Opel Insignia: Repair Instructions

Hydraulic Brake Fluid Replacement

WARNING: Brake Fluid Irritant Warning.

CAUTION: 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.

1. With the engine OFF, apply and release the brake pedal several times until the pedal effort becomes firm to deplete the brake booster power reserve.

2. Clean the outer surface of the master cylinder brake fluid reservoir, on and around the reservoir cap, prior to removing the cap and diaphragm.

3. Fill the master cylinder brake fluid reservoir to the maximum-fill level with GM approved brake fluid from a clean, sealed brake fluid container.

4. Maintain the brake fluid level in the master cylinder brake fluid reservoir to between the minimum and maximum-fill level during the brake fluid replacement procedure.

5. Following the hydraulic brake system bleeding procedure, bleed each of the hydraulic brake wheel circuits until clean, clear brake fluid is observed coming from each bleeder valve.

6. Fill the master cylinder brake fluid reservoir to the maximum-fill level with GM approved brake fluid from a clean, sealed brake fluid container. Brake Master Cylinder Reservoir Filling.

7. Securely install the master cylinder brake fluid reservoir diaphragm and cap.

8. Slowly apply and release the brake pedal, observing the brake pedal feel.

9. If the brake pedal feels spongy, perform the following:

1. Visually inspect the hydraulic brake system for external leaks.
2. Using a scan tool, perform the antilock brake system automated bleed procedure to remove any air that may have become trapped in the brake pressure modulator valve (BPMV).

BRAKE 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 maximumfill 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.

7. Use only GM approved brake fluid from a clean, sealed brake fluid container to SLOWLY fill the brake master cylinder reservoir to avoid spillage due to overfilling.

BRAKE MASTER CYLINDER RESERVOIR REPLACEMENT

Removal Procedure

WARNING: Brake Fluid Irritant Warning.

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

1. Brake Master Cylinder - Remove.

2. Drain and properly dispose of the brake fluid in the master cylinder reservoir.

3.

Brake Master Cylinder Reservoir Retaining Pin (1) - Remove and DISCARD.

4.

Master Cylinder Reservoir (1) - Remove.

5.

Brake Master Cylinder Reservoir Seal (1) - Remove and DISCARD[2x].

Installation Procedure

1. Lubricate the master cylinder reservoir seals with GM approved brake fluid from a clean, sealed, brake fluid container.

2.

NOTE: Ensure the seals are fully seated in the master cylinder.

Brake Master Cylinder Reservoir Seal (1) - Install NEW[2x].

3.

NOTE: Ensure the master cylinder reservoir is fully seated in the master cylinder.

Master Cylinder Reservoir (1) - Install.

4.

Brake Master Cylinder Reservoir Retaining Pin (1) - Install NEW.

5. Brake Master Cylinder - Install.

Brake Master Cylinder Replacement

Removal Procedure

WARNING: Brake Fluid Irritant Warning.

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

1. Place the ignition switch in the OFF position.

2. Apply and release the brake pedal several times until the brake pedal becomes firm to deplete the power vacuum brake booster vacuum reserve.

3. Without draining the coolant and without disconnecting the hoses, position aside the radiator surge tank.

4. Disconnect the brake fluid level sensor electrical connector.

5.

Master Cylinder Secondary Brake Pipe Fitting (1) - Disconnect.

6. Cap the brake pipe fitting and plug the brake master cylinder outlet port to prevent brake fluid loss and contamination.

7.

Master Cylinder Primary Brake Pipe Fitting (1) - Disconnect.

8. Cap the brake pipe fitting and plug the brake master cylinder outlet port to prevent brake fluid loss and contamination.

9.

NOTE: Do NOT reuse the master cylinder nuts.

Master Cylinder Nut (1) - Remove and DISCARD[2x].

10.

Master Cylinder (1) - Remove.

11.

Brake Master Cylinder Seal (1) - Remove and DISCARD.

Installation Procedure

1.

NOTE: Install a NEW seal.

Brake Master Cylinder Seal (1) - Install.

2.

Master Cylinder (1) - Install.

3.

CAUTION: Fastener Caution.

NOTE: Install NEW nuts.

Master Cylinder Nut (1) - Install and tighten55 N.m (41 lb ft)[2x].

4.

Master Cylinder Primary Brake Pipe Fitting (1) - Install and tighten32 N.m (24 lb ft).

5.

Master Cylinder Secondary Brake Pipe Fitting (1) - Install and tighten32 N.m (24 lb ft).

6. Connect the brake fluid level sensor electrical connector.

7. Radiator Surge Tank Replacement - Install.

8. Bleed the brake system.

BRAKE MASTER CYLINDER BENCH BLEEDING

1.

WARNING: Refer to Brake Fluid Irritant Warning.

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

Secure the mounting flange of the brake master cylinder in a bench vise 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 at least the half-way point with GM approved brake fluid from a clean, sealed brake fluid container.

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 vise.

BRAKE FLUID LEVEL SENSOR REPLACEMENT

Removal Procedure

1. Without draining the coolant and without disconnecting the hoses, position aside the radiator surge tank.

2. Disconnect the brake fluid level sensor electrical connector.

3.

