2004 Vauxhall Astra Hatchback Fourth generation facelift (MK4) Brake System Specifications

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Condition Value
expand_moreFront axle brake disc diameter
expand_more1.8 16V Dualfuel with gasoline straight-4 1.8 L 117 HP engine (2002.9–2005.5)
With ABS 11.02 in
Without ABS 10.08 in
expand_more1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.9–2005.5)
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 (1998.2–2005.5) 11.02 in
expand_more2.0 DI with diesel straight-4 2.0 L 80 HP engine (1998.2–2005.5)
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 (1999.8–2005.5)
With ABS 11.02 in
Without ABS 10.08 in
2.0 SRI Turbo with gasoline straight-4 2.0 L 189 HP engine (2001.11–2005.5) 1.01 ft
2.2 16V with gasoline straight-4 2.2 L 145 HP engine (2001.3–2005.5) 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 (2000.9–2005.5)
Internally ventilated brake discs 0.94 in
Otherwise 0.43 in
expand_more1.8 16V Dualfuel with gasoline straight-4 1.8 L 117 HP engine (2002.9–2005.5)
With ABS 0.98 in
Without ABS 0.94 in
expand_more1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.9–2005.5)
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 (1998.2–2005.5) 0.98 in
expand_more2.0 DI with diesel straight-4 2.0 L 80 HP engine (1998.2–2005.5)
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 (1999.8–2005.5)
With ABS 0.98 in
Without ABS 0.94 in
2.0 SRI Turbo with gasoline straight-4 2.0 L 189 HP engine (2001.11–2005.5) 0.98 in
2.2 16V with gasoline straight-4 2.2 L 145 HP engine (2001.3–2005.5) 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 (2000.9–2005.5)
Internally ventilated brake discs 0.83 in
Otherwise 0.31 in
expand_more1.8 16V Dualfuel with gasoline straight-4 1.8 L 117 HP engine (2002.9–2005.5)
With ABS 0.87 in
Without ABS 0.83 in
expand_more1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.9–2005.5)
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 (1998.2–2005.5) 0.87 in
expand_more2.0 DI with diesel straight-4 2.0 L 80 HP engine (1998.2–2005.5)
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 (1999.8–2005.5)
With ABS 0.87 in
Without ABS 0.83 in
2.0 SRI Turbo with gasoline straight-4 2.0 L 189 HP engine (2001.11–2005.5) 0.87 in
2.2 16V with gasoline straight-4 2.2 L 145 HP engine (2001.3–2005.5) 0.87 in
All other modifications 0.83 in
expand_moreFront axle brake lining thickness
expand_more1.8 16V Dualfuel with gasoline straight-4 1.8 L 117 HP engine (2002.9–2005.5)
expand_moreWith ABS
Without backing plate 0.55 in
expand_moreWithout ABS
Without backing plate 0.47 in
expand_more1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.9–2005.5)
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 (1998.2–2005.5)
With backing plate 0.55 in
expand_more2.0 DI with diesel straight-4 2.0 L 80 HP engine (1998.2–2005.5)
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 (1999.8–2005.5)
expand_moreWith ABS
Without backing plate 0.55 in
expand_moreWithout ABS
Without backing plate 0.47 in
expand_more2.0 SRI Turbo with gasoline straight-4 2.0 L 189 HP engine (2001.11–2005.5)
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 (2000.9–2005.5)
Internally ventilated brake discs 2.05 in
Otherwise 1.89 in
expand_more1.8 16V Dualfuel with gasoline straight-4 1.8 L 117 HP engine (2002.9–2005.5)
With ABS 2.24 in
Without ABS 2.05 in
expand_more1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.9–2005.5)
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 (1998.2–2005.5) 2.24 in
expand_more2.0 DI with diesel straight-4 2.0 L 80 HP engine (1998.2–2005.5)
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 (1999.8–2005.5)
With ABS 2.24 in
Without ABS 2.05 in
2.0 SRI Turbo with gasoline straight-4 2.0 L 189 HP engine (2001.11–2005.5) 2.24 in
2.2 16V with gasoline straight-4 2.2 L 145 HP engine (2001.3–2005.5) 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
