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Power Brake Booster: Installation

WARNING: This page is about a different car, the 2003 Pontiac Montana, 2003 Oldsmobile Silhouette, and 2003 Chevrolet Venture. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: When replacing the power booster brake, make sure that the cruise control cable is not routed between the booster and the cowl. If the cable is damaged or pinched, it must be replaced. Failure to do this could result in personal injury.
  1. Position the brake booster to the cowl and the mounting plate. Install the brake booster mounting nuts. Tighten the brake booster mounting nuts to specifications. See TORQUE SPECIFICATIONS  . Install the master cylinder. See MASTER CYLINDER  .
  2. Install the brake booster push rod to the brake pedal install the washer & retaining clip. See Figure . Adjust the stoplight switch. See STOPLIGHT SWITCH ADJUSTMENT  under ADJUSTMENTS & INSPECTIONS.
  3. Install the knee bolster.
    1. Align the clips with the slots in the instrument panel. Push in, in order to secure the knee bolster.
    2. Install the bolts/screws to the bottom of the knee bolster. Tighten to specifications. See TORQUE SPECIFICATIONS  .
    3. Install the I/P insulator.
  4. Rotate the engine back and install the engine mounts, bolts, nuts.
  5. Install the vacuum hose to the check valve. Install the ABS module bracket and module. See appropriate ANTI-LOCK article.
  6. Connect the brake lines to the module.
  7. Connect the electrical connector to the ABS module and clip the electrical harness to the bracket.
  8. Install the brake master cylinder and connect the brake lines. See MASTER CYLINDER  .
  9. Connect fluid level sensor switch on the master cylinder.
  10. Install the fuel lines to the pipes and the vapor line.
    1. Remove the caps from the fuel pipes. Lubricate the NEW O-ring with clean engine oil.
    2. Install the O-ring and the engine fuel return pipe to the fuel pressure regulator.
    3. Lubricate the NEW O-ring with clean engine oil.
    4. Install the O-ring and the engine fuel feed pipe to the fuel rail. Tighten to specifications. See TORQUE SPECIFICATIONS  .
    5. Install the upper intake manifold assembly. See appropriate ENGINE MECHANICAL article in ENGINES.
    6. Connect the quick-connect fittings in the engine compartment.
    7. Tighten the fuel filler cap. Turn ON the ignition for 2 seconds. Turn OFF the ignition for 10 seconds. Turn ON the ignition. Inspect for fuel leaks.
  11. Install the heater cross over pipe.
  12. Install the air cleaner and duct assembly.
    1. Position the air cleaner housing on the stud.
    2. Install the 2 bolts through the housing. Tighten bolts to specifications. See TORQUE SPECIFICATIONS  .
    3. Carefully install the PCM into the housing. Install the upper cover and snap in to place.
    4. Install the air cleaner element and air cleaner cover and snap them in place. Install the air inlet duct/MAF sensor assembly and tighten the 2 clamps.
    5. Connect the MAF sensor electrical connector. Position the support brace and install the 3 bolts. Install the coolant tank and install the retaining fastener.
  13. Install the PCM. Tighten strut base retaining bolts to specifications. See TORQUE SPECIFICATIONS  .
  14. Install the PCM cover.
  15. Install the left front cross brace.
    1. Install the front end sheet metal diagonal brace to the engine compartment.
    2. Align the rear hole of the front end sheet metal diagonal brace to the hole in the wheelhouse.
    3. Align the holes of the front end sheet metal diagonal brace to the holes in the upper tie bar.
    4. Install the bolts to the front of the front end sheet metal diagonal brace at the upper tie bar. Tighten bolts to specifications. See TORQUE SPECIFICATIONS  .
    5. Install the bolt to the rear hole in the front end sheet metal diagonal brace at the wheelhouse. Tighten the bolts to specifications. See TORQUE SPECIFICATIONS  .
    6. Install the windshield wiper system module cover.
  16. Install Cruise control bracket and the cruise control module.
    1. Install the cruise control module to the mounting bracket. See Figure .
    2. Install the mounting bracket bolt to the cruise control module. Tighten to specifications. See TORQUE SPECIFICATIONS  .
    3. Connect the electrical connector to the module. See Figure . Install the cruise control cable to the module.
    4. Adjust the cruise control cable. See CRUISE CONTROL CABLE ADJUSTMENT in appropriate CRUISE CONTROL SYSTEMS article in ACCESSORIES & EQUIPMENT.
  17. Install the coolant reservoir.
  18. Fill and bleed cooling system.
  19. Bleed the brake system. See MANUAL BLEEDING  under BLEEDING BRAKE SYSTEM.
Fig 1: Removing & Installing Power Brake Booster
G00076373Courtesy of GENERAL MOTORS CORP.
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