Using an appropriate tool, lift upward to release the brake fluid level sensor locking tab (1).

4.

Brake Fluid Level Sensor(1) - Remove.

Installation Procedure

1.

Brake Fluid Level Sensor(1) - Install.

2.

Ensure the brake fluid level sensor locking tab (1) is fully engaged.

3. Connect the brake fluid level sensor electrical connector.

4. Radiator Surge Tank Replacement - Install.

Brake and Accelerator Pedal Assembly Replacement

Removal Procedure

1. Without disconnecting the hoses, remove and position aside the radiator surge tank.

2. Instrument Panel Tie Bar - Remove.

3.

Power Brake Booster Bolt(1) - Loosen[2x].

4. Floor Front Air Outlet Duct - Left Side - Remove.

5. Accelerator Pedal Position Sensor Electrical Connector - Disconnect.

6. Brake Pedal Position Sensor Electrical Connector - Disconnect.

7.

Compress the brake pedal retainer (1)locking tabs.

8.

NOTE: Pull the brake pedal rearward to disconnect the retainer.

Brake Pedal (1) - Disconnect.

9.

Retainer(1) - Remove and DISCARD.

10.

Upper Intermediate Steering Shaft(1) - Remove.

11.

Brake and Accelerator Pedal Assembly Nut (1) - Remove.

12.

Brake and Accelerator Pedal Assembly Bolt (1) - Remove[2x].

13.

Brake and Accelerator Pedal Assembly (1) - Remove.

14. Brake Pedal Position Sensor - Remove.

Installation Procedure

1. Brake Pedal Position Sensor - Install.

2.

Brake and Accelerator Pedal Assembly (1) - Install.

3.

CAUTION: Fastener Caution

Brake and Accelerator Pedal Assembly Bolt (1) - Install and tighten[2x]9 N.m (80 lb in).

4.

Brake and Accelerator Pedal Assembly Nut (1) - Install and tighten9 N.m (80 lb in).

5.

Upper Intermediate Steering Shaft(1) - Install - Upper Intermediate Steering Shaft Replacement.

6.

Retainer(1) - Install NEW.

7.

Brake Pedal (1) - Connect.

8. Ensure the locking tabs on the brake pedal retainer are fully engaged in the brake pedal (1) the retainer is attached securely to the brake push rod.

9. Brake Pedal Position Sensor Electrical Connector - Connect.

10. Accelerator Pedal Position Sensor Electrical Connector - Connect.

11. Floor Front Air Outlet Duct - Left Side - Install.

12.

Power Brake Booster Bolt(1) - Tighten[2x] 19 N.m (14 lb ft).

13. Instrument Panel Tie Bar - Install.

14. Radiator Surge Tank - Install.

BRAKE PRESSURE MODULATOR VALVE PRIMARY PIPE REPLACEMENT (2.0L LTG)

Removal Procedure

WARNING: Brake Fluid Irritant Warning.

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

1. Place the ignition switch in the OFF position.

2. Remove the battery.

3. Without draining the coolant and without disconnecting the hoses, position aside the radiator surge tank.

4.

Master Cylinder Primary Brake Pipe Fitting (1) - Disconnect.

5. Plug the master cylinder outlet port to prevent brake fluid loss and contamination.

6.

Brake Pressure Modulator Valve Primary Pipe Fitting(1) - Disconnect.

7. Plug the BPMV inlet port to prevent brake fluid loss and contamination.

8. Remove the brake pressure modulator valve primary pipe.

Installation Procedure

1. Install the brake pressure modulator valve primary pipe.

2.

CAUTION: Fastener Caution

Brake Pressure Modulator Valve Primary Pipe Fitting(1) - Install and tighten32N.m (24 lb ft).

3.

Master Cylinder Primary Brake Pipe Fitting (1) - Install and tighten32N.m (24 lb ft).

4. Radiator Surge Tank Replacement - Install.

5. Install the battery.

6. Bleed the brake system.

BRAKE PRESSURE MODULATOR VALVE PRIMARY PIPE REPLACEMENT (3.6L LGX)

Removal Procedure

WARNING: Brake Fluid Irritant Warning

CAUTION: Brake Fluid Effects on Paint and Electrical Components Caution

1. Place the ignition switch in the OFF position.

2. Remove the battery.

3. Without draining the coolant and without disconnecting the hoses, position aside the radiator surge tank.

4.

Clip(1) - Release.

5.

Clip(1) - Release.

6.

Master Cylinder Primary Brake Pipe Fitting (1) - Disconnect.

7. Plug the master cylinder outlet port to prevent brake fluid loss and contamination.

8.

Brake Pressure Modulator Valve Primary Pipe Fitting(1) - Disconnect.

9. Plug the BPMV inlet port to prevent brake fluid loss and contamination.

10. Remove the brake pressure modulator valve primary pipe.

Installation Procedure

1. Install the brake pressure modulator primary valve pipe.

2.

CAUTION: Fastener Caution

Brake Pressure Modulator Valve Primary Pipe Fitting(1) - Install and tighten32 N.m (24 lb ft).

