Omega Owners Forum - brake pedal seems stiff after replacing plenum

Mr Stud Junior Member Offline Posts: 125 somerset Gender: Drives: vectra gsi...MV6 Manual :-)	brake pedal seems stiff after replacing plenum 17. Mar 2011 at 12:50 removed and replaced plenum the other day,and now the brake pedal seems stiff compared to what it was when braking... why?
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henryd Omega Baron Offline Posts: 2172 west cornwall Gender: Drives: Merc E220 estate,previous ride 2.5 elite estate	Re: brake pedal seems stiff after replacing plenum Reply #1 - 17. Mar 2011 at 12:52 sounds like you may have an air leak betwwen plenum and servo,check all the connections and that the pipe hasn't rubbed through where it passes the aircon pipe.Is the car running ok,idle speed correct etc?
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Jimbob Global Moderator Admin Team Offline Third nipple removal completed succesfuly Posts: 20462 Chester / Flintshire Gender: Drives: 52 3.2 MV6 Estate & 98 3.0 MV6 Manual Estate	Re: brake pedal seems stiff after replacing plenum Reply #2 - 17. Mar 2011 at 12:53 assuimng you have removed and replaced the main vac pipe from plenum to brake servo.....maybe this wasnt fully sealed before, and now youve restored the vacuum?
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Mr Stud

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Re: brake pedal seems stiff after replacing plenum
Reply #3 - 17. Mar 2011 at 12:58

henryd wrote on 17. Mar 2011 at 12:52:

sounds like you may have an air leak betwwen plenum and servo,check all the connections and that the pipe hasn't rubbed through where it passes the aircon pipe.Is the car running ok,idle speed correct etc?

the car running fine,and idling ok...what the four black pipes on top plenum as around there seems loud like it sucking air,and which way round do the two little ones go

Jimbob wrote on 17. Mar 2011 at 12:53:

assuimng you have removed and replaced the main vac pipe from plenum to brake servo.....maybe this wasnt fully sealed before, and now youve restored the vacuum?

which ones that the one that screws into side of plenum?

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« Last Edit: 17. Mar 2011 at 12:59 by Mr Stud »

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Jimbob Global Moderator Admin Team Offline Third nipple removal completed succesfuly Posts: 20462 Chester / Flintshire Gender: Drives: 52 3.2 MV6 Estate & 98 3.0 MV6 Manual Estate	Re: brake pedal seems stiff after replacing plenum Reply #4 - 17. Mar 2011 at 13:00 the one that needs (iirc) 19mm and 17mm spanners to do - thickish black pipe from servo by brake resivoir to passenger side of plenum, towards the back, shoulc be clipped to aircon pipe as well to stop it chaffing.
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Jimbob Global Moderator Admin Team Offline Third nipple removal completed succesfuly Posts: 20462 Chester / Flintshire Gender: Drives: 52 3.2 MV6 Estate & 98 3.0 MV6 Manual Estate	Re: brake pedal seems stiff after replacing plenum Reply #5 - 17. Mar 2011 at 13:03 actually, heres a couple of pics... green outline shows the original pipe, red is a poor copy, but show the connector on the plenum better
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Mr Stud Junior Member Offline Posts: 125 somerset Gender: Drives: vectra gsi...MV6 Manual :-)	Re: brake pedal seems stiff after replacing plenum Reply #6 - 17. Mar 2011 at 13:29 will take it off again and have a look around..as far as know put everything back on need to sell it so best look
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Weds

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Re: brake pedal seems stiff after replacing plenum
Reply #7 - 17. Mar 2011 at 14:12

henryd wrote on 17. Mar 2011 at 12:52:

sounds like you may have an air leak betwwen plenum and servo,check all the connections and that the pipe hasn't rubbed through where it passes the aircon pipe. Is the car running ok,idle speed correct etc?

I'm surprised this has never been a recall, as its happened to others here including me..

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Marks DTM Calib

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Re: brake pedal seems stiff after replacing plenum
Reply #8 - 17. Mar 2011 at 14:15

Weds wrote on 17. Mar 2011 at 14:12:

henryd wrote on 17. Mar 2011 at 12:52:

sounds like you may have an air leak betwwen plenum and servo,check all the connections and that the pipe hasn't rubbed through where it passes the aircon pipe. Is the car running ok,idle speed correct etc?

I'm surprised this has never been a recall, as its happened to others here including me..

No need as they are fine on leaving the factory, its only when its been fiddled with and somebody has lost the spacer that it can happen Thumbs Up!

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Marks DTM Calib

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Re: brake pedal seems stiff after replacing plenum
Reply #9 - 17. Mar 2011 at 14:25

Mr Stud wrote on 17. Mar 2011 at 12:58:

henryd wrote on 17. Mar 2011 at 12:52:

sounds like you may have an air leak betwwen plenum and servo,check all the connections and that the pipe hasn't rubbed through where it passes the aircon pipe.Is the car running ok,idle speed correct etc?

the car running fine,and idling ok...what the four black pipes on top plenum as around there seems loud like it sucking air,and which way round do the two little ones go

Jimbob wrote on 17. Mar 2011 at 12:53:

assuimng you have removed and replaced the main vac pipe from plenum to brake servo.....maybe this wasnt fully sealed before, and now youve restored the vacuum?

which ones that the one that screws into side of plenum?

This is a concern, there should be some vac noise around the centre of the plenum but, anything excessive at the rear is wrong (and would explain the issue).

Check the 4 pipes at the rear are connected correctly (there is details in the breather guide) and if ok, examine the pipes etc for damage.

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Mr Stud Junior Member Offline Posts: 125 somerset Gender: Drives: vectra gsi...MV6 Manual :-)	Re: brake pedal seems stiff after replacing plenum Reply #10 - 17. Mar 2011 at 14:35 thanks,looked at guide,will have a look,as said will strip it down and start again so looking at a pipe somewhere then.. ...if no go,got a big box of matches
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MutantCav

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Re: brake pedal seems stiff after replacing plenum
Reply #11 - 17. Mar 2011 at 15:34

Its possible the plenum hasnt reseated quite right, maybe one of the o-rings has jammed out of position allowing air to get in...as for the 4 pipes, the left hand of the middle 2 pipes runs to the furthest left of the 2 things they plug into...right to the one on the right...make sense?? I have a decent proper servo hose if you want one??

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Mr Stud

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Re: brake pedal seems stiff after replacing plenum
Reply #12 - 17. Mar 2011 at 17:27

MutantCav wrote on 17. Mar 2011 at 15:34:

Its possible the plenum hasnt reseated quite right, maybe one of the o-rings has jammed out of position allowing air to get in...as for the 4 pipes, the left hand of the middle 2 pipes runs to the furthest left of the 2 things they plug into...right to the one on the right...make sense?? I have a decent proper servo hose if you want one??

yeh makes sense...

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Mr Stud

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Re: brake pedal seems stiff after replacing plenum
Reply #13 - 25. Mar 2011 at 23:05

finally got down to the garage today and had a look...took the top off and checked pipe work and noticed the pipe from servo to plenum got a hole in it...so got another piece of pipe to go on for now and hopefully will be problem solved....trouble is, car now in bits and someone wants to come look at it....typical...

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Mr Stud Junior Member Offline Posts: 125 somerset Gender: Drives: vectra gsi...MV6 Manual :-)	Re: brake pedal seems stiff after replacing plenum Reply #14 - 26. Mar 2011 at 18:13 now have brakes back,hooray,..now to get rid of it....
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