GM Service Manual Online
For 1990-2009 cars only
Makes 🢒 Pontiac 🢒 2007 🢒 Solstice 🢒 Brakes 🢒 Hydraulic Brakes 🢒 Power Vacuum Brake Booster Replacement

Power Vacuum Brake Booster Replacement w/o JL4


Object Number: 1737354 Size: MF

Callout

Component Name

Preliminary Procedure

Remove the left instrument panel (I/P) closeout/insulator panel. Refer to Instrument Panel Insulator Panel Replacement - Left Side .

1

Vacuum Brake Booster Pushrod Clip

2

Vacuum Brake Booster Pushrod Washer

Procedure

Apply a thin coat of high-temperature grease GM P/N 12345996 (Canadian P/N 10953501) to the booster pushrod washer and the pushrod pin on the pedal.

3

Vacuum Brake Booster Pushrod

4

Vacuum Brake Booster Nut (Qty: 4)

Notice: Refer to Fastener Notice in the Preface section.

Tighten
25 N·m (18 lb ft)

5

Vacuum Brake Booster Check Valve Hose Clamp

6

Vacuum Brake Booster Check Valve Hose

Tip
If necessary, a small amount of denatured alcohol can be used as an assembly aid for installing the hose to the check valve. Do not use soap.

7

Brake Master Cylinder Nut (Qty: 2)

Procedure

Discard the master cylinder nuts and install new nuts.

Tighten
15 N·m (11 lb ft)

8

Brake Master Cylinder

Procedure

  1. Release the clamp and disconnect the clutch hose, if equipped. Cap the brake fluid reservoir outlet and plug the clutch master cylinder hose to prevent brake fluid loss and contamination.
  2. Carefully pull the brake master cylinder forward until it is past the vacuum brake booster studs.
  3. Ensure the brake master cylinder to vacuum brake booster seal is correctly seated at the rear of the master cylinder and is not damaged. Replace the seal if necessary.
  4. Position the brake master cylinder aside and secure with heavy mechanics wire or equivalent.

9

Vacuum Brake Booster

Procedure

  1. Carefully pull the vacuum brake booster forward and tilt upward until the studs are past the mounting holes.
  2. If reusing the booster, inspect the dash panel gasket for damage. Replace the gasket if necessary.
  3. Calibrate the brake pedal position sensor. Refer to Brake Pedal Position Sensor Calibration .

10

Vacuum Brake Booster to Dash Panel Insulator

Procedure

Inspect the vacuum brake booster to dash panel insulator for damage. Replace the insulator if necessary.

Power Vacuum Brake Booster Replacement w/JL4

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.

  1. Turn the ignition switch to the OFF position.
  2. Clean the electronic brake control module (EBCM) to brake pressure modulator valve (BPMV) area and the brake pipe port areas of any accumulated dirt and foreign material.

    3. Object Number: 1859458 Size: SH
  3. Disconnect the brake fluid level indicator switch electrical connector.
  4. Disconnect the vacuum brake booster vacuum sensor electrical connector.

    5. Object Number: 1859461 Size: SH
  5. Remove the vacuum brake booster check valve and vacuum sensor assembly from the grommet and position aside.

    6. Object Number: 1859462 Size: SH
  6. Release the wiring harness retainer from the master cylinder mounting stud and position the wiring harness downward.
  7. Remove and discard the 2 master cylinder nuts.
  8. If equipped, disconnect the clutch master cylinder hose from the brake master cylinder reservoir.

    9. Cap the brake fluid reservoir outlet and plug the clutch master cylinder hose inlet to prevent brake fluid loss and contamination.


    Object Number: 1859463 Size: SH
  9. Remove the 2 master cylinder brake pipe fittings from the BPMV.

    10. Cap the brake pipe fittings and plug the BPMV inlet ports to prevent brake fluid loss and contamination.

  10. Remove the brake master cylinder and master cylinder brake pipes as an assembly.

    11. Object Number: 1859464 Size: SH
  11. Lift the locking tabs on the lower edge of the EBCM electrical connector (1)  and disconnect the electrical connector.
  12. Position the EBCM electrical connector and the wiring harness toward the front of the vehicle.
  13. Release the rear brake pipes retainer (2) from the outboard side of the frame rail.

