Power Vacuum Brake Booster Replacement 3.4L

1. Remove the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.
2. Relieve fuel line pressure . Refer to Fuel Pressure Relief in Engine Controls - 3.4L.
3. Remove the left front cross brace. Refer to Front End Sheet Metal Diagonal Brace Replacement - Left Side in Body Front End.
4. Remove the powertrain control module (PCM) cover from the air cleaner housing.
5. Remove the PCM and set aside. It is not necessary to disconnect electrical. Refer to Powertrain Control Module Replacement in Engine Controls - 3.4L.
6. Remove the air cleaner and the duct. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.4L.
7. Remove the fuel lines from the pipes and the vapor line. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls - 3.4L.
8. Disconnect the fluid level sensor switch from the brake master cylinder.
9. Disconnect the brake lines from the master cylinder and remove the master cylinder. Refer to Master Cylinder Replacement .



10. Remove the vacuum hose from the vacuum check valve. Reposition the vacuum hose.
11. Unclip the wire harness from the ABS module bracket and disconnect the electrical connector at the ABS module .
12. Remove the brake lines from the ABS module.
13. Remove the ABS module and bracket . Refer to Brake Pressure Modulator Valve Replacement in Antilock Brake System.




Notice: When disconnecting the pushrod from the brake pedal, the brake pedal must be held stationary or damage to the brake switch may result.

14. Remove the booster push rod retaining clip and washer (2) from the brake pedal assembly.
15. Remove the brake booster push rod (2) from the brake pedal (1).



16. Remove the brake booster mounting nuts.
17. Remove the brake booster.

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.

Notice: Proper stoplamp switch adjustment is essential. Improper stoplamp switch adjustment may cause brake drag, heat buildup and excessive brake lining wear.

1. Install the brake booster and position to the cowl and the mounting plate.

Notice: Refer to Fastener Notice in the Preface section.

2. Install the brake booster mounting nuts.

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




3. Install the brake booster push rod (2) to the brake pedal (1).
4. Install the brake booster rod retaining washer and clip to the brake pedal assembly.
5. Adjust the stop lamp switch. Refer to Stop Lamp Switch Adjustment in Lighting Systems.
6. Install the ABS module bracket and module. Refer to Brake Pressure Modulator Valve Replacement in Antilock Brake System.
7. Connect the brake lines to the module.
8. Connect the electrical connector to the ABS module and clip the electrical harness to the bracket .
9. Install the vacuum hose to the check valve.
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 lines to the pipes and the vapor line. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls - 3.4L.
13. Install the air cleaner and duct assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.4L.
14. Install the PCM . Refer to Powertrain Control Module Replacement in Engine Controls - 3.4L.
15. Install the PCM cover.
16. Install the left front cross brace. Refer to Front End Sheet Metal Diagonal Brace Replacement - Left Side in Body Front End.
17. Install the coolant reservoir . Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.
18. Bleed the brake system. Refer to Hydraulic Brake System Bleeding .

Power Vacuum Brake Booster Replacement 3.6L LY7

1. Lift the coolant reservoir up and away from the left front cross brace.
2. Remove the left front cross brace. Refer to Front End Sheet Metal Diagonal Brace Replacement - Left Side in Body Front End.
3. Remove the engine control module (ECM) cover from the air cleaner housing.
4. Remove the ECM and set aside. It is not necessary to disconnect electrical. Refer to Engine Control Module Replacement in Engine Controls - 3.6L (LY7).
5. Remove the air cleaner and the duct. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.6L (LY7).
6. Remove the fuel line retaining bolt from the intake manifold.
7. Disconnect the fluid level sensor switch from the brake master cylinder.
8. Disconnect the brake lines from the master cylinder and remove the master cylinder. Refer to Master Cylinder Replacement .
9. Remove the vacuum hose from the vacuum check valve. Reposition the vacuum hose.
10. Remove the ABS module and bracket . Refer to Brake Pressure Modulator Valve Replacement in Antilock Brake System.
11. Install the engine support fixture. Refer to Engine Support Fixture in Engine Mechanical - 3.6L (LY7).
12. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information.
13. Remove the left front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.



