LEMON Manuals: Even more car manuals for everyone
Home >> Chevrolet >> 2002 >> Blazer 4D Utility, 4WD, Part Time >> Repair and Diagnosis >> External Pages >> Different car >> Section 53 (Disc Brakes & Drum Brakes) >> Removal & Installation >> Vacuum Brake Booster >> Installation

Vacuum Brake Booster: Installation

WARNING: This page is about a different car, the 2003 Buick Regal, 2003 Buick Century, 2002 Buick Regal, and 2002 Buick Century. However, it is still accessible from the selected car via links, so may be relevant.
CAUTION: Carefully push the pushrod eye through the hole so that you do not damage or dislodge the insulator boot.
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. Inspect the locking flanges on booster and mounting plate. Replace the booster and mounting plate if the locking flanges are bent or damaged.
  1. 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.
    2. CAUTION: Ensure that the locking tab and the flanges are in the full engaged position.
  2. Turn the vacuum brake booster clockwise with a ratchet on the Power Brake Booster Holder. 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.
  3. Remove the Power Brake Booster Holder from the installed vacuum brake booster. Reposition and connect the vacuum hose and check valve assembly to the booster.
  4. Reposition the master cylinder onto the booster and install the master cylinder retaining nuts. Tighten to specifications. See TORQUE SPECIFICATIONS  .
  5. Connect the brake fluid level sensor electrical connector to the brake fluid level sensor. Return the engine to the original rest position. Install the left and right engine mount struts. Install the heater inlet pipe.
  6. Reposition and connect the coolant outlet and inlet bypass hoses. Reposition and connect the EVAP canister purge valve pipe, the fuel feed pipe and return pipe.
  7. Install the air cleaner inlet duct. Install the cross vehicle brace. Fill the cooling system.
  8. Connect the brake booster pushrod to the brake pedal and install the retaining clip. Connect the stoplight switch electrical connector to the stoplight switch. Install the left instrument panel insulator.


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. Inspect the locking flanges on booster and mounting plate. Replace the booster and mounting plate if the locking flanges are bent or damaged.
  1. 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.
    2. NOTE: Ensure that the locking tab and the flanges are in the fully engaged position.
  2. Turn the vacuum brake booster clockwise with a ratchet on the Brake Booster Holder. 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 (1) slides up the flange and engages the locking notch.
  3. Remove the Brake Booster Holder from the installed vacuum brake booster. Install the transmission fluid filler tube bracket retainer and reposition the filler tube.
  4. Install the EGR valve. Install the EGR valve wiring harness heat shield. Tighten to specifications. See TORQUE SPECIFICATIONS  .
  5. Return the engine to the original rest position. Install the left and right engine mount struts. 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.
  6. Connect the throttle and cruise control cables to the throttle body. Reposition and connect the vacuum hose and check valve assembly to the booster.
  7. Reposition the master cylinder onto the booster and install the master cylinder retaining nuts. Tighten to specifications. See TORQUE SPECIFICATIONS  . Connect the brake fluid level sensor electrical connector to the brake fluid level sensor.
  8. Install the fuel injector sight shield. Install the cross vehicle brace.
  9. Connect the brake booster pushrod to the brake pedal and install the retaining clip. Connect the stoplight switch electrical connector to the stoplight switch. Install the left instrument panel insulator.
scientia non olet · About LEMON Manuals