    14. Object Number: 1859465 Size: SH
  14. Remove the 3 BPMV bracket bolts.
  15. Carefully position the brake modulator assembly forward slightly.

    16. Object Number: 1859466 Size: SH
  16. Remove the vacuum brake booster pushrod retaining clip.
  17. Remove the vacuum brake booster pushrod spacer.

    18. Object Number: 1859471 Size: SH
  18. Disconnect the vacuum brake booster pushrod (1) from the brake pedal pushrod pin.
  19. Remove the 4 vacuum brake booster mounting nuts (2).
  20. Remove the vacuum brake booster from the vehicle.

Installation Procedure

    Object Number: 1859472 Size: SH
  1. Inspect the vacuum brake booster to dash panel seal (1) for damage and replace, if necessary.
  2. Inspect the vacuum brake booster to dash panel gasket (2) for damage and replace, if necessary.
  3. Install the vacuum brake booster (3) to the vehicle.

    4. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 1859471 Size: SH
  4. Connect the vacuum brake booster pushrod (1) to the brake pedal pushrod pin.
  5. Install the 4 vacuum brake booster mounting nuts (2).

    6. Tighten
    Tighten the nuts to 25 N·m (18 lb ft).


    Object Number: 1859466 Size: SH
  6. Apply a thin coat of high-temperature grease GM P/N 12345996 (Canadian P/N 10953501) to the vacuum brake booster pushrod spacer and the brake pedal pushrod pin.
  7. Install the vacuum brake booster pushrod spacer.
  8. Install the vacuum brake booster pushrod retaining clip.

    9. Object Number: 1859465 Size: SH
  9. Carefully position the brake modulator assembly to the frame rail.
  10. Install the 3 BPMV bracket bolts.

    11. Tighten
    Tighten the bolts to 10 N·m (89 lb in).


    Object Number: 1859464 Size: SH
  11. Position the EBCM electrical connector and the wiring harness to the EBCM.
  12. Connect the EBCM electrical connector (1) . Ensure the tabs on the cam lever are securely locked in place.
  13. Install the rear brake pipes retainer (2) to the outboard side of the frame rail.

    14. Object Number: 1859463 Size: SH
  14. Install the brake master cylinder and master cylinder brake pipes assembly to the vacuum brake booster.
  15. Install the master cylinder brake pipe fittings to the BPMV.

    16. Tighten
    Tighten the brake pipe fittings to 20 N·m (15 lb ft).


    Object Number: 1859462 Size: SH
  16. If equipped, connect the clutch master cylinder hose to the brake master cylinder reservoir.
  17. Install 2 new brake master cylinder nuts.

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

  18. Position the wiring harness upward and install the wiring harness retainer to the master cylinder mounting stud on the vacuum brake booster.

    19. Important: If necessary, a small amount of denatured alcohol can be used as an assembly aid for installing the check valve to the vacuum brake booster grommet. Do not use soap.


    Object Number: 1859461 Size: SH
  19. Install the vacuum check valve and vacuum sensor assembly to the vacuum brake booster.

    20. Object Number: 1859458 Size: SH
  20. Connect the brake booster vacuum sensor electrical connector.
  21. Connect the brake fluid level indicator switch electrical connector.
  22. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding .
  23. Calibrate the brake pedal position sensor. Refer to Brake Pedal Position Sensor Calibration .

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.

  1. Turn the ignition switch to the OFF position.
  2. Clean the electronic brake control module (EBCM) to brake pressure modulator valve (BPMV) area and the brake pipe port areas of any accumulated dirt and foreign material.

    3. Object Number: 1859458 Size: SH
  3. Disconnect the brake fluid level indicator switch electrical connector.
  4. Disconnect the vacuum brake booster vacuum sensor electrical connector.

    5. Object Number: 1859461 Size: SH
  5. Remove the vacuum brake booster check valve and vacuum sensor assembly from the grommet and position aside.

    6. Object Number: 1859462 Size: SH
  6. Release the wiring harness retainer from the master cylinder mounting stud and position the wiring harness downward.
  7. Remove and discard the 2 master cylinder nuts.
  8. If equipped, disconnect the clutch master cylinder hose from the brake master cylinder reservoir.

