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Home >> GMC >> 2003 >> Safari Van Cargo, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1109 (Hydraulic Brake System) >> Repair Instructions >> Vacuum Brake Booster Replacement (3.4L) >> Installation Procedure

Installation Procedure

WARNING: This page is about a different car, the 2004 Pontiac Aztek and 2004 Buick Rendezvous. 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.
NOTE: Proper stoplamp switch adjustment is essential. Improper stoplamp switch adjustment may cause brake drag, heat buildup and excessive brake lining wear.
    Fig 1: View Of Vacuum Brake Booster Components
    GM180993Courtesy of GENERAL MOTORS CORP.
  1. Install the brake booster and position to the cowl and the mounting plate.
    2. NOTE: Refer to Fastener Notice in Cautions and Notices.
  2. Install the brake booster mounting nuts.

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

    3. Fig 2: Locating Brake Pedal Assembly Components
    GM180291Courtesy of GENERAL MOTORS CORP.
  3. Install the brake booster push rod (2) to the brake pedal (1).
  4. Install the brake booster rod retaining washer and clip to the brake pedal assembly.
  5. Adjust the stop lamp switch. Refer to Stop Lamp Switch Adjustment in Lighting Systems.
  6. Install the ABS module bracket and module. Refer to Brake Pressure Modulator Valve (BPMV) Replacement in Antilock Brake System.
  7. Connect the brake lines to the module.
  8. Connect the electrical connector to the ABS module and clip the electrical harness to the bracket.
  9. Install the vacuum hose to the check valve.
  10. Install the brake master cylinder and connect the brake lines. Refer to Master Cylinder Replacement .
  11. Connect the fluid level sensor switch on the master cylinder.
  12. Install the fuel lines to the pipes and the vapor line. Refer to Fuel Hose/Pipes Replacement - Engine Compartment in Engine Controls - 3.4L.
  13. Install the air cleaner and duct assembly. Refer to Air Cleaner Assembly Replacement in Engine Controls - 3.4L.
  14. Install the PCM. Refer to Powertrain Control Module (PCM) Replacement in Engine Controls - 3.4L.
  15. Install the PCM cover.
  16. Install the left front cross brace. Refer to Brace Replacement - Front Fender Upper Diagonal - Left in Body Front End.
  17. Install the coolant reservoir. Refer to Coolant Recovery Reservoir Replacement in Engine Cooling.
  18. Bleed the brake system. Refer to Hydraulic Brake System Bleeding (Manual)  or Hydraulic Brake System Bleeding (Pressure) .
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