Buick Encore: Repair instructions

Master cylinder reservoir filling

WARNING: Refer to Brake Fluid Irritant Warning

CAUTION: Refer to Brake Fluid Effects on Paint and Electrical Components Caution .

1. Visually inspect the brake fluid level through the brake master cylinder reservoir.
2. If the brake fluid level is at or below the half-full point during routine fluid checks, the brake system should be inspected for wear and possible brake fluid leaks.
3. If the brake fluid level is at or below the half-full point during routine fluid checks, and an inspection of the brake system did not reveal wear or brake fluid leaks, the brake fluid may be topped-off up to the maximum-fill level.
4. If brake system service was just completed, the brake fluid may be topped-off up to the maximum-fill level.
5. If the brake fluid level is above the half-full point, adding brake fluid is not recommended under normal conditions.
6. If brake fluid is to be added to the master cylinder reservoir, clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm. Use only GM approved brake fluid from a clean, sealed brake fluid container.

MASTER CYLINDER RESERVOIR REPLACEMENT

Removal Procedure

WARNING: Refer to Brake Fluid Irritant Warning .

CAUTION: Refer to Brake Fluid Effects on Paint and Electrical Components Caution

1. Remove and properly dispose of the brake fluid from the master cylinder reservoir.
2. Remove the brake master cylinder. Refer to Master Cylinder Replacement

Fig. 10: Brake Master Cylinder Reservoir Roll Pin

3. Remove and discard the brake master cylinder reservoir roll pin (1).

Fig. 11: Master Cylinder Reservoir

4. Remove the master cylinder reservoir (1) by carefully pulling straight upward.
5. Remove the brake fluid level indicator switch, if necessary. Refer to Brake Fluid Level Indicator Switch Replacement.

Fig. 12: Master Cylinder Reservoir Seals

6. Remove the brake master cylinder reservoir seals (1).
7. If replacing the master cylinder reservoir, discard the reservoir seals.

Installation Procedure

Fig. 13: Master Cylinder Reservoir Seals

1. Lightly lubricate the brake master cylinder reservoir seals (1) with GM approved brake fluid from a clean, sealed, brake fluid container.
2. Install the lubricated brake master cylinder reservoir seals to the brake master cylinder.

Fig. 14: Master Cylinder Reservoir

3. Install the master cylinder reservoir (1) by firmly pressing straight downward.
4. Install the brake fluid level indicator switch, if removed. Refer to Brake Fluid Level Indicator Switch Replacement.

Fig. 15: Brake Master Cylinder Reservoir Roll Pin

5. Install a new brake master cylinder reservoir roll pin (1).
6. Install the brake master cylinder. Refer to Master Cylinder Replacement.

Master cylinder replacement

Removal Procedure

WARNING: Refer to Brake Fluid Irritant Warning .

CAUTION: Refer to Brake Fluid Effects on Paint and Electrical Components Caution .

1. Place the ignition switch in the OFF position.
2. Remove the battery. Refer to Battery Replacement .
3. Disconnect the brake fluid level indicator switch electrical connector.
4. Using a suitable suction device, remove and properly discard the brake fluid from the brake master cylinder reservoir.

Fig. 16: Clutch Master Cylinder Reservoir Hose

5. On manual transmission equipped vehicles, disconnect the clutch master cylinder reservoir hose (1).

Fig. 17: Master Cylinder Outlet Port

6. Disconnect the master cylinder secondary brake pipe fitting (1).
7. Cap the brake pipe fitting and plug the master cylinder outlet port to prevent brake fluid loss and contamination.

Fig. 18: Master Cylinder Primary Brake Pipe Fitting

8. Disconnect the master cylinder primary brake pipe fitting (1).
9. Cap the brake pipe fitting and plug the master cylinder outlet port to prevent brake fluid loss and contamination.

Fig. 19: Brake Master Cylinder And Nuts

10. Remove the master cylinder nuts (1).
11. Remove the brake master cylinder.

Fig. 20: Master Cylinder Seal

12. Remove the master cylinder seal (1).
13. Inspect the master cylinder seal for damage or deterioration and replace, if necessary.
14. Remove the brake fluid level indicator switch, if necessary. Refer to Brake Fluid Level Indicator Switch Replacement.
15. Remove the master cylinder reservoir, if necessary. Refer to Master Cylinder Reservoir Replacement.

Installation Procedure

1. Install the master cylinder reservoir, if removed. Refer to Master Cylinder Reservoir Replacement.
2. Bench bleed the master cylinder. Refer to Master Cylinder Bench Bleeding.
3. Install the brake fluid level indicator switch, if removed. Refer to Brake Fluid Level Indicator Switch Replacement.

Fig. 21: Master Cylinder Seal

4. Install the master cylinder seal (1).
5. Install the master cylinder to the power vacuum brake booster.

Fig. 22: Brake Master Cylinder And Nuts

CAUTION: Refer to Fastener Caution

6. Install the master cylinder nuts (1) and tighten to 19 (14 lb ft).

Fig. 23: Master Cylinder Primary Brake Pipe Fitting

7. Connect the master cylinder primary brake pipe fitting (1) and tighten to 18 N.m (13 lb ft).

Fig. 24: Master Cylinder Outlet Port

8. Connect the master cylinder secondary brake pipe fitting (1) and tighten to 18 N.m (13 lb ft).

Fig. 25: Clutch Master Cylinder Reservoir Hose

9. On manual transmission equipped vehicles, connect the clutch master cylinder reservoir hose (1).
10. Connect the brake fluid level indicator switch electrical connector.
11. Install the battery. Refer to Battery Replacement .
12. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual), Hydraulic Brake System Bleeding (Pressure).

Master cylinder bench bleeding

Fig. 26: Depressing And Releasing Primary Piston

WARNING: Refer to Brake Fluid Irritant Warning .

CAUTION: Refer to Brake Fluid Effects on Paint and Electrical Components Caution .

1. Secure the mounting flange of the brake master cylinder in a bench vice so that the rear of the primary piston is accessible.
2. Remove the master cylinder reservoir cap and diaphragm.
3. Install suitable fittings to the master cylinder ports that match the type of flare seat required and also provide for hose attachment.
4. Install transparent hoses to the fittings installed to the master cylinder ports, then route the hoses into the master cylinder reservoir.
5. Fill the master cylinder reservoir to the maximum fill level with brake fluid from a clean, sealed brake fluid container. Refer to Master Cylinder Reservoir Filling.
6. Ensure that the ends of the transparent hoses running into the master cylinder reservoir are fully submerged in the brake fluid.
7. Using a smooth, round-ended tool, depress and release the primary piston as far as it will travel, a depth of about 25 mm (1 in), several times. Observe the flow of fluid coming from the ports.

   As air is bled from the primary and secondary pistons, the effort required to depress the primary piston will increase and the amount of travel will decrease.

8. Continue to depress and release the primary piston until fluid flows freely from the ports with no evidence of air bubbles.
9. Remove the transparent hoses from the master cylinder reservoir.
10. Install the master cylinder reservoir cap and diaphragm.
11. Remove the fittings with the transparent hoses from the master cylinder ports. Wrap the master cylinder with a clean shop cloth to prevent brake fluid spills.
12. Remove the master cylinder from the vice.

BRAKE FLUID LEVEL INDICATOR SWITCH REPLACEMENT

Removal Procedure

1. Disconnect the brake fluid level indicator switch electrical connector.

Fig. 27: Brake Fluid Level Indicator Switch

2. Using a small, flat-bladed tool, lift the locking tab on the underside of the brake fluid level indicator switch (1) and remove the switch.
3. Inspect the master cylinder reservoir for damage and replace, if necessary. Refer to Master Cylinder Reservoir Replacement.

Installation Procedure

1. Install the master cylinder reservoir, if removed. Refer to Master Cylinder Reservoir Replacement.

Fig. 28: Brake Fluid Level Indicator Switch

2. Install the brake fluid level indicator switch (1) by pressing the switch firmly into the brake master cylinder reservoir.
3. Connect the brake fluid level indicator switch electrical connector.

Brake, accelerator, and clutch pedal replacement

Removal Procedure

1. Remove the battery tray. Refer to Battery Tray Replacement .

Fig. 29: Power Vacuum Brake Booster Bolts

2. Remove the power vacuum brake booster bolts (1).

Fig. 30: Brake Pedal Assembly Upper Nuts

3. Remove the brake pedal assembly upper nuts (1)

Fig. 31: Brake Pedal Assembly Lower Nuts

4. Remove the brake pedal assembly lower nuts (1)
5. Remove the steering column. Refer to Steering Column Replacement (Mexico, N40) , Steering Column Replacement (Canada, NJ1) , Steering Column Replacement (United States, NJ1) .

Fig. 32: Brake Pedal Release Bracket Bolt

6. Remove the brake pedal release bracket bolt (1).

Fig. 33: Brake Pedal Release Bracket And Bolts

7. Remove the brake pedal release bracket bolts (1).

Fig. 34: Brake Pedal Release Bracket

8. Remove the brake pedal release bracket (1).
9. Remove the brake pedal position sensor. Refer to Brake Pedal Position Sensor Replacement .
10. On manual transmission equipped vehicles, remove the clutch pedal position sensor. Refer to Clutch Pedal Position Sensor Replacement .
11. Remove the accelerator pedal position sensor. Refer to Accelerator Pedal Position Sensor Replacement .

