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Removal (3.1L)

WARNING: This page is about a different car, the 2003 Buick Regal, 2003 Buick Century, 2002 Buick Regal, and 2002 Buick Century. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the left instrument panel insulator. Disconnect the stoplight switch electrical connector from the stoplight switch. Remove the retaining clip and disconnect the brake booster pushrod from the brake pedal.
  2. Partially drain the cooling system.
  3. Remove the strut tower brace.
    • Remove nuts from the strut tower brace.
      • NOTE: The stud plates will fall out and possibly get caught under the vehicle, a helper should hold the stud plates during removal.
    • Remove the cross vehicle brace from vehicle.
    • Remove the stud plates push on nuts.
    • Remove the stud plates from the vehicle.
  4. Remove the air cleaner inlet duct.
    • Loosen the air cleaner intake duct clamps. Remove the PCV tube from the air cleaner intake duct.
    • Disconnect the Intake Air Temperature (IAT) sensor electrical connector.
    • Remove the air cleaner intake duct from the air cleaner assembly and the throttle body.
  5. Relieve the fuel system pressure.
    • Disconnect negative battery cable. Install the fuel pressure gage fitting to the fuel pressure connection.
    • Connect the fuel pressure gage fitting. Wrap a shop towel around the fuel pressure connection while connecting the pressure gage, to prevent spillage.
    • 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. Drain any fuel remaining in the fuel pressure gage into an approved container.
  6. Disconnect the EVAP canister purge valve pipe, the fuel feed pipe and return pipe. Position them to the side.
  7. Disconnect the coolant outlet (2) and inlet (3) bypass hoses and position them aside. Remove the heater inlet pipe. See Fig 1 .
  8. Rotate the engine forward for service access.
    • Remove the air cleaner intake duct. Apply the parking brake. Put the transaxle in the Neutral position. Remove the engine mount strut bolts. Swing the engine mount struts aside.
    • Install the engine mount strap.
    • Rotate the engine forward for component access.
  9. Disconnect the brake fluid level sensor electrical connector from the brake fluid level sensor.
    10. NOTE: It is not necessary to disconnect the brake pipes from the master cylinder to the Brake Pressure Modulator Valve (BPMV).
  10. Remove the 2 master cylinder retaining nuts and position the master cylinder aside. Disconnect the vacuum brake booster check valve from the brake booster. Position aside the vacuum hose with the check valve as an assembly. Attach the Power Brake Booster Holder (J-22805-B) to the booster using the master cylinder retaining nuts.
  11. Unlock the booster from the cowl. Use a flat bladed tool to depress the brake booster locking tab (1) out of the cowl mounting flange, while turning the booster counterclockwise with a ratchet on the Power Brake Booster Holder (2). Remove the vacuum brake booster.
Fig 1: Disconnecting Coolant Outlet
G00284612Courtesy of GENERAL MOTORS CORP.
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