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Power Brake Booster: Removal

WARNING: This page is about a different car, the 2002 Pontiac Grand Prix and 2002 Oldsmobile Intrigue. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect negative battery cable.
  2. Remove left instrument panel insulator retainers, using door trim pad clip remover to remove clips. Disconnect courtesy lamp from I/P insulator. Remove I/P insulator from stud at accelerator pedal, and remove I/P insulator.
  3. Remove retaining clip, and disconnect brake booster pushrod from brake pedal.
    WARNING: With a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil instantaneously with explosive force. This will cause the solution to spew out over the engine, the fenders, and the person removing the cap. Serious bodily injury may result.
  4. Park the vehicle on a level surface. Remove the coolant pressure cap. Raise and support the vehicle. Place a drain pan under the drain cock. Open the radiator drain cock. Partially drain the cooling system.
  5. Remove the 2 fuel injector sight shield nuts at the front of the fuel injector sight shield. See Fig 1 . Lift the fuel injector sight shield up at the front and slide out of the engine bracket.
    WARNING: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete.
    Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.
  6. Turn the ignition off. Disconnect the negative battery cable in order to avoid possible fuel discharge if an accidental attempt is made to start the engine. Connect the fuel pressure gauge to the fuel pressure valve. Wrap a shop towel around the fitting while connecting the gauge in order to avoid spillage. Install the bleed hose into an approved container. Open the valve in order to bleed the system pressure. The fuel connections are now safe for servicing. Drain any fuel remaining in the gauge into an approved container.
  7. Disconnect the EVAP canister purge valve pipe, the fuel feed and return pipe. Position the pipes aside.
  8. Disconnect the vacuum hose and the booster check valve from the brake booster.
  9. Remove the master cylinder. See MASTER CYLINDER  .
  10. Remove the Brake Pressure Modulator Valve (BPMV) and the brake master cylinder from the vehicle as an assembly. It is not necessary to disconnect the master cylinder from the BPMV. See BRAKE PRESSURE MODULATOR VALVE under appropriate ANTI-LOCK article.
  11. Remove the BPMV bracket.
  12. Remove the EGR valve. Refer to the following procedures:
    • For Oldsmobile Intrigue models, see EGR VALVE in EMISSION SYSTEM & SUB-SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - AURORA & INTRIGUE article in ENGINE PERFORMANCE.
    • For Pontiac Grand Prix models, see EGR VALVE in EMISSION SYSTEM & SUB-SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - CENTURY, GRAND PRIX, IMPALA, MONTE CARLO & REGAL article in ENGINE PERFORMANCE.
  13. Disconnect the coolant bypass hose.
  14. Position the hose aside.
  15. Attach the power brake booster holder to the power brake booster using the master cylinder mounting nuts.
  16. Unlock the power brake booster from the cowl. Use a flat bladed tool to depress the brake booster locking tab out of the cowl mounting flange while turning the booster counterclockwise with a ratchet on the power brake booster holder.
  17. Remove the power brake booster.
Fig 1: Identifying Fuel Injector Sight Shield
G00310765Courtesy of GENERAL MOTORS CORP.
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