Page 489 of 3229
Publi s hed: 11-May-2011
Power Brake Actuation - Brake Booster
Removal and Inst all ati on
Removal
• CAUTIO NS:
Extreme cleanli nes s mus t be exercis ed when handli ng thes e component s.
If brake fluid is s pil t on the pai ntwork, t he affect ed area must be immedi ately washed down wi th col d wat er.
All vehicles
1. W ARNING: Make sure t o s upport the vehicle wit h axles tands .
Rais e and s upport t he vehi cl e.
1.
Di sconnect t he bat t ery ground cable.
Refer t o: Specificati ons (414-00 Bat tery and Charging Sys tem -General Informat ion, Specificati ons).
2.
Remove t he winds hield wiper motor and l inkage.
Refer t o: W i nds hield W i per Mot or (501-16 W ipers and W as hers ,Removal and Ins tall ati on).
3.
Remove t he dri ver l ower ai r bag modul e.
Refer t o: Dri ver Lower Air Bag Module (501-20B SupplementalRes traint Sys t em, Removal and Inst all at ion).
4.
Left-hand drive vehicles
5.
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6.
All vehicles
7. CAUTION: Make s ure that all openi ngs ares ealed.7.
Vehicles with manual transmission
8. CAUTIONS:
Be prepared t o collect es caping flui ds .
Make s ure that all openings are sealed.
8.
Right-hand drive vehicles
Page 491 of 3229
9. CAUTIONS:
Be prepared t o collect es caping flui ds .
Make s ure that all openings are sealed.
9.
Left-hand drive vehicles
10. CAUTIONS:
Be prepared t o collect es caping flui ds .
Make s ure that all openings are sealed.
10.
All vehicles
11. CAUTION: The s eal i s t o be reus ed unles sdamaged.11.
12. CAUTION: The s eal i s t o be reus ed unles sdamaged.12.
Page 492 of 3229

Installation
All vehicles
1. CAUTION: Make s ure that the mati ng faces are cl ean and
free of foreign mat eri al.
Inst all t he brake mas ter cyli nder.
T orque: 26 Nm 1.
2. CAUTION: Make s ure that the mati ng faces are cl ean and
free of foreign mat eri al.
Inst all t he brake boost er.
T orque: 22 Nm 2.
3. CAUTION: Make s ure that the mati ng faces are cl ean and
free of foreign mat eri al.
Inst all t he brake fluid tubes.
T orque: 15 Nm 3.
Vehicles with manual transmission 4. CAUTION: Make s ure that the mati ng faces are cl ean and
free of foreign mat eri al.
Connect t he clutch flui d li ne.
4.
All vehicles Connect t he brake boost er vacuum l ine.
5.
Connect t he low brake fl uid warning i ndi cat or swit ch el ect ri cal
connector.
6.
Left-hand drive vehicles Inst all t he ECM bracket.
T orque: 10 Nm 7.
Inst all t he ECM.
8.
All vehicles Inst all t he dri ver l ower ai r bag modul e.
Refer t o: Dri ver Lower Air Bag Module (501-20B Supplemental
Res traint Sys t em, Removal and Inst all at ion).
9.
Inst all t he winds hield wiper motor and l inkage.
Refer t o: W i nds hield W i per Mot or (501-16 W ipers and W as hers ,
Removal and Ins tall ati on).
10.
Connect t he batt ery ground cable.
11.
Page 493 of 3229
Refer t o: Specificati ons (414-00 Bat tery and Charging Sys tem -General Informat ion, Specificati ons).
Bleed t he brake s ys tem.
Refer t o: Brake Syst em Bl eedi ng (206-00 Brake Syst em - GeneralInformat ion, General Procedures).
12.
Vehicles with manual transmission
Bleed t he clut ch sys t em.
Refer t o: Clutch Sys tem Bleeding (308-00 ManualTrans mi ss ion/Transaxle and Clut ch - General Informati on, GeneralProcedures ).
13.
Page 494 of 3229
Publi s hed: 11-May-2011
Power Brake Actuation - Brake Vacuum PumpI6 3.2L Petrol
Removal and Inst all ati on
Removal
• NOTE: Removal s t eps in t his procedure may cont ain i nst all ati on det ail s.
Remove t he cover and dis connect the bat tery ground cabl e.
Refer t o: Specificati ons (414-00 Bat tery and Charging Sys tem -
General Informat ion, Specificati ons).
1.
Remove t he engi ne cover.
Refer t o: Engi ne Cover - I6 3.2L Pet rol (501-05 Int eri or Trim and
Ornament ati on, Removal and Ins tal lat ion).
2.
Remove t he bat t ery t ray.
Refer t o: Bat t ery Tray (414-01 Bat tery, Mount ing and Cables ,
Removal and Ins tall ati on).
3.
Remove t he air cleaner as s embly.
Refer t o: Air Cleaner (303-12B Intake Ai r Dis tribut ion and Fil tering -
TD4 2.2L Dies el, Removal and Inst all ati on).
4. Remove t he A/C compress or, upper s upport bracket.
T orque: M10 45 Nm M8
25 Nm M6
10 Nm 5.
Di sconnect t he brake boost er vacuum l ine from t he brake vacuum
pump.
6.
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7.
NOTE: Make s ure t hat this component is i nst all ed to
t he noted removal pos it ion.
Remove t he brake vacuum pump.
T orque: 17 Nm 7.
Installation 1. NOTE: Make s ure t hat the component i s clean, free of forei gn
mat eri al and l ubricant.
To i nst all , revers e t he removal procedure.
1.
Page 496 of 3229
Publi s hed: 11-May-2011
Power Brake Actuation - Brake Vacuum PumpTD4 2.2L Diesel
Removal and Inst all ati on
Removal
• NOTE: Removal s t eps in t his procedure may cont ain i nst all ati on det ail s.
Remove t he cover and dis connect the bat tery ground cabl e.
Refer t o: Specificati ons (414-00 Bat tery and Charging Sys tem -
General Informat ion, Specificati ons).
1.
Remove t he engi ne cover.
Refer t o: Engi ne Cover - TD4 2.2L Dies el (501-05 Interior Tri m and
Ornament ati on, Removal and Ins tal lat ion).
2.
Remove t he air cleaner as s embly.
Refer t o: Air Cleaner (303-12B Intake Ai r Dis tribut ion and Fil tering -
TD4 2.2L Dies el, Removal and Inst all ati on).
3. T orque:
9 Nm 4.
5.