chambers. The created pressure difference acts on the diaphragm and, overcoming the force of the spring, moves the piston rod of the GTZ. Understanding the principle of operation of a vacuum brake booster will help when replacing or determining the cause of its breakdown.

The revision of the unit does not require absolutely any tools, it is enough to pay attention to the behavior of the brake pedal when it is pressed. If once the driver finds out that to stop it is necessary to press harder on the pedal, then this indicates the need to check the VUT. The procedure is performed as follows:

  • Stop the engine.
  • Press the brake pedal several times and fix it in the middle of the stroke.
  • Without taking your feet off the pedal, start the car.

If the "vacuum cleaner" is in good working order, the pedal will fail a little, but if this is not the case, then there are some problems with the brake system. As an additional measure, when a breakdown is detected, a visual inspection is used, consisting of the following points:

  • Check the tightness of the connection between the check valve and the branch pipe.
  • Check the flange for damage.
  • Inspect all pipe bends and replace if cracks are found.
  • Remove the mat in the cab from the driver's side and check the protective cap of the shank seal under the steering column, if it sticks, then the car may brake spontaneously.
  • Remove the protective cap and start the engine, then swing the valve shank several times - the presence of a characteristic hiss indicates a breakdown of the part.

Internal breakdowns of the unit are also possible. It is quite common for a valve to malfunction, the material of which hardens. The wear of the diaphragm rubber can lead to its rupture, then replacing the vacuum brake booster will be the only way out of the situation.

The function of the check valve is checked in the following way:

  • disconnect the hose from the valve;
  • remove the branch pipe from the VUT rubber seal;
  • place the nose of a rubber bulb in the hole of the fitting;
  • squeeze the pear and release after 4-5 seconds, if the pear remains in a compressed state, then the valve is operational.

When the diagnostic process is complete and the need to install a new part is quite obvious, you need to prepare tools and spare parts.Together with the new VUT, the masters advise to change the connecting hose if there are signs of wear on it. Also, we must not forget about the plugs and fittings - parts that are unsatisfactory in condition should be replaced.

From the toolkit you need to prepare:

  1. Pliers or round nose pliers.
  2. A set of open-end and socket-type wrenches for "10", "13" and "17".
  3. Screwdriver.

The replacement procedure is absolutely nothing complicated and is performed in a garage in two hours:

  • Dismantle the rod that connects the VUT and the brake pedal. To do this, simply pry off the locking plate with a screwdriver and unscrew the fixing part.
  • Open the hood and unscrew the "vacuum cleaner" from the brake cylinder (TC) using a key or a head on "13".
  • Then there are two options to choose from. The first is to disconnect all tubes from the shopping center, which will greatly facilitate the task of dismantling the VUT, but it will require pumping the brake system after repair. The second is to leave everything in place, unscrew only the nut on "10", which fixes all the tubes on the body.
  • Move the shopping center aside and disconnect the hose from the VUT valve to the intake manifold.
  • Unscrew the nuts at "13" that secure the unit to the wall of the engine compartment.
  • Replace the faulty vacuum brake booster with a new one in reverse order.

After dismantling the broken device, it is necessary to remove the bracket using the head on "17" and move it to the new VUT. Using a vernier caliper, it is measured how much the rod head protrudes above the plane of the unit body. Measurement results should be within 1.05-1.25 mm. In case of non-compliance with these figures, the adjustment is carried out by rotating the head with a wrench to "7", while the stem itself is recommended to be held with pliers.

The VAZ 2115 vacuum brake booster is one of the main working mechanisms of the car brake system. The efficiency of braking largely depends on its serviceability, and therefore your safety. Consequently, the vacuum brake booster must be regularly checked in order to detect its malfunctions or malfunctions in a timely manner.

Checking the vacuum brake booster VAZ 2115

In order to check the vacuum brake booster - no tools are needed, it is quite simple to pay attention to the brake pedal. If you once found that it is necessary to press harder on the brake pedal for braking or that the brakes have become less effective, this is a clear sign of a VUT malfunction.

1. To check the vacuum booster, stop the machine and turn off the engine.

2. Press down firmly on the brake pedal a couple of times, then stop halfway through.

3. Then, without removing your foot from the brake pedal, start the car.

If the vacuum brake booster is working properly, the brake pedal will fall down a little, if this has not happened with the booster or the brake system, something is wrong.

