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Home >> Chevrolet >> 2002 >> Prizm LSi, Standard >> Repair and Diagnosis >> Brakes >> Mechanical - Hydraulic >> Hydraulic Brakes >> Repair Instructions >> Vacuum Brake Booster Replacement >> Installation Procedure

Installation Procedure

NOTE: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.
  1. Install the following components to the bulkhead:
    • A new gasket (11) between the booster assembly (9) and the bulkhead
    • The booster assembly (9)
    • Secure the booster assembly with the 4 nuts (7,8,12,13).

      Tighten 

      Tighten the nuts to 13 N.m (108 in lbs).

  2. Install the clevis (3) to the operating rod.
  3. Install the following components to the clevis (3):
    • The wave washer (2)
    • The clevis pin (1)
    • The cotter pin (4)
  4. Install the brake pedal return spring (6).
    Fig 1: Installing Vacuum Brake Booster
    G01711092Courtesy of GENERAL MOTORS CORP.
  5. If the vehicle has ABS, install the following components to the booster assembly (5):
    1. 5.1. The gasket (2)
    2. 5.2. The bracket for the brake pressure modulator valve assembly (3)
    3. 5.3. The 3 nuts. DO NOT torque the nuts.
  6. Install a new gasket on the master cylinder.
    Fig 2: Installing Master Cylinder
    G01711093Courtesy of GENERAL MOTORS CORP.
  7. Place the J 39567 on the gasket.
  8. Lower the J 39567 pin down until the pin touches the master cylinder piston (2).
  9. Remove the J 39567 from the master cylinder.
    Fig 3: Using J 39567
    G01711094Courtesy of GENERAL MOTORS CORP.
  10. Turn the J 39567 upside down.
  11. If the vehicle has ABS, place the J 39567 on the bracket for the brake pressure modulator valve assembly.
  12. If the vehicle does not have ABS, place the J 39567 on the booster assembly (1).
  13. Measure the clearance (2) between the booster piston rod (3) and the J 39567.

    Specification 

    Ensure that the clearance is 0 mm (0 in).

    Fig 4: Using J 39567
    G01711095Courtesy of GENERAL MOTORS CORP.
  14. If the booster piston rod length does not match the specification, complete the following procedure:
    1. 14.1. Ask an assistant to push the booster piston rod out by pressing the brake pedal.
    2. 14.2. Turn the booster piston rod until the booster piston rod slightly touches the pin head.
    Fig 5: Turning Booster Piston Rod
    G01711096Courtesy of GENERAL MOTORS CORP.
  15. If the vehicle is equipped with ABS, install the brake pressure modulator valve assembly (3). Refer to BRAKE MODULATOR ASSEMBLY REPLACEMENT .
  16. Install the master cylinder (5). Refer to Master Cylinder Replacement .
  17. Torque the 3 master cylinder nuts.

    Tighten 

    Tighten the three nuts to 13 N.m (108 in lbs).

  18. Install the hose to the booster assembly (1).

    Secure the hose with the hose clamp.

  19. Bleed the brake system. Refer to Hydraulic Brake System Bleeding .
  20. Inspect for leaks.
  21. Adjust the brake pedal travel. Refer to Brake Pedal Travel Measurement and Inspection .
    Fig 6: Installing Master Cylinder
    G01711097Courtesy of GENERAL MOTORS CORP.
  22. Tighten the clevis lock nut (5).

    Tighten 

    Tighten the nut to 26 N.m (19 ft lbs).

    Fig 7: Installing Vacuum Brake Booster Components
    G01711098Courtesy of GENERAL MOTORS CORP.
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