14. Remove the left front fender liner.
15. Remove the left ball joint from the steering knuckle. Refer to Lower Control Arm Replacement in Front Suspension.



16. Remove the stabilizer bar links. Refer to Stabilizer Shaft Link Replacement in Front Suspension.
17. Remove the steering gear mounting bolts.



18. Remove the 2 left side frame to body bolts.

Important: DO NOT remove the frame to body bolts on the right side.

19. Loosen, but do not remove, the right frame to body bolts.
20. Position an oil drain pan under the transmission.

Important: Insure that all pipes, hoses, and wires are clear and not being bound or stressed when lowering the frame.

21. Lower the vehicle.
22. Using the engine support fixture, lower the powertrain.
23. Remove the transmission filler tube. Refer to Transmission Fluid Filler Tube Replacement in Automatic Transaxle - 4T65-E.
24. Disconnect the fuel pipe retainer from the wheelhouse stud.




Notice: When disconnecting the pushrod from the brake pedal, the brake pedal must be held stationary or damage to the brake switch may result.

25. Remove the booster push rod retaining clip and washer (2) from the brake pedal assembly.
26. Remove the brake booster push rod (2) from the brake pedal (1).



27. Remove the brake booster mounting nuts.
28. Remove the brake booster.

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.

Notice: Proper stoplamp switch adjustment is essential. Improper stoplamp switch adjustment may cause brake drag, heat buildup and excessive brake lining wear.

1. Install the brake booster and position to the cowl and the mounting plate.

Notice: Refer to Fastener Notice in the Preface section.

2. Install the brake booster mounting nuts.

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




3. Install the brake booster push rod (2) to the brake pedal (1).
4. Install the brake booster rod retaining washer and clip to the brake pedal assembly.
5. Adjust the stop lamp switch. Refer to Stop Lamp Switch Adjustment in Lighting Systems.
6. Connect the fuel pipe retainer to the wheelhouse stud.
7. Install the transmission filler tube. Refer to Transmission Fluid Filler Tube Replacement in Automatic Transaxle - 4T65-E.
8. Using the engine support fixture, raise the powertrain to its original position.
9. Raise the vehicle.
10. Using an appropriate jack, raise the left side of the frame so that the frame to body bolts can be installed.



11. Install the frame to body bolts.

Tighten

•	Tighten the front bolts to 155 N·m (114 lb ft).

•	Tighten the rear bolts to 240 N·m (177 lb ft).

12. Remove the jackstand and oil drain pan.
13. Install the steering gear mounting bolts.

Tighten
Tighten the bolts to 80 N·m (59 lb ft).




14. Install the stabilizer bar links. Refer to Stabilizer Shaft Link Replacement in Front Suspension.
15. Install the ball joint to the steering knuckle. Refer to Lower Control Arm Replacement in Front Suspension.



16. Install the left front fender liner.
17. Install the left front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
18. Lower the vehicle.
19. Remove the engine support fixture.
20. Install ABS module bracket and module. Refer to Brake Pressure Modulator Valve Replacement in Antilock Brake System.
21. Install the vacuum hose to the check valve.
22. Install the brake master cylinder and connect the brake lines . Refer to Master Cylinder Replacement .
23. Connect fluid level sensor switch on the master cylinder.
24. Install the fuel line retaining bolt to the intake manifold.

Tighten
Tighten the bolt to 10 N·m (89 lb in).

25. Install the air cleaner and duct assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.6L (LY7).
26. Install the ECM . Refer to Engine Control Module Replacement in Engine Controls - 3.6L (LY7).
27. Install the ECM cover.
28. Install the left front cross brace . Refer to Front End Sheet Metal Diagonal Brace Replacement - Left Side in Body Front End.
29. Reposition the coolant reservoir to the left front cross brace.
30. Bleed the brake system. Refer to Hydraulic Brake System Bleeding .