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Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 1540 (Hydraulic Brake System) >> Repair Instructions >> Vacuum Brake Booster Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 Chevrolet Corvette. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Brake Booster Mounting Nuts & Washers To Booster Studs
    GM63943Courtesy of GENERAL MOTORS CORP.
  1. Install the seal and brake booster to the front of dash.
    2. NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install brake booster mounting nuts and washers to the booster studs.

    Tighten:  Tighten the brake booster mounting nuts to 27 N.m (19 lb ft).

    3. Fig 2: Isolation Mat To Brake Pedal
    GM63944Courtesy of GENERAL MOTORS CORP.
  3. Install the brake booster pushrod, brake pedal pin, washer, and retainer to the brake pedal. Verify proper engagement of the retainer to the brake pedal by rotating the retainer.
    4. Fig 3: Motor Assembly To Right Of Steering Column
    GM425435Courtesy of GENERAL MOTORS CORP.
  4. Reposition the telescoping column motor assembly to the steering column, if equipped.
  5. Install the screw (3) to the motor mounting bracket (5).

    Tighten:  Tighten the screw to 7 N.m (62 lb in)

  6. Install the instrument panel lower trim panel. Refer to Trim Panel Replacement - Knee Bolster in Instrument Panel, Gages, and Console.
    7. Fig 4: Identifying Vacuum Booster Hose
    GM63936Courtesy of GENERAL MOTORS CORP.
  7. Connect the brake booster vacuum hose to the brake booster check valve.
    8. Fig 5: View Of Master Cylinder & Mounting Nuts
    GM63941Courtesy of GENERAL MOTORS CORP.
  8. Install the master cylinder to the brake booster.
  9. Install the master cylinder mounting nuts.

    Tighten:  Tighten the master cylinder mounting nuts to 29 N.m (21 lb ft).

    10. Fig 6: View Of Brake Fluid Level Sensor Electrical Connector
    GM675866Courtesy of GENERAL MOTORS CORP.
  10. Connect the electrical connector (1) to the brake fluid level sensor.
    11. Fig 7: Electrical Connections & Washer Hose At Container
    GM70094Courtesy of GENERAL MOTORS CORP.
  11. Connect the electrical connector and the washer hose to the washer solvent container.
  12. Install washer solvent container to the wheelhouse.
  13. Install the washer solvent container retaining nuts.

    Tighten:  Tighten the washer solvent container retaining nuts to 7.5 N.m (66 lb in).

  14. Connect the battery negative cable. Refer to Battery Negative Cable Disconnect/Connect Procedure in Engine Electrical.
  15. Program the transmitters. Refer to Transmitter Programming in Keyless Entry.
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