3.

Master Cylinder Primary Brake Pipe Fitting (1) - Install and tighten32 N.m (24 lb ft).

4.

Clip(1) - Secure.

5.

Clip(1) - Secure.

6. Radiator Surge Tank - Install.

7. Install the battery.

8. Bleed the brake system.

Brake Pressure Modulator Valve Secondary Pipe Replacement (2.0L LTG)

Removal Procedure

WARNING: Brake Fluid Irritant Warning

CAUTION: Brake Fluid Effects on Paint and Electrical Components Caution

1. Place the ignition switch in the OFF position.

2. Remove the battery.

3. Without draining the coolant and without disconnecting the hoses, position aside the radiator surge tank.

4.

Master Cylinder Secondary Brake Pipe Fitting (1) - Disconnect.

5. Plug the master cylinder outlet port to prevent brake fluid loss and contamination.

6.

Brake Pressure Modulator Valve Secondary Pipe Fitting(1) - Disconnect.

7. Plug the brake pressure modulator valve (BPMV) inlet port to prevent brake fluid loss and contamination.

8. Remove the brake pressure modulator valve secondary pipe.

Installation Procedure

1. Install the brake pressure modulator valve secondary pipe.

CAUTION: Fastener Caution

2.

Brake Pressure Modulator Valve Secondary Pipe Fitting(1) - Install and tighten32N.m (24 lb ft).

3.

Master Cylinder Secondary Brake Pipe Fitting (1) - Install and tighten32N.m (24 lb ft).

4. Radiator Surge Tank Replacement - Install.

5. Install the battery.

6. Bleed the brake system.

BRAKE PRESSURE MODULATOR VALVE SECONDARY PIPE REPLACEMENT (3.6L LGX)

Removal Procedure

WARNING: Brake Fluid Irritant Warning

CAUTION: Brake Fluid Effects on Paint and Electrical Components Caution

1. Place the ignition switch in the OFF position.

2. Remove the battery.

3. Without draining the coolant and without disconnecting the hoses, position aside the radiator surge tank.

4.

Clip(1) - Release.

5.

Clip(1) - Release.

6.

Master Cylinder Secondary Brake Pipe Fitting (1) - Disconnect.

7. Plug the master cylinder outlet port to prevent brake fluid loss and contamination.

8.

Brake Pressure Modulator Valve Secondary Pipe Fitting(1) - Disconnect.

9. Plug the brake pressure modulator valve (BPMV) inlet port to prevent brake fluid loss and contamination.

10. Plug the master cylinder outlet port to prevent brake fluid loss and contamination.

11.

Brake Pressure Modulator Valve Secondary Pipe Fitting(1) - Disconnect.

12. Plug the brake pressure modulator valve (BPMV) inlet port to prevent brake fluid loss and contamination.

13. Remove the brake pressure modulator valve secondary pipe.

Installation Procedure

1. Install the brake pressure modulator valve secondary pipe.

2.

Brake Pressure Modulator Valve Secondary Pipe Fitting(1) - Install and tighten32 N.m (24 lb ft).

3.

Master Cylinder Secondary Brake Pipe Fitting (1) - Install and tighten32 N.m (24 lb ft).

4.

Clip(1) - Secure.

5.

Clip(1) - Secure.

6. Radiator Surge Tank - Install.

7. Install the battery.

8. Bleed the brake system.

Brake Pipe Replacement

Special Tools

CH-45405 Pipe Flaring Tool Kit

For equivalent regional tools, refer to Special Tools.

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 flaring tool.
• 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 flaring tool, 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.

9.

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

1. Select the appropriate blade on the coating stripping tool included in the CH-45405 flaring tool, 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

2. Insert the brake pipe end to be flared into the stripping tool to the depth of the ledge on the tool rollers.
3. 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.

4. 4. Rotate the stripping tool in a clockwise direction, ensuring that the brake pipe end remains against the tool roller ledges.
5. 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.
6. 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.

7. 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

10.

Chamfer the inside and outside diameter of the pipe with the de-burring tool included in the CH- 45405 flaring tool.

11. Install the tube nuts on the brake pipe, noting their orientation.

12. Clean the brake pipe and the CH-45405 flaring tool of lubricant, contaminants, and debris.

13.

Loosen the die clamping screw of the CH-45405 flaring tool.

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.

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.

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 flaring tool until it bottoms against the die cage.

23.

While guiding the forming mandrel into the exposed end of pipe to be flared, operate the lever of the CH-45405 flaring tool 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.

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 flaring tool 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 flaring tool 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.

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 (Pressure) or Hydraulic Brake System Bleeding (Manual).

37. With the aid of an assistant, inspect the brake pipe flares for leaks by starting the engine and applying the brakes.

Front Brake Pipe Replacement - Right Side

Removal Procedure

WARNING: Brake Fluid Irritant Warning

CAUTION: Brake Fluid Effects on Paint and Electrical Components Caution

1. Place the ignition switch in the OFF position.

2. Without draining the coolant and without disconnecting the hoses, position aside the radiator surge tank.

3.

