084 - Hydraulic Brakes

Brakes
Hydraulic Brakes
SPECIFICATIONS
FASTENER TIGHTENING SPECIFICATIONS
Fastener Tightening Specifications

Specification
Application Metric English
Brake and Accelerator Pedal Assembly Bolt 22 N.m 16 lb ft
Brake Hose Fitting Bolt 40 N.m 30 lb ft
Brake Pipe Fitting 18 N.m 13 lb ft
Master Cylinder Nut 50 N.m 37 lb ft
Master Cylinder Reservoir Bolt 4 N.m 35 lb in
Power Brake Booster Pump Nut 10 N.m 89 lb in
Power Vacuum Brake Booster Bolt 19 N.m 14 lb ft
BRAKE COMPONENT SPECIFICATIONS
Brake Component Specifications

Specification
Brake Caliper Bleeder Valve- Front 14 N.m 124 lb in
Brake Caliper Bleeder Valve- Rear 14 N.m 124 lb in
BRAKE SYSTEM SPECIFICATIONS
Brake System Specifications

Specification
Brake Pedal Travel
 Maximum specification with 450 N (101 lbs) of force 48-58 mm 1.9-2.3 in

applied to the pedal with the ignition OFF and the
booster power reserve depleted.
ADHESIVES, FLUIDS, LUBRICANTS, AND SEALERS
Adhesives, Fluids, Lubricants, and Sealers

GM Part Number
Application Type of Material United States Canada
DOT 4 Hydraulic
Hydraulic Brake System Brake Fluid 88958860 88901244
SCHEMATIC WIRING DIAGRAMS

HYDRAULIC BRAKE SYSTEM WIRING SCHEMATIC
Hydraulic Brakes (except CZ2)
Fig. 1: Hydraulic Brakes (except CZ2)

Courtesy of GENERAL MOTORS COMPANY
Hydraulic Brakes (CZ2)

Fig. 2: Hydraulic Brakes (CZ2)
DIAGNOSTIC INFORMATION AND PROCEDURES

DIAGNOSTIC CODE INDEX
DIAGNOSTIC CODE INDEX

DTC Description
DTC C0267 DTC C0267 Low Brake Fluid Indicated
DTC C0273 DTC C0273 Brake Fluid Level Switch Circuit
DTC C027B DTC C027B 00 Brake Booster Electric Vacuum Pump
DTC C0299 DTC C0299 56 Brake Booster Large Vacuum Leak Detected Too
Many Transitions
DTC C025E DTC C025E Brake Booster Vacuum Sensor Circuit
DTC C0267: LOW BRAKE FLUID INDICATED
Diagnostic Instructions
 Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure.
 Review Strategy Based Diagnosis for an overview of the diagnostic approach.
 Diagnostic Procedure Instructions provides an overview of each diagnostic category.
DTC Descriptor
DTC C0267
Low Brake Fluid Indicated
For symptom byte information refer to Symptom Byte List .
Diagnostic Fault Information
Short to Open/High Short to Signal

Circuit Ground Resistance Voltage Performance
Signal - C0267 00 - -
Ground - C0267 00 - -
Circuit/System Description
The brake fluid level switch monitors the level of the brake fluid in the brake fluid reservoir. When the
electronic brake control module sees low brake fluid level, the DTC is set.
Conditions for Running the DTC
Ignition ON.
Conditions for Setting the DTC
Low brake fluid level is detected for 8 s.
Action Taken When the DTC Sets
 The electronic brake control module disables the traction control and stability control for the duration of
the ignition cycle.
 The traction control/stability control-active indicator turns ON.
 The brake warning indicator turns ON.
Conditions for Clearing the DTC
The condition for setting the DTC is no longer present.
Reference Information
Schematic Reference
Hydraulic Brake Schematics

Connector End View Reference
COMPONENT CONNECTOR END VIEWS - INDEX
Description and Operation
Brake Warning System Description and Operation
Electrical Information Reference
 Circuit Testing
 Connector Repairs
 Testing for Intermittent Conditions and Poor Connections
 Wiring Repairs
Scan Tool Reference
Control Module References for scan tool information
Circuit/System Verification
1. Verify that the brake is above minimum level.

 If low
Refer to Brake Fluid Loss.
 If above minimum level
Refer to Circuit/System Testing.
Circuit/System Testing
1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the B20 Brake Fluid Level
Switch. It may take up to 2 min for all vehicle systems to power down.
2. Test for less than 10 ohms between the ground circuit terminal 2 and ground.
 If 10 ohms or greater
1. Ignition OFF.
2. Test for less than 2 ohms in the ground circuit end to end.
 If 2 ohms or greater, repair the open/high resistance in the circuit.
 If less than 2 ohms, repair the open/high resistance in the ground connection.
 If less than 10 ohms
3. Ignition ON.
4. Verify the scan tool Brake Fluid Level Sensor parameter is Low.
 If the parameter is not Low
1. Ignition OFF, disconnect the harness connector at the K17 Electronic Brake Control Module.
2. Test for infinite resistance between the signal circuit terminal 1 and ground.
 If less than infinite resistance, repair the short to ground on the circuit.
 If infinite resistance, replace the K17 Electronic Brake Control Module.
 If the parameter is Low
5. Install a 3 A fused jumper wire between the signal circuit terminal 1 and ground.
6. Verify the scan tool Brake Fluid Level Sensor parameter is Ok.
 If the parameter is not Ok
1. Ignition OFF, disconnect the harness connector at the K17 Electronic Brake Control Module,
ignition ON.
2. Test for less than 1 V between the signal circuit and ground.
 If 1 V or greater, repair the short to voltage on the circuit.
 If less than 1 V.
3. Test for less than 2 ohms in the signal circuit end to end.
 If less than 2 ohms, replace the K17 Electronic Brake Control Module.
 If the parameter is Ok
7. Test or replace the B20 Brake Fluid Level Switch.
Repair Instructions
Perform the Diagnostic Repair Verification after completing the repair.
 Brake Fluid Level Indicator Switch Replacement

 Control Module References for electronic brake control module replacement, programming and setup.
DTC C0273: BRAKE FLUID LEVEL SWITCH CIRCUIT
DTC Descriptor
DTC C0273
Brake Fluid Level Switch Circuit

Signal C0267 00 C0273 05 C0273 05 -
Ground - C0273 05 - -
The brake fluid level switch monitors the level of the brake fluid in the brake fluid reservoir. When the
electronic brake control module sees the brake fluid level switch input open, the DTC is set.
Ignition ON.
A open or short to battery is detected on the signal circuit.
 The brake warning indicator turns ON.

 ABS indicator turns ON.
 Traction control indicator turns ON.
Schematic Reference
Hydraulic Brake System Description and Operation
 Circuit Testing
 Wiring Repairs
Scan Tool Reference
1. Ignition OFF, disconnect the harness connector at the B20 Brake Fluid Level Switch. It may take up to 2
min for all vehicle systems to power down.
1. Ignition OFF.
3. Ignition ON.
4. Verify the scan tool Brake Fluid Level Sensor parameter is OK.
 If the parameter is not OK
 If the parameter is OK
ignition ON.

Repair Instructions

DTC C027B: BRAKE BOOSTER ELECTRIC VACUUM PUMP
DTC Descriptors
DTC C027B 00
Brake Booster Electric Vacuum Pump

Vacuum Pump Relay B+ - - - -
Vacuum Pump Relay Control C027B 00 C027B 00 C027B 00 -
Vacuum Pump Relay Ground - - - -
The brake booster vacuum sensor measures the vacuum in the brake booster assembly. The electronic brake
control module supplies a 5 V reference and a low reference circuit to the brake booster vacuum sensor. The
vacuum sensor supplies a voltage signal in relation to the pressure in the brake booster to the electronic brake
control module. When the vacuum within the system becomes weak, the electronic brake control module turns
ON the brake booster pump motor by providing battery voltage to the brake booster pump motor relay. The
relay activates and supplies ground to the brake booster pump motor.
Ignition ON.
A short to ground, short to voltage or open/high resistance is detected on the control circuit.

Schematic Reference
Brake Assist System Description and Operation
 Circuit Testing
 Wiring Repairs
Scan Tool Reference
1. Verify that the brake booster vacuum system has no damage, leakage or incorrect installation.
 If damage, leakage or incorrect installation is found
Refer to Brake Assist System Diagnosis
 If no damage, leakage or incorrect installation is found

2. Ignition ON.
3. Verify the brake booster pump motor turns ON and OFF when commanding the brake booster electric
vacuum pump ON and OFF with a scan tool.
 If the brake booster pump motor does not turn ON and OFF
If the brake booster pump motor turn ON and OFF


4. All OK.
1. Ignition OFF and all vehicle systems OFF, disconnect the X1 harness connector at the KR14 Brake
Booster Pump Motor Relay. It may take up to 2 min for all vehicle systems to power down.
3. Ignition ON.
4. Verify that a test lamp illuminates between the B+ circuit terminal 5 and ground.
 If the test lamp does not illuminate and the circuit fuse is good
1. Ignition OFF.
2. Test for less than 2 ohms in the B+ circuit end to end.
 If less than 2 ohms, verify the fuse is not open and there is voltage at the fuse.
 If the test lamp does not illuminate and the circuit fuse is open
1. Ignition OFF.
2. Test for infinite resistance between the B+ circuit and ground.
 If infinite resistance, replace the M9 Brake Booster Pump Motor.
 If the test lamp illuminates
5. Connect a test lamp between the control circuit terminal 2 and ground.
6. Verify the test lamp turns ON and OFF when commanding the brake booster electric vacuum pump ON
and OFF with a scan tool.
 If the test lamp is always OFF
2. Test for infinite resistance between the control circuit and ground.
 If infinite resistance
3. Test for less than 2 ohms in the control circuit end to end.
 If the test lamp is always ON
ignition ON.
2. Test for less than 1 V between the control circuit and ground.
If less than 1 V, replace the K17 Electronic Brake Control Module.

 If the test lamp turns ON and OFF
7. Replace the KR14 Brake Booster Pump Motor Relay.
Repair Instructions
 Power Brake Booster Pump Replacement (LTG), Power Brake Booster Pump Replacement (LUK)
DTC C0299: BRAKE BOOSTER LARGE VACUUM LEAK DETECTED TOO MANY TRANSITIONS
DTC Descriptor
DTC C0299 56
Brake Booster Large Vacuum Leak Detected Too Many Transitions
control module.
Ignition ON.
The EBCM detected a too low vacuum in the brake booster assembly for 120 s.
The brake warning indicator turns ON.
 A current DTC clears when the diagnostic runs and passes.

 The electronic brake control module will turn OFF the indicator in the next ignition cycle.
Schematic Reference
 Circuit Testing
 Wiring Repairs
Scan Tool Reference
Control Module References
1. Ignition ON.
2. Verify that DTC C1100 is not set.
 If the DTC is set
Refer to DTC C025E: Brake Booster Vacuum Sensor Circuit.
If the DTC is not set

Refer to Brake Assist System Diagnosis.
If the inspection is OK

4. Replace the B19B Brake Booster Vacuum Sensor.
5. Verify the DTC does not set while operating the vehicle under the Conditions for Running the DTC.
 If the DTC sets
Replace the K17 Electronic Brake Control Module.
If the DTC does not set


6. All OK.
Repair Instructions
Control Module References for Electronic Brake Control Module replacement, programming and setup.
DTC C025E: BRAKE BOOSTER VACUUM SENSOR CIRCUIT
DTC Descriptor
DTC C025E
Brake Booster Vacuum Sensor Circuit

5V Reference C025E 00 C025E 06 C025E 00 -
C025E 1F, C025E
Sensor Signal C025E 06 C025E 06 C025E 01
5A
Low Reference - C025E 01 - -
The brake booster vacuum sensor monitors the pressure in the brake booster. The electronic brake control
module supplies a 5 V reference and a low reference circuit to the brake booster vacuum sensor. The vacuum
sensor supplies a voltage signal in relation to the pressure in the brake booster to the electronic brake control
module.
C025E 00, C025E 01, C025E 06, C025E 1F

Ignition ON
C025E 5A
 Ignition ON.
 Brakes are not applied.
C025E 00
 A short to ground is detected on the 5V reference circuit.

 A short to voltage is detected on the 5V reference circuit.
C025E 01
 A short to voltage is detected on the signal circuit.

 An open/high resistance is detected on the low reference circuit.
C025E 06
 An open/high is detected on the signal circuit.

 A short to ground is detected on the signal circuit.
 An open/high is detected on the 5V reference circuit.
C025E 1F
The vacuum sensor signal is erratic.
C025E 5A
The vacuum sensor signal is not plausible.
Service Brake Assist message is displayed on the driver information center
The DTC clears when the diagnostic runs and passes
Schematic Reference

 Circuit Testing
 Wiring Repairs
DTC Type Reference
Powertrain Diagnostic Trouble Code (DTC) Type Definitions
Scan Tool Reference
Refer to Brake Assist System Diagnosis
If no damage, leakage or incorrect installation is found

2. Refer to Circuit/System Testing.
1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the B19B Brake Booster
Vacuum Sensor. It may take up to 2 min for all vehicle systems to power down.
2. Test for less than 10 ohms between the low reference circuit terminal 2 and ground.
1. Disconnect the harness connector at the K17 Electronic Brake Control Module.
2. Test for less than 2 ohms in the low reference circuit end to end.

