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Home >> Chevrolet >> 2006 >> Cobalt LTZ >> Repair and Diagnosis >> External Pages >> Different car >> Section 755 (Hydraulic Brake System) >> Repair Instructions >> Power Vacuum Brake Booster Replacement >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2008 Pontiac G5 and 2008 Chevrolet Cobalt. However, it is still accessible from the selected car via links, so may be relevant.
    Fig 1: Identifying Power Brake Vacuum Booster Gasket
    GM1912328Courtesy of GENERAL MOTORS CORP.
  1. Install the power brake vacuum booster gasket (1).
    2. Fig 2: Identifying Power Brake Vacuum Booster
    GM1912326Courtesy of GENERAL MOTORS CORP.
  2. Install the power brake vacuum booster (1).
    3. NOTE: Refer to Fastener Notice .
    Fig 3: Identifying Brake Booster Nuts
    GM1912303Courtesy of GENERAL MOTORS CORP.
  3. Install the vacuum brake booster nuts (1).

    Tighten:  Tighten the nuts to 17 N.m (14 lb ft).

    4. Fig 4: Identifying Brake Pedal Pushrod Washer
    GM1912300Courtesy of GENERAL MOTORS CORP.
  4. Apply a thin coating of high temperature grease GM P/N 12345996 (Canadian P/N 10953501) to the pushrod pin on the brake pedal.
  5. Connect the brake pedal pushrod to the brake pedal pivot pin.
  6. Install the brake pedal pushrod washer (1).
    7. Fig 5: Locating Brake Pedal Pushrod Nut
    GM1912299Courtesy of GENERAL MOTORS CORP.
  7. Install the brake pedal pushrod nut (1).

    Tighten:  Tighten the nut to 10 N.m (89 lb in).

  8. Install the steering column opening filler. Refer to Steering Column Opening Filler Replacement .
    9. Fig 6: Identifying Master Cylinder Seal
    GM1912268Courtesy of GENERAL MOTORS CORP.
  9. Inspect the master cylinder seal (1) for damage and replace if necessary.

    Ensure the master cylinder seal is properly seated in the groove in the master cylinder body.

  10. Position the master cylinder to the power vacuum brake booster.
  11. Connect the master cylinder clutch hose quick connect to the clutch master cylinder, if equipped.
    12. Fig 7: Identifying Master Cylinder Mounting Nuts
    GM1912323Courtesy of GENERAL MOTORS CORP.
  12. Install the master cylinder nuts (1).

    Tighten:  Tighten the nuts to 25 N.m (18 lb ft).

  13. Install the vacuum power brake booster check valve and hose assembly to the brake booster grommet.

    If necessary, a small amount of denatured alcohol can be used as an assembly aid for installing the check valve and hose assembly to the vacuum booster grommet. Do not use soap.

  14. Connect the vacuum power brake vacuum sensor electrical connector, if equipped.
  15. Connect the brake fluid level indicator switch electrical connector.
  16. Position the electrical center and the powertrain control modules to the underhood electrical center bracket and install the bracket. Refer to Underhood Electrical Center or Junction Block Bracket Replacement .
  17. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
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