Right Front Brake Pipe Fitting (1) - Disconnect.

4. Plug the brake pressure modulator valve (BPMV) outlet port to prevent brake fluid loss and contamination.

5.

Clip(1) - Release.

6.

Clip(1) - Release.

7. Clip(2) - Release.

8. Raise and support the vehicle.

9.

Clip(1)@Side Rail - Release.

10.

Brake Pipe Fitting(1)@Brake Hose - Disconnect.

11. Cap the brake hose to prevent brake fluid loss and contamination.

12. Brake Pipe - Remove.

Installation Procedure

1. Brake Pipe - Install.

2.

CAUTION: Fastener Caution

Brake Pipe Fitting(1)@Brake Hose - Install and tighten18 N.m (13 lb ft).

3.

Clip(1)@Side Rail - Secure.

4. Lower the vehicle.

5.

Clip(1) - Secure.

6. Clip(2) - Secure.

7.

Clip(1) - Secure.

8.

Right Front Brake Pipe Fitting (1) - Install and tighten18 N.m (13 lb ft).

9. Radiator Surge Tank Replacement - Install.

10. Bleed the brake system.

FRONT BRAKE PIPE REPLACEMENT - LEFT SIDE

Removal Procedure

WARNING: Brake Fluid Irritant Warning

CAUTION: Brake Fluid Effects on Paint and Electrical Components Caution

1. Place the ignition switch in the OFF position.

2. Without draining the coolant and without disconnecting the hoses, position aside the radiator surge tank.

3.

Left Front Brake Pipe Fitting (1) - Disconnect.

4. Plug the brake pressure modulator valve (BPMV) outlet port to prevent brake fluid loss and contamination.

5.

Clip(1) - Release.

6. Raise and support the vehicle. 7.

Clip(1)@Side Rail - Release.

8.

Brake Pipe Fitting(1)@Brake Hose - Disconnect.

9. Cap the brake hose to prevent brake fluid loss and contamination.

10. Brake Pipe - Remove.

Installation Procedure

1. Brake Pipe - Install.

2.

CAUTION: Fastener Caution

Brake Pipe Fitting(1)@Brake Hose - Install and tighten18 N.m (13 lb ft).

3.

Clip(1)@Side Rail - Secure.

4. Lower the vehicle.

5.

Clip(1) - Secure.

6.

Left Front Brake Pipe Fitting (1) - Install and tighten18 N.m (13 lb ft).

7. Radiator Surge Tank Replacement - Install.

8. Bleed the brake system.

Front Brake Hose Replacement (JQ5)

Removal Procedure

WARNING: Brake Fluid Irritant Warning.

WARNING: Use of eye goggles is necessary to prevent personal injury.

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

1. Remove the front tire and wheel assembly.

2.

Front Brake Pipe Fitting(1)@Front Brake Hose(3) - Remove.

3. Brake Hose Retainer(2)@Front Brake Hose(3) - Remove.

4. Front Brake Hose(3) - Disengage.

5. Cap the brake pipe fitting to prevent brake fluid loss and contamination.

6. Cap the brake hose fitting to prevent brake fluid loss and contamination.

7.

Open (arrow b) the 2 brake hose retainers (1, 2)and move aside (arrows a).

8.

Front Brake Hose Bracket Bolt(2)@Front Brake Hose(1) - Remove.

9. Front Brake Hose(1) - Disengage.

10.

Brake Hose Fitting Bolt(1) - Remove.

11. Front Brake Hose(2) - Remove.

NOTE: The front brake hose washers may stuck to the brake caliper and/or the brake hose end.

12. Front Brake Hose Washer(3) - Remove and DISCARD[2x].

13. Cap the brake hose fitting to prevent brake fluid loss and contamination.

14. Cap the brake caliper inlet port to prevent brake fluid loss and contamination.

Installation Procedure

1.

Remove the caps from the brake caliper inlet port and the brake hose fitting.

2. Front Brake Hose Washer(3) - Install[2x] - Use NEW seals.

3. Front Brake Hose(2) - Install.

4. Brake Hose Fitting Bolt(1) - Install and hand tighten.

WARNING: Make sure the brake hose is not twisted, tensioned or kinked after installation. With the suspension settled, check that there is no contact with the surrounding components when moving the steering from stop to stop. Failure to comply could result in damage to the brake hose and lead to severe or fatal injuries.

5. Brake Hose Fitting Bolt(1) - Tighten40N.m (30 lb ft).

6.

Front Brake Hose(1) - Engage.

7. Front Brake Hose Bracket Bolt(2)@Front Brake Hose(1) - Install and tighten9N.m (80 lb in).

8.

Position the 2 brake hose retainers (1, 2)and close them.

9.

Remove the caps from the brake hose fitting and the brake pipe fitting.

