2004 Opel Astra Hatchback G facelift Brake System Specifications

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Condition Value
Rear axle first brake drum machining size 9.09 in
expand_moreFront axle brake disc diameter
expand_more1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.9–2005.1)
With ABS 11.02 in
Without ABS 10.08 in
2.0 16V with gasoline straight-4 2.0 L 134 HP at 5600 RPM, 185 N⋅m at 4000 RPM engine (1998.2–2005.1) 11.02 in
2.0 16V with gasoline straight-4 2.0 L 134 HP at 5600 RPM, 185 N⋅m at 4000 RPM engine (1998.2–2005.1) 11.02 in
expand_more2.0 DI with diesel straight-4 2.0 L 80 HP at 4300 RPM, 185 N⋅m at 1800 RPM engine (1998.2–2005.1)
With ABS 11.02 in
Without ABS 10.08 in
expand_more2.0 DTI 16V with diesel straight-4 2.0 L 99 HP at 4300 RPM, 205 N⋅m at 1600 RPM engine (1999.8–2005.1)
With ABS 11.02 in
Without ABS 10.08 in
2.0 OPC with gasoline straight-4 2.0 L 189 HP engine (2002.9–2005.1) 1.01 ft
2.0 OPC with gasoline straight-4 2.0 L 197 HP engine (2002.11–2005.1) 1.01 ft
2.2 16V with gasoline straight-4 2.2 L 145 HP at 5800 RPM, 203 N⋅m at 4000 RPM engine (2000.6–2005.1) 11.02 in
2.2 DTI with diesel straight-4 2.2 L 115 HP at 4000 RPM, 270 N⋅m at 1500 RPM engine (2002.9–2005.1) 11.02 in
2.2 DTI with diesel straight-4 2.2 L 123 HP engine (2002.9–2005.1) 11.02 in
All other modifications 10.08 in
expand_moreFront axle brake disc thickness
expand_more1.2 16V with gasoline straight-4 1.2 L 74 HP at 5600 RPM, 110 N⋅m at 4000 RPM engine (2000.9–2005.1)
Internally ventilated brake discs 0.94 in
Otherwise 0.43 in
expand_more1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.9–2005.1)
With ABS 0.98 in
Without ABS 0.94 in
2.0 16V with gasoline straight-4 2.0 L 134 HP at 5600 RPM, 185 N⋅m at 4000 RPM engine (1998.2–2005.1) 0.98 in
2.0 16V with gasoline straight-4 2.0 L 134 HP at 5600 RPM, 185 N⋅m at 4000 RPM engine (1998.2–2005.1) 0.98 in
expand_more2.0 DI with diesel straight-4 2.0 L 80 HP at 4300 RPM, 185 N⋅m at 1800 RPM engine (1998.2–2005.1)
With ABS 0.98 in
Without ABS 0.94 in
expand_more2.0 DTI 16V with diesel straight-4 2.0 L 99 HP at 4300 RPM, 205 N⋅m at 1600 RPM engine (1999.8–2005.1)
With ABS 0.98 in
Without ABS 0.94 in
2.0 OPC with gasoline straight-4 2.0 L 189 HP engine (2002.9–2005.1) 0.98 in
2.0 OPC with gasoline straight-4 2.0 L 197 HP engine (2002.11–2005.1) 0.98 in
2.2 16V with gasoline straight-4 2.2 L 145 HP at 5800 RPM, 203 N⋅m at 4000 RPM engine (2000.6–2005.1) 0.98 in
2.2 DTI with diesel straight-4 2.2 L 115 HP at 4000 RPM, 270 N⋅m at 1500 RPM engine (2002.9–2005.1) 0.98 in
2.2 DTI with diesel straight-4 2.2 L 123 HP engine (2002.9–2005.1) 0.98 in
All other modifications 0.94 in
expand_moreFront axle brake disc minimal thickness
expand_more1.2 16V with gasoline straight-4 1.2 L 74 HP at 5600 RPM, 110 N⋅m at 4000 RPM engine (2000.9–2005.1)
Internally ventilated brake discs 0.83 in
Otherwise 0.31 in
expand_more1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.9–2005.1)
With ABS 0.87 in
Without ABS 0.83 in
2.0 16V with gasoline straight-4 2.0 L 134 HP at 5600 RPM, 185 N⋅m at 4000 RPM engine (1998.2–2005.1) 0.87 in
2.0 16V with gasoline straight-4 2.0 L 134 HP at 5600 RPM, 185 N⋅m at 4000 RPM engine (1998.2–2005.1) 0.87 in
expand_more2.0 DI with diesel straight-4 2.0 L 80 HP at 4300 RPM, 185 N⋅m at 1800 RPM engine (1998.2–2005.1)
With ABS 0.87 in
Without ABS 0.83 in
expand_more2.0 DTI 16V with diesel straight-4 2.0 L 99 HP at 4300 RPM, 205 N⋅m at 1600 RPM engine (1999.8–2005.1)
With ABS 0.87 in
Without ABS 0.83 in
2.0 OPC with gasoline straight-4 2.0 L 189 HP engine (2002.9–2005.1) 0.87 in
2.0 OPC with gasoline straight-4 2.0 L 197 HP engine (2002.11–2005.1) 0.87 in
2.2 16V with gasoline straight-4 2.2 L 145 HP at 5800 RPM, 203 N⋅m at 4000 RPM engine (2000.6–2005.1) 0.87 in
2.2 DTI with diesel straight-4 2.2 L 115 HP at 4000 RPM, 270 N⋅m at 1500 RPM engine (2002.9–2005.1) 0.87 in
