Vacuum Brake Servo

[Tonks4x4]

There are several types of servos and there is a number of different spacer adapters that can be fitted to the rear of the servo where it bolts to the bulkhead.
Along with this there is several lengths of push rod lengths from servo to pedal.
So be prepared to do some cutting and welding if you want to use a different spacer width to give you more clearance in the engine bay.

The standard S2 master cylinder can be used on all the different types of servo.
However a spacer rod needs to be machined for the inside of the master cylinder where it locates onto the pin inside the servo.

Then the easiest way to cure the pump problem is remove the front set of pistons as already mentioned earlier in the post.

Then wait to do the power steering mod at a later stage when someone has a good working setup that works well.

[Error404]

That's what I'm going to do, if you ask Vas I'm sure he'll post up a pic of his which has a curve in it to go around the vacuum servo.

Edit : You can see it in this post here, LHD, but you get the idea.

http://www.s2forum.com/forum/showpos...&postcount=482

I think Pat means the little horizontal web brackets between the strut tower and the firewall. Vas is using a bigger servo on the LHD than we can use on the RHD, due to the strut turret not having enough clearance - i don't think there is an issue with the strut brace on the RHD using the vac servo

[Pat D]

I managed to get the grinder in my freshly painted engine bay and cut the brackets out. I used a dremel to do the cuts and an angle grinder to smooth it all out. There is also another little bracket in the curved section of the strut & from memory holds a fuel line rubber mount that needs to be cut out as well.

I placed it in position and it fits perfectly, the linkage to the pedal seems spot on.
The S2 master cylinder bolts straight on to the vacuum servo and will look like it should also work fine. I measured the length of the linkage shaft on both master cylinders and they were very much the same, a couple mm difference was all that I could see.

Gave the servo a birthday, then etch primed & epoxy coated the bare metal in the engine bay. I'll fit it all in once it dries and then see if I should weld an alternative strut to firewall bracket in there.

Some pics in the process:

[Biturbo]

Any one sorted problem with speedo computer after converting to vacuum servo?It's show and blink red exclamation mark.

[Pirvu Eugen]

short the 2 wires from the old pressure sensor at the old servo.

[Biturbo]

short the 2 wires from the old pressure sensor at the old servo.

I did that but same.Still sing on screen

[Pirvu Eugen]

That error is given by that sensor, the brake fluid level sensor or the hydraulic oil level sensor.
Check those switches too.....maibe one of them is not connected or not in closed contact position.
Hope this helps!

[Biturbo]

That error is given by that sensor, the brake fluid level sensor or the hydraulic oil level sensor.
Check those switches too.....maibe one of them is not connected or not in closed contact position.
Hope this helps!

All sorted now.My problem was that I conect hydraulic oil sensor switch cables together.Thanks for help

[Pirvu Eugen]

glad is sorted!
Please let us know how is running with the vacuum conversion.
Regards!

[Biturbo]

glad is sorted!
Please let us know how is running with the vacuum conversion.
Regards!

I will test car on Sunday.Is no abs and using opel astra electrik power steering

[Pirvu Eugen]

Let us know...
All the best!

[sailaz]

long time ..... And how it went with Astra electric power steering ? Any pics under the bonnet ?

[Rusty]

Is there a parts list for this conversion? Couldn't see one... Part numbers etc. would be great.

[Rusty]

[Error404]

Servo - 8A2 612 105 A
Try and get the rigid vacuum line with it, will make life easier.


I plumbing mine into the vacuum nipple on the underside of the inlet manifold that connects to the breather system on the ABY. I used an extra check valve to give double security against boosting the servo.






PAS pump - you can either do the ghetto mod and remove the pistons from the OE pump, or go custom

http://www.s2forum.com/forum/showthread.php?p=808266&highlight=C4+pump+100+bar#post808266

You need to cut out the bracket between the bulkhead and the turret. You also need to cut & weld the POS/plug bracket to clear the servo. Plug the fluid return line from the hydro servo to the rack return line with a bleed valve. Leave the hydro pressure switch plugs loose. I think that's it