Removal (2000 Intrigue)

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: Inspect the locking flanges on booster and mounting plate. Replace the booster and mounting plate if the locking flanges are bent or damaged.

Tools Required

J 22805-01 Power Brake Booster Holder

Remove the fuel injector sight shield.
Remove the master cylinder nuts and position the master cylinder to one side. Refer to MASTER CYLINDER Replacement.
Remove the brake pressure modulator valve (BPMV) bracket.
Remove the EGR valve.
Remove the vacuum hose from the vacuum brake booster.
NOTE: When disconnecting the pushrod from the brake pedal, the brake pedal must be held stationary or damage to the brake switch may result. Notice: Do not attempt to remove the booster until pushrod is disconnected from the brake pedal.
Remove the vacuum brake booster pushrod from the brake pedal.
Attach the J 22805-01 to the vacuum brake booster using the nuts.
Tighten

Tighten the nuts to 27 N.m (20 lb ft).

Fig 1: Vacuum Brake Booster Removal Tools
Courtesy of GENERAL MOTORS COMPANY
Unlock the vacuum brake booster (2) from the front of the dash.
Use a screwdriver (4) in order to pry the locking tab (5) on the vacuum brake booster out of the locking notch (3) on the mounting flange. Perform the above action while turning the vacuum brake booster counterclockwise with the wrench (1) on J 22805-01 .
IMPORTANT: Carefully pull the pushrod through the eyehole so that you do not damage the insulator boot mounted on the front of the dash.
Remove the vacuum brake booster (2).