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. 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 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. 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. 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. 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.

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.

1. Position the brake booster 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 master cylinder. Refer to Master Cylinder Replacement .



4. Install the brake booster push rod (2) to the brake pedal (1). Install the washer and retaining clip.

Notice: 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. 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 in Engine Cooling.
20. Bleed the brake system. Refer to Hydraulic Brake System Bleeding .