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Power Brake Booster: Removal

WARNING: This page is about a different car, the 2002 Pontiac Montana, 2002 Oldsmobile Silhouette, and 2002 Chevrolet Venture. However, it is still accessible from the selected car via links, so may be relevant.
  1. Relieve the fuel line pressure:
    1. Disconnect the negative battery terminal. Remove the fuel pressure connection valve cap.
    2. Install the Fuel Pressure Gage Fitting (J-34730-262) to the fuel pressure connection. Install the fuel pressure gauge fitting above the belt in order to avoid contact with the belt.
    3. Connect the Fuel Pressure Gage (J-34730-1A) to the fuel pressure connection. Wrap a shop towel around the fuel pressure connection while connecting the fuel pressure gauge in order to avoid spillage.
    4. Install the bleed hose into an approved container and open the valve to bleed the system pressure. The fuel connections are now safe for servicing.
    5. Drain any fuel remaining in the fuel pressure gauge into an approved container. Remove the Fuel Pressure Gage and install the fuel pressure port cap.
  2. Drain cooling system.
  3. Remove the coolant reservoir.
    1. Reposition the reservoir hose clamp at the radiator overflow fitting using the Hose Clamp Pliers (J-38185).
    2. Remove the reservoir hose at the radiator overflow fitting.
    3. Remove the mounting clip to the reservoir. Remove the coolant reservoir.
  4. Remove Cruise control module and cruise control bracket and set aside.
    1. Remove the cruise control cable from the module. See Fig 1 .
    2. Disconnect the electrical connector. See Fig 2 .
    3. Remove the mounting bracket bolt from the cruise control module. Remove the cruise control module from the mounting bracket. See Fig 3 .
  5. Remove left front cross brace.
    1. Remove the windshield wiper system module cover.
    2. Remove the bolt from the rear hole in the front end sheet metal diagonal brace at the wheelhouse. Remove the bolts from the front of the front end sheet metal diagonal brace at the upper tie bar.
    3. Remove the front end sheet metal diagonal brace from the engine compartment.
  6. Remove the PCM cover from air cleaner housing. Remove the PCM and set aside. Not necessary to disconnect electrical.
  7. Remove the air cleaner and the duct.
  8. Remove the fuel lines from the pipes and vapor line.
  9. Remove the heater hose from the coolant cross over pipe and reposition to the side.
  10. Unclip Fuel lines from the shock tower for easier access to the brake pipes. Disconnect fluid level sensor switch from brake master cylinder.
  11. Disconnect brake lines from the master cylinder and remove master cylinder. See MASTER CYLINDER  .
  12. Unclip the wire harness from the ABS module bracket and disconnect the electrical connector at the ABS module. Remove the brake lines from the ABS module.
  13. Remove the ABS module and bracket.
  14. Remove the vacuum hose from the vacuum check valve. See Fig 4 .
  15. Remove the knee bolster. Remove the booster push pin retaining clip and washer from the brake pedal assembly. See Fig 5 . Remove the brake booster push rod from the brake pedal. See Fig 5 .
  16. Remove the brake booster mounting nuts.
  17. Remove the 2 front Engine mounts, nuts and bolts.
  18. Rotate the engine forward to gain access to the brake booster removal.
  19. Remove the brake booster.
Fig 1: Identifying Cruise Control Module
G00307617Courtesy of GENERAL MOTORS CORP.
Fig 2: Identifying Cruise Control Electrical Connector
G00307618Courtesy of GENERAL MOTORS CORP.
Fig 3: Removing/Installing Cruise Control Module From Mounting Bracket
G00307619Courtesy of GENERAL MOTORS CORP.
Fig 4: Identifying Vacuum Hose
G00307620Courtesy of GENERAL MOTORS CORP.
Fig 5: Identifying Booster Push Pin
G00307621Courtesy of GENERAL MOTORS CORP.
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