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Power Brake Booster: Installation

WARNING: This page is about a different car, the 2002 Pontiac Grand Prix and 2002 Oldsmobile Intrigue. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Inspect the locking flanges on booster and mounting plate. Replace the booster and mounting plate if the locking flanges are bent or damaged. Carefully push the pushrod eye through the hole so that you DO NOT damage or dislodge the insulator boot.
  1. Install the power brake booster.
  2. Position the power brake booster on the cowl counterclockwise from the final installation position so that the locking flanges on the power brake booster engage with the mounting flanges on the cowl.
  3. Turn the power brake booster clockwise with a ratchet on power brake booster holder. DO NOT use a flat bladed tool in the locking tab to install the power brake booster. When the power brake booster is correctly installed, the locking tab slides up the flange and engages the locking notch.
  4. Remove power brake booster holder from the installed power brake booster.
  5. Install the coolant bypass pipe.
  6. Reconnect the coolant bypass hose.
  7. Install the EGR valve. Refer to the following procedures:
    • For Oldsmobile Intrigue models, see EGR VALVE in EMISSION SYSTEM & SUB-SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - AURORA & INTRIGUE article in ENGINE PERFORMANCE.
    • For Pontiac Grand Prix models, see EGR VALVE in EMISSION SYSTEM & SUB-SYSTEMS in REMOVAL, OVERHAUL & INSTALLATION - CENTURY, GRAND PRIX, IMPALA, MONTE CARLO & REGAL article in ENGINE PERFORMANCE.
  8. Install the BPMV bracket.
  9. Install the vacuum hose to the vacuum brake booster.
  10. Install the brake pressure modulator valve. See BRAKE PRESSURE MODULATOR VALVE under appropriate ANTI-LOCK article.
  11. Install the master cylinder. See MASTER CYLINDER  .
  12. Install the vacuum hose and booster check valve to the brake booster.
  13. Connect the EVAP canister purge valve pipe, the fuel feed and return pipe.
  14. Insert the tab of the fuel injector sight shield under the engine bracket. Lower the fuel injector sight shield. Align the holes in the fuel injector sight shield with the studs. Install the 2 fuel injector sight shield nuts onto the studs. Tighten the fuel injector sight shield nuts to specifications. See TORQUE SPECIFICATIONS  .
  15. Fill the cooling system.
  16. Connect the power brake booster pushrod to the brake pedal and install the retaining clip.
  17. Position the left side insulator to the instrument panel. Install the courtesy lamp to the insulator. Secure the lamp by rotating 1/4 turn clockwise. Install the left instrument panel insulator to the stud at the accelerator pedal. Install the left side insulator retainers.
  18. Connect the negative battery cable.
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