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Home >> Saturn >> 2006 >> Relay 3.5 L, FWD >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Hydraulic Brakes >> Repair Instructions >> Power Vacuum Brake Booster Replacement >> Installation Procedure

Installation Procedure

CAUTION: When replacing the power booster brake, make sure that the cruise control cable is not routed between the booster and the cowl. If the cable is damaged or pinched, it must be replaced. Failure to do this could result in personal injury.
    Fig 1: View Of Vacuum Brake Booster Components
    GM180993Courtesy of GENERAL MOTORS CORP.
  1. Position the brake booster to the cowl and the mounting plate.
    2. NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the brake booster mounting nuts.

    Tighten:  Tighten the brake booster mounting nuts to 25 N.m (18 lb ft).

  3. Install the master cylinder. Refer to Master Cylinder Replacement .
    4. Fig 2: Locating Brake Pedal Assembly Components
    GM180291Courtesy of GENERAL MOTORS CORP.
  4. Install the brake booster push rod (2) to the brake pedal (1). Install the washer and retaining clip.
    5. NOTE: Proper stoplamp switch adjustment is essential. Improper stoplamp switch adjustment may cause brake drag, heat buildup and excessive brake lining wear.
  5. Calibrate the brake pedal position sensor. Refer to Brake Pedal Position Sensor Calibration in Lighting Systems.
  6. Install the knee bolster. Refer to Knee Bolster, Insulator, Molding Replacement - Instrument Panel in Instrument Panel, Gages, and Console.
  7. Rotate the engine back and install the engine mounts, bolts, and nuts. Refer to Rotating the Engine for Service Access in Engine Mechanical - 3.5L.
    8. Fig 3: Locating Vacuum Hose From Vacuum Check Valve
    GM177473Courtesy of GENERAL MOTORS CORP.
  8. Install the brake booster vacuum hose to the vacuum brake booster check valve.
  9. Install the ABS module bracket and module. Refer to Brake Pressure Modulator Valve Replacement in Antilock Brake System.
  10. Install the brake master cylinder and connect the brake lines. Refer to Master Cylinder Replacement .
  11. Connect the fluid level sensor switch on the master cylinder.
  12. Install the fuel pipes to the pipes shock tower.
  13. Install the heater hose to the coolant cross over pipe. Refer to Heater Inlet Hose/Pipe and Heater Outlet Hose/Pipe Replacement in HVAC Systems - Manual.
  14. Install the air cleaner and duct. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls - 3.5L.
  15. Install the PCM. Refer to Powertrain Control Module Replacement in Engine Controls - 3.5L.
  16. Install the PCM cover.
  17. Install the left front cross brace. Refer to Front End Sheet Metal Diagonal Brace Replacement in Body Front End.
  18. Install the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.
  19. Fill and bleed the cooling system. Refer to Cooling System Draining and Filling (Static Fill LX9) or Cooling System Draining and Filling (Static Fill LZ9) or Cooling System Draining and Filling (Vac-N-Fill) in Engine Cooling.
  20. Bleed the brake system. Refer to Hydraulic Brake System Bleeding (Manual)  or Hydraulic Brake System Bleeding (Pressure) .
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