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.

Tools Required

J 22805-B Power Brake Booster Holder

1. Remove the left instrument panel insulator. Refer to in Instrument Panel, Gauges, and Console.
2. Disconnect the stoplamp switch electrical connector from the stoplamp switch.
3. Remove the retaining clip and disconnect the brake booster pushrod from the brake pedal.
4. Partially drain the cooling system. Refer to Cooling System Draining and Filling in Engine Cooling.
5. Remove the cross vehicle brace. Refer to in Body Front End.
6. Remove the air cleaner inlet duct. Refer to in Engine Controls-3.4L.
7. Relieve the fuel system pressure. Refer to in Engine Controls-3.4L.
8. Disconnect the EVAP canister purge valve pipe, the fuel feed pipe and return pipe. Position them aside.



9. Disconnect the coolant outlet (2) and inlet (3) bypass hoses and position them aside.
10. Remove the heater inlet pipe.
11. Rotate the engine forward for service access. Refer to in Engine Mechanical - 3.4L.
12. Disconnect the brake fluid level sensor electrical connector from the brake fluid level sensor.

Important: It is not necessary to disconnect the brake pipes from the master cylinder to the BPMV.

13. Remove the two master cylinder retaining nuts and position the master cylinder aside.
14. Disconnect the vacuum brake booster check valve from the brake booster. Position aside the vacuum hose with the check valve as an assembly.
15. Attach the J 22805-B to the booster using the master cylinder retaining nuts.



16. Unlock the booster from the cowl.
17. Use a flat bladed tool to depress the brake booster locking tab (1) out of the cowl mounting flange, while turning the booster counterclockwise with a ratchet on the J 22805-B  (2).
18. Remove the vacuum brake booster.

Notice: Internal components of this booster are not serviceable. The housing must not be unstaked and separated. Separating the housing will cause permanent deformation, preventing the booster from holding proper volume.

Notice: Inspect the locking flanges on booster and mounting plate. Replace the booster and mounting plate if the locking flanges are bent or damaged.

Important: Carefully push the pushrod eye through the hole so that you do not damage or dislodge the insulator boot.

1. Install the vacuum brake booster.

Position the vacuum brake booster on the cowl counterclockwise from the final installation position so that the locking flanges on the vacuum brake booster and on the cowl mounting flange engage.

Important: Ensure that the locking tab and the flanges are in the full engaged position.




2. Turn the vacuum brake booster clockwise with a ratchet on the J 22805-B  (2). DO NOT use a flat bladed tool in the locking tab to install the vacuum brake booster. When the vacuum brake booster is correctly installed, the locking tab (1) slides up the flange and engages the locking notch.
3. Remove the J 22805-B  (2) from the installed vacuum brake booster.
4. Reposition and connect the vacuum hose and check valve assembly to the booster.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

5. Reposition the master cylinder onto the booster and install the master cylinder retaining nuts.

Tighten
Tighten the master cylinder retaining nuts to 25 (18 lb ft).

6. Connect the brake fluid level sensor electrical connector to the brake fluid level sensor.
7. Return the engine to the original rest position. Install the left and right engine mount struts. Refer to and in Engine Mechanical - 3.4L.
8. Install the heater inlet pipe.



9. Reposition and connect the coolant outlet (2) and inlet (3) bypass hoses.
10. Reposition and connect the EVAP canister purge valve pipe, the fuel feed pipe and return pipe.
11. Install the air cleaner inlet duct. Refer to in Engine Controls-3.4L.
12. Install the cross vehicle brace. Refer to in Body Front End.
13. Fill the cooling system. Refer to in Engine Cooling.
14. Connect the brake booster pushrod to the brake pedal and install the retaining clip.
15. Connect the stoplamp switch electrical connector to the stoplamp switch.
16. Install the left instrument panel insulator. Refer to in Instrument Panel, Gauges, and Console.