Replacing the vacuum booster (for use on VAZ 2110 / 2111 / 2112 models)

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Signs of VUT malfunction

Partial output of the vacuum brake booster will certainly manifest itself, and from the worst side and quite clearly. So, symptoms of a malfunctioning amplifier include:

  • Significant effort when pressing the brake pedal . To feel this for yourself, you can press the pedal four or five times with a known good vacuum seal and the engine turned off. At the last squeeze, the force on the pedal will increase significantly. Sometimes the opposite situation occurs - the pedal is too soft. This indicates “airing” of the brake system.
  • The influence of the vacuum booster on engine operation . Since the VUT takes vacuum from the intake manifold, the engine can change its operating mode during braking (although this should not happen in normal mode). This happens because excess air is sucked into the manifold, affecting the composition of the air-fuel mixture.
  • The vacuum brake booster hisses . In particular, hissing occurs when the pedal is depressed. A hissing sound clearly indicates the presence of depressurization either in the vacuum amplifier itself (for example, when the diaphragm ruptures), or in its pipeline or in the check valve (for example, when its rubber seals are significantly worn).
  • Vacuum pumps knocking . If a mechanical vacuum pump fails, the usual sign of this is a hum emitted by its drive rod (error p1479 may also appear). If an electric vacuum pump is installed on a car, then motorists often experience overheating of its drive motor.
  • Knocking noise when braking hard . Moreover, the sound is inertial in nature, since it is caused by the membrane fastening becoming loose.

Accordingly, the occurrence of one or more signs directly indicates to the car owner that it is necessary to check the vacuum brake booster and its components.

Error p1479

In modern cars equipped with an electronic control unit (ECU), an error code p1479 is often generated in the device’s memory - “Brake booster vacuum system mechanical malfunction.” Owners of a wide variety of cars encounter it - Audi, Volkswagen (Touareg, Passat), Ford and others. The cause of an error in the control unit can be very different. For example, when air is sucked in the hose between the intake manifold and the vacuum brake booster itself.

Another common option is the result of measuring the vacuum value with a vacuum sensor. In particular, it occurs if moisture appears inside the vacuum booster and/or its tubes. The solution is to clean and dry the tubes, and in rare cases, replace the sensor itself.

It also makes sense to check the integrity of the fuse going from the control to the sensor. Each machine will have its own electrical circuit, so it is impossible to provide specific information within the framework of this material.

Another option is the performance of the electric vacuum pump. In particular, its electric motor, impeller, bearings, fastenings, connection blocks, as well as relays and fuses.

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Master brake cylinder

Now let's talk about the master brake cylinder on a VAZ 2110 car. If you do not want to allow the brakes to fail while driving, they should be checked periodically, and if problems arise, take appropriate action immediately.

A common reason for replacing the master brake cylinder of a VAZ 2110 is precisely the fact that the brakes are lost.

Symptoms of a problem

Of course, brakes can completely lose their effectiveness for various reasons, but now we are talking specifically about the master cylinder. If the reason lies therein, then it can be determined by the following signs:

  • The master cylinder shows signs of brake fluid leakage;
  • The pedal has an idle motion, that is, when it is pressed, no force is created;
  • The brake pedal simply won't press.

Replacement

To repair the master brake cylinder of a VAZ 2110, you will need to first disassemble it and then install a new element.

The most difficult process is disassembly. Therefore, let's talk about it in more detail.

Carefully disconnect the master cylinder from the pipeline. Disconnect the block, which is equipped with wiring, from the emergency brake fluid indicator. The connection to the “ten” is made by terminals. Cover the pipe and assembly openings with something to prevent brake fluid from leaking. It will pollute the interior space, which is undesirable. Now remove the cylinder along with the reservoir. To do this, simply unscrew the fastening nuts that connect the element to the vacuum booster. After removing the brake fluid level sensor, drain the brake fluid present from the cylinder and the cylinder itself. If there is no serious need, you should not remove the tank. But for complete assembly, the tank is removed and then installed in place in strict order. Before reassembly, each element is washed with purified brake fluid.

A good alternative is isopropyl alcohol. Do not forget to dry the parts with a compressor and wipe with a clean, dry cloth. Carefully avoid contact of the main cylinder with fuel or kerosene. Pay special attention to the O-rings. If you wash them with special alcohol, do not keep the rings in this liquid for more than 20 seconds.

