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Power Vacuum Brake Booster Replacement

Power Vacuum Brake Booster Replacement

Removal Procedure


1. Remove the left side instrument panel insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side .

2. Disconnect the brake pedal position sensor electrical connector.

3.
Note

Do not reuse the power vacuum brake booster pushrod retainer.


Release the power vacuum brake booster pushrod retainer (1) from the brake pedal arm by pulling the brake pedal rearward.


4. Discard the power vacuum brake booster pushrod retainer.

5. Disconnect the brake fluid level indicator switch electrical connector.


6. Remove the master cylinder (1) and the master cylinder O-ring seal (2). Refer to Master Cylinder Replacement .

7. Disconnect the power brake booster vacuum sensor (1) electrical connector.


8. Remove the power brake booster vacuum sensor and hose assembly and position aside.

9. Remove the brake pressure modulator valve (BPMV) assembly. Refer to Brake Pressure Modulator Valve Replacement .

10.
Note

The power vacuum brake booster bolts are captured and withdraw with the power vacuum brake booster assembly.


Completely loosen the power vacuum brake booster bolts (1).


11. Remove the power vacuum brake booster.

12. Inspect the power vacuum brake booster gasket for damage. Replace it if necessary.


Installation Procedure


1. Position the power vacuum brake booster gasket to the power vacuum brake booster, if removed.


2. Install the power vacuum brake booster.

3. Refer to Fastener Caution .

Note

Do not over tighten the power vacuum brake booster bolts. If the power vacuum brake booster bolts are over tightened, the brake pedal may remain applied after a high pressure brake pedal application.


Tighten the power vacuum brake booster bolts (1) to 23 Nm (17 lb ft) .

4. Install the brake pressure modulator valve (BPMV) assembly. Refer to Brake Pressure Modulator Valve Replacement .

5.
Note

A small amount of denatured alcohol may be used to ease installation of the power brake booster vacuum sensor. Do not use soap.


Install the power brake booster vacuum sensor and hose assembly (1).


6. Connect the power brake booster vacuum sensor electrical connector.

7. Install the master cylinder (1) and master cylinder O-ring seal (2). Refer to Master Cylinder Replacement .


8. Connect the brake fluid level indicator switch electrical connector.

9.
Note

Install a new power vacuum brake booster pushrod retainer.


Install a new power vacuum brake booster pushrod retainer (1) to the power vacuum brake booster pushrod.


10.
Note

Ensure the power vacuum brake booster pushrod retainer is fully seated in the brake pedal arm.


Install the power vacuum brake booster pushrod and retainer to the brake pedal arm.

11. Connect the brake pedal position sensor electrical connector.

12. Calibrate the brake pedal position sensor. Refer to Brake Pedal Position Sensor Calibration .

13. Install the left side instrument panel insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side .