Power Vacuum Brake Booster Replacement L47

1. Place the vehicle on a level surface.
2. Block the front wheels.
3. Apply the park brake.
4. Shift the vehicle into low gear.
5. Remove the left closeout insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side in Instrument Panel, Gages, and Console.
6. Remove the left knee bolster. Refer to Knee Bolster Replacement in Instrument Panel, Gages and Console.



7. Remove the retainer clip for the from the brake pedal clevis pin.
8. Remove the foam spacer from the brake pedal clevis pin.
9. Disconnect the vacuum brake booster pushrod from the brake pedal clevis pin.
10. Remove the brake pedal to booster mounting nuts.
11. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 4.0L.



12. Remove the master cylinder from the vacuum brake booster. Refer to Master Cylinder Replacement and carefully position the master cylinder out of the way. Do not disconnect the hydraulic brake pipes.



13. Remove the cruise control module (1) and position out of the way. Refer to Cruise Control Module Replacement in Cruise Control.
14. Disconnect the electrical connector (2) at the left strut tower. Refer to Master Electrical Component List in Engine Electrical.
15. Remove the accelerator control cable bracket from the throttle body and position the cables and bracket out of the way. Refer to Accelerator Control Cable Bracket Replacement in Engine Mechanical - 4.0L.
16. Remove the left carpet retainer. Refer to Front Carpet Retainer Replacement in Interior Trim.
17. Disconnect the shift control cable from the shaft lever pin. Refer to Range Selector Lever Cable Replacement in Automatic Transaxle - 4T80 - E.
18. Remove the shift control cable and bracket and position out of the way. Refer to Range Selector Lever Cable Replacement in Automatic Transaxle - 4T80 - E.
19. Disconnect the vacuum brake check valve and hose as an assembly from the vacuum brake booster.
20. Remove the inlet heater pipe. Refer to Heater Inlet Pipe Replacement in Heating, Ventilation and Air Conditioning.



21. Remove the vacuum brake booster from the vehicle.
22. Remove the vacuum brake booster mounting gasket, if gasket replacement is necessary.

1. Install the brake booster mounting gasket to booster, if removed previously.



2. Install the vacuum brake booster to the vehicle.



3. Install the vacuum brake booster pushrod to the brake pedal clevis pin.
4. Install the foam spacer to the brake pedal clevis pin.
5. Install the retaining clip to the brake pedal clevis pin.

Notice: Refer to Fastener Notice in the Preface section.

6. Install the booster stud mounting nuts to the booster studs.

Tighten
Tighten the brake pedal to booster stud mounting nuts to 23 N·m (17 lb ft).

7. Install the left knee bolster. Refer to Knee Bolster Replacement in Instrument Panel, Gages, and Console.
8. Install the left closeout insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side in Instrument Panel, Gages, and Console.
9. Install the left carpet retainer. Refer to Front Carpet Retainer Replacement in Interior Trim.
10. Install the inlet heater pipe. Refer to Heater Inlet Pipe Replacement in Heating, Ventilation and Air Conditioning.
11. Install the shift control cable and bracket. Refer to Range Selector Lever Cable Replacement in Automatic Transaxle - 4T80 - E.
12. Connect the shift control cable to the shaft lever pin. Refer to Range Selector Lever Cable Replacement in Automatic Transaxle - 4T80 - E.
13. Shift the vehicle into park.



14. Install the master cylinder to the vacuum brake booster. Refer to Master Cylinder Replacement .
15. Install the master cylinder mounting nuts.

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

16. Reposition and connect the vacuum check valve to the vacuum brake booster.



17. Connect the electrical connector (2) to the left strut tower. Refer to Master Electrical Component List in Engine Electrical.
18. Install the cruise control module. Refer to Accelerator Control Cable Bracket Replacement in Cruise Control.
19. Install the accelerator control cables and bracket. Refer to Accelerator Control Cable Bracket Replacement in Engine Controls- 4.0L.
20. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls- 4.0L.
21. Remove the blocks from the front wheels.
22. Release the park brake.