Fig. 35: Clutch Master Cylinder Pushrod Locking Tabs

12. On manual transmission equipped vehicles, compress the clutch master cylinder pushrod locking tabs (1) and release the clutch pedal by lifting the pedal upward.

Fig. 36: Clutch Master Cylinder Bolts

13. On manual transmission equipped vehicles, remove the clutch master cylinder bolts (1) and position the clutch master cylinder aside. Refer to Clutch Master Cylinder Replacement .
14. Position aside any wiring harnesses attached to the brake pedal assembly bracket, as necessary.

Fig. 37: Upper Brake Pedal Assembly Bolts

15. Remove the 2 upper brake pedal assembly bolts (1).

Fig. 38: Brake Pedal AssemblyAnd Dash Panel

16. Pull the brake pedal assembly away from the dash panel.
17. From behind the brake pedal assembly, remove the brake pedal assembly bracket nut (1).

Fig. 39: Brake Pedal Assembly

18. Remove the brake pedal assembly bracket (1).
19. Remove the brake pedal assembly from the vehicle.
20. Remove any necessary components from the brake pedal assembly.

Installation Procedure

1. Install any removed components from the brake pedal assembly.
2. Install the brake pedal assembly to the vehicle.

Fig. 40: Brake Pedal Assembly

3. Install the brake pedal assembly bracket (1).

Fig. 41: Brake Pedal AssemblyAnd Dash Panel

4. Pull the brake pedal assembly away from the dash panel.

CAUTION: Refer to Fastener Caution .

5. From behind the brake pedal assembly, install the brake pedal assembly bracket nut (1) and tighten to 9 (80 lb in).

Fig. 42: Brake Pedal Assembly Lower Nuts

6. Install the brake pedal assembly lower nuts (1) and tighten to 19 N.m (14 lb ft).

Fig. 43: Brake Pedal Assembly Upper Nuts

7. Install the brake pedal assembly upper nuts (1) and tighten to 19 N.m (14 lb ft).

Fig. 44: Upper Brake Pedal Assembly Bolts

8. Install the 2 upper brake pedal assembly bolts (1) and tighten to 9 N.m (80 lb in).
9. Reposition any wiring harnesses attached to the brake pedal assembly bracket, as necessary.

Fig. 45: Clutch Master Cylinder Bolts

10. On manual transmission equipped vehicles, install the clutch master cylinder and bolts (1). Refer to Clutch Master Cylinder Replacement .

Fig. 46: Clutch Master Cylinder Pushrod Locking Tabs

11. On manual transmission equipped vehicles, compress the clutch master cylinder pushrod locking tabs (1) and install the clutch pedal to the clutch master cylinder pushrod.
12. Install the brake pedal position sensor. Refer to Brake Pedal Position Sensor Replacement .
13. On manual transmission equipped vehicles, install the clutch pedal position sensor. Refer to Clutch Pedal Position Sensor Replacement .
14. Install the accelerator pedal position sensor. Refer to Accelerator Pedal Position Sensor Replacement

Fig. 47: Brake Pedal Release Bracket

15. Install the brake pedal release bracket (1).

Fig. 48: Brake Pedal Release Bracket And Bolts

16. Install the brake pedal release bracket bolts (1) and tighten to 22 N.m (16 lb ft).

Fig. 49: Brake Pedal Release Bracket Bolt

17. Install the brake pedal release bracket bolt (1) and tighten to 22 N.m (16 lb ft).
18. Connect the brake pedal position sensor electrical connector.
19. Install the steering column. Refer to Steering Column Replacement (Mexico, N40) , Steering Column Replacement (Canada, NJ1) , Steering Column Replacement (United States, NJ1) .

Fig. 50: Power Vacuum Brake Booster Bolts

20. Install the power vacuum brake booster bolts (1) and tighten to 19 N.m (14 lb ft).
21. Install the battery tray. Refer to Battery Tray Replacement .

Brake proportion valve replacement

Removal Procedure

WARNING: Refer to Brake Fluid Irritant Warning .

CAUTION: Refer to Brake Fluid Effects on Paint and Electrical Components Caution .

1. Remove the battery. Refer to Battery Replacement .
2. Clean the area surrounding the proportion valve of any accumulated dirt and debris.

Fig. 51: Master Cylinder Secondary Brake Pipe Fitting

3. Disconnect the master cylinder secondary brake pipe fitting (1) from the brake proportion valve.
4. Cap the brake pipe fitting and plug the proportion valve inlet port to prevent brake fluid loss and contamination.

Fig. 52: Master Cylinder Primary Brake Pipe Fitting

5. Disconnect the master cylinder primary brake pipe fitting (1) from the brake proportion valve.
6. Cap the brake pipe fitting and plug the proportion valve inlet port to prevent brake fluid loss and contamination.

Fig. 53: Master Cylinder Right Rear Brake Pipe Fitting

7. Disconnect the right rear brake pipe fitting (1).
8. Cap the brake pipe fitting and plug the proportion valve outlet port to prevent brake fluid loss and contamination.

Fig. 54: Master Cylinder Left Rear Brake Pipe Fitting

9. Disconnect the left front brake pipe fitting (1).
10. Cap the brake pipe fitting and plug the proportion valve outlet port to prevent brake fluid loss and contamination.

Fig. 55: Master Cylinder Right Front Brake Pipe Fitting

11. Disconnect the right front brake pipe fitting (1).
12. Cap the brake pipe fitting and plug the proportion valve outlet port to prevent brake fluid loss and contamination.

Fig. 56: Master Cylinder Left Rear Brake Pipe Fitting

13. Disconnect the left rear brake pipe fitting (1).
14. Cap the brake pipe fitting and plug the proportion valve outlet port to prevent brake fluid loss and contamination.

Fig. 57: Proportion Valve Nut

15. Remove the proportion valve nut (1).

Fig. 58: Proportion Valve

16. Remove the proportion valve (1).

Installation Procedure

Fig. 59: Proportion Valve

1. Install the proportion valve (1).

Fig. 60: Proportion Valve Nut

CAUTION: Refer to Fastener Caution .

2. Install the proportion valve nut (1) and tighten to 15 (11 lb ft).

Fig. 61: Master Cylinder Left Rear Brake Pipe Fitting

3. Connect the left rear brake pipe fitting (1) and tighten to 18 (13 lb ft).

Fig. 62: Master Cylinder Right Front Brake Pipe Fitting

4. Connect the right front brake pipe fitting (1) and tighten to 18 (13 lb ft).

Fig. 63: Master Cylinder Left Rear Brake Pipe Fitting

5. Connect the left front brake pipe fitting (1) and tighten to 18 (13 lb ft).

Fig. 64: Master Cylinder Right Rear Brake Pipe Fitting

6. Connect the right rear brake pipe fitting (1) and tighten to 18 (13 lb ft).

Fig. 65: Master Cylinder Primary Brake Pipe Fitting

7. Connect the master cylinder primary brake pipe fitting (1) to the brake proportion valve and tighten to 18 (13 lb ft).

Fig. 66: Master Cylinder Secondary Brake Pipe Fitting

8. Connect the master cylinder secondary brake pipe fitting (1) to the brake proportion valve and tighten to 18 (13 lb ft).
9. Install the battery. Refer to Battery Replacement .
10. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual), Hydraulic Brake System Bleeding (Pressure).

Brake pressure modulator valve front pipe replacement

Removal Procedure

WARNING: Refer to Brake Fluid Irritant Warning .

CAUTION: Refer to Brake Fluid Effects on Paint and Electrical Components Caution

1. Remove the battery. Refer to Battery Replacement .

Fig. 67: Master Cylinder Primary Brake Pipe Fitting

2. Disconnect the brake pressure modulator valve (BPMV) front pipe fitting (1) from the master cylinder.
3. Plug the master cylinder outlet port to prevent brake fluid loss and contamination.

Fig. 68: Master Cylinder Primary Brake Pipe Fitting

4. Disconnect the BPMV front pipe fitting (1) from the BPMV.
5. Plug the BPMV inlet port to prevent brake fluid loss and contamination.
6. Remove the brake pipe from the vehicle.

Installation Procedure

1. Install the brake pipe to the vehicle.

Fig. 69: Master Cylinder Primary Brake Pipe Fitting

CAUTION: Refer to Fastener Caution .

2. Install the BPMV front pipe fitting (1) to the BPMV and tighten the fitting to 18 N.m (13 lb ft).

Fig. 70: Master Cylinder Primary Brake Pipe Fitting

3. Install the BPMV front pipe fitting (1) to the master cylinder and tighten the fitting to 18 N.m (13 lb ft).
4. Install the battery. Refer to Battery Replacement .
5. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual), Hydraulic Brake System Bleeding (Pressure).

BRAKE PRESSURE MODULATOR VALVE REAR PIPE REPLACEMENT

Removal Procedure

WARNING: Refer to Brake Fluid Irritant Warning .

CAUTION: Refer to Brake Fluid Effects on Paint and Electrical Components Caution

1. Remove the battery. Refer to Battery Replacement

Fig. 71: Master Cylinder Outlet Port

2. Disconnect the brake pressure modulator valve (BPMV) rear pipe fitting (1) from the master cylinder.
3. Plug the master cylinder outlet port to prevent brake fluid loss and contamination.