10. Front Brake Hose(3) - Engage.

11. Brake Hose Retainer(2)@Front Brake Hose(3) - Install.

12. Front Brake Pipe Fitting(1)@Front Brake Hose(3) - Install and tighten18N.m (13 lb ft).

13. Bleed the brake system.

14. Install the front tire and wheel assembly.

FRONT BRAKE HOSE REPLACEMENT (J60)

Removal Procedure

WARNING: Brake Dust Warning

WARNING: Brake Fluid Irritant Warning

1. Raise and support the vehicle.

. Remove the tire and wheel assembly.

3.

Brake Pipe Fitting(1) - Disconnect.

4. Cap the brake pipe fitting to prevent brake fluid loss and contamination.

5.

Brake Hose Retainer(1) - Remove.

6.

Wheel Speed Sensor Harness Clip(1)@Front Brake Hose - Release[2x].

7.

Bolt(1) - Remove.

8.

Brake Hose Fitting Bolt(1) - Remove.

9.

NOTE: Do NOT reuse the brake hose fitting gaskets.

Brake Hose Fitting Gasket (1)@Brake Hose(2) - Remove and DISCARD [2x].

10. Cap the brake caliper inlet port to prevent brake fluid loss and contamination.

11. Remove the brake hose.

Installation Procedure

1. Install the brake hose to the vehicle.

2.

NOTE: Install NEW brake hose fitting gaskets.

Brake Hose Fitting Gasket(1)@Brake Hose(2) - Install[2x].

3.

WARNING: Make sure the brake hose is not twisted, tensioned or kinked after installation. With the suspension settled, check that there is no contact with the surrounding components when moving the steering from stop to stop. Failure to comply could result in damage to the brake hose and lead to severe or fatal injuries.

CAUTION: Fastener Caution

Brake Hose Fitting Bolt(1) - Install and tighten 40 N.m (30 lb ft)

4.

Bolt(1) - Install and tighten 9 N.m (80 lb in)

5.

Wheel Speed Sensor Harness Clip(1)@Front Brake Hose - Secure[2x].

6.

Brake Hose Retainer(1) - Install.

7.

Brake Pipe Fitting(1) - Install and tighten 18 N.m (13 lb ft).

8. Bleed the brake system.

9. Install the tire and wheel assembly.

Front Brake Hose Replacement (J17)

Removal Procedure

WARNING: Brake Dust Warning

WARNING: Brake Fluid Irritant Warning

1. Raise and support the vehicle.

2. Remove the tire and wheel assembly.

3.

Brake Pipe Fitting(1) - Disconnect.

4. Cap the brake pipe fitting to prevent brake fluid loss and contamination.

5.

Brake Hose Retainer(1) - Remove.

6.

Wheel Speed Sensor Harness Clip(1)@Front Brake Hose - Release[2x].

7.

Bolt(1) - Remove.

8.

Brake Hose Fitting Bolt(1) - Remove.

9.

NOTE: Do NOT reuse the brake hose fitting gaskets.

Brake Hose Fitting Gasket (1)@Brake Hose(2) - Remove and DISCARD [2x].

10. Cap the brake caliper inlet port to prevent brake fluid loss and contamination.

11. Remove the brake hose.

Installation Procedure

1. Install the brake hose to the vehicle.

2.

NOTE: Install NEW brake hose fitting gaskets.

Brake Hose Fitting Gasket(1)@Brake Hose(2) - Install[2x].

3.

WARNING: Make sure the brake hose is not twisted, tensioned or kinked after installation. With the suspension settled, check that there is no contact with the surrounding components when moving the steering from stop to stop. Failure to comply could result in damage to the brake hose and lead to severe or fatal injuries.

CAUTION: Fastener Caution

Brake Hose Fitting Bolt(1) - Install and tighten40N.m (30 lb ft).

4.

Bolt(1) - Install and tighten9N.m (80 lb in).

5.

Wheel Speed Sensor Harness Clip(1)@Front Brake Hose - Secure[2x].

6.

Brake Hose Retainer(1) - Install.

7.

Brake Pipe Fitting(1) - Install and tighten18N.m (13 lb ft).

8. Bleed the brake system.

9. Install the tire and wheel assembly.

Rear Brake Hose Replacement (GNC)

Removal Procedure

WARNING: Brake Dust Warning

WARNING: Brake Fluid Irritant Warning

1. Raise and support the vehicle.

2. Remove the tire and wheel assembly.

3.

Brake Pipe Fitting(1) - Disconnect.

4. Cap the brake pipe fitting to prevent brake fluid loss and contamination.

5.

Brake Hose Retainer(1) - Remove.

6.

Brake Hose Fitting Bolt (1) - Remove.

7.

NOTE: Do NOT reuse the brake hose fitting gaskets.

Brake Hose Fitting Gasket (1)@ Brake Hose Fitting (2) - Remove and DISCARD[2x].

8. Plug the caliper inlet to prevent brake fluid loss and contamination.

9. Remove the brake hose.

Installation Procedure

1. Install the brake hose to the vehicle.

2.

NOTE: Install NEW brake hose fitting gaskets.

Brake Hose Fitting Gasket (1)@ Brake Hose Fitting (2) - Install[2x].

3.

CAUTION: Fastener Caution

Brake Hose Fitting Bolt (1) - Install and tighten 40 N.m (30 lb ft).