2.2 DTI with diesel straight-4 2.2 L 123 HP engine (2002.9–2005.1) 0.87 in
All other modifications 0.83 in
expand_moreFront axle brake lining thickness
expand_more1.6 16V with gasoline straight-4 1.6 L 99 HP at 5800 RPM, 135 N⋅m at 3400 RPM engine (1998.2–2005.1)
Without backing plate 0.47 in
expand_more1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.9–2005.1)
expand_moreWith ABS
Without backing plate 0.55 in
expand_moreWithout ABS
Without backing plate 0.47 in
expand_more2.0 16V with gasoline straight-4 2.0 L 134 HP at 5600 RPM, 185 N⋅m at 4000 RPM engine (1998.2–2005.1)
With backing plate 0.55 in
expand_more2.0 DI with diesel straight-4 2.0 L 80 HP at 4300 RPM, 185 N⋅m at 1800 RPM engine (1998.2–2005.1)
expand_moreWith ABS
Without backing plate 0.55 in
expand_moreWithout ABS
Without backing plate 0.47 in
expand_more2.0 DTI 16V with diesel straight-4 2.0 L 99 HP at 4300 RPM, 205 N⋅m at 1600 RPM engine (1999.8–2005.1)
expand_moreWith ABS
Without backing plate 0.55 in
expand_moreWithout ABS
Without backing plate 0.47 in
expand_more2.0 OPC with gasoline straight-4 2.0 L 189 HP engine (2002.9–2005.1)
With backing plate 0.55 in
expand_more2.2 16V with gasoline straight-4 2.2 L 145 HP at 5800 RPM, 203 N⋅m at 4000 RPM engine (2000.6–2005.1)
With backing plate 0.55 in
expand_moreAll other modifications
expand_moreWithout backing plate
Disc brake 0.41 in
Otherwise 0.47 in
expand_moreFront axle brake lining minimal thickness
Without backing plate 0.079 in
expand_moreFront axle brake piston diameter
expand_more1.2 16V with gasoline straight-4 1.2 L 74 HP at 5600 RPM, 110 N⋅m at 4000 RPM engine (2000.9–2005.1)
Internally ventilated brake discs 2.05 in
Otherwise 1.89 in
expand_more1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.9–2005.1)
With ABS 2.24 in
Without ABS 2.05 in
2.0 16V with gasoline straight-4 2.0 L 134 HP at 5600 RPM, 185 N⋅m at 4000 RPM engine (1998.2–2005.1) 2.24 in
2.0 16V with gasoline straight-4 2.0 L 134 HP at 5600 RPM, 185 N⋅m at 4000 RPM engine (1998.2–2005.1) 2.24 in
expand_more2.0 DI with diesel straight-4 2.0 L 80 HP at 4300 RPM, 185 N⋅m at 1800 RPM engine (1998.2–2005.1)
With ABS 2.24 in
Without ABS 2.05 in
expand_more2.0 DTI 16V with diesel straight-4 2.0 L 99 HP at 4300 RPM, 205 N⋅m at 1600 RPM engine (1999.8–2005.1)
With ABS 2.24 in
Without ABS 2.05 in
2.0 OPC with gasoline straight-4 2.0 L 189 HP engine (2002.9–2005.1) 2.24 in
2.0 OPC with gasoline straight-4 2.0 L 197 HP engine (2002.11–2005.1) 2.24 in
2.2 16V with gasoline straight-4 2.2 L 145 HP at 5800 RPM, 203 N⋅m at 4000 RPM engine (2000.6–2005.1) 2.24 in
2.2 DTI with diesel straight-4 2.2 L 115 HP at 4000 RPM, 270 N⋅m at 1500 RPM engine (2002.9–2005.1) 2.24 in
2.2 DTI with diesel straight-4 2.2 L 123 HP engine (2002.9–2005.1) 2.24 in
All other modifications 2.05 in
Maximum lateral run-out of front axle brake disc 0.0043 in
Maximum lateral run-out of rear axle brake disc 0.0051 in
expand_moreMaximum rear axle brake drum adjustment dimension
1.2 16V with gasoline straight-4 1.2 L 74 HP at 5600 RPM, 110 N⋅m at 4000 RPM engine (2000.9–2005.1) 7.91 in
All other modifications 9.09 in
expand_moreRear axle brake disc diameter
expand_more1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.9–2005.1)
With ABS 10.39 in
Without ABS 9.45 in
2.0 16V with gasoline straight-4 2.0 L 134 HP at 5600 RPM, 185 N⋅m at 4000 RPM engine (1998.2–2005.1) 10.39 in
2.0 16V with gasoline straight-4 2.0 L 134 HP at 5600 RPM, 185 N⋅m at 4000 RPM engine (1998.2–2005.1) 10.39 in
expand_more2.0 DI with diesel straight-4 2.0 L 80 HP at 4300 RPM, 185 N⋅m at 1800 RPM engine (1998.2–2005.1)
With ABS 10.39 in
Without ABS 9.45 in
expand_more2.0 DTI 16V with diesel straight-4 2.0 L 99 HP at 4300 RPM, 205 N⋅m at 1600 RPM engine (1999.8–2005.1)
With ABS 10.39 in
Without ABS 9.45 in
2.0 OPC with gasoline straight-4 2.0 L 189 HP engine (2002.9–2005.1) 10.39 in
2.0 OPC with gasoline straight-4 2.0 L 197 HP engine (2002.11–2005.1) 10.39 in