    9. Cap the brake fluid reservoir outlet and plug the clutch master cylinder hose inlet to prevent brake fluid loss and contamination.


    Object Number: 1859463 Size: SH
  9. Remove the 2 master cylinder brake pipe fittings from the BPMV.

    10. Cap the brake pipe fittings and plug the BPMV inlet ports to prevent brake fluid loss and contamination.

  10. Remove the brake master cylinder and master cylinder brake pipes as an assembly.

    11. Object Number: 1859464 Size: SH
  11. Lift the locking tabs on the lower edge of the EBCM electrical connector (1)  and disconnect the electrical connector.
  12. Position the EBCM electrical connector and the wiring harness toward the front of the vehicle.
  13. Release the rear brake pipes retainer (2) from the outboard side of the frame rail.

    14. Object Number: 1859465 Size: SH
  14. Remove the 3 BPMV bracket bolts.
  15. Carefully position the brake modulator assembly forward slightly.

    16. Object Number: 1859466 Size: SH
  16. Remove the vacuum brake booster pushrod retaining clip.
  17. Remove the vacuum brake booster pushrod spacer.

    18. Object Number: 1859471 Size: SH
  18. Disconnect the vacuum brake booster pushrod (1) from the brake pedal pushrod pin.
  19. Remove the 4 vacuum brake booster mounting nuts (2).
  20. Remove the vacuum brake booster from the vehicle.

Installation Procedure

    Object Number: 1859472 Size: SH
  1. Inspect the vacuum brake booster to dash panel seal (1) for damage and replace, if necessary.
  2. Inspect the vacuum brake booster to dash panel gasket (2) for damage and replace, if necessary.
  3. Install the vacuum brake booster (3) to the vehicle.

    4. Notice: Refer to Fastener Notice in the Preface section.


    Object Number: 1859471 Size: SH
  4. Connect the vacuum brake booster pushrod (1) to the brake pedal pushrod pin.
  5. Install the 4 vacuum brake booster mounting nuts (2).

    6. Tighten
    Tighten the nuts to 25 N·m (18 lb ft).


    Object Number: 1859466 Size: SH
  6. Apply a thin coat of high-temperature grease GM P/N 12345996 (Canadian P/N 10953501) to the vacuum brake booster pushrod spacer and the brake pedal pushrod pin.
  7. Install the vacuum brake booster pushrod spacer.
  8. Install the vacuum brake booster pushrod retaining clip.

    9. Object Number: 1859465 Size: SH
  9. Carefully position the brake modulator assembly to the frame rail.
  10. Install the 3 BPMV bracket bolts.

    11. Tighten
    Tighten the bolts to 10 N·m (89 lb in).


    Object Number: 1859464 Size: SH
  11. Position the EBCM electrical connector and the wiring harness to the EBCM.
  12. Connect the EBCM electrical connector (1) . Ensure the tabs on the cam lever are securely locked in place.
  13. Install the rear brake pipes retainer (2) to the outboard side of the frame rail.

    14. Object Number: 1859463 Size: SH
  14. Install the brake master cylinder and master cylinder brake pipes assembly to the vacuum brake booster.
  15. Install the master cylinder brake pipe fittings to the BPMV.

    16. Tighten
    Tighten the brake pipe fittings to 20 N·m (15 lb ft).


    Object Number: 1859462 Size: SH
  16. If equipped, connect the clutch master cylinder hose to the brake master cylinder reservoir.
  17. Install 2 new brake master cylinder nuts.

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

  18. Position the wiring harness upward and install the wiring harness retainer to the master cylinder mounting stud on the vacuum brake booster.

    19. Important: If necessary, a small amount of denatured alcohol can be used as an assembly aid for installing the check valve to the vacuum brake booster grommet. Do not use soap.


    Object Number: 1859461 Size: SH
  19. Install the vacuum check valve and vacuum sensor assembly to the vacuum brake booster.

    20. Object Number: 1859458 Size: SH
  20. Connect the brake booster vacuum sensor electrical connector.
  21. Connect the brake fluid level indicator switch electrical connector.
  22. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding .
  23. Calibrate the brake pedal position sensor. Refer to Brake Pedal Position Sensor Calibration .