Power Vacuum Brake Booster Replacement 3.8L

1. Remove the fuel injector sight shield. Refer to Intake Manifold Cover Replacement .
2. Disconnect the electrical connector from the exhaust gas recirculation (EGR) valve (1).
3. Disconnect the engine harness clips (3).
4. Position the harness to the side.



5. Disconnect the brake fluid level sensor (1).



6. Remove the master cylinder mounting bolts.
7. Remove the master cylinder. Position the master cylinder to the side and support with heavy mechanics wire or equivalent.



8. Disconnect the vacuum brake booster check valve and hose (2).
9. Remove the left knee bolster. Refer to Driver Knee Bolster Replacement .
10. Remove the steering column support mounting bolts. Refer to Steering Column Replacement .
11. Lower the steering column and support with heavy mechanics wire.
12. Disconnect the brake pedal position sensor electrical connector.



13. Remove the vacuum brake booster pushrod retainer clip (2).
14. Remove the vacuum brake booster pushrod spacer (3).



15. Remove the mounting nuts (1) for the steering column.



16. Remove the vacuum brake booster.

Important: If damaged, DO NOT reuse the vacuum brake booster gasket. Replace the gasket with new.

17. Remove the vacuum brake booster gasket.

1. Install the vacuum brake booster gasket.
2. Install the vacuum brake booster.



3. Install the pushrod to the brake pedal.
4. Install the spacer (3).
5. Install the retaining clip (2).

Notice: Refer to Fastener Notice in the Preface section.




6. Install the mounting nuts (1).

Tighten
Tighten the nuts to 30 N·m (22 lb ft).

7. Connect the brake pedal position sensor electrical connector.



8. Install the master cylinder. Refer to Master Cylinder Replacement .
9. Position the steering column.
10. Install the steering column. Refer to Steering Column Replacement .
11. Install the knee bolster panel. Refer to Driver Knee Bolster Replacement .



12. Install the vacuum brake booster check valve and hose (2).



13. Install the brake fluid level sensor electrical connector (1).



14. Position the engine wiring harness (2).
15. Connect the electrical connector for the EGR valve (1).
16. Connect the engine harness clips (3).
17. Install the fuel injector sight shield. Refer to Intake Manifold Cover Replacement .
18. Calibrate the brake pedal position sensor. Refer to Brake Pedal Position Sensor Calibration .

Power Vacuum Brake Booster Replacement 4.6L

1. Place the vehicle on a flat surface.
2. Block the front wheels.
3. Apply the parking brake.
4. To allow access for the removal of the vacuum brake booster, position the gearshift lever into the lowest gear.
5. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
6. Disconnect the fuel vapor lines in front of the brake booster.

•	For the lines that have the plastic connectors, refer to Plastic Collar Quick Connect Fitting Service .

•	For the lines that have the metal connectors, refer to Metal Collar Quick Connect Fitting Service .




7. Remove the master cylinder mounting nuts (3).

Important: In the following service step, the master cylinder does not have to be removed. Move the master cylinder forward just enough to clear the studs on the vacuum brake booster. This will flex the brake pipes slightly. Do not bend or distort the pipes.

8. Disconnect the master cylinder (1) from the brake booster (2).
9. Disconnect the shift control cable from the shaft lever pin and position it out of the way. Refer to Automatic Transmission Range Selector Cable Replacement - Console .



10. Disconnect the vacuum check valve (2) from the vacuum booster.
11. Remove the left closeout insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side .
12. Remove the left knee bolster. Refer to Driver Knee Bolster Replacement .
13. To access the left lower brake pedal to vacuum brake booster mounting nut, remove the steering column mounting nuts. Refer to Steering Column Replacement .
14. Lower the steering column and secure it.



15. Remove the vacuum brake booster pushrod retaining clip (2) from the brake pedal clevis pin.
16. Remove the foam spacer (3) from the brake pedal clevis pin.
17. Disconnect the brake booster pushrod from the brake pedal clevis pin.



18. Remove the vacuum brake booster mounting nuts (1) from the brake pedal assembly.
19. Raise the vehicle. Refer to Lifting and Jacking the Vehicle .



20. Support the front frame with jack stands.
21. Loosen the left side bolts from the frame to the body. Refer to Front Frame Replacement .
22. Lower the left side frame 2-3 inches to gain enough clearance to remove the brake booster. Refer to Front Frame Replacement .



23. Remove the vacuum brake booster from the vehicle.

Important: The gasket does not have to be replaced every time the booster is removed. Replace the gasket only if necessary.

24. Remove the vacuum brake booster mounting gasket.

1. Install the vacuum brake booster mounting gasket to the booster, if removed previously.
2. Install the vacuum brake booster to the vehicle.
3. Lower the vehicle onto the engine frame. Refer to Front Frame Replacement .
4. Remove the jack stands.
5. Lower the vehicle.

Notice: Refer to Fastener Notice in the Preface section.




6. Install the brake pedal assembly to booster stud mounting nuts (1) to the booster studs.

Tighten
Tighten the brake pedal assembly to booster stud mounting nuts to 30 N·m (22 lb ft).




7. Apply a small amount of lubricant, GM P/N 12346293 or equivalent to the clevis pin of the brake pedal.
8. Connect the vacuum brake booster pushrod to the brake pedal clevis pin.
9. Install the foam spacer (3) to the brake pedal clevis pin.
10. Install the retainer clip (2) to the brake pedal assembly clevis pin.
11. Install the steering column.
12. Install the steering column mounting attaching nuts. Refer to Steering Column Replacement .
13. Install the left knee bolster. Refer to Driver Knee Bolster Replacement .
14. Install the left closeout insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side .



15. Install the shift control cable to the shift cable bracket. Refer to Automatic Transmission Range Selector Cable Replacement - Console .
16. Position the gearshift lever into park.



17. Install the brake booster vacuum check valve (2) to the vacuum brake booster.
18. Install the master cylinder to the vacuum brake booster. Refer to Master Cylinder Replacement .
19. Connect the fuel vapor lines in front of the brake booster.

•	For the lines that have the plastic connectors, refer to Plastic Collar Quick Connect Fitting Service .

•	For the lines that have the metal connectors, refer to Metal Collar Quick Connect Fitting Service .

20. Remove the blocks from the front wheels.
21. Release the parking brake.