Power Vacuum Brake Booster Replacement 2.4L

1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls-2.4L.
2. Disconnect the underhood electrical center from the bracket and set aside. Refer to Underhood Electrical Center or Junction Block Replacement in Engine Electrical.
3. Remove the underhood junction block bracket.
4. Remove the master cylinder. Refer to Master Cylinder Replacement .

Do not lose or dislodge the insulator between the booster and the front of the dash.




5. Disconnect the vacuum hose from the vacuum check valve (1).



6. Remove the left sound insulator.
7. Remove the booster attaching nuts (2).



8. Remove the booster pushrod (1) from the brake pedal (2).

Tilt the entire vacuum booster slightly in order to work the booster pushrod off the pedal clevis pin. Do not put undue side pressure on the pushrod.

9. Remove the booster from the vehicle.

1. Install the booster to the vehicle.
2. Install the booster pushrod (1) to the brake pedal (2).

Tilt the entire vacuum booster slightly in order to work the booster pushrod onto the pedal clevis pin without putting undue side pressure on the pushrod. Use the left hand in order to align the pushrod with the pedal and push together.





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.

3. Install the booster attaching nuts (2).

Tighten
Tighten the booster to brake pedal attaching nuts to 27 N·m (20 lb ft).

Important: Be sure to check the brake switch adjustment so that the brake lights do not remain on.

4. Inspect the brake switch adjustment. Refer to Stop Lamp Switch Adjustment in Hydraulic Brakes.
5. Install the left sound insulator.



6. Connect the vacuum hose to the vacuum check valve (1).



7. Install the master cylinder. Refer to Master Cylinder Replacement .
8. Install the master cylinder attaching nuts.

Tighten
Tighten the master cylinder to booster attaching nuts to 27 N·m (20 lb ft).

9. Install the underhood junction block bracket.
10. Install the underhood electrical center. Refer to Underhood Electrical Center or Junction Block Replacement in Engine Electrical.
11. Install the cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls-2.4L.

Power Vacuum Brake Booster Replacement 3.4L

1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls-3.4L.
2. Disconnect and position aside the underhood electrical center from the bracket. Refer to Underhood Electrical Center or Junction Block Replacement in Wiring Systems.
3. Remove the underhood electrical center bracket.
4. Remove the EGR valve. Refer to Exhaust Gas Recirculation Valve Replacement in Engine Controls-3.4L.
5. Remove the master cylinder (2) from the hydraulic brake booster (1). Refer to Master Cylinder Replacement .

Careful not lose or dislodge the insulator between the booster and the front of the dash.




6. Disconnect the vacuum hose and the vacuum brake booster check valve (1) from the booster as an assembly.



7. Remove the left Closeout/Insulator Panel. Refer to in Instrument Panel Gauges and Console.
8. Remove the booster retaining nuts (2).



9. Disconnect the booster pushrod (1) from the brake pedal (2).

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

10. Remove the booster from the vehicle.

1. Install the booster to the vehicle.
2. Install the booster pushrod (1) to the brake pedal (2).

Tilt the vacuum brake booster slightly in order to work the booster pushrod onto the pedal clevis pin. Do not apply excessive side pressure on the pushrod. Align the pushrod with the pedal and assemble.





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.

3. Install the booster retaining nuts (2).

Tighten
Tighten the booster to brake pedal retaining nuts to 27 N·m (20 lb ft).

4. Install the left Closeout/Insulator Panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side in Instrument Panel Gauges and Console.



5. Connect the vacuum hose and the vacuum brake booster check valve (1) to the booster as an assembly.



6. Install the master cylinder (2) to the booster (1).
7. Install the master cylinder. Refer to Master Cylinder Replacement .
8. Install the EGR valve. Refer to Exhaust Gas Recirculation Valve Replacement in Engine Controls-3.4L.
9. Install the underhood electrical center bracket.
10. Position back and connect the underhood electrical center. Refer to Underhood Electrical Center or Junction Block Replacement in Wiring Systems.
11. Install the cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls-3.4L.