Visual inspection of the VAZ 2115 vacuum amplifier

1. Check the tightness of the connection of the branch pipe with the check valve;

2. Make sure there is no damage to the flange;

3. Next, inspect all the bends of the branch pipes, finding cracks or wet traces - replace them immediately;

4. If the liner seal located under the steering column is damaged, the vehicle may start to brake spontaneously. In order to check this, take out the mat and conduct a careful examination of the protective cap, if it sticks, it can be assumed that it is defective.

5. Then you need to remove the cap and start the engine. Swing the valve stem a couple of times, hissing is a sure sign of breakage.

6. Having found the slightest hint of a malfunction, replace the VAZ 2115 vacuum brake booster, given its low cost and ease of replacement procedure, it will be better than hoping for serviceability and risking your own health.

Replacing the VAZ 2115 vacuum amplifier with your own hands

- A set of keys, open-end and socket for "10, 13, 17";

- A couple of hours of free time.

one.Disconnect the rod protruding from the vacuum booster from the brake pedal.

2. After that, in the engine compartment, it is necessary to unscrew the brake cylinder (TC) from the VUT.

3. Further, many "manuals" recommend to disconnect all tubes, which supposedly complicate the process of removing the vacuum brake booster. However, I do not like pumping the brakes, this is a waste of time, which is not so much already, so I decided that I would do without this item and did it my own way.

4. Three of the four tubes coming from the shopping center are attached to the body; they do not allow the cylinder to be removed from the vacuum. If you unscrew only one nut by "10", you can easily remove the cylinder from the vacuum.

5. After you have eliminated the obstacle - the brake cylinder, disconnect the hose that goes from the intake manifold to the VAZ 2115 vacuum brake booster valve.

6. Next, you need to unscrew the mounting bracket from the body, for this it is better to have a special cardan, see the photo. The vacuum cleaner itself is attached to the body with four turnkey nuts at "13".

7. When the removal is done, move the mounting bracket to the new VUT, for this you need to unscrew the two nuts at "17".

Assembly is carried out upside-down. Recall that in the previous article we looked at how to install speakers in the rear doors of Grants with our own hands. High-quality music is the key to a good mood for the whole day.

This video instruction demonstrates a way to restore the performance of a vacuum booster at home (removing the spring from the brake booster). It is not uncommon for a vacuum booster to become the cause of a triple engine. In order to fix the breakdown, you can buy a new one, but you can try to repair it. The wizard will show you how to disassemble and produce repair of the vacuum brake booster VAZ.

As a rule, no one repairs this unit responsible for the car brake, but changes it entirely, but if it is not possible to buy, then this method of self-restoring work will be very useful. For all the details and the sequence of disassembly, see the video plot.

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Replacing the VAZ 2115 vacuum brake booster is a manipulation that can be easily performed on your own. Replacing a vacuum brake booster with a VAZ 2115 is carried out for a number of reasons, which will be studied in detail in this publication.

Image - DIY repair of a vacuum brake booster VAZ 2115

Vaz 2115 replacement of the vacuum booster

As you know, the braking system of a modern car is a rather complex design, where several units and mechanisms are combined. Indeed, there are a lot of details and components here.

Note. It is clear that the braking system or vehicle of these years is qualitatively different, for example, from the vehicle of previous years. And the most important difference, of course, is the vacuum amplifier, which is the most effective mechanism that increases the stability of operation, reliability and durability of the entire system.

The vacuum amplifier or VU fails and this has its own fundamental factors. On the other hand, thanks to the ingenious invention of engineers, this unit is made in such a way that it is quite easy to repair, even in your own garage.

Image - DIY repair of a vacuum brake booster VAZ 2115

Replacing the vacuum amplifier VAZ 2115

Let's consider the most important features of this type of vehicle:

  • As a rule, the amplifier is installed on the car near the brake master cylinder.
  • The amplifier housing is divided into two parts: vacuum, which is located on the side of the master cylinder, and atmospheric, located near the brake pedal.
  • A specially designed air intake manifold is needed so that the vacuum chamber has a source for vacuum. It is connected to the camera through a special element.

Note.There is no diesel unit on the VAZ 2115, but if on some cars it is installed instead of a gasoline one, an electric pump is also needed for the normal operation of the vacuum amplifier.

