| Removal and Installation Special Tool(s) | | Disconnect Tool, Spring-Lock Coupling 5/8 inch (black) 412 - 038 (34 - 003) | General Equipment Removal All vehicles Vehicles with stability assist | | -
Disconnect the brake booster solenoid valve electrical connector. | All vehicles | | -
Disconnect the brake pedal switches. - Unlock the switches.
- Detach the switches.
| | | -
Detach the brake booster actuating rod from the brake pedal. - Depress the brake pedal.
- Depress the clip.
- Remove the brake booster actuating rod pin.
| | | -
Remove the brake booster retaining nuts. | | | -
Detach the wiring harness. | | | -
Detach the power steering reservoir and position to one side. | Vehicles with 1.8L or 2.0L engine | | -
WARNING:Do not smoke or carry tobacco or open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and can ignite. Failure to follow these instructions may result in personal injury. Disconnect the fuel pipes. | Vehicles with air conditioning | | -
Disconnect the air conditioning (A/C) pressure switch electrical connector. | | | -
Remove the right - hand side fender splash shield. | | | -
CAUTION:Cap the A/C line connections to prevent material loss and dirt ingress. Using the special tool disconnect the A/C line to the accumulator at the evaporator. | | | -
CAUTION:Cap the A/C line connections to prevent material loss and dirt ingress. Using the special tool disconnect the A/C line to the condenser at the evaporator. | | | -
CAUTION:Cap the A/C line connections to prevent material loss and dirt ingress. Remove the A/C condenser line. | | | -
Detach the A/C lines from the wheel housing bracket. | | | -
Detach the A/C lines from the wheel housing bracket. | | | -
Remove the A/C line retaining bracket. | | | -
NOTE:Pull the A/C lines through the hole in the fender. Remove the A/C lines from the engine compartment. | All except vehicles with diesel engine Vehicles with 1.8L or 2.0L engine | | -
Remove the rear support insulator. | Vehicles with 1.4L or 1.6L engine | | -
Remove the rear support insulator. | All vehicles | | -
Detach the coolant expansion tank. - Remove the bolt.
- Detach the tank
| Vehicles with 1.4L or 1.6L engine | | -
Detach the engine mounting bracket. | | | -
CAUTION:Make sure excessive force is not placed on the remaining engine mounts when moving the engine forward. Move the engine mount towards the front of the vehicle approximately 20 mm. | | | -
CAUTION:Make sure that any pipes or tubes are clear from the front of the brake booster. With the aid of another technician, remove the brake booster. - Prevent the engine load from dropping back towards the bulkhead.
- Lift the base of the brake booster past the valve cover.
| Vehicles with 1.8L or 2.0L engine All vehicles | | -
CAUTION:Make sure that any pipes or tubes are clear from the front of the brake booster. Remove the brake booster. | Installation All vehicles | | -
CAUTION:Make sure that the brake booster actuator rod is correctly positioned through the bulkhead rubber boot. CAUTION:Make sure the brake booster gasket is correctly positioned on the brake booster before installation. NOTE:Compress the brake booster actuator rod before installation. Install the booster. | Vehicles with 1.8L or 2.0L engine Vehicles with 1.4L or 1.6L engine | | -
Install the engine mounting bracket. | All vehicles | | -
Install the coolant expansion tank. - Position the tank.
- Install the bolt.
| Vehicles with 1.4L or 1.6L engine | | -
Install the rear support insulator bolt. | Vehicles with 1.8L or 2.0L engine | | -
Install the rear support insulator bolt. | Vehicles with air conditioning | | -
Position the A/C lines into the engine compartment. | | | -
Install the A/C line retaining bracket. | | | -
Install the A/C lines to the wheel arch bracket. | | | -
Install the A/C lines to the wheel arch bracket. | | | -
Install the A/C condenser line. | | | -
Install the A/C line to the condenser at the evaporator. | | | -
Install the A/C line to the accumulator at the evaporator. | | | -
Install the right - hand side wheel fender splash shield. | | | -
Install the air conditioning (A/C) pressure switch electrical connector. | Vehicles with 1.8L or 2.0L engine | | -
WARNING:Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related components. Highly flammable mixtures are always present and can ignite. Failure to follow these instructions may result in personal injury. Install the fuel pipes. | All vehicles | | -
Install the power steering reservoir. | | | -
CAUTION:Install a new actuator rod pin. Install the brake booster actuator rod. - Depress the brake pedal.
- Install the brake booster actuator.
| | | -
Remove the air duct (left - hand drive shown, right - hand drive similar). - Remove the fastener.
- Remove the air duct.
| | | -
Loosen the brake pedal retractor bolt. | | | -
CAUTION:Make sure there is clearance between the brake pedal and brake pedal retractor to allow free movement. Align the brake pedal retractor to the brake pedal bracket. | All vehicles | | -
Tighten the brake pedal bracket nuts. | Vehicles built 1/1999 onwards | | -
Tighten the brake pedal retractor arm bolt. | | | -
With the engine running depress the brake pedal three times to make sure the brake pedal moves freely and returns to the full brake off position. | All vehicles | | -
Set the stoplamp switch. - Pull the switch plunger out to its full extent.
| | | -
NOTE:Slowly release the brake pedal. Install the pedal switches. - Install the switches.
- Lock the switches in position.
| | | -
Slowly release the brake pedal. | Vehicles with Stability Assist | | -
Install the brake booster solenoid valve electrical connector. | All vehicles | 
