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Home >> Buick >> 2004 >> Century Limited >> Repair and Diagnosis >> External Pages >> Different car >> Section 124 (Hydraulic Brake System) >> Repair Instructions >> Vacuum Brake Booster Replacement (3.8L) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 Pontiac Grand Prix. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Internal components of this booster are not serviceable. The housing must not be unstaked and separated. Separating the housing will cause permanent deformation, preventing the booster from holding proper volume.
NOTE: Inspect the locking flanges on booster and mounting plate. Replace the booster and mounting plate if the locking flanges are bent or damaged.
  1. Install the vacuum brake booster.

    Position the vacuum brake booster on the cowl counterclockwise from the final installation position so that the locking flanges on the vacuum brake booster and on the cowl mounting flange engage.

    2. IMPORTANT: Ensure that the locking tab and the flanges are in the fully engaged position.
  2. Turn the vacuum brake booster clockwise with a ratchet on the J 22805-B  (2). See Special Tools and Equipment . DO NOT use a flat bladed tool in the locking tab to install the vacuum brake booster. When the vacuum brake booster is correctly installed, the locking tab (1) slides up the flange and engages the locking notch.
  3. Remove the J 22805-B  (2) from the installed vacuum brake booster. See Special Tools and Equipment .
    4. Fig 1: Locking/Unlocking Booster To Cowl
    GM739251Courtesy of GENERAL MOTORS CORP.
  4. Install the brake pressure modulator valve. Refer to Brake Pressure Modulator Valve (BPMV) Bracket Replacement in Anti-lock Brake System.
  5. Install the transmission fluid filler tube bracket retainer and reposition the filler tube. Refer to Fluid Filler Tube Replacement in Automatic Transaxle - 4T65-E.
  6. Install the EGR valve. Refer to Exhaust Gas Recirculation (EGR) Valve Replacement in Engine Controls - 3.8L.
    7. NOTE: Refer to Fastener Notice in Cautions and Notices.
  7. Install the EGR valve wiring harness heat shield.

    Tighten:  Tighten the EGR valve wiring harness heat shield nut and bolt to 10 N.m (89 lb in).

    8. Fig 2: View Of EGR Valve Wiring Harness Heat Shield
    GM190554Courtesy of GENERAL MOTORS CORP.
  8. Return the engine to the original rest position. Install the left and right engine mount struts. Refer to Engine Mount Strut Replacement - Left and Engine Mount Strut Replacement - Right in Engine Mechanical - 3.8L.
  9. Reposition and connect the vacuum hose and check valve assembly to the booster.
  10. Reposition the master cylinder onto the booster and install the master cylinder retaining nuts.

    Tighten:  Tighten the master cylinder retaining nuts to 33 N.m (24 lb ft).

    11. Fig 3: Installing Master Cylinder Retaining Bolts
    GM748291Courtesy of GENERAL MOTORS CORP.
  11. Connect the brake fluid level sensor electrical connector to the brake fluid level sensor.
  12. Install the fuel injector sight shield. Refer to Fuel Injector Sight Shield Replacement (L26) or Fuel Injector Sight Shield Replacement (L32) in Engine Mechanical - 3.8L.
    13. Fig 4: View Of Fuel Injector Sight Shield
    GM370383Courtesy of GENERAL MOTORS CORP.
  13. Connect the brake booster pushrod to the brake pedal and install the retaining clip.
  14. Install the left instrument panel insulator.
  15. Connect the negative battery cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
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