After processing, immediately dry and wipe the seals. Treat the surface of the piston and mirror to remove all rust. When replacing the master cylinder, new O-rings must be installed, regardless of their current condition. Check the elasticity of the piston springs under load. Refer to the VAZ 2110 repair manual, which indicates the appropriate loads and forces for testing. When free, the length of the spring should be 59.8 millimeters. If the indicator deviates from the norm, be sure to replace the springs.

https://youtube.com/watch?v=gYLFHjMr2Fk

Leveling up

If you think that after replacing the brake master cylinder you can safely go out on the roads, then you are mistaken. In fact, a complete repair of brake cylinders on a VAZ 2110 includes bleeding.

Proper bleeding will ensure the efficiency of the newly installed master cylinder.

The procedure is not complicated, but requires following the instructions.

  • Find someone who will help you in this matter. One will be near the car, and the second will be directly in the cabin.
  • Inflate the brake pedal by pressing it several times.
  • The assistant presses the pedal, and meanwhile you slightly unscrew the fitting on one of the brake system pipes.
  • This should release air, as well as a small amount of brake fluid. Don't be alarmed by leaks, this is completely normal.
  • Retighten the fitting using the same wrench as when unscrewing - 10.
  • Command your assistant to lower the part.
  • The procedure is repeated until air bubbles begin to come out when unscrewing the fitting.
  • Each of the four circuits is pumped using similar actions.
  • First make sure that the brake fluid in the expansion tank is filled to the required level.

Actually, at this point the repair work related to the master brake cylinder can be considered complete. Experience in operating a car like the VAZ 2110 suggests that you should always store a container of brake fluid in the trunk. All sorts of situations happen on the road, and you need to be prepared for them.

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Replacement of rear brake cylinders

The best rear brake cylinders on the VAZ 2110 can work for a long time. An example of a defective product would be a brake cylinder in which the pistons extend out of the cylinder only a few millimeters, which is not enough to move the brake pads apart.

The quality of the brake fluid also plays a role in the service life of the brake cylinders. The instructions indicate that the rear brake cylinders are removed with the brake drum removed.

Advice: It is advisable that the replacement of the rear brake cylinders of the VAZ 2110 be carried out simultaneously on both brakes. Wear of one of the elements indicates that the second one will soon fail.

And the price of the work will be reduced by disassembling the car once.

  1. The machine is installed on an inspection pit or a lift.
  2. The front wheels are fixed.
  3. The rear ones are removed.
  4. Using a rubber hammer, the brake disc is pulled out of its place.
  5. Carefully remove the end of the upper tension spring, position 7 in the first photo.
  6. Previously, it was connected to the brake pad.
  7. The handbrake handle is raised all the way. In this case, the brake pads move apart and are removed without much effort.
  8. The brake pipe is unscrewed from the cylinder.
  9. The rear brake cylinder is removed.

Removing the rear brake cylinder of a VAZ 2110

  1. If necessary, the rear brake cylinder of the VAZ 2110 is replaced with a new one.
  2. Assembly of the unit is performed in reverse order.
  3. The job ends with bleeding the brakes.

Tip: Replacing the brake cylinder on a VAZ 2110 car is carried out in strict sequence - both dismantling and installing spare parts. The main condition is serviceability and tightness in the hydraulic system.

How the rear brake cylinder is replaced on a VAZ 2110 car can be seen in the video.

Repair of rear brake cylinders of VAZ 2110

There are times when, to save money, it is enough to replace worn parts of an assembly. In this case, after removal from the vehicle, the rear brake cylinder is disassembled.

Dismantling the rear brake cylinder of a VAZ 2110

  1. Remove the protective caps, pos. 10 in the picture above.
  2. Pistons are pressed out of the cylinder body along with parts to automatically regulate the gap formed between the drum and the brake pads.
  3. After installing the piston pos. 9, turn it onto a special device and remove the thrust screw, pos. 3.
  4. Remove the sealing ring pos. 8 and support cup pos. 7 with crackers pos. 5 and spring pos. 6 from the screw.
  5. The thrust ring pos. is disconnected. 4 and a stop screw.

