Solstice 2006-2008, Sky 2007-2008

Power Vacuum Brake Booster

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Brake Pedal Position Sensor Calibration




NOTE
Do not apply the brake pedal during the brake pedal position sensor calibration procedure. Any movement of the brake pedal during this procedure will cause the calibration procedure to fail. If this occurs, the brake pedal position sensor calibration must be repeated.

Brake pedal position sensor calibration must be performed after the brake pedal position sensor or Body Control Module (BCM) have been serviced. The calibration procedure will set brake pedal position sensor home value. This value is used by the BCM to determine the action of the driver applying the brake system and to provide this information to the vehicle subsystems via the GMLAN communication bus.

  1. Perform the calibration procedure as follows:

    Apply the parking brake.
     
    Place the transmission in the PARK position for automatic transmission or NEUTRAL for manual transmission.
     
    Install a scan tool.
     
    Clear all BCM DTCs before proceeding.
     
    Turn ON the ignition, with the engine OFF.
     
    Navigate to the BCM menu.
     
    Select Module Setup menu item.
     
    Select BPP Sensor Calibration procedure and follow the directions displayed on the screen.
     

  2.  

Removal & Installation



With Active Brake Control System (Jl4)
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Turn the ignition switch to the OFF position.
  4.  
  5. Clean the Electronic Brake Control Module (EBCM) to Brake Pressure Modulator Valve (BPMV) area and the brake pipe port areas of any accumulated dirt and foreign material.
  6.  
  7. Disconnect the brake fluid level indicator switch electrical connector.
  8.  
  9. Disconnect the vacuum brake booster vacuum sensor electrical connector.
  10.  
  11. Remove the vacuum brake booster check valve and vacuum sensor assembly from the grommet and position aside.
  12.  
  13. Release the wiring harness retainer from the master cylinder mounting stud and position the wiring harness downward.
  14.  
  15. Remove and discard the 2 master cylinder nuts.
  16.  
  17. If equipped, disconnect the clutch master cylinder hose from the brake master cylinder reservoir.
  18.  
  19. Cap the brake fluid reservoir outlet and plug the clutch master cylinder hose inlet to prevent brake fluid loss and contamination.
  20.  
  21. Remove the 2 master cylinder brake pipe fittings from the BPMV. Cap the brake pipe fittings and plug the BPMV inlet ports to prevent brake fluid loss and contamination.
  22.  
  23. Remove the brake master cylinder and master cylinder brake pipes as an assembly.
  24.  
  25. Lift the locking tabs on the lower edge of the EBCM electrical connector and disconnect the electrical connector.
  26.  
  27. Position the EBCM electrical connector and the wiring harness toward the front of the vehicle.
  28.  
  29. Release the rear brake pipes retainer from the outboard side of the frame rail.
  30.  
  31. Remove the 3 BPMV bracket bolts.
  32.  
  33. Carefully position the brake modulator assembly forward slightly.
  34.  
  35. Remove the vacuum brake booster pushrod retaining clip.
  36.  
  37. Remove the vacuum brake booster pushrod spacer.
  38.  
  39. Disconnect the vacuum brake booster pushrod from the brake pedal pushrod pin.
  40.  
  41. Remove the 4 vacuum brake booster mounting nuts.
  42.  
  43. Remove the vacuum brake booster from the vehicle.

    Click image to see an enlarged view

    Fig. Brake booster, (3) dash panel gasket, (2) dash panel seal

  44.  