2.2 16V with gasoline straight-4 2.2 L 145 HP at 5800 RPM, 203 N⋅m at 4000 RPM engine (2000.6–2005.1) 10.39 in
2.2 DTI with diesel straight-4 2.2 L 115 HP at 4000 RPM, 270 N⋅m at 1500 RPM engine (2002.9–2005.1) 10.39 in
2.2 DTI with diesel straight-4 2.2 L 123 HP engine (2002.9–2005.1) 10.39 in
All other modifications 9.45 in
Rear axle brake disc thickness 0.39 in
Rear axle minimal brake disc thickness 0.31 in
expand_moreRear axle brake drum diameter
1.2 16V with gasoline straight-4 1.2 L 74 HP at 5600 RPM, 110 N⋅m at 4000 RPM engine (2000.9–2005.1) 7.87 in
All other modifications 9.06 in
Rear axle brake drum diameter wear limit 9.09 in
expand_moreRear axle brake lining thickness
expand_more1.2 16V with gasoline straight-4 1.2 L 74 HP at 5600 RPM, 110 N⋅m at 4000 RPM engine (2000.9–2005.1)
expand_moreWith drum brake
Without backing plate 0.2 in
expand_more1.4 16V with gasoline straight-4 1.4 L 89 HP engine (1998.2–2005.1)
expand_moreWith drum brake
Without backing plate 0.2 in
expand_more1.6 16V with gasoline straight-4 1.6 L 99 HP at 5800 RPM, 135 N⋅m at 3400 RPM engine (1998.2–2005.1)
expand_moreWith disc brake
Without backing plate 0.41 in
expand_moreWith drum brake
Without backing plate 0.2 in
expand_more1.6 with gasoline straight-4 1.6 L 102 HP engine (2002.12–2009.12)
expand_moreWith drum brake
Without backing plate 0.2 in
expand_more1.7 CDTI with diesel straight-4 1.7 L 79 HP at 4400 RPM, 170 N⋅m at 1800 RPM engine (2003.4–2009.12)
expand_moreWith drum brake
Without backing plate 0.2 in
expand_moreAll other modifications
Without backing plate 0.41 in
expand_moreRear axle minimal brake lining thickness
expand_more1.2 16V with gasoline straight-4 1.2 L 74 HP at 5600 RPM, 110 N⋅m at 4000 RPM engine (2000.9–2005.1)
expand_moreWith drum brake
Without backing plate 0.039 in
expand_moreWithout backing plate
Disc brake 0.079 in
expand_more1.4 16V with gasoline straight-4 1.4 L 89 HP engine (1998.2–2005.1)
expand_moreWith drum brake
Without backing plate 0.039 in
expand_moreWithout backing plate
Disc brake 0.079 in
expand_more1.6 16V with gasoline straight-4 1.6 L 99 HP at 5800 RPM, 135 N⋅m at 3400 RPM engine (1998.2–2005.1)
expand_moreWith disc brake
Without backing plate 0.079 in
expand_moreWith drum brake
Without backing plate 0.039 in
expand_more1.6 with gasoline straight-4 1.6 L 102 HP engine (2002.12–2009.12)
expand_moreWith drum brake
Without backing plate 0.039 in
expand_moreWithout backing plate
Disc brake 0.079 in
expand_more1.7 CDTI with diesel straight-4 1.7 L 79 HP at 4400 RPM, 170 N⋅m at 1800 RPM engine (2003.4–2009.12)
expand_moreWith drum brake
Without backing plate 0.039 in
expand_moreWithout backing plate
Disc brake 0.079 in
expand_moreAll other modifications
Without backing plate 0.079 in
expand_moreRear axle brake piston diameter
expand_more1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.9–2005.1)
With ABS 1.42 in
Without ABS 1.34 in
2.0 16V with gasoline straight-4 2.0 L 134 HP at 5600 RPM, 185 N⋅m at 4000 RPM engine (1998.2–2005.1) 1.42 in
2.0 16V with gasoline straight-4 2.0 L 134 HP at 5600 RPM, 185 N⋅m at 4000 RPM engine (1998.2–2005.1) 1.42 in
expand_more2.0 DI with diesel straight-4 2.0 L 80 HP at 4300 RPM, 185 N⋅m at 1800 RPM engine (1998.2–2005.1)
With ABS 1.42 in
Without ABS 1.34 in
expand_more2.0 DTI 16V with diesel straight-4 2.0 L 99 HP at 4300 RPM, 205 N⋅m at 1600 RPM engine (1999.8–2005.1)
With ABS 1.42 in
Without ABS 1.34 in
2.0 OPC with gasoline straight-4 2.0 L 189 HP engine (2002.9–2005.1) 1.42 in
2.0 OPC with gasoline straight-4 2.0 L 197 HP engine (2002.11–2005.1) 1.42 in
2.2 16V with gasoline straight-4 2.2 L 145 HP at 5800 RPM, 203 N⋅m at 4000 RPM engine (2000.6–2005.1) 1.42 in
2.2 DTI with diesel straight-4 2.2 L 115 HP at 4000 RPM, 270 N⋅m at 1500 RPM engine (2002.9–2005.1) 1.42 in
2.2 DTI with diesel straight-4 2.2 L 123 HP engine (2002.9–2005.1) 1.42 in
All other modifications 1.34 in
Wheel brake cylinder diameter 0.75 in

