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Home >> Chevrolet >> 2001 >> Venture Base, Van Passenger >> Repair and Diagnosis >> External Pages >> Different car >> Section 353 (Disc Brakes) >> Removal & Installation >> Power Brake Booster >> Installation (3.8L)

Installation (3.8L)

WARNING: This page is about a different car, the 2003 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.
  1. Inspect the locking flanges on booster and mounting plate. Replace the booster and mounting plate if the locking flanges are bent or damaged.
  2. 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. Ensure that the locking tab and the flanges are in the fully engaged position.
  3. Turn the vacuum brake booster clockwise with a ratchet on the J-22805-B. 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 slides up the flange and engages the locking notch.
  4. Remove the J-22805-B from the installed vacuum brake booster.
  5. Install the brake pressure modulator valve. See REMOVAL & INSTALLATION in appropriate ANTI-LOCK article.
  6. Install the transmission fluid filler tube bracket retainer and reposition the filler tube.
  7. Install the EGR valve. See EGR VALVE under EMISSIONS SYSTEMS & SUBSYSTEMS in appropriate REMOVAL & INSTALLATION article in ENGINE PERFORMANCE.
  8. Install the EGR valve wiring harness heat shield. Tighten the EGR valve wiring harness heat shield nut and bolt to specification. See TORQUE SPECIFICATIONS  .
  9. 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.
  10. Reposition the throttle bracket and cables to the throttle body. Install the throttle bracket, throttle cable, and the cruise control cable assembly to the throttle body.
  11. Connect the throttle and cruise control cables to the throttle body.
  12. Reposition and connect the vacuum hose and check valve assembly to the booster.
  13. Reposition the master cylinder onto the booster and install the master cylinder retaining nuts. See TORQUE SPECIFICATIONS  .
  14. Connect the brake fluid level sensor electrical connector to the brake fluid level sensor.
  15. Install the fuel injector sight shield.
  16. Connect the brake booster pushrod to the brake pedal and install the retaining clip.
  17. Install the left instrument panel insulator.
  18. Connect the negative battery cable.
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