Power Brake Master Cylinder Booster Assembly Replacement
Removal Procedure

WarningBrake Fluid Irritant Warning

CautionBrake Fluid Effects on Paint and Electrical Components Caution

Caution: Do not lift or carry the electric brake booster by the input rod, electrical connectors or master cylinder reservoir. Failure to follow these steps may damage the electric brake booster.

    Caution: If there is no brake fluid in the master cylinder, remove one of the brake booster fuses before applying the brake pedal. Failure to do so may damage the electric brake booster.

  1. Remove one of the electric brake booster fuses from the engine compartment fuse block.
  2. Dash Upper Extension Panel Opening Cover Replacement»Remove

    3. Object ID: 4168637
  3. Electrical Connector(1)@Power Brake Booster(2)»Disconnect
  4. Electrical Connector(3)@Power Brake Booster(2)»Disconnect

    5. Object ID: 4084596
  5. Electrical Connector(2)@Brake Fluid Level Sensor(1)»Disconnect

    6. Object ID: 4091185
  6. Clip(2)@Brake Master Cylinder Reservoir(3)»Unclip[2x]
  7. Clip(4)@Brake Master Cylinder Reservoir»Unclip
  8. Body Wiring Harness(1)@Brake Master Cylinder Reservoir»Remove

    9. Object ID: 4084518
  9. Clip(2)@Radiator Surge Tank(1)»Remove

    10. Note: Do NOT disconnect the engine coolant hoses.

  10. Slide the radiator surge tank forward and lift to remove.

    11. Object ID: 4168638
  11. Brake Master Cylinder Reservoir Hose(2)@Brake Master Cylinder Reservoir(1)»Disconnect
  12. Brake Pressure Modulator Valve Secondary Pipe Fitting(7)@Brake Master Cylinder(8)»Remove
  13. Brake Pressure Modulator Valve Secondary Pipe(6)@Brake Master Cylinder»Remove
  14. Brake Pressure Modulator Valve Primary Pipe Fitting(4)@Brake Master Cylinder»Remove
  15. Brake Pressure Modulator Valve Primary Pipe(5)@Brake Master Cylinder»Remove
  16. Remove the master cylinder without removing the master cylinder reservoir. Brake Master Cylinder Replacement

    17. Object ID: 4168635
  17. Bolt(2)@Power Brake Booster(1)»Loosen[2x]
  18. Brake Pedal Position Sensor Replacement»Remove

    19. Object ID: 4171512
  19. Disconnect the brake pedal push rod (1) from the brake pedal (2). Press the 2 tabs of the click fit connector (3) together and pull the brake pedal to facilitate the removal.

    20. Object ID: 4091509
  20. Remove and DISCARD the click fit connector (1) from the brake pedal (2).

    21. Note: Protect the windshield edge before removing the component.

  21. Power Brake Booster@Vehicle»Remove

    22. Object ID: 4168633
  22. Remove and DISCARD the power brake booster gasket (1).
  23. Remove the power brake booster heat shield.(2)
Installation Procedure

    Object ID: 4168633
  1. Install the power brake booster heat shield (2).

    2. Note: Ensure that the old gasket was removed from the vehicle.

  2. Install the NEW power brake booster gasket (1).
  3. Power Brake Booster@Vehicle»Install

    4. Object ID: 4091509
  4. Install the NEW click fit connector (1) to the brake pedal (2).

    5. Object ID: 4171512
  5. Connect the brake pedal push rod (1) to the brake pedal (2).
  6. Brake Pedal Position Sensor Replacement»Install

    7. Object ID: 4168635

    CautionFastener Caution

  7. Bolt(2)@Power Brake Booster(1)»Tighten[2x]22 N·m (16 lb ft)
  8. Install the master cylinder with the master cylinder reservoir. Brake Master Cylinder Replacement

    9. Object ID: 4168638
  9. Brake Pressure Modulator Valve Primary Pipe(5)@Brake Master Cylinder(8)»Install
  10. Brake Pressure Modulator Valve Primary Pipe Fitting(4)@Brake Master Cylinder»Tighten32N·m (24 lb ft)
  11. Brake Pressure Modulator Valve Secondary Pipe(6)@Brake Master Cylinder»Install
  12. Brake Pressure Modulator Valve Secondary Pipe Fitting(7)@Brake Master Cylinder»Tighten32N·m (24 lb ft)
  13. Brake Master Cylinder Reservoir Hose(2)@Brake Master Cylinder Reservoir(1)»Install

    14. Object ID: 4168640
  14. Ensure the brake pipes are correctly installed.
    1. Brake Pressure Modulator Valve Primary Pipe Fitting(1)
    2. Brake Pressure Modulator Valve Secondary Pipe(2)

    Object ID: 4084518
  15. Radiator Surge Tank(1)»Install
  16. Radiator Surge Tank Bracket Clip(2)»Install

    17. Object ID: 4091185
  17. Body Wiring Harness(1)Install
  18. Clip(2)@Brake Master Cylinder Reservoir(3)»Install[2x]
  19. Clip(4)@Brake Master Cylinder Reservoir»Install

    20. Object ID: 4084596
  20. Electrical Connector(2)@Brake Fluid Level Sensor(1)»Connect

    21. Object ID: 4168637
  21. Electrical Connector(1)@Power Brake Booster(2)»Connect
  22. Electrical Connector(3)@Power Brake Booster»Connect
  23. Dash Upper Extension Panel Opening Cover Replacement»Install
  24. Install the electric brake booster fuse to the engine compartment fuse block.
  25. Hydraulic Brake System Bleeding
  26. Program and calibrate the power brake booster control module. Refer to Control Module References.