Removal
All cars
1. Remove the brake master cylinder. Refer to Section 206-06 for additional information.
Vehicles with stability control
2. Disconnect the brake booster solenoid valve plug.
3. Disconnect the hydraulic control unit (HCU) plug connector.
- 1. Loosen the clamp.
- 2. Disconnect the plug connector.
4.
CAUTION: Cap the brake line to prevent brake fluid from leaking and dirt from entering the hose.
Disconnect the brake lines from the HCU.
5. Remove the HCU.
All cars
6. Release the brake lines from the clamps on the bulkhead.
7. Disconnect the brake booster pushrod from the brake pedal.
- 1. Depress the brake pedal.
- 2. Release the clamp.
- 3. Remove the brake booster push rod pin.
8. Loosen the brake booster mounting nuts.
9. Remove the brake booster.
Installation
All cars
1.
CAUTION: Make sure the brake booster pushrod is properly positioned through the rubber boot on the bulkhead.
CAUTION: Before installation, make sure the gasket is properly installed on the brake booster.
Install the brake booster.
2.
NOTE: Do not tighten completely at this stage.
Install the brake booster mounting nuts.
3.
CAUTION: Install a new brake booster pushrod to brake pedal connecting pin.
Install the brake booster push rod pin.
- 1. Depress the brake pedal.
- 2.Install the brake booster push rod pin.
Cars produced since 01.1999.
4. Disconnect the lower section of the instrument panel.
- 1. Remove the screws.
- 2. Release the clamp.
5. Disconnect the data link connector and remove the lower section of the instrument panel.
6. Remove the air duct.
- 1.Remove the retainer.
- 2.Remove the air duct.
7. Loosen the brake pedal return lever mounting bolt.
8.
CAUTION: Make sure there is clearance between the brake pedal and the brake pedal return lever to allow freedom of movement.
Align the brake pedal return lever with the brake pedal bracket.
All cars
9. Tighten the brake booster mounting nuts.
10. With the engine running, depress the brake pedal three times to ensure that the brake pedal moves freely and returns to the unapplied position.
Cars produced since 01.1999.
11. Tighten the brake pedal return lever mounting bolt.
12. Install the air duct.
- 1. Install the air duct.
- 2. Fasten the clamp.
13. Secure the data link connector to the lower section of the instrument panel.
14. Install the lower section of the instrument panel.
- 1. Fasten the clamp.
- 2. Tighten the screw.
All cars
15. Secure the brake pipes to the bulkhead.
Vehicles with stability control
16. Install HCU.
17. Connect the brake lines to the HCU.
18. Connect the HCU plug connector.
- 1.Connect the plug connector.
- 2. Press the lock.
19. Connect the brake booster solenoid valve plug.
20. Install the brake master cylinder. Refer to Section 206-06 for additional information.
21. Bleed the brake system. Refer to Section 206-00 for additional information.
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