Vacuum Brake Booster: Service and Repair

Vacuum Brake Booster Replacement

Removal Procedure

1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (L36) in Engine Mechanical.
2. Remove the accelerator control cable and position the cable out of the way. Refer to Accelerator Controls Cable Replacement in Engine Controls.
3. Remove the accelerator control cable bracket and position the cables out of the way. Refer to Accelerator Controls Cable Replacement in Engine Controls.
4. Remove the cruise control module (1) and position out of the way. Refer to Cruise Control Module Replacement in Cruise Control.
5. Disconnect the electrical connector from the EGR valve (1).
6. Disconnect the engine harness clips (3).
7. Position the wiring harness (2) out of the way.
8. Disconnect the brake fluid level sensor wire connector (1).
9. Remove the master cylinder attaching nuts.
10. Remove the master cylinder from the vacuum brake booster. Carefully set the master cylinder aside.
11. Remove the vacuum brake booster check valve from the vacuum brake booster.
12. Remove the left insulator panel. Refer to Closeout/Insulator Panel Replacement - Left in Instrument Panel, Gages, and Console.
13. Remove the left knee bolster bracket. Refer to Bracket Replacement - knee Bolster in Instrument Panel, Gages, and Console.
14. Remove the steering column support mounting nuts. Refer to Steering Column Replacement in Steering Wheel and Column.
15. Lower the steering column and support the steering column with mechanical wire.
16. Disconnect the stop lamp/ABS/shift lock switch from the brake pedal assembly. Refer to Stop Lamp Switch Replacement in Lighting Systems.
17. Disconnect the TCC/cruise control release switch from the brake pedal assembly. Refer to Torque Converter Clutch/Cruise Control Release Switch Replacement in Automatic Transaxle-4T65-E.
18. Remove the vacuum brake booster pushrod retainer clip (3).
19. Remove the vacuum brake booster foam spacer (2).
20. Remove the vacuum brake booster pushrod (1) from the brake pedal.
21. Remove the vacuum booster attaching nuts (1) from the brake pedal assembly.
22. Remove the vacuum brake booster from the vehicle.
23. Remove the vacuum brake booster mounting gasket, if gasket replacement us necessary.

Installation Procedure

1. Install the vacuum brake booster mounting gasket to booster, if removed previously.
2. Install the booster to the vehicle.
3. Connect the vacuum brake booster pushrod (1) to the brake pedal clevis pin.
4. Connect the vacuum brake booster pushrod foam spacer (2) to the brake pedal clevis pin.
5. Install the vacuum brake booster pushrod retainer clip (3) to the brake pedal clevis pin.

Notice: Refer to Fastener Notice in Cautions and Notices.

6. Install the booster attaching nuts (1) onto the booster studs.
Tighten
Tighten the brake pedal to booster stud nuts to 23 N.m (17 lb ft).
7. Connect the TCC/cruise control release switch to the brake pedal assembly. Refer to Torque Converter Clutch/Cruise Control Release Switch Replacement in Automatic Transaxle - 4T65-E.
8. Connect the stop lamp/ABS/shift lock switch to the brake pedal assembly. Refer to Stop Lamp Switch Replacement in Lighting Systems.
9. Install the master cylinder onto the booster. Refer to Master Cylinder Replacement. Master Cylinder Replacement
10. Install the steering column. Refer to Steering Column Replacement in Steering Wheel and Column.
11. Install the left knee bolster bracket. Refer to Bracket Replacement - knee Bolster in Instrument Panel, Gages, and Console.
12. Install the left insulator panel. Refer to Closeout/Insulator Panel Replacement - Left in Instrument Panel, Gages, and Console.
13. Install the vacuum booster check valve to the vacuum booster.
14. Connect the brake fluid level sensor wire connector (1).
15. Connect the cruise control module (1). Refer to Cruise Control Module Replacement in Cruise Control.
16. Install the accelerator control cable bracket. Refer to Accelerator Controls Cable Replacement in Engine Controls.
17. Install the accelerator control cable. Refer to Accelerator Controls Cable Replacement in Engine Controls.
18. Connect the electrical connector to the EGR valve (1).
19. Connect the engine harness clips (3).
20. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (L36) in Engine Mechanical.