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

Vacuum Booster (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 connector from brake fluid level sensor.
  4. Release the forward light harness retainer from the ABS modulator bracket or proportioning valve bracket, to allow the underhood electrical center to be repositioned adequately.
  5. Remove underhood electrical center bracket from the vehicle and reposition the electrical center to access the brake master cylinder and brake booster.
  6. Release wiring harness retainers above the brake booster, to allow the electrical center to be repositioned adequately.
  7. Release wiring harness retainer from the side of the left strut tower. Reposition harness upward to allow clearance for booster removal.
  8. Release brake master cylinder pipes from the 6-position pipe clip along the frame rail.
  9. Disconnect brake pipes from master cylinder.
  10. Cap the open brake pipe fitting ends to prevent brake fluid loss and contamination.
  11. Remove brake master cylinder auxiliary reservoir mounting bolts.
  12. Remove master cylinder mounting nuts.
  13. Remove master cylinder and auxiliary reservoir, as an assembly, from vacuum brake booster.
  14. Inspect master cylinder-to-vacuum brake booster seal for damage. Replace seal, if necessary.
  15. Disconnect electrical connector from the Park/Neutral position switch, and reposition wiring harness toward engine.
  16. Disconnect vacuum check valve from brake booster and position aside check valve and vacuum hose.
  17. Disconnect the EVAP purge hose from the purge solenoid. Reposition purge hose toward the engine.
  18. Position the underhood electrical center further toward the left hood hinge and secure the center in place.
  19. Install engine support fixture.
  20. Raise and support vehicle.
  21. Remove through-bolt from the front transmission mount.
  22. Remove through-bolt and heat shield from the rear transmission mount.
  23. Lower vehicle. Leave vehicle positioned on the hoist.
  24. Remove transmission side mount-to-transmission bolts.
  25. Using the engine support fixture, slowly lower the transmission about 1" (25 mm).
  26. Position the master cylinder pipes rearward and outboard, behind the wiring harness along the strut tower.
  27. Remove accelerator pedal mounting nuts. Reposition the accelerator pedal to improve tool access to the left lower booster mounting nut.
  28. Loosen brake booster mounting nuts.
  29. Remove retaining clip and washer from brake pedal.
  30. Release brake booster push rod from the brake pedal.
  31. Remove brake booster mounting nuts.
    32. NOTE: Use care to ensure that no oil or contaminants enter the vacuum brake booster through the master cylinder opening. Cover opening on the booster, if possible.
  32. Pull brake booster away from firewall, enough to clear the booster studs.
  33. With the booster directed toward the coolant surge tank, continue to remove the booster until the push rod is just free of the opening in the firewall.
  34. Turn the booster to face the left strut tower.
  35. Ensure that rear of booster shell is clear of the valve body cover on top of the transmission.
  36. Rotate booster, while it remains sideways to the firewall, and carefully remove the booster up and out from between the cowl and the transmission. If necessary, lower transmission slightly to aid with booster removal.
  37. Remove brake booster and booster mounting gasket from vehicle.
  38. Inspect mounting gasket for damage and replace if necessary.
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