SPECIFICATIONS
Torque Specifications
DESCRIPTION AND OPERATION
Brake Booster
The power brake actuation system includes a vacuum sorce (engine manifold or vacuum pump), vacuum assisted brake booster, vacuum check valve and a vacuum supply tube. Vehicles equipped with 3.5L and 3.7L engines utilize engine manifold vacuum and vehicles equipped with 2.0L GTDI engines utilize an engine-mounted/cam-driven vacuum pump and engine manifold vacuum to supply vacuum.
Vacuum is delivered through the vacuum supply tube to the vacuum check valve. The vacuum check valve is a one-way valve that allows supplied vacuum to the booster then closes when the vacuum supply is removed. The vacuum is applied to a rubber diaphragm on the vacuum side of the brake booster chamber which then pulls the piston rod in when the brakes are applied to provide power assist, reducing the amount of effort required at the brake pedal to actuate the foundation brakes.
REMOVAL AND INSTALLATION
Brake Booster
Removal
WARNING: Before beginning any service procedure in this section, refer to Safety Warnings in Section 100-00. Failure to follow this instruction may result in serious personal injury.
NOTE: Removal steps in this procedure may contain installation details.
All vehicles
-
- To install, tighten to 63 Nm (46 lb-ft).
Vehicles equipped with 3.5 L Ti-VCT, 3.7L Ti-VCT or 2.0L Gasoline Turbocharged Direct Injection (GTDI) engines
- Remove the Air Cleaner (ACL) outlet pipe. Refer to Section 303-12.
- Remove the Hydraulic Control Unit (HCU). Refer to Section 206-09.
Vehicles equipped with 3.5L GTDI engine
-
- To install, tighten the nut to 6 Nm (53 lb-in).
- To install, tighten the clamps to 5 Nm (44 lb-in)
- Disconnect the ABS module electrical connector.
All vehicles
- Remove the brake master cylinder. Refer to Section 206-06.
- NOTICE: Do not service the brake pedal or brake booster
without first removing the stoplamp switch. This switch must be removed with
the brake pedal in the at-rest position. The switch plunger must be
compressed for the switch to rotate in the bracket. Attempting to remove the
switch when the plunger is extended (during pedal apply) will result in
damage to the switch.
Remove the stoplamp switch. Refer to Section 417-01.
- NOTE: The booster push rod clevis-locking pin is a one-time use only part. Any time the booster push rod clevis-locking pin is removed, a new booster push rod clevis-locking pin should be used. Remove the clevis-locking pin by squeezing the locking tabs and pulling outward on the opposite end.
-
- To install, tighten the new nuts to 25 Nm (18 lb-ft).
Installation
- To install, reverse the removal procedure.
Brake Vacuum Pump
Removal and Installation
NOTE: Removal steps in this procedure may contain installation details.
- Remove the air cleaner outlet pipe. For additional information, refer to Intake Air System Components-Exploded View in Section 303-12.
- To install, tighten to 10 Nm (89 lb-in).
- Inspect and, if necessary, install a new brake vacuum pump gasket.
- To install, reverse the removal procedure.
Brake Booster Vacuum Sensor
Removal
WARNING: Before beginning any service procedure in this section, refer to Safety Warnings in Section 100-00. Failure to follow this instruction may result in serious personal injury.
- Disconnect the brake booster vacuum sensor electrical connector.
- Remove the brake booster vacuum sensor.
Installation
- NOTE: Please note the correct installation position in the
exploded view. It is critical that the sensor be installed in the exact
position that it was removed.
To install, reverse the removal procedure.
Hydraulic Brake Actuation
SPECIFICATIONS
Material
Torque Specifications
DESCRIPTION AND OPERATION
Adjustable Pedals
Overview
The adjustable pedal feature uses an electrical motor to adjust the brake and
accelerator pedal po ...
Anti-Lock Brake System (ABS) and Stability Control
SPECIFICATIONS
Torque Specifications
DESCRIPTION AND OPERATION
Anti-Lock Brake System (ABS) and Stability Control
Overview
The ABS and stability control system is comprised of the following subsystem ...
Other materials:
Disassembly
Engine
Special Tool(s)
Material
WARNING: Do not smoke, carry lighted tobacco or have an open flame of any
type when working on or near any fuel-related component. Highly flammable
mixtures are always present and may be ignited. Failure to follow these
instructions may result in serious person ...
Assembly
Engine
Special Tool(s)
Material
Engine - External Components
Engine - Front and Upper Components
Engine - Lower Block Components
NOTICE: Do not loosen or remove the crankshaft pulley bolt without
first installing the special tools as instructed in this procedure. The
crankshaft pu ...
Cleaning leather seats
• Remove dust and loose dirt with a vacuum cleaner.
• Clean spills and stains as quickly as possible.
• For routine cleaning, wipe the surface with a soft, damp cloth. For
more thorough cleaning, wipe the surface with a mild soap and water
solution. Dry the area with a soft cloth.
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