Fig. 72: Master Cylinder Secondary Brake Pipe Fitting

4. Disconnect the BPMV rear pipe fitting (1) from the BPMV.
5. Plug the BPMV inlet port to prevent brake fluid loss and contamination.
6. Remove the brake pipe from the vehicle.

Installation Procedure

1. Install the brake pipe to the vehicle.

Fig. 73: Master Cylinder Secondary Brake Pipe Fitting

CAUTION: Refer to Fastener Caution .

2. Install the BPMV pipe fitting (1) to the BPMV and tighten the fitting to 18 N.m (13 lb ft).

Fig. 74: Master Cylinder Outlet Port

3. Install the BPMV front pipe fitting (1) to the master cylinder and tighten the fitting to 18 N.m (13 lb ft).
4. Install the battery. Refer to Battery Replacement .
5. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual), Hydraulic Brake System Bleeding (Pressure).

Brake pressure modulator valve front brake pipe replacement (LEFT)

Removal Procedure

WARNING: Refer to Brake Dust Warning .

WARNING: Refer to Brake Fluid Irritant Warning .

CAUTION: Refer to Brake Fluid Effects on Paint and Electrical Components Caution

1. Remove the battery. Refer to Battery Replacement .

Fig. 75: Brake Pressure Modulator Valve (BPMV) Front Brake Pipe Fitting

2. Disconnect the brake pressure modulator valve (BPMV) front brake pipe fitting (1) from the BPMV.
3. Plug the BPMV outlet port to prevent brake fluid loss and contamination.

Fig. 76: Front Brake Pipe Retaining Clip

4. Release the BPMV front brake pipe from the retaining clip (1).
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
6. Remove the left front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation

Fig. 77: Brake Pipe Fitting

7. Disconnect the BPMV front brake pipe fitting (1) from the left front brake hose.
8. Remove the BPMV front brake pipe from the vehicle.

Installation Procedure

1. Install the BPMV front brake pipe to the vehicle.
2. Position, but do not secure, the BPMV front brake pipe to the retaining clip.

Fig. 78: Brake Pipe Fitting

CAUTION: Refer to Fastener Caution .

3. Install the BPMV front brake pipe fitting (1) to the left front brake hose and tighten the fitting to 18 N.m (13 lb ft).
4. Lower the vehicle to access the brake pipe retaining clip.

Fig. 79: Front Brake Pipe Retaining Clip

5. Secure the BPMV front brake pipe to the retaining clip (1).

Fig. 80: Brake Pressure Modulator Valve (BPMV) Front Brake Pipe Fitting

6. Install the BPMV front brake pipe fitting (1) to the BPMV and tighten the fitting to 18 N.m (13 lb ft).
7. Install the battery. Refer to Battery Replacement .
8. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual), Hydraulic Brake System Bleeding (Pressure).
9. Install the left front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .

Brake pressure modulator valve front brake pipe replacement (RIGHT)

Removal Procedure

WARNING: Refer to Brake Dust Warning .

WARNING: Refer to Brake Fluid Irritant Warning .

CAUTION: Refer to Brake Fluid Effects on Paint and Electrical Components Caution .

1. Remove the battery. Refer to Battery Replacement

Fig. 81: Brake Pressure Modulator Valve (BPMV) Front Brake Pipe Fitting

2. Disconnect the brake pressure modulator valve (BPMV) front brake pipe fitting (1) from the BPMV.
3. Plug the BPMV outlet port to prevent brake fluid loss and contamination.

Fig. 82: Front Brake Pipe Retaining Clips

4. Release the BPMV front brake pipe from the retaining clips (1).
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

Fig. 83: BPMV Front Pipe Clip

6. Release the BPMV front brake pipe from the retaining clip (1).
7. Remove the right front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation

Fig. 84: Front Brake Pipe Fitting

8. Disconnect the BPMV front brake pipe fitting (1) from the right front brake hose.
9. Remove the BPMV front brake pipe from the vehicle.

Installation Procedure

1. Install the BPMV front brake pipe to the vehicle.
2. Position, but do not secure, the BPMV front brake pipe to the retaining clips.

Fig. 85: Front Brake Pipe Fitting

CAUTION: Refer to Fastener Caution .

3. Install the BPMV front brake pipe fitting (1) to the right front brake hose and tighten the fitting to 18 N.m (13 lb ft).

Fig. 86: BPMV Front Pipe Clip

4. Secure the BPMV front brake pipe to the retaining clip (1).
5. Lower the vehicle to access the upper brake pipe retaining clips.

Fig. 87: Front Brake Pipe Retaining Clips

6. Secure the BPMV front brake pipe to the retaining clips (1).

Fig. 88: Brake Pressure Modulator Valve (BPMV) Front Brake Pipe Fitting

7. Install the BPMV front brake pipe fitting (1) to the BPMV and tighten the fitting to 18 N.m (13 lb ft).
8. Install the battery. Refer to Battery Replacement .
9. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual), Hydraulic Brake System Bleeding (Pressure).
10. Install the right front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .

Brake pipe replacement

Special Tools

CH-45405 Brake Pipe Flaring Tool Kit

For equivalent regional tools, refer to Special Tools.

Fig. 89: Sectioning Brake Pipe Using Pipe Cutter

WARNING: Refer to Brake Fluid Irritant Warning .

WARNING: Always use double walled steel brake pipe when replacing brake pipes. The use of any other pipe is not recommended and may cause brake system failure. Carefully route and retain replacement brake pipes. Always use the correct fasteners and the original location for replacement brake pipes. Failure to properly route and retain brake pipes may cause damage to the brake pipes and cause brake system failure.

CAUTION: Refer to Brake Fluid Effects on Paint and Electrical Components Caution .

NOTE:

When servicing the brake pipes, note the following:

• If sectioning the brake pipe, use replacement pipe of the same type and outside diameter.
• Use fittings of the appropriate size and type.
• Only create flares of the same type or design as originally equipped on the vehicle.

1. Inspect the area of brake pipe to be repaired or replaced.
2. Release the brake pipe to be replaced from the retainers, as required.
3. Select an appropriate location to section the brake pipe, if necessary.

• Allow adequate clearance in order to maneuver the CH-45405 Brake Pipe Flaring Tool Kit.
• Avoid sectioning the brake pipe at bends or mounting points.

4. Using a string or wire, measure the length of the pipe to be replaced including all pipe bends.
5. Add to the measurement taken the appropriate additional length required for each flare to be created.

Specification

• 6.35 mm (0.250 in) for 4.76 mm (3/16 in) diameter pipe
• 9.50 mm (0.374 in) for 6.35 mm (1/4 in) diameter pipe
• 12.67 mm (0.499 in) for 7.94 mm (5/16 in) diameter pipe

NOTE: Ensure that the brake pipe end to be flared is cut at a square, 90 degree angle to the pipe length.

6. Using the pipe cutter included in the CH-45405 Brake Pipe Flaring Tool Kit , carefully cut the brake pipe squarely to the measured length.
7. Remove the sectioned brake pipe from the vehicle.
8. Select the appropriate size of brake pipe and tube nuts, as necessary. The brake pipe outside diameter determines brake pipe size.

Fig. 90: Stripping Nylon Coating From Brake Pipe Ends

9. Strip the nylon coating from the brake pipe end to be flared, if necessary

• Select the appropriate blade on the coating stripping tool included in the CH-45405 Brake Pipe Flaring Tool Kit , by unthreading the blade block from the stripping tool and installing the block with the desired blade facing the tool rollers.

Specification

• 6.35 mm (0.250 in) blade for 4.76 mm (3/16 in) diameter pipe
• 9.50 mm (0.374 in) blade for 6.35 mm (1/4 in) and 7.94 mm (5/16 in) diameter pipe

• Insert the brake pipe end to be flared into the stripping tool to the depth of the ledge on the tool rollers.
• While holding the brake pipe firmly against the stripping tool roller ledges, rotate the thumbwheel of the tool until the blade contacts the brake pipe coated surface.

NOTE: Do not gouge the metal surface of the brake pipe.

• Rotate the stripping tool in a clockwise direction, ensuring that the brake pipe end remains against the tool roller ledges.
• After each successive revolution of the stripping tool, carefully rotate the thumbwheel of the tool clockwise, in order to continue stripping the coating from the brake pipe until the metal pipe surface is exposed.
• Loosen the thumbwheel of the tool and remove the brake pipe.

NOTE: Ensure that all loose remnants of the nylon coating have been removed from the brake pipe.

• Inspect the stripped end of the brake pipe to ensure that the proper amount of coating has been removed.

Specification

• 6.35 mm (0.250 in) for 4.76 mm (3/16 in) diameter pipe
• 9.50 mm (0.374 in) for 6.35 mm (1/4 in) and 7.94 mm (5/16 in) diameter pipe

Fig. 91: Chamfering Pipe Using De-Burring Tool

10. Chamfer the inside and outside diameter of the pipe with the de-burring tool included in the CH-45405 Brake Pipe Flaring Tool Kit.
11. Install the tube nuts on the brake pipe, noting their orientation.
12. Clean the brake pipe and the CH-45405 Brake Pipe Flaring Tool Kit of lubricant, contaminants, and debris.

