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Power Brake Booster: Installation

WARNING: This page is about a different car, the 2003 Pontiac Sunfire and 2003 Chevrolet Cavalier. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the brake booster to the vehicle. Ensure that the inner washer is in position on the brake pedal. Apply a thin coating of lithium grease to the pushrod pin on the brake pedal.
  2. Connect the brake booster pushrod to the brake pedal. Tilt the entire brake booster slightly in order to work the booster pushrod onto the pedal clevis pin without putting undue pressure on the pushrod.
  3. Install the outer washer and retaining clip to the brake pedal.
  4. Install the vacuum brake booster mounting nuts. Tighten to specifications. See TORQUE SPECIFICATIONS  .
  5. Install the vacuum hose to the vacuum check valve.
  6. Move the master cylinder and the proportioning valve assembly or the anti-lock brake modulator assembly onto the brake booster studs.
  7. Install the master cylinder mounting nuts. Tighten to specifications. See TORQUE SPECIFICATIONS  .
  8. Install the air cleaner assembly.
    1. Slide the pin, part of air cleaner assembly, into the bracket hole on the left strut tower.
    2. Position and install the air cleaner inlet over the resonator neck.
    3. Install the push in retainer from the air cleaner to the battery tray.
    4. Install the relay center and the push in retainer.
    5. Connect the relay battery feed cable into the upper air cleaner cover retaining clips.
    6. Install the battery and connect the battery cables.
    7. Connect the air cleaner outlet duct. Tighten to specifications. See TORQUE SPECIFICATIONS  .
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