3. Ignition ON.
4. Test for 4.8-5.2 V between the 5 V reference circuit terminal 3 and ground.
 If less than 4.8 V
2. Test for infinite resistance between the 5 V reference circuit and ground.
3. Test for less than 2 ohms in the 5 V reference circuit end to end.
 If greater than 5.2 V
ignition ON.
2. Test for less than 1 V between the 5 V reference circuit and ground.
 If less than 1 V, replace the K17 Electronic Brake Control Module.
 If between 4.8-5.2 V
5. Ignition OFF, disconnect the harness connector at the K17 Electronic Brake Control Module, Ignition
ON.
6. Test for less than 1 V between the B19B Brake Booster Vacuum Sensor signal circuit terminal 1 and
ground.
 If greater than 1 V
Repair the short to voltage on the circuit.
 If less than 1 V
7. Ignition OFF.
8. Test for infinite resistance between the B19B Brake Booster Vacuum Sensor signal circuit terminal 1 and
ground.
 If less than infinite resistance
Repair the short to ground on the circuit.
9. Test for less than 2 ohms between the B19B Brake Booster Vacuum Sensor signal circuit terminal 1 and
the K17 Electronic Brake Control Module signal circuit terminal 34.
Repair the open/high resistance in the circuit.

10. Test or replace the B19B Brake Booster Vacuum Sensor.
Repair Instructions
 Power Brake Booster Vacuum Sensor Replacement

 Control Module References for electronic brake control module replacement, programming and setup
BRAKE BOOSTER PUMP MOTOR MALFUNCTION

Vacuum Pump Relay B+ 2 2 - -
Vacuum Pump Relay Control 2 2 1 -
Vacuum Pump Relay Ground 2 2 - -
Brake Booster Vacuum Sensor
C025E 00 C025E 06 C025E 00 -
5V Reference
Brake Booster Vacuum Sensor C025E 1F, C025E
C025E 06 C025E 06 C025E 01
Signal 5A
- C025E 01 - -
Low Reference
Brake Booster Pump Motor
2 2 1 -
Control
Brake Booster Pump Motor
1 2 - -
Ground
1. Brake Booster Pump Motor Always ON
2. Brake Booster Pump Motor Always OFF
control module. When the vacuum within the system becomes weak, the electronic brake control module turns
ON the brake booster pump motor by providing battery voltage to the brake booster pump motor relay. The
relay activates and supplies ground to the brake booster pump motor.
Schematic Reference
Brake Booster Vacuum Assist Description and Operation
 Circuit Testing
 Wiring Repairs
Scan Tool Reference
Control Module References
1. Ignition ON.
2. Verify that DTC C025E is not set.
 If the DTC is set
Refer to DTC C025E.
If the DTC is not set

3. Verify the brake booster pump motor turns ON and OFF when commanding the Brake Booster Electric
Vacuum Pump On and Off with a scan tool.
 If the brake booster pump motor does not turn ON and OFF
If the brake booster pump motor turn ON and OFF

Refer to Brake Assist System Diagnosis.

If the inspection is OK

5. All OK.
1. Ignition OFF and all vehicle systems OFF, disconnect the X1 harness connector at the KR14 Brake
Booster Pump Motor Relay. It may take up to 2 minutes for all vehicle systems to power down.
3. Ignition ON.
4. Verify that a test lamp illuminates between the B+ circuit terminal 5 and ground.
 If the test lamp does not illuminate and the circuit fuse is good
1. Ignition OFF.
2. Test for less than 2 ohms in the B+ circuit end to end.
 If less than 2 ohms, verify the fuse is not open and there is voltage at the fuse.
 If the test lamp does not illuminate and the circuit fuse is open
1. Ignition OFF.
2. Test for infinite resistance between the B+ circuit and ground.
 If infinite resistance, replace the M9 Brake Booster Pump Motor.
 If the test lamp illuminates
5. Connect a test lamp between the control circuit terminal 2 and ground.
6. Verify the test lamp turns ON and OFF when commanding the Brake Booster Electric Vacuum Pump On
and Off with a scan tool.
 If the test lamp is always OFF
2. Test for infinite resistance between the control circuit and ground.
3. Test for less than 2 ohms in the control circuit end to end.
 If the test lamp is always ON
ignition ON.
2. Test for less than 1 V between the control circuit and ground.
 If less than 1 V, replace the K17 Electronic Brake Control Module.
7. Ignition OFF, connect the X1 harness connector at the KR14 Brake Booster Pump Motor Relay.
Disconnect the X2 harness connector at the KR14 Brake Booster Pump Motor Relay.
8. Connect a test lamp between the ground circuit terminal 2 and the B+ circuit terminal 1 at the KR14
Brake Booster Pump Motor Relay, ignition ON.
9. Verify the test lamp turns ON and OFF when commanding the Brake Booster Electric Vacuum Pump On
and Off with a scan tool.
 If the test lamp does not turn ON and OFF
Replace the KR14 Brake Booster Pump Motor Relay.

10. Install a 30 A fused jumper wire between the M9 Brake Booster Pump Motor terminal 1 and B+. Install a
jumper wire between the M9 Brake Booster Pump Motor terminal 2 and ground.
11. Verify the M9 Brake Booster Pump Motor activates.
 If the brake booster pump motor does not activate
Replace the M9 Brake Booster Pump Motor.
If the brake booster pump motor activates


12. All OK.
Repair Instructions
 Power Brake Booster Pump Replacement (LTG), Power Brake Booster Pump Replacement (LUK)
 Relay Replacement (Within an Electrical Center) , Relay Replacement (Attached to Wire Harness)
 Control Module References for Electronic Brake Control Module replacement, programming and setup.
BRAKE WARNING INDICATOR MALFUNCTION

Signal C0267 1 1 -
Ground - 1 - -
1. Brake Warning Indicator Malfunction
The electronic brake control module monitors the brake fluid level in the brake fluid reservoir. When the fluid
within the brake fluid reservoir is below the MIN level, contacts within the brake fluid level switch closes
causing the voltage within the signal circuit to drop. The electronic brake control module will detect the voltage
drop and will send a serial data message to the instrument cluster commanding the brake warning indicator to
illuminate.
Schematic Reference
Brake Warning System Description and Operation
 Circuit Testing
 Wiring Repairs
Scan Tool Reference
1. Verify that the brake fluid has the proper level. The fluid level should be above minimum level.
 If low
Refer to Brake Fluid Loss.

 If above minimum level
2. Ignition ON.
3. Verify the scan tool Brake Fluid Level Sensor parameter. The reading should be Ok.
Refer to Circuit/System Testing
If the parameter is Ok

4. Verify the brake warning indicator turns ON and OFF, when commanding the instrument cluster All
Indicators ON and OFF with a scan tool.
 If the brake warning indicator does not turn ON and OFF
Replace the P16 Instrument Cluster.
If the brake warning indicator turns ON and OFF


5. All OK.
1. Ignition OFF and all vehicle systems OFF, disconnect the harness connector at the B20 Brake Fluid Level
Switch. It may take up to 2 min for all vehicle systems to power down.
1. Ignition OFF.
3. Ignition ON.
6. Verify the scan tool Brake Fluid Level Sensor parameter is Ok.
ignition ON.
 If the parameter is Ok
Repair Instructions

 Control Module References for electronic brake control module and instrument cluster replacement,
programming and setup.
BRAKE PULSATION
Brake Pulsation
Step Action Yes No
DEFINITION: Fluctuation or pulsation is felt through the brake pedal, steering wheel, seat, floor, and/or
in the vehicle ONLY when braking.
Were you sent here from the Hydraulic Brake Symptom Go to Diagnostic
1 table? Starting Point -
Go to Step 2 Vehicle
1. Inspect the disc brake system for the following
conditions.
 Excessive thickness variation of rotor
friction surfaces
 Excessive assembled lateral runout (LRO)
of rotor friction surfaces
 Hard spots, heat checks, bluing
discoloration of rotor friction surfaces;
2 possibly due to brake drag
 Excessive corrosion of rotor friction
surfaces; including red, gray or black
oxidation
 Loose, damaged or missing caliper or lining
hardware
 Bent or damaged caliper or mounting
component
Excessive LRO of wheel hub/axle flange;
due to damage and/or loose or excessively
worn bearings
2. Adjust, repair or replace components as
necessary. Refer to Disc Brake System
Diagnosis. Go to Diagnostic
Starting Point -
Did you find and correct a condition? Go to Step 3 Vehicle
1. Install or connect components that were removed
or disconnected during diagnosis.
2. Road test the vehicle in order to confirm proper
3 operation. Refer to Brake System Vehicle Road
Test.
Is the condition still present? Go to Step 2 System OK
BRAKE SYSTEM NOISE
Brake System Noise

Step Action Yes No
DEFINITION: Vehicle exhibits abnormal noise when braking; vehicle may exhibit abnormal noise
during motion just after brake pedal release.

conditions.
 Lining wear indicator contact with rotor
 Debris trapped between rotor and splash

shield or backing plate; and/or debris
trapped between rotor and linings
 Contaminated linings
 Aftermarket linings
2
 Glazed linings
 Distorted, cracked or damaged linings
 Excessively worn linings
 Damaged or excessively worn caliper

hardware and/or lining hardware
 Incorrectly installed, loose or missing
caliper hardware and/or lining hardware
 Lack of lubrication or excessive corrosion
on metal to metal contact surfaces
Bent or damaged splash shield or backing
plate
 Hard spots, heat checks, blueing
discoloration of rotor friction surfaces
 Glazed rotor friction surfaces

component
Diagnosis.
Did you find and correct a condition? Go to Step 6 Go to Step 3

1. Inspect the brake assist system for the following
conditions.
 Lack of lubrication or excessively worn
pushrod or pedal pivots or pivot bushings
 Bent or damaged pedal pushrod, pedal, or
3 pedal bracket
 Damaged or improperly operating vacuum
booster and/or check valve, if equipped
necessary.

1. Inspect the hydraulic brake system for the
following conditions.
 Improper operation of caliper pistons
 Contaminated brake fluid

4
necessary. Refer to Hydraulic Brake System
Diagnosis.

Inspect the park brake system for proper operation. Go to Diagnostic
5 Did you find and correct a condition? Starting Point -
Test.

BRAKING ACTION UNEVEN - PULLS TO ONE SIDE
Test Description
The numbers below refer to the step numbers on the diagnostic table.
Suspension components that are not operating properly may cause a disturbance to the vehicle during
application of the brake system.
Steering components that are not operating properly may cause a disturbance to the vehicle during
Braking Action Uneven - Pulls to One Side

Step Action Yes No
DEFINITION: Vehicle pulls to one side only when braking.
 Kinked, pinched or damaged brake pipe or
flexible brake hose
 Sticking or improperly operating caliper
2 piston
 Brake fluid leak

Diagnosis.

conditions.
 Glazed linings
 Distorted, cracked or damaged linings on

3
one side
 Loose, damaged or missing caliper
 Incorrect linings on one side

discoloration of rotor friction surfaces;
possibly due to brake drag

component
Diagnosis.

1. Inspect the suspension system for the following
conditions.
 Incorrect tire pressures
 Loose suspension component connections
 Excessively worn or damaged suspension

4 components
necessary. Refer to Diagnostic Starting Point -
Vehicle .

1. Inspect the steering system for the following
conditions.
 Loose steering component connections
 Excessively worn or damaged steering
5 components
Vehicle . Go to Diagnostic
Starting Point -
Test.
BRAKING ACTION UNEVEN - FRONT TO REAR
Test Descriptions
The number below refers to the step number on the diagnostic table.
Suspension components that are not operating properly may cause a disturbance to the vehicle during
Braking Action Uneven - Front to Rear

Step Action Yes No
DEFINITION: Braking action or stopping force sensitive or grabbing and/or more pronounced at the
front or at the rear axle. Sensitive or grabbing brakes: Excessive brake jump-in force relative to brake
pedal input.
following conditions:
 Kinked, pinched or damaged brake pipe or

flexible brake hose
2  Brake fluid leak

Diagnosis.

conditions:
 Glazed linings
 Distorted, cracked or damaged linings
 Aftermarket linings

3

Diagnosis.

1. Inspect the suspension system for the following
conditions:
 Loose suspension component connections
 Excessively worn or damaged suspension
4 components
Vehicle . Go to Diagnostic
Starting Point -
Test.
BRAKE PEDAL EXCESSIVE TRAVEL
Brake Pedal Excessive Travel

Step Action Yes No
DEFINITION: Brake pedal travels further than expected to obtain firm pedal and/or firm pedal cannot be
obtained, pedal fades away, or pedal is spongy.
Inspect the travel and feel of brake pedal applies.
Perform the following:
1. Apply the brake pedal several times to fully

deplete the power reserve.
2. With power reserve depleted, apply the brake pedal
with light, steady pressure and hold for 15 seconds.
Observe pedal travel and feel.
2 3. Apply the brake pedal with light, steady pressure, -
then without pumping the pedal, reduce pressure
and reapply pressure several times. Observe pedal
travel and feel for each apply.
4. Apply the brake pedal slowly, then release and
apply the pedal quickly. Observe pedal travel and
feel for each apply.
Did you complete the brake pedal travel and feel
inspections? Go to Step 3
conditions listed, based on the following symptoms
observed during the pedal travel and feel
inspections:
 Pedal feel was spongy
 Air in hydraulic system
 External brake fluid leaks
 Soft, weak or damaged hydraulic

hoses; expanding under pressure
 Pedal fell away and/or traveled to or almost
to floor
 External brake fluid leaks
 Poor brake fluid quality; low boiling

point
 Internal brake fluid leaks; improperly
functioning master cylinder
 Pedal was somewhat firm then dropped
3 slightly, or pedal rose with successive

applies, or pedal travel was different
between slow and quick applies
 Poor brake fluid quality; low boiling
point
 Pedal returned to rest slowly after any of the
applies
 Internally damaged flexible brake
hoses; hindering fluid return
 Binding caliper pistons

2. Repair or replace components as necessary. Refer
to Hydraulic Brake System Diagnosis.
3. Re-inspect brake pedal apply travel and feel.

conditions:
 Cracked, excessively worn or damaged
linings
Cracked, excessively worn or damaged
rotors
 Improperly operating, binding or damaged
 Loose or missing caliper hardware and/or
lining hardware
 Excessive assembled lateral runout (LRO) of
4 rotor friction surfaces
component
2. Adjust, repair or replace components as necessary.
Refer to Disc Brake System Diagnosis.
3. Re-inspect brake pedal apply travel and feel.

