Power Brake Booster: Removal
- Remove fuel injector sight shield. Remove the 2 fuel injector sight shield nuts at the front of the fuel injector sight shield. Lift the fuel injector sight shield up at the front and slide out of the engine bracket.
- Twist oil cap and filler tube counterclockwise to remove from valve cover. Lift sight shield up at front and slide tab out of engine bracket. Replace filler tube and oil cap when shield is removed.
- Remove the brake modulator. Depending on ABS application, see:
- DELCO VI
ANTI-LOCK/TCS - ABS-VI - Bosch 5.3
ANTI-LOCK - TCS - BOSCH 5.3
- DELCO VI
- To remove the transmission filler tube:
- Remove fluid level indicator.
- Raise and support vehicle.
- Remove front exhaust manifold pipe.
- Remove power steering gear heat shield.
- Remove bolt and screw from fluid filler tube. Remove tube. See Fig 1.
- Remove heat shield from EGR valve on the 3800 engine only. EGR is located on flywheel side of engine.
- Disconnect vacuum hose from brake booster.
- Disconnect brake booster push rod from brake pedal. See Fig 2.
- Attach Power Brake Booster Holder (J-22805-01), or equivalent, to brake booster. Tighten nuts to 20 ft. lbs. (27 N.m). See Fig 3 and Fig 4 .
- Unlock brake booster from front of dashboard. Use a flat-bladed tool to pry locking tab on booster out of locking notch on mounting flange. Simultaneously turn brake booster counter clockwise using a wrench on Special Tool J-22805-01 (or equivalent). See Fig 3 and Fig 4.
- Remove brake booster from vehicle.
NOTE:
When disconnecting the pushrod from the brake pedal, the brake pedal must be held stationary or damage to the brake switch may result.
NOTE:
Do not attempt to remove the booster until pushrod is disconnected from the brake pedal.