Fig. 92: Installing Die Halves Into Die Cage

13. Loosen the die clamping screw of the CH-45405 Brake Pipe Flaring Tool Kit.
14. Select the corresponding die set and install the die halves into the die cage with the full, flat face of one die facing the clamping screw, and the counterbores of both dies facing the forming ram.

Fig. 93: View Of Clamping Screw & Unused Die

15. Place the flat face of an unused die (1) against the die halves in the clamping cage and hold firmly against the counterbored face of the dies.
16. Insert the prepared end of the pipe to be flared through the back of the dies until the pipe is seated against the flat surface of the unused die (1).
17. Remove the unused die (1).
18. Ensure that the rear of both dies are seated firmly against the enclosed end of the die cage.
19. Firmly hand tighten the clamping screw (2) against the dies.

Fig. 94: Rotating Brake Pipe Flaring Tool To Bottom Against Die Cage

20. Select the appropriate forming mandrel and place into the forming ram.
21. Rotate the hydraulic fluid control valve clockwise to the closed position.
22. Rotate the body of the CH-45405 Brake Pipe Flaring Tool Kit until it bottoms against the die cage.

Fig. 95: Bottoming Forming Mandrel Against Clamping Dies Using Pipe Flaring Tool

23. While guiding the forming mandrel into the exposed end of pipe to be flared, operate the lever of the CH- 45405 Pipe Flaring Tool Kit until the forming mandrel bottoms against the clamping dies.
24. Rotate the hydraulic fluid control valve counterclockwise to the open position to allow the hydraulic forming ram to retract.

Fig. 96: Using Pipe Flaring Tool

25. Insert the finishing cone into the forming ram.
26. Rotate the hydraulic fluid control valve clockwise to the closed position.
27. Rotate the body of the CH-45405 Brake Pipe Flaring Tool Kit until it bottoms against the die cage.
28. While guiding the finishing cone into the exposed end of pipe to be flared, operate the lever of the CH- 45405 Brake Pipe Flaring Tool Kit until the finishing cone bottoms against the dies.
29. Rotate the hydraulic fluid control valve counterclockwise to the open position to allow the hydraulic forming ram to retract.
30. Loosen the die clamping screw and remove the dies and pipe.
31. If necessary, lightly tap the dies until the die halves separate.

Fig. 97: Identifying Correct Brake Pipe Flare Shape & Diameter

32. Inspect the brake pipe flare for correct shape and diameter (a).

Specification

• 6.74-7.10 mm (0.265-0.279 in) flare diameter for 4.76 mm (3/16 in) diameter pipe
• 8.57-9.27 mm (0.344-0.358 in) flare diameter for 6.35 mm (1/4 in) diameter pipe
• 10.42-10.79 mm (0.410-0.425 in) flare diameter for 7.94 mm (5/16 in) diameter pipe

33. If necessary, using the removed section of brake pipe as a template, shape the new pipe with a suitable brake pipe bending tool.

NOTE: When installing the pipe, maintain a clearance of 19 mm (3/4 in) from all moving or vibrating components.

34. Install the pipe to the vehicle with the appropriate brake pipe unions, as required.
35. If previously released, secure the brake pipe to the retainers.
36. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual), Hydraulic Brake System Bleeding (Pressure).
37. With the aid of an assistant, inspect the brake pipe flares for leaks by starting the engine and applying the brakes.

Front brake hose replacement

Removal Procedure

WARNING: Refer to Brake Dust Warning .

WARNING: Refer to Brake Fluid Irritant Warning .

CAUTION: Refer to Brake Fluid Effects on Paint and Electrical Components Caution

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation

Fig. 98: Brake Pipe Fitting

3. Remove the brake pipe fitting (1) from the front brake hose.
4. Cap the brake pipe fitting to prevent brake fluid loss and contamination.

Fig. 99: Brake Hose Retainer

5. Remove the brake hose retainer (1).

Fig. 100: Brake Hose Grommet

6. Release the brake hose grommet (1) from the strut bracket.

Fig. 101: Brake Hose Fitting Bolt

7. Remove the brake hose fitting bolt (1).

NOTE: Do not reuse the brake hose fitting gaskets.

8. Remove and discard the brake hose fitting gaskets (2) from the brake hose fitting (3).
9. Remove the brake hose.

Installation Procedure

Fig. 102: Brake Hose Fitting Bolt

1. Assemble the brake hose fitting bolt (1) and the new brake hose fitting gaskets (2) to the brake hose fitting (3).

CAUTION: Refer to Fastener Caution .

2. Install the brake hose assembly to the brake caliper and tighten the fitting bolt to 40 (30 lb ft).

Fig. 103: Brake Hose Grommet

3. Install the brake hose grommet (1) to the strut bracket.

Fig. 104: Brake Hose Retainer

4. Install the brake hose to the wheelhouse bracket and install the retainer (1).

Fig. 105: Brake Pipe Fitting

5. Install the brake pipe fitting (1) to the front brake hose and tighten the fitting to 18 (13 lb ft).
6. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual), Hydraulic Brake System Bleeding (Pressure).
7. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .

Rear brake intermediate pipe replacement (left)

Removal Procedure

WARNING: Refer to Brake Fluid Irritant Warning .

1. Remove the battery. Refer to Battery Replacement

Fig. 106: Left Rear Intermediate Pipe Fitting

2. Disconnect the left rear intermediate pipe fitting (1) from the brake pressure modulator valve (BPMV).
3. Plug the BPMV outlet port to prevent brake fluid loss and contamination

Fig. 107: Front Brake Pipe Retaining Clips

4. Release the left rear intermediate pipe from the retaining clips (1).
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

Fig. 108: Rear Intermediate Pipe And Retaining Clip

6. Release the left rear intermediate pipe from the retaining clip (1).

Fig. 109: Rear Intermediate Pipe

7. Release the left rear intermediate pipe from the front floor retaining clips (1).

Fig. 110: Underbody Cross Sill Shield

8. Remove the 2 nuts and the underbody cross sill shield (1).
9. Remove the fuel tank. Refer to Fuel Tank Replacement (AWD) .

Fig. 111: Rear Floor Retaining Clips

10. Release the left rear intermediate pipe from the rear floor retaining clips (1).

Fig. 112: Left Rear Intermediate Pipe

11. Release the left rear intermediate pipe from the retaining clips (1).

Fig. 113: Left Rear Intermediate Pipe And Cross Vehicle Retaining Clips

12. Release the left rear intermediate pipe from the cross vehicle retaining clips (1).

Fig. 114: Rear Intermediate Pipe And Left Rail Retaining Clips

13. Release the left rear intermediate pipe from the left rail retaining clips (1).

Fig. 115: Left Rear Rail Retaining Clips

14. Release the left rear intermediate pipe from the left rear rail retaining clips (1).

Fig. 116: Left Rear Intermediate Pipe Fitting

15. Disconnect the left rear intermediate pipe fitting (1) from the rear brake hose fitting.
16. Cap the brake hose fitting to prevent brake fluid loss and contamination.
17. Remove the left rear intermediate pipe from the vehicle.

Installation Procedure

1. Install the left rear intermediate pipe from the vehicle.
2. Position, but do not secure, the left rear intermediate pipe to the retaining clips.

Fig. 117: Left Rear Intermediate Pipe Fitting

CAUTION: Refer to Fastener Caution .

3. Install the left rear intermediate pipe fitting (1) to the rear brake hose fitting and tighten the fitting to 18 (13 lb ft).

Fig. 118: Left Rear Rail Retaining Clips

4. Secure the left rear intermediate pipe to the left rear rail retaining clips (1).

Fig. 119: Rear Intermediate Pipe And Left Rail Retaining Clips

5. Secure the left rear intermediate pipe to the left rail retaining clips (1).

Fig. 120: Left Rear Intermediate Pipe And Cross Vehicle Retaining Clips

6. Secure the left rear intermediate pipe to the cross vehicle retaining clips (1).

Fig. 121: Left Rear Intermediate Pipe

7. Secure the left rear intermediate pipe to the retaining clips (1).

Fig. 122: Rear Floor Retaining Clips

8. Secure the left rear intermediate pipe to the rear floor retaining clips (1).
9. Install the fuel tank. Refer to Fuel Tank Replacement (AWD)

Fig. 123: Underbody Cross Sill Shield

10. Install the underbody cross sill shield (1) and the 2 nuts.

Fig. 124: Rear Intermediate Pipe

11. Secure the left rear intermediate pipe to the front floor retaining clips (1).

Fig. 125: Rear Intermediate Pipe And Retaining Clip

12. Secure the left rear intermediate pipe to the retaining clip (1).

Fig. 126: Front Brake Pipe Retaining Clips

13. Secure the left rear intermediate pipe to the retaining clips (1).

Fig. 127: Left Rear Intermediate Pipe Fitting

14. Connect the left rear intermediate pipe fitting (1) to the BPMV and tighten the fitting to 18 (13 lb ft).
15. Install the battery. Refer to Battery Replacement .
16. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual), Hydraulic Brake System Bleeding (Pressure).

Rear brake intermediate pipe replacement (right)

Removal Procedure

WARNING: Refer to Brake Fluid Irritant Warning .

1. Remove the battery. Refer to Battery Replacement .

Fig. 128: Brake Pressure Modulator Valve (BPMV) And Rear Intermediate Pipe Fitting

2. Disconnect the right rear intermediate pipe fitting (1) from the brake pressure modulator valve (BPMV).
3. Plug the BPMV outlet port to prevent brake fluid loss and contamination.

