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Removal Procedure

WARNING: This page is about a different car, the 2006 Pontiac Montana SV6, 2006 Chevrolet Uplander, and 2006 Buick Terraza. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: Refer to Brake Fluid Irritant Caution in Cautions and Notices.
NOTE: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Cautions and Notices.
  1. Relieve fuel line pressure. Refer to Fuel Pressure Relief Procedure in Engine Controls - 3.5L.
  2. Drain the cooling system. Refer to Draining and Filling Cooling System (Static Fill) or Draining and Filling Cooling System (Vac-N-Fill) in Engine Cooling.
  3. Remove the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.
  4. Remove the left front cross brace. Refer to Brace Replacement - Sheet Metal Diagonal (Chevrolet) or Brace Replacement - Sheet Metal Diagonal (Pontiac) or Brace Replacement - Sheet Metal Diagonal (Buick) in Body Front End.
  5. Remove the powertrain control module (PCM) cover from the air cleaner housing.
  6. Remove the PCM and set aside. It is not necessary to disconnect the electrical connector. Refer to Powertrain Control Module (PCM) Replacement in Engine Controls - 3.5L.
  7. Remove the air cleaner and the duct. Refer to Air Cleaner Intake Duct Replacement in Engine Controls - 3.5L.
  8. Remove the fuel lines from the pipes and vapor line. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls - 3.5L.
  9. Remove the heater hose from the coolant cross over pipe and reposition out of the way. Refer to Heater Hose/Pipe Replacement - Inlet/Outlet in HVAC Systems - Manual.
  10. Unclip the fuel lines from the shock tower for easier access to the brake pipes.
  11. Disconnect the fluid level sensor switch from the brake master cylinder.
  12. Disconnect the brake lines from the master cylinder and remove the master cylinder. Refer to Master Cylinder Replacement .
  13. Remove the ABS module and bracket. Refer to Brake Pressure Modulator Valve (BPMV) Replacement in Antilock Brake System.
    14. Fig 1: Locating Vacuum Hose From Vacuum Check Valve
    GM177473Courtesy of GENERAL MOTORS CORP.
  14. Remove the brake booster vacuum hose from the vacuum brake booster check valve. Reposition the vacuum hose.
  15. Remove the knee bolster. Refer to Knee Bolster, Insulator, Molding Replacement - Instrument Panel in Instrument Panel, Gages and Console.
    16. Fig 2: Locating Brake Pedal Assembly Components
    GM180291Courtesy of GENERAL MOTORS CORP.
  16. Remove the booster push pin retaining clip and washer (2) from the brake pedal assembly.
  17. Remove the brake booster push rod (2) from the brake pedal (1).
    18. Fig 3: View Of Vacuum Brake Booster Components
    GM180993Courtesy of GENERAL MOTORS CORP.
  18. Remove the brake booster mounting nuts.
  19. Remove the 2 front engine mounts, nuts and bolts. Refer to Engine Mount Strut Replacement - Left and Engine Mount Strut Replacement - Right in Engine Mechanical - 3.5L.
  20. Rotate the engine forward to gain access to the brake booster removal. Refer to Rotating the Engine for Service Access in Engine Mechanical - 3.5L.
  21. Remove the brake booster.
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