Inspect for proper brake pedal travel. Refer to Brake
Pedal Travel Measurement and Inspection.
5
Is the brake pedal travel distance within the acceptable
limits? Go to Step 7 Go to Step 6
1. Inspect for worn, missing, misaligned, bent or
damaged brake pedal system components.
2. Inspect the brake pedal bushings for binding,
excessive wear and/or damage and inspect the
brake pedal for a misaligned, bent, and/or damaged
6 condition.
3. Replace the brake pedal system components that
are worn, missing, misaligned, bent or damaged.
Did you find and replace any worn, missing, misaligned,

bent or damaged brake pedal system components? Go to Step 8 Go to Step 7
conditions:
 Vacuum leaks and/or improperly operating
check valve, if equipped with vacuum assist
7  Damaged or improperly operating brake
booster assembly
2. Adjust, repair or replace components as necessary. Go to Diagnostic
Starting Point -
8
operation. Refer to Brake System Vehicle Road
Test.
BRAKE PEDAL EXCESSIVE EFFORT
Brake Pedal Excessive Effort

Step Action Yes No
DEFINITION: Brake pedal requires an increased amount of input from the driver to obtain good braking
action and/or stopping distance is increased.
conditions:
 Vacuum leaks, if equipped with vacuum
power assist
 Lack of lubrication, binding or excessively
worn pushrod or pedal pivots or pivot
bushings
2  Bent or damaged pedal pushrod, pedal, or
pedal bracket
 Damaged or improperly operating brake
booster assembly
necessary.

 Binding caliper pistons
 Internally damaged flexible brake hoses;

hindering fluid flow
 Kinked or damaged flexible brake hoses
and/or pipes
3  Internal brake fluid leaks; improperly
operating master cylinder
 Poor brake fluid quality; low boiling point

Diagnosis.

conditions:
 Glazed linings
 Cracked, distorted or damaged linings
 Binding, damaged or excessively worn

4 on metal to metal contact surfaces

 Excessively worn or corroded rotor friction
surfaces

Starting Point -
Test.
BRAKES DRAG
Brakes Drag
Step Action Yes No
DEFINITION: Brake system does not fully release or has delayed release; vehicle motion may be
hindered by brake system without applying brakes.
Is the vehicle equipped with an adjustable stop lamp
2 switch and/or an adjustable cruise control release
switch? Go to Step 3 Go to Step 7
1. Inspect the stop lamp switch for proper
adjustment to ensure that the brake pedal is fully
releasing.
2. Inspect the cruise control release switch, if
equipped, for proper adjustment to ensure that the
3 brake pedal is fully releasing.

Inspect the park brake system for proper operation.
4
conditions:
 Binding, incorrectly installed or missing
caliper hardware and/or lining hardware-
Ensure free movement of linings and of
caliper, if equipped with sliding type caliper
on metal to metal contact surfaces
 Distorted or damaged linings
5
component
Diagnosis.

1. Separate the brake booster pushrod from the brake
pedal.
2. Inspect the brake corners to determine if the brake
6 drag condition is still present.
Do the brake corners still exhibit the brake drag

condition? Go to Step 8 Go to Step 7
1. Inspect the pushrod for improper positioning
and/or damage. Correctly position or replace the
pushrod if necessary.
7 2. Inspect the brake pedal assembly for damage and -
replace if necessary.
Did you complete the repair or replacement? Go to Step 11
1. For vacuum boost systems, disconnect the

vacuum check valve from the booster to relieve
vacuum reserve.
2. Separate the master cylinder from the brake
booster. Do not disconnect any brake pipes.
3. Inspect the brake corners to determine if the brake
8 drag condition is still present.
Do the brake corners still exhibit the brake drag

condition? Go to Step 10 Go to Step 9
Replace the brake booster assembly.
9 -
Did you complete the replacement? Go to Step 11
 Contaminated brake fluid

hindering brake release
10
 Damaged or improperly operating master
cylinder
Starting Point -
Test.
BRAKE SYSTEM SLOW RELEASE
Brake System Slow Release

Step Action Yes No
DEFINITION: Brake system releases and returns to rest slowly; vehicle motion is hindered by brake
system briefly after release of brake pedal.

hindering brake release
Contaminated brake fluid
 Damaged or improperly operating master
cylinder
2 2. Adjust, repair or replace components as
Diagnosis.

conditions:
 Binding, bent or damaged pedal pushrod,
pedal, or pedal bracket
 Damaged or improperly operating vacuum
3 booster, if equipped
 Damaged or improperly operating hydraulic
booster, if equipped
necessary.

conditions:
 Distorted or damaged linings
4 on metal to metal contact surfaces

component
Starting Point -
Test.
BRAKE FLUID LOSS

Brake Fluid Loss
Step Action Yes No
DEFINITION: Brake fluid level is low not related to lining wear.
1. Inspect the following hydraulic brake system
components for brake fluid leaks:
 Flexible brake hose connections; threaded
and bolted
 Flexible brake hose crimp joints
 Brake pipe fittings
2  Caliper piston seals
 Master cylinder reservoir
 Master cylinder reservoir low pressure

hose, if equipped
2. Repair or replace components as necessary. Refer
to Hydraulic Brake System Diagnosis.

3 Is the vehicle equipped with a vacuum brake booster? Go to Step 4 Go to Step 6
1. Disconnect the vacuum check valve from the
booster to relieve vacuum reserve.
2. Separate the master cylinder from the vacuum
brake booster. Do not disconnect any brake pipes.
4 3. Inspect the rear of the master cylinder for a brake
fluid leak.
4. Inspect for brake fluid in the vacuum brake
booster. Go to Diagnostic
Starting Point -
Did you find a brake fluid leak? Go to Step 5 Vehicle
Replace the brake master cylinder and the vacuum
5 brake booster. -
6 2. Road test the vehicle to confirm proper operation.
Refer to Brake System Vehicle Road Test.
DISC BRAKE SYSTEM DIAGNOSIS

Test Description
The numbers below refer to the step numbers on the diagnostic table:
Lubricant leaks from non-brake system components may come in contact with and contaminate brake
system components.
10
Lubricant leaks from non-brake system components may come in contact with and contaminate brake
system components.
12
Disc brake rotor shields/backing plates that come in contact with disc brake rotors may cause brake
system noise.
15
Disc brake rotor thickness variation that exceeds the maximum acceptable level can cause brake
pulsation.
19
Disc brake rotor thickness variation that exceeds the maximum acceptable level can cause brake
pulsation.
22
Disc brake rotor assembled lateral runout (LRO) that exceeds the maximum acceptable level can lead to
thickness variation.
Disc Brake System Diagnosis

Step Action Yes No
DEFINITION: This diagnostic table is designed to diagnose ONLY the components of the DISC brake
system in order to determine if the DISC brake system is operating properly. You will be directed by the
appropriate Symptom table to go to other brake system diagnostic tables as appropriate.
Were you sent here from a Brake Symptom table? Go to Diagnostic
1 Starting Point -
Visually inspect the disc brake pads for the following
conditions:
Refer to Brake Pad Inspection .
 Lining thickness below specifications

 Uneven and/or abnormal wear - edge-to-edge
and/or side-to-side
 Looseness or damage - including pad hardware
 Evidence of contamination from an external
2 substance
Did you find any conditions to indicate a concern with

any of the front and/or rear disc brake pads? Go to Step 3 Go to Step 12
Are any of the front and/or rear disc brake pads
3
contaminated? Go to Step 8 Go to Step 4
Are any of the front and/or rear disc brake pads worn
4
unevenly? Go to Step 7 Go to Step 5
Are any of the front and/or rear disc brake pads and/or
5
pad hardware loose or damaged? Go to Step 7 Go to Step 6
1. Remove and inspect the worn disc brake pads
for glazing, looseness, heat spots or damage.
2. Replace the worn disc brake pads as a complete
axle set. Refer to Front Disc Brake Pads
6 Replacement (J60, J61) , Front Disc Brake -
Pads Replacement (J64) , and/or Rear Disc
Brake Pads Replacement .
Did you complete the inspection and replacement? Go to Step 12

CAUTION:
Support the brake caliper with heavy
mechanic wire, or equivalent, whenever it is
separated from its mount and the hydraulic
flexible brake hose is still connected. Failure
to support the caliper in this manner will
cause the flexible brake hose to bear the
weight of the caliper, which may cause
damage to the brake hose and in turn may
cause a brake fluid leak.
NOTE:
Do NOT disconnect the hydraulic brake flex
hoses from the calipers.
1. Remove the front and/or rear disc brake calipers,

as appropriate, from the mounting brackets or
from the suspension knuckles and support the
calipers. Refer to Front Brake Caliper
Replacement (J60, J61) , Front Brake Caliper
Replacement (J64) , and/or Rear Brake
Caliper Replacement .
2. Inspect the disc brake caliper mounting bracket
and the mounting/sliding hardware for the
Refer to Front Disc Brake Mounting and

Hardware Inspection , and/or Rear Disc
Brake Mounting and Hardware Inspection .
 Binding or seized hardware

 Worn, damaged or missing hardware
components
 Loose, bent, cracked, or damaged caliper
mounting bracket
7 3. Replace components as required. Refer to the -
following procedures, as required:
 Front Brake Caliper Bracket
Replacement
 Rear Brake Caliper Bracket
Replacement
4. Replace the unevenly-worn, loose or damaged
disc brake pads as a complete axle set. Refer to
Front Disc Brake Pads Replacement (J60,
J61) , Front Disc Brake Pads Replacement
(J64) , and/or Rear Disc Brake Pads
Replacement .
Did you complete the inspection and replacement? Go to Step 12

1. Inspect the disc brake calipers, brake hoses and
brake pipes for evidence of an external brake
fluid leak.
2. Replace any components found to be leaking
brake fluid. Refer to the following procedures as
required:
 Front Brake Caliper Replacement (J60,
J61) , Front Brake Caliper
8 Replacement (J64)
 Rear Brake Caliper Replacement
 Front Brake Hose Replacement (J60,

J61), Front Brake Hose Replacement
(J64)
 Rear Brake Hose Replacement
 Brake Pipe Replacement
Did you find and correct the source of the leak causing
contamination of the pads? Go to Step 11 Go to Step 9
1. Inspect the wheel drive shaft outer seals for
damage and evidence of a grease leak.
2. Replace any wheel drive shaft seal that is found
9 to be leaking grease which may be the source of
the contamination to the pads.
contamination of the pads? Go to Step 11 Go to Step 10
1. Inspect the automatic transmission cooling
system lines, if equipped, for damage and
evidence of an external fluid leak which may be
the source of the contamination to the pads.
2. Inspect the power steering system hoses for
damage and evidence of an external fluid leak
10 which may be the source of the contamination to -
the pads.
3. Replace any components found to be leaking
fluid which may be the source of the
contamination to the pads.
contamination of the pads? Go to Step 11
1. Clean the remaining disc brake system
components to remove any traces of the
contaminant.
CAUTION:
Support the brake caliper with heavy
mechanic wire, or equivalent, whenever it is
separated from its mount and the hydraulic
flexible brake hose is still connected. Failure
to support the caliper in this manner will
cause the flexible brake hose to bear the
weight of the caliper, which may cause
damage to the brake hose and in turn may
cause a brake fluid leak.
NOTE:
Do NOT disconnect the hydraulic brake flex
hoses from the calipers.
2. Remove the front and/or rear disc brake calipers,

as appropriate, from the mounting brackets and
support the calipers. Refer to Front Brake
Caliper Replacement (J60, J61) , Front Brake
Caliper Replacement (J64) , and/or Rear
Brake Caliper Replacement .
3. Inspect the disc brake caliper mounting/sliding
hardware for the following conditions:
Front Disc Brake Mounting and Hardware

Inspection , and/or Rear Disc Brake Mounting
and Hardware Inspection .
Binding or seized hardware