Fig. 129: Front Brake Pipe Retaining Clips

4. Release the right rear intermediate pipe from the retaining clips (1).
5. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

Fig. 130: Rear Intermediate Pipe And Retaining Clip

6. Release the right rear intermediate pipe from the retaining clip (1).

Fig. 131: Rear Intermediate Pipe

7. Release the right rear intermediate pipe from the front floor retaining clips (1).

Fig. 132: Underbody Cross Sill Shield

8. Remove the 2 nuts and the underbody cross sill shield (1).
9. Remove the fuel tank. Refer to Fuel Tank Replacement (AWD) .

Fig. 133: Rear Floor Retaining Clips

10. Release the right rear intermediate pipe from the rear floor retaining clips (1).

Fig. 134: Left Rear Intermediate Pipe

11. Release the right rear intermediate pipe from the retaining clips (1).

Fig. 135: Right Rear Intermediate Pipe And Right Rail

12. Release the right rear intermediate pipe from the right rail retaining clips (1).

Fig. 136: Right Rear Rail Retaining Clips

13. Release the right rear intermediate pipe from the right rear rail retaining clips (1).

Fig. 137: Right Rear Intermediate Pipe Fitting

14. Disconnect the right rear intermediate pipe fitting (1) from the rear brake hose fitting.
15. Cap the brake hose fitting to prevent brake fluid loss and contamination.
16. Remove the right rear intermediate pipe from the vehicle.

Installation Procedure

1. Install the right rear intermediate pipe to the vehicle.
2. Position, but do not secure, the right rear intermediate pipe to the retaining clips.

Fig. 138: Right Rear Intermediate Pipe Fitting

CAUTION: Refer to Fastener Caution .

3. Install the right rear intermediate pipe fitting (1) to the rear brake hose fitting and tighten the fitting to 18 (13 lb ft).

Fig. 139: Right Rear Rail Retaining Clips

4. Secure the right rear intermediate pipe to the right rear rail retaining clips (1).

Fig. 140: Right Rear Intermediate Pipe And Right Rail

5. Secure the right rear intermediate pipe to the right rail retaining clips (1).

Fig. 141: Left Rear Intermediate Pipe

6. Secure the right rear intermediate pipe to the retaining clips (1).

Fig. 142: Rear Floor Retaining Clips

7. Secure the right rear intermediate pipe to the rear floor retaining clips (1).
8. Install the fuel tank. Refer to Fuel Tank Replacement (AWD) .

Fig. 143: Underbody Cross Sill Shield

9. Install the underbody cross sill shield (1) and the 2 nuts.

Fig. 144: Rear Intermediate Pipe

10. Secure the right rear intermediate pipe to the front floor retaining clips (1).

Fig. 145: Rear Intermediate Pipe And Retaining Clip

11. Secure the right rear intermediate pipe to the retaining clip (1).

Fig. 146: Front Brake Pipe Retaining Clips

12. Secure the right rear intermediate pipe to the retaining clips (1).

Fig. 147: Brake Pressure Modulator Valve (BPMV) And Rear Intermediate Pipe Fitting

13. Connect the right rear intermediate pipe fitting (1) to the BPMV and tighten the fitting to 18 (13 lb ft).
14. Install the battery. Refer to Battery Replacement .
15. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual), Hydraulic Brake System Bleeding (Pressure).

Rear brake rear pipe replacement

Removal Procedure

WARNING: Refer to Brake Dust Warning .

WARNING: Refer to Brake Fluid Irritant Warning

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation

Fig. 148: Rear Brake Rear Pipe Fitting And Rear Brake Hose

3. Disconnect the rear brake rear pipe fitting (1) from the rear brake hose.
4. Cap the brake hose fitting to prevent brake fluid loss and contamination.

Fig. 149: Rear Brake Rear Pipe Fitting And Rear Brake Cylinder

5. Disconnect the rear brake rear pipe fitting (1) from the rear brake cylinder.
6. Remove the rear brake rear pipe from the vehicle.

Installation Procedure

1. Install the rear brake rear pipe to the vehicle.

Fig. 150: Rear Brake Rear Pipe Fitting And Rear Brake Cylinder

CAUTION: Refer to Fastener Caution .

2. Install the rear brake rear pipe fitting (1) to the rear brake cylinder and tighten the fitting to 18 (13 lb ft).

Fig. 151: Rear Brake Rear Pipe Fitting And Rear Brake Hose

3. Install the rear brake rear pipe fitting (1) to the rear brake hose and tighten the fitting to 18 (13 lb ft).
4. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual), Hydraulic Brake System Bleeding (Pressure).
5. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation

Rear brake hose replacement (drum brake)

Removal Procedure

WARNING: Refer to Brake Dust Warning .

WARNING: Refer to Brake Fluid Irritant Warning .

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .

Fig. 152: Left Rear Intermediate Pipe Fitting

3. Remove the brake pipe fitting (1) from the rear brake hose.
4. Cap the brake pipe fitting to prevent brake fluid loss and contamination.

Fig. 153: Brake Hose Retainer

5. Remove the brake hose retainer (1).

Fig. 154: Rear Brake Rear Pipe Fitting And Rear Brake Hose

6. Remove the brake pipe fitting (1) from the rear brake hose.
7. Cap the brake pipe fitting to prevent brake fluid loss and contamination.

Fig. 155: Brake Hose Retainer

8. Remove the brake hose retainer (1).
9. Remove the brake hose.

Installation Procedure

1. Install the brake hose.

Fig. 156: Brake Hose Retainer

2. Install the brake hose retainer (1).

CAUTION: Refer to Fastener Caution .

3. Install the brake pipe fitting (1) to the rear brake hose and tighten the fitting to 18 (13 lb ft).

Fig. 157: Brake Hose Retainer

4. Install the brake hose to the wheelhouse bracket and install the retainer (1).

Fig. 158: Left Rear Intermediate Pipe Fitting

5. Install the brake pipe fitting (1) to the rear brake hose and tighten the fitting to 18 (13 lb ft).
6. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual), Hydraulic Brake System Bleeding (Pressure).
7. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .

Rear brake hose replacement (disc brake)

Removal Procedure

WARNING: Refer to Brake Dust Warning .

WARNING: Refer to Brake Fluid Irritant Warning .

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle
2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .

Fig. 159: Left Rear Intermediate Pipe Fitting

3. Remove the brake pipe fitting (1) from the rear brake hose.
4. Cap the brake pipe fitting to prevent brake fluid loss and contamination.

Fig. 160: Brake Hose Retainer

5. Remove the brake hose retainer (1).

Fig. 161: Brake Hose Fitting Bolt

6. Remove the brake hose fitting bolt (1).

NOTE: Do not reuse the brake hose fitting gaskets.

7. Remove and discard the brake hose fitting gaskets (2) from the brake hose fitting (3).
8. Remove the brake hose.

Installation Procedure

Fig. 162: Brake Hose Fitting Bolt

1. Assemble the brake hose fitting bolt (1) and the new brake hose fitting gaskets (2) to the brake hose fitting (3).

CAUTION: Refer to Fastener Caution .

2. Install the brake hose assembly to the brake caliper and tighten the fitting bolt to 40 (30 lb ft).

Fig. 163: Brake Hose Retainer

3. Install the brake hose to the wheelhouse bracket and install the retainer (1).

Fig. 164: Left Rear Intermediate Pipe Fitting

4. Install the brake pipe fitting (1) to the rear brake hose and tighten the fitting to 18 (13 lb ft).
5. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual), Hydraulic Brake System Bleeding (Pressure).
6. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .

Hydraulic brake system bleeding (manual)

WARNING: Refer to Brake Fluid Irritant Warning .

CAUTION: Refer to Brake Fluid Effects on Paint and Electrical Components Caution .

CAUTION: Only use products that comply with GM specifications and check manufacturer information respectively. We recommend the use of GM genuine products. Instructions must be followed at all times. The use ofany type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components.

If hydraulic components were serviced on only one wheel hydraulic circuit, perform the following procedure

Bleeding a Single Hydraulic Brake Circuit

1. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve.
2. Place a clean shop cloth beneath the brake master cylinder to catch brake fluid spills.
3. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm.
4. Fill the brake master cylinder reservoir to the maximum-full level with GM approved brake fluid from a clean, sealed brake fluid container. Add brake fluid as needed to ensure that the brake master cylinder reservoir remains at least half-full throughout the bleed procedure. The reservoir cap must be installed at all times except when filling the reservoir. Refer to Fluid and Lubricant Recommendations .
5. Install a proper box-end wrench onto the wheel hydraulic circuit bleeder valve which has been serviced.
6. Install a transparent hose over the end of the bleeder valve.
7. Submerge the open end of the transparent hose into a transparent container partially filled with brake fluid from a clean, sealed brake fluid container.
8. Have an assistant slowly press the brake pedal fully and maintain steady pressure on the pedal.
9. Loosen the bleeder valve to purge air from the wheel hydraulic circuit.
10. Tighten the bleeder valve, then have the assistant slowly release the brake pedal.
11. Wait 15 seconds, then repeat steps 8-10 until all air is purged from the wheel hydraulic circuit.
12. After all air has been purged from the hydraulic circuit, tighten the bleeder valve and install the dust cap.
13. Fill the brake master cylinder reservoir to the maximum-fill level with GM approved brake fluid from a clean, sealed brake fluid container.
14. Slowly press and release the brake pedal. Observe the brake pedal feel.
15. If the brake pedal feels spongy, perform the Bleeding the Complete Brake Hydraulic System procedure:
16. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated.

