SMU - Revised Vacuum Brake Booster Replacement Procedure

This bulletin is being issued to revise the Vacuum Brake Booster Replacement procedure in the Hydraulic Brakes sub-section of the Service Manual. Please replace the current information in the Service Manual with the following information.

The following information has been updated within SI2000. If you are using a paper version of this Service Manual, please make a reference to this bulletin on the affected page.

Removal Procedure

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



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




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

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



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

Installation Procedure

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 Cautions and Notices.

Install the brake booster mounting nuts.

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




2. Install the brake booster push rod (2) to the brake pedal (1).
3. Install the brake booster rod retaining washer and clip to the brake pedal assembly.
4. Adjust the stop lamp switch. Refer to Stop Lamp Switch Adjustment in Lighting System.
5. Install ABS module bracket and module. Refer to Brake Pressure Modulator Valve (BPMV) Replacement in Antilock Brake Systems.
6. Connect the brake lines to the module.
7. Connect the electrical connector to the ABS module and clip the electrical harness to the bracket .
8. Install the vacuum hose to the check valve.
9. Install the brake master cylinder and connect the brake lines . Refer to Master Cylinder Replacement.
10. Connect fluid level sensor switch on the master cylinder.
11. Install the fuel lines to the pipes and the vapor line. Refer to Fuel Hose/Pipes Replacement-Engine Compartment in Engine Controls.
12. Install the air cleaner and duct assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls.
13. Install the PCM. Refer to Powertrain Control Module (PCM) Replacement in Body and Accessories.
14. Install the PCM cover.
15. Install the left front cross brace. Refer to Brace Replacement-Front Fender Upper Diagonal-Left in Body and Accessories.
16. Install the cruise control bracket and the cruise control module. Refer to Cruise Control Module Replacement in Body and Accessories.
17. Install the coolant reservoir . Refer to Coolant Recover Reservoir in Engine Controls.
18. Bleed the brake system. Refer to Hydraulic Brake System Bleeding.