 Distorted, worn, damaged or missing
11 -
hardware components
4. Replace the caliper mounting/sliding hardware
components as required.
5. Replace the contaminated disc brake pads as a
complete axle set. Refer to Front Disc Brake
Pads Replacement (J60, J61) , Front Disc
Brake Pads Replacement (J64) , and/or Rear
Disc Brake Pads Replacement .
Did you complete the cleaning, inspection and

replacement? Go to Step 12
Visually inspect each of the rear disc brake rotor
shields/backing plates, if equipped, for evidence of
12 contact with the brake rotors.
Are any of the brake rotor shields/backing plates
contacting the brake rotors? Go to Step 13 Go to Step 14
Repair or replace the disc brake rotor shields/backing
plates as required. Refer to Front Brake Shield
13 -
Replacement , or Rear Brake Shield Replacement .
Did you complete the repair or replacement? Go to Step 14
1. Check the thickness of each of the disc brake
rotors.
NOTE:
Make the following determination AND
ANSWER the question INDIVIDUALLY for
EACH rotor.
14
2. Make a determination for each brake rotor if the
rotor can be REFINISHED and REMAIN
ABOVE the minimum requirements.
Refer to Brake Rotor Thickness Measurement .Does

the disc brake rotor meet the minimum requirements
for REFINISHING? Go to Step 15 Go to Step 18
NOTE:
Perform the following inspection AND ANSWER the
question INDIVIDUALLY for EACH rotor.
15 Inspect each of the disc brake rotors for thickness

variation that exceeds the maximum acceptable level.
Refer to Brake Rotor Thickness Variation
Measurement .Does the brake rotor exhibit thickness
variation that exceeds the maximum acceptable level? Go to Step 17 Go to Step 16
1. Inspect each of the disc brake rotors for the
following surface and wear conditions:
Refer to Brake Rotor Surface and Wear

Inspection .
 Heavy rust and/or pitting

 Cracks and/or heat spots
 Excessive blueing discoloration
 Deep or excessive scoring beyond
maximum acceptable level
16
NOTE:
EACH rotor.

rotor requires refinishing based upon the results
of the inspection.
If the brake rotor exhibits any of the conditions

listed previously, it requires refinishing.
Does the brake rotor require REFINISHING? Go to Step 17 Go to Step 22

1. Refinish the brake rotor. Refer to Brake Rotor
Refinishing .
2. Inspect the brake rotor thickness. Refer to Brake
17 Rotor Thickness Measurement .
Were you able to REFINISH the brake rotor within the

minimum requirements? Go to Step 22 Go to Step 21
Is the brake rotor at or below the DISCARD
18
requirements? Go to Step 21 Go to Step 19
NOTE:
19 Inspect each of the disc brake rotors for thickness

variation that exceeds the maximum acceptable level.
Refer to Brake Rotor Thickness Variation
Measurement .Does the brake rotor exhibit thickness
variation that exceeds the maximum acceptable level? Go to Step 21 Go to Step 20
1. Inspect each of the disc brake rotors for the
following surface and wear conditions:
Refer to Brake Rotor Surface and Wear

Inspection .
 Heavy rust and/or pitting

 Cracks and/or heat spots
 Excessive blueing discoloration
 Deep or excessive scoring beyond
maximum acceptable level
20
NOTE:
EACH rotor.

rotor requires replacement based upon the
results of the inspection.
If the brake rotor exhibits any of the conditions

listed previously, it requires replacement.
Does the brake rotor require REPLACEMENT? Go to Step 21 Go to Step 22

NOTE:
Whenever a brake rotor is replaced, the assembled
lateral runout (LRO) of the rotor must be measured
to ensure optimum performance of the disc brakes.
21 -
Replace the brake rotor. Refer to Front Brake Rotor
Replacement (J60, J61) , Front Brake Rotor
Replacement (J64) , or Rear Brake Rotor
Replacement .Did you complete the replacement? Go to Step 24
NOTE:
Inspect each of the disc brake rotors for assembled
LRO that exceeds the maximum acceptable level.
22 Refer to Brake Rotor Assembled Lateral Runout
Measurement .Does the brake rotor exhibit assembled
LRO that exceeds the maximum acceptable level? Go to Step 23 Go to Step 24
Correct the LRO for each brake rotor that was
determined to have LRO exceeding the maximum
23 acceptable level. Refer to Brake Rotor Assembled -
Lateral Runout Measurement .
Did you complete the operation? Go to Step 24
Install or connect components that were removed or Disc Brake System
disconnected during diagnosis. OK
24 -
Did you complete the operation? Return to Symptom
Table
HYDRAULIC BRAKE SYSTEM DIAGNOSIS
Hydraulic Brake System Diagnosis

Step Action Yes No
DEFINITION: This diagnostic table is designed to diagnose ONLY the components of the hydraulic
brake system in order to determine if the hydraulic brake system is operating properly. You will be
directed by the appropriate Symptom table to go to other brake system diagnostic tables as appropriate.
Were you sent here from a Brake Symptom table? Go to Diagnostic
1 Starting Point -
Inspect and adjust the brake fluid level in the brake master
2 cylinder.
Was the brake fluid level low? Go to Step 3 Go to Step 4
1. Inspect the brake fluid for the following conditions,
indicating brake fluid contamination:
 Fluid separation, indicating 2 types of fluid are
present
 Swirled appearance-Oil-based substance
 Layered appearance-Silicone-based
substance
3  Fluid discoloration
 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 fluid contamination.
Do any of the above conditions exist? Go to Step 5 Go to Step 6

1. Inspect the brake fluid for the following conditions,
indicating brake fluid contamination:
 Fluid separation, indicating 2 types of fluid are
present
 Swirled appearance- Oil-based
substance
 Layered appearance -Silicone-based
substance
4  Fluid discoloration
 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 fluid contamination.
Do any of the above conditions exist? Go to Step 5 Go to Step 12

1. Flush the hydraulic brake system.
2. If the brake fluid WAS contaminated with an oil-
based or a silicone-based fluid, indicated by fluid
separation and/or a swollen master cylinder reservoir
cap diaphragm and/or swollen reservoir-to-master
cylinder grommets, perform the following steps.
Refer to the procedures indicated.
1. Remove ALL of the following components
listed. Each component contains internal
rubber seals/linings which have been
contaminated.
2. Clean out the hydraulic brake pipes using
denatured alcohol, or equivalent.
5 3. Dry the brake pipes using non-lubricated, -
filtered air.
4. Repair or replace ALL of the following
components listed. Each component contains
internal rubber seals/linings which have been
contaminated.
 Master Cylinder Replacement (LEA,
LUK) or Master Cylinder
Replacement (LTG)
 Master Cylinder Reservoir
Replacement
 Replace the brake master cylinder
reservoir cap diaphragm.
 Front Brake Hose Replacement (J60,
J61), Front Brake Hose Replacement
(J64)
 Inspect front caliper.
 Inspect rear caliper.
3. If the brake fluid was NOT contaminated with an

oil-based fluid, 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 moisture or dirt to enter the
system.
4. Refill and bleed the hydraulic brake system. Refer to
Hydraulic Brake System Bleeding (Manual),
Hydraulic Brake System Bleeding (Pressure).
Did you complete the operation and any required repairs

and/or replacements? Go to Step 9
1. Inspect the following hydraulic brake system
components for external fluid leaks Repair or replace
any of the components found to be leaking brake
fluid. Refer to the appropriate procedures:
 Master Cylinder Replacement (LEA, LUK)
or Master Cylinder Replacement (LTG)
 Brake master cylinder reservoir cap diaphragm
 Front Brake Hose Replacement (J60, J61),

Front Brake Hose Replacement (J64)
 Inspect front caliper.

6
 Inspect rear calliper.
2. If you repaired or replaced any of the brake system

components listed, bleed the hydraulic brake system.
Refer to Hydraulic Brake System Bleeding
(Manual), Hydraulic Brake System Bleeding
(Pressure). While bleeding the hydraulic brake
system, observe for the following conditions:
 The presence of air in the system at a bleeder
valve location other than at the repair location,
except if the brake master cylinder was
replaced
 An unrestricted and even flow of brake fluid
per axle during the bleeding procedure
Did you find and correct a condition?
Go to Step 7 Go to Step 12
Was there air in the system at a bleeder valve location
7 other than at the repair location, except if the brake master
cylinder was replaced? Go to Step 18 Go to Step 8
Was the flow of brake fluid unrestricted and even per axle
8
during the bleeding procedure? Go to Step 9 Go to Step 10
Inspect the hydraulic function of the brake calipers for
proper operation. Refer to Hydraulic Brake Component
9 Operation Visual Inspection.
Was the hydraulic function of the brake calipers operating
properly? Go to Step 20 Go to Step 14
Was the flow of brake fluid restricted or uneven through
10 front axle hydraulic components during the bleeding
procedure? Go to Step 13 Go to Step 11
Was the flow of brake fluid restricted or uneven through
11 rear axle hydraulic components during the bleeding -
procedure? Go to Step 17
Inspect the hydraulic function of the brake calipers for
proper operation. Refer to Hydraulic Brake Component
12 Operation Visual Inspection.
Was the hydraulic function of the brake calipers operating
properly? Go to Step 15 Go to Step 13
Determine if the brake caliper is restricting the flow of
brake fluid and/or not operating properly:
1. Raise and support the vehicle. Refer to Lifting and

Jacking the Vehicle .
2. Remove the tire and wheel assemblies. Refer to Tire
and Wheel Removal and Installation .
3. Open the suspected caliper bleeder valve.
13
4. Using a large C-clamp, compress the caliper piston
and observe for an unrestricted flow of brake fluid
and for free movement of the caliper piston.
5. Close the caliper bleeder valve.
Was the flow of brake fluid unrestricted and did the caliper
piston move freely? Go to Step 17 Go to Step 14
Repair or replace any brake caliper that was not operating
properly. Refer to the appropriate procedure.
14  Front Brake Caliper Replacement (J60, J61) , -

Front Brake Caliper Replacement (J64)
Did you complete the repair and/or replacement? Go to Step 20
Bleed the hydraulic brake system to observe for the
presence of air in the system and to observe for an
unrestricted and even flow of brake fluid per axle during
15 the bleeding procedure. Refer to Hydraulic Brake System
Bleeding (Manual), Hydraulic Brake System Bleeding
(Pressure).
Was there air in the system? Go to Step 18 Go to Step 16
Was the flow of brake fluid unrestricted and even per axle
16
during the bleeding procedure? Go to Step 20 Go to Step 17
1. Inspect the hydraulic brake pipes and flexible brake
hoses for signs of a fluid restriction; such as being
bent, kinked, pinched or damaged. Refer to Brake
Pipe and Hose Inspection.
2. Replace any of the hydraulic brake pipes and/or
flexible brake hoses found to be bent, kinked,
pinched, or damaged. Refer to the following
procedures as necessary:
 Front Brake Hose Replacement (J60, J61),
17
Front Brake Hose Replacement (J64)
3. If none of the hydraulic brake pipes or flexible brake

hoses were visibly bent, kinked, pinched, or
damaged, replace the hydraulic brake flex hose at the
restricted location.

1. Inspect the hydraulic brake system components for
brake fluid seepage at a seal and/or fitting location,
which may have drawn air into the system.
2. Inspect the hydraulic brake system components for
18 evidence of a recent repair, which may have
introduced air into the system.
3. Repair or replace any of the components found to be
installed incorrectly or seeping brake fluid.

1. Inspect the brake master cylinder for internal fluid
leaks. Refer to Brake System Internal Leak Test.
19 2. Repair or replace the brake master cylinder if it is
found to be leaking brake fluid internally. Refer to
Master Cylinder Replacement (LEA, LUK) or
Master Cylinder Replacement (LTG).
Return to
Did you find and correct a condition? Go to Step 20 Symptom Table
Install or connect components that were removed or Hydraulic Brake
disconnected during diagnosis. System OK
20 -
Did you complete the operation? Return to
Symptom Table
BRAKE ASSIST SYSTEM DIAGNOSIS
Brake Assist System Diagnosis

Step Action Yes No
DEFINITION: This diagnostic table is designed to diagnose ONLY the components of the brake ASSIST
system in order to determine if the brake ASSIST system is operating properly. You will be directed by
the appropriate Symptom table to go to other brake system diagnostic tables as appropriate.
1 Were you sent here from a Brake Symptom table? Go to Step 3 Go to Step 2
Were you sent here directly from an electrical Go to Diagnostic
2 diagnostic to investigate vacuum as a possible Starting Point -
concern? Go to Step 5 Vehicle
Inspect for proper brake pedal travel. Refer to Brake
Pedal Travel Measurement and Inspection.
3
Is the brake pedal travel distance within the
acceptable limits? Go to Step 5 Go to Step 4
1. Inspect for worn, missing, misaligned, bent or
damaged brake pedal system components.
 Inspect the brake pedal for a misaligned,
bent and/or damaged condition.
 Inspect the brake pedal bushings for
excessive wear and/or damage. Go to Hydraulic
4
2. Replace the brake pedal system components Brake System
that are worn, missing, misaligned, bent or Diagnosis to check
damaged. for internal and
external fluid leaks
Did you find and replace any worn, missing, and air in the
misaligned, bent or damaged brake pedal system hydraulic brake
components? Go to Step 5 system
Check the engine vacuum source that supplies Go to Engine
vacuum to the vacuum brake booster. Refer to Brake Controls Diagnostics
System Vacuum Source Test. Information to check
5 Is the vacuum reading within the acceptable limits? for vacuum issues,
including vacuum
pump operation, if
Go to Step 6 equipped
Does the condition occur during cold start-up
6
conditions? Go to Step 7 Go to Step 8
Check engine vacuum, and vacuum pump operation,
if equipped, under the same cold start-up conditions.
7
Refer to Engine Controls Diagnostics.
During the vacuum source test, did the vacuum
8
booster check valve operate properly? Go to Step 10 Go to Step 9
Replace the vacuum booster check valve. Refer to
Power Brake Booster Vacuum Sensor
Replacement, or Power Brake Booster Vacuum
9 -
Pipe Replacement (LUK), Power Brake Booster
Vacuum Pipe Replacement (LTG).
If equipped with a booster mounted separate vacuum
sensor, inspect the vacuum sensor grommet for
10 cracks, cuts, dry-rot, or damage.
Does the vacuum sensor grommet exhibit any of the
conditions listed? Go to Step 11 Go to Step 12
Replace the vacuum sensor grommet.
11 -
1. If the vehicle is equipped with a vacuum sensor,
install a scan tool.
2. Using the Data Display function, determine if
brake booster vacuum sensor data is available
12 within either the chassis brake controls area or
the powertrain engine controls area.
Is vacuum sensor data available through the scan

tool? Go to Step 13 Go to Step 16
Perform the vacuum booster leak-down test using a

scan tool:
1. Release the brake pedal.