4.

Brake Hose Retainer(1) - Install.

5.

Brake Pipe Fitting(1) - Install and tighten 18 N.m (13 lb ft).

6. Bleed the brake system.

7. Install the tire and wheel assembly.

REAR BRAKE HOSE REPLACEMENT (GNQ)

Removal Procedure

WARNING: Brake Dust Warning

WARNING: Brake Fluid Irritant Warning

1. Raise and support the vehicle.

2. Remove the tire and wheel assembly.

3. Partially remove the rear wheelhouse liner enough to access the rear brake hose fitting.

4.

Brake Pipe Fitting(1) - Disconnect.

5. Cap the brake pipe fitting to prevent brake fluid loss and contamination.

6.

Brake Hose Retainer(1) - Remove.

7.

Brake Hose Fitting Bolt (1) - Remove.

8.

Brake Hose Fitting Gasket (1)@ Brake Hose Fitting (2) - Remove and DISCARD[2x].

9. Plug the caliper inlet to prevent brake fluid loss and contamination.

10.

Rear Brake Hose(1) - Remove.

Installation Procedure

1.

Rear Brake Hose(1) - Install.

2.

Brake Hose Fitting Gasket (1)@ Brake Hose Fitting (2) - Install NEW[2x].

3.

CAUTION: Fastener Caution

Brake Hose Fitting Bolt (1) - Install and tighten 40 N.m (30 lb ft).

4.

Brake Hose Retainer(1) - Install.

5.

Brake Pipe Fitting(1) - Install and tighten 18 N.m (13 lb ft).

6. Rear Wheelhouse Liner - Install.

7. Bleed the brake system.

8. Install the tire and wheel assembly.

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 Brake Master Cylinder Bench Bleeding.

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.

6. 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.

7. Install the appropriate master cylinder reservoir adapter and connect the brake pressure bleeder.

8. 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.

9. 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.

10. Wait approximately 30 seconds, then inspect the entire hydraulic brake system for external brake fluid leaks.

11. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve.

12. Install a transparent hose over the end of the bleeder valve.

13. 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.

14. Loosen the bleeder valve to purge air from the wheel hydraulic circuit.

15. Allow fluid to flow until air bubbles stop flowing from the bleeder.

16. After all air has been purged from the hydraulic circuit, tighten the bleeder valve and install the dust cap.

17. Install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve, then repeat steps 12-16.

18. Install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve, then repeat steps 12-16.

19. Install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve, then repeat steps 12-16.

20. 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.

21. Remove the brake pressure bleeding equipment from the vehicle.

22. 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.

23. Slowly press and release the brake pedal. Observe the brake pedal feel.

24. 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.

25. If the brake pedal still feels spongy, pressure bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Pressure) or Hydraulic Brake System Bleeding (Manual).

26. 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.

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

Hydraulic Brake System Bleeding (Manual)

WARNING: Refer to Brake Fluid Irritant Warning.

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

1. Place a clean shop cloth beneath the brake master cylinder to prevent brake fluid spills.

2. 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.

3. If you have performed a brake master cylinder bench bleeding on this vehicle, or if you disconnected the brake pipes from the master cylinder, you must perform the following steps:

1. Ensure that the brake master cylinder reservoir is full to the maximum-fill level. If necessary, add GM approved brake fluid from a clean, sealed brake fluid container.

   If removal of the reservoir cap and diaphragm is necessary, clean the outside of the reservoir on and around the cap prior to removal.

2. With the rear brake pipe installed securely to the master cylinder, loosen and separate the front brake pipe from the front port of the brake master cylinder.
3. Allow a small amount of brake fluid to gravity bleed from the open port of the master cylinder.
4. Reconnect the brake pipe to the master cylinder port and tighten securely.
5. Have an assistant slowly depress the brake pedal fully and maintain steady pressure on the pedal.
6. Loosen the same brake pipe to purge air from the open port of the master cylinder.
7. Tighten the brake pipe, then have the assistant slowly release the brake pedal.
8. Wait 15 seconds, then repeat steps 3.3 - 3.7 until all air is purged from the same port of the master cylinder.
9. With the front brake pipe installed securely to the master cylinder, after all air has been purged from the front port of the master cylinder, loosen and separate the rear brake pipe from the master cylinder, then repeat steps 3.3 - 3.8.
10. After completing the final master cylinder port bleeding procedure, ensure that both of the brake pipe-to-master cylinder fittings are properly tightened.

4. Fill the brake master cylinder reservoir with GM approved brake fluid from a clean, sealed brake fluid container. Ensure that the brake master cylinder reservoir remains at least half-full during this bleeding procedure. Add fluid as needed to maintain the proper level.

Clean the outside of the reservoir on and around the reservoir cap prior to removing the cap and diaphragm.

5. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit bleeder valve.

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 GM approved brake fluid from a clean, sealed brake fluid container.

8. Have an assistant slowly depress 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 same wheel hydraulic circuit.

12. With the right rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the right rear hydraulic circuit, install a proper box-end wrench onto the LEFT FRONT wheel hydraulic circuit bleeder valve.

