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Power Brake Booster: Installation

WARNING: This page is about a different car, the 2005 Jeep Grand Cherokee. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Booster Mounting Hole
GC0026820Courtesy of DAIMLERCHRYSLER CORP.
1 - INTERMEDIATE SHAFT
2 - BOOSTER MOUNTING HOLES
  1. Check condition of grommet that secures check valve in booster. Replace grommet if cut, torn, or loose.
  2. Install new booster dash seal.
  3. Align and position booster in the mounting holes (2) of the dash panel.
    Fig 2: Brake Booster Push Rod
    GC0026819Courtesy of DAIMLERCHRYSLER CORP.
    1 - BOOSTER PUSH ROD
    2 - BRAKE PEDAL
  4. Inside the vehicle, Lubricate pedal pin Mopar multi-mileage grease.
    Fig 3: Brake Booster Bolts
    GC0026818Courtesy of DAIMLERCHRYSLER CORP.
    1 - ADJUSTABLE PEDALS MOTOR
    2 - STEERING COLUMN
    3 - BOOSTER MOUNTING NUTS
  5. Install booster attaching nuts (3) on studs. Tighten attaching nuts to 39 N.m (29 ft. lbs.).
    Fig 4: Brake Booster Push Rod
    GC0026819Courtesy of DAIMLERCHRYSLER CORP.
    1 - BOOSTER PUSH ROD
    2 - BRAKE PEDAL
  6. Slide booster push rod (1) on pedal pin. Then secure rod to pin with retainer clip.
  7. Install a new brake lamp switch and reconnect the electrical connector.
    Fig 5: Column Access Cover
    GC0026817Courtesy of DAIMLERCHRYSLER CORP.
  8. Install the steering column opening cover (2).
    Fig 6: Left Hush Panel
    GC0026827Courtesy of DAIMLERCHRYSLER CORP.
  9. Install the hush panel (2).
    Fig 7: Power Brake Booster
    GC0026816Courtesy of DAIMLERCHRYSLER CORP.
    1 - CHECK VALVE
    2 - MASTER CYLINDER MOUNTING STUDS
    2 - BOOSTER PUSH ROD
  10. In engine compartment, attach vacuum hose to booster check valve (1).
    Fig 8: Power Brake Booster Installed
    GC0026821Courtesy of DAIMLERCHRYSLER CORP.
    1 - POWER BRAKE BOOSTER
    2 - HCU CHASSIS LINES
  11. Install the master cylinder to the power brake booster (1) with new gasket and nuts.
    Fig 9: Electrical Wires
    GC0026823Courtesy of DAIMLERCHRYSLER CORP.
    1 - ELECTRICAL HARNESS
    2 - BRAKE BOOSTER
    3 - CLIP
  12. Reroute the wire harness (1) back into position and install the routing clip (3).
    Fig 10: Master Cylinder Mounted
    GC0026809Courtesy of DAIMLERCHRYSLER CORP.
    1 - POWER BRAKE BOOSTER
    2 - FLUID RESERVOIR
    3 - FLUID CAP
    4 - HCU CHASSIS LINES
    5 - HCU
    6 - MASTER CYLINDER
    7 - BRAKE LINES
    8 - FLUID LEVEL SENSOR ELECTRICAL CONNECTOR
    9 - MOUNTING NUTS
    10 - VACUUM HOSE AND CHECK VALVE
  13. Reconnect the brake fluid level electrical connector (8).
    Fig 11: HCU/ABM
    GC0026826Courtesy of DAIMLERCHRYSLER CORP.
    1 - HCU
    2 - BRACKET
  14. Install the HCU (1) with bracket (2) to the vehicle and tighten the 2 mounting nuts.
    Fig 12: HCU Lines/Connector
    GC0026825Courtesy of DAIMLERCHRYSLER CORP.
    1 - MASTER CYLINDER
    2 - ABM
    3 - CHASSIS LINES
    4 - HCU
    5 - ELECTRICAL CONNECTOR
  15. Reconnect the HCU electrical connector (5).
  16. Install the 4 chassis lines (3) at the HCU (4).
  17. Install the secondary brake line at the HCU (4).
  18. Install the secondary brake line at the master cylinder.
  19. Install the primary brake line at the HCU (4).
  20. Install the primary brake liner at the master cylinder.
  21. Fill and bleed brake system.
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