  • When the engine stops, the manifold and valve are automatically disconnected from each other. Thus, the amplifier is only able to function when the car's engine is running. And in other cases, in fact, it is not needed.
  • When any breakdown is observed, the vacuum booster is also disconnected.

Note. This amplifier may stop working even while the vehicle is in motion if it detects any breakdown. But this does not mean that the car will lose its brakes. They will continue to function, although not at their full strength.

  • A special follower valve is responsible for the connection of the atmospheric chamber with the vacuum chamber. After the driver engages the pedal, this valve will begin to monitor the connection with the atmosphere.
  • A pusher, which is installed nearby, is directly connected by a pedal. Its main task is, in turn, to move the follower valve.
  • There is another detail in the vacuum brake system. This is the diaphragm of the connection body, which is located on the side of the vacuum chamber, and is connected to the cylinder rod.
    Thus, there is a never-ending effect on the TJ (brake fluid), which is carried out by means of a piston directly on the working cylinders.
  • The mechanism also has a return spring, the task of which is to return the diaphragm to its initial position.

Detailed scheme of the VU operation

Note. The advantage of VU brakes is their simplicity. This mechanism works due to the pressure difference formed in the atmospheric and vacuum chambers. At the right time, this very difference affects the pusher, and he continues it, passing it on to the piston rod of the master cylinder.

Note. It is important to remember that when this mechanism leaves the normal operation mode, the brakes continue their work. This is one of the advantages of such a system. In such a situation, the driver of the VAZ 2115 will simply have to put a little more effort on the brake pedal. On the other hand, there may be some difficulties with the controls, but they are insignificant.

  • One of the reasons for the breakage of the element can be a rupture of the hose or even a crack in it. As you know, this very hose plays a very important role, connecting the manifold of the power unit and the amplifier.
    In the event of a hose rupture or other problems associated with it, the entire system is depressurized.

Advice. It is not difficult to be able to determine that this is a depressurization. The characteristic hiss sound is evidence of this. The vacuum booster tends to hiss in this case.

  • Depressurization is eliminated in the following way: the hose is inspected, breaks and cracks are wrapped around, the clamps are carefully checked, which can also be relaxed.
  • Another reason for the failure of this mechanism is called the rupture of the diaphragm located right inside the mechanism. If air begins to escape from the valve, then this is the symptom.

To check the functionality of this element, it is recommended to do the following:

  • Press the brake pedal several times (5-6) while the car is not yet started. Thus, pressing the brakes, we create the same pressure in both cavities, close to atmospheric.
  • Keeping your foot on the pedal, start the engine. If the vacuum booster is in good condition, the pedal should move forward arbitrarily.
  • If the pedal does not go forward automatically, then you need to check the attachment of the hose tip, as well as other points that negatively affect the efficiency of the amplifier.
  • If all else fails, the vacuum booster is defective and must be replaced.

To start replacing the vacuum amplifier, you first need to arm yourself with the necessary tools and materials:

  • A screwdriver and pliers.
  • Keys 13 and 17.
  • Brake fluid.
  • Rubber caps and special plugs.

In some cases, it is not necessary to dismantle the vacuum booster. It will be enough just to replace the master cylinder.

Note. You can also say this: if the brake pedal on a car with a vacuum booster becomes softer, and pumping out air locks from the entire system does not lead to anything, the master cylinder will need to be replaced.

  • The block with wires is disconnected from the brake fluid level regulator.
  • We take a key for 10 and begin to unscrew alternately the union from the main cylinder.
  • We put plugs on the brake pipes and the cylinder.

Note. The plugs make it possible to avoid air penetration into the brake system, so as not to pump out the plugs later, which is not so easy.

  • We take the 17 key and unscrew the two nuts with which the cylinder is fixed to the vacuum amplifier.
  • Remove the cylinder.
  • We put a new one.
  • Disconnect the block with wires from the regulator again.
  • We remove the union.

Image - DIY repair of a vacuum brake booster VAZ 2115

Replacing the vacuum amplifier with a VAZ 2115

Note. The master cylinder may not be removed. It will be enough just to disconnect the fittings on the left. Then you will need to take the cylinder to the side.

  • Disconnect the hose from the valve.
  • We take out the bracket from the passenger compartment, which locks the brake pedal finger.
  • We remove the finger.
  • We take the 13 spanner wrench and unscrew the 4 nuts that fix the vacuum booster to the car body. We dismantle the old amplifier.