2. Accelerate the engine to approximately 3000
RPM, then release the throttle. Wait 2-3
seconds and repeat once.
13 3. Turn the ignition OFF.
4. Turn the ignition ON. Do not start the engine.
5. Observe and record the vacuum sensor reading
on the scan tool over a period of 60 seconds.
NOTE:
Vacuum readings will decrease by
approximately 2.7 kPa (0.8 Hg) for every 305
m (1000 ft) of elevation above sea level.
6. Determine the rate of vacuum leak.
Specification
Maximum allowable vacuum leak rate: 10 kPa

(3 in Hg) in 60 seconds
Was the rate of vacuum leak within the specified

allowable range? Go to Step 18 Go to Step 14
1. Deplete the vacuum reserve by pressing the
brake pedal several times, or by removing the
vacuum booster check valve.
brake booster. Do not disconnect any brake
pipes. Refer to Master Cylinder Replacement
(LEA, LUK) or Master Cylinder
Replacement (LTG).
14 3. If equipped with a vacuum seal on the rear of
the master cylinder, inspect the seal for damage
and correct positioning on the master cylinder.
Replace the vacuum seal as necessary.
4. Carefully reinstall the master cylinder to the
brake booster. Refer to Master Cylinder
Replacement (LEA, LUK) or Master
Cylinder Replacement (LTG).
Did you complete the operation? Go to Step 15 -
Perform the vacuum booster leak-down test using a

scan tool:

15 3. Turn the ignition OFF.
4. Turn the ignition ON. Do not start the engine.
5. Observe and record the vacuum sensor reading
on the scan tool over a period of 60 seconds.
NOTE:
Vacuum readings will decrease by
approximately 2.7 kPa (0.8 Hg) for every 305
m (1000 ft) of elevation above sea level.
6. Determine the rate of vacuum leak.
Specification
Maximum allowable vacuum leak rate: 10 kPa

(3 in Hg) in 60 seconds
Was the rate of vacuum leak within the specified

allowable range? Go to Step 22 Go to Step 21
brake booster. Do not disconnect any brake
pipes. Before removing the master cylinder,
first deplete the vacuum by removing the check
valve or applying the brake pedal several times.
Refer to Master Cylinder Replacement (LEA,
LUK) or Master Cylinder Replacement
(LTG).
16
2. If equipped with a vacuum seal on the rear of
the master cylinder, inspect the seal for damage
and correct positioning on the master cylinder.
3. If equipped with a vacuum seal that is part of
the booster, inspect the seal for damage.
Does the vacuum seal exhibit any of the conditions

listed? Go to Step 17 Go to Step 18
1. If equipped with a vacuum seal on the rear of
the master cylinder, replace the vacuum seal as
necessary. Ensure the seal is positioned
correctly during installation.
2. If equipped with a vacuum seal that requires
replacement and which is part of the booster,
17 the booster assembly must be replaced. -
3. Carefully reinstall the master cylinder to the
brake booster. Refer to Master Cylinder

Perform the vacuum boost functional test:
1. If still separated, reinstall the master cylinder to

the booster. Refer to Master Cylinder
2. If the engine was started after reinstalling the
master cylinder to the booster, perform the
following:
With the engine OFF, depress the brake pedal

several times to deplete the vacuum reserve.
3. Depress and maintain moderate foot pressure

18 on the brake pedal.
4. Start the engine and observe pedal operation.
5. Observe for audible vacuum leaks.
The brake pedal should fall slightly, then hold.
Is there an audible vacuum leak coming from the

brake pedal area? Go to Step 21 Go to Step 19
Did the brake pedal fall slightly after the engine was
19
started, then hold? Go to Step 20 Go to Step 21
Perform the vacuum booster leak-down test:

3. Turn the ignition OFF.
4. Wait 60 seconds.
20 5. Depress the brake pedal 2 times to check for
vacuum booster available vacuum reserve.
Observe pedal effort.
 Both pedal applies should be assisted
 The amount of assist could diminish

slightly with the second apply
Were both pedal applies power assisted? Go to Step 22 Go to Step 21

Replace the vacuum brake booster. Refer to Power
21 Vacuum Brake Booster Replacement. -
Install or connect any components that were removed Brake Assist
or disconnected during diagnosis. System OK
22 -
Did you complete the operation? Return to Symptom
Table
BRAKE SYSTEM VEHICLE ROAD TEST
Preliminary Inspections
1. Visually inspect easily accessible brake system components for obvious damage and/or leaks which may
indicate that the vehicle should not be driven until further inspections have been completed.
2. Inspect the brake master cylinder reservoir fluid level and adjust only if necessary for brake system road
testing.
3. Inspect the tire inflation pressures and adjust as necessary.
4. Inspect the tire tread patterns to ensure that they are the same or very similar, especially per axle.
5. Ensure that the vehicle is not loaded unevenly prior to brake system road testing.
Road Testing Procedure
WARNING: Road test a vehicle under safe conditions and while obeying all traffic
laws. Do not attempt any maneuvers that could jeopardize vehicle control.
Failure to adhere to these precautions could lead to serious personal
injury and vehicle damage.
1. Start the engine and allow it to idle.

2. Check to see if the brake system warning lamp remains illuminated.
3. If the brake system warning lamp remains illuminated, DO NOT proceed to test drive the vehicle until it
is diagnosed and repaired. Refer to Diagnostic Starting Point - Vehicle .
4. Select a smooth, dry, clean and level road or large lot that is as free of traffic and obstacles as possible for
brake system low speed road testing.
5. With the transmission in PARK, lightly apply the brake pedal. Observe both the pedal feel and the pedal
travel.
6. If the brake pedal travel was excessive, DO NOT drive the vehicle until it is repaired.
7. If the brake pedal travel was not excessive, proceed to step 8.
8. Release and apply the brakes.
9. While continuing to apply the brakes, shift the transmission into DRIVE, release the brakes and allow the
engine to idle the vehicle away from the stopped position. Observe for a slow release of the brake system.
10. With the aid of an assistant to observe the vehicle's performance from outside of the vehicle, drive the
vehicle at a low speed and lightly apply the brakes while driving past the assistant. Have the assistant
observe for brake system noise from the side of the vehicle closest to them, while you observe both the
pedal effort and the pedal travel.
11. If the brake pedal apply effort was excessive, or the pedal travel was excessive, DO NOT continue to test
drive the vehicle until it is repaired.
12. If the brake pedal apply effort was not excessive and the pedal travel was not excessive, proceed to step
13.
13. Drive the vehicle in the opposite direction, at the same low speed and lightly apply the brakes while
driving past the assistant. Have the assistant observe for brake system noise from the side of the vehicle
closest to him.
14. Drive the vehicle at a low speed and shift the transmission into NEUTRAL without applying the brakes.
Observe for a rapid deceleration in vehicle speed, indicating possible brake drag.
15. Select a smooth, dry, clean and level road that is as free of heavy traffic as possible for brake system
moderate speed road testing.
16. Drive the vehicle at a moderate speed. Observe for a pull and/or incorrect tracking of the vehicle without
the brakes applied.
17. While continuing to drive the vehicle at a moderate speed, perform several light applies of the brakes.
Observe the pedal effort and the pedal travel, observe for brake system noise, pulsation and/or brake drag.
19. If the brake pedal apply effort was not excessive and the pedal travel was not excessive, proceed to step
20.
20. While continuing to drive the vehicle at a moderate speed, perform several moderate applies of the
brakes. Observe the pedal effort and the pedal travel, observe for brake system pulsation and/or uneven
braking action - either side to side, or front to rear.
A small amount of vehicle front end dip is expected during a moderate apply of the brakes.
BRAKE PEDAL TRAVEL MEASUREMENT AND INSPECTION
Special Tools
CH-28662 Brake Pedal Effort Gauge
For equivalent regional tools, refer to Special Tools.
1. With the ignition OFF and the brakes cool, apply the brakes 3-5 times, or until the brake pedal becomes
firm, in order to deplete the brake booster power reserve.
2. Install the CH-28662 Brake Pedal Effort Gauge to the brake pedal.
Fig. 3: Measuring Brake Pedal Travel
3. Measure and record the distance (1) from the brake pedal to the rim of the steering wheel; note the points
of measurement.
4. Apply and maintain the brakes with 450 N (101 lb) of force to the brake pedal, as indicated on the brake
pedal effort gauge.
5. While maintaining 450 N (101 lb) of force to the brake pedal, measure and record the distance (2) from
the same point on the brake pedal to the same point on the rim of the steering wheel.
6. Release the brakes and repeat steps 4 and 5 to obtain a second measurement. After obtaining a second
measurement, proceed to step 7.
7. Average the first and second measurements recorded during the two applies of the brakes.
8. Subtract the initial measurement, unapplied (1), from the averaged, applied measurement (2) to obtain the
brake pedal travel distance.
Specification
Maximum brake pedal travel (measured with the ignition OFF, brake booster power assist depleted, and
the brakes cool): 48-58 mm (1.89-2.28 in).
BRAKE SYSTEM VACUUM SOURCE TEST

NOTE:  Engine temperature, accessory load, and elevation level will affect
engine vacuum.
 Vacuum readings will decrease by approximately 2.7 kPa (0.8 in Hg)
for every 305 m (1000 ft) of elevation above sea level.
1. Disconnect the engine vacuum hose from the vacuum brake booster check valve or brake booster vacuum
sensor, if equipped.
2. Install a vacuum gauge to the engine vacuum hose.
3. Start the engine and allow the engine to idle until normal operating temperatures are reached.
4. With the vehicle in PARK, the engine idling, and the air conditioning (A/C) system OFF, check to see if
the engine vacuum reading is within the specified normal engine vacuum range.
Specification
 Engine Driven Mechanical Vacuum Pump: 90-95 kPa (27-28 in Hg)

 Electric Vacuum Pump: 40-70 kPa (12-21 in Hg)

6. If the engine vacuum reading is within the specified normal range, proceed to step 10.
7. If the engine vacuum reading is NOT within the specified normal range, inspect the engine vacuum hose
for the following conditions:
 Loose connection to the engine
 Collapse, deformation or contamination
 Cracks, cuts, dry-rot
8. If any of these conditions were found with the engine vacuum hose, replace the hose, then repeat steps 2-
4.
9. If none of these conditions were found with the engine vacuum hose, then there is an engine vacuum
source problem, check the engine vacuum system.
10. Remove the vacuum brake booster check valve or the brake booster vacuum sensor, if equipped, from the
power vacuum brake booster.
11. Install the check valve or brake booster vacuum sensor, if equipped, to the engine vacuum hose.
12. Install the vacuum gauge to the check valve or brake booster vacuum sensor, if equipped.
13. Start the engine and allow the engine to idle in PARK with the A/C system OFF, until normal operating
temperatures are reached.
15. Ensure the engine vacuum reading is maintained within the specified normal engine vacuum range.
Specification
 Engine Driven Mechanical Vacuum Pump: 90-95 kPa (27-28 in Hg)

 Electric Vacuum Pump: 40-70 kPa (12-21 in Hg)
16. If the engine vacuum reading is maintained within the specified normal range, proceed to step 18.
17. If the engine vacuum reading is NOT maintained within the specified normal range, replace the brake
booster check valve or brake booster vacuum sensor, if equipped, then repeat steps 11-15.
18. Inspect the brake booster check valve grommet for the following conditions:
 Loose connection to the vacuum brake booster
 Deformation or contamination
 Cracks, cuts, dry-rot
19. If any of these conditions were found with the check valve grommet, replace the grommet.
BRAKE SYSTEM EXTERNAL LEAK INSPECTION
WARNING: Refer to Brake Fluid Irritant Warning .
CAUTION: Refer to Brake Fluid Effects on Paint and Electrical Components Caution .
1. In order to inspect for external brake fluid leaks, first check the fluid level in the master cylinder.
While a slight brake fluid level drop can be considered a normal condition due to brake lining wear, a
very low level may indicate a brake fluid leak in the hydraulic system.
2. If the fluid level is abnormally low, adjust the brake fluid level.
4. Apply constant, moderate foot pressure to the brake pedal.
If the brake pedal gradually falls away while under foot pressure, there may be a brake fluid leak.
5. Turn OFF the ignition.