NOTE: DO NOT allow the vehicle to be driven until it is diagnosed and repaired.

17. If the brake system warning lamp remains illuminated, refer to Diagnostic Starting Point - Vehicle .

Bleeding the Complete Brake Hydraulic System

1. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve.
2. Place a clean shop cloth beneath the brake master cylinder to catch brake fluid spills.
3. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm.
4. Fill the brake master cylinder reservoir to the maximum-full level with GM approved brake fluid from a clean, sealed brake fluid container. Add brake fluid as needed to ensure that the brake master cylinder reservoir remains at least half-full throughout the bleed procedure. The reservoir cap must be installed at all times except when filling the reservoir. Refer to Fluid and Lubricant Recommendations .
5. If the master cylinder was replaced, the master cylinder must be bench bled. Refer to Master Cylinder Bench Bleeding.
6. If the brake pipes have been removed from the master cylinder, the following steps must be performed.

1. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe fitting from the front port of the brake master cylinder.
2. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder.

   Capture and properly dispose of the brake fluid in an approved container.

3. Install the front brake pipe fitting to the front port of the brake master cylinder and tighten the fitting. Refer to Fastener Tightening Specifications.
4. Have an assistant slowly press the brake pedal fully and maintain steady pressure on the pedal.
5. Loosen the front brake pipe fitting from the front port of the brake master cylinder to purge air from the master cylinder port.
6. Tighten the front brake pipe fitting, then have the assistant slowly release the brake pedal.
7. Wait 15 seconds, then repeat steps 6.4-6.6 until all air is purged from the front brake pipe fitting of the front port of the master cylinder.
8. After all air is purged from the front port of the brake master cylinder, tighten the front master cylinder brake pipe fitting. Refer to Fastener Tightening Specifications.
9. With the front brake pipe fitting installed securely to the front port of the brake master cylinder, loosen and separate the rear brake pipe fitting from the rear port of the brake master cylinder.
10. Repeat steps 6.2-6.7 for the rear port of the brake master cylinder.
11. After all air is purged from the rear port of the brake master cylinder, tighten the rear master cylinder brake pipe fitting. Refer to Fastener Tightening Specifications.
12. Slowly press and release the brake pedal. Observe the brake pedal feel.
13. If the brake pedal feels spongy, proceed to step 7.
14. If the brake pedal feels firm, proceed to step 24.

7. If the brake pipes have been removed from the brake pressure modulator valve (BPMV) assembly, if equipped, or the brake proportion valve assembly, if equipped, air must be purged from each port of the respective assembly beginning with the feed pipes from the master cylinder.

1. Loosen and separate one of the master cylinder brake pipe fittings from the inlet port of the assembly to be bled.
2. Allow a small amount of brake fluid to gravity bleed from the open port of the assembly. Capture and properly dispose of the brake fluid in an approved container.
3. Install the brake pipe fitting and to the inlet port of the assembly and tighten securely.
4. Have an assistant slowly press the brake pedal fully and maintain steady pressure on the pedal.
5. Loosen the same brake pipe fitting to purge air from the open port of the assembly.
6. Tighten the brake pipe fitting, then have the assistant slowly release the brake pedal.
7. Wait 15 seconds, then repeat steps 7.4-7.6 until all air is purged from the brake pipe fitting of the assembly.
8. Repeat steps 7.1-7.7 for all of the remaining ports of the assembly.
9. After bleeding each port of the assembly, tighten all of the brake pipe fittings on the assembly.

   Refer to Fastener Tightening Specifications.

10. Fill the master cylinder reservoir to the maximum-full level with GM approved brake fluid from a clean, sealed brake fluid container.
11. Slowly press and release the brake pedal. Observe the brake pedal feel.
12. If the brake pedal feels spongy, proceed to step 8.
13. If the brake pedal feels firm, proceed to step 24.

8. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve.
9. Install a transparent hose over the end of the bleeder valve.
10. Submerge the open end of the transparent hose into a transparent container partially filled with GM approved brake fluid from a clean, sealed brake fluid container.
11. Have an assistant slowly press the brake pedal fully and maintain steady pressure on the brake pedal.
12. Loosen the bleeder valve to purge air from the wheel hydraulic circuit.
13. Tighten the bleeder valve, then have the assistant slowly release the brake pedal.
14. Wait 15 seconds, then repeat steps 11-13 until all air is purged from the wheel hydraulic circuit.
15. Tighten the RIGHT REAR hydraulic wheel circuit bleeder valve securely.
16. Install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve, then repeat steps 9-14..
17. Install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve, then repeat steps 9-14..
18. Install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve, then repeat steps 9-14..
19. After completing the final wheel hydraulic circuit bleeding procedure, tighten all of the wheel hydraulic circuit bleeder valves and install the bleeder valve dust caps.
20. Fill the master cylinder reservoir to the maximum-full level with GM approved brake fluid from a clean, sealed brake fluid container.
21. Slowly press and release the brake pedal. Observe the brake pedal feel.
22. If the brake pedal feels spongy, perform the following procedure.

1. If equipped with antilock brakes, install a scan tool and perform the Antilock Brake System Automated Bleed to remove air which may be trapped in the BPMV.
2. Inspect the hydraulic brake system for external leaks. Refer to Brake System External Leak Inspection.
3. Repeat the Bleeding the Complete Brake Hydraulic System procedure.

23. If the brake pedal still feels spongy, pressure bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual), Hydraulic Brake System Bleeding (Pressure)
24. Turn the ignition switch ON with the engine OFF. Check to see if the brake system warning lamp remains illuminated.

NOTE: DO NOT allow the vehicle to be driven until the brake system is diagnosed and repaired.

25. If the brake system warning lamp remains illuminated, refer to Diagnostic Starting Point - Vehicle .

Hydraulic brake system bleeding (pressure)

WARNING: Refer to Brake Fluid Irritant Warning .

CAUTION: Refer to Brake Fluid Effects on Paint and Electrical Components Caution .

CAUTION: Only use products that comply with GM specifications and check manufacturer information respectively. We recommend the use of GM genuine products. Instructions must be followed at all times. The use of any type of fluid other than the recommended type of brake fluid, may cause contamination which could result in damage to the internal rubber seals and/or rubber linings of hydraulic brake system components.

If hydraulic components were serviced on only one wheel hydraulic circuit, perform the following procedure

Bleeding a Single Hydraulic Brake Circuit

1. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve.
2. Place a clean shop cloth beneath the brake master cylinder to catch brake fluid spills.
3. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm.
4. Fill the brake master cylinder reservoir to the maximum-full level with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Fluid and Lubricant Recommendations

NOTE: The pressure bleeding equipment must be the diaphragm type. The rubber diaphragm between the air supply and the brake fluid prevents air, moisture, oil, and other contaminants from entering the hydraulic system.

5. Following the brake pressure bleeder manufacturer's instructions, fill the brake pressure bleeder with GM approved brake fluid from a clean, sealed brake fluid container.
6. Install the appropriate master cylinder reservoir adapter and connect the brake pressure bleeder.
7. Charge the brake pressure bleeder air tank to 170-200 kPa/1.7-2.0 bar (25-30 psi), or as recommended by the brake pressure bleeder manufacturer's instructions.
8. Open the brake pressure bleeder fluid tank valve to allow pressurized brake fluid to enter the brake hydraulic system.

NOTE: Any brake fluid leaks identified require repair prior to completing this procedure.

9. Wait approximately 30 seconds, then inspect the entire hydraulic brake system for external brake fluid leaks.
10. Install a proper box-end wrench onto the wheel hydraulic circuit bleeder valve which has been serviced.
11. Install a transparent hose over the end of the bleeder valve.
12. Submerge the open end of the transparent hose into a transparent container partially filled with brake fluid from a clean, sealed brake fluid container.
13. Loosen the bleeder valve to purge air from the wheel hydraulic circuit.
14. Allow fluid to flow until air bubbles stop flowing from the bleeder.
15. After all air has been purged from the hydraulic circuit, tighten the bleeder valve and install the dust cap.

NOTE: The brake reservoir may have residual pressure after the bleeding operation is complete. Wrap a clean shop towel around the bleeder adapter and all hose connections before disconnecting the pressure bleeding equipment to prevent brake fluid from contacting and damaging vehicle components and painted surfaces.

16. Close the brake pressure bleeder fluid tank valve then disconnect the brake pressure bleeder from the master cylinder reservoir bleeder adapter.
17. Remove the master cylinder reservoir bleeder adapter from the master cylinder reservoir.
18. Fill the brake master cylinder reservoir to the maximum-fill level with GM approved brake fluid from a clean, sealed brake fluid container.
19. Slowly press and release the brake pedal. Observe the brake pedal feel.
20. If the brake pedal feels spongy, perform the Bleeding the Complete Brake Hydraulic System procedure:
21. Turn the ignition key ON, with the engine OFF. Check to see if the brake system warning lamp remains illuminated.

