Power Vacuum Brake Booster Replacement L36

1. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical - 3.8L.
2. Remove the air inlet duct. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls - 3.8L.
3. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls -3.8L.
4. Remove the accelerator control cable bracket and position the cables out of the way. Refer to Accelerator Control Cable Bracket Replacement in Engine Controls - 3.8L.
5. Remove the cruise control module (1) and position out of the way. Refer to Cruise Control Module Replacement in Cruise Control.
6. Disconnect the engine electrical harness (2) at the left strut tower.



7. Disconnect the electrical connector from the exhaust gas recirculation (EGR) valve (1).
8. Disconnect the engine harness clips (3).
9. Position the wiring harness (2) out of the way.



10. Disconnect the brake fluid level sensor wire connector (1).



11. Remove the master cylinder attaching nuts.
12. Remove the master cylinder from the booster and carefully position the master cylinder out of the way.
13. Remove the vacuum brake booster check valve from the booster. Refer to Vacuum Brake Booster Check Valve and/or Hose Replacement .
14. Remove the left closeout/insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side in Instrument Panel, Gages, and Console.
15. Remove the knee bolster. Refer to Knee Bolster Replacement in Instrument Panel, Gages, and Console.



16. Remove the vacuum brake booster pushrod retainer (3) from the brake pedal clevis pin.
17. Remove the foam spacer (2) from the brake pedal clevis pin.
18. Disconnect the pushrod (1) from the brake pedal clevis pin.



19. Remove the vacuum brake booster mounting nuts (1) from the brake pedal assembly.



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

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



2. Install the brake booster to the vehicle.




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 brake pedal assembly to booster stud mounting nuts (1).

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

4. Apply a small amount lubricant, (GM P/N 12346293) or equivalent to the clevis pin of the brake pedal.



5. Connect the brake booster pushrod (1) to the brake pedal clevis pin.
6. Install the foam spacer (2) to the brake pedal clevis pin.
7. Install the booster pushrod retainer clip (3) to the brake pedal clevis pin.
8. Install the knee bolster. Refer to Knee Bolster Replacement in Instrument Panel, Gages, and Console.
9. Install the left closeout/insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side in Instrument Panel, Gages, and Console.



10. Install the master cylinder onto the vacuum brake booster.
11. Install the master cylinder mounting nuts. Refer to Master Cylinder Replacement .
12. Install the vacuum brake booster check valve to the booster. Refer to Vacuum Brake Booster Check Valve and/or Hose Replacement .



13. Connect the brake fluid level sensor wire connector (1).



14. Install the cruise control module (1). Refer to Cruise Control Module Replacement in Cruise Control.
15. Connect the electrical connector (2) to the left strut tower.



16. Connect the electrical connector to the EGR valve (1).
17. Connect the engine harness clips (3).
18. Install the accelerator control cable bracket. Refer to Accelerator Control Cable Bracket Replacement in Engine Controls - 3.8L.
19. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.8L.
20. Install the air inlet duct. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls - 3.8L.
21. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical - 3.8L.

Power Vacuum Brake Booster Replacement LD8

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 cross vehicle brace. Refer to Cross Vehicle Brace Replacement in Body Front End.



6. Remove the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical - 3.8L.
7. Remove the air inlet duct. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls - 3.8L.
8. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.8L.
9. Remove the accelerator control cable bracket and position the cables out of the way. Refer to Accelerator Control Cable Bracket Replacement in Engine Controls - 3.8L.
10. Remove the cruise control module (1) and position out of the way. Refer to Cruise Control Module Replacement in Cruise Control.
11. Disconnect the engine electrical harness (2) at the left strut tower.



12. Disconnect the electrical connector from the exhaust gas recirculation (EGR) valve (1).
13. Disconnect the engine harness clips (3).
14. Position the wiring harness (2) out of the way.



15. Disconnect the brake fluid level sensor wire connector (1).



16. Remove the master cylinder attaching nuts.
17. Remove the master cylinder from the booster and carefully position the master cylinder out of the way.
18. 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 in Automatic Transaxle - 4T80-E.
19. Remove the vacuum brake booster check valve from the booster. Refer to Vacuum Brake Booster Check Valve and/or Hose Replacement .
20. Remove the inlet heater pipe. Refer to Heater Inlet Pipe Replacement in Heating, Ventilation and Air Conditioning.
21. Remove the left closeout/insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side in Instrument Panel, Gages, and Console.
22. Remove the knee bolster. Refer to Knee Bolster Replacement in Instrument Panel, Gages, and Console.



23. Remove the vacuum brake booster pushrod retainer (3) from the brake pedal clevis pin.
24. Remove the foam spacer (2) from the brake pedal clevis pin.
25. Disconnect the pushrod (1) from the brake pedal clevis pin.



26. Remove the vacuum brake booster mounting nuts (1) from the brake pedal assembly.



27. Remove the vacuum brake booster from the vehicle.
28. Remove the brake booster mounting gasket, if gasket replacement is necessary.

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



2. Install the brake booster to the vehicle.

Notice: Refer to Fastener Notice in the Preface section.




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

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

4. Apply a small amount lubricant, GM P/N 12346293 or equivalent, to the clevis pin of the brake pedal.



5. Connect the brake booster pushrod (1) to the brake pedal clevis pin.
6. Install the foam spacer (2) to the brake pedal clevis pin.
7. Install the booster pushrod retainer clip (3) to the brake pedal clevis pin.
8. Install the knee bolster. Refer to Knee Bolster Replacement in Instrument Panel, Gages, and Console.
9. Install the left closeout/insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side in Instrument Panel, Gages, and Console.
10. Install the inlet heater pipe. Refer to Heater Inlet Pipe Replacement in Heating, Ventilation and Air Conditioning.
11. Install the shift control cable to the shift cable bracket. Refer to Automatic Transmission Range Selector Cable Replacement - Console in Automatic Transaxle - 4T80-E.
12. Position the gearshift lever into park.



13. Install the master cylinder onto the vacuum brake booster.
14. Install the master cylinder mounting nuts. Refer to Master Cylinder Replacement .
15. Install the vacuum brake booster check valve to the booster. Refer to Vacuum Brake Booster Check Valve and/or Hose Replacement .



16. Connect the brake fluid level sensor wire connector (1).



17. Install the cruise control module (1). Refer to Cruise Control Module Replacement in Cruise Control.
18. Connect the electrical connector (2) to the left strut tower.



19. Connect the electrical connector to the EGR valve (1).
20. Connect the engine harness clips (3).
21. Install the accelerator control cable bracket. Refer to Accelerator Control Cable Bracket Replacement in Engine Controls - 3.8L.
22. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.8L.
23. Install the air inlet duct. Refer to Air Cleaner Inlet Duct Replacement in Engine Controls - 3.8L.
24. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement in Engine Mechanical - 3.8L.
25. Remove the blocks from the front wheels.
26. Release the parking brake.