6. Visually inspect the following brake system components for brake fluid leaks, excessive corrosion, and
damage. Give particular attention to all brake pipe and flexible hose connections to ensure that there are
not any slight brake fluid leaks - even though the brake pedal may feel firm and hold steady:
 Master cylinder brake pipe fittings
 All brake pipe connections
 Brake pipes
 Brake hoses and connections
 Brake calipers and/or wheel cylinders, if equipped
7. While slight dampness around the master cylinder reservoir can be considered acceptable, brake fluid
leaking from any of the brake system components requires immediate attention. If any of these
components exhibit signs of brake fluid leakage, repair or replace those components. After the repair or
replacement, reinspect the hydraulic brake system to assure proper function.
BRAKE SYSTEM INTERNAL LEAK TEST


2. Apply light, steady pressure to the brake pedal. Observe both the brake pedal feel and travel.
3. Release the brakes and turn OFF the ignition.
4. If the brake pedal apply felt spongy, but the brake pedal travel was not excessive, perform the following
steps:
1. Inspect the brake system for external leaks. Refer to Brake System External Leak Inspection.
2. Pressure bleed the brake system in order to purge any air that may be trapped in the system. Refer
to Hydraulic Brake System Bleeding (Manual), Hydraulic Brake System Bleeding (Pressure).
Fig. 4: Identifying Brake Master Cylinder (Cross Sectional View)

5. If the brake pedal apply did not feel spongy, but the brake pedal travel was excessive, perform the
following steps:
1. Loosen the master cylinder-to-brake power booster mounting nuts.
2. Carefully pull the master cylinder away from the brake power booster just enough to inspect the
mounting surface of the master cylinder.
3. Inspect the master cylinder mounting surface at the primary piston (2) for brake fluid leaks.
6. If the master cylinder exhibits any leakage around the primary piston (2), then the primary piston primary
seal (4) and/or secondary seal (3) is leaking and the master cylinder requires overhaul or replacement.
7. If the master cylinder primary piston (2) does not exhibit any leakage, pressure bleed the brake system.
Refer to Hydraulic Brake System Bleeding (Manual), Hydraulic Brake System Bleeding (Pressure).
8. If the brake pedal apply did not feel spongy, and the brake pedal travel was initially steady and not
excessive, but then gradually fell, then the master cylinder requires overhaul or replacement due to an
internal leak past the secondary piston (1) from the secondary piston primary seal (6) or secondary seal
(5).
HYDRAULIC BRAKE COMPONENT OPERATION VISUAL INSPECTION

Fig. 5: Identifying Brake Caliper/Pad Inspection Areas

CAUTION: Refer to Brake Fluid Effects on Paint and Electrical Components
Caution .
1. With the tire and wheel assemblies removed and the brake rotors retained by wheel lug nuts, visually
inspect the caliper piston dust boot (2) sealing area to ensure that there are no brake fluid leaks.
2. If any evidence of a brake fluid leak is present, the brake caliper requires overhaul or replacement.
3. While the brake system is at rest (4), observe the position of the caliper piston (1) in relation to the caliper
housing.
4. Have an assistant apply and release the brake pedal several times while you observe the operation of the
hydraulic brake caliper.
1. Observe the caliper piston (1) for unrestricted and even movement during each apply of the brake
system (5).
2. Observe the caliper piston (1) for an unrestricted and even return motion during each release of the
brake system (6).
5. If the caliper piston (1) did not exhibit unrestricted and even movement during brake system apply and/or
release, the piston square seal (3) may be worn or damaged and the caliper may require overhaul or
replacement.
BRAKE PIPE AND HOSE INSPECTION
1. Visually inspect all of the brake pipes for the following conditions:
 Kinks, improper routing, missing or damaged retainers
 Leaking fittings, excessive corrosion
2. If any of the brake pipes exhibited any of the conditions listed, then the identified pipe, or pipes, require
replacement.
3. Ensure that the vehicle axles are properly supported at ride height in order to maintain the proper
relationship of the flexible brake hoses to the chassis.
Fig. 6: Identifying Flexible Brake Hose Failure Conditions
4. Visually inspect all of the flexible brake hoses for the following conditions:
 Kinks (1), improper routing, twists, chafing, missing or damaged retainers
 Leaking connections, cracking, dry-rot, blisters, bulges
5. If any of the flexible brake hoses exhibited any of the conditions listed, then the identified flexible brake
hose, or hoses require replacement.
6. Squeeze the flexible brake hoses with firm finger pressure to check for soft spots (2), indicating an
internal restriction. Check the entire length of each flexible brake hose.
7. If any of the flexible brake hoses were found to have soft spots (2), then the identified flexible brake hose,
or hoses require replacement.
REPAIR INSTRUCTIONS
MASTER CYLINDER RESERVOIR FILLING
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
1. Using a suitable tool, remove and properly discard the brake fluid from the master cylinder reservoir.
2. Disconnect the brake fluid level indicator switch electrical connector.
Fig. 7: Master Cylinder Reservoir Bolt
3. Remove the master cylinder reservoir bolt (1).

Fig. 8: View Of Master Cylinder Reservoir
4. Lift the master cylinder reservoir (1) upward to release the reservoir from the reservoir seals and the
master cylinder.
Fig. 9: Master Cylinder Reservoir Seals
5. Remove the 2 master cylinder reservoir seals (1).
Installation Procedure
1. Lubricate the master cylinder reservoir seals with GM approved brake fluid from a clean, sealed, brake
fluid container.
Fig. 10: Master Cylinder Reservoir Seals
NOTE: Ensure the reservoir seals are fully seated in the master cylinder.
2. Install the 2 master cylinder reservoir seals (1).

Fig. 11: View Of Master Cylinder Reservoir
NOTE: Ensure the master cylinder reservoir is fully seated in the master cylinder.
3. Firmly and squarely press the master cylinder reservoir (1) into the master cylinder.
Fig. 12: Master Cylinder Reservoir Bolt
CAUTION: Refer to Fastener Caution .
4. Install the master cylinder reservoir bolt (1) and tighten to 4 N.m (35 lb in).
5. Connect the brake fluid level indicator switch electrical connector.
6. Fill the master cylinder reservoir. Refer to Master Cylinder Reservoir Filling.
MASTER CYLINDER REPLACEMENT (LEA, LUK)
Removal Procedure
1. Turn the ignition switch to 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. Remove the intake manifold cover, if necessary. Refer to Intake Manifold Cover Replacement for the
2.4L engine.
4. Using a suitable tool, remove and properly dispose of the brake fluid from the master cylinder reservoir.
5. Without draining the coolant and without disconnecting the hoses, remove and position aside the radiator
surge tank. Refer to Radiator Surge Tank Replacement (LUK) .
6. If equipped with the manual transmission, disconnect the clutch master cylinder reservoir hose. Refer to
Clutch Master Cylinder Reservoir Hose Replacement .
Fig. 13: Master Cylinder Primary And Secondary Brake Pipe Fittings
8. Disconnect the master cylinder primary brake pipe fitting (1).

9. Cap the brake pipe fitting to prevent brake fluid loss and contamination.
10. Disconnect the master cylinder secondary brake pipe fitting (2).
Fig. 14: Master Cylinder Nuts
12. Remove the master cylinder nuts (1).

Fig. 15: Master Cylinder & O-Ring Seal
13. Remove the master cylinder (1).

14. Remove the master cylinder O-ring seal (2).
1. If installing a new master cylinder, bench bleed the master cylinder. Refer to Master Cylinder Bench
Bleeding.
NOTE: Ensure the O-ring seal is properly seated in the groove in the master
cylinder body and is not distorted.
2. Install the master cylinder (1) and master cylinder O-ring seal (2).
3. Install the master cylinder nuts (1) and tighten to 50 N.m (37 lb ft).
4. Connect the master cylinder primary brake pipe fitting (1) and tighten to 18 N.m (13 lb ft).
5. Connect the master cylinder secondary brake pipe fitting (2) and tighten to 18 N.m (13 lb ft).
7. If equipped with the manual transmission, connect the clutch master cylinder reservoir hose. Refer to
8. Install the radiator surge tank. Refer to Radiator Surge Tank Replacement (LUK) .
9. Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual), Hydraulic
Brake System Bleeding (Pressure).
10. Install the intake manifold cover, if removed. Refer to Intake Manifold Cover Replacement for the 2.4L
engine.
MASTER CYLINDER REPLACEMENT (LTG)
Removal Procedure

1. Turn the ignition switch to the OFF position.

2. Apply and release the brake pedal several times until the brake pedal becomes firm to deplete the power
3. Remove the intake manifold cover, if necessary. Refer to INTAKE MANIFOLD COVER
REPLACEMENT for the 2.0L engine.
4. Using a suitable tool, remove and properly dispose of the brake fluid from the master cylinder reservoir.
surge tank. Refer to RADIATOR SURGE TANK REPLACEMENT (LTG)
6. If equipped with the manual transmission, disconnect the clutch master cylinder reservoir hose. Refer to
8. Disconnect the master cylinder primary brake pipe fitting (1).

10. Disconnect the master cylinder secondary brake pipe fitting (2).



14. Remove the master cylinder O-ring seal (2).
1. If installing a new master cylinder, bench bleed the master cylinder. Refer to Master Cylinder Bench
Bleeding.
NOTE: Ensure the O-ring seal is properly seated in the groove in the master
cylinder body and is not distorted.
2. Install the master cylinder (1) and master cylinder O-ring seal (2).

4. Connect the master cylinder primary brake pipe fitting (1) and tighten to 18 N.m (13 lb ft).
5. Connect the master cylinder secondary brake pipe fitting (2) and tighten to 18 N.m (13 lb ft).
7. If equipped with the manual transmission, connect the clutch master cylinder reservoir hose. Refer to
8. Install the radiator surge tank. Refer to RADIATOR SURGE TANK REPLACEMENT (LTG)
10. Install the intake manifold cover, if removed. Refer to INTAKE MANIFOLD COVER
REPLACEMENT for the 2.0L engine.
MASTER CYLINDER BENCH BLEEDING

Fig. 25: Bleeding Master Cylinder

Caution .
1. 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. 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 vise.
BRAKE FLUID LEVEL INDICATOR SWITCH REPLACEMENT
Fig. 26: Brake Fluid Level Indicator Switch

Brake Fluid Level Indicator Switch Replacement

Callout Component Name
Brake Fluid Level Indicator Switch
Procedure
1
 Disconnect the electrical connector.
 Turn the indicator switch clockwise to release.
BRAKE AND ACCELERATOR PEDAL ASSEMBLY REPLACEMENT
Removal Procedure
1. Remove the instrument panel tie bar. Refer to Instrument Panel Tie Bar Replacement
2. Disconnect the accelerator pedal position sensor electrical connector.
3. Remove the brake pedal position sensor. Refer to Brake Pedal Position Sensor Replacement
Fig. 27: Brake Pedal

4. Pull the brake pedal (1) rearward to release the power vacuum brake booster pushrod retainer.
NOTE: Do not reuse the power vacuum brake booster pushrod retainer.
5. Remove and discard the power vacuum brake booster pushrod retainer.
6. Remove the power vacuum brake booster. Refer to Power Vacuum Brake Booster Replacement
Fig. 28: Brake Pedal Assembly And Nuts

7. Remove the brake pedal assembly nuts (1).

8. Remove the brake pedal assembly.
1. Install the brake pedal assembly.

Fig. 29: Brake Pedal Assembly And Nuts
CAUTION: Refer to Fastener Caution
2. Install the brake pedal assembly nuts (1) and tighten to 22 N.m (16 lb ft).
3. Install the power vacuum brake booster. Refer to Power Vacuum Brake Booster Replacement
NOTE: Install a new power vacuum brake booster pushrod retainer.
4. Install a new power vacuum brake booster pushrod retainer to the power vacuum brake booster pushrod.
NOTE: Ensure the power vacuum brake booster pushrod retainer is fully seated in
the brake pedal arm.
5. Install the power vacuum brake booster pushrod retainer to the brake pedal (1).
6. Install the brake pedal position sensor. Refer to Brake Pedal Position Sensor Replacement
7. Connect the accelerator pedal position sensor electrical connector.
8. Install the instrument panel tie bar. Refer to Instrument Panel Tie Bar Replacement
BRAKE PRESSURE MODULATOR VALVE PRIMARY PIPE REPLACEMENT (LEFT HAND

DRIVE)
Fig. 31: Brake Pressure Modulator Valve Primary Pipe (Left Hand Drive)
Brake Pressure Modulator Valve Primary Pipe Replacement (Left Hand Drive)
WARNING:
Refer to Brake Fluid Irritant Warning .
Preliminary Procedures Remove the surge tank. Refer to Radiator Surge Tank Replacement (LUK) ,
Radiator Surge Tank Replacement (LTG) .
Brake Pipe Fitting
CAUTION:
Refer to Fastener Caution .
1
Procedure
Cap the brake pipe fitting to prevent brake fluid loss and contamination.
Tighten
18 N.m (13 lb ft)
Brake Pressure Modulator Valve Primary Pipe
Procedure
2
Bleed the hydraulic brake system. Refer to Hydraulic Brake System Bleeding (Manual),
BRAKE PRESSURE MODULATOR VALVE SECONDARY PIPE REPLACEMENT (LEFT HAND
DRIVE)
Fig. 32: Brake Pressure Modulator Valve Secondary Pipe (Left Hand Drive)
Brake Pressure Modulator Valve Secondary Pipe Replacement (Left Hand Drive)
WARNING:
Preliminary Procedures Remove the surge tank. Refer to Radiator Surge Tank Replacement (LUK) ,
Radiator Surge Tank Replacement (LTG) .
Brake Pipe Fitting
CAUTION:
1
Procedure
Tighten
18 N.m (13 lb ft)
Brake Pressure Modulator Valve Secondary Pipe
Procedure
2
BRAKE PIPE REPLACEMENT
Special Tools
CH-45405 Brake Pipe Flaring Tool Kit
For equivalent regional tools, refer to Special Tools.
Fig. 33: Sectioning Brake Pipe Using Pipe Cutter