NOTE: DO NOT allow the vehicle to be driven until it is diagnosed and repaired.

22. If the brake system warning lamp remains illuminated, refer to Diagnostic Starting Point - Vehicle .

Bleeding the Complete Brake Hydraulic System

1. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal effort increases significantly, in order to deplete the brake booster power reserve.
2. Place a clean shop cloth beneath the brake master cylinder to catch brake fluid spills.
3. Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm.
4. Fill the brake master cylinder reservoir to the maximum-full level with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Fluid and Lubricant Recommendations .
5. If the master cylinder was replaced, the master cylinder must be bench bled. Refer to Master Cylinder Bench Bleeding.
6. If the brake pipes have been removed from the master cylinder, the following steps must be performed.

1. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe fitting from the front port of the brake master cylinder.
2. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder.

   Capture and properly dispose of the brake fluid in an approved container.

3. Install the front brake pipe fitting to the front port of the brake master cylinder and tighten the fitting.
4. Have an assistant slowly press the brake pedal fully and maintain steady pressure on the pedal.
5. Loosen the front brake pipe fitting from the front port of the brake master cylinder to purge air from the master cylinder port.
6. Tighten the front brake pipe fitting, then have the assistant slowly release the brake pedal.
7. Wait 15 seconds, then repeat steps 6.4-6.6 until all air is purged from the front brake pipe fitting of the front port of the master cylinder.
8. After all air is purged from the front port of the brake master cylinder, tighten the front master cylinder brake pipe fitting. Refer to Fastener Tightening Specifications.
9. With the front brake pipe fitting installed securely to the front port of the brake master cylinder, loosen and separate the rear brake pipe fitting from the rear port of the brake master cylinder.
10. Repeat steps 6.2-6.7 for the rear port of the brake master cylinder.
11. After all air is purged from the rear port of the brake master cylinder, tighten the rear master cylinder brake pipe fitting. Refer to Fastener Tightening Specifications.
12. Slowly press and release the brake pedal. Observe the brake pedal feel.
13. If the brake pedal feels spongy, proceed to step 7.
14. If the brake pedal feels firm, proceed to step 24.

7. If the brake pipes have been removed from the brake pressure modulator valve (BPMV) assembly, if equipped, or the brake proportion valve assembly, if equipped, air must be purged from each port of the respective assembly beginning with the feed pipes from the master cylinder.

1. Loosen and separate one of the master cylinder brake pipe fittings from the inlet port of the assembly to be bled.
2. Allow a small amount of brake fluid to gravity bleed from the open port of the assembly. Capture and properly dispose of the brake fluid in an approved container.
3. Install the brake pipe fitting and to the inlet port of the assembly and tighten securely.
4. Have an assistant slowly press the brake pedal fully and maintain steady pressure on the pedal.
5. Loosen the same brake pipe fitting to purge air from the open port of the assembly.
6. Tighten the brake pipe fitting, then have the assistant slowly release the brake pedal.
7. Wait 15 seconds, then repeat steps 7.4-7.6 until all air is purged from the brake pipe fitting of the assembly.
8. Repeat steps 7.1-7.7 for all of the remaining ports of the assembly.
9. After bleeding each port of the assembly, tighten all of the brake pipe fittings on the assembly.

   Refer to Fastener Tightening Specifications.

10. Fill the master cylinder reservoir to the maximum-full level with GM approved brake fluid from a clean, sealed brake fluid container.
11. Slowly press and release the brake pedal. Observe the brake pedal feel.
12. If the brake pedal feels spongy, proceed to step 8.
13. If the brake pedal feels firm, proceed to step 24.

NOTE: The pressure bleeding equipment must be the diaphragm type. The rubber diaphragm between the air supply and the brake fluid prevents air, moisture, oil, and other contaminants from entering the hydraulic system.

8. Following the brake pressure bleeder manufacturer's instructions, fill the brake pressure bleeder with GM approved brake fluid from a clean, sealed brake fluid container.
9. Install the appropriate master cylinder reservoir adapter and connect the brake pressure bleeder.
10. Charge the brake pressure bleeder air tank to 170-200 kPa/1.7-2.0 bar (25-30 psi), or as recommended by the brake pressure bleeder manufacturer's instructions.
11. Open the brake pressure bleeder fluid tank valve to allow pressurized brake fluid to enter the brake hydraulic system.

NOTE: Any brake fluid leaks identified require repair prior to completing this procedure.

12. Wait approximately 30 seconds, then inspect the entire hydraulic brake system for external brake fluid leaks.
13. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve.
14. Install a transparent hose over the end of the bleeder valve.
15. Submerge the open end of the transparent hose into a transparent container partially filled with GM approved brake fluid from a clean, sealed brake fluid container.
16. Have an assistant slowly press the brake pedal fully and maintain steady pressure on the brake pedal.
17. Loosen the bleeder valve to purge air from the wheel hydraulic circuit.
18. Tighten the bleeder valve, then have the assistant slowly release the brake pedal.
19. Wait 15 seconds, then repeat steps 11-13 until all air is purged from the wheel hydraulic circuit.
20. Tighten the RIGHT REAR hydraulic wheel circuit bleeder valve securely.
21. Install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve, then repeat steps 9-14.
22. Install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve, then repeat steps 9-14.
23. Install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve, then repeat steps 9-14.
24. After completing the final wheel hydraulic circuit bleeding procedure, tighten all of the wheel hydraulic circuit bleeder valves and install the bleeder valve dust caps.
25. Close the brake pressure bleeder fluid tank valve.

NOTE: The brake reservoir may have residual pressure after the bleeding operation is complete. Wrap a clean shop towel around the bleeder adapter and all hose connections before disconnecting the pressure bleeding equipment to prevent brake fluid from contacting and damaging vehicle components and painted surfaces.

26. Remove the brake pressure bleeding equipment from the vehicle.
27. Fill the brake master cylinder reservoir to the maximum-full level with GM approved brake fluid from a clean, sealed brake fluid container. Refer to Fluid and Lubricant Recommendations .
28. Slowly press and release the brake pedal. Observe the brake pedal feel.
29. If the brake pedal feels spongy, perform the following procedure.

1. If equipped with antilock brakes, install a scan tool and perform the Antilock Brake System Automated Bleed to remove air which may be trapped in the BPMV.
2. Inspect the hydraulic brake system for external leaks. Refer to Brake System External Leak Inspection.
3. Repeat the Bleeding the Complete Brake Hydraulic System procedure.

30. If the brake pedal still feels spongy, pressure bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual), Hydraulic Brake System Bleeding (Pressure) .
31. Turn the ignition switch ON with the engine OFF. Check to see if the brake system warning lamp remains illuminated.

NOTE: DO NOT allow the vehicle to be driven until the brake system is diagnosed and repaired.

32. If the brake system warning lamp remains illuminated, refer to Diagnostic Starting Point - Vehicle .

Hydraulic brake system flushing

WARNING: Refer to Brake Fluid Irritant Warning .

CAUTION: Refer to Brake Fluid Effects on Paint and Electrical Components Caution .

1. Inspect the brake fluid for the following conditions, indicating brake fluid contamination:

Fluid separation, indicating 2 types of fluid are present. A substance other than the recommended brake fluid has been introduced into the brake hydraulic system.

• Swirled appearance - oil-based substance
• Layered appearance - silicone-based substance

Fluid discoloration, indicating the presence of moisture or particles that have been introduced into the brake hydraulic system.

• Cloudy appearance - moisture
• Dark appearance/suspended particles in fluid - dirt, rust, corrosion and/or brake dust

2. Inspect the master cylinder reservoir cap diaphragm and the reservoir-to-master cylinder grommets for swelling, indicating brake fluid contamination.
3. If the brake fluid WAS contaminated with an oil-based or a silicone-based substance, indicated by fluid separation and/or a swollen master cylinder reservoir cap diaphragm and/or swollen reservoir-to-master cylinder grommets, perform the following:

1. Remove ALL of the following components listed from the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic system.

Refer to the procedures indicated:

• Master Cylinder Replacement
• Front Brake Hose Replacement
• Rear Brake Hose Replacement (Drum Brake), Rear Brake Hose Replacement (Disc Brake)
• Front Brake Caliper Replacement
• Rear Brake Caliper Replacement , if equipped
• Rear Brake Cylinder Replacement , if equipped
• Brake Proportion Valve Replacement , if equipped
• Brake Pressure Modulator Valve Replacement , if equipped

2. Clean out all the hydraulic brake pipes using denatured alcohol.
3. Dry the brake pipes using non-lubricated, filtered air.
4. Repair or replace ALL of the following components listed and install them to the vehicle. Each component contains internal rubber seals/linings which have been contaminated by the contaminated brake fluid in the brake hydraulic system.

