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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1109 (Hydraulic Brake System) >> Repair Instructions >> Vacuum Brake Booster Replacement (3.4L) >> Removal Procedure

Removal Procedure

WARNING: This page is about a different car, the 2004 Pontiac Aztek and 2004 Buick Rendezvous. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.
  2. Relieve fuel line pressure. Refer to Fuel Pressure Relief Procedure in Engine Controls - 3.4L.
  3. Remove the left front cross brace. Refer to Brace Replacement - Front Fender Upper Diagonal - Left in Body Front End.
  4. Remove the powertrain control module (PCM) cover from the air cleaner housing.
  5. Remove the PCM and set aside. It is not necessary to disconnect electrical. Refer to Powertrain Control Module (PCM) Replacement in Engine Controls - 3.4L.
  6. Remove the air cleaner and the duct. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.4L.
  7. Remove the fuel lines from the pipes and the vapor line. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls - 3.4L.
  8. Disconnect the fluid level sensor switch from the brake master cylinder.
  9. Disconnect the brake lines from the master cylinder and remove the master cylinder. Refer to Master Cylinder Replacement .
    10. Fig 1: Locating Vacuum Hose From Vacuum Check Valve
    GM177473Courtesy of GENERAL MOTORS CORP.
  10. Remove the vacuum hose from the vacuum check valve. Reposition the vacuum hose.
  11. Unclip the wire harness from the ABS module bracket and disconnect the electrical connector at the ABS module.
  12. Remove the brake lines from the ABS module.
  13. Remove the ABS module and bracket. Refer to Brake Pressure Modulator Valve (BPMV) Replacement in Antilock Brake System.
    14. Fig 2: Locating Brake Pedal Assembly Components
    GM180291Courtesy of GENERAL MOTORS CORP.
    NOTE: When disconnecting the pushrod from the brake pedal, the brake pedal must be held stationary or damage to the brake switch may result.
  14. Remove the booster push rod retaining clip and washer (2) from the brake pedal assembly.
  15. Remove the brake booster push rod (2) from the brake pedal (1).
    16. Fig 3: View Of Vacuum Brake Booster Components
    GM180993Courtesy of GENERAL MOTORS CORP.
  16. Remove the brake booster mounting nuts.
  17. Remove the brake booster.
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