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 .
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

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. 34: 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. 35: 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. 36: 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. 37: 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. 38: Rotating J 45405 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. 39: 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. 40: 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. 41: 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
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.
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
Fig. 42: Front Brake Pipe - Right Side

Front Brake Pipe Replacement - Right Side

WARNING:
Preliminary Procedures
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 .
3. Remove the surge tank. Refer to Radiator Surge Tank Replacement (LUK) , Radiator Surge
Tank Replacement (LTG) .
4. Move the air cleaner assembly to make space.
Front Brake Pipe Fitting
CAUTION:
1
Procedure
Tighten
18 N.m (13 lb ft)
2 Brake Pipe Clip (Qty: 3)
Procedure
3 Cap the brake pipe fitting to prevent brake fluid loss and contamination.
Tighten
18 N.m (13 lb ft)
Front Brake Pipe
Procedure
4
FRONT BRAKE PIPE REPLACEMENT - LEFT SIDE
Fig. 43: Front Brake Pipe - Left Side

Front Brake Pipe Replacement - Left Side

WARNING:
3. Remove the surge tank. Refer to Radiator Surge Tank Replacement (LUK) , Radiator Surge
CAUTION:
1
Procedure
Tighten
18 N.m (13 lb ft)
2 Brake Pipe Clip
Procedure
3 Cap the brake pipe fitting to prevent brake fluid loss and contamination.
Tighten
18 N.m (13 lb ft)
Front Brake Pipe
Procedure
4
FRONT BRAKE HOSE REPLACEMENT (J60, J61)

Fig. 44: Front Brake Hose (J60, J61)
Front Brake Hose Replacement (J60, J61)

WARNING:
WARNING:
Refer to Brake Dust Warning .
Brake Pipe Fitting
CAUTION:
1
Procedure
Tighten
18 N.m (13 lb ft)
Brake Hose Fitting Bolt
2 Tighten
40 N.m (30 lb ft)
Brake Hose Fitting Gasket (Qty: 2)
3 Procedure
Install new brake hose fitting gaskets.
Front Brake Hose
Procedure
4
FRONT BRAKE HOSE REPLACEMENT (J64)
Removal Procedure
WARNING: Refer to Brake Dust Warning .
Fig. 45: Brake Pipe Fitting
3. Disconnect the brake pipe fitting (1) from the brake hose.
5. Remove the brake hose retaining clip.
Fig. 46: Front Strut Assembly Pinch Bolt
6. Remove the front strut assembly pinch bolt (1) from the steering knuckle and brake hose bracket.
Fig. 47: 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.
1. Install the brake hose.

Fig. 48: Brake Hose Fitting Bolt
2. Assemble the brake hose fitting bolt (1). with new brake hose fitting gaskets (2) to the brake hose fitting
(3).
3. Install the brake hose assembly to the brake caliper and tighten the brake hose fitting bolt to 40 N.m (30
lb ft).
Fig. 49: Front Strut Assembly Pinch Bolt
4. Install the front strut assembly pinch bolt (1) to the steering knuckle and brake hose bracket. Refer to
Strut Assembly Removal and Installation (GNB) , Strut Assembly Removal and Installation
(GNA) .
5. Install the front brake hose to the wheelhouse bracket.
6. Install the brake hose retaining clip.
Fig. 50: Brake Pipe Fitting
7. Connect the brake pipe fitting (1) to the brake hose.

8. Tighten the brake pipe fitting to 18 N.m (13 lb ft).
10. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation .
REAR BRAKE HOSE REPLACEMENT

Fig. 51: Rear Brake Hose & Mounting Components
Rear Brake Hose Replacement

WARNING:
WARNING:
Refer to Brake Dust Warning .
2. Remove the tire and wheel. Refer to Tire and Wheel Removal and Installation .
Brake Pipe Fitting
CAUTION:
1
Procedure
Tighten
18 N.m (13 lb ft)
2 Brake Hose Retainer
Brake Hose Fitting Bolt
3 Tighten
40 N.m (30 lb ft)
Brake Hose Fitting Gasket (Qty: 2)
4 Procedure
Install new brake hose fitting gaskets.
Rear Brake Hose
Procedure
5
HYDRAULIC BRAKE SYSTEM BLEEDING (MANUAL)
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. 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
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
diaphragm.
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.
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
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.
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
8. Install a proper box-end wrench onto the RIGHT REAR wheel hydraulic circuit 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.
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.
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.
HYDRAULIC BRAKE SYSTEM BLEEDING (PRESSURE)
If hydraulic components were serviced on only one wheel hydraulic circuit, perform the following procedure.
Bleeding a Single Hydraulic Brake Circuit
diaphragm.
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
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.
12. Submerge the open end of the transparent hose into a transparent container partially filled with brake fluid
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.
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.
Bleeding the Complete Brake Hydraulic System
diaphragm.
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.
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
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
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.
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
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
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.
15. Submerge the open end of the transparent hose into a transparent container partially filled with GM
16. Have an assistant slowly press the brake pedal fully and maintain steady pressure on the brake pedal.
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.
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.
HYDRAULIC BRAKE SYSTEM FLUSHING
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 procedures indicated:

 Master Cylinder Replacement (LEA, LUK) or Master Cylinder Replacement (LTG)
 Front Brake Hose Replacement (J60, J61), Front Brake Hose Replacement (J64)
 Front Brake Caliper Replacement (J60, J61) , Front Brake Caliper Replacement (J64)
 Electronic Brake and Traction Control Module with Brake Pressure Modulator Valve
Replacement
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 procedures indicated:
 Master Cylinder Replacement (LEA, LUK) or Master Cylinder Replacement (LTG) -

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 Master Cylinder Reservoir Replacement.
Replace the brake master cylinder reservoir cap diaphragm.
 Front Brake Hose Replacement (J60, J61), Front Brake Hose Replacement (J64)
 Front Brake Caliper Replacement (J60, J61) , Front Brake Caliper Replacement (J64)
 Electronic Brake and Traction Control Module with Brake Pressure Modulator Valve
Replacement
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.
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.
surge tank. Refer to Radiator Surge Tank Replacement (LUK) , Radiator Surge Tank Replacement
(LTG) .
3. Disconnect the brake pedal position sensor electrical connector. Refer to Brake Pedal Position Sensor
Replacement .

4. Release the brake pedal (1) from the power vacuum brake booster pushrod by lifting the pedal upward.
NOTE: Do not reuse the brake pedal retainer.
5. Remove and discard the brake pedal retainer.

6. Disconnect the power vacuum brake booster vacuum sensor electrical connector.
Fig. 53: Power Brake Booster Vacuum Rear Pipe
7. Release the power brake booster vacuum inlet pipe from the retainers (1) on the dash panel.
Fig. 54: Power Brake Booster Vacuum Sensor
8. Remove the power brake booster vacuum sensor (1) from the power vacuum brake booster and position
aside.
10. Remove the electronic brake and traction control module (EBTCM). Refer to Electronic Brake and
Traction Control Module with Brake Pressure Modulator Valve Replacement .

Fig. 56: Master Cylinder

13. Inspect the master cylinder O-ring seal for damage and replace, if necessary.
Fig. 57: Power Vacuum Brake Booster Bolts
14. Completely loosen the power vacuum brake booster bolts (1).
Fig. 58: Power Vacuum Brake Booster
15. Remove the power vacuum brake booster (1).

16. Inspect the power vacuum brake booster gasket (2) for damage and replace, if necessary.
Fig. 59: Power Vacuum Brake Booster
1. Install the power vacuum brake booster (1) and gasket (2).
Fig. 60: Power Vacuum Brake Booster Bolts
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.
2. Install the power vacuum brake booster bolts (1) and tighten to 19 N.m (14 lb ft).
Fig. 61: Master Cylinder
3. Install the master cylinder (1) to the power vacuum brake booster.
6. Install the EBTCM. Refer to Electronic Brake and Traction Control Module with Brake Pressure
Modulator Valve Replacement .
NOTE: A small amount of denatured alcohol may be used as a lubricant to assist

the installation of the power brake booster vacuum sensor.
7. Install the power brake booster vacuum sensor (1) to the power vacuum brake booster.
8. Install the power brake booster vacuum inlet pipe to the retainers (1) on the dash panel.
9. Connect the power vacuum brake booster vacuum sensor electrical connector.
NOTE: Install a new power vacuum brake booster pushrod retainer.
10. Install a new power vacuum brake booster pushrod retainer to the power vacuum brake booster pushrod.
NOTE: Ensure the power vacuum brake booster pushrod retainer is fully seated in
the brake pedal arm.
11. Connect the power vacuum brake booster pushrod retainer (1) to the brake pedal.
12. Connect the brake pedal position sensor electrical connector. Refer to Brake Pedal Position Sensor
Replacement .
13. Install the radiator surge tank. Refer to Radiator Surge Tank Replacement (LUK) , Radiator Surge
POWER BRAKE BOOSTER VACUUM SENSOR REPLACEMENT
Removal Procedure
1. Apply the brake pedal several times until the brake pedal becomes firm to deplete the power vacuum
brake booster vacuum reserve.
2. Disconnect the power brake booster vacuum sensor electrical connector.

3. Release the power brake booster vacuum rear pipe from the clips (1) on the vehicle front of dash.
4. Remove the power brake booster vacuum sensor (1) from the power vacuum brake booster.
Fig. 68: Power Brake Booster Vacuum Rear Pipe Hose
5. Release the clamps and remove the power brake booster vacuum rear pipe hose (1) from the power brake
booster vacuum sensor (2) and the power vacuum brake booster.
Fig. 69: Power Brake Booster Vacuum Rear Pipe Hose
1. Install the power brake booster vacuum rear pipe hose (1) to the power brake booster vacuum rear pipe
and secure the clamp.
2. Install the power brake booster vacuum sensor (2) to the power brake booster vacuum rear pipe and
secure the clamp.
3. Install the power brake booster vacuum sensor (1) to the power vacuum brake booster.
4. Install the power brake booster vacuum rear pipe to the clips (1) on the vehicle front of dash.
5. Connect the power brake booster vacuum sensor electrical connector.
POWER BRAKE BOOSTER VACUUM PIPE REPLACEMENT (LTG)
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 vacuum brake booster vacuum reserve.
Fig. 72: Power Brake Booster Vacuum Pipe Quick Connection
2. Release the power brake booster vacuum pipe quick connect (1) from the power brake booster pump.
3. Remove the power brake booster vacuum pipe (2) by releasing the power brake booster vacuum rear pipe
quick connect.
Fig. 73: Power Brake Booster Vacuum Pipe Clamp
4. Remove and discard the power brake booster vacuum pipe clamp (1).
5. Remove the power brake booster vacuum pipe hose (2) from the vacuum port on the intake manifold.
6. Release the power brake booster vacuum pipe (3) from the retainer on the charge air cooler intake pipe.
7. Remove the power brake booster vacuum pipe assembly.
Fig. 74: Power Brake Booster Vacuum Pipe Clamp
1. Install a new power brake booster vacuum pipe clamp (1) to the power brake booster vacuum pipe hose
(2).
2. Install the power brake booster vacuum pipe hose to the vacuum port on the intake manifold.
3. Secure the power brake booster vacuum pipe clamp.
4. Install the power brake booster vacuum pipe (3) to the retainer on the charge air cooler intake pipe.
5. Install the power brake booster vacuum pipe quick connect (1) to the power brake booster pump.
6. Install the power brake booster vacuum pipe (2) to the power brake booster vacuum rear pipe quick
connect.
POWER BRAKE BOOSTER VACUUM PIPE REPLACEMENT (LUK)
Removal Procedure
1. Turn the engine OFF.

Fig. 76: Power Brake Booster Vacuum Pipe Quick Connect
2. Apply and release the brake pedal several times until the pedal becomes firm to deplete the power
3. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
4. Disconnect the power brake booster vacuum pipe quick connect (1).
Fig. 77: Power Brake Booster Vacuum Pipe Clips
5. Release the power brake booster vacuum pipe clips (1).

Fig. 78: Power Brake Booster Vacuum Pipe And Clamp
6. Release the clamp (1) and remove the power brake booster vacuum pipe (2) from the intake manifold
vacuum port.
Fig. 79: Power Brake Booster Vacuum Pipe And Clamp
1. Install the clamp (1) and install the power brake booster vacuum pipe (2) to the intake manifold vacuum
port.
Fig. 80: Power Brake Booster Vacuum Pipe Clips
2. Install the power brake booster vacuum pipe to the clips (1).
3. Connect the power brake booster vacuum pipe quick connect (1).
4. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
POWER BRAKE BOOSTER VACUUM REAR PIPE REPLACEMENT (LTG)
Removal Procedure
Fig. 82: Power Brake Booster Vacuum Rear Pipe Vacuum Check Valve
2. Release the power brake booster vacuum rear pipe (1) from the retainer.
3. Remove the power brake booster vacuum rear pipe vacuum check valve (2) from the power vacuum
brake booster.
4. Release the power brake booster vacuum rear pipe quick connect and disconnect the power brake booster
vacuum pipe (3).
5. Remove the power brake booster vacuum rear pipe assembly.
Fig. 83: Power Brake Booster Vacuum Rear Pipe Vacuum Check Valve
1. Install the power brake booster vacuum rear pipe (1) to the retainer.
2. Install the power brake booster vacuum rear pipe vacuum check valve (2) to the power vacuum brake
booster.
3. Connect the power brake booster vacuum rear pipe quick connect to the power brake booster vacuum
pipe (3).
POWER BRAKE BOOSTER VACUUM REAR PIPE REPLACEMENT (LUK)
Removal Procedure

2. Apply the brake pedal several times until the brake pedal becomes firm to deplete the power vacuum
brake booster vacuum reserve.
3. Disconnect the power brake booster vacuum pipe quick connect (1).
Fig. 85: Power Brake Booster Vacuum Rear Pipe Retainer & Sensor
4. Disconnect the power brake booster vacuum sensor electrical connector.