Refer to the procedures indicated:

• Master Cylinder Replacement ; also perform the following:
• Clean the brake master cylinder reservoir using denatured alcohol, then dry the reservoir using non-lubricated, filtered air. Inspect the reservoir for cracks and/or damage and replace if necessary. Refer to Master Cylinder Reservoir Replacement.
• Front Brake Hose Replacement
• Rear Brake Hose Replacement (Drum Brake), Rear Brake Hose Replacement (Disc Brake)
• Front Brake Caliper Replacement
• Rear Brake Caliper Replacement , if equipped
• Rear Brake Cylinder Replacement , if equipped
• Brake Proportion Valve Replacement , if equipped
• Brake Pressure Modulator Valve Replacement , if equipped

4. If the brake fluid WAS NOT contaminated with an oil-based or a silicone-based substance, but WAS contaminated with water or dirt, rust, corrosion, and/or brake dust, replace the brake master cylinder reservoir cap diaphragm which may have allowed the moisture or particles to enter the hydraulic system.
5. Fill the brake master cylinder reservoir to the maximum-fill level with GM approved brake fluid from a clean, sealed brake fluid container.
6. Pressure bleed the hydraulic brake system. Begin the procedure with the pressure bleeder reservoir filled to the maximum-fill level with the correct brake fluid as indicated. Refer to Hydraulic Brake System Bleeding (Manual), Hydraulic Brake System Bleeding (Pressure).

Power vacuum brake booster replacement

Removal Procedure

1. With the engine OFF, apply and release the brake pedal several times until the pedal becomes firm to deplete the power vacuum brake booster vacuum reserve.
2. Remove the battery tray. Refer to Battery Tray Replacement .
3. Disconnect the power vacuum brake booster vacuum sensor electrical connector, if equipped.

Fig. 165: Power Brake Booster Vacuum Check Valve

4. Remove the power brake booster vacuum check valve (1) from the power vacuum brake booster.
5. Remove the driver side instrument panel knee bolster. Refer to Instrument Panel Knee Bolster Replacement (Encore) , Instrument Panel Knee Bolster Replacement (Encore) .

Fig. 166: Brake Booster Pushrod And Brake Pedal

6. Compress the tabs on the top and bottom of the brake booster pushrod retainer (1) and lift the brake pedal (2) rearward to disconnect the brake pedal from the power brake booster pushrod.
7. Inspect the brake booster pushrod retainer for damage and replace, if necessary.
8. Remove the master cylinder. Refer to Master Cylinder Replacement.

Fig. 167: Front And Rear Brake Pipe Fittings

9. If equipped with antilock brakes, disconnect the front and rear brake pipe fittings (1) from the brake pressure modulator valve (BPMV). Refer to Brake Pressure Modulator Valve Replacement .

Fig. 168: Power Vacuum Brake Booster And Bolts

10. Completely loosen the power vacuum brake booster bolts (1).
11. Remove the power vacuum brake booster.
12. Inspect the power vacuum brake booster gasket for damage and replace, if necessary.

Installation Procedure

1. Install the power vacuum brake booster gasket, if removed.

Fig. 169: Power Vacuum Brake Booster And Bolts

2. Install the power vacuum brake booster and bolts.

CAUTION: Refer to Fastener Caution .

NOTE: Do not over tighten the power vacuum brake booster bolts. If the power vacuum brake booster bolts are over tightened, the brake pedal may remain applied after a high pressure brake pedal application.

3. Install the power vacuum brake booster bolts (1) and tighten to 19 N.m (14 lb ft).

Fig. 170: Front And Rear Brake Pipe Fittings

4. If equipped with antilock brakes, connect the front and rear brake pipe fittings (1) to the BPMV. Refer to Brake Pressure Modulator Valve Replacement .
5. Install the master cylinder. Refer to Master Cylinder Replacement.

Fig. 171: Power Brake Booster Vacuum Check Valve

6. Install the power brake booster vacuum check valve (1) to the power vacuum brake booster.
7. Connect the power vacuum brake booster vacuum sensor electrical connector, if equipped.

Fig. 172: Brake Booster Pushrod And Brake Pedal

8. Install the power brake booster pushrod retainer (1) to the power brake booster pushrod, if removed.

NOTE: Ensure the power vacuum brake booster pushrod retainer is fully seated in the brake pedal arm.

9. Position the brake pedal (2) to the power brake booster pushrod retainer and firmly seat the brake pedal to the retainer.
10. Install the driver side instrument panel knee bolster. Refer to Instrument Panel Knee Bolster Replacement (Encore) , Instrument Panel Knee Bolster Replacement (Encore) .
11. Install the battery tray. Refer to Battery Tray Replacement .

Power brake booster vacuum hose replacement

Removal Procedure

1. With the engine OFF, apply and release the brake pedal several times to deplete the power vacuum brake booster vacuum reserve.
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

Fig. 173: Power Brake Booster Vacuum Hose Quick Connect

3. Through the left front wheelhouse, disconnect the power brake booster vacuum hose quick connect (1) from the power brake booster pump port.
4. Lower the vehicle.

Fig. 174: Booster Vacuum Hose Quick Connect

5. Disconnect the power brake booster vacuum hose quick connect (1) from the intake manifold vacuum port.
6. Disconnect the power brake booster vacuum sensor electrical connector.

Fig. 175: Power Brake Booster Vacuum Sensor And Hose Assembly

7. Remove the power brake booster vacuum sensor and hose assembly (1) from the power vacuum brake booster grommet.

Fig. 176: Power Brake Booster Vacuum Sensor

8. Release the clamp and remove the power brake booster vacuum sensor (1).
9. Remove the power brake booster vacuum hose assembly.

Installation Procedure

1. Install the power brake booster vacuum hose assembly to the vehicle.

Fig. 177: Power Brake Booster Vacuum Sensor

NOTE: A small amount of denatured alcohol may be used as a lubricant for assembly.

2. Release the clamp and install the power brake booster vacuum sensor (1).

Fig. 178: Power Brake Booster Vacuum Sensor And Hose Assembly

NOTE: A small amount of denatured alcohol may be used as a lubricant for assembly.

3. Install the power brake booster vacuum sensor and hose assembly (1) to the power vacuum brake booster grommet.
4. Connect the power brake booster vacuum sensor electrical connector.

Fig. 179: Booster Vacuum Hose Quick Connect

5. Connect the power brake booster vacuum hose quick connect (1) to the intake manifold vacuum port.
6. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

Fig. 180: Power Brake Booster Vacuum Hose Quick Connect

7. Through the left front wheelhouse, connect the power brake booster vacuum hose quick connect (1) to the power brake booster pump port.

Power brake booster pump replacement

Removal Procedure

1. With the engine OFF, apply and release the brake pedal several times until the brake pedal becomes firm to deplete the power brake booster vacuum reserve.
2. Remove the battery tray. Refer to Battery Tray Replacement .
3. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

Fig. 181: Power Brake Booster Vacuum Hose Quick Connect

4. Through the left front wheehouse, disconnect the power brake booster vacuum hose quick connect (1) from the power brake booster pump port.
5. Lower the vehicle.
6. Disconnect the power brake booster pump electrical connector.

Fig. 182: Power Brake Booster Pump Vent Hose And Grommet

7. Release the power brake booster pump vent hose and grommet (1) from the left side rail.

Fig. 183: Brake Booster Pump Bracket Nuts

8. Remove the power brake booster pump bracket nuts (1).
9. Remove the power brake booster pump assembly.
10. If replacing the power brake booster pump, remove the power brake booster pump bracket. Refer to Power Brake Booster Pump Bracket Replacement.

Installation Procedure

1. Install the power brake booster pump bracket, if removed. Refer to Power Brake Booster Pump Bracket Replacement.
2. Install the power brake booster pump assembly.

Fig. 184: Brake Booster Pump Bracket Nuts

CAUTION: Refer to Fastener Caution .

3. Install the power brake booster pump bracket nuts (1).

• 5 speed manual transmission: Tighten the nuts to 58 (43 lb ft)
• 6 speed automatic transmission, 6 speed manual transmission: Tighten the nuts to 22 (16 lb ft)

Fig. 185: Power Brake Booster Pump Vent Hose And Grommet

4. Install the power brake booster pump vent hose and grommet (1) to the left side rail.
5. Connect the power brake booster pump electrical connector.
6. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .

Fig. 186: Power Brake Booster Vacuum Hose Quick Connect

7. Through the left front wheelhouse, connect the power brake booster vacuum hose quick connect (1) to the power brake booster pump port.
8. Install the battery tray. Refer to Battery Tray Replacement .

Power brake booster pump bracket replacement

Removal Procedure

1. Remove the power brake booster pump assembly. Refer to Power Brake Booster Pump Replacement.

Fig. 187: Power Brake Booster Pump

2. Disconnect the power brake booster pump vent hose (1).
3. Release the power brake booster pump electrical harness and retainer from the power brake booster pump bracket.

Fig. 188: Power Brake Booster Pump Nuts

4. Remove the power brake booster pump nuts (1).

Fig. 189: Power Brake Booster Pump Bolts

5. Remove the power brake booster pump bolts (1).
6. Remove the power brake booster pump bracket.

Installation Procedure

Fig. 190: Power Brake Booster Pump Bolts

1. Install the power brake booster pump bracket to the power brake booster pump.
2. Install the power brake booster pump bolts (1).

Fig. 191: Power Brake Booster Pump Nuts

CAUTION: Refer to Fastener Caution .

3. Install the power brake booster pump nuts (1) and tighten to 7 (62 lb in).

Fig. 192: Power Brake Booster Pump

4. Connect the power brake booster pump vent hose (1).
5. Install the power brake booster pump electrical harness and retainer to the power brake booster pump bracket.
6. Install the power brake booster pump. Refer to Power Brake Booster Pump Replacement.

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