Power Vacuum Brake Booster Replacement LX5

1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3 .5 L.
2. Remove the accelerator control cable. Refer to Accelerator Control Cable Replacement in Engine Controls - 3.5 L.
3. Remove the cruise control cable. Refer to Cruise Control Cable Replacement in Cruise Control.
4. Remove the shift control cable from the shaft lever pin. Refer to Range Selector Lever Cable Replacement in Automatic Transaxle - 4T65E.
5. Remove the shift cable from the shift cable bracket. Refer to Range Selector Lever Cable Replacement in Automatic Transaxle - 4T65E.



6. Disconnect the electrical connector (2) at the left strut tower. Refer to Master Electrical Component List in Wiring Systems.



7. Remove the brake master cylinder from the vacuum brake booster and carefully position the master cylinder out of the way. Refer to Master Cylinder Replacement . Do not disconnect the hydraulic brake pipes from the master cylinder.
8. Disconnect the vacuum brake booster vacuum check valve and hose as an assembly from the vacuum brake booster.



9. Remove the support brace bolt (5) attaching the secondary AIR injection pump tube (2) to the secondary AIR injection valve bracket.
10. Loosen the support brace nut (5) attaching the secondary AIR injection pump tube (2) to the transaxle.
11. Disconnect the secondary AIR injection pump hose (1) from the secondary AIR injection valve (6).
12. Position the secondary air tube (2) down and out of the way.
13. Remove the EGR inlet pipe. Refer to Exhaust Gas Recirculation Pipe Replacement in Engine Controls - 3.5L.
14. Remove the fuel injection sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical - 3.5L.
15. Remove the left closeout insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side in Instrument Panel, Gages and Console.
16. Remove the left knee bolster. Refer to Knee Bolster Replacement in Instrument Panel, Gages and Console.



17. Remove the retaining clip from the brake pedal clevis pin.
18. Remove the foam spacer from the brake pedal clevis pin.
19. Remove the vacuum brake booster pushrod from the brake pedal clevis pin.
20. Remove the vacuum brake booster mounting nuts.



21. Remove the vacuum booster from the vehicle.
22. Remove the vacuum brake booster mounting gasket, if gasket replacement is necessary.

1. Install the vacuum brake booster gasket to booster, if removed previously.



2. Install the booster to the vehicle.



3. Install the booster pushrod to the brake pedal clevis pin.
4. Install the brake pedal foam spacer to the brake pedal clevis pin.
5. Install the retaining clip to the brake pedal clevis pin.

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.

6. Install the brake pedal to booster mounting stud nuts onto the booster studs.

Tighten
Tighten the brake pedal to booster mounting stud nuts to 23 N·m (17 lb ft).

7. Install the accelerator control cable. Refer to Accelerator Control Cable Replacement In Engine Controls - 3.5 L.
8. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement In Engine Controls - 3.5 L.
9. Install the left knee bolster. Refer to Knee Bolster Replacement in Instrument Panel, Gages and Console.
10. Install the left closeout insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side In Instrument Panel, Gages and Console.



11. Install the master cylinder to the vacuum brake booster. Refer to Master Cylinder Replacement .



12. Connect the secondary AIR injection pump hose (1) to the secondary AIR injection valve (6).
13. Install the support brace bolt (5) attaching the secondary AIR injection pump tube (2) to the secondary AIR injection valve bracket.

Tighten
Tighten the support brace bolt to 9 N·m (80 lb in).

14. Tighten the support brace nut (5) attaching the secondary AIR injection pump tube (2) to the transaxle.

Tighten
Tighten the support brace nut to 9 N·m (80 lb in).

15. Install the EGR inlet pipe. Refer to Exhaust Gas Recirculation Pipe Replacement in Engine Controls - 3.5L
16. Install the fuel injection sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical - 3.5L.



17. Connect the electrical connector (2) at the left strut tower. Refer to Master Electrical Component List in Wiring Systems.
18. Install the shift cable to the shift cable bracket. Refer to Range Selector Lever Cable Replacement in Automatic Transaxle - 4T65E.
19. Connect the shift control cable to the shaft lever pin. Refer to Range Selector Lever Cable Replacement in Automatic Transaxle - 4T65E.
20. Reposition and connect the vacuum check to the vacuum brake booster.
21. Install the cruise control cable. Refer to Cruise Control Cable Replacement In Cruise Control.