To install:

  1. Inspect the vacuum brake booster to dash panel seal for damage and replace, if necessary.
  2.  
  3. Inspect the vacuum brake booster to dash panel gasket for damage and replace, if necessary.
  4.  
  5. Install the vacuum brake booster to the vehicle.
  6.  
  7. Connect the vacuum brake booster pushrod to the brake pedal pushrod pin.
  8.  
  9. Install the 4 vacuum brake booster mounting nuts and tighten to 18 ft. lbs. (25 Nm).
  10.  
  11. Apply a thin coat of high-temperature grease to the vacuum brake booster pushrod spacer and the brake pedal pushrod pin.
  12.  
  13. Install the vacuum brake booster pushrod spacer.
  14.  
  15. Install the vacuum brake booster pushrod retaining clip.
  16.  
  17. Carefully position the brake modulator assembly to the frame rail.
  18.  
  19. Install the 3 BPMV bracket bolts and tighten to 89 inch. lbs. (10 Nm).
  20.  
  21. Position the EBCM electrical connector and the wiring harness to the EBCM.
  22.  
  23. Connect the EBCM electrical connector. Ensure the tabs on the cam lever are securely locked in place.
  24.  
  25. Install the rear brake pipes retainer to the outboard side of the frame rail.
  26.  
  27. Install the brake master cylinder and master cylinder brake pipes assembly to the vacuum brake booster.
  28.  
  29. Install the master cylinder brake pipe fittings to the BPMV. Tighten the brake pipe fittings to 15 ft. lbs. (20 Nm).
  30.  
  31. If equipped, connect the clutch master cylinder hose to the brake master cylinder reservoir.
  32.  
  33. Install 2 new brake master cylinder nuts and tighten to 15 ft. lbs. (20 Nm).
  34.  
  35. Position the wiring harness upward and install the wiring harness retainer to the master cylinder mounting stud on the vacuum brake booster.
    NOTE
    If necessary, a small amount of denatured alcohol can be used as an assembly aid for installing the check valve to the vacuum brake booster grommet. Do not use soap.

  36.  
  37. Install the vacuum check valve and vacuum sensor assembly to the vacuum brake booster.
  38.  
  39. Connect the brake booster vacuum sensor electrical connector.
  40.  
  41. Connect the brake fluid level indicator switch electrical connector.
  42.  
  43. Bleed the hydraulic brake system.
  44.  
  45. Calibrate the brake pedal position sensor.
  46.  

Without Active Brake Control System (Jl4)
  1. Before servicing the vehicle, refer to the Precautions Section.
  2.  
  3. Remove the left Instrument Panel (I/P) closeout/insulator panel.
  4.  
  5. Remove vacuum brake booster pushrod clip and washer.
  6.  
  7. Remove the brake booster vacuum check valve hose clamp.
  8.  
  9. Remove the brake booster vacuum hose.
  10.  
  11. Release the clamp and disconnect the clutch hose, if equipped. Cap the brake fluid reservoir outlet and plug the clutch master cylinder hose to prevent brake fluid loss and contamination.
  12.  
  13. Ensure the brake master cylinder to vacuum brake booster seal is correctly seated at the rear of the master cylinder and is not damaged. Replace the seal if necessary.
  14.  
  15. Carefully position the brake master cylinder aside and secure with heavy mechanics wire or equivalent.
  16.  
  17. Carefully pull the brake master cylinder forward until it is past the vacuum brake booster studs.
  18.  
  19. Remove the vacuum brake booster mounting nuts. Discard the nuts.
  20.  
  21. Carefully pull the vacuum brake booster forward and tilt upward until the studs are past the mounting holes.
  22.  
  23. If reusing the booster, inspect the dash panel gasket for damage. Replace the gasket if necessary.
  24.  
  25. Calibrate the brake pedal position sensor.
  26.  
  27. Inspect the vacuum brake booster to dash panel insulator for damage. Replace the insulator if necessary

    Click image to see an enlarged view

    Fig. Brake booster, master cylinder and related parts

  28.  

To install:

  1. Installation is the reverse of removal procedure.
  2.  
  3. Please take note of the following tightening specifications:

    Tighten new vacuum brake booster nuts to 18 ft. lbs. (25 Nm).
     
    Tighten new master cylinder mounting nuts to 11 ft. lbs. (15 Nm).
     

  4.  

 
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