For 1990-2009 cars

### Removal Procedure

1. Remove the air cleaner and the duct. Refer to Air Filter Element Replacement in Engine Controls-3.4L.
2. Remove the vacuum hose (2) from the vacuum check valve (1). Reposition the vacuum hose.
3. Remove the throttle cables from the throttle body and the bracket. Refer to Accelerator Control Cable Replacement in Engine Controls-3.4L.
4. Remove the heater inlet pipe. Refer to Heater Inlet Pipe Replacement in Heating, Ventilation and Air Conditioning
5. Remove the fuel lines from the pipes and the vapor line. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls-3.4L.
6. Remove the ABS hydraulic modulator/master cylinder. Refer to Master Cylinder Replacement .
7. Remove the EGR tube.
8. Remove exhaust crossover. Refer to Exhaust Crossover Pipe Replacement in Engine Exhaust.
9. Remove the transmission fluid filler tube. Refer to Transmission Fluid Filler Tube Replacement in Automatic Transaxle - 4T65-E.
10. Remove the left side instrument panel insulator. Refer to Instrument Panel Insulator Panel Replacement - Left Side in Instrument Panel, Gauges and Console.
11. Remove the knee bolster. Refer to Knee Bolster Replacement in Instrument Panel, Gauges and Console.
12. Disable the SIR system. Refer to Disabling the SIR System in SIR.

Notice: When disconnecting the pushrod from the brake pedal, the brake pedal must be held stationary or damage to the brake switch may result.

13. Remove the brake booster push rod (2) from the brake pedal (1).
14. Remove the brake booster mounting nuts.
15. 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.

Notice: Proper stoplamp switch adjustment is essential. Improper stoplamp switch adjustment may cause brake drag, heat buildup and excessive brake lining wear.

1. Position the brake booster to the cowl and the mounting plate.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

2. Install the brake booster mounting nuts.

Tighten
Tighten the brake booster mounting nuts to 25 N·m (18 lb ft).

3. Install the brake booster push rod (2) to the brake pedal (1).
4. Adjust the stoplamp switch. Refer to Stop Lamp Switch Adjustment .
5. Enable the SIR system. Refer to Enabling the SIR System in SIR.
6. Install the knee bolster. Refer to Knee Bolster Replacement in Instrument Panel, Gauges and Console.
7. Install the left side instrument panel insulator. Refer to Instrument Panel Insulator Panel Replacement - Left Side in Instrument Panel, Gauges and Console.
8. Install the transmission fluid filler tube. Refer to Transmission Fluid Filler Tube Replacement in Automatic Transaxle - 4T65-E.
9. Install exhaust crossover. Refer to Exhaust Crossover Pipe Replacement in Engine Exhaust.
10. Install the EGR tube.
11. Install the ABS hydraulic modulator/master cylinder. Refer to Master Cylinder Replacement .
12. Install the fuel lines to the pipes and the vapor line. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls-3.4L.
13. Install the heater inlet pipe. Refer to Heater Inlet Pipe Replacement in Heating, Ventilation and Air Conditioning.
14. Install the throttle cables to the throttle body and the bracket. Refer to Accelerator Control Cable Replacement in Engine Controls-3.4L.
15. Install the vacuum hose (2) to the check valve (1).
16. Install the air cleaner and duct assembly. Refer to Air Filter Element Replacement in Engine Controls-3.4L.