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Vacuum Brake Booster: Installation

  1. Install the booster to the vehicle. Install the booster pushrod to the brake pedal. See Figure. Tilt the vacuum brake booster slightly in order to work the booster pushrod onto the pedal clevis pin. DO NOT apply excessive side pressure on the pushrod. Align the pushrod with the pedal and assemble.
  2. Install the booster retaining nuts. Tighten the booster to brake pedal retaining nuts to specification. See TORQUE SPECIFICATIONS 
  3. Install the left closeout/insulator panel.
    • Install the right half of the sound insulator on the drivers side to the instrument panel (I/P) carrier and install the bolts to the sound insulator. See Figure. Tighten the bolts to specification. See TORQUE SPECIFICATIONS .
    • Install the left half of the sound insulator on the drivers side to the I/P carrier and install the push pin.
  4. Connect the vacuum hose and the vacuum brake booster check valve to the booster as an assembly. See Figure.
  5. Install the master cylinder to the booster. Install the master cylinder. See MASTER CYLINDER .
  6. Install the underhood electrical center bracket.
  7. Position back and connect the underhood electrical center.
    1. With the electrical center turned upside down, install the electrical center box into the electrical center. Connect the forward lamp wiring harness connector to the junction block.
    2. Connect the I/P wiring harness connector to the junction block. Connect the engine wiring harness connector to the junction block.
    3. Install the bolts retaining the engine, I/P, and forward lamp wiring harness connectors to the junction block. Tighten the electrical center junction block bolts to specification. See TORQUE SPECIFICATIONS .
    4. Connect the I/P wiring harness individual connectors to the junction block. Connect the retainers for the electrical cable at the rear of the electrical center. Install the box retainers by the electrical cables.
    5. Close the lower cover of the electrical center. Turn the electrical center right side up. Attach the box retainer next to the electrical cables. Connect the electrical cable retainers at the rear of the electrical center.
    6. Slide the electrical center to the rear until the center snaps into the retainer tab. Install all of the fuses and the relays. Install the electrical center cover.
    7. Install the positive battery cable lead to the stud on underhood electrical center, then install the positive battery cable lead retaining nut. Tighten the positive battery cable lead retaining nut to specification. See TORQUE SPECIFICATIONS . Connect the negative battery cable.
  8. Install the air cleaner assembly.
    1. Install the air cleaner element in the air cleaner assembly. Position the air cleaner cover on the air cleaner assembly.
    2. Install the air cleaner retainer screws. Tighten the screws to specification. See TORQUE SPECIFICATIONS . Install the mass air flow (MAF) sensor to the air cleaner cover.
    3. Place the air cleaner assembly in the vehicle. Install the air cleaner assembly retainer screws. Tighten the air cleaner retainer screws to specification. See TORQUE SPECIFICATIONS .
    4. Install the air intake duct. Tighten the 2 air intake duct clamps. Connect the breather tube to the air intake duct. Connect the intake air temperature (IAT) sensor electrical connector and MAF sensor electrical connector.
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