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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1135 (Hydraulic Brake System) >> Repair Instructions >> Vacuum Brake Booster Replacement (3.6L LY7) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 Pontiac Aztek and 2004 Buick Rendezvous. 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.
NOTE: Proper stoplamp switch adjustment is essential. Improper stoplamp switch adjustment may cause brake drag, heat buildup and excessive brake lining wear.
    Fig 1: View Of Vacuum Brake Booster Components
    GM180993Courtesy of GENERAL MOTORS CORP.
  1. Install the brake booster and position to the cowl and the mounting plate.
    2. NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the brake booster mounting nuts.

    Tighten:  Tighten the brake booster mounting nuts to 25 N.m (18 lb ft).

    3. Fig 2: Locating Brake Pedal Assembly Components
    GM180291Courtesy of GENERAL MOTORS CORP.
  3. Install the brake booster push rod (2) to the brake pedal (1).
  4. Install the brake booster rod retaining washer and clip to the brake pedal assembly.
  5. Adjust the stop lamp switch. Refer to Stop Lamp Switch Adjustment in Lighting Systems.
  6. Connect the fuel pipe retainer to the wheelhouse stud.
  7. Install the transmission filler tube. Refer to Fluid Filler Tube Replacement (LA1) or Fluid Filler Tube Replacement (LY7) in Automatic Transaxle - 4T65-E.
  8. Using the engine support fixture, raise the powertrain to its original position.
  9. Raise the vehicle.
  10. Using an appropriate jack, raise the left side of the frame so that the frame to body bolts can be installed.
    11. Fig 3: Locating Left Side Frame To Body Bolts
    GM478740Courtesy of GENERAL MOTORS CORP.
  11. Install the frame to body bolts.

    Tighten: 

    • Tighten the front bolts to 155 N.m (114 lb ft).
    • Tighten the rear bolts to 240 N.m (177 lb ft).

  12. Remove the jackstand and oil drain pan.
  13. Install the steering gear mounting bolts.

    Tighten:  Tighten the bolts to 80 N.m (59 lb ft).

    14. Fig 4: View Of Stabilizer Bar Links
    GM623048Courtesy of GENERAL MOTORS CORP.
  14. Install the stabilizer bar links. Refer to Stabilizer Shaft Link Replacement in Front Suspension.
  15. Install the ball joint to the steering knuckle. Refer to Lower Control Arm Replacement in Front Suspension.
    16. Fig 5: Locating Left Front Fender Liner
    GM621343Courtesy of GENERAL MOTORS CORP.
  16. Install the left front fender liner.
  17. Install the left front tire and wheel assembly. Refer to Tire and Wheel Removal and Installation in Tires and Wheels.
  18. Lower the vehicle.
  19. Remove the engine support fixture.
  20. Install ABS module bracket and module. Refer to Brake Pressure Modulator Valve (BPMV) Replacement in Antilock Brake System.
  21. Install the vacuum hose to the check valve.
  22. Install the brake master cylinder and connect the brake lines. Refer to Master Cylinder Replacement .
  23. Connect fluid level sensor switch on the master cylinder.
  24. Install the fuel line retaining bolt to the intake manifold.

    Tighten:  Tighten the bolt to 10 N.m (89 lb in).

  25. Install the air cleaner and duct assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.6L (LY7).
  26. Install the ECM. Refer to Engine Control Module (ECM) Replacement in Engine Controls - 3.6L (LY7).
  27. Install the ECM cover.
  28. Install the left front cross brace. Refer to Brace Replacement - Front Fender Upper Diagonal - Left in Body Front End.
  29. Reposition the coolant reservoir to the left front cross brace.
  30. Bleed the brake system. Refer to Hydraulic Brake System Bleeding (Manual)  or Hydraulic Brake System Bleeding (Pressure) .
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