Astra 1.7 Diesel Major Brake Problem !?

Question:
S Reg astra Diesel brake pedal is very hard but the car still stop`s with a little bit more pressure on the pedal , here is the work i have done so far ( i am a fully qualified mechanic NVQ Level 3 for 10 year`s )
This is the low blow engine and i have Changed :
Servo
Master Cylinder
Brake disc`s
Brake pad`s
Brake fluid
Caliper`s and slave cylinder`s are not siezed .
Rear shoe`s are ok , drum`s are ok .
Brake pump has plenty of suction when the vacume pipe is removed .
This is the NONE ABS Model .
Renewed the pipe from the servo to the pump .
Everything is as it should be But The pedal still remains Very Hard .
The servo is in working order as it has been tested and there is good pressure when i have bled the brake system ?
ANY Help would be Welcome , Please no suggestion`s about taking it to a "proper" garage , i worked in a vauxhall dealership for 8 years but this has puzzled fitter`s who have over 80 years experience between them .

Answers:

What is Air Suspension Mechanism used in Automobiles?

Have your hoses started to break-up inside? I have seen hoses only a couple of years old that have started to collapse inside and the little tears in the walls of the hoses act like one-way valves, and I have experience of the hydraulic pressure from the master cylinder staying applied to the calipers and cylinders because the hoses won't allow the fluid to return to the master cylinder.

My car makes a ticking noise when I accelerate(like a baseball card stuck in a bicycle) what could that be?


By the way, plurals don't need apostrophes (fitters, drums, brakes etc.). An apostrophe denotes the possessive pronoun (the fitter's spanner)

Puddle under car... Help?

is tha vacume pump working?
if it is not the brake booster will not be working properly

Hard Starting / Cold weather starting problem?

is there a way to adjust the pedal for different pressures to where you apply the brakes according to how hard or soft you touch the brake pedal? and is that car from a different country? Sounds wierd but cool at the same time. Good luck :)

Ignition Problems on a VW Polo?

the vaccum -brake booster is damage.(it is not working)
since You are a mechanic and You are in a difficult task

Is there a difference between the fuel injection cleaner I can buy at the store vs. what my auto shop uses?


I would like to know the end of the problem.
please pass it on.
that gonna hit me in the future.

Where is hearter control valve on 1990 Ford Aerostar?

have you tried the turbo in mine (the 1.7tdi) the turbo and the braking system are linked i think by the servo hope its of help

Does a clutch need freeplay?

pump on the back of the alternator must be at fault,, you've done everything else

car mileage?

low blow engine is uprated opel engine as you have replaced almost everything by a process of elimination i would suggest changing the vac pump also make sure no one has fitted a smaller than std bore master cylinder
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