OEM 2005 Chevrolet Malibu Brake Booster

2005 Chevrolet Malibu Parts Questions & Experts Answers

• Q: How to replace the Vacuum Brake Booster (ABS) on 2005 Chevrolet Malibu?

  A: To change out the vacuum Brake Booster (ABS), proceed by turning the ignition to the off position, in order to avoid damaging the ebcm/ ebtcm by unplugging the wiring harness. Raise and support vehicle and remove left front tire and wheel assembly. Remove the 3 nuts that hold the electronic brake control module (EBCM)/brake pressure modulator valve (BPMV) bracket to the left front wheelhouse and lower the vehicle. Disconnect the electrical connector from the ebcm, then drain the vacuum off from the vacuum Brake Booster using the vacuum check valve from the vacuum Brake Booster grommet without disconnecting it from the vacuum brake hose . Remove the 4 brake pipes out of the bpmv using the bleeder valve caps for avoiding any loss of fluid and contamination. Next, remove the terminal nut from the wbrake booster followed by ebcm/bpmv bracket assembly with the brake master cylinder. Remove the close out panel together with the electrical connector of the brake apply sensor, then unscrew the 2 Brake Pedal assembly to cowl mounting nuts. Remove the Brake Pedal pushrod retaining clip, wave washers, and Brake Booster pushrod from the Brake Pedal pin so as to tilt the vacuum Brake Booster and just work the booster pushrod off the pin applying excessive side pressure. You'll need to take the booster off the vehicle. For installation positioning, place the booster back into the vehicle, tilting it slightly so that the side with the pushrod and booster is consistent with the Brake Pedal pin, and the fixation clip , wave washer , pushrod are fixed to the pin. Secure the 2 Brake Pedal assembly onto cowl mounting nuts and tighten to 15 nm (11 ft. Lbs.). Connect the brake apply sensor's electrical connector, reinstall the closeout panel, as well as attach the ebcm/bpmv bracket assembly and master cylinder to the vehicle. Torque the master cylinder nuts to the vacuum Brake Booster, which are recommended to be 25 nm (18 ft. Lbs.), while ensuring the fitting of gasket on the master cylinder is intact. Lift the vehicle once more, mount the 3 nuts that attach the ebcm/bpmv bracket assembly to the left wheelhouse and tighten them to 10 nm (86 inch lbs.), and reinstall the left-front tire and wheel assembly and lower the vehicle. Then, remove the caps from the 4 brake pipes and connect them to the bpmv, tightening them to 20 nm (15 ft. Lbs.). Connect the electrical connector back to the ebcm and the vacuum Brake Booster check valve back to the vacuum Brake Booster grommet. Lastly, bleed the hydraulic brake system and dial in the Brake Pedal position sensor.