GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Saturn 🢒 2009 🢒 Astra 🢒 Brakes 🢒 Hydraulic Brakes 🢒 Power Brake Booster Pump Fluid Accumulator Replacement

Removal Procedure
  1. Remove the cover of brake fluid reservoir.
  2. Siphon out as much brake fluid as possible with a siphon bottle.

    3. Warning: Refer to Battery Disconnect Warning in the Preface section.

  3. Disconnect the battery.

    4. Object Number: 1998474 Size: LH
  4. Remove the battery shield (2).
    5. • Remove the bolt (3).
    • Remove the 2 shields (1) from the battery tray.

    Object Number: 1941092 Size: SH
  5. Remove the battery holder (1) and unscrew the bolt.
  6. Remove the battery.

    7. Object Number: 1936907 Size: SH
  7. Remove the battery tray.
    8. • Cut the 2 cable ties (1).
    • Remove the 3 bolts (2).

    Note: The cooling system remains sealed.

  8. Remove the coolant surge tank.
    9. • Disconnect the wiring harness plug.
    • Set the coolant compensation tank aside.
  9. Remove the wiring harness from the brake fluid reservoir.
  10. Disconnect the wiring harness plug from the brake fluid level sensor.

    11. Object Number: 1947422 Size: SH
  11. Remove the hydraulic modulator.
    12. • Disconnect the hydraulic modulator wiring harness plug.
    • Remove the 6 hydraulic lines (1, 2, and 4).
    • Remove the 3 screws (3)

    Object Number: 1937848 Size: SH
  12. Remove the hydraulic modulator bracket.
    13. • Remove the 3 bolts (1).
    • Remove the hydraulic modulator bracket.

    Object Number: 1937843 Size: SH

    Note: Collect brake fluid and seal apertures.

  13. For vehicles with a manual transmission, remove the supply line (1) for clutch master cylinder from brake fluid reservoir.
  14. Remove the brake line from brake master cylinder and remove the 2 union bolts (3).
  15. Remove the brake master cylinder from the brake servo and remove 2 nuts (2).
  16. Remove the vacuum line from the brake servo.
  17. Remove the drivers side footwell paneling.
    18. • Detach the clip.
    • Remove the 2 bolts.

    Object Number: 1937851 Size: SH
  18. Remove the piston rod for brake servo (1) from the brake pedal.
  19. Remove the pedal bolt from the brake pedal (2).
    20. • Remove the retaining spring.
    • Remove the pedal bolt.

    Object Number: 1942006 Size: SH
  20. Remove the brake servo from bulkhead and unscrew the 2 nuts.

Installation Procedure
  1. Insert the brake servo.

    2. Caution: Refer to Fastener Caution in the Preface section.

  2. Install the brake servo to the bulkhead.

    3. Tighten
    Tighten the 2 nuts to 20 N·m (15 lb ft).

  3. Install the pedal bolt for the brake pedal.
    4. • Insert the bolt.
    • Install the retaining spring.
  4. Install the driver side footwell paneling.

    5. Install the clip.

    Tighten
    Tighten the 2 driver side footwell paneling bolts to 2.5 N·m (22 lb in).

  5. Install the vacuum line to the brake servo.
  6. Install the brake master cylinder to the brake servo.

    7. Tighten
    Tighten the 2 brake master cylinder nuts to 21 N·m (16 lb ft).

  7. Install the brake line to the brake master cylinder.

    8. Tighten
    Tighten the 2 brake line to retaining bolts to brake master cylinder 14 N·m (124 lb in).

  8. For vehicles with manual transmission, install the supply line for the clutch master cylinder to the brake fluid reservoir.
  9. Connect the wiring harness plug to the brake fluid level sensor.
  10. Install the wiring harness on at the brake fluid reservoir.
  11. Install the hydraulic modulator bracket.

    12. Insert the hydraulic modulator bracket.

    Tighten
    Tighten the 3 hydraulic modulator bracket bolts to 20 N·m (15 lb ft).

  12. Install the hydraulic modulator.

    13. Tighten
    Tighten the 3 hydraulic modulator bolts to 8 N·m (71 lb in).

    • Install 6 hydraulic lines.

    Tighten
    Tighten the 6 hydraulic line retaining bolts to 14 N·m (124 lb in).

    • Connect the hydraulic modulator wiring harness plug.
  13. Install the coolant compensation tank to mounting.

    14. Connect the wiring harness plug for the coolant level sensor.

  14. Install the battery support.

    15. Tighten
    Tighten the 3 battery support bolts to 15 N·m (11 lb ft).

  15. Install the 2 cable ties.
  16. Install the battery.
  17. Install the battery shield.

    18. Install the bolt and attach the 2 shields to the battery carrier.

  18. Install the battery holder.

    19. Tighten
    Tighten the battery holder bolt to 7 N·m (62 lb in).

  19. Connect the battery.
    20. • Connect the positive cable
    • Connect the ground cable
  20. Bleed the brake system. Refer to Hydraulic Brake System Bleeding.
  21. Bleed the ABS MK70 / MK60 ESP. Refer to Antilock Brake System Automated Bleed Procedure.
  22. Top up the brake fluid reservoir to the MAX marking. Refer to Master Cylinder Reservoir Filling.
  23. Install the cover on to the brake fluid reservoir.
  24. For programming procedures, refer to Control Module References.