Maximum rear axle brake drum adjustment dimension 9.09 in
expand_moreRear axle brake disc diameter
2.0 16V with gasoline straight-4 2.0 L 134 HP at 5600 RPM, 185 N⋅m at 4000 RPM engine (1998.2–2005.5) 10.39 in
2.0 SRI Turbo with gasoline straight-4 2.0 L 189 HP engine (2001.11–2005.5) 10.39 in
2.2 16V with gasoline straight-4 2.2 L 145 HP engine (2001.3–2005.5) 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
Rear axle brake drum diameter 9.06 in
expand_moreRear axle brake lining thickness
expand_more1.7 CDTI 16V with diesel straight-4 1.7 L 79 HP at 4400 RPM, 170 N⋅m at 1800 RPM engine (2003.4–2005.5)
expand_moreWith drum brake
Without backing plate 0.2 in
expand_more1.7 DTI 16V with diesel straight-4 1.7 L 74 HP at 4400 RPM, 165 N⋅m at 1800 RPM engine (2000.2–2005.5)
expand_moreWith drum brake
Without backing plate 0.2 in
expand_more1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.9–2005.5)
Without backing plate 0.41 in
expand_more2.0 16V with gasoline straight-4 2.0 L 134 HP at 5600 RPM, 185 N⋅m at 4000 RPM engine (1998.2–2005.5)
Without backing plate 0.41 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 (1999.8–2005.5)
Without backing plate 0.41 in
expand_more2.0 SRI Turbo with gasoline straight-4 2.0 L 189 HP engine (2001.11–2005.5)
Without backing plate 0.41 in
expand_moreAll other modifications
expand_moreWithout backing plate
Disc brake 0.41 in
Drum brake 0.2 in
expand_moreRear axle minimal brake lining thickness
expand_more1.7 CDTI 16V with diesel straight-4 1.7 L 79 HP at 4400 RPM, 170 N⋅m at 1800 RPM engine (2003.4–2005.5)
expand_moreWith drum brake
Without backing plate 0.039 in
expand_moreWithout backing plate
Disc brake 0.079 in
expand_more1.7 DTI 16V with diesel straight-4 1.7 L 74 HP at 4400 RPM, 165 N⋅m at 1800 RPM engine (2000.2–2005.5)
expand_moreWith drum brake
Without backing plate 0.039 in
expand_moreWithout backing plate
Disc brake 0.079 in
expand_more1.8 16V with gasoline straight-4 1.8 L 123 HP engine (2000.9–2005.5)
Without backing plate 0.079 in
expand_more2.0 16V with gasoline straight-4 2.0 L 134 HP at 5600 RPM, 185 N⋅m at 4000 RPM engine (1998.2–2005.5)
Without backing plate 0.079 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 (1999.8–2005.5)
Without backing plate 0.079 in
expand_more2.0 SRI Turbo with gasoline straight-4 2.0 L 189 HP engine (2001.11–2005.5)
Without backing plate 0.079 in
expand_moreAll other modifications
expand_moreWithout backing plate
Disc brake 0.079 in
Drum brake 0.039 in
expand_moreRear axle brake piston diameter
2.0 16V with gasoline straight-4 2.0 L 134 HP at 5600 RPM, 185 N⋅m at 4000 RPM engine (1998.2–2005.5) 1.42 in
2.0 SRI Turbo with gasoline straight-4 2.0 L 189 HP engine (2001.11–2005.5) 1.42 in
2.2 16V with gasoline straight-4 2.2 L 145 HP engine (2001.3–2005.5) 1.42 in
All other modifications 1.34 in
expand_moreWheel brake cylinder diameter
1.7 CDTI 16V with diesel straight-4 1.7 L 79 HP at 4400 RPM, 170 N⋅m at 1800 RPM engine (2003.4–2005.5) 0.75 in
1.7 DTI 16V with diesel straight-4 1.7 L 74 HP at 4400 RPM, 165 N⋅m at 1800 RPM engine (2000.2–2005.5) 0.75 in
All other modifications 0.81 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 Vauxhall.

Please be noted that all capacities listed here are approximate. Check fluid levels when adding or refilling as recommended in your 2004 Vauxhall 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 Vauxhall 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 Vauxhall 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 Vauxhall Astra Hatchback you're not only saving money, but also also improving your technical skills and learning something new.

2004 Vauxhall Astra Hatchback generations

In 2004 Vauxhall 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.

Fifth generation (MK5)

Delta Platform

Vauxhall Astra Hatchback Fourth generation facelift (MK4) model years

Units:
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