Power Vacuum Brake Booster Replacement ABS

Caution: Refer to Brake Fluid Irritant Caution in the Preface section.

Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in the Preface section.

Notice: Always connect or disconnect the wiring harness connector from the EBCM/EBTCM with the ignition switch in the OFF position. Failure to observe this precaution could result in damage to the EBCM/EBTCM.

1. Turn the ignition to the OFF position.
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
3. Remove the left front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.



4. Remove the 3 nuts that attach the electronic brake control module (EBCM)/brake pressure modulator valve (BPMV) bracket to the left front wheelhouse.
5. Lower the vehicle.



6. Disconnect the electrical connector from the EBCM.



7. Deplete the vacuum from the vacuum brake booster by removing the vacuum check valve (1) from the vacuum brake booster grommet (4). Do not disconnect the vacuum check valve (1) from the vacuum brake hose (3).



8. Remove the 4 brake pipes (2) from the BPMV. Use bleeder valve caps or similar rubber caps to plug the brake pipes in order to prevent brake fluid loss and contamination.



9. Remove the master cylinder nuts from the vacuum brake booster.



10. Remove the EBCM/BPMV bracket assembly with the brake master cylinder.
11. Remove the closeout panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side in Instrument Panel , Gages, and Console.
12. Remove the electrical connector from the brake apply sensor.



13. Remove the 2 brake pedal assembly to cowl mounting nuts.



14. Disconnect the brake pedal pushrod retaining clip (1) the wave washers (2) and the brake booster pushrod (3) from the brake pedal pin (4).

Tilt the vacuum brake booster slightly in order to work the booster pushrod off the brake pedal pin. Do not apply excessive side pressure on the pushrod.

15. Remove the booster from the vehicle.

1. Install the booster to the vehicle.
2. Tilt the vacuum brake booster slightly in order to work the booster pushrod onto the brake pedal pin. Do not apply excessive side pressure on the pushrod. Align the pushrod with the pedal and assemble.
3. Connect the brake pedal pushrod retaining clip (1) the wave washers (2) and the brake booster pushrod (3) to the brake pedal pin (4).




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.

4. Install the 2 brake pedal assembly to cowl mounting nuts.

Tighten
Tighten the nuts to 15 N·m (11 lb ft).

5. Install the electrical connector to the brake apply sensor.
6. Install the closeout panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side in Instrument Panel , Gages, and Console.



7. Install the EBCM/BPMV bracket assembly and the master cylinder to the vehicle.




Important: Ensure the gasket on the outside barrel of the master cylinder is positioned properly and is free of cuts and tears.

8. Install the master cylinder nuts to the vacuum brake booster.

Tighten
Tighten the nuts to 25 N·m (18 lb ft).

9. Raise the vehicle.



10. Install the 3 nuts that attach the EBCM/BPMV bracket assembly to the left wheelhouse.

Tighten
Tighten the nuts to 10 N·m (86 lb in).

11. Install the left front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
12. Lower the vehicle.



13. Remove the caps or plugs from the 4 brake pipes (2) and install the 4 brake pipes (2) to the BPMV.

Tighten
Tighten the pipes to 20 N·m (15 lb ft).




14. Connect the electrical connector to the EBCM.



15. Connect the vacuum brake booster check valve (1) to the vacuum brake booster grommet (4).
16. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding .
17. Calibrate the brake pedal position sensor. Refer to Brake Pedal Position Sensor Calibration Description and Operation in Lighting Systems.

Power Vacuum Brake Booster Replacement W/O ABS

Caution: Refer to Brake Fluid Irritant Caution in the Preface section.

Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in the Preface section.

1. Turn the ignition to the OFF position.
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
3. Remove the left front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.



4. Remove the 2 nuts that attach the proportioning valve bracket to the left front wheelhouse.
5. Lower the vehicle.



6. Deplete the vacuum from the vacuum brake booster by removing the vacuum check valve (1) from the vacuum brake booster grommet (4). Do not disconnect the vacuum check valve (1) from the vacuum brake hose (3).



7. Remove the 4 brake pipes (1) from the proportioning valve. Use bleeder valve caps or similar rubber caps to plug the brake pipes in order to prevent brake fluid loss and contamination.



8. Remove the master cylinder nuts from the vacuum brake booster.
9. Remove the proportioning valve bracket assembly with the brake master cylinder from the vehicle.
10. Remove the closeout panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side in Instrument Panel , Gages, and Console.
11. Remove the electrical connector from the brake apply sensor.



12. Remove the 2 brake pedal assembly to cowl mounting nuts.



13. Disconnect the brake pedal pushrod retaining clip (1) the wave washers (2) and the brake booster pushrod (3) from the brake pedal pin (4).

Tilt the vacuum brake booster slightly in order to work the booster pushrod off the brake pedal pin. Do not apply excessive side pressure on the pushrod.

14. Remove the booster from the vehicle.

1. Install the booster to the vehicle.
2. Tilt the vacuum brake booster slightly in order to work the booster pushrod onto the brake pedal pin. Do not apply excessive side pressure on the pushrod. Align the pushrod with the pedal and assemble.
3. Connect the brake pedal pushrod retaining clip (1) the wave washers (2) and the brake booster pushrod (3) to the brake pedal pin (4).




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.

4. Install the 2 brake pedal assembly to cowl mounting nuts.

Tighten
Tighten the nuts to 15 N·m (11 lb ft).

5. Install the electrical connector to the brake apply sensor.
6. Install the closeout panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side in Instrument Panel , Gages, and Console.
7. Install the proportioning valve bracket assembly with the brake master cylinder to the vehicle.




Important: Ensure the gasket on the outside barrel of the master cylinder is positioned properly and is free of cuts and tears.

8. Install the master cylinder nuts to the vacuum brake booster.

Tighten
Tighten the nuts to 25 N·m (18 lb ft).

9. Raise the vehicle.



10. Install the 2 nuts that attach the proportioning valve bracket assembly to the left wheelhouse.

Tighten
Tighten the nuts to 10 N·m (86 lb in).

11. Install the left front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
12. Lower the vehicle.



13. Remove the caps or plugs from the 4 brake pipes (1) and install the 4 brake pipes (1) to the proportioning valve.

Tighten
Tighten the pipes to 20 N·m (15 lb ft).




14. Connect the vacuum brake booster check valve (1) to the vacuum brake booster grommet (4).
15. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding .
16. Calibrate the brake pedal position sensor. Refer to Brake Pedal Position Sensor Calibration Description and Operation in Lighting Systems.