5. Release the power brake booster vacuum rear pipe from the retainer (1) on the dash panel.
6. Remove the power brake booster vacuum rear pipe vacuum sensor and check valve (2) from the power
vacuum brake booster.
Fig. 86: Power Brake Booster Vacuum Rear Pipe Retainers
7. Remove the power brake booster vacuum rear pipe from the retainers (1) on the dash panel.
8. Release the power brake booster vacuum rear pipe from the retainer (2) on the right front brake pipe.
10. Remove the right front wheelhouse front liner. Refer to Front Wheelhouse Front Liner Replacement .
Fig. 87: Power Brake Booster Vacuum Rear Pipe Quick Connect And Retainer
11. Release the power brake booster vacuum rear pipe retainer (1) from the power brake booster pump
bracket.
12. Disconnect the power brake booster vacuum rear pipe quick connect (2).
13. Remove the power brake booster vacuum rear pipe from the vehicle.
Fig. 88: Power Brake Booster Vacuum Rear Pipe Quick Connect And Retainer
1. Position the power brake booster vacuum rear pipe to the vehicle.
2. Install the power brake booster vacuum rear pipe retainer (1) to the power brake booster pump bracket.
3. Connect the power brake booster vacuum rear pipe quick connect (2).
4. Install the right front wheelhouse front liner. Refer to Front Wheelhouse Front Liner Replacement .
Fig. 89: Power Brake Booster Vacuum Rear Pipe Retainers
5. Install the power brake booster vacuum rear pipe to the retainers (1) on the dash panel.
6. Install the power brake booster vacuum rear pipe to the retainer (2) on the right front brake pipe.
Fig. 90: Power Brake Booster Vacuum Rear Pipe Retainer & Sensor
7. Install the power brake booster vacuum rear pipe to the retainer (1) on the dash panel.
8. Install the power brake booster vacuum rear pipe vacuum sensor and check valve (2) to the power
vacuum brake booster.
9. Connect the power brake booster vacuum sensor electrical connector.
10. Connect the power brake booster vacuum pipe quick connect (1).
POWER BRAKE BOOSTER PUMP REPLACEMENT (LTG)
Removal Procedure
2. Release the power brake booster vacuum pipe quick connect (1) from the power brake booster pump.
3. Remove the power brake booster vacuum pipe (2) by releasing the power brake booster vacuum rear pipe
quick connect.
4. Release the power brake booster vacuum pipe from the retainer on the charge air cooler intake pipe.
5. Position the power brake booster vacuum pipe aside.
Fig. 93: Power Brake Booster Pump Bolts
6. Remove the power brake booster pump bolts (1).

Fig. 94: Power Brake Booster Pump
7. Remove the power brake booster pump (1).

8. Inspect the power brake booster pump seal for damage and replace, if necessary.
1. Install the power brake booster pump seal to the power brake booster pump.
2. Align the power brake booster pump drive to the camshaft and install the power brake booster pump (1).
Fig. 96: Power Brake Booster Pump Bolts
3. Install the power brake booster pump bolts (1) and tighten to 25 N.m (18 lb ft).
4. Connect the power brake booster vacuum pipe quick connect (1) to the power brake booster pump.
5. Connect the power brake booster vacuum pipe (2) to the power brake booster vacuum rear pipe quick
connect.
6. Install the power brake booster vacuum pipe to the retainer on the charge air cooler intake pipe.
POWER BRAKE BOOSTER PUMP REPLACEMENT (LUK)

Power Brake Booster Pump Replacement (LUK)

Preliminary Procedure
1. With the engine OFF, apply the brake pedal several times until the brake pedal becomes firm to
deplete the vacuum brake booster vacuum reserve.
3. Remove the right front tire and wheel assembly. Refer to Tire and Wheel Removal and
Installation .
4. Remove the right front wheelhouse front liner. Refer to Front Wheelhouse Front Liner
Replacement .
Power Brake Booster Vacuum Pipe
Procedure
1
1. Release the power brake booster vacuum pipe quick connect.
2. Disconnect the power brake booster pump electrical connector.
Power Brake Booster Pump Nut (Qty: 2)
CAUTION:
2 Tighten
10 N.m (89 lb in)
3 Power Brake Booster Pump
DESCRIPTION AND OPERATION

BRAKE ASSIST SYSTEM DESCRIPTION AND OPERATION
System Component Description
The brake assist system consists of the following:
Brake Pedal
Multiplies the braking effort applied by the driver.
Brake Pedal Pushrod
Transfers multiplied input force received from the brake pedal to the vacuum brake booster.
Vacuum Brake Booster
Uses source vacuum to decrease effort required by the driver when applying the brakes.
Vacuum Brake Booster Control Valve
Regulates the vacuum/atmospheric pressure within the vacuum brake booster. The calibration of the
control valve gives more powerful vacuum assistance during low brake pedal pressure.
Vacuum Source
The source vacuum is either derived from the intake manifold or delivered from a pump, mechanically or
electrically driven. For further information refer to Brake Booster Vacuum Assist Description and
Operation.
Vacuum Source Delivery System
Enables delivery and retention of source vacuum for vacuum brake booster.
System Operation
Brake system input force from the driver is multiplied by the brake pedal and transferred by the pedal pushrod
to the hydraulic brake master cylinder. Effort required to apply the brake system is reduced by the operation of
the vacuum brake booster.
At rest, source vacuum is applied to both sides of each of the diaphragms in the dual booster. Return springs
maintain the booster in a rest position.
When brake system force is applied, vacuum to the rear of the diaphragms is cut off, and air at atmospheric
pressure is admitted in its place. The vacuum acts to pull the diaphragms forward, while the atmospheric
pressure acts to push from behind. As a result, the amount of effort required by the driver is reduced. When
input force is removed, vacuum again replaces atmospheric pressure within the vacuum power brake booster to
help return the booster to rest. Return springs maintain the system in a rest position.
BRAKE BOOSTER VACUUM ASSIST DESCRIPTION AND OPERATION
Hydraulic Brakes Block Diagram
Fig. 99: Hydraulic Brake Block Diagram


HW Hard-Wired
HW Hard-Wired
B19B B19B Brake Booster Vacuum Sensor
K17 K17 Electronic Brake Control Module
M9 M9 Brake Booster Pump Motor
The Brake Booster Vacuum Assist system consists of the following:
Brake Booster Auxiliary Vacuum Pump
The Brake Booster Vacuum Pump is a secondary vacuum supply to the brake booster used to maintain
sufficient vacuum for brake assist.
The vacuum sensor is used to measure the level of vacuum available in the brake booster. The Electronic
Brake Control Module supplies a 5 V reference and a low reference circuit to the brake booster vacuum
sensor. The vacuum sensor is located in the brake booster or vacuum hose. The Brake Booster Vacuum
Sensor supplies a voltage signal in relation to the pressure in the brake booster to the Electronic Brake
Control Module.
Electronic Brake Control Module
The Electronic Brake Control Module monitors the vacuum in the brake booster using the Brake Booster
Vacuum Sensor. When the vacuum within the system drops the Electronic Brake Control Module turns
ON the Brake Booster Auxiliary Vacuum Pump.
Vacuum Brake Booster
When brake system input force is applied, air at atmospheric pressure is admitted to the rear of both
vacuum diaphragms, providing a decrease in brake pedal effort required. When input force is removed,
vacuum replaces the atmospheric pressure within the booster. The booster uses source vacuum to
decrease the effort required by driver when applying the brake.
Vacuum Source
Vacuum is supplied by the engine vacuum or by the Brake Booster Auxiliary Vacuum Pump.
System Operation
The pump can be switched on and off by the Electronic Brake Control Module based on the required vacuum.
Pressure variations during braking can be measured, and the pump can be activated to generate additional
vacuum if required to increase the braking force.
BRAKE WARNING SYSTEM DESCRIPTION AND OPERATION
Brake Warning Indicator
Brake Warning Block Diagram

Fig. 100: Brake Warning Block Diagram

HW Hard-Wired
DA Serial Data
P16 P16 Instrument Cluster
B20 B20 Brake Fluid Level Switch
K17 K17 Electronic Brake Control Module
The instrument cluster turns the brake warning indicator ON when the following occurs:
 The instrument cluster performs the bulb check. The brake warning indicator illuminates for 5 s.
 When the electronic brake control module (EBCM) detects low brake fluid level it sets DTC C0267 and
sends a serial data message to the instrument cluster, which will illuminate the red brake indicator.
Driver Information Center Messages
When the electronic brake control module (EBCM) detects low brake fluid level it sets DTC C0267 and sends a
serial data message to the Driver Information Center , which will display Brake Fluid Low message.
HYDRAULIC BRAKE SYSTEM DESCRIPTION AND OPERATION

The hydraulic brake system consists of the following:
Hydraulic Brake Master Cylinder Fluid Reservoir
Contains supply of brake fluid for the hydraulic brake system.
Hydraulic Brake Master Cylinder
Converts mechanical input force into hydraulic output pressure.

Hydraulic output pressure is distributed from the master cylinder through 2 hydraulic circuits, supplying
diagonally-opposed wheel apply circuits.
Hydraulic Brake Pressure Balance Control System
Regulates brake fluid pressure delivered to hydraulic brake wheel circuits, in order to control the
distribution of braking force.
Pressure balance control is achieved through dynamic rear proportioning (DRP), which is a function of
the ABS modulator.
Hydraulic Brake Pipes and Flexible Brake Hoses
Carries brake fluid to and from hydraulic brake system components.
Hydraulic Brake Wheel Apply Components
Converts hydraulic input pressure into mechanical output force.
System Operation
Mechanical force is converted into hydraulic pressure by the master cylinder, regulated to meet braking system
demands by the pressure balance control system, and delivered to the hydraulic brake wheel circuits by the
pipes and flexible hoses. The wheel apply components then convert the hydraulic pressure back into mechanical
force which presses linings against rotating brake system components.
SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS
Tool
Number/
Illustration Description
CH 28662
J 28662
Brake Pedal
Effort
Gauge
CH 29532-
B
J 29532-B
Pressure
Brake
Bleeder, or
equivalent
CH 35798
J 35798
Brake
Pressure
Bleeder
Adapter
CH 45405
J 45405
Brake Pipe
Flaring Kit

084 - Hydraulic Brakes

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Brakes

Fastener Tightening Specifications

BRAKE COMPONENT SPECIFICATIONS

Brake Component Specifications

BRAKE SYSTEM SPECIFICATIONS

Brake System Specifications

 Maximum specification with 450 N (101 lbs) of force 48-58 mm 1.9-2.3 in

ADHESIVES, FLUIDS, LUBRICANTS, AND SEALERS

Adhesives, Fluids, Lubricants, and Sealers

SCHEMATIC WIRING DIAGRAMS

Hydraulic Brakes (except CZ2)

Fig. 1: Hydraulic Brakes (except CZ2)

Hydraulic Brakes (CZ2)

DIAGNOSTIC INFORMATION AND PROCEDURES

DIAGNOSTIC CODE INDEX

DTC C0267: LOW BRAKE FLUID INDICATED

Low Brake Fluid Indicated

For symptom byte information refer to Symptom Byte List .

Diagnostic Fault Information

Short to Open/High Short to Signal

Conditions for Running the DTC

Conditions for Setting the DTC

Low brake fluid level is detected for 8 s.

Action Taken When the DTC Sets

Conditions for Clearing the DTC

The condition for setting the DTC is no longer present.

Hydraulic Brake Schematics

COMPONENT CONNECTOR END VIEWS - INDEX

Description and Operation

Brake Warning System Description and Operation

Electrical Information Reference

Scan Tool Reference

Control Module References for scan tool information

1. Verify that the brake is above minimum level.

Refer to Brake Fluid Loss.

 If above minimum level

Refer to Circuit/System Testing.

 If less than 10 ohms

 If infinite resistance, replace the K17 Electronic Brake Control Module.

 If the parameter is Low

7. Test or replace the B20 Brake Fluid Level Switch.

Perform the Diagnostic Repair Verification after completing the repair.

 Brake Fluid Level Indicator Switch Replacement

DTC C0273: BRAKE FLUID LEVEL SWITCH CIRCUIT

Brake Fluid Level Switch Circuit

For symptom byte information refer to Symptom Byte List .

Diagnostic Fault Information

Conditions for Running the DTC

Conditions for Setting the DTC

A open or short to battery is detected on the signal circuit.

Action Taken When the DTC Sets

 The brake warning indicator turns ON.

Conditions for Clearing the DTC

The condition for setting the DTC is no longer present.

Hydraulic Brake Schematics

Connector End View Reference

COMPONENT CONNECTOR END VIEWS - INDEX

Description and Operation

Hydraulic Brake System Description and Operation

Electrical Information Reference