Vacuum Brake Booster: Service and Repair

Power Vacuum Brake Booster Replacement

Removal Procedure

Warning:
Refer to Brake Fluid Irritant Warning Brake Fluid Irritant Warning.


Caution:
Refer to Brake Fluid Effects on Paint and Electrical Components Caution Brake Fluid Effects on Paint and Electrical Components Caution.

1. Remove the underhood electrical center. Refer to Underhood Electrical Center or Junction Block Replacement Underhood Electrical Center or Junction Block Replacement.

2. Without draining the engine coolant or removing the hoses, remove and position aside the surge tank. Refer to Radiator Surge Tank Replacement Radiator Surge Tank Replacement.

3. Disconnect the power brake booster vacuum check valve and hose from the vacuum brake booster and position aside. Refer to Power Brake Booster Vacuum Check Valve and Hose Replacement (2.4L) Power Brake Booster Vacuum Check Valve and Hose Replacement (2.4L)Power Brake Booster Vacuum Check Valve and Hose Replacement (3.0L) Power Brake Booster Vacuum Check Valve and Hose Replacement (3.0L).

4. Remove the master cylinder. Refer to Master Cylinder Replacement Removal and Replacement.

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





6. Remove the driver knee bolster. Refer to Driver Knee Bolster Replacement Service and Repair.

7. Remove the power vacuum brake booster pushrod retainer (1).

8. Disconnect the power vacuum brake booster pushrod from the brake pedal.





9. Remove the vacuum brake booster nuts (1).





10. Carefully pull the power vacuum brake booster forward until the mounting studs clear the dash panel.

Note:
Ensure the foam insulator on the mounting surface of the power vacuum brake booster withdraws with the booster.

11. Remove the vacuum brake booster (1).





12. Inspect the power vacuum brake booster gasket (1) for damage and replace if necessary.

Installation Procedure





1. Install the power vacuum brake booster gasket (1).





Note:
Ensure the foam insulator on the mounting surface of the power vacuum brake booster is properly installed on the booster.

2. While guiding the power vacuum brake booster pushrod and mounting studs through the dash panel, install the power vacuum brake booster (1).





Caution:
Refer to Fastener Caution Fastener Caution.

3. Install the power vacuum brake booster nuts (1) and tighten to 25 Nm (18 lb ft).





4. Connect the power vacuum brake booster pushrod to the brake pedal.

5. Install the power vacuum brake booster pushrod retainer (1).

6. Rotate the power vacuum brake booster pushrod retainer 360 degrees to ensure it is properly installed.

7. Install the driver knee bolster. Refer to Driver Knee Bolster Replacement Service and Repair.

8. Install the BPMV. Refer to Brake Pressure Modulator Valve Assembly Replacement Brake Pressure Modulator Valve Assembly Replacement.

9. Install the master cylinder. Refer to Master Cylinder Replacement Removal and Replacement.





10. Connect the power vacuum brake booster vacuum check valve and hose to the vacuum brake booster. Refer to Power Brake Booster Vacuum Check Valve and Hose Replacement (2.4L) Power Brake Booster Vacuum Check Valve and Hose Replacement (2.4L)Power Brake Booster Vacuum Check Valve and Hose Replacement (3.0L) Power Brake Booster Vacuum Check Valve and Hose Replacement (3.0L).

11. Install the surge tank. Refer to Radiator Surge Tank Replacement Radiator Surge Tank Replacement.

12. Install the underhood electrical center. Refer to Underhood Electrical Center or Junction Block Replacement Underhood Electrical Center or Junction Block Replacement.