After disassembling the unit, the parts are checked for faults:

  1. The working surfaces of the pistons, cylinder and thrust rings must be smooth, without scratches or roughness. Otherwise, fluid leakage and premature wear of pistons and seals may occur.
  2. Defects on the mirror surface can be eliminated by grinding or lapping.

Tip: Care must be taken not to increase the internal diameter of the cylinder.

  1. The thrust screw, springs, support cup and crackers are visually checked. If they are damaged, parts are replaced.
  2. Seals pos. 8 are replaced with new ones.
  3. If necessary, change the protective caps pos. 10.
  4. The structure is assembled in the reverse order.

In this case, you need to take into account:

  1. All parts are generously lubricated with brake fluid.
  2. The thrust screws must be tightened to a torque of 3.9 – 6.9 Nm.
  3. The slot located on the thrust rings is directed vertically upward, the deviation should not be more than 30 degrees. This ensures that all air is removed from the drive mechanism when bleeding the brake.
  4. Using the device, the pistons are pressed into the cylinder body.
  5. After assembly, the movement in the housing of each piston is checked, which should be from 1.25 millimeters to 1.65 millimeters.
  6. Protective caps are installed.
  7. Timely repair or replacement of rear brake cylinders is a guarantee of road safety.

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Master brake cylinder

Now let's talk about the master brake cylinder on a VAZ 2110 car. If you do not want to allow the brakes to fail while driving, they should be checked periodically, and if problems arise, take appropriate action immediately.

A common reason for replacing the master brake cylinder of a VAZ 2110 is precisely the fact that the brakes are lost.

Symptoms of a problem

Of course, brakes can completely lose their effectiveness for various reasons, but now we are talking specifically about the master cylinder. If the reason lies therein, then it can be determined by the following signs:

  • The master cylinder shows signs of brake fluid leakage;
  • The pedal has an idle motion, that is, when it is pressed, no force is created;
  • The brake pedal simply won't press.

Replacement

To repair the master brake cylinder of a VAZ 2110, you will need to first disassemble it and then install a new element.

The most difficult process is disassembly. Therefore, let's talk about it in more detail.

Carefully disconnect the master cylinder from the pipeline. Disconnect the block, which is equipped with wiring, from the emergency brake fluid indicator. The connection to the “ten” is made by terminals. Cover the pipe and assembly openings with something to prevent brake fluid from leaking. It will pollute the interior space, which is undesirable. Now remove the cylinder along with the reservoir. To do this, simply unscrew the fastening nuts that connect the element to the vacuum booster. After removing the brake fluid level sensor, drain the brake fluid present from the cylinder and the cylinder itself. If there is no serious need, you should not remove the tank. But for complete assembly, the tank is removed and then installed in place in strict order. Before reassembly, each element is washed with purified brake fluid.

A good alternative is isopropyl alcohol. Do not forget to dry the parts with a compressor and wipe with a clean, dry cloth. Carefully avoid contact of the main cylinder with fuel or kerosene. Pay special attention to the O-rings. If you wash them with special alcohol, do not keep the rings in this liquid for more than 20 seconds.

After processing, immediately dry and wipe the seals. Treat the surface of the piston and mirror to remove all rust. When replacing the master cylinder, new O-rings must be installed, regardless of their current condition. Check the elasticity of the piston springs under load. Refer to the VAZ 2110 repair manual, which indicates the appropriate loads and forces for testing. When free, the length of the spring should be 59.8 millimeters. If the indicator deviates from the norm, be sure to replace the springs.

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Video with replacing the vacuum brake booster on a VAZ-2112

Difficult choice: original or analogue?

We exchanged it for TorgMash. It seems to be working. So we can recommend

Where is the vacuum booster located?

It is attached to the car body and is located in the engine compartment on the driver's side.

When should it be changed?

  1. When the brake booster fails, you may hear a hissing sound when you press the brake pedal.
  2. Also, the engine speed will become uneven.
  3. The brake pedal will also become difficult to press.

All these symptoms indicate that the brake booster needs to be replaced. They may not always appear all together.

You can also check the amplifier as follows: with the car turned off, depress the brake pedal 3-4 times. With the pedal depressed, start the engine. If the pedal sinks a little, this will indicate that the amplifier is working properly.

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