13. Install a transparent hose over the end of the bleeder valve, then repeat steps 7 - 11.

14. With the left front wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the left front hydraulic circuit, install a proper box-end wrench onto the LEFT REAR wheel hydraulic circuit bleeder valve.

15. Install a transparent hose over the end of the bleeder valve, then repeat steps 7 - 11.

16. With the left rear wheel hydraulic circuit bleeder valve tightened securely, after all air has been purged from the left rear hydraulic circuit, install a proper box-end wrench onto the RIGHT FRONT wheel hydraulic circuit bleeder valve.

17. Install a transparent hose over the end of the bleeder valve, then repeat steps 7 - 11.

18. After completing the final wheel hydraulic circuit bleeding procedure, ensure that each of the 4 wheel hydraulic circuit bleeder valves are properly tightened.

19. Fill the brake master cylinder reservoir to the maximum-fill level with GM approved brake fluid from a clean, sealed brake fluid container.

20. Slowly depress and release the brake pedal. Observe the feel of the brake pedal.

NOTE: If it is determined that air was induced into the system upstream of the ABS modulator prior to servicing, the Antilock Brake System Automated Bleed must be performed.

21. If the brake pedal feels spongy, repeat the bleeding procedure again. If the brake pedal still feels spongy after repeating the bleeding procedure, perform the following steps:

1. Inspect the brake system for external leaks. Brake System External Leak Inspection
2. Pressure bleed the hydraulic brake system in order to purge any air that may still be trapped in the system.

22. 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.

23. If the brake system warning lamp remains illuminated.

Hydraulic Brake System Flushing

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.

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, 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 applicable procedures:

• Brake Master Cylinder Replacement
• Front Brake Hose Replacement (JQ5), Front Brake Hose Replacement (J60), or Front Brake Hose Replacement (J17)
• Rear Brake Hose Replacement (GNC) or Rear Brake Hose Replacement (GNQ)
• Front Brake Caliper Replacement (JQ5) , Front Brake Caliper Replacement (J60) , or Front Brake Caliper Replacement (J17)
• Rear Brake Caliper Replacement (GNC) or Rear Brake Caliper Replacement (GNQ)
• Electronic Brake and Traction Control Module with Brake Pressure Modulator Valve Replacement (2.0L LTG) or Electronic Brake and Traction Control Module with Brake Pressure Modulator Valve Replacement (3.6L LGX)

2. Clean out all the hydraulic brake pipes using denatured alcohol, or equivalent.
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 applicable procedures:

• Brake Master Cylinder Replacement - Also perform the following: Clean the brake master cylinder reservoir using denatured alcohol, or equivalent, then dry the reservoir using non-lubricated, filtered air. Inspect the reservoir for cracks and/or damage and replace if necessary. Refer to Brake Master Cylinder Reservoir Replacement or Brake Master Cylinder Replacement.

  Replace the brake master cylinder reservoir cap diaphragm.

• Front Brake Hose Replacement (JQ5), Front Brake Hose Replacement (J60), or Front Brake Hose Replacement (J17)
• Rear Brake Hose Replacement (GNC) or Rear Brake Hose Replacement (GNQ)
• Front Brake Caliper Replacement (JQ5) , Front Brake Caliper Replacement (J60) , or Front Brake Caliper Replacement (J17)
• Rear Brake Caliper Replacement (GNC) or Rear Brake Caliper Replacement (GNQ)
• Electronic Brake and Traction Control Module with Brake Pressure Modulator
• Valve Replacement (2.0L LTG) or Electronic Brake and Traction Control Module with Brake Pressure Modulator Valve Replacement (3.6L LGX)

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. Refer to Fluid and Lubricant Recommendations.

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 (Pressure) or Hydraulic Brake System Bleeding (Manual).

Power Brake Booster Vacuum Sensor Replacement (2.0L LTG)

Removal Procedure

1. Without draining the coolant and without disconnecting the hoses, position aside the radiator surge tank.

2.

Power Brake Booster Vacuum Pipe Fitting (1)@Power Brake Booster Vacuum Sensor - Disconnect.

3. Power Brake Booster Vacuum Sensor Electrical Connector - Disconnect.

4.

Power Brake Booster Vacuum Sensor(1) - Remove.

Installation Procedure

1.

NOTE: A small amount of denatured alcohol may be used to ease assembly.

Power Brake Booster Vacuum Sensor(1) - Install.

2.

Power Brake Booster Vacuum Pipe Fitting (1)@Power Brake Booster Vacuum Sensor - Connect.

3. Power Brake Booster Vacuum Sensor Electrical Connector - Connect.

4. Radiator Surge Tank Replacement - Install.

POWER BRAKE BOOSTER VACUUM SENSOR REPLACEMENT (3.6L LGX)

Removal Procedure

1. Without draining the coolant and without disconnecting the hoses, position aside the radiator surge tank.

2.

Power Brake Booster Vacuum Pipe Fitting (1) - Disconnect.

3. Electrical Connector - Disconnect.

4.

Power Brake Booster Vacuum Sensor(1) - Remove.