Brake system is the most important system in your 2004 Astra Hatchback. Check pads and disks from time to time and replace them as they worn below minimum thickness allowed by Opel.

Please be noted that all capacities listed here are approximate. Check fluid levels when adding or refilling as recommended in your 2004 Opel Astra Hatchback user's manual. Keep in mind that all information here is provided “as is” without any warranty of any kind.

Before doing any DIY service please check your insurance policy and Opel warranty policy for your region. In some regions DIY service may invalidate your warranty.

Table of Contents

Conquer your fears and never give up!

DIY car service is not as difficult as it looks like and it might save you thousands of dollars per year. It might be even fun and a good thing to do with your kids on a weekend to teach them how basic machinery works. It's really hard to screw something up and damage your car permanently if you use right tools, follow Opel Astra Hatchback service manual and use right parts and fluids in prescribed amounts. Even modern cars stuffed with electronics can be serviced in your garage or even in your driveway. Changing engine oil, brake fluid, ATF, replacing brake pads, and etc. It's all may be done by yourself in a mater of a couple of hours.

Doing basic service for your 2004 Opel Astra Hatchback you're not only saving money, but also also improving your technical skills and learning something new.

2004 Opel Astra Hatchback generations

In 2004 Opel offered 2 generations of the Astra Hatchback. Brake system specifications may vary in different generations. Be sure that you are looking at the rigt modification.

H

Delta Platform

Opel Astra Hatchback G facelift model years

Units:
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