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Installation (3.1L)

WARNING: This page is about a different car, the 2003 Pontiac Grand Prix. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Internal components of this booster are not serviceable. The housing must not be unstaked and separated. Separating the housing will cause permanent deformation, preventing the booster from holding proper volume.
  1. Inspect the locking flanges on booster and mounting plate. Replace the booster and mounting plate if the locking flanges are bent or damaged.
  2. Carefully push the pushrod eye through the hole so that you do not damage or dislodge the insulator boot.
  3. Install the vacuum brake booster.
    4. NOTE: Ensure that the locking tab and the flanges are in the full engaged position. DO NOT use a flat bladed tool in the locking tab to install the vacuum brake booster.
  4. Turn the vacuum brake booster clockwise with a ratchet on the Power Brake Booster Holder.
  5. When the vacuum brake booster is correctly installed, the locking tab slides up the flange and engages the locking notch.
  6. Remove the Power Brake Booster Holder from the installed vacuum brake booster.
  7. Reposition and connect the vacuum hose and check valve assembly to the booster.
  8. Reposition the master cylinder onto the booster and install the master cylinder retaining nuts. See TORQUE SPECIFICATIONS  .
  9. Connect the brake fluid level sensor electrical connector to the brake fluid level sensor.
  10. Return the engine to the original rest position. Install the left and right engine mount struts.
  11. Install the heater inlet pipe.
  12. Reposition and connect the coolant outlet and inlet bypass hoses.
  13. Install the brake pressure modulator valve. See REMOVAL & INSTALLATION in appropriate ANTI-LOCK article.
  14. Reposition and connect the EVAP canister purge valve pipe, the fuel feed pipe and return pipe.
  15. Install the air cleaner inlet duct.
  16. Fill the cooling system.
  17. Connect the brake booster pushrod to the brake pedal and install the retaining clip.
  18. Install the left instrument panel insulator.
  19. Connect the negative battery cable.
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