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Home >> Saturn >> 2003 >> Ion 1 Standard >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Disc Brakes & Drum Brakes >> Removal & Installation >> Vacuum Booster (Except Vehicles Equipped With CVT) >> Removal

Vacuum Booster (Except Vehicles Equipped With CVT): Removal

  1. Disconnect negative battery cable.
  2. Remove cover from underhood electrical center.
  3. Pull back on the Connector Position Assurance (CPA) tab of the electrical connector, then disconnect the connector from brake fluid level sensor.
  4. Remove underhood electrical center bracket from vehicle and reposition electrical center to access brake master cylinder and brake booster.
  5. Remove brake master cylinder auxiliary reservoir.
  6. Release brake master cylinder pipes from the 6-position pipe clip along the frame rail.
  7. Remove master cylinder mounting nuts.
  8. Remove master cylinder from vacuum brake booster. Carefully reposition master cylinder up and outboard, with brake pipes still attached. Secure master cylinder in position.
  9. Inspect master cylinder-to-vacuum brake booster seal for damage. Replace seal if necessary.
  10. Disconnect vacuum check valve from brake booster and position aside check valve and vacuum hose.
  11. Remove accelerator pedal mounting nuts. Reposition accelerator pedal to improve tool access to the lower left booster mounting nut.
  12. Loosen brake booster mounting nuts.
  13. Remove retaining clip and washer from brake pedal.
  14. Release brake booster push rod from brake pedal.
  15. Remove brake booster mounting nuts.
  16. Remove brake booster and booster mounting gasket from vehicle.
  17. Inspect mounting gasket for damage and replace if necessary.
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