Installation Procedure

1.

NOTE: A small amount of denatured alcohol may be used to ease assembly.

Power Brake Booster Vacuum Sensor(1) - Install.

2.

Power Brake Booster Vacuum Pipe Fitting (1) - Connect.

3. Electrical Connector - Connect.

4. Radiator Surge Tank - Install.

POWER BRAKE BOOSTER VACUUM PIPE REPLACEMENT (2.0L LTG)

Removal Procedure

1. Without draining the coolant and without disconnecting the hoses, position aside the radiator surge tank.

2. Intake Manifold Cover Replacement - Remove.

3.

Power Brake Booster Vacuum Pipe Fitting (1)@Power Brake Booster Vacuum Sensor - Disconnect.

4.

Power Brake Booster Vacuum Pipe Fitting (1)@Vacuum Pump - Disconnect.

5. Power Brake Booster Vacuum Pipe - Remove.

Installation Procedure

1. Power Brake Booster Vacuum Pipe - Install.

2.

Power Brake Booster Vacuum Pipe Fitting (1)@Vacuum Pump - Connect.

3.

Power Brake Booster Vacuum Pipe Fitting (1)@Power Brake Booster Vacuum Sensor - Connect.

4. Intake Manifold Cover Replacement - Install.

5. Radiator Surge Tank Replacement - Install.

POWER BRAKE BOOSTER VACUUM PIPE REPLACEMENT (3.6L LGX)

Removal Procedure

1. Without draining the coolant and without disconnecting the hoses, remove and position aside the radiator surge tank.

2. Air Cleaner Element - Remove.

3.

Power Brake Booster Vacuum Pipe Quick Connect Fitting(1) - Disconnect.

4.

Power Brake Booster Vacuum PipeClip(1) - Release.

5.

Power Brake Booster Vacuum Pipe Quick Connect Fitting(1) - Disconnect.

6.

Power Brake Booster Vacuum Pipe(1) - Remove.

Installation Procedure

1.

Power Brake Booster Vacuum Pipe(1) - Install.

2.

Power Brake Booster Vacuum Pipe Quick Connect Fitting(1) - Connect.

3.

Power Brake Booster Vacuum PipeClip(1) - Secure.

4.

Power Brake Booster Vacuum Pipe Quick Connect Fitting(1) - Connect.

5. Air Cleaner Element - Install.

6. Reposition and install the radiator surge tank.

POWER BRAKE BOOSTER REPLACEMENT

Removal Procedure

1. Floor Front Air Outlet Duct - Left Side - Remove.

2. Without draining the coolant and without disconnecting the hoses, remove and position aside the radiator surge tank.

3.

Power Brake Booster Vacuum Pipe(1)@Power Brake Booster Vacuum Sensor - Disconnect.

4. Power Brake Booster Vacuum Sensor Electrical Connector - Disconnect.

5.

Power Brake Booster Vacuum Sensor(1) - Remove.

6.

Brake Pressure Modulator Valve Primary Pipe(1) - Remove.

7.

Brake Pressure Modulator Valve Secondary Pipe(1) - Remove.

8.

Brake Master Cylinder - Remove.

9.

Electronic Traction Control Brake Pressure Modulator Valve(1) - Remove.

10.

NOTE: Completely loosen the power brake booster bolts.

Power Brake Booster Bolt(1) - Loosen[2x]

NOTE: Assistant required.

11. Perform the following to release the brake pedal retainer:

1.  

Compress the brake pedal retainer (1) locking tabs.

2. Slowly have an assistant pull the power brake booster away from the cowl panel until the brake pedal retainer clears the brake pedal assembly.
3.  

Brake Pedal Retainer (1) - Remove and DISCARD

12.

Power Brake Booster(1) - Remove.

Installation Procedure

1.

Position the power brake booster in the vehicle.

NOTE: Assistant required.

2. Perform the following to engage the brake pedal retainer:

1.  

Brake Pedal Retainer (1) - Install NEW

NOTE: Ensure the locking tabs on the brake pedal retainer are fully engaged in the brake pedal assembly.

2. Slowly have an assistant push the power brake booster toward the cowl panel until the brake pedal retainer fully engages the brake pedal assembly.

3.

CAUTION: Fastener Caution.

Power Brake Booster Bolt(1) - Tighten 19 N.m (14 lb ft) [2x].

4.

Electronic Traction Control Brake Pressure Modulator Valve - Install.

5.

Brake Master Cylinder - Install.

6.

Brake Pressure Modulator Valve Primary Pipe(1) - Install.

7.

Brake Pressure Modulator Valve Secondary Pipe(1) - Install.

8.

NOTE: A small amount of denatured alcohol may be used to ease assembly.

Power Brake Booster Vacuum Sensor(1) - Install.

9. Power Brake Booster Vacuum Sensor Electrical Connector - Connect.

10.

Power Brake Booster Vacuum Pipe(1)@Power Brake Booster Vacuum Sensor - Connect.

11. Reposition and install the radiator surge tank.

12. Floor Front Air Outlet Duct - Left Side - Install.

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