Removal Procedure
Caution: Refer to Brake Fluid Irritant Caution in the Preface section.
Notice: Refer to Brake Fluid Effects on Paint and Electrical Components Notice in the Preface section.
- Relieve fuel line pressure. Refer to
Fuel Pressure Relief
in Engine Controls - 3.5L.
- Drain the cooling system. Refer to
Cooling System Draining and Filling
in Engine Cooling.
- Remove the coolant reservoir. Refer to
Coolant Recovery Reservoir Replacement
in Engine Cooling.
- Remove the left front cross brace. Refer to
Front End Sheet Metal Diagonal Brace Replacement
in Body Front End.
- Remove the powertrain control module (PCM) cover from the air cleaner
housing.
- Remove the PCM and set aside. It is not necessary to disconnect the electrical
connector. Refer to
Powertrain Control Module Replacement
in Engine Controls - 3.5L.
- Remove the air cleaner and the duct. Refer to
Air Cleaner Inlet Duct Replacement
in Engine Controls - 3.5L.
- Remove the fuel lines from the pipes and vapor line. Refer to
Fuel Hose/Pipes Replacement - Engine Compartment
in Engine
Controls - 3.5L.
- Remove the heater hose from the coolant cross over pipe and reposition
out of the way. Refer to
Heater Inlet Hose/Pipe and Heater Outlet Hose/Pipe Replacement
in HVAC Systems - Manual.
- Unclip the fuel lines from the shock tower for easier access to the brake
pipes.
- Disconnect the fluid level sensor switch from the brake master cylinder.
- Disconnect the brake lines from the master cylinder and remove the master
cylinder. Refer to
Master Cylinder Replacement
.
- Remove the ABS module and bracket. Refer to
Brake Pressure Modulator Valve Replacement
in Antilock Brake System.
- Remove the brake booster vacuum hose from
the vacuum brake booster check valve. Reposition the vacuum hose.
- Remove the knee bolster. Refer to
Knee Bolster, Insulator, Molding Replacement - Instrument Panel
in Instrument Panel,
Gages, and Console.
- Remove the booster push pin retaining clip
and washer (2) from the brake pedal assembly.
- Remove the brake booster push rod (2) from the brake pedal (1).
- Remove the brake booster mounting nuts.
- Remove the 2 front engine mounts, nuts, and bolts. Refer to
Engine Mount Strut Replacement - Left Side
and
Engine Mount Strut Replacement - Right Side
in Engine Mechanical - 3.5L.
- Rotate the engine forward to gain access to the brake booster removal.
Refer to
Rotating the Engine for Service Access
in
Engine Mechanical - 3.5L.
- 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.
- Position the brake booster to the cowl and
the mounting plate.
Notice: Refer to Fastener Notice in the Preface section.
- Install the brake booster mounting nuts.
Tighten
Tighten the brake booster mounting nuts to 25 N·m (18 lb ft).
- Install the master cylinder. Refer to
Master Cylinder Replacement
.
- Install the brake booster push rod (2)
to the brake pedal (1). Install the washer and retaining clip.
Notice: Proper stoplamp switch adjustment is essential. Improper stoplamp switch
adjustment may cause brake drag, heat buildup and excessive brake lining wear.
- Calibrate the brake pedal position sensor. Refer to
Brake Pedal Position Sensor Calibration
in Lighting Systems.
- Install the knee bolster. Refer to
Knee Bolster, Insulator, Molding Replacement - Instrument Panel
in Instrument Panel,
Gages, and Console.
- Rotate the engine back and install the engine mounts, bolts, and nuts.
Refer to
Rotating the Engine for Service Access
in
Engine Mechanical - 3.5L.
- Install the brake booster vacuum hose to
the vacuum brake booster check valve.
- Install the ABS module bracket and module. Refer to
Brake Pressure Modulator Valve Replacement
in Antilock Brake System.
- Install the brake master cylinder and connect the brake lines. Refer to
Master Cylinder Replacement
.
- Connect the fluid level sensor switch on the master cylinder.
- Install the fuel pipes to the pipes shock tower.
- Install the heater hose to the coolant cross over pipe. Refer to
Heater Inlet Hose/Pipe and Heater Outlet Hose/Pipe Replacement
in HVAC Systems - Manual.
- Install the air cleaner and duct. Refer to
Air Cleaner Inlet Duct Replacement
in Engine Controls - 3.5L.
- Install the PCM. Refer to
Powertrain Control Module Replacement
in Engine Controls - 3.5L.
- Install the PCM cover.
- Install the left front cross brace. Refer to
Front End Sheet Metal Diagonal Brace Replacement
in Body Front End.
- Install the coolant reservoir. Refer to
Coolant Recovery Reservoir Replacement
in Engine Cooling.
- Fill and bleed the cooling system. Refer to
Cooling System Draining and Filling
in Engine Cooling.
- Bleed the brake system. Refer to
Hydraulic Brake System Bleeding
.