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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 >> Removal Procedure

Removal Procedure

CAUTION: Refer to Brake Fluid Irritant Caution in Cautions and Notices.
NOTE: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in Cautions and Notices.
  1. Relieve fuel line pressure. Refer to Fuel Pressure Relief in Engine Controls - 3.5L.
  2. Drain 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.
  3. Remove the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.
  4. Remove the left front cross brace. Refer to Front End Sheet Metal Diagonal Brace Replacement in Body Front End.
  5. Remove the powertrain control module (PCM) cover from the air cleaner housing.
  6. Remove the PCM and set aside. It is not necessary to disconnect the electrical connector. Refer to Powertrain Control Module Replacement in Engine Controls - 3.5L.
  7. Remove the air cleaner and the duct. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls - 3.5L.
  8. Remove the fuel lines from the pipes and vapor line. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls - 3.5L.
  9. Remove the heater hose from the coolant cross over pipe and reposition out of the way. Refer to Heater Inlet Hose/Pipe and Heater Outlet Hose/Pipe Replacement in HVAC Systems - Manual.
  10. Unclip the fuel lines from the shock tower for easier access to the brake pipes.
  11. Disconnect the fluid level sensor switch from the brake master cylinder.
  12. Disconnect the brake lines from the master cylinder and remove the master cylinder. Refer to Master Cylinder Replacement .
  13. Remove the ABS module and bracket. Refer to Brake Pressure Modulator Valve Replacement in Antilock Brake System.
    14. Fig 1: Locating Vacuum Hose From Vacuum Check Valve
    GM177473Courtesy of GENERAL MOTORS CORP.
  14. Remove the brake booster vacuum hose from the vacuum brake booster check valve. Reposition the vacuum hose.
  15. Remove the knee bolster. Refer to Knee Bolster, Insulator, Molding Replacement - Instrument Panel in Instrument Panel, Gages, and Console.
    16. Fig 2: Locating Brake Pedal Assembly Components
    GM180291Courtesy of GENERAL MOTORS CORP.
  16. Remove the booster push pin retaining clip and washer (2) from the brake pedal assembly.
  17. Remove the brake booster push rod (2) from the brake pedal (1).
    18. Fig 3: View Of Vacuum Brake Booster Components
    GM180993Courtesy of GENERAL MOTORS CORP.
  18. Remove the brake booster mounting nuts.
  19. Remove the 2 front engine mounts, nuts, and bolts. Refer to Engine Mount Strut Replacement - Left Side and Engine Mount Strut Replacement - Right Side in Engine Mechanical - 3.5L.
  20. Rotate the engine forward to gain access to the brake booster removal. Refer to Rotating the Engine for Service Access in Engine Mechanical - 3.5L.
  21. Remove the brake booster.
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