Power Brake Booster: Installation

WARNING: This page is about a different car, the 2003 Pontiac Vibe. 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.

If you are installing a new booster, adjust booster piston rod. See BRAKE BOOSTER PISTON ROD under ADJUSTMENTS & INSPECTIONS.
Use paint on the new booster push rod in order to copy the location of the paint mark on the old booster push rod.
Install the check valve grommet to the booster. Install the check valve to the booster.
Install the cowl gasket to the booster. Install the booster to the bulkhead. Install the 4 nuts in order to retain the booster to the bulkhead.
Push the brake pipes into the bulkhead bracket. Install the clevis nut to the paint mark on the booster push rod. Install the clevis to the push rod.
Apply Lubriplate lubricant, GM P/N 1052196 (Canadian P/N 5264008), or the equivalent, to the push rod clevis pin and to the clevis pin hole in the brake pedal.
Install the push rod clevis pin and the washer in order to retain the clevis to the brake pedal. Install the clip in order to retain the pin to the brake pedal.
Install the vacuum hose to the check valve. Install the hose clamp on the hose to the check valve.
On vehicles with cruise control, install cruise control module. Tighten to specifications. See TORQUE SPECIFICATIONS .
On all vehicles, install the left front brake pipe.
Install the brake master cylinder and connect the brake lines. See MASTER CYLINDER .
Connect fluid level sensor switch on the master cylinder.
Bleed the brake system. See MANUAL BLEEDING under BLEEDING BRAKE SYSTEM.